1993 Pontiac Firebird Service Manual

TABLE OF CONTENTS
SECTION
GENERAL INFORMATION
General lnformatior,
Maintenance and Lubrication
HEATING AND AIR CONDITIONING
Heater and Ventilation

Heater, Ventilation and Air
Conditioning
Manual Control Air Conditioning
HD6/HR6-HE Air Conditioning
Compressor Service or Unit Repair
OA
OB
1
1A
102
3
3A
38
381A
3818
3C
30
3E
ELECTRICAL - BODY AND CHASSIS
3F5B
Electrical Diagnosis
Lighting Systems and Horns
Instrument Panel, Gages and
Console
Windshield Wiper/Washer System
4A
48
BRAKES
Brakes
Master Cylinder
Front Disc Brakes
Rear Disc Brakes
Duo-Servo Drum Brakes
Vacuum Booster System
Antilock Brake System
Parking Brake
5
SA
581
582
5C2
501
5E1
SF
ENGINE
Engine General Description

3.4 Liter V6 Engine On-Vehicle
Service RPO L32 - VIN S
3.4 Liter V6 Engine Unit Repair
RPO L32 - VIN S
5.7 Liter V8 Engine On-Vehicle
Service RPO LT1 -VIN P
5. 7 Liter V8 Engine Unit Repair
RPO LT1 -VIN P
Cooling and Radiator
Engine Fuel
Engine Electrical
Battery
Cranking System
Charging System
Ignition System
Engine Wiring
Driveability and Emissions General Information
Automatic and Manual Transmission

Automatic Transmission On-Vehicle
Service
HYDRA-MATIC 4L60 Automatic
Transmission Diagnosis RPO MD8
HYDRA-MATIC 4L60 Automatic
Transmission Unit Repair
RPO MD8
Manual Transmission On-Vehicle
Service
Borg-Warner (T5) 5-Speed Manual
RPO M49
Borg-Warner (T56) 6-Speed Manual
RPO M28 and M29
Clutch
3F
FINAL DRIVE
Propeller Shaft
Rear Axle
Driveability and Emissions Fuel Injection (Port) (3.4L)

Driveability and Emissions Fuel Injection (Port) (5.7L)
Exhaust System
SECTION
6E3 (3.4L)
6E3 (5.7L)
SF
TRANSMISSION
18
181
STEERING, SUSPENSION, TIRES

AND WHEELS
Steering, Suspension, Tires and

Wheels Diagnosis
Wheel Alignment
Power Steering Gear and Pump
On-Vehicle Service
Power Steering Gear Unit Repair
Power Steering Pump Unit Repair
Front Suspension
Rear Suspension
Tires and Wheels
Steering Wheel and Column
On-Vehicle Service
Supplemental Inflatable Restraint
(SIR) Tilt Steering Column Unit
Repair
TABLE OF CONTENTS
ACCESSORIES
Audio Systems
Cruise Control
Theft Deterrent Systems
Engine Coolant Heater
(SIR) System Introduction
(SIR) System Diagnosis
(SIR) System Removal and
Installation Procedures
Remote Keyless Entry
7
7A
7A-15A
7A-158
78
78-68
78-108
7C
8
SA
88
SC
SE
9
9A
98
90
9E
9J
9J-A
9J-B
9K
6
BODY SERVICE
6A2A
6A2B
6A3A
6A3B
68
SC
60
601
602
603
604
605
SE
General Body Service

Stationary Windows
Body Dimensions, and Underbody
Bumpers
Body Front End
Doors
Rear Quarters
Body Rear End
Roof
Seats and Carpet
Seat Belts
10
10-1
10-2
10-3
10-4
10-5
10-6
10-7
10-8
10-9
10-10
10-11
BODY STRUCTURE
Structural Body Repair and

Dimensions
INDEX'
11
INDEX
1993 SERVICE MANUAL COMMENT FORM
Use this form to advise us of any errors you might find in this manual. We also welcome
suggestions for improving the Service Manuals.
Service Manual(s) that have the error - - - - - - - - - - - - - - - - - - Page number(s) that have the error _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
Figure number(s) that have the error _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __
VIN (if available) or model and applicable options _ _ _ _ _ _ _ _ _ _ _ _ _ __
Describe in detail, the error found or the suggestion(s). Attach additional pages if necessary.
From: Dealer Firm Name _ _ _ _ _ _ _ _ _ _ _ _ Dealer Code _ _ _ _ __

State
Zip Code_ _ _ __
Cityfl'own
Name of Person Submitting This Comment Form _ _ _ _ _ _ _ _ _ _ __
Signature
Mail To: Service Technology Group
Service Information Production
(030-5)
C.C.O. Building
30007 Van Dyke Ave.
Warren, Mi. 48090

Additional comment forms at back of manual.
Date _ _ _ _ Phone (
ST'&
Service Technology Group
GENERAL INFORMATION OA1
1993 FIREBIRD
SECTION OA
GENERAL INFORMATION
CAUTION: This vehicle is equipped with Supplemental Inflatable Restraint (SIR). Refer to
CAUTIONS in Section 9J under "ON-VEHICLE SERVICE" and the SIR Component and Wiring
Location view in Section 9J before performing service on or around SIR components or
wiring. Failure to follow CAUTIONS could result in possible air bag deployment, personal
injury, or otherwise unneeded SIR system repairs.
CONTENTS
Supplemental Inflatable Restraint (SIR)
Handling ...............................
Disconnecting the Battery Negative Cable
Assembly ..............................
Handling Electrostatic Discharge (ESD)
Sensitive
Parts ..................................
Special Tool Ordering Information ............
Body Identification ........................
Federal Vehicle Theft Prevention Standard ......
Vehicle Identification Number ................
Model Identification .......................
Engine Identification .......................
Transmission Usage ........................
Transmission Identification ..................
Differential Ratios and Tire Information ........
General Vehicle Lifting and Jacking ...........
OA-1
OA-1
OA-1
OA-2
OA-2
OA-2
OA-2
OA-4
OA-4
OA-5
OA-5
OA-6
OA-6
Lock Cylinder Coding ...................... OA-6

Key Identification and Usage .............. OA-6
Cutting Keys ........................... OA-6
Replacement Lock Cylinders . . . . . . . . . . . . . . . OA-6
Assembling and Coding Lock Cylinders ...... OA-8
Metric Fasteners ........................... OA-9
Fastener Strength Identification ............... OA-9
Prevailing Torque Fasteners .................. OA-9
English-Metric Conversions . . . . . . . . . . . . . . . . OA-11
Decimal and Metric Equivalents . . . . . . . . . . . . . OA-11
Standard Nomenclature for Electrical/Electronic
Components and Systems ................ OA-11
Abbreviations ............................ OA-16
Replacement Labels . . . . . . . . . . . . . . . . . . . . . . . OA-19
Service Parts Identification Label . . . . . . . . . . . . OA-19
Option Codes ............................ OA-19
Option and Process Codes .................. OA-21
SUPPLEMENTAL INFLATABLE RESTRAINT

(SIR) HANDLING
HANDLING ELECTROSTATIC DISCHARGE

(ESD) SENSITIVE PARTS
Refer to CAUTIONS and the SIR Component and

Wiring Location view in Section 9J when performing service on or around SIR components or SIR wiring. SIR
equipped vehicles can be identified by:
Figure 1
Steering wheel
RESTRAINT."
hub
marked
"INFLATABLE
"INFLATABLE RESTRAINT" indicator lamp in

instrument cluster.
Code "2," "3" or "5" for the seventh digit of the
vehicle identification number (VIN).
DISCONNECTING THE BATTERY NEGATIVE

CABLE ASSEMBLY
CAUTION: Before removing or instal
ling any electrical unit or when a tool or
equipment could easily come in contact with "live" exposed electrical terminals, disconnect the battery negative
cable assembly to help prevent personal injury and/or damage to the
vehicle or components. Unless instructed otherwise, the ignition switch
must be in the "OFF" or "LOCK" position. --
NOTICE: When handling an electronic part that has

an ESD sensitive label (Figure 1) or is identified as
ESD sensitive in the list that follows, the service
technician should follow these guidelines to reduce
any possible electrostatic charge buildup on the service technician's body and the electronic part in the
dealership:
1. Do not open package until it is time to install the
part.
2. Do not touch electrical terminals of the part or its
pigtail connector(s) with a finger or tool.
3. Before removing the part from its package, ground
the package to a known good ground on the vehicle.
4. Always touch a known good ground before handling
the part. This should be repeated while handling the
part and more frequently after sliding across the
seat, sitting down from a standing position or walking a distance.
Not all parts that can be damaged by ESD have an
ESD label. Components that can be damaged by ESD are:
Inflatable restraint diagnostic energy reserve module
(DERM) and resistor module
Engine control module (ECM)
Instrument panel cluster
1993 FIREBIRD
OA2 GENERAL INFORMATION

Solid state components also can be damaged if they
are bumped or dropped, or if they are laid on a metal work
bench or on an electrically operated item such as a radio, a
TV or an oscilloscope.
NOTICE
SPECIAL TOOL ORDERING INFORMATION

Special service tools that are shown in this service
manual that have tool product numbers beginning with
"J" or "BT" are available for worldwide distribution
from:
Kent-Moore
SPX Corporation
29784 Little Mack
CONTENTS SENSITIVE
TO
STATIC ELECTRICITY
Roseville, MI 48066-2298
1-800-345-2233
Monday through Friday
8:00 a.m. through 8:00 p.m. EST
Telex: 244040 KMTR VR
Fax: 313-578-7375
General Motors dealers can purchase TECH 1 scan
tools and accessories through Kent-Moore at the above
address and phone number. Non General Motors dealer
repair facilities can purchase TECH 1 scan tools and
accessories from Kent-Moore at the above address or:
MC0007-0A-B-RP
Figure 1 - ESD Sensitive Parts Label
Sun Electric Corporation

One Sun Parkway
Crystal Lake, IL 60014
1-800-CALLSUN (225-5786)
6:45 a.m. through 7:00 p.m. CST.
BODY IDENTIFICATION
A body identification tag is attached to the vehicle
on the center of the radiator tie. The tag gives a schedule
number and the last four digits of the vehicle identification number (VIN) sequence number. Refer to "Vehicle
Identification Number" in this section
Paint codes, trim numbers, seat option codes and
other body information are included on the Service Parts
Identification Label. Refer to "Service Parts Identification Label" in this section.
FEDERAL VEHICLE THEFT PREVENTION

STANDARD
Federal law requires General Motors to place a
vehicle identification number (VIN) label on certain parts
of selected vehicles. The purpose of the standard is to
reduce motor vehicle thefts by making parts removed
from stolen vehicles easier to trace and recover.
The label is permanently attached to an interior surface of the part and displays the complete VIN. The label
on a replacement part contains the letter "R," the
manufacturer's logo and the symbol "DOT."
[I] Important
THESE LABELS ARE NOT TO BE DEFACED,
REMOVED OR COVERED. The labels must be
shielded from paint, rustproofing and undercoating
(dealer preparation included).
Th~ theft deterrent labels are found on the front side
door windows.
VEHICLE IDENTIFICATION NUMBER

Figures 2 through 4
The vehicle identification number (VIN) legally
identifies the vehicle. A VIN plate is attached to the upper
left of the instrument panel and can,be seen from outside
the vehicle. Each sequential unit number is prefixed by
letters and numbers that are explained in Figure 2. The
VIN also appears on the Vehicle Certificate of Title and
Registration.
A derivative of the VIN is stamped on the engine
and transmission. The code gives the model year, plant of
manufacture and a sequence number that also indicates
the car division. A VIN number is also stamped on the
frame.
A bar code VIN is also on the vehicle identification
plate.
GENERAL INFORMATION OA-3
1993 FIREBIRD
y--------------
Vehicle Identification Number

9 p 2 200001
1G2 FS 2 2
~
PLANT SEQUENCE NUMBER
VIN POSITIONS
#12 THROUGH #17
G.M. MAKE IDENTIFIERS

VIN POSITIONS #1, 2, 3
MAKE
USA
CODE
PONTIAC
G.M. PLANT CODES

VIN POSITION #11
CANADA
CODE
1G2
2G2
MODEL YEAR CODES

VIN POSITION #10
CODE
YEAR
1992
1993
SERIES AND MODEL TABLE

VIN POSITIONS #4 AND #5
#4
#5
DIVISION
CAR
LINE
SERIES
PONTIAC
FIRE BIRD
FORMULNTRANS AM
CHECK
DIGIT
VIN
POSITION #9
LAKEWOOD
DORAVILLE
LINDEN
VAN NUYS
TARRYTOWN
WILMINGTON
OSHAWA#2
ST.THERESE
BOWLING GREEN
OKLAHOMA
CITY
OSHAWA#1
ENGINE CODES
VIN POSITION #8
BODY TYPES
VIN POSITION #6
CODE
DESCRIPTION
TWO DOOR COUPE/SEDAN
TWO DOOR HATCHBACK
TWO DOOR CONVERTIBLE
VIN
CODE
RPO
CODE
ENG.
TYPE
CARBURETION
DISPL.
(LITERS)
MFT.
DIVISION
L32
V6
MFI
3.4
CPC
LT1
V8
MFI
5.7
CPC
I~ ~
RESTRAINT CODES
VIN POSITION #7
CODE
DESCRIPTION
MANUAL BELTS
MANUAL BELTS WITH DRIVER

AND PASSENGER INFLATABLE
RESTRAINT SYSTEM
MANUAL BELTS WITH DRIVER INFLATABLE

RESTRAINT SYSTEM
AUTOMATIC BELTS
AUTOMATIC BELTS WTH DRIVER

INFLATABLE RESTRAINT SYSTEM
PC2001-0A-F-RP
Figure 2 -VIN Codes
OA-4 GENERAL INFORMATION
1993 FIREBIRD
VIN NUMBER PLATE

LOCATION
MODEL IDENTIFICATION
Models (series) and body styles for the current year
are listed in Figure 2.
ENGINE IDENTIFICATION
KC1002-0AF-RP
Figure 3 - VIN Plate Location

1 G 2 F S 2 2 S 9 P 2 200001
MieT
Dilon
Year
______.....,-I Plant of
Manufacture
I
Sequence
Number
-- - -- --2 P 2 200001
VIN Derivative
PC2002-0A-F-RP
Figures 2 and 4 through 6

The VIN code (Figure 2) provides detailed engine
information by the engine code letter located on the
vehicle identification plate.
Stick-on-labels attached to the engine indicate the
engine unit number and code. These labels also contain
bar codes for in-plant identification.
Engines are stamped with an engine identification
number which identifies the assembly plant, the month
produced, the day produced and the engine type code.
All engines and transmissions are stamped with a
VIN derivative, created from the complete VIN. Refer to
"Vehicle Identification Number" in this section. The
stamping contains nine positions. Position 1 is the GM car
division identifier. Position 2 is the model year code. Position 3 is the car assembly plant code. Positions 4 through 9
contain the assembly plant sequential number of the
vehicle (Figure 4).
If the engine in the vehicle is the original engine,
information can be derived from the eighth VIN position
letter or number (Figure 2). To determine if the engine is
original, compare the VIN and the VIN derivative. The
VIN derivative should be the same as positions 3 and 10
through 17 of the VIN.
Figure 4 - VIN Derivative
A
B
C
D
E
V6
V8
VIN DERIVATIVE (PRIMARY)
VIN DERIVATIVE (OPTIONAL)
ENGINE ID NUMBER VERIFICATION LABEL
LOCATED ON OIL PAN ASSEMBLY
Figure 5 - Engine Identification Locations (Typical)
PC0005-0AF-RP
GENERAL INFORMATION OAS
1993 FIREBIRD
TRANSMISSION USAGE
Figure 7
Transmission usage affects axle usage. The transmission usage chart lists each engine with the axles and
transmissions used for each.
TRANSMISSION IDENTIFICATION
Figures 8 and 9
The transmission has two identifying stampings: the
transmission identification and the VIN derivative. The
transmission identification number gives the transmission

model and when it was made. On the automatic transmission, the transmission identification number is located on
the plate on the automatic transmission case. On the
manual transmission, the transmission identification number is located either on the transmission case or the bell
housing. The VIN derivative is created from the complete
VIN and is stamped in either of 2 places (Figure 8). Refer
to "Vehicle Identification Number" in this section. For
more information on rear axle differential ratio codes,
refer to SECTION 4B.
Engine Identification Number
00
00
000
Type Code
Source Code
F-Flint Motor
V-Flint Engine
T-Tonawanda
$-Saginaw Parts
K-GM of Canada LTD.
M-GM of Mexico
H-Hydra-Matic
Month Produced
01 January
02 February
. Day Produced
12 December
LC0003-0A-B-RP
Figure 6 - Engine Identification Number
TRANSMISSION USAGE
Engine
Axle (RPO-Ratio)
Transmission
3.4L, V6 (VIN S)
GUS 3.23
M49-Borg-Warner Manual 5-speed

MDS-Hydra-Matic 4L60
5.7L, VS (VIN P)
GU2-2.73 or GUS-3.23
M49-Borg-Warner Manual 5-Speed

MDS-Hydra-Matic 4L60
PC0001-0A-F-RP
Figure 7 - Transmission Usage Chart

A PRIMARY LOCATION
B SECONDARY LOCATION
JULIAN DATE
(OR DAY OF THE YEAR)
HYDRA-MATIC 4L60
CALENDAR
YEAR
SOME MODELS
(3 = 1993)
SHIFT BUILT
A & B = FIRST SHIFT
C & H = SECOND SHIFT
PC0002-0A-F-RP
Figure 8 - Automatic Transmission Identification
OA6 GENERAL INFORMATION
1993 FIREBIRD
DIFFERENTIAL RATIOS AND TIRE

INFORMATION
For differential ratios, refer to SECTION 4B. For
tire information, refer to SECTION 3E.
GENERAL VEHICLE LIFTING AND JACKING

Figure 10
CAUTION: To help avoid personal
injury when a vehicle is on a hoist,
provide additional support for the vehi
cle at the opposite end from which
components are being removed. The
additional support will reduce the pos
sibility of the vehicle's falling off the
hoist. When removing major compo
nents of the vehicle while the vehicle is
on a hoist, the vehicle frame should be
chained to the hoist pads at the same
end as the removed components to
prevent tip-off. Failure to follow these
precautionary measures could result in
vehicle damage, serious personal in
jury or death.
NOTICE: When jacking or lifting a vehicle at the
frame side rails or other prescribed lift points, be
certain that lift pads do not contact the catalytic converter, brake pipes or fuel lines. Such contact may
result in damage or unsatisfactory vehicle performance.
When a vehicle is lifted with a vehicle jack or floor

jack, the wheels at the opposite end should be blocked.
Jackstands should be used to provide additional support.
Jackstands should be placed under either the frame, the
front suspension crossmember or the axle.
The vehicle should be on a clean, hard, level surface
before any lifting procedure begins. All lifting equipment
must meet weight standards and be in good working order.
Make sure all vehicle loads are equally distributed and
secure. If the only support for the vehicle is at the frame
side rails, make sure the lifting equipment does not put too
much stress on or weaken the frame side rails.
Recommended vehicle lifting points are shown in
Figures 9 and 10. If any other hoist methods are used, take
special care not to damage the fuel tank, filler neck,
exhaust system or underbody.
LOCK CYLINDER CODING
Key Identification and Usage

Figure 11
The lock cylinder keyway is designed so that other
model keys will not enter a current model lock cylinder.
Two noninterchangeable keys are used.
Square-headed key is used in the ignition lock cylinder.
Oval-headed key is used in all other lock cylinders.
Key identification is obtained from the four-character key code stamped on the knockout portion of the key
head and from an identification letter stamped on the key
shank. After the code number has been recorded by the
owner, the plugs should be knocked out of the key head.
Using these numbers, owners of key-cutting equipment
can determine the lock combination by consulting a code
list available from equipment suppliers. If the key code
numbers are not available from records or from the
knockout plug, the lock combination (tumbler numbers
and position) can be determined by laying the key on the
diagram (Figure 11 ). For information on the squareheaded ignition key and lock cylinder, refer to SECTION
9D.
Cutting Keys
Figure 11
1. Determine special code from the code list or key
code diagram.
2. Cut a blank key to proper level for each of six tumbler positions or according to directions supplied by
the key-cutting equipment manufacturer.
3. Check key operation in lock cylinder.
Replacement Lock Cylinders
Figure 12
A
B
C
D
SIX-SPEED
FIVE-SPEED
PRIMARY LOCATION
SECONDARY LOCATION
PC0003-0A-F-RP
Figure 9 - Manual Transmission Identification
Lock cylinders (3) are available from service parts

warehouses completely coded and with a new key. The
new lock cylinder (3) has a locking bar staked in place.
Tumblers (1) and springs are also available and must be
assembled into the lock cylinder (3) according to the key
code.
1993 FIREBIRD
A USING FRAME CONTACT HOIST REARWARD OF

FRONT TIRE
B USING FRAME CONTACT HOIST FORWARD OF
REAR TIRE
C USING SUSPENSION CONTACT HOIST UNDER FRONT
LOWER CONTROL ARM ASSEMBLY
D USING SUSPENSION CONTACT HOIST LIFTING ON REAR
AXLE ASSEMBLY
PC0004-0AF-RP
Figure 1O- Vehicle Lifting Points
8[iJ
1993 FIREBIRD
'
'-J
MARK OF EXCELLENCE
111111
....
123456
1 2 3 4 5
B
A POSITION
B LEVELS
PC4011-0AB-RP
A STAKE POINTS FOR RETAINER

2 CYLINDER HEAD, LOCK
5 RETAINER, SPRING
Figure 11 - Key Code Diagram
PC6006-0A-D-RP
Figure 13 - Installing Spring Retainer
~5
3
1
1
2
3
4
TUMBLER
CYLINDER HEAD, LOCK
CYLINDER, LOCK
SIDE BAR
~v
PC6005-0A-D-RP
Figure 12 - Lock Cylinder Components
Assembling and Coding Lock Cylinders
1
2
4
5
6
TUMBLER
CYLINDER HEAD, LOCK
SIDE BAR
RETAINER, SPRING
SPRING, TUMBLER
PC6007-0AD-RP
Figure 14 - Installing Tumblers
All Lock Cylinders Except Rear Stowage

Compartment
Figures 11 through 14
Tumblers (1) for all locks are shaped exactly alike,
with the exception of the notch position on one side. As
the key is inserted in the lock cylinder (3), tumblers (1) are
lowered to the correct height so that notches on each tumbler ( 1) are at the same level. When the notches on all six
tumblers line up, the side bar (4) is pushed into the
notches by two small springs. This allows the lock cylinder (3) to turn in its bore. Five types of tumblers (1) are
used to make the various lock combinations. Each tumbler
(1) is coded according to a number, one through five,
stamped on its side.
l+!+I Assemble
1. Determine tumbler numbers and arrangement.
With the numerical key code, use code list provided by the key cutting equipment supplier.
B. Start with position number one. Find and

record the lowest level (tumbler number)
that is visible. Repeat for each of the
remaining five positions.
2. Tumblers ( 1) in their proper slots in the order called
for by the code (Figure 12).
Start with position number one, nearest open
end or lock cylinder head (2).
3. Tumblers (1) by pulling side bar (4) out with fingers.
4. One tumbler spring (6) above each tumbler (1).
5. Spring retainer (5) so that end prongs slide into slots
at each end of lock cylinder (3).
Press spring retainer (5) down (Figure 13).
6. Insert key into lock cylinder (3) to check for proper
installation.
Without the numerical key code or without the

code list, refer to Figure 11.
Side bar (4) will drop down if tumblers ( l) are

installed properly. If incorrectly assembled,
take apart and assemble correctly.
A. Lay key on the key code diagram. Be sure

key is outlined by the diagram.
NOTICE: Use leather or wood at each vise jaw to

prevent damage to the cylinder.
1993 FIREBIRD
7. Remove key and secure lock cylinder (3) in a vise
with spring retainer (5) exposed.
A. Stake spring retainer (5) securely in place at
each end. Use a suitable staking tool and stake
cylinder metal over the spring retainer (5).
B. Black lock cylinders should be lubricated with
Multi-Purpose Lubricant (GM P/N 12345120
or equivalent) or light machine oil. All other
lock cylinders should be lubricated with a general purpose silicone lubricant.
Rear Stowage Compartment Lock Cylinder

Figures 12, 14 and 15
A lock cylinder with snap-in tumblers ( 1) is used for
the rear stowage compartment lock. The lock cylinder has
four or five tumbler positions. The number one or two
position (closest to the lock cylinder head (2)) is a brass
retainer tumbler. The two through five positions or three
through five positions are standard tumbler positions
depending upon cylinder type. Therefore, only the last
four or five tumbler combinations are required.
l+!+I Assemble
1. Determine tumbler numbers and arrangement as
previously described and install tumblers (1).

2. After installation, tap tumblers ( 1) flush with the
cylinder.
METRIC FASTENERS
Figure 16
NOTICE: When fasteners are removed, always
reinstall them at the same location from which they
were removed. If a fastener needs to be replaced, use
the correct part number fastener for that application.
If the correct part number fastener is not available, a
fastener of equal size and strength (or stronger) may
be used. Fasteners that are not reused, and those
requiring thread locking compound will be called
out. The correct torque value must be used when
installing fasteners that require it. If the above
conditions are not followed, parts or system damage

could result.
Many fasteners are metric. Metric fasteners may be
close in dimension to well-known customary fasteners in
the inch system. Replacement fasteners must be the correct nominal diameter, thread pitch and strength.
Original equipment metric fasteners, except for
exposed bumper bolts and other beauty bolts and cross-recess head screws, have numbers on their heads that identify them as metric. Cross-recess head screws can be
identified by a Posidriv or a Type lA cross-recess. Either
type of cross-recess screwdriver can be used to remove
Posidriv recess head screws, but Type lA will perform
better.
NOTICE: Most metric fasteners have a blue color
coating. This coating should not be used to positively identify fasteners because not all metric fasteners are color-coated. Damage to the fastener or
part could result if a customary fastener is incorrectly used to replace a metric fastener.
Metric and customary thread notations differ
slightly. For example, the thread major diameter of a
1/4-20 bolt/screw is 1/4 inch, and the bolt/screw has 20
threads per inch. The thread major diameter of an M6.0xl
bolt/screw is 6.0 mm, and the bolt/screw has 1 mm
between threads.
FASTENER STRENGTH IDENTIFICATION

Figure 17
Most commonly used metric fastener strength property classes are 9.8 and 10.9. The class identification is
embossed on the head of each bolt/screw. Customary fastener strength property classes range from grade 2 to 8.
Radial lines are embossed on the head of each bolt/screw
to identify the strength class. Some metric nuts are
marked with strength identification numbers on the nut
face (Figure 17).
When replacing fasteners, be careful to use bolts/
screws and nuts of a strength class equal to, or higher than,
the original fasteners (the same number marking or
higher). Also select replacement fasteners of the correct
size. Correct replacement bolts/screws and nuts are available through General Motors Service Parts Operation
(GMSPO).
Many metric fasteners available in the aftermarket
parts channels were designed to metric standards of countries other than the United States. The fasteners may have
different strength or thread pitch and may not have the
numbered head marking system. The metric fasteners
used on GM products are designed to new international
standards that might not be used by some nondomestic
bolt/screw and nut suppliers.
PREVAILING TORQUE FASTENERS
WOODEN BLOCK
KC00&0-101-B-RP
Figure 15 - Locking Tumblers in Place
Figures 18 and 19
A prevailing torque nut is designed to develop an
interference between the nut and bolt/screw threads. This
interference is usually created by distortion of the top of
an all-metal nut or by a nylon patch in the threads in the
middle of a hex flat. In other cases, a nylon insert may be
used (Figure 18).
1993 FIREBIRD
METRIC
CUSTOMARY
1/4
THREAD MAJOR
DIAMETER IN INCHES
M6.0
20
NUMBER OF THREADS
PER INCH
THREAD MAJOR DIAMETER

IN MILLIMETERS
1
DISTANCE BETWEEN
THREADS IN MILLIMETERS
I
THREAD PITCH
PC40160AB-RP
Figure 16 - Thread Notation
GRADE 2
(GM 260-M)
GRADE 5
(GM 280-M)
GRADE 7
(GM 290-M)
GRADES
(GM 300-M)
CUSTOMARY (INCH) BOLTS/SCREWS - IDENTIFICATION MARKS CORRESPOND TO

BOLT/SCREW STRENGTH - INCREASING NUMBERS REPRESENT INCREASING STRENGTH.
NUT STRENGTH
IDENTIFICATION
METRIC BOLTS/SCREWS - IDENTIFICATION CLASS NUMBERS CORRESPOND TO BOLT/SCREW

STRENGTH- INCREASING NUMBERS REPRESENTINCREASING STRENGTH.
PC6006-0ADRP
Figure 17 - Fastener Strength Markings
A prevailing torque bolt/screw is designed to

develop an interference between the bolt/screw and nut
threads or between the bolt/screw and tapped hole threads.
This interference is created by distorting some of the
threads or by using a nylon patch or adhesive (Figure 18).
Rusty or damaged bolts/screws and nuts should be
replaced with new parts of the same strength class or
higher. Clean, unrusted bolts/screws and nuts can be
reused. Be sure to use the following recommendations:
1. Clean dirt and other foreign material from nut or
bolt/screw.
2. Inspect nut or bolt/screw for cracks, elongation or
other signs of abuse or overtightening.
If nut or bolt/screw is worn in any way, replace
with a nut or bolt/screw of the same strength

class or higher.
3. Assemble the parts and hand-start nut or bolt/screw.
4. Check that nut or bolt/screw develops the proper
torque before it seats (Figure 19).
If nut or bolt/screw fails to develop torque cor-
rectly, replace with a nut or bolt/screw of the

same strength class or higher.
5. Tighten fastener to the torque specified in the
appropriate installation procedure in this manual.
1993 FIREBIRD
DECIMAL AND METRIC EQUIVALENTS
CENTER
LOCK
TOP
LOCK
NYLON
PATCH
a a
DRY
ADHESIVE
CO~TING
THREAD
PROFILE
DEFORMED
NYLON
WASHER
INSERT
NYLON
INSERT
NYLON
STRIP
OUT OF
ROUND
THREAD
AREA
520012-0A
Figure 18 - Prevailing Torque Nuts and Bolts/Screws
ENGLISH-METRIC CONVERSIONS
Figure20
To convert customary units to metric units, multiply
the customary units by the conversion factor shown in
Figure 20. To convert metric units to customary units,
divide the metric units by the conversion factor shown in
Figure 20.
FASTENER
TORQUE
TYPE
UNITS
Nuts and All
Nm
Metal Bolts/Screws
Lb. In.
Adhesive or Nylon
Nm
Coated Bolts/Screws
Lb. In.
FASTENER
TORQUE
TYPE
UNITS
Figure 21
Inch-to-millimeter decimal equivalents are shown in
Figure 21.
STANDARD NOMENCLATURE FOR

ELECTRICAL/ELECTRONIC COMPONENTS
AND SYSTEMS
Figures 22 and 23
Starting with the 1993 model, General Motors will
be complying with the Society of Automotive Engineers
(SAE) Recommended Practice J1930. J1930, an industry~ide standa~d that. was. adopted into government regulations, reqmres identical nomenclature for certain
electrical/electronic components and systems that have
the san.1e .function. The standard is also being applied to
abbreviat10ns and acronyms and is being used in all 1993
GM service publications.
To make this standard work, some names and

abbreviations are being replaced with those recommended
by the SAE Standard. Figures 22 and 23 are a listing of
former GM names and abbreviations beside the new
J1930 name and abbreviations.
METRIC-SIZE FASTENERS
6.3
10
12
14
16
20
0.4
4
0.4
4
0.8
7
1.4
12
2.2
19
3.0
27
4.2
37
7.0
62
0.4
4
0.4
4
0.6
5
1.2
11
1.6
14
2.4
21
3.4
30
5.6
50
.250
.312
.375
.437
.500
.562
.625
.750
1.8
16
2.4
21
3.2
28
4.2
37
6.2
55
1.4
12
1.8
16
2.6
23
3.4
30
5.2
49
INCH-SIZE FASTENERS
Nm
Lb. In.
0.4
4
0.6
5
1.4
12
Adhesive Nylon
Nm
Coated Bolts/Screws
Lb. In.
0.4
4
0.6
5
1.0
9
Nuts and All

Metal Bolts/Screws
PC60090A-D-RP
Figure 19 - Prevailing Torque Fastener Specifications
1993 FIREBIRD
TEMPERATURE
To convert Fahrenheit temperature
to Celsius temperature, use formula:
C = 5/9 (F-32)
To convert Celsius temperature

to Fahrenheit temperature, use formula:
F = 9 /5 C + 32
LC1005-0A-F-RP
Figure 20 - English-Metric Conversion Chart
1993 FIREBIRD
DECIMAL AND METRIC EQUIVALENTS

Decimal
Metric
In.
MM.
1/64
.015625
.39688
1/32
.79375
3/64
.03125
.046875
1/16
.0625
5/64
3/32
Fractions
33/64
17/32
Decimal
Metric
In.
MM.
.515625
13.09687
.53125 ....
13.49375
...
13.89062
14.28750
14.68437
.546875
1.58750
35/64
9/16
.078125
1.98437
37/64
....
.578125 ...
7/64
.09375
.109375
2.38125
2.77812
19/32
39/64
.59375 ....
.609375 ...
15.08125
15.47812
1/8
.125
3.1750
5/8
9/64
5/32
.140625
41/64
21/32
15.87500
16.27187
.15625
3.57187
3.96875
.625 .....
.640625 ...
.65625 ....
16.66875
11/64
.171875
4.36562
43/64
17.06562
4.76250
11/16
...
.6875 . ...
.703125 . ..
3/16
1.19062
Fractions
.....
......
.....
.1875
.5625
.671875
.....
17.46250
13/64
.203125
5.15937
45/64
7/32
.21875
5.55625
23/32
.71875 ....
18.25625
15/64
1/4
.234375
5.95312
.734375
...
18.65312
6.35000
47/64
3/4
.....
19.05000
17/64
.265625
6.74687
49/64
.765625
...
19.44687
9/32
19/64
.28125
7.14375
25/32
.78125 ....
19.84375
.296875
7.54062
51/64
20.24062
7.93750
13/16
.250
......
.750
17.85937
5/16
21/64
.3125
.328125
8.33437
53/64
...
.8125 . ...
.828125 ...
11/32
.34375
8.73125
27/32
.84375 ....
21.03437
21.43125
23/64
.359375
9.12812
55/64
.859375 ...
21.82812
9.52500
9.92187
7/8
22.22500
57/64
.....
.890625 ...
10.31875
29/32
59/64
3/8
25/64
13/32
27/64
.....
.... ..
.375
.390625
.40625
.421875
7/16
29/64
15/32
.4375 .....
.453125
10.71562
11.11250
11.50937
.46875
11.90625
31/64
1/2
.484375
12.30312
.500
......
12.70000
.796875
.875
.90625 ....
.921875 ...
15/16
61/64
31/32
63/64
1
.....
.9375 . ...
.953125 ...
.96875 ....
.984375 . ..
1.00
20.63750
22.62187
23.01875
23.41562
23.81250
24.20937
24.60625
25.00312
25.40000
520014-0A
Figure 21 - Inch-to-Millimeter Decimal Equivalents
Former GM Name
1993 FIREBIRD
New SAE Name Term
Absolute Pressure Sensor Aps -APS

Air Cleaner Assembly
Air Cleaner Filter Element
Air Injection Reaction System - A.I.R. System
Assembly Line Communication Link -ALCL
Assembly Line Data Link -ALDL
Manifold Absolute Pressure Sensor - MAP Sensor

Air Cleaner -ACL
Air Cleaner Filter -ACL Filter
Secondary Air Injection System -AIR System
Data Link Connector - DLC
Data Link Connector - DLC
Barometric Pressure Sensor - BARO Sensor

BCM-PCM Data Problem
Barometric Pressure Sensor - BARO Sensor

BCM-PCM Data Link
Calibration Pack - CAL-PAK
Electronically Erasable Programmable Read Only

Memory - EEPROM
Erasable Programmable Read Only Memory - EPROM
Programmable Read Only Memory - PROM
Camshaft Position Sensor - CMP Sensor
Evaporator Emission Canister Purge - EVAP
Canister Purge
Oxidation Catalytic Converter - OC
Three Way+ Oxidation Catalytic Converter - TWC + OC
Three Way Catalytic Converter - TWC
Warm Up Oxidation Catalytic Converter - WU-OC
Warm Up Three Way Catalytic Converter - WU-TWC
Malfunction Indicator Lamp - MIL
Diagnostic Trouble Code - DTC
Engine Control Module - ECM
Electronic Ignition - El
Evaporative Emission Canister Purge - EVAP
Canister P\Jrge
Engine Coolant Temperature Sensor - ECT Sensor
Engine Coolant Temperature Switch - ECT Switch

Camshaft Sensor
Canister Purge - CP
Catalytic Converter - Cat. Conv.
Check Engine Indicator
Code
Computer Command Control - CCC
Computer Controlled Coil Ignition - C31
Controlled Canister Purge - CCP
Coolant Temperature Sensor - CTS
Coolant Temperature Switch - CTS
Detonation Sensor
Diagnostic Circuit Check
Digital Electronic Fuel Injection - DEFI
Digital Electronic Fuel Injection - DEFI
Digital Fuel Injection - DFI
Digital Fuel Injection - DFI
Direct Ignition System - DIS
Distributor HEI Module
Distributorless Ignition System - DIS
Dual Bed Monolith - DBM
Dual Bed Monolith - DBM
Electronic Air Control - EAC
Electronic Air Switching - EAS
Electronic Control Module - ECM
Electronic Fuel Injection - EFI
Electronic Spark Control Circuit - ESC Circuit
Electronic Spark Control System - ESC System
Knock Sensor - KS
On-Board Diagnostic System Check - OBD System
Check
Multiport Fuel Injection - MFI
Sequential Multiport Fuel Injection - SFI
Sequential Multi port Fuel Injection - SFI
Electronic Ignition System - El System
Distributor Ignition Control Module - DI Control
Module
Electronic Ignition System - El System
Oxidation Catalytic Converter - OC
Three Way Catalytic Converter-TWC
Secondary Air Injection Bypass Valve - AIR
Bypass Valve
Secondary Air Injection Switching Valve - AIR
Switching Valve
Engine Control Module - ECM
Sequential Multi port Fuel Injection - SFI
Throttle Body Fuel Injection - TBI
Knock Sensor Circuit- KS Circuit
Knock Sensor System - KS System
PC601 OOA-D-RP
Figure 22 - Standard Nomenclature for Electrical/Electronic Components and Systems (1 of 2)
1993 FIREBIRD
Former GM Name
Electronic Spark Timing - EST
Electronic Spark Timing Circuit - EST Circuit
Electronic Vacuum Regulator Valve - EVRV
Engine Calibration Unit - ECU

Evaporative Emission Control System - EECS
Exhaust Gas Recirculation(fhermostatic Vacuum
Switch - EGR(fVS
New SAE Name Term

Ignition Control - IC
Ignition Control Circuit - IC Circuit
Exhaust Gas Recirculation Electronic Vacuum
Regulator Solenoid Valve - EGR Electronic
Vacuum Regulator Solenoid Valve
Evaporative Emission System - EVAP System
Exhaust Gas Recirculation Thermal Vacuum
Valve - EGR TVV
Fuel CAL-PAK Missing
Programmable Read Only Memory Missing PROM Missing
High Energy Ignition - HEI
Distributor Ignition - DI
Lean Exhaust
Lean Exhaust
Lean Heated Oxygen Sensor Signal - Lean H02 S

Lean Oxygen Sensor Signal - Lean 0 2 S Signal
Manifold Air Temperature Sensor- MAT Sensor

MEM-CAL Error
Memory and Calibration Unit - MEM-CAL

Memory and Calibration Unit - MEM-CAL
Multi-Port Fuel Injection - MPFI
Intake Air Temperature Sensor - IAT Sensor

Erasable Programmable Read Only - Only Memory
Error - EPROM Error
Programmable Read Only Memory Error - PROM
Error
Erasable Programmable Read Only Memory - EPROM
Oxygen Sensor - 0 2
Oxygen Sensor - 0 2
Heated Oxygen Sensor - H02 S

Oxygen Sensor - 0 2 S
Park/Neutral Switch - P/N Switch

Port Fuel Injection - PFI
Pulse Air Injection System - PAIR
Park/Neutral Position Switch - PNP Switch

Pulsed Secondary Air Injection System - PAIR System
Revolutions Per Minute - rpm

Rich Exhaust
Rich Exhaust
Engine Speed - RPM

Rich Heated Oxygen Sensor Signal - Rich H02 S Signal
Rich Oxygen Sensor Signal - Rich 0 2 S Signal
"Scan" Data
Service Engine Soon Indicator - SES Indicator
Scan Tool Data - ST Data

Malfunction Indicator Lamp - MIL
Thermal Vacuum Switch - TVS

Thermostatic Air Cleaner -TAC
Throttle Body Injection - TBI
Throttle Position Sensor - TPS
Throttle Position Switch - TPS
Throttle Switch
Throttle Switch
Tuned Port Injection - TPI
Thermal Vacuum Valve - TVV

Air Cleaner -ACL
Throttle Body Fuel Injection - TBI
Throttle Position Sensor - TP Sensor
Closed Throttle Position Switch - CTP Switch
Closed Throttle Position Switch - CTP Switch
Wide Open Throttle Switch - WOT Switch
Viscous Converter Clutch - VCC
Torque Converter Clutch - TCC
MEM-CAL Error
PC6012-0A-D-RP
Figure 23 - Standard Nomenclature for Electrical/Electronic Components and Systems (2 of 2)
1993 FIREBIRD
ABBREVIATIONS
The following abbreviations may appear in this manual.
A
A-6
NC
A/F
ABDC
ABS
ac
AC
ACC
ACL
AID
ADP
AIR
Al
ALC
AM/FM
amp
API-GL
APT
ARS
ASM
ASR
A/T
ATC
ATDC
ATS
Auto
avg
AWD
AWG
Axial 6 Cylinder A/C Compressor

Air Conditioning
Air/Fuel (A/F Ratio)
After Bottom Dead Center
(Body) Acrylonitrile-Butadiene-Styrene
(Brake) Antilock Brake System
alternating current
A GM Division
Automatic Climate Control
Air Cleaner
Analog-to-Digital
Air Deflector Valve
Air Injection Reaction
Aluminum
Automatic Level Control
Amplitude Modulation/
Frequency Modulation
amperes
American Petroleum Institute-Gear
Lubricant
Adjustable Part Throttle
Automatic Restraint System
Assembly
Acceleration Slip Regulation
Automatic Transmission
Automatic Temperature Control
After Top Dead Center
Air Temperature Sensor
Automatic
average
All Wheel Drive
American Wire Gage
B
BARO
batt
BAT+
BBDC
BCM
BHP
BLM
BP
BTDC
Btu
Barometric Absolute Pressure Sensor

battery
battery positive
Before Bottom Dead Center
Body Computer Module
Brake Horsepower
Block Learn Multiplier
Back Pressure
Before Top Dead Center
British thermal units
c
c
CLOOP
C-4
CAD
CAM
CCM
CCOT
Cd
CD
CDRV
CEAB
CEMF
cfm
cg
CHA
CID
ckt
CLCC
CLTBI
cm 3
CMP
co
COA
CPA
CPS
CPU
CRT
CRTC
CTP
CTS
cu ft or ft 3
cu in or in3
CV
CYL
D
dB
dBA
DBB
de
DEC
DERM
DI
dia
DIFF
DLC
DRL
DTC
DVM
decibels
decibels on A-weighted scale
Dual Bed Bead
direct current
Digital Electronic Controller
Diagnostic Energy Reserve Module
Distributor Ignition
diameter
Differential
Data Link Connector
Daytime Running Lamps
Diagnostic Trouble Code
Digital Volt Meter (10 Megaohm)
E/P
EBTCM
Celsius
Closed Loop
Computer Controlled Catalytic
Converter
Computer Aided Design
Computer Aided Manufacturing
Central Control Module

Cycling Clutch Orifice Tube
Cadmium
Compact Disc
Crankcase Depression Regulator Valve
Cold Engine Airbleed
Counter Electromotive Force
cubic feet per minute
center of gravity
Carburetor Hot Air
Cubic Inch Displacement
circuit
Closed Loop Carburetor Control
Closed Loop Throttle Body Injection
cubic centimeter
Camshaft Position
Carbon monoxide
Carburetor Outside Air
Connector Position Assurance
Central Power Supply
Central Processing Unit
Cathode Ray Tube
Cathode Ray Tube Controller
Closed Throttle Position
Cold Trapped Spark
cubic foot, or feet
cubic inch, or inches
constant velocity
Cylinder(s)
ECC
ECI
ECM
ECS
ECT
Ethylene/Propylene
Electronic Brake Traction Control
Module
Electronic Climate Control
Extended Compressor at Idle
Engine Control Module
Emission Control System
Engine Coolant Temperature
GENERAL INFORMATION OA 17
1993 FIREBIRD
EDES
EEC
EEPROM
BES
EE-VIR
EEVIR
EFE
EGR
EGR TVV
EI
ELC
EMF
EOS
EPR
EPROM
ETC
ETCC
ETR
EVAP
Electric Divert/Electric Air Switching

Valve
Evaporative Emission Control
Electronically Eraseable Programmable
Read Only Memory
Evaporative Emission System
Evacuator Equalized
Values-In-Receiver
Evaporator Equalized Values in
Receiver
Early Fuel Evaporation
Exhaust Gas Recirculation
Exhaust Gas Recirculation Thermal
Vacuum Valve
Electronic Ignition
Electronic Level Control
Electromotive Force
Exhaust Oxygen Sensor
Exhaust Pressure Regulator
Erasable Programmable Read Only
Memory
Electronic Temperature Control
Electronic Touch Comfort Control,
Electronic Touch Climate Control
Electronically Tuned Receiver
Evaporator Emission
hex
Hg
Hi Alt
HIC
H02S
hp
HPCA
HPL
HPV
HVAC
HVACM
HVM
Hz
hexagon
mercury
High Altitude
High Idle Compensator
Heated Oxygen Sensor
horsepower
Housing Pressure Cold Advance
High Pressure Liquid
High Pressure Vapor
Heater-Vent-Air Conditioning
Heater-Vent-Air Conditioning Module
Heater Vent Module
hertz
I
IAC
IAT
IC
ID
IDI
1gn
ILC
INJ
I/P
ISC
Idle Air Control

Intake Air Temperature
Integrated Circuit, Ignition Control
Inside Diameter, identification
Integrated Direct Ignition
ignition
Idle Load Compensator
Injection
Instrument Panel
Idle Speed Control
K
F
FDC
FEC
Fed
FI
FICO
4WAL
ft
FWD
Fahrenheit
Fuel Data Center
Fuel Evaporator Control
Federal (all states except California)
Fuel Injection
Fast Idle Control Diaphragm
Four Wheel Antilock
foot, feet
Front Wheel Drive, Four Wheel Drive
km/1
kPa
KS
kv
Keep Alive Memory

kilogram
kilohertz
kilometers per hour
kilometers per liter
kilopascals
Knock Sensor
kilovolts
G
g
GA
gal
gas
GCW
Gen
GM
gnd
KAM
kg
kHz
km/h
gravitational acceleration, grams

gage
gallon
gasoline
Gross Combination Weight
Generator
General Motors
ground
1
L4
L6
lb. ft.
lb. in
LCD
LF
LH
LR
lt
liter
Four Cylinder, In-Line Engine
Six Cylinder, In-Line Engine
pound feet (torque)
pound inch (torque)
Liquid Crystal Display
Left Front
Left Hand
Left Rear
left
H
M
H20
H/CMPR
HC
HD
HDC
water
High Compression
hydrocarbons
Heavy Duty
Heavy Duty Cooling
M/C
MAP
Man
MAP
Mixture Control
Mass Air Flow
Manual
Manifold Absolute Pressure

Max
MDP
MFI
mgd
mi
MIL
mm
ml
mm
MFI
mpg
mph
ms
Mff
MV
mv
MVS
MVSS
Maximum
Manifold Differential Pressure
Multi-port Fuel Injection
million gallons per day
miles
Malfunction Indicator Lamp
minimum
milliliters
millimeters
Multiport Fuel Injection
miles per gallon
miles per hour
millisecond
Manual Transmission
megavolt
millivolt
Metering Valve Sensor
Motor Vehicle Safety Standards
N
NC
NEG
NEU
NLGI
Ni
Nm
NO
N03
NPTC
NPTF
oc
OD
OEM
ORC
oz
Normally Closed
Negative
neutral
National Lubricating Grease Institute
nickel
Newton-meters (torque)
Normally Open
oxides of nitrogen
National Pipe Thread Coarse
National Pipe Thread Fine
Oxygen Sensor
On-Board Diagnostic
Oxidation Catalytic Converter
Outside Diameter
Original Equipment Manufacturer
Oxidizing Reducer Converter
ounce(s)
PIN
PA
PAIR
PBT
PC
PCV
PE
PECV
PEDESV
PF
PM
PNP
POA
POLYE
POLYP
POLYP
POLYU
POS
POT
POM
pp
PPE
ppm
PROM
PS
PSPS
psi
psia
psig
pt
PTO
PUR
PWM
polypropylene
polyurethane
Positive
Potentiometer (Variable Resistor)
polyoxymethylene
polypropylene
polyphenylene ether
parts per million
Programmable Read Only Memory
Power Steering
Power Steering Pressure Switch
pounds per square inch
pounds per square inch absolute
pounds per square inch gage
pint
Power Take Off
polyurethane (thermoset)
Pulse Width Modulated
0
02S
OBD
1993 FIREBIRD
Part Number
polyamide
Pulsed Air Injection Reaction
polybutylene terephthalate
polycarbonate
Positive Crankcase Ventilation
polyethylene
Power Enrichment Control Valve
Pressure Operated Electric Divert/Air
Electric Switching Valve
phenol-formaldehyde
Permanent Magnet (Generator)
Park/Neutral Position
Pilot Operated Absolute Valve
polyethylene
polyfoam
qt
quart(s)
R-4
R-12
R-134A
RAM
RAP
Ref
RF
RFI
RH
RIM
RPM
RPO
RR
RRIM
rt
RTV
RVB
RVR
RWAL
RWD
Radial Four Cylinder Air Compressor

Refrigerant-12
Refrigerant-R 134A
Random Access Memory
Retained Accessory Power
Reference
Right Front
Radio Frequency Interference
Right Hand
Reaction Injection Molded Urethane
Engine Speed
Regular Production Option
Right Rear
Reinforced Reaction Injection Molded
Urethane
right
Room Temperature Vulcanizing (sealer)
Rear Vacuum Brake
Response Vacuum Reducer
Rear Wheel Antilock
Rear Wheel Drive
s
SAE
sec
SEO
SES
SFI
SI
Si
SIR
SLA
SMC
S02
sq ft, ft 2
Society of Automotive Engineers

second(s)
Special Equipment Option
Service Engine Soon
Sequential Multiport Fuel Injection
System International
silicone
short/long arm
Sheet Molded Compound
sulfur dioxide
square foot(feet)
GENERAL INFORMATION OA19
1993 FIREBIRD
sq in, in2
ST
square inch(es)
Scan Tool
T
TBI
TCC
TCCTVMV
TDC
TEMP
THM
THERMAC
TP
TPE
TPO
TPU
TRANS
TRC
Turbo
TV
TVBV
TVRS
TVV
TWC
TWC-OC
TXV
Throttle Body Fuel Injection

Torque Converter Clutch, Transmission
Converter Clutch
Torque Converter Clutch Trim Vacuum
Modulator Valve
Top Dead Center
Temperature
Turbo Hydra-Matic
Thermostatic Air Cleaner
Throttle Position
Thermo Plastic Elastomer
Thermo Plastic Olefin
Polyurethane (thermoplastic)
Transmission
Throttle Return Control
Turbocharger
Throttle Valve
Turbocharger Vacuum Bleed Valve
Television and Radio Suppression
Thermal Vacuum Valve
Three Way Catalytic Converter
Three Way Oxidation Catalytic
Converter
Thermal Expansion Valve
V4
V6
V8
Vac
VATS
VDV
vel
VF
VIN
VIR
VLV
VLVMV
VMV
VRV
vss
w
WIS
WOT
wss
WU-OC
WU-TWC
Windshield
Wide Open Throttle
Wheel Speed Sensor
Warm Up Oxidation Catalytic
Converter
Warm Up Three Way Catalytic
Converter
x
X-valve
Four Cylinder Engine

Six Cylinder Engine
Eight Cylinder Engine
vacuum
Vehicle Anti-Theft System
Vacuum Delay Valve
velocity
Vacuum Fluorescent
Valves In Receiver
Vacuum Limiting Valve
Vacuum Limiting Vacuum Modulator
Valve
Vacuum Modulator Valve
Vacuum Reducer Valve
Vehicle Speed Sensor
expansion valve
U-joint
universal joint
yd
yard
v
volt(s), voltage
REPLACEMENT LABELS
Replacement labels are available through GM Service Parts Operations for the following:
Vehicle Emission Control Information (Exhaust
Emission Tune Up)
Spare Wheel Caution
Superlight Shock Absorber Information
Jacking
Spare Tire Storage
Serpentine Belt Routing (when it is a separate label)
Engine Fan Caution
IRS/SIR Service Caution
Odometer Reset
These and other labels will be found in the Standard
Parts Catalog.
Zn
zinc
The Vehicle Certification Label, Tire Pressure Placard and Service Parts Identification Label are NOT available as service parts.
SERVICE PARTS IDENTIFICATION LABEL

Figure24
The Service Parts Identification Label has been
developed and placed on the vehicle to aid service and
parts personnel in identifying parts and options originally
installed on the vehicle. The label is attached to the inside
of the console door.
OPTION CODES
Vehicle options are identified on the Service Parts
Identification Label by option codes. Option codes are
three-digit combinations of letters and numbers. They
identify equipment installed on the vehicle, and trim and
paint colors. Refer to "Option and Process Codes" in this
section.
1993 FIREBIRD
1aw,11am1:1omu1@i1,,1,-11~,.,1;1@1~,w:,-
,G4BN5371 NIN400001
AG9 A90 848 C09
AUE SMD 884 C49
A01
BSI 893 C60
A42 832 896 DF3
A52 833 CD4 DIC
D33
864
D85
E5Z
E6E
E9Z LC3 NSI

F40 MX1 MNI
GU2 M31 POI
K19 NA5 DJIN
K64
TR9
TT5
T63
T87
UF7
UN3
UN9
UPS
U26
U29
U35
U76
U81
VE5
N30
YT9
ZX5
41A
42L
420
. 4BN69
42T 609
6PA
608 BXY
601 9XY
lWA8358 SILVER LOWER
INA7686 DARK BLUE UPPER

PAINT ALANTIC PROMOTION TINO TONE
/BASE GOAT - CLEAR GOAT
INA-
L8318
A8320
-f-h'
F
A VEHICLE IDENTIFICATION NUMBER (VIN)

B ENGINEERING MODEL NUMBER (CAR DIVISION,
CARLINE AND BODY STYLE)
C SPECIAL ORDER PAINTS
D TYPE OF PAINT TECHNOLOGY
E LOWER EXTERIOR PAINT COLOR
U8318
F
G
J
K
UPPER EXTERIOR PAINT COLOR

ACCENT COLOR
INTERIOR TRIM AND DECOR LEVEL
OPTION CONTENT
PC1004-0ABRP
Figure 24 - Service Parts Identification Label
1993 FIREBIRD
OPTION AND PROCESS CODES

AAA
ACM
AC3
AH3
AK5
AN4
AQ9
AR9
AUO
AU3
AX4
A26
A31
A90
BF9
B3E
B35
B84
CCl
C41
C49
C60
DD9
DE4
DG7
D3W
D35
DSR
DSX
D81
DSM
D8N
D9Z
EXP
E7Z
FE2
F41
GU2
GUS
G80
G92
ILD
IL2
IPB
J41
J65
KC4
KG7
KOS
K34
Standard Equipment
Lead Units
Adjuster, 6-Way Power, Driver Seat
Adjuster, 4-Way Manual, Driver Seat
Restraint System Front Seat, Inflatable,
Driver and Passenger
Restraint Provisions, Child
Seat, Passenger and Driver, Recline
Seat, Passenger and Driver, Recline
(European Style)
Lock Control, Remote Entry
Lock, Side Door, Electric
Restraint Conversion Seat, Manual,
European
Window, European Glazing, All
Window, Power Operated, Side
Lock, Rear Compartment Lid, Remote
Control, Electric
Delete Floor Mats
Noise Control
Floor Mats, Rear, Carpeted Insert
Ornamentation Exterior Molding, Body
Side
Roof Hatch, Removable Glass Panels
HVAC System, Heater
Defogger, Rear Window Electric
HVAC System, Air Conditioner,
Manual Control
Mirror, Outside, LH and RH, Remote
Control, Electric, Breakaway, Painted
Sunshade, Removable Hatch Roof
Mirror, Outside LH & RH, Remote
Control, Electric, Painted
Speedometer Driven Gear
Mirror, Outside LH Remote, RH
Manual, Painted
Sensor, Vehicle Speed
Export I.E.S.
Sensor, Vehicle Speed - Delete
Suspension System, Ride Handling
Suspensions System, Firm Ride
Handling, Front and Rear
Axle, Rear 2. 73 Ratio
Axle, Rear 3.23 Ratio
Axle, Rear Positraction (Limited Slip)
Axle, Rear Ratio Performance
Trim, Interior Design
Brake System, Power, Front Disc, Rear
Drum, Cast Iron
Brake System, Power, Front and Rear
Disc
Cooling System, Engine Oil
Generator, 125 Amp
Heater, Engine Block
Cruise Control, Automatic Electronic
K68
LTl
L32
MD8
MM5
MN6
MXO
M28
M29
M49
NA5
NB2
NB8
NC3
NP5
N36
PW7
QA7
QII
QLC
QMT
QPE
STE
TR7
TUB
T2H
T2J
T39
T61
T79
T84
T90
T96
UB3
UK2
UK3
UL2
UM6
UQO
UW2
Generator, 105 AmpEXP

Engine, 5.7L (V8) MFI
Engine, 3.4L (V6) MFI
Transmission - Automatic, 4-Speed,
THM700R4
Transmission - 5-Speed Manual
(Merchandising Option)
Transmission - 6-Speed Manual
Transmission - Automatic 0/D
Transmission, Manual, 6-Speed, Borg
Warner, 85 mm, 3.36 1st, 1.35 3rd
Warner, 85 mm 2.97 1st, 1.44 3r
Warner, 77 mm, 3.75 1st, .76 5th, 0/D
Emission System - Federal
Requirements.
Emission System - California
Requirements
Emission System - Override California
Tailpipe Modifications
Steering Wheel, Leather Wrapped
Steering Wheel, 4 Spokes, Sport
Wheel, 16 x 8, Aluminum Styled
Wheel, 16 x 7.5, Aluminum
Tire, P215/60R16 BW RIPE ST TL
AL394H
Tire, P245/50ZR16/N BL RIPE ST TL
HW4
Tire, P235/55R16/N BL RIPE ST TL
AL2
Tire, P215/60R16/N BL RIPE ST TL
AL2
Plant Code-St. Therese, PQ, GM of
Canada
Headlamps, Automatic Control
Leveling System
Lamp, Interior, Stop, High Level Delete
Ornamentation, Exterior, Export
Ornamentation, Interior, Export
Lamp Turn Signal, Auxiliary
Lighting - Daytime Running
Lamps, Fog, Rear
Headlamps, RH Rule Of Road
Lamp Signaling and Marker, Export
Lamp, Fog
Instrument Cluster, Oil, Coolant,
Temperature, Volts, Trip Odometer,
Tachometer
Lever, Directional Signal, Multifunction
Electronic System Accessory Control
European Radio Frequencies
Radio, AM/FM Stereo, Seek/Scan, Auto
Reverse Cassette, Clock, ETR
Speaker System 4, Dual Front Door
Mounted, Standard Range Quarter/Shelf
Speaker System 10, Quad Front Door
Mounted, Dual Rear Sail Panel,
Amplifier

UXI
UIA
NB2
U18
U19
U73
U75
VAS
VCI
VC3
VC4
VG8
VHS
VK3
VL5
VP6
VR7
V73
V76
V78
WS9
WX7
W66
YA7
YE8
YF5
Y81
Y83
Z49
05P
ISA
ISB
ISC
ISD
ISE
ISF
IOQ
IOU
12B
12D
121
122
14B
14D
141
142
17P
40P
41Q
41U
48Q
48U
Radio, AM Stereo and FM Stereo,

Seek/Scan, Auto Reverse Music Search
Cassette, Equalizer, Clock, ETR
Radio, AM Stereo and FM Stereo,
Seek/Scan, Compact Disc, Equalizer,
Clock, ETR
Speedometer Instrument, Kilometers
Speedometer Instrument, Kilometers
and Miles, Kilometer Odometer
Antenna, Fixed
Antenna, Power
Language Label, English
Label, Price/Fuel Economy
Label, Price/Fuel Economy, US
Territories
Label, Price/Fuel Economy, Puerto Rico
Vehicle Buyer Notice Label
Plate, Vehicle Identification
License Plate, Front Mounting Package
License Plate, Front Mounting Package,
Export
Noise Control
Hook Tow, Rear, Second
Vehicle Statement, US/Canada
Hook, Tow
Vehicle Statement - Delete
Model Conversion Formula
Wiring Provisions
Merchandised Package - Formula
Emission Test - California Assembly
Line
Vehicle Test, Engineering
Emission Certification - California
Merchandised Package - Firebird
Merchandised Package - Trans Am
Canadian Modifications
Wheel Color Argent
Package Option 01
Package Option 02
Package Option 03
Package Option 04
Package Option 05
Package Option 06
Molding Color - Arctic White
Primary Color - Exterior, Arctic White
Trim Combination - Cloth, Graphite
Trim Combination - Cloth, Graphite
Interior Trim - Graphite
Trim Combination - Leather, Graphite
Trim Combination - Cloth, Lt. Gray
Trim Combination - Cloth, Lt. Gray
Interior Trim - Lt. Gray
Trim Combination - Leather, Lt. Gray
Wheel Color - Silver
Wheel Color - White
Molding Color - Black
Primary Color - Exterior, Black
Molding Color- Dark Yellow Green
Metallic
Primary Color- Exterior, Dark Yellow
Green Metallic
1993 FIREBIRD
54Q
54U
6DN
6DR
6DS
6DT
6DV
6DX
6DY
6EA
6EB
6ED
6EG
6EH
6EJ
6EK
6EL
6EV
6EW
6EX
6EY
6GA
6GB
6GD
6GE
6GG
6GH
6GJ
6GK
64B
64D
641
642
Molding Color- Sunfire Yellow

Primary Color - Exterior, Sunfire
Yellow
Suspension - Computer Selected.
FRT,LH
Suspension - Computer Selected,
FRT,LH
FRT,LH
FRT,LH
FRT,LH
FRT,LH
FRT,LH
FRT,LH
FRT,LH
FRT,LH
Suspensioni - Computer Selected,
FRT,LH
FRT,LH
FRT,LH
FRT,LH
FRT,LH
FRT,LH
FRT,LH
FRT,LH
FRT,LH
FRT,LH
FRT,LH
FRT,LH
FRT,LH
FRT,LH
FRT,LH
FRT,LH
FRT,LH
Trim Combination - Cloth, Lt. Beige
Trim Combination-Cloth, Lt. Beige
Interior Trim - Lt. Beige
Trim Combination - Leather, Lt. Beige
1993 FIREBIRD
7DN
7DR
7DS
7DT
7DV
7DX
7DY
7EA
7EB
7ED
7EG
7EH
7EJ
7EK
7EL
7EV
7EW
7EX
7EY
7GA
7GB
7GD
7GE
7GG
7GH
7GJ
7GK
Suspension FRT,RH
Suspension FRT,RH
Suspension FRT,RH
Suspension FRT,RH
Suspension FRT,RH
Suspension FRT,RH
Suspension FRT,RH
Suspension FRT,RH
Suspension FRT,RH
Suspension FRT,RH
Suspension FRT,RH
Suspension FRT,RH
Suspension FRT,RH
Suspension FRT,RH
Suspension FRT,RH
Suspension FRT,RH
Suspension FRT,RH
Suspension FRT,RH
Suspension FRT,RH
Suspension FRT,RH
Suspension FRT,RH
Suspension FRT,RH
Suspension FRT,RH
Suspension FRT,RH
Suspension FRT,RH
Suspension FRT,RH
Suspension FRT,RH
Computer Selected,
71Q
71U
Computer Selected,
8TA
Computer Selected,
71U
Computer Selected,
8TA
Computer Selected,
8TB
Computer Selected,
8TC
Computer Selected,
8TD
Computer Selected,
8TF
Computer Selected,
8TH
Computer Selected,
8TJ
Computer Selected,
8TK
Computer Selected,
8TM
Computer Selected,
80Q
Computer Selected,
80U
Computer Selected,
81Q
Computer Selected,
81U
Computer Selected,
9TA
Computer Selected,
9TB
Computer Selected,
9TC
Computer Selected,
9TD
Computer Selected,
9TF
Computer Selected,
9TH
Computer Selected,
9TJ
Computer Selected,
9TK
Computer Selected,
9TM
Computer Selected,
Computer Selected,
91Q
91U
Molding Color - Red

Primary Color - Exterior, Medium
Patriot Red
RR,LH
RR,LH
RR,LH
RR,LH
RR,LH
RR,LH
RR,LH
RR,LH
RR,LH
Molding Color - Medium Quasar Blue
Metallic
Primary Color - Exterior, Medium
Quasar Blue Metallic
Molding Color - Bright Red
Primary Color - Exterior, Bright Red
RR,RH
Suspension - Computer Selected
RR,RH
RR,RH
RR,RH
RR,RH
RR,RH
RR,RH
RR,RH
RR,RH
RR,RH
RR,RH
RR,RH
Molding Color - Purple Pearl
Primary Color - Exterior, Purple Pearl
MAINTENANCE AND LUBRICATION 081
SECTION OB
MAINTENANCE AND LUBRICATION

CONTENTS
Scheduled Maintenance Service . . . . . . . . . . . . . .
Normal Vehicle Use . . . . . . . . . . . . . . . . . . . . . .
Schedule I . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Schedule II . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Explanation of Scheduled
Maintenance Services . . . . . . . . . . . . . . . . . .
Engine Oil and Oil Filter Change . . . . . . . . .
Chassis Lubrication . . . . . . . . . . . . . . . . . . . .
Tire and Wheel Assembly Inspection
and Rotation . . . . . . . . . . . . . . . . . . . . . . .
Serpentine Drive Belt Inspection . . . . . . . . . .
Cooling System Service . . . . . . . . . . . . . . . . .
Front Wheel Bearing Assembly Repack . . . .
Transmission Service . . . . . . . . . . . . . . . . . . .
Spark Plug Assembly Replacement . . . . . . . .
Spark Plug Wire Assembly Inspection . . . . .
OB-1
OB-1
OB-1
OB-1
OB-1
OB-1
OB-4
OB-4
OB-4
OB-4
OB-4
OB-4
OB-5
OB-5
SCHEDULED MAINTENANCE
SERVICE
Air Cleaner and Crankcase Ventilation

Filter Replacement ...................
Fuel Tank, Cap and Lines Inspection .......
Owner Inspection and Services . . . . . . . . . . . . . . .
While Operating the Vehicle . . . . . . . . . . . . . . .
At Each Fuel Fill . . . . . . . . . . . . . . . . . . . . . . . .
At Least Monthly . . . . . . . . . . . . . . . . . . . . . . . .
At Least Twice a Year . . . . . . . . . . . . . . . . . . . .
At Least Annually . . . . . . . . . . . . . . . . . . . . . . .
Each Time Oil Is Changed . . . . . . . . . . . . . . . . .
Recommended Fluids and Lubricants . . . . . . . . . .
Maintenance Items . . . . . . . . . . . . . . . . . . . . . . . . .
Approximate Fluid Capacities . . . . . . . . . . . . . . . .
Wheel Nut Torque . . . . . . . . . . . . . . . . . . . . . . . . .
Rear Axle Filler Plug Torque . . . . . . . . . . . . . . . . .
Belt Tension Specifications . . . . . . . . . . . . . . . . . .
Tire Pressure Specifications . . . . . . . . . . . . . . . . . .
OB-5
OB-5
OB-5
OB-5
OB-5
OB-6
OB-6
OB-6
OB-7
OB-8
OB-8
OB-9
OB-9
OB-9
OB-9
OB-9
Towing a trailer. Do not exceed trailering limits. See

the Owner's Manual for details.
Operating in dusty areas.
NORMAL VEHICLE USE

The maintenance instructions contained in the Maintenance Schedule are based on the assumption that the
vehicle will be used as designed:
The vehicle is used in delivery service, police, taxi

or other commercial applications.
SCHEDULE II
To carry passengers and cargo within the limitation

indicated on the Tire Placard located on the edge of
the driver's door.
Figure2
On reasonable road surfaces within legal operating

limits.
Follow Schedule II ONLY if none of the driving

conditions specified in Schedule I apply.
On unleaded gasoline.
SCHEDULE I
Figure 1
Follow Schedule I if the vehicle is operated under
one or more of the following conditions:
When most trips are less than 6 km (4 miles).
Operating when outside temperatures remain below
freezing and when most trips are less than 16 km
(10 miles).
When most trips include extended idling and/or
frequent low-speed operation as in stop-and-go
traffic.
EXPLANATION OF SCHEDULED
MAINTENANCE SERVICES
Refer to Figures 1 and 2 for the schedules of time
and/or mileage intervals. The following text and
illustrations (Figures 3 and 4) give details of the required
maintenance services.
Engine Oil and Oil Filter Change

ALWAYS USE SG QUALITY ENERGY CONSERVING II OILS OF PROPER VISCOSITY. Oils
designated "SG" will protect better than SF/CC or
SF/CD oils. The "SG" designation may be shown alone
or in combination with other designations such as SG/CC,
SG/CD, etc.
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SCHEDULED MAINTENANCE SERVICES

SCHEDULE I
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Follow Schedule I if your vehicle is MAINLY driven under one or more of the following conditions:
When most trips are less than 6 kilometers (4 miles) .
When most trips are less than 16 kilometers (10 miles) and outside temperatures remain below freezing.
When most trips include extended idling and/or frequent low-speed operation as in stop-and-go traffic.t
Towing a trailer.**
Operating in dusty areas.
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ITEM
NO.
TO BE SERVICED
WHEN TO PERFORM
Kilometers (Miles) or Months,
Whichever Occurs First
KILOMETERS (000)
MILES (000)
I.
Engine Oil & Oil Filter Change*
Every 5 000 km (3,000 mi.) or 3 mos.
2.
Chassis Lubrication
Every other oil change
3.
Tire & Wheel Assembly Inspection & Rotation
At IO 000 km (6,000 mi.) and then every
<ii
::::,
4.
Serpentine Drive Belt Inspection
Ill
::::,
5.
Cooling System Service*
6.
Transmission Service
C)
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7.
Spark Plug Assembly Replacement*
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CD
25 000 km (15,000 mi.)
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8.
Spark Plug Wire Assembly lnspection*t
co
9.
Air Cleaner & Crankcase Ventilation Filter Replacement*
10.
*
*
**
Fuel Tank, Cap & Lines lnspection*t
Every 50 000 km (30,000 mi.)
20
12
5
3
IO
15
25
15
30
18
35
21
40
24
45
27
50
30
55
33
60
65
36
39
70
42
75
45
80
48
Note: Schedule I should also be followed if the vehicle is used for delivery service, police, taxi or other commercial applications.
The U.S. Environmental Protection Agency has determined that the failure to perform this maintenance Item will not nullify the emission warranty or limit recall liability prior to the completion of
vehicle useful life. General Motors, however, urges that all recommended maintenance services be performed at the indicated intervals and the maintenance be recorded in section E of the owner's
maintenance schedule.
An Emission Control Service
Do not exceed trailering limits. See your Owner's Manual for details.
PC2001-0B-F-RP
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The services shown in this schedule up tp 80 000 km (48,000 miles)

are to be performed after 80 000 km (48,000 miles) at the same intervals.
See explanation for service interval.
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Every 50 000 km (30,000 mi.) or 24 mos.
SCHEDULED MAINTENANCE SERVICES

SCHEDULE II
Follow schedule II ONLY if none of the driving conditions specified in Schedule I apply.
WHEN TO PERFORM
Kilometers (Miles) or Months,
Whichever Occurs First
TO BE SERVICED
ITEM
NO.
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MILES (000)
Engine Oil Change*
Every 12 500 km (7,500 mi.) or 12 mos.
Oil Filter Change*
At first and then every other oil change
2.
Chassis Lubrication
Every 12 500 km (7,500 mi.) or 12 mos.
3.
Tire & Wheel Assembly Inspection & Rotation
At 12 500 km (7,500 mi.) and then

every 25 OOOkm (15,000mi.)
4.
5.
Cooling System Service*
6.
7.
Spark Plug Assembly Replacement*
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8.
Spark Plug Wire Assembly Inspection*:!:
9.
Air Cleaner & Crankcasse Ventilation Filter Replacement*
10.
Every 50 000 km (30,000 mi.) or 24 mos.
12.. 5
25
37.5
50
62.5
75
7.5
15
22.5
30
37.5
45
See explanation for service interval.
()
::,-
KILOMETERS (000)
The services shown in this schedule up to 75 000 km (45,000 miles)

are to be performed after 75 000 km (45,000 miles) at the same intervals.
Fuel Tank Cap & Lines Inspection*:!:
Every 50 000 km (30,000 mi.)
:s:::
:j: The U.S. Environmental Protection Agency has determined that the failure to perform this maintenance item will not nullify the emission warranty or limit recall liability prior to the completion of vehicle useful life.
;!:::
General Motors, however, urges that all recommended maintenance services be performed at the indicated intervals and the maintenance be recorded in section E of the owner's maintenance schedule.
An Emission Control Service.
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PC2002-0BF-RP
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08-4 MAINTENANCE AND LUBRICATION
Tire and Wheel Assembly Inspection and

Rotation
HOT WEATHER
Figure 4
Check tires for abnormal wear or damage. To
equalize wear and obtain maximum tire life, rotate as
shown in Figure 4.
If the vehicle is equipped with P245/50ZR16 size
tires, special rotation provisions must be followed
because the tires are directional. See Figure 4 for the
recommended rotation. Directional tires have color-coded
arrows on both sides of the sidewall pointing in the
direction the tires must roll for the correct performance.
Follow these steps:
1. Dismount tires from the wheel assemblies.
IAI IOW-]O
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,11,11110
COLD W(ATHH
NC4001-08-B-RP
Figure 3 - Engine Oil Viscosity Recommendation
2. Rotate the tires (not the wheel assemblies) in the

rotation pattern shown in Figure 4. Make sure the
tires rotate in the direction of the arrows as they are
remounted on the wheel assemblies.
3. Rebalance the tires.
4. Replace wheel assemblies in their original position.
Engine oil viscosity (thickness) has an effect on fuel

economy and cold-weather operation (starting and oil
flow). Lower viscosity engine oils can provide better fuel
economy and cold-weather performance; however, higher
temperature weather conditions require higher viscosity
engine oils for satisfactory lubrication. Using oils of any
viscosity other than those viscosities recommended
could result in engine damage.
When choosing an oil, consider the range of
temperatures the vehicle will be operated in before the
next oil change. Then, select the recommended oil
viscosity from the chart (Figure 3).
Chassis Lubrication
Lubricate transmission shift linkage.
If irregular or premature wear exists, check wheel

alignment. Also, check for damaged wheel assemblies.
Do not include the compact spare tire in rotation.
While the tire and wheel assemblies are removed,

perform the brake systems inspection specified. Refer to
"Each Time Oil Is Changed" in this section.

Inspect drive belt for cracks or fraying. If sections
of the drive belt are missing, the drive belt should be
replaced. Refer to SECTION 6A2A or SECTION 6A3A.
Cooling System Service
Lubricate all grease fittings in the suspension and

steering linkage as described by the following.
Drain, flush and refill system with new or approved

recycled coolant. Refer to "Recommended Fluids and
Lubricants" in this section, or SECTION 6B.
Lubricating Joints that Have Grease Fittings
Front Wheel Bearing Assembly Repack
Wipe off all dirt from the grease fitting before

lubricating the joint. Use a low-pressure grease gun on all
joints to prevent seal damage.
The front wheel bearing assemblies are not serviceable. Complete replacement of the front wheel bearing
assembly hubs is required.
Steering tie rod assemblies - Apply grease until

grease flows out between seal and tie rod end housing.
Lower ball stud assemblies - Lower ball stud assemblies should not be lubricated unless their temperature
is -l2C (10F) or warmer. During cold weather, the ball
stud assembly should be allowed to warm up as necessary
before being lubricated. Apply grease slowly while
watching grease seal. Apply grease until the seal expands
or grease is seen bleeding from the seal. If the seal
expands but no grease is seen, do not apply any more
grease. Allow time for the grease to bleed from the seal.
All joints - Wipe off all excess grease.
For the manual transmission, fluid does not require

changing.
For the automatic transmission, change both the
fluid and the filter every 25 000 km ( 15,000 miles) if the
vehicle is mainly driven under one or more of these
conditions:
In heavy city traffic where outside temperature
regularly reaches 32C (90F) or higher.
On hilly or mountainous terrain.
MAINTENANCE AND LUBRICATION 08-5
....
Air Cleaner and Crankcase Ventilation Filter

Replacement
l-
Replace the air cleaner filter every 50 000 km

(30,000 miles) or 36 months, whichever comes first.
Replace more often under dusty conditions.
a:
LL
Fuel Tank, Cap and Lines Inspection

Inspect fuel tank, cap and lines for damage or leaks.
Inspect fuel cap gasket for an even filler neck imprint or
any damage. Inspect injection assemblies. Replace parts
as needed. Periodic replacement of the fuel filter is not
required.
A
OWNER INSPECTION AND SERVICES
....
Listed below are vehicle inspections and services

that should be made by either the owner or a qualified
technician at the frequencies indicated to help ensure
proper safety, emission systems performance and
dependability of the vehicle. Whenever repairs are
necessary, have them completed at once.
Any safety related or emissions related components
that could have been damaged in an accident should be
inspected and all needed repairs should be performed
before operating the vehicle.
l-
a:
LL
ll lt
WHILE OPERATING THE VEHICLE
Automatic transmission shift indicator operation
A NORMAL FOUR-WHEEL ROTATION PATTERN FOR TIRES

DESIGNED TO ROLL IN EITHER DIRECTION
B SPECIAL FOUR-WHEEL ROTATION PATTERN FOR
DIRECTIONAL TIRES DESIGNED TO ROLL MAINLY IN ONE
DIRECTION
IMPORTANT: DO NOT INCLUDE COMPACT SPARE TIRE
ASSEMBLY IN ROTATION.
PC0004-3E-F-RP
Figure 4 - Recommended Tire Rotation Pattern
Frequent trailer pulling. Do not exceed trailering

limits. See the Owner's Manual or 1993 dealership
trailering brochure for details.
Used for delivery service, police, taxi or other
commercial applications.
If the vehicle is not used under any of these
conditions, change both the fluid and filter (or service the
screen) every 160 000 km (100,000 miles). Refer to
SECTION 7A for more information.
- Make sure the indicator points to the gear chosen.

Horn assembly operation - Blow the horn
assembly occasionally to make sure it works. Check all
button locations.
Brake system operation - Be alert to abnormal
sounds, increased brake pedal travel or repeated pulling to
one side when braking. Also, if the brake warning lamp or
antilock brake system warning lamp goes on or flashes,
something may be wrong with part of the brake system.
Exhaust system operation - Be alert to any
changes in the sound of the system or any smell of fumes.
These are signs the system may be leaking or overheating.
Have it inspected and repaired at once.
Tires, wheel assemblies and alignment operation
Replace spark plug assemblies every 50 000 km

(30,000 miles) on the 3.4L L32 engine and every 160 000
km (100,000 miles) on the 5.7L LTl engine with type
listed. Refer to "Maintenance Items" in this section.
- Be alert to a vibration of the steering wheel or seat at

normal highway speeds. This may mean a wheel assembly
balance is needed. Also, a pull right or left on a straight
and level road may show the need for a tire pressure
adjustment or a wheel alignment.
Steering system operation - Be alert to changes in
steering action. An inspection is needed when the steering
wheel is harder to turn, or has too much free play, or if
unusual sounds are noted when turning or parking.
Headlamp capsule assembly aim - Take note of
the light pattern occasionally. If beams seem to be
improperly aimed, headlamps should be checked and
adjusted as necessary.
Spark Plug Wire Assembly Inspection
AT EACH FUEL FILL
Clean wire assemblies and inspect for burns, cracks

or other damage. Check the wire assembly boot fit at the
ignition distributor assembly and/or ignition distributor
coil assembly, and at the spark plug assemblies. Replace
the wire assemblies as needed.
A fluid loss in any system (except windshield

washer) may indicate a problem. Have the system
inspected and repaired at once.
Engine oil level - Check level and add oil if
Spark Plug Assembly Replacement
necessary. The best time to check the engine oil level is

wh~n the oil is warm. After stopping the engine with the
vehicle on a level surface, wait a few minutes for the oil to
drain back to the oil pan. On the 5.7L LTl engine, pinch
the end of the oil level indicator (dipstick) and pull the
indicator out. The oil level indicator will be wiped clean
as it is removed. On the 3.4L L32 engine, pull out the oil
level indicator and wipe it clean. Push the oil level inciator
back down all the way. Pull out the oil level indicator
(without pinching the holder on the 5.7L LTl), keeping
the tip down, and look at the oil level on it.
Add oil, if needed, to keep the oil level above the
"ADD" line and within the cross-hatched operating range
are~. Avoid overfilling the engine since this may cause
engme damage. Push the oil level indicator back down all
the way after taking the reading.
If you check the oil level when the oil is cold, do not
run the engine first. The cold oil will not drain back to the
pan fast enough to give a true oil level.
Engine coolant level and condition - Check engine
coolant level in the coolant reservoir and add coolant if
necessary.
Windshield washer solvent level - Check washer

solvent level in reservoir and add solvent if necessary.
Hood lat~h operation - When opening the hood,
note the operat10n of the secondary latch. It should keep
!he hood from opening all the way when the primary latch
1s released. Make sure that the hood closes firmly.
AT LEAST MONTHLY
Tire and wheel assembly inspection and pressure
check - Check tires for abnormal wear or damage. Also
check for damaged wheel assemblies. Pressure should be
checked when tires are "cold." Maintain pressures as
show~ in "Tire Pressure Specifications" in this section, or
the Tire Placard on the driver's door.
Lamp operation - Check operation of the license
plate lamp, sidemarker lamps, headlamps (including high
~earns)? fog lamps, par~ing lamps, taillamps, brake lamps
(mcludmg the center high-mounted stoplamp), turn signals, backup lamps, hazard warning flasher and interior
lamps.
Fluid leak check - Periodically inspect the surface
beneath the vehicle for water, oil, fuel or other fluids after
the vehicle has been parked for a while. Water dripping
from the air conditioning system after use is normal. The
cause of fuel leaks or fumes should be found and
corrected at once.
AT LEAST TWICE A YEAR

Power steering system reservoir level - Check and
keep at proper level. Refer to SECTION 3B1B.
Brake master cylinder reservoir level - Check
fluid. Refer to SECTION SA. Keep fluid at proper level.
A low fluid level can indicate worn disc brake pads which
may need to be serviced. Also refer to SECTION 5El.
Weatherstrip lubrication - Clean the surface and
then apply a thin film of silicone grease, GM PIN
12345579 or equivalent, using a clean cloth.
AT LEAST ANNUALLY
CAUTION: Before checking the holding
ability of the parking brake and automatic transmission park mechanism,
park on a fairly steep hill with enough
room for movement in the downhill
direction. To reduce the risk of personal injury or property damage, be prepared to apply the regular brakes
promptly if the vehicle begins to move.
Parking brake and transmission park mechanism operation - To check the parking brake, with the
engine running, parking brake set and transmission in
"NEUTRAL," slowly remove foot pressure from the
regular brake pedal until the vehicle is held only by the
parking brake.
'
To check the automatic transmission park mechanism holding ability, release all brakes after shifting the
transmission to "PARK."
CAUTION: Before performing the following transmission neutral start

switch check, be sure to have enough
room around the vehicle. Then, firmly
apply both the parking brake and the
regular brakes. Do not use the accelerator pedal. If the engine starts, be ready
to turn off the ignition promptly. Take
these precautions because the vehicle
could move without warning and possibly cause personal injury or property
damage.
Transmission neutral start switch operation - On
automatic transmission vehicles, try to start the engine in
each gear. The starter should crank only in "PARK" or
"NEUTRAL."
On manual transmission vehicles, place the shift
lever in "NEUTRAL," push the clutch pedal halfway and
try to start. The starter should crank only when the clutch
pedal is fully depressed.
Steering column lock operation - While parked,
try to turn the key to "LOCK" in each gear range. On
vehicles with automatic transmissions, the key should
turn to "LOCK" only when the gear selector is in
"PARK." On vehicles with key release button, try to turn
to "LOCK" without depressing the button. The key
should turn to "LOCK" only with the key button
depressed.
Seatback latch operation - Be sure seatbacks latch
on those vehicles with folding seats using mechanical
latches.
Lap and shoulder belts condition and operation Inspect belt system, including webbing, buckles, latch
plates, retractor, guide loops and anchors.
Movable head restraint operation - Make sure
movable head restraints stay in the desired position.
Seatback recliner operation (if equipped) - Make
sure the recliner is holding by pushing and pulling on the
top of the seatback while it is reclined.
MAINTENANCE AND LUBRICATION 08-7

Spare tire and jack storage - Be alert to rattles in
rear of the vehicle. Make sure the spare tire, all jacking
equipment and any covers or doors are securely stowed at
all times. Oil the jack screw mechanism after each use.
Key lock service - Lubricate the key lock cylinder
(except instrument panel compartment lock).
Body lubrication service - Lubricate all body door
hinges, including the hood, fuel door and rear
compartment hinges and latches, the instrument panel
compartment door, and any folding seat hardware.
Lubricate all pivot points in the headlamp door
assembly, including the spring links for each door.
Underbody flushing - At least every spring, flush
from the underbody any corrosive materials used for ice
and snow removal and dust control. Use plain water. Take
care to thoroughly clean any areas where mud or other
debris can collect. Sediment packed in closed areas of the
vehicle should be loosened before being flushed.
Engine cooling system - Inspect coolant and freeze
protection. Keep coolant at the proper mixture for proper
freeze protection, corrosion inhibitor level and best
engine operating temperature. Inspect hoses and replace if
cracked, swollen or deteriorated. Clean outside of radiator
and air conditioning condenser. Wash filler cap and neck.
To help ensure proper operation, a pressure test of both the
cooling system and cap is also recommended.
EACH TIME OIL IS CHANGED

Automatic transmission fluid level - Maintain
level within operating range on the oil level indicator.
Refer to SECTION 7A.
Manual transmission - Check fluid level and add
as required. Refer to SECTION 7B.
Brake systems inspection - For convenience, the
following should be done when wheel assemblies are
removed for rotation: Inspect lines and hoses for proper
hookup, binding, leaks, cracks, chafing, etc. Inspect disc
brake pads for wear and rotors for surface condition. Also
inspect drum brake linings for wear and cracks. Inspect
other brake parts, including drums, wheel cylinders,

parking brake, etc., at the same time. The parking brake is
self-adjusting and no manual adjustment is required.
Inspect brakes more often if habit or conditions
result in frequent braking.
Steering and suspension inspection - Inspect front
and rear suspension and steering system for damaged,
loose or missing parts, signs of wear or lack of lubrication.
Inspect power steering lines and hoses for proper hookup,
binding, leaks, cracks, chafing, etc.
Exhaust system inspection - Inspect complete
system, including catalytic converter. Inspect body near
the exhaust system. Look for broken, damaged, missing
or out-of-position parts as well as open seams, holes,
loose connections and other conditions which could cause
a heat buildup in the floor pan or could let exhaust fumes
seep into the trunk or passenger compartment. Check heat
shields. Tighten connections or replace parts as necessary.
Throttle linkage inspection - Inspect for
interference, binding, and damaged or missing parts.
Serpentine drive belt - Inspect drive belt for
cracks, fraying, wear and proper tension. Drive belts
cannot be adjusted. Replace tensioner or drive
belt as needed. Refer to SECTION 6A2A or SECTION
6A3A.
Rear axle assembly - Check fluid level and add if
needed. To check or add fluid, hoist vehicle at suspension
contact points. Refer to SECTION OA. Keep vehicle
level. Clean dirt or foreign material from around filler
plug opening before removing the filler plug. Maintain
fluid level from flush with bottom of opening to no lower
than 6 mm (1/4 inch) below opening. Always replace
filler plug. Tighten to 35 Nm (26 lb. ft.).
If the vehicle is used to pull a trailer, change
lubricant every 12 500 km (7,500 miles) in either type
differential.
Limited slip differentials should have fluid drained
and refilled at the first 12 500 km (7,500 miles). Be sure to
add limited slip additive.
RECOMMENDED FLUIDS AND LUBRICANTS

Engine oil - GM Goodwrench motor oil or equivalent for API service SG of recommended viscosity.
Engine coolant - 50/50 mixture of water (preferably distilled) and good quality ethylene glycol base
antifreeze or approved recycled coolant conforming to GM Specification 1825M (GM PIN 1052753 or
equivalent).
Hydraulic brake system - Delco-Supreme 11 brake fluid (GM PIN 1052535) DOT-3 brake fluid.
Hydraulic clutch system - Hydraulic clutch fluid (GM PIN 12345347 or equivalent).
Power steering system - Power steering fluid meeting requirements of GM 9985010 (GM PIN
1050017, GM PIN 1052884 or equivalent). In cold climates use GM PIN 12345867, GM PIN 12345866
or equivalent. (System should be drained and refilled prior to using this fluid).
Automatic transmission - Dexron-IIE automatic transmission fluid (GM PIN 12345881 or equivalent).
Automatic transmission shift linkage - Engine oil. Clutch linkage pivot points - Engine oil.
Manual transmission-Dexron-IIE automatic transmission fluid (GM PIN 12345881 or equivalent).
Manual transmission shift linkage - Chassis lubricant meeting requirements of NLGI Grade 2,
Category LB or GC-LB (GM PIN 1052497).
Key lock cylinders (except instrument panel compartment lock) - Lubricate with Multi-Purpose
Lubricant (GM PIN 12345120 or equivalent) or synthetic SAE 5W-30 engine oil or silicone lubricant
(GM PIN 1052276 or 1052277). Do not use aerosols.
Weatherstrips - Dielectric silicone grease (GM PIN 12345579 or equivalent).
Chassis lubrication - Chassis lubricant meeting requirements of NLGI Grade 2, Category GC or GCLB (GM PIN 1051344 or equivalent).
Standard differential rear axle assembly - SAE 80W-90 GL-5 gear lubricant or axle lubricant (GM
PIN 1052271, GM PIN 1052272 or equivalent).
Limited slip differential rear axle assembly - All models require 118 ml (4 fl. oz.) of limited slip
differential additive lubricant (GM PIN 1052358 or equivalent) and axle lubricant (GM PIN 1052271,
GM PIN 1052272 or equivalent) or SAE 80W-90 GL-5 gear lubricant.
Windshield washer solvent - GM Optikleen Washer Solvent (GM PIN 1051515 or equivalent).
Hood latch assembly and pivots - Engine oil.
Hood latch assembly release pawl - Chassis lubricant meeting requirements of NLGI Grade 2,
Category LB or GC-LB (GM PIN 1052497).
Hood and door hinges, hatchback lid hinge and linkage. Headlamp door assemblies, if equipped.
Rear folding seat. Fuel door hinge. Rear compartment lid hinges. - Engine oil or Lubriplate lubricant (GM PIN 1050104).
MAINTENANCE ITEMS
Air Cleaner Filter
All VIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AC Type A1163C
Engine Oil Filter
3.4L (VIN S) ........................................................ AC Type PF47
5.7L (VIN P) ........................................................ AC Type PF25
Fuel Filter
All VIN ........................................................... AC Type GF578
PCV Valve
3.4L (VIN S) .................................................... AC Type CV789C
5.7L (VIN P) ..................................................... AC Type CV895C
Spark Plug Assemblies and Gap
3.4L (VIN S) .......................................... AC.R43TSK 1.14 mm (0.045")
5.7L (VIN P) .......................................... AC.R45LTSP 1.27 mm (0.050")
MAINTENANCE AND LUBRICATION 089
APPROXIMATE FLUID CAPACITIES

Air Conditioning
R-134A ........................................................... 0.91 kg (2.0 lb.)
Engine Crankcase
Without Filter Change (All VIN) ...................................... 3.8 liters (4.0 qt.)
With Filter Change
3.4L (VIN S) .................................................... 3.8 liters (4.0 qt.)
5.7L (VIN P) .................................................... 4.3 liters (4.5 qt.)
Fuel Tank ........................................................ 58.7 liters (15.5 gal.)
Transmission
Manual - Drain and Refill and Overhaul
Five-Speed ..................................................... 2.8 liters (5.9 pt.)
Six-Speed ...................................................... 3.8 liters (8.0 pt.)
Automatic (HYDRA-MATIC 4L60)
3.4L (VIN S) Drain & Refill ........................................ 4.7 liters (10.0 pt.)
3.4L (VIN S) Overhaul ............................................ 7.9 liters (16.7 pt.)
5.7L (VIN P) Drain and Refill ....................................... 4.7 liters (10.0 pt.)
5.7L (VIN P) Overhaul ............................................ 10.6 liters (22.4 pt.)
Cooling System
3.4L (VIN S)
With Automatic Transmission .................................... 11.6 liters (12.3 qt.)
With Manual Transmission ....................................... 11.8 liters (12.5 qt.)
5.7L (VIN P)
With Automatic Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14.3 liters (15.1 qt.)
With Manual Tranmission ........................................ 14.5 liters (15.3 qt.)
The capacities shown here are approximate. Add fluid as necessary to bring to appropriate level.
WHEEL NUT TORQUE

Wheel Nuts ...................................................... 140 Nm (100 lb. ft.)
REAR AXLE FILLER PLUG TORQUE

Filler Plug ......................................................... 35 Nm (26 lb. ft.)
BELT TENSION SPECIFICATIONS

Engines equipped with serpentine belts have an automatic tensioner. No adjustment of this belt is necessary.
TIRE PRESSURE SPECIFICATIONS

Compact Spare
..................................................... 420 kPa (60 psi)
Front and Rear-All
................................................. 210 kPa (30 psi)
HEATING AND AIR CONDITIONING 1-1
SECTION 1
HEATING AND AIR CONDITIONING

CONTENTS
Heater and Ventilation ................................................... Section IA
Heater, Ventilation and Air Conditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section 1B
Manual Control Air Conditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section 1B 1
HD6/HR6-HE Air Conditioning Compressor Service or Unit Repair .............. Section 102
HEATER AND VENTILATION 1A1
SECTION 1A
HEATER AND VENTILATION

NOTICE: When fasteners are removed, always reinstall them at the same location from which they were removed.
If a fastener needs to be replaced, use the correct part number fastener for that application. If the correct part
number fastener is not available, a fastener of equal size and strength (or stronger) may be used. Fasteners that are
not reused and those requiring thread locking compound will be called out. The correct torque value must be used
when installing fasteners that require it. If the above conditions are not followed, parts or system damage could
result.
CONTENTS
General Description ........................
Base Heater System . . . . . . . . . . . . . . . . . . . . . .
Control Assembly . . . . . . . . . . . . . . . . . . . . . . .
Temperature Control Knob ..............
Mode Control Knob . . . . . . . . . . . . . . . . . . . .
Blower Motor Assembly Speed Control
Knob ..............................
Air Distribution System ...................
Vacuum System . . . . . . . . . . . . . . . . . . . . . . .
Temperature Valve and Heater Core .......
Mode Valve Housing . . . . . . . . . . . . . . . . . . .
Air Outlets . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ventilation ...........................
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Functional Test . . . . . . . . . . . . . . . . . . . . . . . . . .
Heater Output Temperature Check ..........
Insufficient Heating or Defrosting ...........
High or Low Heater Control Effort ..........
Blower Motor Assembly Noise . . . . . . . . . . . . .
Excessive Heat . . . . . . . . . . . . . . . . . . . . . . . . . .
lA-1
lA-1
lA-1
lA-2
lA-2
lA-3
lA-5
lA-5
lA-5
lA-5
lA-5
lA-7
lA-7
lA-7
lA-7
lA-8
lA-8
lA-8
lA-8
GENERAL DESCRIPTION
BASE HEATER SYSTEM
Figures 1 through 4
The base heater system provides heating, ventilation, side window defogging and windshield defrosting.
Outside air is drawn from the plenum at the base of the
windshield assembly into the heater module assembly (1)
by the blower motor fan (18).
Within the heater module assembly (1), the air is
heated as required and then routed through ducts to the
proper outlets for discharge into the passenger compartment. A control assembly (2) in the instrument panel
assembly allows the operator to control blower motor
assembly speed, mode of operation and the temperature of
the air coming from the heater system.
The heater module assembly (1) contains components that heat the air flowing through it and direct the air
to the proper ducts and outlets. The heater module assembly (1) is a single unit, including the blower motor assembly (6), that is mounted to the rear surface of the dash front
panel in front of the instrument panel assembly.
Hot coolant from the engine's cooling system is
directed through the heater core (14) and returned to the
On-Vehicle Service ........................ lA-8

Replacement Procedures .................. lA-8
Control Assembly and Vacuum Selector
Valve and/or Blower Motor Assembly
Switch . . . . . . . . . . . . . . . . . . . . . . . . . . lA-8
Control Assembly Lamp Bulb ........... lA-14
Temperature Control Cable Assembly ..... lA-15
Blower Motor Resistor Assembly ........ lA-16
Blower Motor Assembly and Blower
Motor Fan ........................ lA-16
Vacuum Harness . . . . . . . . . . . . . . . . . . . . . . lA-17
Vacuum Tank ........................ lA-18
Vacuum Actuators .................... lA-18
Air Deflectors ....................... lA-18
Heater Hose Assembly and Heater
Hose Pipes ........................ lA-18
Heater Core ......................... lA-19
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . lA-22
Fastener Tightening Specifications . . . . . . . . . lA-22
Electrical Specifications ................. lA-22
cooling system when the engine is running. The heater

core ( 14) transfers heat from the coolant to the air passing
through the heater core fins. There is no hot water valve in
the heater system to prevent flow of coolant through the
heater core (14 ).
CONTROL ASSEMBLY
Figures 1 through 4
Three knobs in the instrument panel allow a front

seat occupant to operate the heating and ventilation. These
knobs are in the control assembly, in the center of the
instrument panel, just above the radio. To the left of the
blower motor speed control knob is the control button for
the electric rear window defogger, if equipped.
The controls are lit when the headlamps are on.
Electrical power is provided by the instrument panel lighting circuit. The control assembly lamp is in parallel with
the instrument cluster bulbs, the radio dial bulb and certain other interior illumination bulbs. Brightness of the
dial illumination is controlled by the dimmer control of
the headlamp switch. For electrical circuit diagrams and
more information, refer to SECTION 8A.
1A-2 HEATER AND VENTILATION
Mode Control Knob

3
The right knob, called the mode control knob, is a

rotary vacuum switch that regulates airflow from the outlets by routing engine vacuum to vacuum actuators at the
heater module assembly. The mode control knob also controls an electrical switch that supplies power to operate the
blower motor assembly for specific mode selections.
A choice of six operating modes can be selected by
turning the mode control knob in the control assembly.
From left to right, the six modes are "OFF," "....._,.;'' (vent),
~,.;" (bi-level), ':._)" (heater), "::_;'' (blend) and "@"
(defrost).
"OFF" Mode
13
1
2
3
4
5
6
7
8
9
10
11
12
13
MODULE ASSEMBLY, HEATER

CONTROL ASSEMBLY
VALVE, VENT MODE
VALVE, Bl-LEVEL MODE
CABLE ASSEMBLY, TEMPERATURE CONTROL
MOTOR ASSEMBLY, BLOWER
KNOB, MODE CONTROL
KNOB, TEMPERATURE CONTROL
KNOB, BLOWER MOTOR ASSEMBLY SPEED CONTROL
ACTUATOR, Bl-LEVEL MODE VALVE
ACTUATOR, DEFROSTER/HEATER VALVE
OUTLET, FLOOR AIR
HARNESS, VACUUM
When the mode control knob is in the "OFF" position, no electrical power is supplied to the blower motor
assembly. A limited flow of air, caused by movement of
the vehicle, may come from the defrost outlet and the
floor outlets. This is the only mode in which the blower
motor assembly will not operate.
~,.; " (Vent) Mode

With the mode control knob in the "~" position,
outside air is delivered through the instrument panel outlets to ventilate the vehicle. If preferred, the air may be
warmed by setting the temperature control knob to the
desired temperature.
PC0001-1A-F-RP
Figure 1 - Heater Module Assembly and Controls
Temperature Control Knob

The temperature control knob is the middle knob in
the control assembly. It regulates the temperature of the
air being discharged into the passenger compartment from
the heater or ventilation system. The temperature control
knob controls the position of a ''door'' called the temperature valve in the heater module assembly. The temperature
valve governs the relative amounts of heated and unheated air discharged from the heater system. Full warm,
full cool or any intermediate temperature mixture can be
selected by moving the knob to the right (red area) for
warm air and to the left (blue area) for cool air or anywhere in between.
~,.;" (Bi-level) Mode

With the mode control knob in the '~" position,
electrical power is supplied to the blower motor assembly.
Outside air is drawn in and heated (depending on the position of the temperature control knob). Then the airflow is
split between the instrument panel outlets and the floor
outlets. Blower motor assembly speed may be varied.
''.,,_;" (Heater) Mode

With the mode control knob in the "...)" position,
outside air is drawn into the vehicle, heated (depending on
the position of the temperature control knob) and directed
to the floor air outlets. A small amount of air is routed to
the windshield assembly through the defrost outlet.
Blower motor assembly speed may be varied as in
other operating modes.
7 KNOB, MODE CONTROL

8 KNOB, TEMPERATURE CONTROL
9 KNOB, BLOWER MOTOR ASSEMBLY SPEED CONTROL
PC2001-1A-F-RP
Figure 2 - Control Assembly
'
A OUTSIDE AIR
B PLENUM
CHEATED AIR
D UNHEATED AIR
E
F
G
H
TO INSTRUMENT PANEL OUTLETS

TO FLOOR OUTLETS
TO WINDSHIELD DEFROSTER OUTLETS
TO SIDE WINDOW DEFOGGER OUTLETS
1
3
4
6
14
15
16

VALVE, VENT MODE
CORE, HEATER
VALVE, DEFROSTER/HEATER
VALVE, TEMPERATURE
PC0002-1A-F-RP
Figure 3 - Heater Module Assembly Schematics
This mode is the normal selection for cold weather

operation unless the windshield assembly must be cleared
of heavy frost.
~;" (Blend) Mode
With the mode control knob in this position, outside
air is drawn into the vehicle, heated (depending on the
position of the temperature control knob) and split
between the defrost outlet and the floor air outlets.
'\mt" (Defrost) Mode

With the mode control knob in the "@" position,
outside air is drawn into the vehicle, heated (depending on
the position of the temperature control knob) and directed
to the defrost outlet. A small amount of air is routed to the
floor air outlets. Blower motor assembly speed may be
varied.
Side Window Defogging
In all modes except "OFF" and ",,.)" (vent), air is
supplied to the side window defrost outlets, located at the
end of the instrument panel upper trim pad assembly.
Blower Motor Assembly Speed Control Knob

With the ignition switch in the "RUN" position, the
blower motor assembly runs in all mode control knob
positions except "OFF." Blower motor assembly speed is
controlled by a four-position electrical blower switch at
the left side of the control assembly. The blower switch
provides a choice of low blower motor assembly speed,
two medium blower motor assembly speeds and a high

blower motor assembly speed.
The blower motor assembly circuit splits into two
parallel branches from the mode lever switch. One branch
goes to the blower switch in the control assembly and the
other branch goes directly to the blower motor resistor
assembly. When the blower switch is in "LOW," the
blower switch circuit is open. Current cannot flow
through the blower switch so it is conducted directly to the
resistor assembly by the other branch of the circuit. At the
resistor assembly, the current passes through all three
resistors and is reduced to provide the low blower motor
assembly speed.
When the blower switch is in either of the two medium speed positions, it closes to send current through
either two or one of the resistors in the resistor assembly.
Because the current follows the path of least resistance,
the circuit branch leading directly to all three resistors
becomes ineffective and the current bypasses either one or
two resistors, depending upon which medium speed position is selected. The reduced resistance increases current
flow and blower motor assembly speed. In "LOW" or
either of the two medium speed positions, current from
the resistor goes through the high blower relay to the
blower motor assembly.
When the blower switch is in the "HIGH" position,
it routes current directly to the coil of the high blower
relay and from there to ground at the instrument panel
assembly through the instrument panel wiring harness.
When the coil is energized, it switches the relay so power
for the blower motor assembly is taken from a separate
17
11
10
15
A
A
B
C
D
E
F
G
H
COMPONENT LOCATIONS
"Bl-LEVEL" MODE AIRFLOW
"VENT" MODE AIRFLOW
"HEATER" MODE AIRFLOW
"DEFROST" MODE AIRFLOW
"BLEND" MODE AIRFLOW
OUTSIDE AIR
J TO FLOOR AIR OUTLET
K TO WINDSHIELD DEFROSTER NOZZLES
L
3
4
10
11
15
17
18
19
TO SIDE WINDOW DEFOGGER OUTLETS

VALVE, VENT MODE
VALVE, DEFROSTER/HEATER
HEATER ASSEMBLY
FAN, BLOWER MOTOR
ACTUATOR, VENT MODE VALVE
Figure 4 - Operating Mode Airflow Distribution
PC0003-1AF-RP
HEATER AND VENTILATION 1A-5

parallel circuit that is protected by a fusible link. This separate power circuit is "hot" at all times and has the capacity to handle the current demands of the blower motor
assembly at high speed.
chambers allows external torsion springs to center the

linkage. The center position of the defroster/heater valve
creates the blend mode.
The circuit to the blower motor assembly is completed to ground at the instrument panel assembly through
the instrument panel wiring harness. Refer to SECTION
8A.
Temperature Valve and Heater Core
AIR DISTRIBUTION SYSTEM

Air enters the heater module assembly where it is
heated as necessary before being sent to the proper outlets
for discharge into the passenger compartment. Within the
heater module, valves ("doors") guide the airflow in
response to the positions of the temperature control knob
and the mode control knob in the control assembly.
Vacuum System
Figure 5
All valves in the heater module assembly except the
temperature valve are controlled by engine vacuum drawn
from the vacuum tank in the engine compartment. The
vacuum is routed by a vacuum selector valve in the control assembly to spring-loaded vacuum actuators on the
heater module assembly. Vacuum stored in the vacuum
tank is prevented from bleeding back to its source during
conditions of low engine manifold vacuum (acceleration,
hard pulling, etc.) by a check valve in the vacuum line.
The vacuum selector valve in the control assembly is
controlled by the mode control knob. For each mode control knob position, the vacuum selector valve directs vacuum to specific hoses to overcome the force of the spring
within the appropriate vacuum actuators. The vacuum
selector valve also vents (to normal air pressure) the hoses
to each remaining vacuum actuator, allowing the actuator's external spring to expand. This results in the valves
being properly positioned for the selected operating
mode.
The bi-level and vent valves have two-position vacuum actuators. When vacuum is directed to either actuator's vacuum chamber, the vacuum pulls in a flexible
diaphragm that forms one wall of the chamber. This draws
a movable shaft attached to the diaphragm. The shaft is
linked to the corresponding valve, and it operates the
valve when vacuum is applied.
Figure 3
The temperature of the air discharged from the heater system is regulated by controlling the relative amounts
of warm and cool air that are mixed together downstream
from the heater core area. The part of the total airflow that
is allowed to pass through the heater core ( 14) is governed
by the position of the temperature valve (16).
Hot coolant from the engine's cooling system is
directed through the heater core (14). The heater core (14)
transfers heat from the coolant to the air passing through
the heater core fins.
Mode Valve Housing

After the heated and unheated airflows are mixed,
the combined airflow comes to the mode valve housing.
In vent mode, the vent mode valve actuator is engaged as
well as the bi-level mode valve actuator. This directs all
the air to the instrument panel outlets.
In bi-level mode, the vent mode valve remains
closed (allowing air to the defroster/heater door), while
the bi-level mode valve opens, allowing air to the instrument panel outlets. The defroster/heater door directs air to
the floor air outlets. A small amount of air goes to the side
window defrost outlets.
In heater mode, both the vent and bi-level doors
remain closed and the defroster/heater door moves up,
directing most of the air to the floor air outlets.
In every mode knob position except ";:;" (blend),
vacuum is routed to one of the two vacuum chambers. In
"~,i" (vent), vacuum is directed to the lower vacuum
chamber. This tilts the mode valve downward to direct the
airflow toward the air distributor assembly and the instrument panel outlets. In "OFF," :._,; " (heater) and "<w"
(defrost), vacuum is directed to the upper vacuum chambers. This tilts the mode valve upward to direct the airflow
toward the floor outlets and defrost outlet. In ~,;" (bilevel), both vacuum chambers are vented to normal air
pressure and the mode valve actuator holds the mode
valve in a centered position. This allows the airflow to go
to all outlets, although only an extremely small amount
reaches the defrost outlet.
When the vacuum chamber is vented to normal air

pressure, an external spring moves the shaft back to its
original position. The shaft, in tum, returns the valve to its
original position.
Air Outlets
The defroster/heater valve has a three-position mode

valve actuator with two vacuum hoses and two vacuum
chambers, one at each end of the actuator. In effect, the
three-position mode valve actuator acts like a pair of twoposition actuators placed end-to-end. When vacuum is
directed to either chamber, that chamber's diaphragm
moves the mode valve operating linkage from its centered
position to one extreme of travel. Venting that chamber
while directing vacuum to the opposite chamber causes
the linkage to move to its opposite extreme. Venting both
There are five adjustable high-level air outlets in the

instrument panel assembly. Three near the center and one
at each extreme end of the panel assembly. In addition,
there are two side window defrost outlets, one at each end
of the instrument panel upper trim pad assembly. All
seven outlets are fed by the air distributor assembly.
Heated air can be discharged from the floor outlets
centered on the transmission tunnel in the front floor pan
and from the defrost outlet.
Figure 6
A
B
C
D
E
F
G
H
2
10
11
19
20
BLACK HOSE
ORANGE HOSE
BLACK HOSE
YELLOW HOSE
GREEN HOSE
VIOLET HOSE
TO VACUUM SOURCE
RED HOSE
CONTROL ASSEMBLY
ACTUATOR, VENT MODE VALVE
TANK, VACUUM
PC0004-1A-F-RP
Figure 5 - Vacuum Circuit
24
12
21
22
23
24
OUTLET, FLOOR AIR

OUTLET, LEFT-HAND
DEFOGGER, SIDE WINDOW
OUTLET, CENTER
OUTLET, RIGHT-HAND
12
PC20021A-F-RP
Figure 6 - Air Outlets
Ventilation
Figure 7
The air distribution system provides fresh air ventilation for the passenger compartment in all operating
modes. Even in the "OFF" mode, fresh outside air is
forced into the air distribution system by the forward
movement of the vehicle.
After being warmed or cooled to the desired temperature, the air is discharged from the outlets appropriate to
the selected operating mode. When all windows are
closed, the addition of outside air builds a slight positive
pressure within the passenger compartment. The pressure
forces stale air to leave the vehicle through a pressure
relief valve near the base of the rear compartment after it
has circulated through the passenger compartment.
3. Move mode control knob to the '.:._,i" (heater)

position.
Most of the air should come from floor outlets
with remainder coming out of defroster
nozzles and defogger outlets.
Air should not come from instrument panel
outlets in '..:...) " (heater) position.
All air from heater system should be at nearly
the same temperature as outside air.
4. Move the mode control knob from '.:._,; " (heater)
position to the "~,;'' (blend) position. Air should
come equally from the defroster nozzle and the
heater outlet with some air coming from the side
window defogger.
5. Move mode control knob from '\; " (heater) position to "@" (defrost) position. ..
Most of the air should be discharged onto
windshield from defroster nozzles.
A small amount of air should also be discharged from floor outlets.
6. Move mode control knob back to
(bi-level)
position and move temperature control knob all the
way to the right.
Air should come from instrument panel outlets, and its temperature should climb rapidly
to approximately 55C (131 F) or higher, depending upon outside air temperature. For a
more precise heater output temperature check,
refer to "Heater Output Temperature Check"
in the following procedure.
Defroster nozzle airflow should diminish and
airflow from floor outlets may increase
slightly.
7. Move temperature control knob all the way to the
left and check to be sure air temperature drops back
to nearly the temperature of the outside air once
again.
8. Slowly tum blower motor assembly speed control
knob toward "OFF," stopping briefly at each intermediate position to notice force of airflow coming
from instrument panel center outlets and sound of
blower.
Both airflow and blower noise should reduce
noticeably at each intermediate step.
"~>"
A PLENUM
25 VALVE, PRESSURE RELIEF
PC20031AF-RP
Figure 7 - Flow-Through Ventilation
DIAGNOSIS
FUNCTIONAL TEST
The following operational test sequence will aid in
determining whether the heater system is working properly. Coolant temperature should be close to 90C
(194F).
Preparation
Engine should be started and allowed to idle for
about 20 minutes or until thermostat is open.
HEATER OUTPUT TEMPERATURE CHECK
Test
1. Set mode control knob to "~,i" (bi-level), temperature control knob all the way to the left and blower
switch to "HIGH."
Air at nearly the same temperature as outside
air should come from all outlets.
2. Set mode control knob to ''...) " (vent).
Air at nearly the same temperature as outside
air should come from instrument panel outlets.
Air should not come from floor outlets,
defroster nozzle or side window defogger
outlets.
Figure 8
The heat output of the heater system can be checked
with the following procedure.
Preparation
With the engine sufficiently cool, the radiator cap
should be removed and the engine started and allowed to
idle. Heater controls should be set to ':._,; " (heater) mode,
temperature control knob turned all the way to the right
and "HIGH" blower speed. When coolant flow in the radiator is visible through the filler neck, the radiator cap
should be installed.
1A8 HEATER AND VENTILATION
EXCESSIVE HEAT
OUTSIDE AIR
TEMPERATURE
-18C
(0F)
-4C
(25F)
l0C
(50F)
24C
(75F)
HEATER AIR
TEMPERATURE
43C
(110F)
50C
(125F)
60C
(140F)
66C
(150F)
* Temperature at floor air outlet assembly controls at "HI"

blower, "HEATER" mode and full warm, engine at
operating temperature and vehicle speed of 48 km/h (30 mph).
PC00051A-F-RP
Figure 8 - Heater Output Temperature Chart
The most likely cause of excessive heat from the

heater system is a disconnected or nonfunctional temperature control cable assembly. Refer to "Temperature Control Cable Assembly Adjustment" in this section. A hot
air leak from the engine compartment to the blower inlet
is also a remote possibility.
ON-VEHICLE SERVICE
REPLACEMENT PROCEDURES
Control Assembly and Vacuum Selector

Valve and/or Blower Motor Assembly Switch
Temperature Check
When the engine is warmed up (after approximately
20 minutes of operation), the vehicle should be driven. An
accurate thermometer should be used to determine the
temperature of the outside air and the temperature of the
air discharged at the floor outlets with the vehicle being
driven at 48 km/h (30 mph). Minimum acceptable heater
output temperatures at four different outside air temperatures are shown in Figure 8.
Minimum acceptable heater output temperatures for
outside air temperatures other than those shown in Figure
8 can be approximated by using the Fahrenheit scale and
rounding off the outside air temperature to the nearest 5.
For every additional 5 of outside temperature, an additional 1.8 of heater output temperature should be
allowed when the outside temperature is below 50F. An
additional 1.6 of heater output temperature should be
allowed for every 5 of outside temperature when the
outside temperature is above 50.
INSUFFICIENT HEATING OR DEFROSTING

The most likely causes of insufficient heating outside the heater system include a low coolant level, a faulty
thermostat, a partially or fully clogged heater core or heater hose, an obstruction to air circulation (often under the
front seat) or an air leak past a faulty seal into the passenger compartment. For an organized diagnosis procedure,
refer to Figures 9 and 10.
HIGH OR LOW HEATER CONTROL EFFORT

A kinked control cable, a binding valve or a faulty
control assembly are possible causes of excessive temperature control knob effort. For an organized diagnosis procedure and an effective "fix" for too little temperature
control effort, refer to Figure 11.
BLOWER MOTOR ASSEMBLY NOISE

A constant air rush noise is typical of all heater systems when operating on "HIGH" blower speed. Some
systems and modes may be worse than others. If possible,
check a similar vehicle to determine whether the noise is
typical or excessive. For diagnosis of excessive blower
motor assembly noise, refer to Figures 12 and 13.
Figures 2 and 14
l++I Remove or Disconnect

1. Control assembly trim plate (27).
Pull control assembly trim plate (27) rearward
and off instrument panel lower trim pad.
2. Heater and air conditioning control bolts/screws
(26).
3. Control assembly (2).
Pull control assembly (2) out far enough to
reach the vacuum, electrical and temperature
control cable connections.
4. Blower motor assembly switch connector.
5. Vacuum harness connector from vacuum selector
valve.
6. Temperature control cable assembly from control
assembly (2).
A. Release temperature control cable clips from
control assembly.
B. Pry temperature control cable with small
screwdriver from control assembly (2).
7. Vacuum selector valve, if necessary.
Remove two retaining screws and remove vacuum selector valve.
8. Blower motor assembly switch, if necessary.
A. Remove blower motor assembly speed control
knob (9) and retaining clip from shaft of
blower motor assembly switch.
B. Remove blower motor assembly switch.
lll 1nspect
Electrical terminals for corrosion. Remove corrosion or replace component as necessary
Temperature and mode knobs for freedom of movement. Lubricate, repair or replace as necessary.
Temperature control cable assembly for kinks, binding and other damage. Adjust, repair or replace as
necessary.
INSUFFICIENT HEATING OR DEFROSTING

CHECK FOR LOW COOLANT LEVEL, LOOSE OR WORN BELTS, LEAKING
OR KINKED HOSES, LOSS OF RADIATOR CAP PRESSURE SEAL.
ADJUST THE HEATER CONTROLS TO "HEATER" MODE, "HIGH"

BLOWER SPEED AND FULL "WARM."
WITH VEHICLE IDLING, CHECK THE AIR FLOW OUT OF THE

FLOOR AIR OUTLET AND CHECK OUTLET ATTACHMENT.
I
I
HIGH AIRFLOW.
RUN THE FUNCTIONAL TEST IN THIS

SECTION. IF THE PROBLEM IS NOT
RESOLVED, CHECK THE AIRFLOW.FROM
DEFROSTER AND VENT OUTLETS.
CHECK BLOWER SPEEDS

FOR AIRFLOW CHANGE.
I
I
SPEED CHANGE.
NO SPEED
CHANGE.
I
CHECK BLOWER
SWITCH AND
RESISTOR ASSEMBLY.
REPAIR AS
NECESSARY.
LOW OR NO AIRFLOW.
HIGH AIRFLOW FROM

DEFROSTER OR VENT
OUTLETS.
LOW OR NO AIRFLOW
FROM DEFROSTER OR
VENT OUTLETS.
I
CHECK VACUUM SYSTEM.
REPAIR AS REQUIRED.
SWITCH THE MODE

CONTROL KNOB TO
"DEFROST" AND CHECK
AIRFLOW.
I
'
DEFROSTER
AIRFLOW CORRECT.
LOW OR NO
DEFROSTER AIRFLOW .
REMOVE
FLOOR AIR
OUTLET AND
CHECK FOR
OBSTRUCTIONS.
CHECK BLOWER
SPEEDS FOR
AIRFLOW
CHANGE.
RUN.THE HEATER OUTPUT

TEMPERATURE CHECK IN THIS
SECTION.
NO SPEED
CHANGE.
SPEED CHANGE.
CHECK BLOWER SWITCH

AND RESISTOR ASSEMBLY.
REPAIR AS NECESSARY.
HEArER OUTPUT
TEMPERATURE CORRECT.
HEATER OUTPUT
TEMPERATURE LOW.
I CONTINUED 1
,.l..
CONTINUED
CHECK FOR AIRFLOW

OBSTRUCTIONS AT
BLOWER INLET AND
PLENUM.
I CONTINUED I
l
,.l..
Figure 9 - Insufficient Heating or Defrosting Diagnostic Procedure (1 of 2)
,..l,
PC0006 1A-F-RP
INSUFFICIENT HEATING OR DEFROSTING (Continued)

CHECKFO A AIRFLOW
OBSTRUC TIONSAT
BLOWER INLET AND
PLEN UM.
HEATER OUTPUT
TEMPERATURE CORRECT.
HEATER OUTPUT
TEMPERATURE LOW.
CHECK VEHICLE FOR

COLD AIR LEAKS AT COWL,
HEATER CASE AND
VENTS. CHECK UNDER
SEAT FOR OBSTRUCTIONS.
WITH THE IGNITION SWITCH IN "RUN" AND

THE BLOWER ON LOW, ROTATE THE
TEMPERATURE CONTROL KNOB TO THE
MID-POSITION, THEN RAPIDLY TO FULL
"HOT." LISTEN FOR VALVE SLAM AT THE
END OF CONTROL KNOB ROTATION.
NO OBSTRUCTIONS
ATBLO WEA INLET
ORPL ENUM.
NO VALVE SLAM.
VALVE SLAM.
WITH THE TEMPERATURE

VALVE FULL "WARM," START THE
VEHICLE. CHECK THE TEMPERATURE OF THE HEATER INLET
AND OUTLET HOSES BY FEEL.
THE AIR TEMPERATURE
AROUND THE HOSES MUST
BE AT LEAST 24C (85F).
CHECK THE TEMPERATURE CONTROL CABLE

ASSEMBLY FOR PROPER
ATTACHMENT AT CONTROL
ASSEMBLY AND HEATER
MODULE ASSEMBLY.
WITH THE B LOWER ON

"HIGH," MOVETHE TE.MPERATURE CO NTROL KNOB
FROM FULL WARM"TO
FULL "COOL" AND LISTEN
FOR AIRFLO WCHANGE.
II
NO AIRFLOW
CHANGE.
STILL NO VALVE SLAM.
AIRFL OW CHANGE.
I
REPLACE TEMPERATURE
CONTROL CABLE ASSEMBLY.
I
HOT INLET AND WARM OUTLET. ,
BOTH WARM.
CHECK THE THERMOSTAT

FOR PROPER INSTALLATION AND SEATING.
CHECKFO A AIRFLOW
OBSTR UCTION
BETW EENTHE
BLOWER AND THE
SYSTEM OUTLETS.
I
I
INCORRECT.
I CORRECT.
REINSTALL
AND RECHECK.
CHECK THE TE MPERATURE VALVE, CA BLES AND

CONTROL. REPLACE
AS REQUI RED.
BACK FLUSH HEATER

CORE, DRAIN AND
REPLACE COOLANT. RETEST.
REPLACE
THERMOSTAT.
BOTH HOSES
WARM.
HOT INLET AND WARM

OUTLET HOSES.
I
REPLACE HEATER CORE.
RETEST AND
VERIFY SYMPTOMS.
PC0007-1 AF-RP
Figure 1O- Insufficient Heating or Defrosting Diagnostic Procedure (2 of 2)
TEMPERATURE CONTROL EFFORT
CHECKTEMPERATURE
CONTROL EFFORT.
EXCESSIVE EFFORT.
PROPER
EFFORT.
EFFORT TOO LOW.

TEMPERATURE VALVE
MOVES ON HIGH BLOWER.
I NO CONTROL PROBLEM.
REPLACE CABLE WITH A LONGER
CABLE AND ADD A LOOP TO THE
CABLE ROUTING TO INCREASE
CONTROL EFFORT. CHECK
INSTRUMENT PANEL
INTERFERENCES
WITH NEW CABLE ROUTING TO
INSURE PROPER OPERATION.
CHECK CABLE FOR ROUTING, A KINK,

WIRING INTERFERENCE OR OTHER INSTRUMENT
PANEL INTERFERENCE.
I
PROBLEM NOT FOUND.
PROBLEM FOUND.
I
REMOVE CABLE
FROM TEMPERATURE
VALVE AND CYCLE
VALVE MANUALLY.
CHECK FOR VALVE
BINDING.
REPAIR AS
NECESSARY.
I NO VALVE BIND. I
VALVE BINDS.
I
CHECk VALVE SEAL TO
INSURE PROPER SEAL
INSTALLATION.
CHECK FOR
CONTROL BINDING.
I
ICONTROL BINDS. I
NO CONTROL
BIND.
I GOOD SEAL. I
SEAL CAUSES BINDING.
I
RE INSTALL AND
RECHECK CLEAR
ANCES TO DASH
COMPONENTS.
REMOVE CABLE AND

RECHECK CONTROL
FOR BINDING.
I CONTROL BINDS. I
I
NO CONTROL BIND.
I
I
I
CHECK TEMPERATURE VALVE
FOR SHAFT ALIGNMENT, BENT
SHAFT OR VALVE, WARPED CASE.
REPLACE
CONTROL.
REPLACE CABLE(S).
MC0011-1A-F-RP
Figure 11 - Temperature Control Effort Diagnostic Procedure
BLOWER MOTOR ASSEMBLY NOISE
CHECK ALL ELECTRICAL CONNECTIONS AND GROUNDS FOR PROPER CONNECTIONS. IF IN DOUBT, USE
VOLTMETER TO CHECK FOR CONSTANT VOLTAGE AT BLOWER MOTOR ASSEMBLY.
SIT IN VEHICLE WITH DOORS AND WINDOWS CLOSED, WITH IGNITION SWITCH ASSEMBLY IN "RUN" AND
ENGINE "OFF." RUN BLOWER MOTOR ASSEMBLY ON HIGH SPEED WITH TEMPERATURE SET FOR MAXIMUM
COOLING. CYCLE THROUGH BLOWER MOTOR ASSEMBLY SPEEDS, MODES AND TEMPERATURE SETTINGS TO
FIND WHERE NOISE OCCURS AND WHERE NOISE DOES NOT OCCUR. TRY TO DEFINE TYPE OF NOISE: AIR
RUSH, WHINE, TICK/CLICK, SQUEAL/SCREECH, FLUTTER, RUMBLE OR SCRAPE. CHECK ANOTHER VEHICLE IF
POSSIBLE (SAME MODEL) TO DETERMINE IF NOISE IS TYPICAL.
I
I
NOISE IS CONSTANT AT HIGH

BLOWER MOTOR ASSEMBLY
SPEEDS IN CERTAIN MODES BUT
CAN BE ELIMINATED AT LOWER
SPEEDS OR IN OTHER MODES.
TYPICAL NOISES ARE FLUTTER OR
RUMBLE. REFER TO FIGURE 5.
NOISE IS ONLY AT START-UP OR IS

INTERMITTENT. MAY OCCUR AT
COLD AMBIENTS AND LOW BLOWER
MOTOR ASSEMBLY SPEEDS.
TYPICAL NOISE IS AN
OBJECTIONABLE SQUEAL/SCREECH.
NOISE IS CONSTANT BUT

LESSENS WITH BLOWER
MOTOR ASSEMBLY SPEED
REDUCTION. TYPICAL NOISES
ARE WHINE, TICK/CLICK,
FLUTTER OR SCRAPE.
CHECK FOR MOTOR ASSEMBL y AND BLOWER IMPELLER VIBRATION AT

EACH BLOWER MOTOR ASSEMBLY SPEED BY FEELING THE BLOWER
MOTOR COVER.
NO EXCESS VIBRATION.
VIBRATION EXCESSIVE.
REMOVE BLOWER MOTOR ASSEMBLY AND

BLOWER IMPELLER AND CHECK FOR
FOREIGN MATERIAL AT THE ORIFICE OF
THE BLOWER INLET.
I
PROBLEM
FOUND.
I I
PROBLEM
STILL EXISTS.
REPAIR OR
REPLACE AS
NECESSARY AND
RECHECK.
I
[
EXAMINE BLOWER IMPELLER FOR WEAR

SPOTS, CRACKED BLADES OR HUB, AND
ALIGNMENT. EXAMINE BLOWER CASE
FOR WEAR SPOTS.
PROBLEM STILL EXISTS.
I
CONTINUED
PROBLEM FOUND.
l
REPLACE
BLOWER IMPELLER
AND RECHECK.
PC0009-1A-F-RP
Figure 12 - Blower Motor Assembly Noise Diagnostic Procedure (1 of 2)
BLOWER MOTOR ASSEMBLY NOISE (Continued)
CONTINUED
NOISE IS CONSTANT AT HIGH

SPEEDS IN CERTAIN MODES BUT
CAN BE ELIMINATED AT LOWER
SPEEDS OR IN OTHER MODES.
REPLACE BLOWER MOTOR

ASSEMBLY AND BLOWER
IMPELLER AND RECHECK.
I
I
PROBLEM
FOUND.
PROBLEM
STILL EXISTS.
I
REINSTALL ORIGINAL
BLOWER MOTOR
ASSEMBLY.
I
AT HIGH BLOWER MOTOR ASSEMBLY SPEED, CHECK FOR
NOISE AT TEMPERATURE SELECTIONS
(INCLUDING DEFROSTER OPERATION).
I
I
NOISE IN ALL
MODES AND
IN ALL
TEMPERATURE
SETIINGS.
NOISE IN ALL
MODES BUT
NOT ALL
TEMPERATURE
SETIINGS.
CHECK
TEMPERATURE
VALVE SEALS.
REPAIR OR
REPLACE AS
NECESSARY AND
RECHECK.
CHECK DUCTS FOR

OBSTRUCTIONS OR
FOREIGN MATERIALS AND
REMOVE. CHECK
DEFROSTER VALVE
FUNCTION. REPAIR OR
REPLACE AS NECESSARY
AND RECHECK.
CHECK SYSTEM FOR

OBSTRUCTIONS OR
FOREIGN MATERIALS
BETWEEN THE
BLOWER IMPELLER
AND THE
TEMPERATURE VALVE.
REMOVE, REPAIR OR
REPLACE AS
NECESSARY AND
RECHECK.
NOISE ONLY
IN "VENT"
MODE.
NOISE ONLY
IN "DEFROST"
OR "HEATER"
MODE.
CHECK DUCTS FOR

OBSTRUCTIONS OR
FOREIGN MATERIALS AND
REMOVE. CHECK
DEFROSTER VALVE
SEALS. REPAIR OR
REPLACE AS NECESSARY
AND RECHECK.
PC00101AF-RP
Figure 13 - Blower Motor Assembly Noise Diagnostic Procedure (2 of 2)
2 CONTROL ASSEMBLY
26 BOLT/SCREW, HEATER AND AIR CONDITIONING
CONTROL
27 TRIM PLATE, CONTROL ASSEMBLY
PC2004-1A-F-RP
Figure 14 - Control Assembly Removed
l++I Install or Connect

1.
2.
3.
4.
5.
6.
7.
NOTICE: See "Notice" on page lA-1 of this

section.
Blower motor assembly switch, if removed.
A. Hold blower motor assembly switch in position and install retaining clip.
B. Install blower motor assembly speed control
knob (9).
Vacuum selector valve and retaining screws, if
removed.
Temperature control cable assembly.
A. Slip temperature control cable assembly into
position on lever arm. Align shaft with temperature control cable slot.
B. Press temperature control cable clip into slot in
control assembly (2). Make sure all three clips
are in place.
Vacuum harness connector to vacuum selector
valve.
Blower motor assembly switch connector.
Control assembly (2).
Heater and air conditioning control bolts/screws
(26).
Install lower right bolt/screw (26) first to align
control assembly (2) properly.
l~I Tighten
Heater and air conditioning control bolts/
screws (26) to 1.9 Nm (17 lb. in.).
Hold control assembly trim plate (27) in position and press it forward to engage four retaining clips.
9. Test operation of temperature control knob, mode
control knob and blower motor assembly switch.
Control Assembly Lamp Bulb

Figure 14

Pull control assembly trim plate (27) forward
and off instrument panel lower trim pad.
(26).
reach control assembly lamp bulb socket.
4. Bulb and socket by twisting socket.
5. Bulb from socket.
Pull bulb straight out from socket.
ll'l'I Inspect
Control assembly lamp bulb socket for corrosion
and damage. Clean or replace as necessary.
Wires for damage and secure connection to bulb
socket. Repair or replace as necessary.

1.
2.
3.
4.

section.
New bulb.
Push bulb straight into socket.
Bulb and socket by twisting socket into place.
Control assembly (2).
Heater and air conditioning bolts/screws (26).
lJ Tighten

Hold control assembly trim plate (27) in position and press it rearward to engage four retaining clips.
6. Test operation of control assembly lamp bulb.
Temperature Control Cable Assembly

reach temperature control cable assembly
connection.
6. Temperature control cable assembly (5).
Release temperature control cable clips from
control assembly (2).
Pry temperature control cable with small
screwdriver from control assembly (2).
Figures 14 and 15
I++) Remove or Disconnect

1. Right instrument panel sound insulator assembly.
Refer to SECTION 8C.
2. Temperature control cable assembly (5) at heater

module assembly (1).
Remove temperature control cable bolt/screw
~~-

Pull control cable assembly trim plate (27)
rearward and off instrument panel lower trim
pad.
(26).

section.
1. Temperature control cable assembly (5) to control
assembly (2).
A. Slip temperature control cable into position
over lever arm. Align shaft with temperature
control cable slot.
B. Press temperature control cable clip into slot in
control assembly (2). Make sure all three clips
are in place.
(26).
Install lower right bolt/screw (26) first to align
control assembly (2) properly.
A
29
A
1
2
5
28
29
SNAPS
CONTROL ASSEMBLY
CABLE ASSEMBLY, TEMPERATURE CONTROL
RETAINER, TEMPERATURE CONTROL CABLE
BOLT/SCREW, TEMPERATURE CONTROL CABLE
5
PC00111AF-RP
Figure 15 - Temperature Control Cable Assembly

1. Blower motor resistor assembly (30) and blower
motor resistor bolt/screw (31).
l~I Tighten
Hold control assembly trim plate (27) in
position and press it forward to engage four
retaining clips.
5. Temperature control cable assembly (5) at heater
module assembly (1) with temperature control cable
bolt/screw (29).
l~I Tighten
Temperature control cable bolt/screw (29) to
1.9 Nm (17 lb. in.).
l~I Tighten
Blower motor resistor bolt/screw (31) to 2.0
Nm (18 lb. in.).
2. Carpet assembly.
4. Test blower motor operation at all four speeds.
Blower Motor Assembly and Blower Motor

Fan
Figure 17
Blower Motor Resistor Assembly
1. Key from ignition switch to assure that switch will

remain "OFF."
Figure 16
2. Right instrument panel sound insulator assembly

and side trim panel. Refer to SECTION 8C.
3. Blower motor bolts/screws (32).
1. Key from ignition to assure that switch will remain

in "OFF."
3. Pull carpet assembly away from heater module
assembly.
4. Blower motor resistor bolt/screw (31).
5. Blower motor resistor assembly (30).

section.
Blower motor assembly (6) and blower motor

fan (18) will drop down.
!L'S'I
Inspect
Blower motor terminals for corrosion. Clean corrosion from terminals or replace blower motor assembly (6) as necessary.
Flange of blower motor assembly (6) for damage or
distortion that could cause an air leak. Repair as
necessary.
Blower motor fan (18) for damage and distortion.
Repair or replace as necessary.

section.
31
~~-,
/~_---.....:;,.,._
30
6 MOTOR ASSEMBLY, BLOWER
30 RESISTOR ASSEMBLY, BLOWER MOTOR

31 BOLT/SCREW, BLOWER MOTOR RESISTOR
PC00121AFRP
Figure 16 - Blower Motor Resistor Assembly Removed
18
6 MOTOR ASSEMBLY, BLOWER
18 FAN, BLOWER MOTOR
32 BOLT/SCREW, BLOWER MOTOR
PC0014-1A-f.RP
Figure 17 - Blower Motor Assembly and Blower Motor Fan

Removed

1. Blower motor assembly (6).
Guide blower motor assembly (6) and blower
motor fan (18) into position, being careful not
to catch blower motor fan (18) on protruding
parts.
2. Blower motor bolts/screws (32).
l~I Tighten
Blower motor bolts/screws (32) to 2.3 Nm
(20 lb. in.).
3. Right instrument panel sound insulator assembly
and side trim panel. Refer to SECTION 8C.
4. Check blower operation.

1. Open instrument panel compartment and push in on
both sides of compartment. This will cause compartment to "drop" open completely for access to
vacuum harness.
2. Vacuum hose connectors at vacuum actuators.
Trace each vacuum hose to its actuator on
heater module assembly (1), noting its routing
for reference during installation.
3. Pry apart connector and remove harness through
instrument panel compartment.
ll'l'I
Inspect
Vacuum hoses for leaks by attempting to blow

through hose while covering opposite end with a fingertip. Replace any hose that leaks.
Vacuum switches and connecting hose at control
assembly for leaks and proper function. Replace
faulty components.
Vacuum Harness
Figure 18
It is not necessary to replace an entire vacuum harness in case of a localized leakage or hose collapse. A
repair can be made by cutting the hose and inserting a
plastic retainer.
If an entire hose must be replaced in the harness that
connects to the round vacuum selector valve on the control assembly, cut off all hoses at the connector and then
attach all the hoses (including the replacement hose)
directly to the vacuum selector valve.

1. Vacuum harness.
2. Vacuum hose connectors to vacuum actuators.
Be sure connectors are snapped securely in
place.
3. Push in on sides of instrument panel compartment
and return it to its normal position.
19
A VACUUM HARNESS CONNECTORS, MAIN HARNESS

TO ENGINE COMPARTMENT HARNESS
B CONNECTOR , ELECTRICAL
1 MODULE ASSEMBLY, HEATER
2 CONTROL ASSEMBLY
10 ACTUATOR, Bl-LEVEL MODE
11 ACTUATOR, DEFROSTER/HEATER VALVE
13 HARNESS, VACUUM
19 ACTUATOR, VENT MODE VALVE
PC00151AF-RP
Figure 18 - Vacuum Harness
Vacuum Tank
The vacuum tank that supplies the heater vacuum
system is an oblong-shaped tank mounted on the front
outer engine rail.

1. Raise and suitably support vehicle. Refer to SECTION OA.
2. Right lower side air baffle.
3. Vacuum line from lower connection.
4. Two vacuum tank mounting bolts/screws from top
of vacuum tank.
5. Vacuum tank.

section.
1. Vacuum tank and vacuum tank mounting bolts/
screws.
l~I Tighten
Vacuum tank mounting bolts/screws to 2.5
Nm (22 lb. in.).
2. Vacuum line to lower connection.
3. Right lower side air baffle.
4. Lower vehicle.
Vacuum Actuators
Figure 18
Defroster/Heater Valve

1. Instrument panel. Refer to SECTION SC.
2. Defroster/heater valve actuator (11) from linkage.

1. Defroster/heater valve actuator ( 11) to linkage.
Bi-Level Mode Valve
!++I Remove or Disconnect

2. Bi-level mode valve linkage bolt/screw from
linkage.
3. Bi-level mode valve actuator (10).
Unsnap bi-level mode valve actuator (10).

section.
1. Bi-level mode valve actuator (10).
Snap bi-level mode valve actuator (10) into
place.
2. Bi-level mode valve linkage bolt/screw to linkage.
!~I Tighten
Bi-level mode valve linkage bolt/screw to 2.3
Nm (20 lb. in.).
Vent Mode Valve

2. Vent mode valve linkage bolt/screw.
3. Vent mode valve actuator (19).
Disconnect linkage from vent mode valve
actuator (19).
!++I Install or Connect

section.
1. Vent mode valve actuator (19).
Connect linkage to vent mode valve actuator
(19).
2. Vent mode valve linkage bolt/screw.
l~I Tighten
Vent mode valve linkage bolt/screw to 2.3
Nm (20 lb. in.).
Air Deflectors
The right (passenger's side) and three center air deflectors of the heater system can be removed by closing
the deflector and then pulling it out. The left (driver's
side) deflector can be removed by inserting a screwdriver
or similar object into the locking tabs. Gently pry up to
remove the deflector. The deflectors can be installed by
pressing them into place.
Heater Hose Assembly and Heater Hose

Pipes
Figures 19 and 20
The heater hose inlet pipe (37) and heater hose outlet
pipe (36) extend forward from the dash front panel next to
the heater module assembly. The heater hose inlet pipe
(37) is toward the left side of the vehicle from the heater
hose outlet pipe (36).
On the 3.4L L32 engine, the heated coolant supply
for the heater comes from a fitting at the front of the lower
inlet manifold, just below the throttle body air inlet. A
pipe from the fitting extends across the front of the engine

and connects to a heater inlet hose assembly (33) that
leads to a pipe mounted on the right side rail in the engine
compartment. The rear end of the pipe is connected to a
short inlet hose that leads to the heater hose inlet pipe
(37). The fitting on the pipe across the front of the engine
has two hose nipples that connect to short inlet and outlet
hoses which heat the fuel injection system throttle body
air inlet.
On the 5.7L LTl engine, the heated coolant supply
for the heater comes from a fitting at the water pump
assembly.
On both engines, the heater hose outlet pipe (36) discharges coolant to a short heater outlet hose that is connected to a pipe mounted on the right side rail in the
engine compartment. The forward end of the pipe is connected to an outlet hose that crosses in front of the engine
and feeds the coolant into the water pump assembly.
The hoses are attached at each end with a spring tension clamp (34 and 35 or 151 and 152).

1. Engine coolant.
Drain enough coolant into a clean container for
reuse.
NOTICE: The heater core can be damaged if excessive force is applied on the core pipes during hose
removal.
2. Heater hose assembly (33).
A. Squeeze clamps with pliers and slide clamps
(34 and 35 or 151 and 152) away from fittings.
B. Remove heater hose assembly (33) by twisting
and pulling. If hose will not come off heater
hose inlet pipe (37) or outlet pipe (36) easily
with this method, cut off hose forward of heater hose pipes. Then cut hose remaining on
pipes lengthwise to remove it.
C. Remove and discard hose clamps (34 and 35 or
151 and 152) if hose assembly (33) is to be
reused.

1. Heater hose assembly (33).
A. Cut replacement hose(s) to same length as
original hose(s), if necessary.
B. Apply rubber lubricant to inside diameter of
hose(s), if desired.
C. Squeeze clamp ends and slip new hose clamp
(34, 35, 151 or 152) over one end of heater
hose. Push hose onto fitting with twisting motion. Hose end should be 1.0 mm (0.04 inch)
away from touching nearest surface (dash front
panel, fitting hex head, etc.).
D. Install clamp (34, 35, 151 or 152) beyond any
bead around fitting, but not closer than 3.0 mm
(0.12 inch) to nearest surface (dash front panel,
fitting hex head, etc.).
E. Repeat hose and clamp installation procedure
at other end of hose.
2. Engine coolant.
Use coolant drained earlier only if it is uncontaminated. Discard contaminated coolant and
add fresh 50/50 coolant and water mixture.
lll
1nspect
Be sure installed hose does not sag or rub against

other components. Adjust or support hose as necessary to correct hose position.
Operate engine and check hose installation for leaks.
Check coolant level after engine has been warmed
up. Add coolant as necessary.
Heater Core
Figure21

1. Open instrument panel compartment. Push in on
sides of compartment to release it to reach heater
core.
2. Coolant. Refer to SECTION 6B.
Drain engine coolant into a clean container for
reuse.
NOTICE: Heater core can be damaged if too much
force is applied to heater core pipes during hose removal.
3. Heater module bolts/screws (41).
4. Heater module assembly cover.
5. Heater core bolt/screw (42) and heater core clamp
(43).
6. Hose pipe clamp bolt/screw (45) and hose pipe
clamp (44).
7. Heater hose assembly from heater hose pipes.
8. Heater core (14).
Carefully pull heater core toward you.

section.
1. Heater core (14).
2. Heater hose assembly to heater hose pipes.
rn
Important
Lubricate heater pipes for good seal.

Be sure seals around heater pipes remain in
place when installing.
3. Hose pipe clamp bolt/screw (45) and hose pipe
clamp (44).
l~I Tighten
Hose pipe clamp bolt/screw (45) to 1.8 Nm
(16 lb. in.).
4. Heater core bolt/screw (42) and heater core clamp
(43).
148
33
33
34
35
36
37
146
147
148
149
HOSE ASSEMBLY, HEATER INLET

CLAMP, HEATER OUTLET FRONT HOSE
CLAMP, HEATER INLET FRONT HOSE
PIPE, HEATER HOSE OUTLET
PIPE, HEATER HOSE INLET
HOSE ASSEMBLY, HEATER OUTLET
HOSE, THROTTLE BODY HEATER RETURN
CLAMP, THROTTLE BODY HEATER RETURN HOSE
PIPE, HEATER OUTLET
PC0016-1A-F-RP
Figure 19 - Heater Hose Assembly and Heater Hose Pipes (3.4L L32 Engine)
40
150
38
36 PIPE, HEATER HOSE OUTLET

37 PIPE, HEATER HOSE INLET
38 VALVE, FLOW CONTROL
39 HOSE, THROTTLE BODY HEATER RETURN
40 VALVE, BLEED
150 HOSE ASSEMBLY, HEATER INLET
151 CLAMP, HEATER OUTLET FRONT HOSE
152 CLAMP, HEATER INLET FRONT HOSE
153 PIPE, HEATER INLET
154 PIPE, HEATER OUTLET
155 HOSE ASSEMBLY, HEATER OUTLET
PC0017-1AF-RP
Figure 20- Heater Hose Assembly and Heater Hose Pipes (5.7L LT1 Engine)
~5"'
44~
41
A
A
1
14
41
42
43
44
45
SEALS
CORE, HEATER
BOLT/SCREW, HEATER MODULE
BOLT/SCREW, HEATER CORE
CLAMP, HEATER CORE
CLAMP, HEATER HOSE PIPE
BOLT/SCREW, HEATER HOSE PIPE
!VIEWA
PC00181A-F-RP
Figure 21 - Heater Core Removed
l~I
Tighten
Heater core bolt/screw to 1.8 Nm (16 lb. in.).

5. Heater module assembly cover.
6. Heater module bolts/screws (41).
l~I
Tighten
Heater module bolts/screws (41) to 2.0 Nm

(18 lb. in.).
7. Coolant.
A. Use coolant drained earlier only if it is uncontaminated. Discard contaminated coolant and
add fresh 50/50 coolant and water mixture.
B. Operate engine and check for leaks at heater
core pipes. Tighten hose clamp screw a bit at a
time as necessary to stop a leak.
C. Check coolant level after engine has been
warmed up. Add coolant as necessary.
8. Instrument panel compartment.
SPECIFICATIONS
FASTENER TIGHTENING SPECIFICATIONS
Bi-Level Mode Valve Linkage Bolt/Screw ...............................
Blower Motor Bolt/Screw ............................................
Blower Motor Resistor Bolt/Screw .....................................
Heater and A/C Control Bolt/Screw ....................................
Heater Core Bolt/Screw .............................................
Heater Hose Pipe Bolt/Screw .........................................
Heater Module Bolt/Screw ...........................................
Hose Pipe Clamp Bolt/Screw .........................................
Temperature Control Cable Bolt/Screw .................................
Vacuum Tank Mounting Bolt/Screw ....................................
Vent Mode Valve Linkage Bolt/Screw ..................................
2.3 Nm (20 lb.

2.3 Nm (20 lb.
2.0 Nm (18 lb.
1.9 Nm (17 lb.
1.8 Nm (16 lb.
1.8 Nm (16 lb.
2.0 Nm (18 lb.
1.8 Nm (16 lb.
1.9 Nm (17 lb.
2.5 Nm (22 lb.
2.3 Nm (20 lb.
in.)
in.)
in.)
in.)
in.)
in.)
in.)
in.)
in.)
in.)
in.)
ELECTRICAL SPECIFICATIONS
Blower Motor Fuse (Labeled "HVAC") .................................. 25 Amp. (White)
Control Assembly Dial Fuse (Labeled "IP DIMMER") . . . . . . . . . . . . . . . . . . . . . . . . . 5 Amp. (Tan)
Control Assembly Dial Lamp Bulb Number ........................................... 37
HEATER, VENTILATION AND AIR CONDITIONING 18-1
SECTION 18
HEATER, VENTILATION AND AIR

CONDITIONING
not reused, and those requiring thread locking compound will be called out. The correct torque value must be used
result.
CONTENTS
General Description ........................ IB-3
Heater, Ventilation and Air Conditioning
System Operation ...................... lB-3
Heater System .............. Refer to Section IA
Air Distribution ..... Refer to Sections IA and lBl
Refrigeration System . . . . . . . . . . . . . . . . . . . . . I B-4
Refrigerant- I 34a . . . . . . . . . . . . . . . . . . . . . . I B-4
Air Conditioning Receiver and
Dehydrator Assembly . . . . . . . . . . . . . . . . lB-4
Air Conditioning Compressor Assembly .... IB-4
Air Conditioning Condenser Assembly ..... lB-4
Electric Engine Coolant Fan Assembly . . . . . lB-4
Thermostatic Expansion Valve Assembly . . . I B-4
Air Conditioning Evaporator ............. IB-5
High Pressure Relief Valve .............. lB-5
Relays and Switches ..................... lB-5
Blower Motor Assembly Relay . . . . . . . . . . . lB-5
Air Conditioning Compressor Relay ....... IB-5
Air Conditioning Low Pressure Cutoff
Switch Assembly .................... IB-5
Air Conditioning Refrigerant Pressure
Sensor Assembly .................... lB-5
Air Conditioning Evaporator Temperature
Sensor Assembly .................... IB-5
Diagnosis ................................ IB-5
Air Distribution System . . . . . . Refer to Section I BI
Blower Motor Assembly .... Refer to Section 8A-63
Compressor Assembly
Circuit . . . . . . . . . . . . . Refer to Section 6E3-C IO
Refrigeration System/Insufficient
Cooling ................. Refer to Section lBl
Heater System/Insufficient
Heating .................. Refer to Section IA
Leak-Testing the Refrigeration System ....... lB-5
Electric Halogen Leak Detector . . . . . . . . . . . 1B-6
Fluorescent Leak Detector . . . . . . . . . . . . . . . IB-7
Liquid Leak Detectors and Pressure Testing . 1B-7
Eliminating Air Conditioning Odor . . . . . . . . . . I B-7
On-Vehicle Service . . . . . . . . . . . . . . . . . . . . . . . . I B-7
Refrigeration System Services . . . . . . . . . . . . . . 1B-7
Replacing 0-Rings ..................... lB-7

Handling Refrigerant- I 34a . . . . . . . . . . . . . . I B-8
Handling Refrigerant Lines and Fittings . . . . lB-8
Maintaining Chemical Stability in the
Refrigeration System . . . . . . . . . . . . . . . . . I B-9
Refrigerant Recovery and Recycling, Adding Oil,
Evacuating and Recharging Procedures ..... lB-9
General Description . . . . . . . . . . . . . . . . . . . . lB-9
Station (ACR 4 ) Setup and Maintenance .... lB-9
Refrigerant Recovery . . . . . . . . . . . . . . . . . . I B-11
Evacuation . . . . . . . . . . . . . . . . . . . . . . . . . . 1B- I 2
A/C System Oil Charge Replenishing . . . . . 1B-13
Refrigerant Oil Distribution . . . . . . . . . . . . . I B-13
Refrigerant Oil Loss Due to a Large Leak . . I B-14
Compressor System ................... 1B-I4
Charging the A/C System (Engine Off) .... 1B-I4
Successful Transfer Complete ......... IB-I4
Unsuccessful Transfer . . . . . . . . . . . . . . . I B-14
Replacement Procedures . . . . . . . . . . . . . . . . . 1B- I 5
Blower Motor and
Fan Assembly .......... Refer to Section lA
Air Ducts and
Deflector Outlets ........ Refer to Section lA
Vacuum Tank . . . . . . . . . . . . . Refer to Section I A
Heater Hoses and Pipes ..... Refer to Section IA
Air Conditioning Compressor and
Condenser Hose Assembly ........... 1B-I6
Air Conditioning Receiver
Dehydrator Tube . . . . . . . . . . . . . . . . . . . I B-16
Air Conditioning Evaporator Tube . . . . . . . I B-18
Air Conditioning Thermostatic
Expansion Valve Assembly ........... 1B-I8
Air Conditioning Receiver and
Dehydrator Assembly ............... lB-19
Sensor Assembly ....... Refer to Section IBI
Air Conditioning Compressor
Low Pressure Cutoff
Switch Assembly ..... Refer to Section lBI
Air Conditioning Condenser Assembly .... lB-19
1B-2 HEATER, VENTILATION AND AIR CONDITIONING
.__.....,,,,,,,,
1 "-f,
-~
12
33
PC-0001-18-F-RP
Figure 1 - Refrigeration System Components

Air Conditioning Compressor Assembly ... lB-20
Air Conditioning Refrigerant Service Valve lB-22
Generator and Air Conditioning Compressor and
Power Steering Pump Bracket
Assembly (5.7L LTl Engine) ....... lB-23
Generator and Air Conditioning Compressor
Bracket Assembly (3.4L L32 Engine) ... lB-23
GENERAL DESCRIPTION
HEATER, VENTILATION AND AIR
CONDITIONING SYSTEM OPERATION
NOTICE: The refrigeration system on this vehicle
uses R-134a which is not compatible with refrigerant R-12. Before servicing the system always make
sure the proper servicing equipment is used or the
system could become severely damaged. Always
refer to the service text and manufacturer instructions included with service equipment before proceeding.
The air conditioning system (C60) delivers air that
has been heated or cooled and dehumidified for occupant
comfort. It also provides power ventilation, windshield
assembly and side window defrosting.
During most operating conditions, outside air is
drawn through the heater and air conditioning module
assembly by the blower motor assembly. Additional outside air is also forced into the vehicle by foreward movement of the vehicle.
1 MODULE ASSEMBLY, HEATER AND AIR CONDITIONING

EVAPORATOR
2 COMPRESSOR ASSEMBLY, AIR CONDITIONING
3 CONDENSER ASSEMBLY, AIR CONDITIONING
4 RECEIVER AND DEHYDRATOR ASSEMBLY, AIR
CONDITIONING
5 EVAPORATOR, AIR CONDITIONING
6 VALVE ASSEMBLY, AIR CONDITIONING
THERMOSTATIC EXPANSION
7 HOSE ASSEMBLY, AIR CONDITIONING COMPRESSOR
AND CONDENSER
8 TUBE, AIR CONDITIONING EVAPORATOR
9 TUBE, AIR CONDITIONING RECEIVER DEHYDRATOR
10 BRACKET, AIR CONDITIONING RECEIVER DEHYDRATOR
11 BOLT/SCREW, AIR CONDITIONING RECEIVER
DEHYDRATOR CLAMP
DEHYDRATOR BRACKET
13 0-RING, AIR CONDITIONING RECEIVER DEHYRATOR
TUBE
14 0-RING, AIR CONDITIONING EVAPORATOR TUBE
15 SEAL, AIR CONDITIONING EVAPORATOR TUBE
16 SEAL, AIR CONDITIONING COMPRESSOR AND
CONDENSER HOSE
17 0-RING, AIR CONDITIONING CONDENSER FITIING
18 SEAL, AIR CONDITIONING COMPRESSOR HOSE
19 SEAL, AIR CONDITIONING REFRIGERANT SERVICE
VALVE
20 0-RING, AIR CONDITIONING REFRIGERANT PRESSURE
SENSOR
Compressor Assembly On-Vehicle Minor

Component Replacement .............
Specifications ............................
General Specifications . . . . . . . . . . . . . . . . . . .
Fastener Tightening Specifications .........
Fitting Tightening Specifications ...........
Special Tools ............................
lB-24
lB-24
lB-24
lB-24
lB-25
lB-26
Within the evaporator module assembly, air is

pushed by the blower motor assembly through the evaporator, then through the heater core then into the passenger
compartment. For air conditioning or defroster operation
at ambient temperatures above 7C (45F), the refrigeration system will chill the evaporator to almost freezing.
As the air passes through the evaporator, the air temperature drops which causes the moisture in the air to condense on the evaporator core fins. This moisture leaves
the vehicle by gravity feed through a drain hole, dehumidifying the vehicle.
From the evaporator, some or all of the air may pass
through the heater core assembly, which is warmed by
engine coolant. Any of the air which is not to be heated
will mix with the heated air before entering the passenger
compartment.
When maximum air conditioning mode is selected,
most of the air entering the blower motor assembly is
taken from the passenger compartment (recirculated)
where it is most likely to be cooler than the outside air.
Only outside air is used in all other modes.
21 VALVE, AIR CONDITIONING REFRIGERANT PRESSURE

SENSOR
22 SENSOR ASSEMBLY, AIR CONDITIONING
REFRIGERANT PRESSURE
23 CORE, AIR CONDITIONING REFRIGERANT SERVICE
VALVE
24 CAP, AIR CONDITIONING REFRIGERANT CHARGE
VALVE (SERVICE VALVE)
25 VALVE, AIR CONDITIONING REFRIGERANT SERVICE
26 CAP, AIR CONDITIONING REFRIGERANT CHARGE
VALVE (CHARGE VALVE)
DEHYDRATOR TUBE
28 BOLT/SCREW, AIR CONDITIONING COMPRESSOR AND
CONDENSER HOSE
29 BOLT/SCREW, AIR CONDITIONING THERMOSTATIC
EXPANSION VALVE
CONDENSER HOSE CLIP
32 BRACKET, AIR CONDITIONING COMPRESSOR HOSE
CLIP (5.7L LT1 ENGINE)
33 RETAINER, RADIATOR AIR UPPER BAFFLE
34 STRAP, AIR CONDITIONING COMPRESSOR AND
CONDENSER HOSE
35 SWITCH ASSEMBLY, AIR CONDITIONING
COMPRESSOR LOW PRESSURE CUT-OFF
36 VALVE, AIR CONDITIONING COMPRESSOR LOW
PRESSURE CUT-OFF SWITCH
37 0-RING, AIR CONDITIONING COMPRESSOR LOW
38 BOLT/SCREW, AIR CONDITIONING COMPRESSOR
PC0002 1B-F-RP
Figure 2 - Refrigeration System Components - Legend
REFRIGERATION SYSTEM
Air Conditioning Compressor Assembly
Figures 1 and 2
The air conditioning compressor assembly is driven

by a belt from the engine crankshaft through the compressor clutch pulley. The compressor pulley rotates freely,
without turning the compressor shaft, until an electromagnetic clutch coil is energized. When voltage is applied to
energize the clutch coil, a clutch plate and hub assembly is
drawn rearward toward the pulley. The magnetic force
locks the clutch plate and pulley together as one unit to
drive the compressor shaft. For unit repair information,
refer to SECTION 102.
Refrigerant-134a
CAUTION: Avoid breathing A/C Refrigerant-134a and lubricant vapor or mist.
Exposure may irritate eyes, nose, and
throat. To remove R-134a from the A/C
system, use service equipment certi
fied to meet the requirements of SAE
J2210 (R-134a recycling equipment). If
accidental system discharge occurs,
ventilate work area before resuming
service. Additional health and safety information may be obtained from refrigerant and lubricant manufacturers.
Like the coolant in the engine cooling system, the
refrigerant is the substance in the air conditioning system
that absorbs, carries and then releases heat. Although various substances are used as refrigerants in other types of
refrigeration systems, past automotive air conditioning
systems used a type called Refrigerant-12 (R-12).
This vehicle uses a new type of refrigerant called
Refrigerant-134a (R-134a). It is a non-toxic, non-flammable, clear, colorless, liquefied gas.
While the R-134a A/C system is very similar to an
R-12 A/C system, the differences in the refrigerant, lubricants, and service equipment are important.
NOTICE: R-l 34a refrigerant is not compatible with
R-12 refrigerant in an air conditioning system. R-12
in a R-134a system will cause compressor failure,
refrigerant oil sludge or poor air conditioning system performance.
Refrigerant-134a carries a charge of a special lubricating oil, polyalkaline glycol (PAG) refrigerant oil.
GM PAG refrigerant oil will have a slight blue tint.
The oil is hydroscopic (absorbs water from the
atmosphere) and should be stored in closed containers.
Use only polyalkylene glycol (PAG) synthetic
refrigerant oil for internal circulation through the
R-134a A/C system and only mineral base 525 viscosity refrigerant oil on fittings threads and 0-rings.
If lubricants other than those specified are used,
compressor failure and/or fitting seizure is likely to
occur.
Air Conditioning Receiver and Dehydrator

Assembly
The receiver and dehydrator assembly is located on
the right side wheelhouse panel, just downstream from the
condenser assembly. It functions as a moisture separator
that receives refrigerant liquid and refrigerant oil from the
condenser. It only allows refrigerant liquid and a small
amount of oil to continue on to the thermostatic expansion
valve assembly.
At the bottom of the receiver and dehydrator assembly is the desiccant, which acts as a drying agent for moisture that may have entered the system. A filter is also
located near the bottom of the receiver and dehydrator
assembly outlet pipe to keep any particles from plugging
the thermostatic expansion valve assembly.
Air Conditioning Condenser Assembly

The air conditioning condenser assembly in front of
the radiator assembly is made up of coils, which carry the
refrigerant and cooling fins to provide rapid transfer of
heat. The air passing through the condenser assembly
cools the high-pressure refrigerant vapor, causing it to
condense into a liquid.
Electric Engine Coolant Fan Assembly

Coolant fan assembly operation is crucial to the
proper operation of the air conditioning system. The coolant fan assembly ensures the proper amount of air flow
across the condenser throughout the vehicle operating
range.
Fan assembly operation should be checked during
any air conditioning diagnosis procedure. Special attention should be given to the fan assembly whenever excessive high side pressures are encountered.
Thermostatic Expansion Valve Assembly

Figure3
The purpose of the thermostatic expansion valve
assembly is to regulate the flow of refrigerant through the
evaporator to optimize its cooling performance. This is
accomplished by monitoring the refrigerant conditions at
the evaporator outlet and adjusting the inlet flow accordingly. This assures that all the liquid is evaporated before
it is returned to the compressor assembly.
The refrigerant flow is controlled by the movement
of a shaft that pushes a ball from its seat. As the ball is
unseated, more flow is allowed through the evaporator.
Shaft movement is controlled by the power dome which
has two separate sides. The thermal side of the power
dome is sealed and charged with refrigerant. The system
side of the power dome is exposed to the pressure of the
evaporator outlet or low side. Refrigerant exiting the
evaporator flows over part of the thermal side of the
power dome. The sealed refrigerant in the thermal side
responds to the temperature changes of the refrigerant
flowing out of the evaporator. As the refrigerant temperature rises, the pressure of the thermal side increases.
If the pressure on the thermal side of the power
dome is greater than the pressure on the system side (the
evaporator outlet or low-side pressure), the shaft moves
down and pushes the ball off the seat allowing more
refrigerant flow through the evaporator. When the opposite is true, the shaft moves up and reseats the ball reducing flow. A spring at the bottom of the thermostatic
expansion valve assembly is not adjustable.
Although the thermostatic expansion valve assembly controls evaporator refrigerant flow, air conditioning

high blower motor assembly speed. The blower motor
resistor assembly is used to provide power to the blower
motor assembly in all other speed settings. The blower
motor relay is located in the underhood electrical center.
Refer to SECTION 8A-63 for more information.
Air Conditioning Compressor Relay

F
The air conditioning compressor relay is used to provide battery voltage to the compressor clutch coil. The
relay is controlled by the engine control module (ECM)
only. The relay is located in the underhood electrical center. Refer to SECTION 8A-64 for more information.
Air Conditioning Low Pressure Cutoff Switch

Assembly
A
B
C
D
POWER DOME
THERMAL-SIDE PRESSURE
AIR CONDITIONING SYSTEM LOW-SIDE PRESSURE
FROM AIR CONDITIONING RECEIVER AND
DEHYDRATOR ASSEMBLY (HIGH SIDE)
E TO AIR CONDITIONING EVAPORATOR (LOW SIDE)
F FROM AIR CONDITIONING EVAPORATOR
G TO AIR CONDITIONING COMPRESSOR ASSEMBLY
PC0003-1B-F-RP
Figure 3 - Thermostatic Expansion Valve Assembly
capacity control (to prevent ice build-up) is managed by

compressor cycling which is controlled by the engine control module (ECM).
Air Conditioning Evaporator

The evaporator is a device which cools and dehumidifies the air before it enters the vehicle. High-pressure
refrigerant flows through the thermostatic expansion
valve assembly and becomes low-pressure refrigerant
before entering the evaporator. The heat in the air passing
through the evaporator core is lost to the cooler surface of
the core, thereby cooling the air. As the process of heat
loss from the air to the evaporator core surface is taking
place, any moisture (humidity) in the air condenses on the
outside of the evaporator core and is drained off as water.
High Pressure Relief Valve

The compressor assembly is equipped with a pressure relief valve which is placed in the system as a safety
factor. Under certain conditions, the refrigerant on the discharge side may exceed the designed operating pressure.
To prevent system damage, the valve is designed to open
automatically at approximately 3036 kPa (440 psi). Any
condition that causes this valve to open should be corrected, and the refrigerant oil should be replaced as necessary. The air conditioning refrigerant pressure sensor
should also be checked for proper calibration. Refer to
SECTION 6E3 (DTC 61).
RELAYS AND SWITCHES

Blower Motor Assembly Relay
The blower motor assembly relay is used to provide
battery voltage to the blower motor assembly only during
The cutoff switch assembly is used to prevent continuous compressor assembly operation if the refrigerant
system becomes low on charge. The cutoff switch assembly is wired in-line with the compressor clutch coil circuit.
This is the only switch that can override the ECM command to engage the compressor assembly. For more
information, refer to SECTION 8A-64.

Sensor Assembly
The A/C refrigerant pressure sensor assembly
attached to the air conditioning evaporator line, senses
refrigerant pressure on the air conditioning system highside. The refrigerant pressure status is sent to the ECM.
The purpose of this sensor is to inform the ECM of highside pressure status so the ECM can:
1. Control cooling fan assembly operation.
2. Prevent compressor assembly operation if ambient
temperatures are too cold.
3. Disable the compressor assembly before high-side
pressure becomes too high.
Refer to SECTION 8A-64 for more information.

Sensor Assembly
The air conditioning evaporator temperature sensor
assembly mounted to the heater and air conditioning
evaporator module assembly has a probe inserted into the
evaporator which measures evaporator temperature and
sends a signal to the ECM. Within the probe is a thermistor which varies resistance according to temperature, as
temperature increases, thermistor resistance decreases.
The purpose of this sensor assembly is to inform the ECM
of the evaporator temperature so the compressor assembly
can be disabled before the evaporator freezes. The evaporator temperature sensor assembly is a solid state device,
do not attempt to measure resistance unless instructed to
do so. Measuring resistance across pins can cause sensor
damage. Refer to SECTION 8A-64 for more information.
DIAGNOSIS
LEAK-TESTING THE REFRIGERATION
SYSTEM
A refrigerant leak test should be performed on the
system whenever a leak is suspected due to system indication of low charge or after any service operation which
disturbs the components, lines, or connections. Many
J 39400
PC6015-1 B-D-RP
A SERVICE FITTING VALVE
Figure 4 - Electric Halogen Leak Detector
methods and special tools are available for this purpose;

however, no matter which tool is used, care and diligence
are the biggest keys to success.
Electric Halogen Leak Detector

Figures 4 and 5
Tool Required:
J 39400 Halogen Leak Detector
This type of leak detector has been found to be the
most useful tool in locating refrigerant leaks. The J 39400
is a small unit which operates on 12 volts DC and provides
an audible signal which increases in frequency when leaking refrigerant is detected. There are three settings: one
for R-12, one for R-134a, and one for gross leaks. The
gross leak setting is for isolating very large leaks already
found at one of the other two settings. Care must be taken
that the instrument is properly calibrated, per the included
instructions, and that it is used at the proper setting for the
type of refrigerant in the system being tested.
J 39400
B REFRIGERANT LINE
J 39400
Evaporator Core
Because the evaporator core is contained in a closed
module and is inaccessible to leak detectors, it is one of
the most difficult parts of the air conditioning system to
check for leaks. To leak-test the evaporator core:
1. Turn the blower motor assembly on to high for 15 or
more seconds then shut it off.
2. Wait 10 minutes.
3. Remove blower motor resistor assembly. Refer to
SECTION lA.
4. Insert the leak detector probe into the resistor opening. If the detector goes to a solid alarm, a leak has
been found.
Compressor and Block Fitting

1. Blow shop air behind and in front of the compressor
clutch/pulley for at least 15 seconds.
2. Probe the compressor area. If the detector goes to a
solid alarm, a leak has been found.
C REFRIGERANT PRESSURE SENSOR ASSEMBLY OR

COMPRESSOR LOW PRESSURE CUT-OFF SWITCH
ASSEMBLY
PC0004-1BFRP
Figure 5 - Checking for Refrigerant Leaks
HEATER, VENTILATION AND AIR CONDITIONING 1B-7
Fluorescent Leak Detector

No fluorescent detection additive is currently
approved by GM for use in R-134a systems.
3.
Liquid Leak Detectors and Pressure Testing

Due to their lack of sensitivity, liquid/bubble leak
detectors have very limited usefulness and are not recommended.
CAUTION: R-134a service equipment or
vehicle A/C systems should not be
pressure tested or leak-tested with
compressed air. Some mixtures of
air/R134a have been shown to be combustible at elevated pressures. These
mixtures are potentially dangerous and
may result in fire or explosion causing
injury or property damage. Additional
health and safety information may be
obtained from refrigerant and lubricant
manufacturers.
4.
5.
6.
7.
8.
9.
ELIMINATING AIR CONDITIONING ODOR

Tool Required:
J 36645 A/C Evaporator Cleaning Gun
Some vehicles may experience odors emitted from
the air conditioning system primarily at start up in hot,
humid climates. This odor may be the result of debris in
the evaporator module case and/or microbial growth on
the evaporator core. To eliminate this condition, the following equipment and procedure should be used.
CAUTION: This procedure should only
be performed on a cold vehicle to prevent the disinfectant from coming in
contact with hot engine components
which could cause irritating vapors to
form.
Disinfectant can cause substantial, but
temporary, eye injury. Do not get in
eyes or on clothing. Wash thoroughly
with soap and water after handling disinfectant. If disinfectant gets into eyes,
hold eyelids open and flush with a
steady, gentle stream of water for fif
teen minutes. Obtain medical attention
if irritation persists.
10.
11.
12.
13.
14.
15.
[I] Important
This procedure will eliminate debris or microbial growth which can cause odors but will not
keep such debris or microbes present in the
environment from causing a recurrence of the
problem.
1. Remove heater core assembly. Refer to SECTION
IA.
2. Check evaporator module assembly case for debris,
remove any debris present. If debris is imbedded
into evaporator core face and cannot be removed,
the core will have to be removed from vehicle and
cleaned. If a large amount of debris is present in
evaporator module assembly case, the air inlet
16.
17.
screen will require sealing around the windshield

wiper post holes and fender edges.
Place drain pan with at least a two-liter (two-quart)
capacity below evaporator drain hole to collect disinfectant and rinse water runoff.
The evaporator drain hole is located at the bottom of the evaporator lower case approximately 25 mm (1 inch) from the dash panel
assembly (engine compartment side).
Connect battery charger to avoid draining battery
assembly during cleaning procedure.
Position pedestal fan and turn it on high speed to
provide cross ventilation during cleaning procedure.
Turn ignition switch to the "RUN" position but do
not start vehicle.
Set heater and air conditioning control assembly to
"LOW" blower motor speed, full "HOT" and
"HEATER."
Open all windows and doors and exit vehicle.
Put on rubber gloves, safety goggles (ordinary safety
glasses are not sufficient), and NIOSH-approved
acid gas/organic vapor respirator with chlorine dioxide cartridges, 3M P/N C1842 or equivalent.
Pour small bottle of two-part GM Goodwrench air
conditioning system disinfectant kit, GM P/N
25533404 or equivalent, into large bottle. Seal and
invert large container once or twice to mix contents.
Use J 36645 or equivalent siphon-type parts-cleaning spray gun capable of delivering 60 ml (2 ounces)
per minute of liquid when driven with 552 to 621
kPa (80 to 90 psi) of compressed air. Insert nozzle of
spray gun through heater core opening and insert
siphon hose into container of disinfectant. Direct
spray toward evaporator face taking extra care to
ensure adequate coverage of the corners and edges,
completely saturating the entire core. Use entire
container of solution.
Turn ignition switch to the "OFF" position and
allow core to soak for five minutes.
Check underneath vehicle to verify proper drain
operation. If necessary, unclog and increase drain
plug hole with a rat-tail file.
Turn the ignition switch to the "RUN" position but
do not start vehicle.
Thoroughly rinse evaporator core with one liter (one
quart) of clean water using spray gun to remove any
disinfectant residue.
Turn ignition switch to the "OFF" position and
install heater core assembly. Refer to SECTION IA.
Dispose of disinfectant and rinse water runoff collected in drain pan in an approved manner.
ON-VEHICLE SERVICE
REFRIGERATION SYSTEM SERVICES
Replacing 0-Rings
Install new GM-approved service replacement air
conditioning 0-rings when a joint or a fitting is installed,
except when the 0-rings are provided on new replacement
Always wear goggles and wrap a clean cloth around

fittings, valves, and connections when performing work
that involves opening the refrigerant system. Always
work in a well ventilated area and avoid breathing any
refrigerant fumes. Do not weld or steam clean on or near
any vehicle-installed air conditioning lines or components.
ers that meet DOT SPEC 4BA or 4BW

should be used.
NOTICE: R-12 refrigerant and R-134a refrigerant
must never be mixed, even in the smallest of
amounts, as they are incompatible with each other. If
the refrigerants are mixed, compressor failure is
likely to occur.
R-134a A/C system and only mineral base 525 viscosity refrigerant oil on fitting threads and 0-rings.
If lubricants other than those specified are used,
compressor failure and/or fitting seizure is likely to
occur.
Do not introduce compressed air to any refrigerant
container or refrigerant component, because contamination will occur.
Before attempting any service which requires opening refrigeration system lines or components, refer to
"Handling of Refrigerant Lines and Fittings" and "Maintaining Chemical Stability" that follow. Carefully follow
the instructions for refrigerant recovery and recycling,
adding oil, evacuating, and recharging the refrigeration
system.
All Refrigerant-134a disposable (colored blue) containers are shipped with a heavy metal screw cap to protect the valve and safety plug of the container from
damage. It is good practice to replace the cap after each
use of the container to continue protection.
If R-134a should come in contact with any part of

the body, flush the exposed area with water and immediately seek medical attention.
Handling Refrigerant Lines and Fittings
components. Unless service replacement 0-rings of the

specified part numbers are used, excessive leakage of
Refrigerant-134a may occur. Refer to the part number for
identification, not to the former color-coating method of
identification, because some formerly color-coated service replacement 0-rings may be black.
Air conditioning 0-rings should be coated with mineral base 525 viscosity refrigerant oil just before installation and should be slipped onto the flange tube to assure
proper locating and sealing. To prevent the possibility of
swelling and a reduction in sealing effectiveness, 0-rings
should not be allowed to soak in refrigerant oil. Before
installation, the 0-rings and the fittings should be
examined to insure that they have not been nicked or
deformed. Nicked or deformed parts must be replaced or
excessive refrigerant leakage may result.
Handling Refrigerant-134a
The air conditioning system in this vehicle contains
Refrigerant-134a (R-134a). This chemical mixture
requires special handling procedures to avoid personal
injury.
CAUTION: Avoid breathing A/C refrigerant and lubricant vapor or mist. Exposure may irritate eyes, nose, and throat.
To remove R-134a from the A/C system,
use service equipment certified to meet
the requirements of SAE J221 O or SAE
J2209. If accidental system discharge
occurs, ventilate work area before
resuming service. Additional health
and safety information may be
obtained from refrigerant and lubricant
manufacturers.
Do not store or heat refrigerant containers above 125F (52C).
Do not heat a refrigerant container with

an open flame; if container warming is
required, place the bottom of the container in a pail of warm water.
Do not intentionally drop, puncture, or

incinerate refrigerant containers.
Refrigerant will displace oxygen, therefore be certain to work in well ventilated

areas to prevent suffocation.
If it is necessary to carry a container of

"Dot CFR" Refrigerant-134a in a
vehicle, it should not be carried in the
passenger compartment. Only contain-
CAUTION: For personal protection,

goggles should be worn and a clean
cloth wrapped around fittings, valves
and connections when doing work that
includes opening the refrigeration system. If Refrigerant-134a comes in contact with any part of the body, severe
frostbite and personal injury can result.
The exposed area should be flushed
immediately with cold water and
prompt medical help should be
obtained.
All metal tubing lines should be free of dents or
kinks to prevent loss of system capacity due to line
restriction.
The flexible hose lines should never be bent to a
radius of less than four times the diameter of the
hose.
The flexible hose lines should never to allowed to
come within a distance of 63.5 mm (2 1/2 inches) of
the exhaust manifold.
Flexible hose lines should be inspected regularly for
leaks or brittleness and replaced with new lines if
deterioration or leaking is found.
When disconnecting any fitting in the refrigeration
system, the system must first be discharged of all
Refrigerant-134a. Refer to "Refrigerant Recovery

and Recycling, Adding Oil, Evacuating and
Recharging Procedures" in this section.
Once a refrigerant line is opened to the atmosphere,
it should be capped or taped immediately to prevent
entry of moisture and dirt.
The use of the proper wrenches when making connections on 0-ring fittings is important. The opposing fitting should always be backed up with a
wrench to prevent distortion of connecting lines or
components. Tighten all tubing connections to the
specified torque for the fitting. Too little or too much
torque when tightening can result in loose joints or
deformed joint parts. Either condition can result in
refrigerant leakage and an inoperative air conditioning system. Refer to "Fitting Tightening Specifications" at the end of this section.
0-rings and seats must be in perfect condition. A
burr or piece of dirt may cause a refrigerant leak.
Install new 0-rings that have been lubricated with
mineral base 525 viscosity refrigerant oil. Do not
use PAG oil.
Keep polyalkaline glycol (PAG) refrigerant oil off
fitting threads. Long term contact of PAG oil on
threads may cause future disassembly difficulties.
Flush threads of fittings with mineral base 525 viscosity refrigerant oil. Do not use PAG oil. Do not
wipe threads with a cloth.
Maintaining Chemical Stability in the

Refrigeration System
The efficient operation and life of the air conditioning system is dependent upon the chemical stability of the
refrigeration system. When foreign materials such as dirt,
air, or moisture, contaminate the refrigeration system, the
stability of the Refrigerant-134a and polyalkylene glycol
(PAG) synthetic refrigerant oil will change. Contaminants
will also affect pressure-temperature relationship, reduce
efficient operation and possibly cause interior corrosion
and abnormal wear of moving parts.
The following general practices should be observed
to ensure the chemical stability in the system:
Before breaking a refrigerant connection, wipe away
any dirt or oil to reduce the possibility of dirt entering the system. Both sides of the connection should
be capped, plugged or taped as soon as possible to
prevent the entry of dirt, foreign material and moisture.
Keep tools clean and dry. This includes the manifold
gage set and replacement parts.
When adding polyalkylene glycol (PAG) synthetic
refrigerant oil, the transfer device and container
should be exceptionally clean and dry to assure that
refrigerant oil remains as moisture-free as possible.
When it is necessary to "open" an A/C system, have
everything needed ready and handy so that as little
time as possible will be required to perform the
operation. Do not leave the A/C system open any
longer than is necessary.
Any time the A/C system has been "opened," it

should be properly evacuated before recharging with
Refrigerant-134a.
All service parts are dehydrated and sealed prior to
shipping. They should remain sealed until just prior
to making connections. All parts should be at room
temperature before uncapping. This prevents condensation of moisture from the air entering the system. If for any reason caps are removed but the
connections are not made, parts should be resealed
as soon as possible.
REFRIGERANT RECOVERY AND

RECYCLING, ADDING OIL, EVACUATING
AND RECHARGING P~CED_lJRJ:J...
General Description
.k ~,-#
I ,,,..03..- -/~
Figure 6
/The J 39500 air conditioning refrigerant recovery,
recycling and recharging (ACR 4 ) system removes Refrigerant-134a from the vehicle A/C system, recycles and
recharges all with one hook-up.
Single pass filtering during recovery cycle, plus
automatic multiple pass filtering during evacuation cycle
assures constant supply of clean/dry refrigerant for A/C
system charging.
NOTICE: R-12 and R-134a require separate and
non-interchangeable sets of recovery, recycling, and
recharging equipment, because the refrigerants and
lubricants are not compatible and cannot be mixed
even in the smallest amounts. Do not attempt to use
one set of equipment for both R-12 and R-134a, as
all equipment contains residual amounts of refrigerant and/or lubricant, which will result in contamination, and damage to the recovery/recyle equipment.
Adaptors to convert from one size fitting to the other
must never be used; refrigerant/lubricant contamination will occur and system failure may result.
Station (ACR4 ) Setup and Maintenance

Initial Setup
Refer to the manufacturer instructions for all initial
setup procedures.
Operation Setup
Figure 6
CAUTION: Always wear goggles and
gloves when doing work that involves
opening the refrigeration system. If liquid refrigerant comes into contact with
the skin or eyes, injury may result.
CAUTION: Use only authorized 23 kg
(SO-pound) refillable refrigerant tanks
(J 39500-50). Use of other tanks could
cause personal injury and void the warranty.
NOTICE: Refrigerant-134a systems have special
fittings (per SAE specifications) to avoid cross-contamination with Refrigerant-12 systems. Do not
attempt to adapt this unit to Refrigerant-12 systems
as severe system failure will result.
18-10 HEATER, VENTILATION AND AIR CONDITIONING
E
A
B
C
D
E
F
G
H
I
J
K
L
M
BOTTLE, OIL STORAGE

VALVE, OIL DRAIN
HOSE, BLUE
HOSE, RED
BOTTLE, OIL CATCH
HOSE, YELLOW
BOTTLE, SELECTED OIL
HOSE, LOW SIDE (BLUE)
COUPLER, QUICK DISCONNECT, LOW SIDE
COUPLER, QUICK DISCONNECT, HIGH SIDE
HOSE, HIGH SIDE (RED)
GROMMETS
VALVE, OIL INJECTION
A
B
C
D
E
F
G
H
I
DISPLAY, DIGITAL
GAGE, LOW SIDE
BEEPER
GAGE, HIGH SIDE
VLAVE, HIGH SIDE
INDICATOR, MOISTURE
VALVE, LOW SIDE
KEYPAD
SWITCH, MAIN POWER
PC0006-1 B-F-RP
PC0005-1 B-F-RP
Figure 6 - Complete Operational Setup
Figure 7 - Control Panel
Connect high-side (red) and low-side (blue) hoses to

the ACR4 unit. Be sure to route hoses through hose reel
bracket grommets.
In addition to the number keys, the control panel

contains special keys that accomplish specific operating
functions (Figure 8).
RECYCLE- activates the recycling sequence.
RECOVER- activates the recovery sequence.
SHIFT/RESET - activates "shifted" position of
keys on the keypad and resets the program mode.
FILTER - automatically recovers and evacuates to
57 kPa ( 17 inches Hg) vacuum from the filter and
low side of the unit.
CHG - automatically charges the A/C system with
the programmed amount of refrigerant.
HOLD/CONT - interrupts the automatic cycle in
the "HOLD" position, and then resumes functions
in the "CONT" position. Press this button once for
"HOLD" and again for "CONT."
VACUUM - activates the vacuum and automatic
recycling sequence.
ENTER - enters programmed data into the unit control memory.
Control Panel Functions

Figures 7 and 8
This section explains the functions of the various
components of the unit control panel (Figure 7).
Main Power Switch - supplies electrical power to
the control panel.
Beeper - emits an audible tone to alert the operator
to unit operating functions.
Digital Display - shows the time programmed for
vacuum and the weight of refrigerant programmed
for recharging.
Low-Side Manifold Gage - when connected to an
A/C system, this gage shows the system low-side
pressure.
High-Side Manifold Gage - when connected to an
A/C system, this gage shows the system high-side
pressure.
Moisture Indicator - shows if the refrigerant is wet
or dry.
Low-Side Valve - connects the low side of the A/C
system to the unit.
High-Side Valve - connects the high side of the A/C
system to the unit.
Digital Display Functions

For information regarding the functions of the digital display, refer to the manufacturer instructions.
Maintenance
Refer to manufacturer instructions for all maintenance procedures.
[I] Important
If there is no refrigerant in the A/C system, do
RECYCLE
FILTtA
GJC?JrnG
4.
'4'
'61~G)
L !'51
J~
~
6.
CIJ@B
~Mi ~ @!!.)
~
'QI
(ENTEA)
5.
7.
8.
9.
10.
PC0007-1B-F-RP
Figure 8 - Keypad Functions
Refrigerant Recovery
Figures 6 through 9
Important
Use only the 23 kg (50-pound) unit refrierant

tank (J 39500-50) designed for the ACR . The
unit overfill limitation mechanism has been
calibrated specifically for use with this tank,
and the tank valving is set up specifically for
use with the unit.
Connect battery charger to vehicle battery
assembly to prevent battery assembly drain.
1. Attach the high-side (red) hose with the quick disconnect coupler to the high-side refrigerant service
valve fitting of the vehicle A/C system. This valve is
located in the receiver dehydrator tube, between the
receiver and dehydrator assembly and the condenser
assembly. Open the coupler valve after attachment.
2. Attach the low-side (blue) hose with the quick disconnect coupler to the low-side refrigerant charge
valve fitting of the vehicle A/C system. This valve is
located in the compressor and condenser hose
assembly, between the compressor assembly and the
thermostatic expansion valve assembly. Open the
coupler valve after attachment.
3. Check the high-side and low-side gages on the unit
control panel to be sure the A/C system has pressure.
If there is no pressure, there is no refrigerant in the
system to recover.
not continue with the recovery operation. Air

will be drawn into the recovery tank.
Open both the high-side and the low-side valves on
the control panel (Figure 7).
Open both the red "GAS" (vapor) and the blue
"LIQUID" valves on the tank.
Slowly open the oil drain valve to see if the oil separator contains oil (Figure 6).
If any oil drains into the catch bottle at the bottom of the unit, allow it to drain until there is
no more oil in the separator.
Close the oil drain valve.
Dispose of the oil in the catch bottle in an
appropriate manner and return the bottle to its
place on the unit.
Plug the unit into the proper voltage outlet and turn
on the "MAIN POWER" switch.
Start engine and run for one minute with A/C system
"ON" in order to stabilize system.
Turn ignition switch "OFF," then back to "RUN,"
and blower motor assembly to "HIGH." A battery
charger should be connected to prevent battery
assembly drain.
[I] Important
Blower motor assembly setting to "HIGH"
will increase the rate at which refrigerant can
be recovered.
11. Press ''RECOVER'' on the keypad. Before recovery
begins, the unit will clear itself of refrigerant.
"CL-L" will appear on the display. The cleaning
process takes from thirty seconds to three minutes to
complete (Figure 9).
[I] Important
Maintain A/C blower motor assembly on
"HIGH" during recovery operation.
12. When cleaning is complete. The unit will automatically start recovery, and the control panel display
will show the unit is in the "RECOVER" mode of
the "AUTOMATIC" cycle. Also, the weight of
refrigerant being recovered will be displayed.
13. The compressor shuts off automatically when initial
recovery has occurred, at approximately 57 kPa (17
inches Hg) vacuum.
14. At the end of the initial recovery process, the display
shows "CPL" and then alternately flashes the
weight of refrigerant recovered and "OIL/OZ"
("OIL/GMS ").
[I] Important
A small amount of A/C system lubricating oil
polyalkylene glycol (PAG) might be removed
with the refrigerant during recovery. The
amount of oil removed (often there will be
MAIN POWER ~ . - n
SWITCH
20. If the "LOW-SIDE GAGE" pressure rises above

"O," this indicates the presence of more refrigerant
in the system. In this case, press the "HOLD/
CONT" key on the keypad to recover the additional
refrigerant. Repeat this step as needed until the system maintains vacuum for two minutes.
D
mmrno
rn
l!l@B
01!ll!l0
@80
RECOVER
CL-L
DISPLAY
-D.DD
La
Ill
DISPLAY
-OJ>
CPL
OI.IIUCIESI
DISPLAY
HCIU)
7.5*
La
Ill
DISPLAY
("Sample Value)
PCOOOB-1 B-F-RP
Figure 9 - Refrigerant Recovery
15.
16.
17.
18.
19.
none) will vary greatly depending on a variety

of conditions of the vehicle being serviced.
The ACR4 separates the oil from the refrigerant.
The "OIL/OZ" ("OIL/GMS") flashing is a
reminder to always drain the recovered oil at
this time. The same amount of oil must be
replaced in to the A/C system later when the
system is recharged with refrigerant.
Slowly open the oil drain valve and drain the oil into
the calibrated oil catch bottle at the bottom of the
unit (Figure 6).
After the oil is completely drained, close the valve.
Read and record the amount of oil removed in the
catch bottle.
Dispose of the recovered oil in an appropriate manner. Never reuse this oil.
Check the control panel "LOW-SIDE GAGE."
If the A/C system has maintained a vacuum,
the recovery is complete.
Important
If the display flashes "FULL" during the

recovery process, and the unit shuts off, the
unit tank is full.
An empty unit tank (J 39500-50) must be
installed to accommodate additional refrigerant, before proceeding to the next step in the
recovery operation. Do not use any other kind
of tank.
It is possible to lower the amount of refrigerant
in the unit tank by charging other vehicles.
Evacuation
Figures 10 and 11
Make sure the unit tank has sufficient R-134a refrigerant for charging. Simultaneously press "RESET" and
"ENTER" to enter the diagnostic mode. Then press "6."
The display must show 16 kg (36 pounds) or more. If less
than 16 kg (36 pounds) is displayed, add new refrigerant
to the tank. See the manufacturer instructions for this procedure.
1. With the high side and low side hoses connected to
the vehicle A/C system, open both the high-side
(red) and the low-side (blue) valves on the unit control panel.
2. Open both the red "GAS" (vapor) and the blue
"LIQUID" valves on the tank.
rn
Important
To remove all the air and properly dry the A/C

system, the unit automatically goes to a preprogrammed evacuation time.
It is possible to evacuate longer. Press keys to
enter time desired. New entry will show on the
display. Press "ENTER," the display will
blink indicating input of data (Figure 10).
15.0
DISPLAY
PC0009-1 BfRP
Figure 10 - System Evacuation (1 of 2)

3. Press "VACUUM" to start the vacuum pump. The
display counts down the vacuum time to zero to indicate operation time remaining. The display reads
"RECYCLE" five seconds after the vacuum pump
starts and continues while the process takes place.
rn
Important
Automatic refrigerant recycling during each

evacuation is a feature of the ACR4 system. No
action is required by the technician.
The control panel "MOISTURE INDICATOR" must be green during recycling verifying refrigerant moisture content is within
specifications. Yellow indicates a set condition
requiring a filter/drier cartridge change. See
the manufacturer instructions for this procedure.
Non-condensable gases (mostly air) are automatically vented from the tank during the
recycling process. An audible sound of pressure release may be heard as this happens. This
is a normal function.
4. At approximately the 12-minute mark on the display
(pump has run for three minutes), press "HOLD/
CONT" key to stop vacuum pump (Figure 11 ).
A. A "O" vacuum reading indicates a major system leak. Repair leak and restart evacuation
procedure.
B. If a vacuum reading of 91-101 kPa (27-30
inches of Hg) is indicated, close the low-side
and high-side valves. Observe the vacuum
level for a few minutes as a leak check of the
A/C system. If vacuum is not maintained, find
~nd repair the A/C system leak before continuing.
C. If a vacuum reading of 91-101 kPa (27-30
inches of Hg) is maintained, open the high-side

and low-side valves and press the "HOLD/
CONT" key to restart the vacuum pump.
5. When the vacuum sequence has run the programmed time, the display shows "CPL" to indicate
that evacuation is complete.
rn
12.0
Important
The vacuum pump oil must be changed frequently.

When the pump has run for a total time of ten
hours, the message "OIL" will flash on the
control panel display as a reminder to change
the oil.
If the "OIL" warning flashes during operation,
press "CONT" and change the oil before the
next operation. See the manufacturer instructions for this procedure.
A/C System Oil Charge Replenishing

If oil was removed from the AC system during the
recovery process or due to component replacement, it
must be replenished at this time. Refer to "Refrigerant Oil
Distribution" that follows for proper oil capacities.
DISPLAY
HOLD/CONT
@)o@J
0
; ;
A
A LOW SIDE VALVE OPEN

B HIGH SIDE VALVE OPEN
PC0010-1 B-F-RP
Figure 11 - System Evacuation (2 of 2)
1. Select the graduated bottle of replenishing polyalkylene glycol (PAG) synthetic refrigerant oil (GM PIN
12345923 or equivalent).
2. Adjust the 0-ring around the PAG oil bottle to the
required oil charge level.
Example: If bottle oil level is at 4 ounces and 1/2
ounce of oil is required, adjust 0-rings to 3 1/2
ounces as final level mark.
3. Install the bottle on the oil injection system on the
back of the unit.
rn
Important
Keep the oil bottles tightly capped at all times

to keep out moisture and contamination.
Do not open the oil injection valve while there
is positive pressure in the A/C system. This
will result in oil blow-back through the bottle
vent. A/C system vacuum is required for this
operation.
Never let the oil level drop below the pick-up
tube while charging or replenishing. This will
allow air into the A/C system.
4. Open the valve at the top of the plastic container and
watch the level of oil being drawn into the system.
5. Close the valve when the required oil charge has
been pulled into the system.
Refrigerant Oil Distribution

Compressor systems require 240 ml (8 fluid ounces)
of polyalkylene glycol (PAG) synthetic refrigerant oil

(GM P/N 12345923 or equivalent). During component
replacement and conditions stated, new oil quantities
should be added to the system as follows:
Compressor assembly replaced.
- If less than 30 ml ( 1 fluid ounce) is drained,
add 60 ml (2 fluid ounces).
If more than 30 ml (1 fluid ounce) is drained,
add same amount.
Receiver and dehydrator assembly replaced.
- Add 30 ml (1 fluid ounce) more than what was
drained from old receiver and dehydrator
assembly.
Evaporator replaced.
- Add 90 ml (3 fluid ounces) oil.
Condenser assembly replaced.
- Add 30 ml ( 1 fluid ounce) oil.
Refrigerant Oil Loss Due to a Large Leak

If the refrigerant charge is abruptly lost due to a large
refrigerant leak, approximately 90 ml (3 fluid ounces) of
refrigerant oil will be carried out of the system suspended
in the refrigerant. Any failure that caused an abrupt refrigerant discharge will experience this oil loss. Failures that
allow the refrigerant to seep or bleed off over time do not
experience this oil loss.
Upon replacement of a component which caused a
large refrigerant leak, add 90 ml (3 fluid ounces) of new
polyalkylene glycol (PAG) synthetic refrigerant oil (GM
P/N 12345923 or equivalent) plus the required amount of
oil for the particular component (as outlined above).
Add the oil directly to the replaced component if
possible. If the oil cannot easily be added to the replaced
part, add the oil to the receiver dehydrator assembly.
Compressor System
Up to 120 ml (4 fluid ounces) of oil can collect in the
crankcase. Therefore, it is important when replacing a
compressor assembly that the oil in the old compressor
crankcase be drained and measured (discard the oil after
recording the amount).
All replacement compressor assemblies will be
shipped with approximately 240 ml (8 fluid ounces) of oil
in the crankcase. The oil must be drained and retained.
Then replace the oil in the same amount as previously
recorded from the old compressor assembly.
Charging the A/C System (Engine Off)

[I] Important
The A/C system must be evacuated prior to
charging.
Check that the "LB/KG" switch on the back of
the unit to be sure it is set for the desired units
of weight system (operate switch with main
power "OFF").
1. Close the low-side valve on the control panel.
2. Open the high-side valve on the control panel.

3. Press "CHG" on the keypad to be sure the unit is in
the program mode.
4. Enter the amount of refrigerant charge to charge the
A/C system by pressing the appropriate number
keys. Be sure to use correct unit of weight (pounds
or Kg).
[I] Important
Charge A/C system with amounts of R-134a
specified. Do not overcharge.
Charge A/C system (C60) with 0.91 kg (2.0
pounds).
5. Press "ENTER."
A blink of the display indicates the charge
amount is in the unit memory.
6. Press "CHG" on the keyboard to begin the charging
process.
7. The display shows "AUTOMATIC" and the
amount of refrigerant programmed for charging.
The display counts down to zero as the charging process proceeds.
At the end of the process, the display shows
"CPL."
[I] Important
If the transfer of refrigerant stops before complete, refer to "Unsuccessful Transfer" that
follows.
Successful Transfer Complete

1. Close the high-side valve on the unit control panel
(both valves should now be closed).
2. Start the vehicle and the A/C system and let run until
the readings on the high-side and low-side gages stabilize. Compare readings, outlet temperatures and
ambient temperature and humidity to the "Air
Conditioning Performance Chart" in SECTION
lBl.
3. With the A/C system running, close the high-side
coupler valve and disconnect the high-side (red)
hose from the vehicle.
4. Open both the high-side and low-side valves on the
control panel.
5. Refrigerant from both hoses will be drawn quickly
into the A/C system through the low-side (blue)
hose.
6. Close the low-side coupler valve and disconnect
from the vehicle.
Unsuccessful Transfer
On rare occasions, the total charge does not transfer
to the vehicle A/C system. There are two reasons why this
can occur.
1. If the transfer is too slow because the pressure in the
unit tank and the vehicle A/C system are about the
same, the unit will emit an audible signal and the
display shows the weight remaining for transfer. In
this case:

CHG
HOLD/CONT \
a
0@(1)0
ENTER~~
--....
a Du
000
~ ~
0(!)(1)0
r1_~ -
Q_r__QJ
SHIFT/ RESET-/-;-
j=;o.o
-\:
...
Ill
DISPLA'l
AlllaMIIC
1.9
DISPLAY
...
Ill
A BEEPER
B HIGH SIDE VALVE CLOSEO
C LOW SIDE VALVE OPEN
DISPLAY
,QD
PC00121B-F-RP
CPL
Figure 13 - System Charging (2 of 2)
DISPLAY
C. Recover the refrigerant that has been charged

into the system, refer to "Refrigerant Recovery" in this section.
A LOW SIDE VALVE CLOSED

B HIGH SIDE VALVE OPEN
PC0011-1B-FRP
Figure 12 - System Charging (1 of 2)
A. Close the high-side valve (Figure 13).

B. Open the low-side valve.
C. Start the vehicle A/C system, and press
"HOLD/CONT" on the keyboard. This will
put the remainder of the charge into the A/C
system.
D. Continue with the previous procedure, "Successful Transfer Complete."
2. If the transfer will not complete and the display
shows "CHECK REFRIGERANT," there is not
enough refrigerant in the tank to complete the process. This condition requires the recovery of the partial charge of refrigerant in the vehicle A/C system
and another complete evacuation and charge procedure.
A. Press "HOLD/CONT" on the keypad to interrupt the cycle.
B. Press "RESET" to reset the unit.
3. Add refrigerant to the tank following the manufacturer instructions, and refer to "Evacuation" in this
section.
REPLACEMENT PROCEDURES
CAUTION: For personal protection,
goggles should be worn and a clean
cloth wrapped around fittings, valves
and connections when doing work that
includes opening the refrigeration system. If Refrigerant-134a comes in contact with any part of the body, severe
frostbite and personal injury can result.
The exposed area should be flushed
immediately with cold water and
prompt medical help should be
obtained.
NOTICE: Tighten all tubing connections to the specified torque for the fitting. Too little or too much
torque when tightening can result in loose joints or
deformed joint parts. Either condition can result in
refrigerant leakage and an inoperative air conditioning system. Refer to "Fitting Tightening Specifications" at the end of this section.
Air Conditioning Compressor and

Condenser Hose Assembly
Figures 1, 2 and 14
l++I
Remove or Disconnect
1. Recover refrigerant. Refer to "Refrigerant Recovery

2. Electrical connector from switch (35).
3. Strap (34) from compressor and condenser hose
assembly (7).
4. Compressor and condenser hose assembly fitting at
thermostatic expansion valve assembly (6).
Discard seal ( 16).
condenser assembly (3).
Use a back-up wrench to hold condenser
assembly fitting while loosening compressor
and condenser hose assembly fitting.
Discard 0-ring ( 17).
7. Bolt/screw (30).
8. Compressor assembly. Refer to "Air Conditioning
Compressor Assembly" in this section.
9. Compressor and condenser hose assembly (7).
Discard seals (18).
l++I
1.
2.
3.
4.
5.
6.
Install or Connect
NOTICE: See "Notice" on page lB-1 of this section.

Clean fittings with mineral base 525 viscosity refrigerant oil.
Do not allow refrigerant oil to enter A/C system.
Seals (18) to compressor and condenser hose assembly (7).
Lightly coat seals (8) with mineral base 525
viscosity refrigerant oil.
Compressor and condenser hose assembly (7) into
position.
Compressor assembly. Refer to "Air Conditioning
Compressor Assembly" in this section.
0-ring (17) to compressor and condenser hose
assembly (7).
Compressor and condenser hose assembly fitting to
condenser assembly (3).
l~I
l~I
Bolt/screw (30) to 10 Nm (89 lb. in.).

8. Lower vehicle.
9. Seal (16) to compressor and condenser hose assembly fitting.
Lightly coat seal ( 16) with mineral base 525
10. Compressor and condenser hose assembly fitting to
l~I
11.
12.
13.
14.
Tighten
Compressor and condenser hose assembly fitting to 37 Nm (27 lb. ft.).

Strap (34) to compressor and condenser hose assembly (7).
Electrical connector to switch (35).
Charge A/C system. Refer to "Refrigerant Recovery
Leak-test fittings. Refer to "Leak-Testing the
Refrigeration System" in this section.
Air Conditioning Receiver Dehydrator Tube

Figures 1, 2 and 14
!++I

CAUTION: Refer to "Caution" under
"Disconnecting the Battery Negative
Cable Assembly" in SECTION OA.
2. Negative battery cable.
3. Bolt/screw (27).
4. Receiver dehydrator tube fitting at receiver and
dehydrator assembly (4).
Use a back-up wrench to hold receiver and
dehydrator assembly port while loosening
receiver dehydrator tube fitting.
5. Receiver dehydrator tube (9).
Discard 0-rings (13).
l++I
1.
2.
Tighten

7. Bolt/screw (30).
Tighten
3.
4.
Install or Connect

0-rings (13) to receiver dehydrator tube (9).
Lightly coat 0-rings (13) with mineral base
525 viscosity refrigerant oil.
Receiver dehydrator tube (9).
Bolt/screw (27).
18
28
oo
~oA
~46
IVIEWC I
A
2
3
4
6
7
8
9
13
14
16
VERTICAL REFERENCE LINE

COMPRESSOR ASSEMBLY, AIR CONDITIONING
CONDENSER ASSEMBLY, AIR CONDITIONING
RECEIVER DEHYDRATOR ASSEMBLY, AIR
CONDITIONING
VALVE ASSEMBLY, AIR CONDITIONING
HOSE ASSEMBLY, AIR CONDITIONING COMPRESSOR
AND CONDENSER
TUBE, AIR CONDITIONING EVAPORATOR
TUBE ASSEMBLY, AIR CONDITIONING RECEIVER
DEHYDRATOR
0-RING, AIR CONDITIONING RECEIVER DEHYDRATOR
TUBE
0-RING, AIR CONDITIONING EVAPORATOR TUBE
SEAL, AIR CONDITIONING COMPRESSOR AND
CONDENSER HOSE
17 0-RING, AIR CONDITIONING CONDENSER FITTING

18 SEAL, AIR CONDITIONING HOSE
DEHYDRATOR TUBE
CONDENSER HOSE
29 BOLT/SCREW, AIR CONDITIONING THERMOSTATIC
EXPANSION VALVE
CONDENSER HOSE CLIP BRACKET
32 BRACKET, AIR CONDITIONING COMPRESSOR AND
CONDENSER HOSE CLIP
34 STRAP, AIR CONDITIONING COMPRESSOR AND
CONDENSER HOSE
46 VALVE, AIR CONDITIONING REFRIGERANT CHARGE
PC0013-1B-F-RP
Figure 14 - Refrigerant Lines and Hoses

Do not tighten at this time.
5. Receiver dehydrator tube fitting to receiver and
l~I
Tighten
Receiver dehydrator tube fitting to 27 Nm (20

lb. ft.).
Bolt/screw (27) to 16 Nm (12 lb. ft.).
6. Charge A/C system. Refer to "Refrigerant Recovery
7. Leak-test fittings. Refer to "Leak-Testing the
l~I
Evaporator tube fitting at receiver and dehydrator assembly (4) to 7 Nm (62 lb. in.).
Evaporator tube fitting at thermostatic expansion valve assembly to 18 Nm (13 lb. ft.).
5. Bolt/screw (12).
!~I Tighten
6.
7.
8.
Air Conditioning Evaporator Tube

9.
Figures 1, 2 and 14

2. Electrical connector at refrigerant pressure sensor
assembly (22).
3. Strap (34) from evaporator tube (8).
4. Receiver dehydrator tube. Refer to "Air Conditioning Receiver Dehydrator Tube" in this section.
5. Bolt/screw (12).
6. Evaporator tube fitting at receiver and dehydrator
assembly (4).
evaporator tube fitting.
7. Evaporator tube fitting at thermostatic expansion
valve assembly (6).
8. Evaporator tube (8).

1.
2.
3.
4.

Clean evaporator tube fittings with mineral base 525
Do not allow refrigerant oil to enter evaporator
tube (8).
0-rings to evaporator tube (8).
Lightly coat 0-rings with mineral base 525
Evaporator tube fitting at thermostatic expansion
valve assembly (6).
Evaporator tube fitting at receiver and dehydrator
assembly (4).
Tighten
10.

Receiver dehydrator tube. Refer to "Air Conditioning Receiver Dehydrator Tube" in this section.
Strap (34) to evaporator tube (8).
Electrical connector at refrigerant pressure sensor
(22).
Charge A/C system. Refer to "Refrigerant Recovery
Leak-test fittings. Refer to "Leak-Testing the
Air Conditioning Thermostatic Expansion

Valve Assembly
Figures 1, 2 and 14

2. Evaporator tube. Refer to "Air Conditioning Evaporator Tube" in this section.
Discard seal (16).
4. Bolts/screws (29).
5. Thermostatic expansion valve assembly (6).
6. Seals (15) from evaporator (5).
Discard seals (15).

1. Seals (15) to evaporator (5).
Lightly coat seals with mineral base 525 viscosity refrigerant oil.
2. Thermostatic expansion valve assembly (6).
!~I Tighten
Bolts/screws (29) to 7 Nm (62 lb. in.).
4. Clean compressor and condenser hose assembly fitting with mineral base 525 viscosity refrigerant oil.

5. Seal (16) to compressor and condenser hose assembly (7).
Lightly coat seal with mineral base 525 viscosity refrigerant oil.
6. Compressor and condenser hose assembly fitting to
l~I
Air Conditioning Receiver and Dehydrator

Assembly
Figures 1, 2 and 14
1.
2.
3.
4.
5.
6.
7.
8.
3.
Tighten

7. Evaporator tube. Refer to "Air Conditioning Evaporator Tube" in this section.
l+I
2.

Negative battery cable.
Recover refrigerant. Refer to "Refrigerant Recovery
Bolt/screw (27).
Receiver dehydrator tube fitting at receiver and
receiver dehydrator tube fitting.
Receiver dehydrator tube (9).
Bolt/screw (11) at receiver dehydrator bracket
clamp.
Evaporator tube fitting at receiver and dehydrator
assembly (4).
evaporator tube fitting.
Receiver and dehydrator assembly (4) from bracket
(10).
Discard 0-ring (14).
!++! Install or Connect

1. If receiver and dehydrator assembly is being
replaced, drain and measure amount of PAG oil in
old receiver and dehydrator assembly. Add the
drained amount plus 30 ml (1 fluid ounce) more of
4.
5.
new PAG oil to new receiver and dehydrator assembly.

Receiver and dehydrator assembly (4) to bracket
(10).
0-ring (14) to evaporator tube (8).
Lightly coat 0-ring (14) with mineral base 525
Evaporator tube fitting to receiver and dehydrator
assembly (4).
l~I
Tighten
Evaporator tube fitting to 7 Nm (62 lb. in.).

6. Bolt/screw (11) at receiver dehydrator bracket
clamp.
l~I
Tighten

7. 0-rings (13) to receiver dehydrator tube (9).
8. Receiver dehydrator tube (9).
9. Bolt/screw (27).
10. Receiver dehydrator tube fitting to receiver and
l~I
Tighten
Receiver dehydrator tube fitting to 27 Nm (20

lb. ft.).
Air Conditioning Condenser Assembly

Figures 1, 2, 14 and 15
l+I
2.
3.
4.
5.
6.
7.
8.

Air intake duct. Refer to SECTION 6E3.
Air cleaner assembly. Refer to SECTION 6E3.
Upper radiator shroud assembly. Refer to SECTION
6B.
Raise and suitably support vehicle. Refer to SECTION OA.
Drain engine coolant. Refer to SECTION 6B.
Electric engine cooling fan assembly. Refer to SECTION 6B.
Thermostat by-pass hose assembly at water pump
assembly.
47
A
B
C
3
47
TANG, CONDENSER ASSEMBLY RETAINING

GROOVE
CONDENSER TUBE
CONDENSER ASSEMBLY, AIR CONDITIONING
RADIATOR ASSEMBLY
PC0014-1 B-F-RP
Figure 15 - Condenser Assembly
9. Transmission oil cooler pipe assemblies at radiator

assembly, if equipped. Refer to SECTION 7 A.
10. Coolant level sensor electrical connector at radiator
assembly (47), if equipped.
11. Hose assembly (7) at condenser assembly (3).
Discard 0-ring ( 17).
12. Lower vehicle.
13. Lower radiator hose assembly at water pump assembly. Refer to SECTION 6B.
14. Upper radiator hose assembly. Refer to SECTION
6B.
15. Overflow tube at radiator assembly (47).
17. Condenser assembly (3) with radiator assembly (47)
attached, from vehicle.
18. Condenser assembly (3) from radiator assembly
(47).
Disconnect retaining tangs from grooves.
19. Radiator air upper baffle from condenser assembly,
if necessary. Refer to SECTION 6B.

1. Radiator air upper baffle to condenser assembly, if
removed. Refer to SECTION 6B.
2. Condenser assembly (3) to radiator assembly (47).

Retaining tangs must be fully seated in grooves
(Figure 15).
3. Condenser assembly (3) with radiator assembly (47)
attached, to vehicle.
5. Overflow tube at radiator assembly (47).
6. Upper radiator hose assembly. Refer to SECTION
6B.
7. Lower radiator hose assembly at water pump assembly. Refer to SECTION 6B.
9. Clean hose assembly fitting and condenser assembly
fitting with mineral base 525 viscosity refrigerant
oil.
10. 0-ring (17) to hose assembly (7).
Lightly coat 0-ring with mineral base 525 viscosity refrigerant oil.
11. Hose assembly (7) to condenser assembly {3).
l~I Tighten
Hose assembly fitting to 27 Nm (20 lb. ft.).
12. Coolant level sensor electrical connector at radiator
assembly (47), if equipped.
13. Transmission oil cooler pipe assemblies at radiator
assembly, if equipped. Refer to SECTION 7A.
14. Thermostat by-pass hose assembly at water pump
assembly.
15. Electric engine cooling fan assembly. Refer to SECTION 6B.
16. Lower vehicle.
17. Upper radiator shroud assembly. Refer to SECTION
6B.
18. Air cleaner assembly. Refer to SECTION 6E3.
19. Air intake duct. Refer to SECTION 6E3.
20. Fill and bleed cooling system. Refer to SECTION
6B.
21. Check transmission fluid level and add, if necessary.
Air Conditioning Compressor Assembly


HEATER, VENTILATION AND AIR CONDITIONING 1821
32
41

32 BRACKET, AIR CONDITIONING COMPRESSOR AND
CONDENSER HOSE CLIP
38 BOLT/SCREW, AIR CONDITIONING COMPRESSOR
39 BOLT/SCREW, AIR CONDITIONING COMPRESSOR REAR
BRACKET
40 BRACKET, AIR CONDITIONING COMPRESSOR REAR
41 BOLT/SCREW, AIR CONDITIONING COMPRESSOR REAR
BRACKET
jv1ewA
PC0015-1B-F-RP
Figure 16 - Air Conditioning Compressor Assembly Mounting and Bracket ( 5. 7L LT1 Engine)

3. Serpentine drive belt. Refer to SECTION 6A2A
(3.4L L32 engine) or SECTION 6A3A (5.7L LTl
engine).
4. Drive belt tensioner assembly, 5.7L LTl engine
only. Refer to SECTION 6A3A.
5. Bolt/screw (30).
6. Bolt/screw (28).
7. Hose assembly (7) from compressor assembly (2).
Discard seals (18).
8. Lower transmission oil cooler pipe assembly at
radiator assembly. Refer to SECTION 7A.
9. Electrical connector at compressor assembly (2).
10. Bolt/screw (41) on 5.7L LTl engine only.
11. Bolts/screws (45) on 3.4L L32 engine only.
13. Compressor assembly (2).
14. Bolts/screws (44) and support (43) on 3.4L L32
engine only, if necessary.
15. Bolts/screws (39) and bracket (40) on 5.7L LTl
engine only, if necessary.

1. Polyalkaline glycol (PAG) refrigerant oil.
If compressor assembly (2) is being replaced,

drain refrigerant oil from both defective compressor and new replacement compressor.
Measure amount removed from defective compressor. If measured amount is less than 30 ml
( 1 fluid ounce), add 60 ml (2 fluid ounces) to
new replacement compressor. If more that
30 ml (1 fluid ounce) is drained from defective
compressor add same amount to new compressor. Use PAG refrigerant oil GM P/N
12345923 or equivalent.
2. Bracket (40) and bolts/screws (39) on 5. 7L LTl

engine only, if removed.
l~I
Tighten
Bolts/screws (39) to 25 Nm (18 lb. ft.).

3. Support (43) and bolts/screws (44) on 3.4L L32
engine only, if removed.
l~I
Tighten

4. Compressor assembly (2).
l~I
Tighten

2
38
43
44
45

BOLT/SCREW, AIR CONDITIONING COMPRESSOR
SUPPORT, AIR CONDITIONING COMPRESSOR
SUPPORT
jvrEWA
I
PC0016-1BF-RP
Figure 17 - Air Conditioning Compressor Assembly Mounting and Support (3.4L L32 Engine)
l~I
Tighten

7. Bolt/screw (41) on 5.7L LTl engine only.
l~I
Tighten
Bolt/screw (41) to 33 N m (24 lb. ft.).

8. Electrical connector at compressor assembly (2).
9. Lower transmission oil cooler pipe assembly at
radiator assembly. Refer to SECTION 7A.
10. Seals (18) to hose assembly (7).
Lightly coat seals with mineral base 525 viscosity refrigerant oil.
11. Hose assembly (7) to compressor assembly (2).
12. Bolt/screw (28).
l~I
Tighten

l~I
Tighten

14. Drive belt tensioner assembly, 5.7L LTl engine
only. Refer to SECTION 6A3A.
15. Serpentine drive belt. Refer to SECTION 6A2A

(3.4L L32 engine) or SECTION 6A3A (5.7L LTl
engine).
16. Lower vehicle.
18. Leak-test A/C system. Refer to "Leak-Testing the
Air Conditioning Refrigerant Service Valve

Figures 1 and 2
Tool Required:
J 39037 Octagon Socket

2. Valve cap (24).
3. Service valve (25).
Use J 39037 to remove valve.

1. Service valve (25).
Coat seal ( 19) with mineral base 525 viscosity
refrigerant oil.
Use J 39037 to install valve.
l~I Tighten
Service valve to 11 Nm (97 lb. in.).
2. Valve cap (24).
4. Leak-test valve. Refer to "Leak-Testing the Refrigeration System" in this section.
1. Bracket assembly (48).

2. Spark plug wire support (53).
3. Bolts/screws (49, 50, 51 and 52) loosely.
l~I Tighten
In sequence:

and Power Steering Pump Bracket Assembly
(5.7L LT1 Engine)
Figure 18

4. Air conditioning compressor assembly. Refer to
"Air Conditioning Compressor Assembly" in this
section.

1. Generator assembly. Refer to SECTION 603.
2. Power steering pump assembly. Refer to SECTION
3B.
section.
4. Bolts/screws (49, 50, 51 and 52).
5. Spark plug wire support (53).

3B.
7. Bleed power steering system. Refer to SECTION
3B.
9. Leak-test A/C fitting at rear of compressor assembly. Refer to "Leak-Testing the Refrigeration System" in this section.

Bracket Assembly (3.4L L32 Engine)
Figure 19

section.
3. Serpentine drive belt tensioner assembly. Refer to
SECTION 6A2A.
5. Stud (57).
50
48 BRACKET ASSEMBLY, GENERATOR AND AIR
CONDITIONING COMPRESSOR AND POWER STEERING
PUMP
49 BOLT/SCREW, GENERATOR BRACKET
53 SUPPORT, SPARK PLUG WIRE
54 ENGINE ASSEMBLY (5.7L LT1)
PC00171B-F-RP
Figure 18- Bracket Assembly (5.7L LT1 Engine)

2. Stud (57).
l~I
Tighten

Stud (57) to 33 Nm (24 lb. ft.).
SECTION 6A2A.
section.
8. Leak-test fitting at rear of compressor assembly.
Refer to "Leak-Testing the Refrigeration System"
in this section.

Component Replacement
57
CONDITIONING COMPRESSOR
57 STUD, GENERATOR BRACKET
58 ENGINE ASSEMBLY (3.4L L32)
PC0018 1B-F-RP
Figure 19 - Bracket Assembly (3.4L L32 Engine)
Due to the limited clearance on the 5.7L LTl engine,

it is recommended that the compressor assembly be serviced after the compressor assembly is removed from the
vehicle. Vehicles with 3.4L L32 engines have clearance to
service compressor assembly minor components on-vehicle. For component replacement procedures, refer to
SECTION 102.
SPECIFICATIONS
GENERAL SPECIFICATIONS
A/C System 0-Ring and Fitting Lubricant .......................... 525 Viscosity Mineral Oil,
GM P/N 12301108 or Equivalent
A/C System Internal Lubricant (Including Compressor Assembly) ...... Polyalkaline Glycol (PAG)
SyntheticRefrigerant Oil
GM P/N 12345923 or Equivalent
A/C System R-134a Charge Capacity ...................................... 0.91 kg (2.0 lb.)

Air Conditioning Compressor Bolt/Screw (To Main Bracket, All Engines) ...... 50 Nm (37 lb. ft.)
Air Conditioning Compressor (Rear Support) Bolt/Screw
(To Compressor Assembly, 3.4L L32 Engine) ........................... 25 Nm (18 lb. ft.)
Air Conditioning Compressor and Condenser Hose Bolt/Screw ............... 33 Nm (24 lb. ft.)
Air Conditioning Compressor and Condenser Hose Clip Bolt/Screw ........... 10 Nm (89 lb. in.)
Air Conditioning Compressor Low Pressure Cutoff Switch Assembly ........... 6 Nm (53 lb. in.)
Air Conditioning Compressor Rear Bracket Bolt/Screw
(To Compressor Assembly, 5.7L LTl Engine) ........................... 25 Nm (18 lb. ft.)
Air Conditioning Compressor Rear Bracket Bolt/Screw (To 5.7L LTl Engine) ... 33 Nm (24 lb. ft.)
Air Conditioning Compressor Rear Support Bolt/Screw (To 3.4L L32 Engine) ... 50 Nm (37 lb. ft.)
Air Conditioning Receiver Dehydrator Bracket Bolt/Screw .................. 14 Nm (10 lb. ft.)
Air Conditioning Receiver Dehydrator Bracket Clamp Bolt/Screw .............. 9 Nm (80 lb. in.)
Air Conditioning Receiver Dehydrator Tube Bolt/Screw ..................... 16 Nm (12 lb. ft.)
Air Conditioning Refrigerant Pressure Sensor Assembly ..................... 6 Nm (53 lb. in.)
Air Conditioning Refrigerant Service Valve ............................... 11 Nm (97 lb. in.)
Air Conditioning Thermostatic Expansion Valve Bolt/Screw .................. 7 Nm (62 lb. in.)
Generator Bracket Bolt/Screw ......................................... 33 Nm (24 lb. ft.)
Generator Bracket Stud ............................................... 33 Nm (24 lb. ft.)
FITIING TIGHTENING SPECIFICATIONS

Air Conditioning Compressor and Condenser Hose Assembly Fitting
(At Condenser Assembly) ........................................... 27 Nm (20 lb. ft.)
Air Conditioning Compressor and Condenser Hose Assembly Fitting
(At Thermostatic Expansion Valve Assembly) ........................... 37 Nm (27 lb. ft.)
Air Conditioning Evaporator Tube Fitting
(At Receiver and Dehydrator Assembly) ................................ 7 Nm (62 lb. in.)
Air Conditioning Evaporator Tube Fitting
(At Thermostatic Expansion Valve Assembly) ........................... 18 Nm (13 lb. ft.)
Air Conditioning Receiver Dehydrator Tube Fitting
(At Receiver and Dehydrator Assembly) ............................... 27 Nm (20 lb. ft.)
SPECIAL TOOLS
1.
4.
J 39400
2.
J 39500
5.
J 39037
3.
J 36645
6.
J 6742-03
J 39183-C
7.
1.
2.
3.
4.
HALOGEN LEAK DETECTOR

OCTAGON SOCKET
PRECISION THERMOMETER
AIR CONDITIONING REFRIGERANT RECOVERY,
RECYCLING AND RECHARGING (ACR 4 ) SYSTEM
5. AIR CONDITIONING EVAPORATOR CLEANING GUN
6. R-134a MANIFOLD GAUGE SET
7. 50 LB REFILLABLE RECOVERY TANK
J 39500-50
PCC0019-1B-F-RP
MANUAL CONTROL AIR CONDITIONING 181-1
SECTION 181
MANUAL CONTROL AIR CONDITIONING

CAUTIONS in Section 9J under 'ON-VEHICLE SERVICE" and the SIR Component and Wiring
Location View in Section 9J before performing service on or around SIR components or
result.
CONTENTS
General Description . . . . . . . . . . . . . . . . . . . . . . . 1B 1-1
Overview ............................. lBl-1
Control Assembly ...................... lBl-2
Temperature Control .................. lBl-2
Mode Control ........................ lBl-2
Blower Motor Speed Control ............ lBl-3
Air Distribution System . . . . . . . . . . . . . . . . . . 1B 1-3
Vacuum System ...................... lBl-3
Other Components . . . . . . . . . . . . . . . . . . . . 1B 1-4
Air Inlet Valve ....................... lBl-4
Blower Motor Assembly and Evaporator .. lBl-5
Assembly ......................... lBl-5
Bi-Level Valve ....................... lBl-5
Upper and Lower Mode Valve ........... lBl-5
Heater and Defrost Valve ............... lBl-5
Ducts and Outlets ..................... lBl-5
Ventilation . . . . . . . . . . . . . . . . . . . . . . . . . . 1B 1-5
Refrigeration System . . . . . . . . . . . . . . . . . . . . 1B 1-7
Refrigerant R-134a ................... lBl-7
Compressor Assembly ................. lBl-8
Condenser Assembly .................. lBl-9
Thermostatic Expansion Valve Assembly .. lBl-9
Evaporator . . . . . . . . . . . . . . . . . . . . . . . . . . 1B 1-9
Receiver Dehydrator Assembly .......... lBl-9
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B 1-10
Functional Test . . . . . . . . . . . . . . . . . . . . . . . . 1B 1-10
Insufficient Cooling Check . . . . . . . . . . . . . . 1B 1-10
Improper Air Delivery .................. lBl-10

Air Conditioning Performance Test . . . . . . . . 1B 1-11
Insufficient Heat Check ....... Refer to Section lA
On-Vehicle Service ...................... lBl-15
Refrigeration System
Services . . . . . . . . . . . . . . . . . Refer to Section 1B
Control Assembly and
Components .............. Refer to Section lA
Temperature Control Cable
Assembly ................ Refer to Section lA
Blower Motor Resistor
Assembly ................ Refer to Section lA
Blower Motor Assembly Relay ........... lBl-15
Air Conditioning Compressor Relay ....... lBl-15
Sensor Assembly .................... lBl-15
Sensor Assembly .................... lBl-17
Air Conditioning Compressor Low Pressure
Cutoff Switch Assembly . . . . . . . . . . . . . . 1B 1-1 7
Vacuum Hose Harness ........ Refer to Section lA
Vacuum Actuator Assemblies . . . Refer to Section 1A
Heater Core Assembly ........ Refer to Section lA
Air Conditioning Evaporator . . . . . . . . . . . . . 1B 1-17
Specifications ........................... lBl-20
General Specifications .................. lBl-20
Component Tightening Specifications . . . . . . 1B 1-20
Special Tools ........................... lBl-20
GENERAL DESCRIPTION
assembly by the blower motor assembly. Additional outside air is also forced into the vehicle by forward movement of the vehicle.
OVERVIEW
Figures 1 and 2
The air conditioning system (C60) delivers air that
has been heated or cooled and dehumidified for occupant
comfort. It also provides power ventilation, and windshield assembly and side window defrosting.
During most operating conditions, outside air is
drawn through the heater and air conditioning module
Within the heater and air conditioning evaporator

module assembly, air is pushed by the blower motor
assembly through the evaporator, then through the heater
core assembly and into the passenger compartment. For
air conditioning or defroster operation at ambient temperatures above 7C (45F), the refrigeration system will
chill the evaporator to almost freezing. As the air passes
through the evaporator, the air temperature drops which
1812 MANUAL CONTROL AIR CONDITIONING
F
A
B
C
D
E
F
G
H
I
J
K
L
M
1
LOW BLOWER MOTOR SPEED

MEDIUM 1 BLOWER MOTOR SPEED
MEDIUM 2 BLOWER MOTOR SPEED
HIGH BLOWER MOTOR SPEED
TEMPERATURE CONTROL
"OFF" MODE
"MAX A/C" MODE
"NORMAL A/C" MODE
"Bl-LEVEL A/C" MODE
"VENT" MODE
"HEATER" MODE
"DEFROST BLEND" MODE
"DEFROST" MODE
CONTROL ASSEMBLY, HEATER AND AIR
CONDITIONING
2 SWITCH ASSEMBLY, REAR WINDOW DEFOGGER
PC2001 1B 1-F-RP
Figure 1 - Heater and Air Conditioning Control Assembly
causes moisture in the air to condense on the evaporator

core fins. This moisture leaves the vehicle by gravity feed
through a drain hole, dehumidifying the vehicle.
From the evaporator, some or all of the air may pass
through the heater core assembly, which is warmed by
engine coolant. Any of the air which is not to be heated
will mix with the heated air before entering the passenger
compartment.
When maximum air conditioning mode is selected,
most of the air entering the blower motor assembly is
taken from the passenger compartment (recirculated)
where it is most likely to be cooler than the outside air.
Only outside air is used in all other modes.
CONTROL ASSEMBLY
Temperature Control
Figure 1
The temperature control is mechanically linked to

the air temperature valve (door) by a temperature control
cable. Rotating the temperature control clockwise allows
more of the incoming or recirculated air to flow through
the heater core assembly, thus increasing the air temperature entering the vehicle. Rotating the temperature control
counterclockwise decreases air flow through the heater
core assembly, thus decreasing the air temperature entering the vehicle.
Mode Control
Figure 1
The mode control has eight settings: "OFF,"
"MAX," "A/C," "BI-LEVEL NC," "VENT,"
"HEATER," "DEFROST BLEND," and "DEFROST."
Some settings are symbols on the heater and air conditioning control assembly (1). These symbols are identified
in Figure 1. Each setting is described below.
"OFF" Mode
At this setting, electrical power is not supplied to the
blower motor assembly and A/C is not requested to the
engine control module (ECM). A small amount of air
which is forced into the heater and air conditioning
module assembly by forward movement of the vehicle
will still be discharged through the air outlets. This is the
only mode in which the blower motor assembly does not
operate.
"MAX" A/C Mode
The "MAX" A/C setting is one of five settings
which requests A/C operation to the ECM. At this setting
the blower motor assembly will operate in one of the four
blower motor speed control settings and air will be discharged from the instrument panel air outlets only.
To provide maximum air conditioning, most of the
air entering the heater and air conditioning module assembly is taken from the vehicle interior (recirculated) where
it is most likely cooler than the outside air. This is the only
mode in which air is recirculated, all other modes use
MANUAL CONTROL AIR CONDITIONING 181 3

outside air only. This setting would be most useful during
conditions of high temperature and humidity, or when the
outside air may have an objectionable odor.
Normal "A/C" Mode

The normal "A/C" setting functions the same as
"MAX" NC setting, except only outside air enters the
module. There may be a slight reduction of blower noise
compared to "MAX" A/C mode because the recirculation
valve (door) is closed.
"Bl-LEVEL A/C" Mode

The "BI-LEVEL NC" setting requests NC to the
ECM and allows the blower motor assembly to operate in
one of four settings similar to "MAX" A/C, except only
outside air enters the module and air is distributed through
the instrument panel outlets and the floor outlets (bilevel).
"VENT" Mode
The "VENT" setting does not request NC to the
ECM but allows the blower motor assembly to operate
normally. This is one of two economy modes (other than
"OFF") in which A/C is not requested. Air is discharged
through the instrument panel outlets only.
"HEATER" Mode
The "HEATER" setting functions the same as the
"VENT" setting, except most of the air is discharged
through the floor outlets with a small amount discharged
through the defroster outlets. The "HEATER" mode is
the normal selection for cold weather operation unless
windshield or side window defrosting is required.
"DE!=ROST BLEND" Mode

The "DEFROST BLEND" setting allows operation
of the blower motor assembly and sends an A/C request
signal to the ECM for compressor operation. During this
setting, air is discharged through the defroster and floor
air outlets. This setting allows greater passenger comfort
than "DEFROST" but is not as effective in defrosting the
windshield assembly and side windows.
"DEFROST" Mode
The "DEFROST" setting functions the same as
"DEFROST BLEND" setting except all air is discharged
through the defroster outlets.
Blower Motor Speed Control

Figure 1
With the ignition switch in the "RUN" position, the
blower motor assembly runs in all mode control positions
except "OFF." Blower motor assembly speed is controlled by a four-position electrical blower motor speed
control switch at the left side of the control assembly. The
blower motor speed control switch provides a choice of a
low blower motor assembly speed, two medium speeds,
and a high speed.
Electrical power is routed from the HVAC fuse

number 3 in the fuse block to the mode control switch.
The mode control switch breaks the circuit when it is in
the "OFF" position, and closes the circuit in all other
positions.
From the mode control switch, the circuit then goes
to the blower motor speed control switch. When the
blower motor speed control switch is in "LOW," current
is conducted to the resistor assembly. At the resistor
assembly, the current passes through all three resistors and
is reduced to provide the low blower motor assembly
speed.
When the blower switch is in either of the two
medium speed positions, it closes to send current through
either two or one of the resistors in the resistor assembly.
Because the current follows the path of least resistance,
the circuit branch leading directly to all three resistors
becomes ineffective and the current bypasses either one or
two resistors, depending upon which medium speed position is selected. The reduced resistance increases current
flow and blower motor assembly speed.
When the blower motor speed control switch is in
the "HIGH" position, it energizes the high blower relay
and power is taken from a separate circuit that is protected
by a fusible link. This separate power circuit is "hot" at
all times and has the capacity to handle the current
demands of the blower motor assembly at high speed.
The circuit to the blower motor assembly is completed to ground at the instrument panel assembly through
the instrument panel wiring harness. Refer to SECTION
8A for more electrical information.
AIR DISTRIBUTION SYSTEM

Figures 2 through 5
Air enters the heater and air conditioning evaporator
module assembly where it may be cooled for air conditioning or defrost modes, and then heated as necessary
before being sent to the proper outlets for discharge into
the passenger compartment. Within the heater and air
conditioning evaporator module assembly, valves (doors)
guide the airflow in response to the position of the mode
control.
Vacuum System
All valves in the heater and air conditioning evaporator module assembly except the temperature valve are
controlled by engine vacuum drawn from the vacuum
tank assembly, mounted to the right side body rail, just
behind the radiator support. The vacuum is routed by a
vacuum selector valve in the control assembly to springloaded vacuum actuator assemblies on the heater and air
conditioning evaporator module assembly. Vacuum stored
in the vacuum tank assembly is prevented from bleeding
back to its source during conditions of low engine manifold vacuum (acceleration, hard pulling, etc.) by a check
valve in the vacuum source hose.
The vacuum selector valve in the control assembly is
controlled by the mode control. For each mode control
position, the vacuum selector valve directs vacuum to
specific hoses to overcome the force of the spring within
the appropriate vacuum actuator assemblies. The vacuum
selector valve also vents the hoses to each remaining
181-4 MANUAL CONTROL AIR CONDITIONING
11
9
4
A
B
C
D
E
F
G
3
4
5
6
7
8
9
10
11
TO WINDSHIELD DEFROST OUTLET

TO SIDE WINDOW DEFROST OUTLETS
TO FLOOR OUTLETS
FROM PLENUM AREA (OUTSIDE AIR)
FROM INSIDE VEHICLE (RECIRCULATED AIR)
SMALL PASSAGE
EVAPORATOR. AIR CONDITIONING
CORE,HEATER
VALVE, TEMPERATURE
VALVE, HEATER AND DEFROST
VALVE, Bl-LEVEL
VALVE, UPPER AND LOWER MODE
VALVE, AIR INLET
MODULE ASSEMBLY, HEATER AND AIR CONDITIONING
EVAPORATOR
PC0001-1B1fRP
Figure 2 - Air Distribution System
vacuum actuator assembly to normal air pressure, allowing the actuator spring to expand. This results in the
valves (doors) being properly positioned for the selected
operating mode.
The heater and defrost valve uses a three-position
vacuum actuator. A three-position vacuum actuator has a
diaphragm with a spring on both sides. At rest (no vacuum
applied) the diaphragm will be in a mid-position, allowing
for a "blend" mode. When vacuum is applied to either
end of the diaphragm, the diaphragm will move the heater
and defrost valve to either stop, which will direct airflow
to either the defroster outlets or the floor outlets.
When air is directed to the floor outlets, as in
"HEATER" mode, a small amount of air still bleeds
through the defroster outlets to help eliminate re-frosting
of the windshield.
Other Components
Other components of the air distribution system
include the plenum, the blower motor assembly, the evaporator and the heater core assembly. The plenum provides
a source of outside air to the system. The blower motor
assembly draws air from the plenum or from the vehicle

interior into the heater and air conditioning evaporator
module assembly and forces it through the air distribution
system to the outlets. The evaporator is a part of the
refrigeration system. It cools the air from the blower
motor assembly when operating in an air conditioning or
defrosting mode. The heater core assembly provides heat
which can be used to warm the air downstream from the
evaporator.
Air Inlet Valve

The first valve in the air distribution system is the air
inlet valve. This two-position valve controls the two air
entrances which feed air to the blower motor assembly.
When "MAX" A/C mode is selected, vacuum is applied
to the air inlet vacuum actuator assembly and the air inlet
valve opens the entrance which supplies inside air from
the passenger compartment. In this position, the air inlet
valve partially closes the entrance for outside air so only a
slight amount can enter. Recirculating the cooled air
inside the passenger compartment when outside temperature is very high gives a faster cool down to a more comfortable temperature.
MANUAL CONTROL AIR CONDITIONING 181 5

When any other operating mode (including "OFF")
is selected, the air inlet vacuum actuator assembly is
vented to normal air pressure and the air inlet valve completely closes off the entrance for inside air. Only fresh
outside air is used in the system in these modes.
When the bi-level valve (8) is opened by the upper

and lower mode valve vacuum actuator assembly, as in
"MAX" A/C, normal "A/C" and "VENT" modes both
the upper and lower mode valve (9) and the bi-level valve
(8) move at the same time, directing all airflow through
the instrument panel outlets.
Blower Motor Assembly and Evaporator
Upper and Lower Mode Valve
In any operating mode except "OFF," the blower

motor assembly draws in air from the plenum and pushes
it through the evaporator. When any air conditioning or
defrost mode is selected, the air conditioning refrigeration
system chills the core of the evaporator to slightly above
freezing temperature. This cools the airflow and causes
excess humidity to condense on the fins of the evaporator.
The condensed moisture drips to the bottom of the case
and drains out through a hole that lets the water fall on the
road surface below the vehicle. From the evaporator, the
air flows toward the temperature valve and heater core
assembly.
Figure2
The upper and lower mode valve (9), in its "at rest"
(no vacuum) position, seats against the evaporator module
assembly. The upper and lower mode valve (9), when
opened by the upper and lower mode valve actuator
assembly, will also move the bi-level assembly (8) at the
same time. When the upper and lower mode valve (9) is
opened, as in "MAX" A/C, normal "A/C" and "VENT"
modes all air is directed to the instrument panel outlets.

Assembly
The temperature control in the control assembly is
linked to the temperature valve by a flexible control cable
assembly. When the temperature control is rotated fully
counterclockwise to the full "COOL" position, the temperature valve is held snugly against the air entrance to the
heater core assembly. This causes all of the airflow from
the evaporator to bypass the heater core assembly and
there is no heat transfer.
As the temperature control is moved clockwise
away from the full "COOL" position, the temperature
valve moves away from the air inlet to the heater core
assembly to allow some air to flow through it. The farther
the temperature control is rotated clockwise, the more the
temperature valve is turned away from the heater core air
inlet and the greater the airflow through the heater core
assembly. Heating a greater proportion of the total airflow
in this manner results in a warmer discharge of air because
the heated and unheated airflows join and are mixed
together thoroughly beyond the heater core.
When the temperature lever is rotated fully clockwise to the full "WARM" position, the temperature valve
blocks off the passage that allows air to bypass the heater
core assembly and causes all of the airflow to pass
through the heater core assembly.
Bi-Level Valve
Figure2
The bi-level valve (8) at its "at rest" (no vacuum)
position, seats against the upper and lower mode valve (9)
and the heater and air conditioning evaporator module
assembly (11). The bi-level valve (8) can be opened by
either the bi-level valve vacuum actuator assembly or the
upper and lower mode valve vacuum actuator assembly.
When opened by the bi-level valve vacuum actuator
assembly, as in "BI-LEVEL A/C" mode air will exit the
instrument panel outlets, floor outlets and a small amount
will exit the defroster outlets.
Heater and Defrost Valve

Figure2
The heater and defrost valve (7) is operated by a
three-position heater and defrost vacuum actuator assembly. At its "at rest" (no vacuum applied to either side)
position, the heater and defrost valve (7) is positioned to
allow airflow through both the floor outlets and defroster
outlets, as when in "DEFROST BLEND" mode. During
the "DEFROST" mode, vacuum is applied to one side of
the heater and defrost vacuum actuator assembly, causing
the heater and defrost valve (7) to direct all airflow to the
defroster outlets. A small passage within the heater and air
conditioning evaporator module assembly (11) will allow
some air to bleed out the floor outlets. During the
"HEATER" mode, vacuum is applied to the opposite side
of the heater and defrost vacuum actuator assembly causing the heater and defrost valve (7) to direct all airflow to
the floor outlets with a small bleed to the defroster outlets.
Ducts and Outlets

Figure 3
There are five adjustable high-level outlets in the
instrument panel assembly, three near the center and one
at each extreme end of the panel assembly. In addition,
there are two side window defrost outlets, one at each end
of the instrument panel upper trim pad assembly. All
seven outlets are fed by the air distributor assembly.
Heated or cooled air can be directed to the windshield assembly through the air distributor assembly and
through the floor air outlet duct.
Ventilation
Figure 5
The air distribution system provides fresh air ventilation for the passenger compartment in all operating
modes. A small amount of the air circulated within the
passenger compartment in the "MAX" A/C mode is
taken from outside the vehicle, and all of the air circulated
in the other modes is from outside. Even in the "OFF"
mode, fresh outside air is forced into the air distribution
system by the forward movement of the vehicle.
21

EVAPORATOR
18 DISTRIBUTOR ASSEMBLY, WINDSHIELD DEFROSTER
NOZZLE AND AIR
21 DUCT, SIDE WINDOW DEFOGGER OUTLET (LEFT SIDE)
23 DUCT, INSTRUMENT PANEL OUTER AIR OUTLET
50 GRILLE, SIDE WINDOW DEFOGGER OUTLET
51 OUTLET, INSTRUMENT PANEL OUTER AIR
52 OUTLET, INSTRUMENT PANEL CENTER AIR
53 SCREW, AIR DISTRIBUTOR DUCT
54 SCREW, FLOOR AIR OUTLET DUCT
55 DUCT, FLOOR AIR OUTLET
56 SCREW, INSTRUMENT PANEL OUTER AIR OUTLET
DUCT
60 CARRIER ASSEMBLY, INSTRUMENT PANEL
PC2002-1B1-F-RP
Figure 3 - Air Ducts and Outlets

After being warmed or cooled to the desired temperature, the air is discharged from the outlets appropriate
to the selected operating mode. When all windows are
closed, the addition of outside air builds a slight positive
pressure within the passenger compartment. The pressure
forces stale air to leave the vehicle through a pressure
relief valve assembly, mounted to the left side quarter
panel, behind the rear fascia after it has circulated through
the passenger compartment.
REFRIGERATION SYSTEM
Figure 6
The refrigeration system cools the air flowing
through the air distribution system during air conditioning
operation. It also operates when the "DEFROST" or
"DEFROST BLEND" mode is selected, dehumidifying
the air to aid in fog removal from the windshield assembly. Refrigeration system components and their functions
are as follows:
Refrigerant circulates through the refrigeration
system to absorb heat from the air being cooled, and
to give off the heat to the air outside the vehicle. The
refrigerant also carries a polyalkaline glycol (PAG)
refrigerant oil throughout the system, primarily to
lubricate parts of the compressor assembly (28).
An engine-driven compressor assembly (28) pumps
the refrigerant through the refrigeration system.
A condenser assembly (29) cools the refrigerant in
the same way that the engine cooling system radiator
assembly cools the engine coolant.
A receiver dehydrator assembly (30) dries and filters
the refrigerant and stores it until the compressor
assembly (28) again circulates the refrigerant
through the refrigeration system.
Lines (metal tubes and nylon-core composite hoses)
and leak-resistant connectors join the compressor
assembly (28), condenser assembly (29), receiver
dehydrator assembly (30), evaporator (3) and other
components to provide a closed-loop circuit for the
refrigerant.
The A/C refrigerant pressure sensor assembly (26)
attached to the air conditioning evaporator line and
senses refrigerant pressure on the air conditioning
system high side. The purpose of the A/C refrigerant
pressure sensor assembly (26) is to inform the ECM
of high side refrigerant pressure status so the ECM
can disable the compressor assembly (28) before
high side pressure becomes too high.
The thermostatic expansion valve assembly (31)
lowers the pressure of the refrigerant from the
receiver dehydrator assembly (30) by restricting the
flow. This prepares the refrigerant to pick up heat.
An evaporator (3) in the path of the airflow through
the air distribution system absorbs heat from the
moving air and passes it on to the refrigerant inside
the core of the evaporator (3). This causes the refrigerant to boil and leave the evaporator (3) as a vapor.
The air conditioning evaporator temperature sensor
assembly (25) mounted to the heater and air conditioning evaporator module assembly has a probe
inserted into the evaporator (3) which measures

evaporator temperature and sends a signal to the
ECM. Within the probe is a thermistor which varies
resistance according to temperature, as temperature
increases, thermistor resistance decreases. The purpose of this evaporator temperature sensor assembly
(25) is to inform the ECM of the evaporator temperature so the compressor can be disabled before the
evaporator (3) freezes.
The A/C compressor low pressure cutoff switch
assembly (27) is attached to the air conditioning
compressor and condenser hose assembly, just forward of the thermostatic expansion valve assembly
(31). The switch status is determined by air conditioning system low side pressure. If the low side
pressure drops below 21-62 kPa (3-9 psi) the switch
contacts will open, disabling the compressor assembly (28). Once this has happened, low side pressure
must rise above 165-207 kPa (24-30 psi) before the
switch contacts will close. The purpose of the A/C
compressor low pressure cutoff switch assembly
(27) is to prevent compressor operation when the air
conditioning system is low on refrigerant. This is the
only switch that can override the ECM command to
engage the compressor assembly (28).
Refrigerant-134a
CAUTION: Avoid breathing A/C Refrigerant-134a and lubricant vapor or mist.
Exposure may irritate eyes, nose, and
throat. To remove R-134a from the A/C
system, use service equipment certified to meet the requirements of SAE
J2210 (R-134a recycling equipment). If
accidental system discharge occurs,
ventilate work area before resuming
service. Additional health and safety
information may be obtained from
refrigerant and lubricant manufacturers.
Like the coolant in the engine cooling system, the
refrigerant is the substance in the air conditioning system
that absorbs, carries and then releases heat. Although
various substances are used as refrigerants in other types
of refrigeration systems, past automotive air conditioning
systems used a type called Refrigerant-12 (R-12).
This vehicle uses a new type of refrigerant called
Refrigerant-134a (R-134a). It is a non-toxic, non-flammable, clear colorless liquefied gas.
While the R-134a A/C system is very similar to an
R-12 A/C system, the differences in the refrigerant, lubricants, and service equipment are important.
NOTICE: R-134a refrigerant is not compatible with
R-12 refrigerant in an air conditioning system. R-12
in a R-134a system will cause compressor failure,
refrigerant oil sludge or poor air conditioning
system performance.
Refrigerant- l 34a carries a charge of a special lubricating oil, polyalkaline glycol (PAG) refrigerant
oil. GM PAG refrigerant oil will have a slight
blue tint. The oil is hydroscopic (absorbs water from
the atmosphere) and should be stored in closed
containers.
c
36
37
34
B MULTI-CONNECTOR
C TO VACUUM SOURCE
32 ACTUATOR ASSEMBLY, HEATER AND DEFROST
VACUUM
33 ACTUATOR ASSEMBLY, Bl-LEVEL VACUUM
34 ACTUATOR ASSEMBLY, UPPER AND LOWER MODE
VACUUM
35 ACTUATOR ASSEMBLY, AIR INLET VACUUM
36 VALVE, CONTROL ASSEMBLY VACUUM SELECTOR
37 TANK, VACUUM
38 VALVE, VACUUM CHECK
32
33
35
38
E L
E L
N O
E
D
A
C
K
PC0002-1B1-F-RP
Figure 4 - Vacuum Circuit Diagram
0-rings. If lubricants other than those specified are

used, compressor failure and/or fitting seizure is
likely to occur.
Compressor Assembly
A PLENUM AREA
24 VALVE ASSEMBLY, PRESSURE RELIEF
PC2003-1B1-F-RP
Figure 5 - Ventilation Airflow

R-134A A/C system and only mineral base 525
viscosity refrigerant oil on fittings threads and
The compressor assembly (28) is belt driven from

the engine crankshaft through the compressor clutch
pulley. The compressor pulley rotates without driving the
compressor shaft until an electromagnetic clutch coil is
energized. When voltage is applied to energize the clutch
coil, the clutch plate and hub assembly is drawn rearward
toward the pulley. The magnetic force locks the clutch
plate and pulley together as one unit to drive the compressor shaft.
As the compressor shaft is driven, the compressor
assembly (28) compresses the low-pressure refrigerant
vapor from the evaporator into a high-pressure, hightemperature vapor. Carried with the refrigerant is the
refrigerant oil which is used to lubricate the compressor
assembly (28).
3
27
28
29
30
A PROBE, AIR CONDITIONING EVAPORATOR

TEMPERATURE SENSOR
EVAPORATOR TEMPERATURE

COMPRESSOR LOW PRESSURE CUTOFF
29 CONDENSER ASSEMBLY, AIR CONDITIONING
30 RECEIVER DEHYDRATOR ASSEMBLY, AIR
CONDITIONING
31 VALVE ASSEMBLY, AIR CONDITIONING
PC0003-1 B1-F-RP
Figure 6 - Refrigeration System Schematic
The compressor assembly (28) has a unique lubrication system. The crankcase-suction bleed is routed
through the rotating wobble-plate for lubrication of the
wobble-plate bearing. The rotation acts as an oil separator,
which removes some of the oil from the crankcase-suction
bleed, rerouting it to the crankcase where it can lubricate
the compressor mechanism.
Up to 118 ml (4 fluid ounces) of oil can collect in the
crankcase. Therefore, it is important when replacing a
compressor assembly (28) that the oil in the old compressor crankcase be drained and measured (discard after
recording amount).
All replacement compressor assemblies from service parts will have 237 ml (8 fluid ounces) of oil in the
crankcase. The oil must be drained and retained. Then
replace the oil in the same amount as previously recorded
from the old compressor assembly. For compressor
assembly overhaul, refer to SECTION 102.
valve assembly (31) replaces the orifice tube used in the

CCOT air conditioning systems. It functions by sensing
pressure and temperature on the low side of the system
and then meters the high side of the system to achieve
optimal refrigeration performance.
Evaporator
Air passing through the evaporator (3) gives off
some of its heat to the evaporator core fins when the
refrigeration system is operating. Refer to "Air Distribution System" in this section. The heat is conducted
through the thin metal walls of the evaporator core to the
low-pressure liquid refrigerant flowing through the
evaporator core tubes, causing the refrigerant to boil and
vaporize. The refrigerant leaves the evaporator as a lowpressure vapor, carrying off the heat it absorbed from the
evaporator surfaces.
Receiver Dehydrator Assembly

Condenser Assembly
The high-pressure refrigerant line from the compressor assembly (28) goes to the condenser assembly (29).
The condenser assembly (29), is made up of coils which
carry hot refrigerant vapor routed from the compressor
assembly (28). Thin cooling fins on the coils transfer heat
to the air passing through the condenser assembly (29).
This cools the high-pressure refrigerant vapor and causes
it to condense into a high-pressure liquid.
Thermostatic Expansion Valve Assembly

The thermostatic expansion valve assembly (31)
controls the flow of refrigerant in the air conditioning
system. The valve assembly (31) is a mechanical devise
and does not control compressor assembly cycling. The
The receiver dehydrator assembly (30) is a sealed

container that serves as a refrigerant storage container. A
bag of desiccant (a moisture absorbing material) in the
base of the receiver dehydrator assembly (30) collects and
holds any traces of moisture in the refrigerant that could
otherwise create problems such as corrosion or freezing in
the refrigeration system.
Recent improvement in refrigerant hose materials
and the increased use of metal lines have reduced the
chances for entry of moisture into the refrigerant, and an
improvement in desiccant has increased its moistureholding capacity. As a result, the receiver dehydrator
assembly (30) should be replaced only if leaking as a
result of perforation, a damaged 0-ring seat or damaged
threads, or if the system has been opened to outside air for
an extended period.
INSUFFICIENT COOLING CHECK
DIAGNOSIS
FigureB
FUNCTIONAL TEST
Figure 7
The following operational test sequence will aid in
determining whether the air conditioning electrical, air,
vacuum and refrigeration systems are working properly.
Temperature of the air should be at least l6C (60F).
The air conditioning system can not be properly tested
unless it is at least this warm.
The engine should be started and allowed to idle for
about 20 minutes or until the engine cooling system
thermostat is open.
Perform steps 1-9 on Figure 7 and compare vehicle
response to the normal system response shown on the
chart. If vehicle does not respond correctly during any of
these steps, begin diagnosis as noted below:
Insufficient heating. Refer to SECTION lA.
Insufficient cooling. Refer to "Insufficient
Cooling Check" in this section.
Improper air delivery. Refer to "Improper Air
Delivery" in this section.
Blower motor assembly inoperative or incorrect speed. Refer to SECTION 8A.
To help eliminate any possible mis-diagnosis,

"functional test" must be performed first. Insufficient
cooling could be caused by one of several components or
systems such as the air conditioning compressor assembly, refrigeration system, air delivery system or engine
control module (ECM). Proper diagnosis of insufficient
cooling because the air conditioning compressor is inoperative must begin with an "on board diagnostic system
check" of the ECM. Refer to SECTION 6E3.
IMPROPER AIR DELIVERY

Figures 9 and 1O
System Description
This system is operated completely by vacuum,
except for the electrically powered blower motor assembly (5). Engine vacuum is routed through a vacuum check
valve (38) then to the control assembly vacuum selector
valve (36) and to the vacuum tank (37). The vacuum
check valve (38) is used to prevent vacuum loss due to
heavy acceleration or steep uphill traveling when the
engine assembly is under a heavy load.
When vacuum is applied to a vacuum actuator
assembly, the vacuum actuator assembly will apply sufficient force to overcome any resistance due to air flow
from the blower motor assembly (5) and from the actuator
internal spring, and move the air valve (door) to its correct
position.
HEATER AND AIR CONDITIONING

CONTROL ASSEMBLY SETTING
STEP
MODE CONTROL
LEVER SITTING
TEMPERATURE
CONTROL LEVER
SETTING
BLOWER MOTOR
ASSEMBLY
SWITCH
OFF
COLD
SYSTEM RESPONSE
BLOWER MOTOR
ASSEMBLY
SPEED
HEATER
OUTLETS
A/C
OUTLETS
DEFROSTER
OUTLETS
LOW
OFF
NOAIR FLOW
NO AIR FLOW
NOAIR FLOW
LOW
NOAIR FLOW
AIRFLOW
NO AIRFLOW
A,E
AT LEAST 11'C (20'F) COOLER THAN

AMBIENT
COMMENTS
OUTLET
TEMPERATURE
AMBIENT
MAXA/C
COLD
LOW
MAXA/C
COLD
LOW TO HIGH
LOW TO HIGH
NOAIR FLOW
AIRFLOW
NO AIRFLOW
B,E
AT LEAST 11'C (20'F) COOLER THAN

AMBIENT
NORMALA/C
MID-RANGE
HIGH
HIGH
NOAIR FLOW
AIRFLOW
MINIMUM AIR
FLOW
COOL TO SLIGHTLY WARM
Bl-LEVEL A/C
COLD
HIGH
HIGH
AIR FLOW
AIRFLOW
MINIMUM AIR
FLOW
AT LEAST ll'C (20'F) COOLER THAN

AMBIENT
VENT
COLD
HIGH
HIGH
NOAIR FLOW
AIRFLOW
NOAIR FLOW
AMBIENT
HEATER
HOT
HIGH
HIGH
AIRFLOW
NO AIRFLOW
MINIMUM AIR
FLOW
A,C,D
AT LEAST 49'C (120'F)
DEFROSTER
BLEND
HOT
HIGH
HIGH
AIRFLOW
NOAIR FLOW
AIRFLOW
A,D
DEFROST
HOT
HIGH
HIGH
MINIMUM AIR
FLOW
NO AIR FLOW
AIR FLOW
A,D
A
B
C
D
E
ENGAGEMENT OF DETENT MUST BE FELT IN EACH MODE CONTROL LEVER SETTING.

A NOTICEABLE BLOWER MOTOR ASSEMBLY SPEED INCREASE MUST OCCUR FROM LOW, MEDIUM LOW, MEDIUM HIGH AND HIGH.
TEMPERATURE LEVER MUST TRAVEL FROM FULL COLD TO FULL HOT.
AIR FLOW MUST ALSO BE PRESENT AT SIDE WINDOW DEFOGGER OUTLETS.
INSTRUMENT PANEL OUTLETS MUST HOLD THEIR POSITION DURING HIGH BLOWER MOTOR ASSEMBLY SPEED BUT SHOULD B~ MOVEABLE BY HAND.
PC0004-1B1FRP
Figure 7 - Functional Test
.
.
.
.
.
PERFORM ON BOARD DIAGNOSTIC SYSTEM CHECK. REFER

TO SECTION 6E3.
ARE ANY ECM DIAGNOSTIC TROUBLE CODES DISPLAYED?
YES
OPEN DOORS AND HOOD TO NEUTRALIZE

VEHICLE INTERNAL TEMPERATURE WITH SHOP
TEMPERATURE.
INSTALL J 39183-C (R-134a MANIFOLD GAGE SET)
OR J 39500-GM (ACR4 SYSTEM) ONTO VEHICLE.
REFER TO SECTION 18.
IS LOW SIDE STATIC (ENGINE NOT RUNNING)
PRESSURE ABOVE 310 kPa (45 psi)?
REPAIR DIAGNOSTIC TROUBLE

CODES. REFER TO SECTION 6E3.
.
.
.
NO
LEAK TEST A/C SYSTEM.

REFER TO SECTION 1B.
AFTER REPAIRS HAVE BEEN
MADE CHARGE SYSTEM WITH
0.9 kg (2 POUNDS) OF R-134a.REFER
TO SECTION 1B.
PERFORM "AIR CONDITIONING
PERFORMANCE TEST" IN THIS
SECTION.
YES
PERFORM "AIR CONDITIONING

PERFORMANCE TEST" IN THIS
SECTION.
PC0005-1B1-F-RP
Figure 8 - Insufficient Cooling Check
Preliminary Inspection
1. Inspect vacuum lines at engine assembly and vacuum check valve (38) for proper connection.
2. Disconnect vacuum line leading to engine assembly
at vacuum check valve (38). Start engine assembly
and check for presence of vacuum, if no vacuum is
present, replace vacuum line.
3. Disconnect vacuum line leading to vacuum tank
(37) at vacuum check valve (38). Using hand vacuum pump, apply vacuum to vacuum line leading to
vacuum tank (37). If vacuum does not hold, replace
vacuum line and/or vacuum tank (37).
4. Disconnect vacuum line leading to control assembly
(1) at vacuum check valve (38). Apply vacuum to
check valve port. If vacuum does not hold, replace
vacuum check valve (38).
5. Quickly rotate temperature control from "FULL
COLD" to "FULL HOT" several times. Listen for
temperature valve (6) to seat in both positions. If the
sound indicates that the temperature valve (6) is not
fully seating or opening, check the mechanical
linkage between the control mechanism and the
temperature valve (6).
6. Make sure all six vacuum line seals are positioned
correctly at vacuum line multi-connector under
right-hand sound insulator panel assembly.
7. Perform diagnosis. Refer to Figure 10.
AIR CONDITIONING PERFORMANCE TEST

Tools Required":
J 39500 ACR4 System or
J 39183 R-134a Manifold Gage Set

J 6742-03 Precision Thermometer (or Equivalent)
Before performing the air conditioning performance
test, a functional test should be made to assure that the air
distribution system valves are functioning properly to
route all the air passing through the evaporator to the outlets. Refer to "Functional Test" in this section.
Performance testing provides a measure of air
conditioning system operating efficiency by measuring
and comparing pressures at the high-pressure and lowpressure sides of the refrigeration system, the temperature
of the air being discharged into the passenger compartment, and the evaporator temperature.
Start with the air conditioning performance test in
Figure 11, and compare vehicle air conditioning system
performance with the chart in Figure 12. If system performance is not within sp~cifications, proceed to the
refrigeration system diagnostic chart in Figure 13 to
pinpoint the problem.
MODE CONTROL VACUUM

VALVE POSITIONS
2
3
4
5
6
7
8
OFF
MAXA/C
NORMALA/C
Bl-LEVEL A/C
VENT
HEATER
HEATER/DEFROST BLEND
DEFROSTER
38
36
Y~~
32
1----------
..
_ _ _ _ _ _ _ ..J
~GREEN
35
A
B
C
D
E
F
G
H
J
1
3
4
5
6
32
TO WINDSHIELD DEFROST OUTLETS

TO SIDE WINDOW DEFROST OUTLETS
TO FLOOR OUTLETS
FROM PLENUM AREA (OUTSIDE AIR)
FROM INSIDE VEHICLE (RECIRCULATED AIR)
TO ENGINE ASSEMBLY (VACUUM SOURCE)
PARTIALLY OPEN BY DESIGN
TEMPERATURE CONTROL
CONTROL ASSEMBLY, HEATER AND AIR
CONDITIONING
EVAPORATOR, AIR CONDITIONING
CORE ASSEMBLY, HEATER
VALVE, TEMPERATURE
ACTUATOR ASSEMBLY, HEATER AND DEFROST
VACUUM
33 ACTUATOR ASSEMBLY, Bl-LEVEL VACUUM

34 ACTUATOR ASSEMBLY, UPPER AND LOWER MODE
VACUUM
36 VALVE, CONTROL ASSEMBLY VACUUM SELECTOR
37 TANK, VACUUM
38 VALVE, VACUUM CHECK
PC0006-1B1-F-RP
Figure 9 - Improper Air Delivery Vacuum Schematic
MANUAL CONTROL AIR CONDITIONING 18113
..
.
.
PERFORM PRELIMINARY INSPECTION .

SET MODE SELECTOR VALVE IN THE "OFF" POSITION .
DISCONNECT VACUUM LINE AT CHECK VALVE .
USING A HAND VACUUM PUMP, APPLY VACUUM
TO VACUUM LINE LEADING TO MODE
SELECTOR VALVE.
DOES VACUUM HOLD?
I
I
NO
I
.
.
CHECK BLACK VACUUM

LINE LEADING TO MODE
SELECTOR VALVE. IF LINE IS
CONNECTED AND WORKING
PROPERLY REPLACE MODE
SELECTOR VALVE.
YES
I
APPLY VACUUM TO VACUUM LINE LEADING TO

MODE SELECTOR VALVE AND CHECK IN EACH SETTING
("MAX" A/C TO "DEFROST").
DOES VACUUM HOLD IN EVERY SETTING?
--,
.
.
..
.
YES
I
DISCONNECT VACUUM LINE MULTl-CONNECTOR

AT MODE SELECTOR VALVE.
TURN IGNITION SWITCH TO "RUN" POSITION
(ENGINE NOT RUNNING).
SELECT "HIGH" BLOWER MOTOR ASSEMBLY SPEED .
APPLY VACUUM TO EACH VACUUM LINE INDIVIDUALLY
(EXCEPT BLACK AND ORANGE LINE) AND CHECK
FOR AIR FLOW AT THE PROPER OUTLETS.
REFER TO "DIAGNOSTIC AID CHART" BELOW.
DOES AIR FLOW AT PROPER OUTLETS?
I
.
DISCONNECT VACUUM LINE MULTl-CONNECTOR

AT MODE SELECTOR VALVE.
APPLY VACUUM TO EACH LINE AT MULTICONNECTOR CONTROLLED BY THE MODE SELECTOR
VALVE AT A SETTING WHERE VACUUM DID
NOT HOLD.
IS A VACUUM LEAK PRESENT AT ONE OR
MORE LINES?
NO
I
YES
SYSTEM
OK.
YES
I
I REPAIR OR REPLACE VACUUM LINEI

AND /OR VACUUM ACTUATOR.
REPAIR OR REPLACE ACTUATOR

LINKAGE AND/OR AIR VALVE (DOOR).
NO
NO
I
REPLACE MODE SELECTOR

VALVE.
DIAGNOSTIC AID CHART
YES
NO
I
APPLY VACUUM TO
ORANGE VACUUM
LINE.
DOES BLOWER MOTOR
ASSEMBLY AIR FLOW NOISE
INCREASE?
REPAIR OR REPLACE AIR

INLET VACUUM ACTUATOR
LINKAGE AND/OR AIR
INLET VALVE.
APPLY VACUUM TO:
AIR FLOW SHOULD BE DIVERTED TO:
RED VACUUM LINE
INSTRUMENT PANEL OUTLETS ONLY
YELLOW VACUUM LINE
SIDE WINDOW DEFOGGER AND FLOOR

OUTLETS
PURPLE VACUUM LINE
SIDE WINDOW DEFOGGER, FLOOR AND

INSTRUMENT PANEL OUTLETS
GREEN VACUUM LINE
WINDSHIELD AND SIDE WINDOW

DEFOGGER OUTLETS
ORANGE VACUUM LINE
BLOWER MOTOR ASSEMBLY AIR NOISE

INCREASE
NO VACUUM LINES (ALL

LINES VENTED TO
ATMOSPHERE)
ALL OUTLETS EXCEPT INSTRUMENT PANEL
PC0007-1B1-F-RP
Figure 10 - Improper Air Delivery Diagnostic Chart
.
.
QUICKLY ROTATE TEMPERATURE KNOB FROM "FULL

COLD" TO "FULL HOT" AND BACK TO "FULL COLD".
LISTEN FOR TEMPERATURE VALVE TO SEAT IN BOTH
"FULL HOT" AND "FULL COLD" POSITION (A "THUD"
NOISE SHOULD BE HEARD).
DOES TEMPERATURE VALVE SEAT IN BOTH POSITIONS?
I
I
I
..
.
..
YES
NO
.
..
..
.
YES
NO
INSTALL TECH 1 WITH 93

POWERTRAIN CARTRIDGE.
SELECT "FIELD SERVICE" MODE .
CHECK COOLING FAN OPERATION:
V-6 COOLING FAN OPERATING .
V-8 BOTH COOLING FANS
OPERATING.
ARE COOLING FAN(S) OPERATING?
NO
NO
I
REFER TO SECTION 6E3

FOR NC COMPRESSOR CIRCUIT
DIAGNOSIS
REPAIR COOLING FAN

CIRCUIT. REFER TO
SECTION 6E3-C12.
YES
.
.
.
..
YES
MANUALLY ROTATE TEMPERATURE

VALVE BY HAND.
DOES TEMPERATURE VALVE SEAT IN BOTH
"FULL HOT" AND "FULL COLD"
POSITION WITH APPROXIMATELY 50 DEGREES
OF TRAVEL?
I
I
YES
I
REPLACE TEMPERATURE
CABLE.
REPAIR OR REPLACE
TEMPERATURE CABLE
AS NECESSARY.
I
I
I
I
DISCONNECT TEMPERATURE CABLE AT HEATER

AND EVAPORATOR MODULE ASSEMBLY.
ROTATE TEMPERATURE LEVER FROM "FULL HOT" TO
"FULL COLD" WHILE WATCHING CABLE END.
DOES CABLE END ROTATE WHEN TEMPERATURE LEVER
IS ROTATED?
.
.
CLOSE DOORS AND WINDOWS .

SELECT "FULL COLD, MAX NC" MODE AND "HIGH"
BLOWER MOTOR SPEED.
PLACE VEHICLE IN PARK (AUTOMATIC TRANSMISSION
ASSEMBLY) AND SET PARKING BRAKE (MANUAL
OR AUTOMATIC TRANSMISSION ASSEMBLY).
START ENGINE ASSEMBLY .
DOES COMPRESSOR ENGAGE?
NO
I
REPAIR OR REPLACE
HEATER AND EVAPORATOR
MODULE ASSEMBLY.
INSTALL J 39183-C (R-134a MANIFOLD GAGE SET) OR

J 39500-GM (ACR 4 SYSTEM) ONTO VEHICLE. REFER TO SECTION 1B.
INSTALL J 6742-03 (PRECISION THERMOMETER) OR EQUIVALENT
INTO CENTER INSTRUMENT PANEL OUTLET.
WITH VEHICLE RUNNING IN "MAX NC" MODE, "FULL COLD" AND
"HIGH" BLOWER MOTOR SPEED FOR 5 MINUTES, RECORD THE
FOLLOWING INFORMATION:
- NC SYSTEM HIGH AND LOW SIDE PRESSURE
- EVAPORATOR TEMPERATURE USING TECH 1
- AMBIENT TEMPERATURE AND HUMIDITY
COMPARE WITH AIR CONDITIONING PERFORMANCE CHART (FIGURE 12) .
IS VEHICLE NC PERFORMANCE WITHIN SPECIFICATIONS?
I
I
NO
I
REFER TO
"REFRIGERATION SYSTEM
DIAGNOSIS CHART"
IN THIS SECTION (FIGURE 13).
I
I
YES
I
SYSTEM OK.
PC0009-1B1-F-RP
Figure 11 - Air Conditioning Performance Test
MANUAL CONTROL AIR CONDITIONING 181 -15
CENTER
OUTLETTEMP
EVAPASSEMBLY
TEMP DISPLAYED
ON TECH 1
TEMPERATURE
HUMIDITY
GAGE PRESSURES
LOW
HIGH
21 - 27C
LESS THAN 50%
110-165 kPa 793-1310 kPa

(16 - 24 psi) (115-190 psi)
3 - 9'C
(38 - 48F)
1 - 6C
(33 - 43'F)
(70 - 80F)
HIGHER THAN 50%
145 - 200 kPa 793 - 1379 kPa

(21 - 29 psi) (115- 200 psi)
4 -13'C
(40 - 55'F)
2 - lO'C
(35 - 50'F)
27' - 33C
LESS THAN 50%
131 - 207 kPa 965 - 1482 kPa

(19 - 30 psi) (140 - 215 psi)
3 -13C
(38 - 55F)
1 -l0C
(33 - 50F)
(80 - 90'F)
HIGHER THAN 50%
165- 269 kPa 1034 - 1620 kPa 7' - l8C

(24- 39 psi) (150 - 235 psi) (45' - 65'F)
4 - 16'C
(40' - 60'F)
33 - 38C
LESS THAN 40%
172 - 290 kPa 1138-1793 kPa

(25 - 42 psi) (165 - 260 psi)
7' - 17'C
(45' - 63'F)
4 - 14'C
(40 - 58'F)
(90 - lOO'F)
HIGHER THAN 40%
234- 296 kPa 1276 -1862 kPa

(34- 43 psi) (185 - 270 psi)
13 - 20'C
(55 - 68F)
10 -18'C
(50 - 65'F)
38' - 44'C
LESS THAN 20%
255 - 296 kPa 1448 - 2000 kPa

(37 - 43 psi) (210 - 290 psi)
12' - l8C
(53 - 64'F)
9'-16'C
(48 - 61'F)
(100 - 1lO'F)
HIGHER THAN 20%
262- 352 kPa 1517 - 2137kPa

(38 - 51 psi) (220 - 310 psi)
14 - 21'C
(58 - 70'F)
13 -18'C
(55 - 65'F)
PC0010-1B1-F-RP
Figure 12 - Air Conditioning Performance Chart
ON-VEHICLE SERVICE
BLOWER MOTOR ASSEMBLY RELAY
The blower motor assembly relay is located in the
underhood electrical center. Refer to the label located
under the underhood electrical center cover for relay identification.
AIR CONDITIONING COMPRESSOR RELAY

The air conditioning compressor relay is located in
the underhood electrical center. Refer to the label located
under the underhood electrical center cover for relay identification.
AIR CONDITIONING EVAPORATOR

TEMPERATURE SENSOR ASSEMBLY
Figure 14

1. Heater core assembly. Refer to SECTION lA.
2. Evaporator temperature sensor assembly electrical
connector.
3. Evaporator temperature sensor assembly probe from
evaporator.
Use needle-nose pliers to pull probe straight
out.
4. Evaporator temperature sensor assembly (25) from

heater and air conditioning evaporator module
assembly (11).
Remove grommet with evaporator temperature
sensor assembly (25).

1. Evaporator temperature sensor assembly (25) to
heater and air conditioning evaporator module
assembly (11).
Seat grommet in heater and air conditioning
module assembly (11 ).
[I] Important
Do not insert probe into existing hole. Choose
a location near the existing hole and insert
probe straight into evaporator. If probe is not
inserted straight into evaporator, incorrect
evaporator temperature reading may result,
causing evaporator freeze-up.
2. Evaporator temperature sensor assembly probe
straight into evaporator in new location near previous location.
3. Evaporator temperature sensor assembly electrical
connector.
4. Heater core assembly. Refer to SECTION lA.
PERFORM AIR CONDITIONING PERFORMANCE TEST BEFORE REFRIGERATION SYSTEM DIAGNOSIS

CONDITIONS
CENTER
OUTLET
TEMP
LOWSIOE
PRESSURE
HIGH SIDE
PRESSURE
TECH1
EVAPORATOR
TEMPERATURE
OK OR HIGH
OK OR LOW
OK OR LOW
HIGHER
POSSIBLE
FAULT
CORRECTIVE ACTION
LOW REFRIGERANT
CHARGE
RECEIVER AND
DEHYDRATOR
ASSEMBLY
PLUGGED
RECOVER, MEASURE AND RECHARGE A/C

SYSTEM. REFER TO SECTION 1B.
CHECK FOR PRESSURE DIFFERANCE
GREATER THAN 138 kPa (20 PSI) BETWEEN
TECH 1AND HIGH GAUGE, REPLACE
RECEIVER AND DEHYDRATOR ASSEMBLY.
DEBRIS PLUGGING
THERMOSTATIC
EXPANSION VALVE
CLEAN THERMOSTATIC EXPANSION

VALVE.
INOPERATIVE
THERMOSTATIC
EXPANSION VALVE
TESTTHERMOSTATIC EXPANSION VALVE.

SET A/C BLOWER ON LOW AND REV
ENGINE TO 1,500 RPM. IF LOW GAGE GOES
ABOVE 193 kPa (28 PSI), THERMOSTATIC
EXPANSION VALVE IS STUCK OPEN;
REPLACE IT. IF LOW GAGE
GOES BELOW 138 kPa (20 PSI) SYSTEM OK.
REINSTALL EVAPORATOR TEMPERATURE
SENSOR.
EVAPORATOR
TEMPERATURE
SENSOR OUT OF
POSITION
HIGHER
HIGHER
HIGHER
HIGHER
LOW
HIGHER
HIGH
HIGHER
A/C COMPRESSOR
FAULT
INOPERATIVE
THERMOSTATIC
EXPANSION VALVE
PERFORM COMPRESSOR TEST

TESTTHERMOSTATIC EXPANSION VALVE.
SET A/C BLOWER ON LOW AND REV
ENGINE TO 1,500 RPM. IF LOW GAGE GOES
ABOVE 193 kPa (28 PSI), THERMOSTATIC
EXPANSION VALVE IS STUCK OPEN;
REPLACE IT. IF LOW GAGE
GOES BELOW 138 kPa (20 PSI) SYSTEM OK.
CONDENSOR AIR
RESTRICTION
CONDENSOR AIR
RECIRCULATION
HIGH REFRIGERANT CHARGE
TOO MUCH
REFRIGERANT OIL
FAN PROBLEMS
CLEAN, REMOVE RESTRICTION.

INSTALL OR REPOSITION AIR CONTROL
BAFFLES.
FLUSH A/C SYSTEM. REFER TO SECTION IB.
CHECK FLOW DIRECTION, RELAY, ETC.
HIGHER
COMPRESSOR
CYCLES OFF
AT 3421 kPa
(53 PSI), ON
AT 186+34 kPa
(275PSI)
LOW
OKOR
HIGHER
LOW CHARGE

HIGHER
COMPRESSOR
CYCLES OTHER
THAN 34 TO
186 kPa
(5 TO 27 PSI)
LOW
HIGHER
LOW PRESSURE
SWITCH FAULT
CHECK TECH 1. IFTECH 1 SHOWS

CLUTCH ON, BUT COMPRESSOR IS
CYCLING, THEN REPLACE SWITCH.
OK
OK OR LOW
OK ORLOW
LOW
CIRCUIT FAULT
PERFORM A/C ELECTRICAL CIRCUITTEST.
PCOOOB-181-F-RP
Figure 13 - Refrigeration System Diagnostic Chart

2. Sensor assembly (26).
l~.J Tighten
Sensor assembly (26) to 6 Nm (53 lb. in.).
3. Electrical connector to sensor assembly (26).
AIR CONDITIONING COMPRESSOR LOW

PRESSURE CUTOFF SWITCH ASSEMBLY
Figure 15

1. Electrical connector from switch assembly (27).
2. Switch assembly (27) and seal (40).
Switch assembly (27) is mounted on a
Schrader type valve so it is not necessary to
discharge the refrigeration system.
Discard seal (40).

11
25
A PROBE
B GROMMET
C PERFORATION FOR AIR CONDITIONING EVAPORATOR
REMOVAL
EVAPORATOR
41 BOLT/SCREW, AIR CONDITIONING EVAPORATOR
1. New seal (40) to switch assembly fitting.

Coat seal (40) with mineral base 525 viscosity
refrigerant oil.
2. Switch assembly (27).
l~I Tighten
Switch assembly (27) to 6 Nm (53 lb. in.).
3. Electrical connector to switch assembly (27).
AIR CONDITIONING EVAPORATOR

Figures 14 and 16
PC0011-1B1-F-RP
Figure 14 - Air Conditioning Evaporator Temperature Sensor

Assembly
AIR CONDITIONING REFRIGERANT

PRESSURE SENSOR ASSEMBLY
Figure 15

1. Electrical connector at sensor assembly (26).
2. Sensor assembly (26) and seal (39).
Sensor assembly (26) is mounted on a
Schrader type valve so it is not necessary to
discharge the refrigeration system.
Discard seal (39).

1. New seal (39) to sensor assembly fitting.
Coat seal (39) with mineral base 525 viscosity
refrigerant oil.

1. Discharge refrigerant into a recovery station. Refer
to SECTION 1B.
2. Drain coolant from radiator. Refer to SECTION 6B.
3. Right-hand instrument panel sound insulator panel
assembly. Refer to SECTION 8C.
4. Heater hoses at heater core assembly. Refer to
SECTION IA.
5. Instrument panel compartment. Refer to SECTION
8C.
6. Heater core assembly. Refer to SECTION IA.
7. Air conditioning evaporator temperature sensor
assembly. Refer to "Air Conditioning Evaporator
Temperature Sensor Assembly" in this section.
8. Temperature control cable assembly at temperature
valve case assembly. Refer to SECTION IA.
9. Bolts/screws (48) from temperature valve case
assembly (42).
10. Temperature valve case assembly (42).
Slide case assembly (42) downward to disengage upper case clip.
Remove from under the instrument panel
assembly.

Insert evaporator (3) into module assembly
(11) through the opening enlarged during
removal, slide to the right until fully seated.
2. Bolts/screws (41) to air conditioning evaporator (3).
3. Refrigerant oil into evaporator (3), if necessary.
If installing new evaporator (3), add 89 ml

(3 fluid ounces) of polyalkylene glycol (PAG)
synthetic refrigerant oil, GM PIN 12345923 or
equivalent.
4. Thermostatic expansion valve assembly. Refer to
SECTION lB.

COMPRESSOR LOW PRESSURE CUTOFF
39 SEAL, AIR CONDITIONING REFRIGERANT PRESSURE
SENSOR
40 SEAL, AIR CONDITIONING REFRIGERANT PRESSURE
SWITCH
63 HOSE ASSEMBLY, AIR CONDITIONING COMPRESSOR
AND CONDENSOR
64 TUBE, AIR CONDITIONING EVAPORATOR
PC0012-1B1-F-RP
Figure 15 - Air Conditioning Refrigerant Sensor and

Cutoff Switch ,
5. Apply sealer GM PIN 3012078 (do not use epoxy

glue) between evaporator (3) and evaporator upper
and lower case (44 and 45) just behind thermostatic
expansion valve assembly to prevent air entry from
the engine compartment into the passenger compartment.
6. Position perforated section of heater and air conditioning evaporator module assembly and use epoxy
glue to adhere it to module assembly.
7. Temperature valve case assembly (42).
Install from under instrument panel assembly.
Slide case assembly (42) upward into position
until upper clip engages.
8. Bolts/screws (48) to temperature valve case assembly (42).
Tighten bolts/screws (48) evenly to compress
flange seal.
11. Thermostatic expansion valve assembly. Refer to

SECTION lB.
[I] Important
Remove perforated section of heater and air
conditioning evaporator module assembly as
one piece (it will be reused).
12. Using a small hand saw, remove perforated section
of heater and air conditioning evaporator module
assembly (Figure 14).
13. Bolts/screws (41) retaining air conditioning evaporator (3).
14. Air conditioning evaporator (3) from heater and air
conditioning module assembly (11).
Slide evaporator (3) to the left, then pull out
through the opening enlarged in step 12.
9. Temperature control cable assembly at temperature

valve case assembly. Refer to SECTION IA.
10. Air conditioning evaporator temperature sensor
assembly. Refer to "Air Conditioning Evaporator
Temperature Sensor Assembly" in this section.
11. Heater core assembly. Refer to SECTION IA.
12. Instrument panel compartment. Refer to SECTION
8C.
13. Heater hoses to heater core assembly. Refer to
SECTION IA.
14. Right-hand instrument panel sound insulator panel
15. Fill radiator and bleed cooling system. Refer to
SECTION 6B.
16. Refrigerant.
A. Partially charge system and perform a leak test.

Refer to SECTION lB.
1. Air conditioning evaporator (3) to heater and air

conditioning module assembly (11).
B. Recover refrigerant, and evacuate and charge

system. Refer to SECTION lB.
If replacing old evaporator (3), transfer condensate screen to new evaporator (3).
17. Test system performance. Refer to "Air Conditioning Performance Test" in this section.
44
48

4 CORE ASSEMBLY, HEATER
41 BOLT/SCREW, AIR CONDITIONING EVAPORATOR
42 CASE ASSEMBLY, TEMPERATURE VALVE
43 CLAMP, HEATER CORE TUBE
44 CASE, AIR CONDITIONING EVAPORATOR UPPER
45 CASE, AIR CONDITIONING EVAPORATOR LOWER
46 CASE, AIR DISTRIBUTOR UPPER
47 COVER, HEATER AND AIR CONDITIONING
EVAPORATOR CASE
48 BOLT/SCREW, TEMPERATURE VALVE CASE ASSEMBLY
EVAPORATOR CASE COVER
59 BOLT/SCREW, HEATER CORE TUBE CLAMP
65 CLAMP, AIR CONDITIONING EVAPORATOR
PC00131B1FRP
Figure 16 - Air Conditioning Evaporator and Components
SPECIFICATIONS
A/C System 0-ring and Fitting Lubricant ............ Mineral Base 525 Viscosity Refrigerant Oil,
GM PIN 12301108 or equivalent
A/C System Internal Lubricant
(Including Compressor) ................. Polyalkylene Glycol (PAG) Synthetic Refrigerant Oil,
GM PIN 12345923 or equivalent
A/C System R-134a Capacity ........................................... 0.91 kg (2.0 lbs.)
COMPONENT TIGHTENING SPECIFICATIONS

Air Conditioning Compressor Low Pressure Cutout Switch Assembly ........... 6 Nm (53 lb. in.)
Air Conditioning Refrigerant Pressure Sensor Assembly ..................... 6 Nm (53 lb. in.)
SPECIAL TOOLS
2.
1. R-12 AND R-134a HALOGEN LEAK DETECTOR

2. AIR CONDITIONING REFRIGERANT RECOVERY,
RECYCLING AND RECHARGING SYSTEM (ACR 4 )
3. PRECISION THERMOMETER
4. R-134a MANIFOLD GAUGE SET
PC00141BlFRP
HD6/HR6-HE AIR CONDITIONING COMPRESSOR 102-1
SECTION 102
HD6/HR6-HE
AIR CONDITIONING COMPRESSOR
SERVICE OR UNIT REPAIR R-134a
CAUTIONS in Section 9J under ON-VEHICLE SERVICE and the SIR Component and Wiring Location
view in Section 9J before performing service on or around SIR components or wiring. Failure to
follow CAUTIONS could result in possible air bag deployment, personal injury, or otherwise
unneeded SIR system repairs.
NOTICE: When fasteners are removed, always reinstall them at the same location from which they were removed. If a
fastener needs to be replaced, use the correct part number fastener for that application. If the correct part number fastener is not
available, a fastener of equal size and strength (or stronger) may be used. Fasteners that are not reused, and those requiring thread
locking compound will be called out. The correct torque value must be used when installing fasteners that require it. If the above
conditions are not followed, parts or system damage could result.
CONTENTS
General Description ...........................
Metric Thread Size Information ...............
Unit Repair ..................................
Minor Compressor
Repair Procedures ..........................
Compressor Clutch Plate and
Hub Assembly ..........................
Compressor Clutch Rotor and/or Bearing ......
Compressor Clutch Coil ...................
I D2- l
1D2-3
ID2-3
102-3
ID2-3
1D2-4
1D2-7
Major Compressor
Repair Procedures .......................... 1D2-8
Compressor Shaft Seal Replacement ......... 1D2-8
Seal Leak Detection ...................... 1D2-8
Compressor Pressure Relief Valve .......... 1D2-10
Control Switches ........................ 1D2-ll
Compressor Leak Testing ................. 1D2- l l
Bench-Check Procedures ............... 1D2- l l
Special Tools ........................... 1D2-12
GENERAL DESCRIPTION
The
HD6/HR6-HE
Automotive
Conditioning
Compressor and Clutch Assembly is a lightweight, six cylinder
axial design consisting of three double ended pistons and
weighs 5.8 kg (12.7 lbs.)
CD
CD
(i)
WITHOUT TORQUE
CUSHION
TORQUE
CUSHION
Fig. 1 Clutch Driver Designs

Although this compressor is the same for all vehicle
applications, there are differences in installations, mounting
brackets, pulleys, torque cushions and switches, none of which
will affect the following overhaul procedures.
There are two clutch driver designs for these
compressors. The clutch driver without a torque cushion and
the clutch driver having a thin torque cushion (Fig. 1).
Service compressors are supplied with either the control

switches assembled in the rear head or a plug may be found
where a control switch is required. If the service compressor
requires control switches, the plug may be removed from the
appropriate rear head switch cavity of the replaced compressor
and assembled as prescribed in this manual.
When servicing the compressor, keep dirt or foreign
material from getting on or into the compressor parts and
system. Clean tools and a clean work area are important for
proper service. The compressor connections and the outside of
the compressor should be cleaned before any "on vehicle"
repairs, or before removal of the compressor. The parts must be
kept clean at all times and any parts to be reassembled should
be cleaned with trichloroethane, naphtha, stoddard solvent,
kerosene or equivalent and dried with dry air. When necessary
to use a cloth on any part, it should be of a non-lint producing
type.
The operations described below are based on bench
overhaul with the compressor removed from the vehicle,
except as noted. They have been prepared in order of
accessibility of the components. When a compressor is
removed from the vehicle for servicing, the amount of PAG
lubricant remaining in the compressor should be drained,
102-2 HD6/HR6-HE AIR CONDITIONING COMPRESSOR
1-
CLUTCH DRIVER
2-
ROTOR BEARING
RETAINER
3-
PULLEY BEARING
4 - PULLEY
5-
CLUTCH COIL
ASSEMBLY
6-
SHAFT SEAL PARTS
7-
PUMP ASSEMBLY
8-
SWITCH 0-RING
9-
SYSTEM CONTROL
SWITCH
10 -
HIGH PRESSURE
RELIEF VALVE
11 -
RETAINER RING SWITCH
12 -
SUCTION/DISCHARGE
PORT SEALING
WASHERS
13 -
SPECIAL 134a SUCTION

PORT
14 -
SPECIAL 134a
DISCHARGE PORT
Compressor - Rear Head

As Viewed in Direction of Arrow "Pl'
Fig. 2 Compressor Components -
Disassembly

measured and recorded. This PAG lubricant should then be
discarded and an equal amount of new PAG lubricant added to
the compressor.
The service compressor is shipped with 240 ml (8 oz.) of
PAG lubricant. This lubricant should be drained and retained
for use as replacement lubricant when service procedures
require addition of new lubricant to compressor. NOTE:
Replace only with GM approved PAG oil P/N 12345923.
Most minor repair procedures may be done on the
vehicle without discharging the system. Major repair
procedures require that the system be discharged of refrigerant.
METRIC THREAD SIZE INFORMATION

I.
Compressor to mounting bracket bolts.

Front
MIO x 1.5 - 6H
Rear
MS x 1.25 - 6H
2.
Suction-discharge port screw.

MlOx l.5-6H
3.
Compressor shaft.
M9 x l.25-6H
4.
Internal hub-clutch drive assembly.

M22 x l.5-6H
UNIT REPAIR
center screw into the remover body to remove the clutch
plate and hub assembly (Fig. 3).
MINOR COMPRESSOR REPAIR

PROCEDURES
THE
FOLLOWING
OPERATIONS
TO
THE
COMPRESSOR CLUTCH PLATE AND HUB, ROTOR
AND BEARING, AND COIL ARE COVERED AS
"MINOR" BECAUSE THEY MAY BE PERFORMED
WITHOUT FIRST RECOVERING REFRIGERANT
FROM THE SYSTEM OR REMOVING THE
COMPRESSOR FROM THE VEHICLE.
The Compressor Shaft Seal assembly, control switches,
and Pressure Relief Valve may also be serviced WITHOUT
REMOVING THE compressor from the vehicle but these
operations are covered later in this section as MAJOR REPAIR
PROCEDURES because the system must be reclaimed,
evacuated and recharged to complete service.
Illustrations used in describing these operations show the
compressor removed from the vehicle only to more clearly
illustrate the various operations.
When servicing the compressor, remove only the parts
that preliminary diagnosis shows are in need of service. Refer
to Figures 2 and 5 for information relative to part names and
location.
NOTICE: Do not drive or pound on the clutch hub or

shaft. Internal damage to compressor may result. The
forcing tip on J 33013-B remover-installer center screw
must be flat or the end of the shaft/axial plate assembly
will be damaged.
3.
E3
Remove the shaft key and retain for reassembly.
Install or Connect
1.
Install the
Allow the
out of the
provide an
2.
Be sure the frictional surface of the clutch plate and the

clutch rotor are clean before installing the clutch plate
and hub assembly.
3.
Align the shaft key with the shaft keyway and place the
clutch plate and the hub assembly onto the compressor
shaft.
shaft key into the hub key groove (Fig. 4).

key to project approximately 3.2mm (1/8 11 )
keyway. The shaft key is curved slightly to
interference fit in the hub key groove.
Removal and installation of external compressor parts,

and disassembly and assembly of internal parts, must be
performed on a clean workbench. The work area, tools and
parts must be kept clean at all times.
COMPRESSOR CLUTCH PLATE AND HUB

ASSEMBLY
I+ +I Remove or Disconnect
1.
2.
Clamp the holding fixture J 33026 in a vise and attach

compressor to holding fixture with thumb screws
J 33026-1 (Fig. 3).
With center screw forcing tip in place to thrust against
the end of the shaft, thread the Clutch Plate and Hub
Assembly Installer-Remover J 33013-B into the hub.
Hold the body of the remover with a wrench and turn the
[TI J 33013-B HUB AND

CLUTCH DRIVE PLATE
ASM.REMOVER
J 33026-1 THUMB
SCREW
[I) J 33026 HOLDING

FIXTURE
(I] CLUTCH
PLATE
AND HUB ASM.
G60070-1 D2-C-R1
Fig. 3 Clutch Plate and Hub Assembly Removal

NOTICE: If the center screw is threaded fully onto
the end of the compressor shaft. or if the body of the
installer is held and the center screw is rotated, the key
will wedge and will break the clutch hub.
[JJ CLUTCH PLATE AND HUB ASSY.

[I) CLUTCH PULLEY ROTOR
(TI SHAFT KEYWAY
(I] SHAFT KEY
G60080-1 D2-EK
Fig. 4 Shaft Key, Clutch Plate/Hub Installation
4.
5.
Remove the forcing tip on J 33013-B clutch plate and

hub assembly installer-remover center screw and
reverse the body direction on the center screw, as shown
in Figure 5.
Install the clutch plate and hub installer-remover
J 33013-B with bearing as shown in Figure 8.
The body of the J 33013-B installer-remover should be
backed off sufficiently to allow the center screw to be
threaded onto the end of the compressor shaft.
6.
Hold the center screw with a wrench. Tighten the hex

portion of the installer-remover J 33013-B body to press
the hub onto the shaft. Tighten the body several turns,
remove the installer and check to see that the shaft
key is still in place in the keyway before
installing the clutch plate and hub assembly to
its final position. The air gap between frictional
surfaces of the clutch plate and clutch rotor should be
0.50-0.76mm (.020-.030 11 ).
[I]
J 33013-B DRIVE
PLATE INSTALLER
DRIVE PLATE
INSTALLER BEARING
AIR GAP (0.20"0.30") 0.50-0.76mm
(I]
CLUTCH PLATE
AND HUBASM.
G60090-1 D2-C-R1
Fig. 5 Installing Clutch Plate & Hub Assembly
7.
Remove installer J 33013-B, check for proper

positioning of the shaft key (even or slightly above the
clutch hub).
8.
Spin the pulley rotor by hand to see that the rotor is not
rubbing the clutch drive plate.
COMPRESSOR CLUTCH ROTOR AND/OR

BEARING
I +!
1.
2.
Remove the clutch plate and hub assembly as described
previously.
Remove rotor and bearing assembly retaining ring, using
snap ring pliers J 6083 (Fig. 6).
J 33020 PULLEY ROTOR
ANO BEARING PULLER
G60120-1D2-EK-R1
Fig. 8 Removing Pulley Rotor and Bearing Assembly
[DJ 6083
PLIERS
[!) PULLEY
ROTOR
@J RETAINING
RING
G60060-1 D2-C-R1
Fig. 6 Installing-Removing Pulley Rotor & Bearing Assembly

Retaining Ring
[TI
(i] J 33023-A PULLEY (!]J 33020 PULLER

ROTOR ANO
BEARING PULLER
GUIDE
ENGAGES IN INNER
CIRCLE OF SLOTS
IN ROTOR
J 33020 (LESS
FORCING SCREW)
INVERTED AND
USED TO SUPPORT
HUB OF ROTOR
FOR BEARING
REMOVAL. PULLER
TANGS ENGAGED
IN ROTOR SLOTS.
(!]
PULLEY ROTOR
FACE OOWW
(!]
J 9398-A BEARING
REMOVER
@:)
J 29886 DRIVER
HANDLE
G60130-1 D2-C-R1
G60110-1D2-C-R1
Fig. 9 Pulley Rotor Bearing Removal
Fig. 7 Installing Pulley Rotor/Bearing Puller Guide
3.
Install pulley rotor and bearing puller guide J 33023-A

to the front head (Fig. 7) and install J 33020 pulley rotor
arid bearing puller down into the inner circle of slots in
the rotor. Turn the J 33020 puller clockwise in the slots in
the rotor (Fig. 8).
4.
Hold the J 33020 puller in place and tighten the puller

screw against the puller guide to remove the pulley rotor
and bearing assembly.
5.
To prevent damage to the pulley rotor during bearing

removal the rotor hub must be properly supported.
Remove the forcing screw from J 33020 puller and, with

the puller tangs still engaged in the rotor slots, invert the
assembly onto a solid flat surface or blocks as shown in
Figure 9.
6.
Drive the bearing out of the rotor hub with rotor bearing
remover J 9398-A and J 29886 universal handle (Fig. 9).
NOTICE: It is not necessary to remove the staking in

front of the bearing to remove the bearing, however, it
will be necessary to file away the old stake metal for
proper clearance for the new bearing to be installed into
the rotor bore or the bearing may be damaged.
DJ
J 33019-1 BEARING STAKING GUIDE
II]
RUBBER BAND
J 33019-2 BEARING STAKING PIN

G60150-1 D2-EK-R1
Fig. 11 Staking Bearing In Rotor Hub Bore
[!)
CT]
J 29886 DRIVER
HANDLE
(!]
J 21352-A
~ J 9481-A BEARING
SUPPORT BLOCK
INSTALLER
PULLEY
ROTOR
G60140--1 D2-C-R1
Fig. 10 Installing Pulley Rotor Bearing
I+ +I Install or Connect
1.
Place the pulley rotor on the J 21352-A support block to

fully support the rotor hub during bearing installation
(Fig. 10).
NOTICE: DO NOT support the rotor by resting the

pulley rim on a flat surface during the bearing
installation or the rotor face will be bent.
2.
3.
4.
Align the new bearing squarely with the hub bore and
using puller and bearing installer J 9481-A with
universal handle J 29886, drive the bearing fully into the
hub (Fig. 10). The installer will apply force to the outer
race of the bearing, if used as shown.
Place bearing staking guide J 33019-1 and bearing
staking pin J 33019-2 in the hub bore as shown in
Figure 11. Shift the rotor and bearing assembly on the
J 21352-A support block to give full support of the hub
under the staking pin location. A heavy-duty rubber
band may be used to hold the stake pin in the guide (Fig.
11 ), and the stake pin should be properly positioned in
the guide after each impact on the pin.
520016-102
Fig. 12 Bearing Staked in Place
5.
With the compressor mounted to the J 33026 holding

fixture, position the rotor and bearing assembly ori the
front head (Fig. 13).
6.
Position the J 33017 pulley, rotor and bearing installer

and J 33023-A puller pilot directly over the inner race of
the bearing (Fig. 13).
7.
Position puller crossbar J 8433-1 on the puller pilot

J 33023-A and assemble the two J 33026-2 through bolts
and washers through the puller bar slots and thread them
into the J 33026 holding fixture (Fig. 13). The thread of
the through bolts should engage the full thickness of the
holding fixture.
8.
Tighten the center screw in the J 8433-1 puller crossbar

to force the pulley rotor and bearing assembly onto the
compressor front head (Fig. 13). Should the
J 33017 pulley rotor and bearing installer slip off direct
in-line contact with the inner race of the bearing, loosen
the J 8433-1 center forcing screw and realign the
installer and pilot so that the J 33017 installer will
properly clear the front head.
9.
Install rotor and bearing assembly retainer ring, using

snap ring pliers J 6083 (Fig. 6).
10.
Reinstall clutch plate and hub assembly as described

previously.
Using care to prevent personal injury, strike the staking

pin with a hammer until a metal stake, similar to the
original, is formed down to but not touching the
bearing.
Noisy bearing operation and reduced bearing life may
result if outer bearing race is deformed while staking,
The stake metal should not contact the outer race of the
bearing. Stake three places 120 degrees apart as shown in
Figure 12.
J 8433-3 SCREW
J 33023-A PULLER PILOT

J 33026-2 THROUGH BOLTS
1-J 84333 SCREW
PULLEY ROTOR
2-CLUTCH COi L
ASSEMBLY
J 33017 PULLEY ROTOR AND BEARING INSTALLER
J 8433-1 CROSS BAR
3-J 33024 CLUTCH

COIL INSTALLER
4-J 84331 PULLER
CROSS BAR
G60170-1D2-C-R1
520019-1D2-R1
Fig. 13 Installing Pulley Rotor and Bearing Assembly
Fig. 15 Installing Clutch Coil Assembly
COMPRESSOR CLUTCH COIL
1.
Perform Steps 1 through 4 of "Clutch Rotor and/or

Bearings" removal procedure. Mark clutch coil
terminal location on compressor front head.
2.
Install J 33023-A puller pilot on front head of

compressor (Fig. 14). Also install J 8433-1 puller
crossbar with J 33025 puller legs as shown in Figure 14.
3.
Tighten J 8433-3 forcing screw against the puller pilot to

remove the clutch coil.
[]] J 8433-3 SCREW
[I) J 8433-1
Place the clutch coil assembly on the front head with the
terminals positioned at the "marked" location.
2.
Place the J 33024 clutch coil installer over the internal

opening of the clutch coil housing and align installer
with the compressor front head.
3.
Center the J 8433-1 puller crossbar in the counter- sunk

center hole of the J 33024 clutch coil installer. Install the
J 33026-2 through bolts and washers through the
crossbar slots and thread them into the holding fixture
J 33026 to full fixture thickness (Fig. 15).
4.
Turn the center forcing screw of the J 8433-1 puller

crossbar to force the clutch coil onto the front head. Be
sure clutch coil and J 33024 installer stay "in-line"
during installation.
PULLER
(]] MARK COIL TERMINAL

CROSS BAR
LOCATION ON HEAD
(]] J 33023-A
[I) CLUTCH COIL
1.
PULLER PILOT
ASSEMBLY
[I) J 33025 PULLER

LEG
G60180-1D2-C-R1
Fig. 14 Clutch Coil Assembly Removal
1 - FRONT HEAD SURFACE

1-CLUTCH COIL
3-STAKE IN FRONT
HEAD (3 PLACES)
2-0RIFT PUNCH
2 - STAKE FRONT HEAD 0.28-0.35MM

11
DEEP (0.10- 015 )
520020--102
Fig. 16 Staking Clutch Coil to Front Head
5.
520021-102
Fig. 17 Details of Stakes in Front Head for Clutch Coil
When coil is fully seated on the front head, use a l/8 11

diameter drift punch and stake the front head at three
places 120 degrees apart (Fig. 16), to ensure clutch coil
remains in position.
6.
3- CLUTCH
COIL
HOUSING
Stake size should be only one-half the area of the

punch tip and be only approximately
0.28-0.35mm (.010-.015") deep (Fig. 17).
Install rotor and bearing assembly and the clutch plate

and hub assembly as described previously.
1-STEEL SHELL
2-LIP SEAL
520033-101
Fig. 18 Compressor Shaft Seal
MAJOR COMPRESSOR REPAIR

PROCEDURES
W SUCTION PORT
W DISCHARGE PORT
MOUNTING BOSS (3)
When replacing the shaft seal assembly (Fig. 18),

pressure relief valve or control switches (Fig. 19), it will be
necessary to recover the refrigerant. Other than clutch repair
procedures, the same holds true for any disassembly of the
compressor.
WCONTROL
SWITCHES
[1J PRESSURE
RELIEF VALVE
A clean workbench covered with a sheet of clean paper,

and a place (clean trays, etc.) for all parts being removed and
replaced is important, as is the use of proper clean service tools.
NOTICE: Any attempt to use makeshift or
inadequate service tools or equipment may result in
damage and/or improper compressor operation.
All parts required for servicing the internal compressor
are protected by a preservative process and packaged in a
manner which will eliminate the necessity of cleaning,
washing or flushing of the parts. The parts can be used in the
internal assembly just as they are removed from the service
package. Seals and protective packaging should be left
intact until just prior to installation.

If the compressor rear head, front head or cylinder and
shaft assembly is to be serviced or replaced, the oil in the
compressor must be drained, measured, recorded and replaced.
520020-1 D2-R1
Fig. 19 Compressor -
Rear Head
COMPRESSOR SHAFT SEAL

REPLACEMENT
Seal Leak Detection
A shaft seal should not be changed because of small
amounts of oil found on an adjacent surface but only after
actual refrigerant leakage is found using an approved leak
detector, J 39400 or equivalent.
1.
Recover the refrigerant using J 39500-GM.
2.
Loosen and reposition compressor in mounting brackets,

if necessary.
3.
Remove clutch plate and hub assembly from compressor

as described in minor repairs.
4.
Remove the shaft seal retainer ring, using snap ring

pliers J 5403 (Fig. 21).
5.
Thoroughly clean inside of compressor neck area

surrounding the shaft, the exposed portion of the seal, the
retainer ring groove and the shaft itself. Any dirt or
foreign material getting into compressor may cause
damage.
6.
Fully engage the knurled tangs of Seal RemoverInstaller J 23128-A into the recessed portion of the Seal
by turning the handle clockwise. Remove the Seal from
the compressor with a rotary-pulling motion (Fig. 22).
Discard the seal. The handle must be hand- tightened
securely. Do not use a wrench or pliers.
7.
Remove and discard the seal seat 0-ring from the

compressor neck using 0-ring remover J 9553-01,
Figure 20.
8.
Recheck the shaft and inside of the compressor neck for

dirt or foreign material and be sure these areas are
perfectly clean before installing new parts.
l~I
Clean
Thoroughly clean 0-ring seal groove in front head.
NOTICE: Seals should not be re-used. Always use a

new specification service seal on rebuild (Fig. 18). Be
sure that the seal to be installed is not scratched or
damaged in anyway. Make sure that the seal seat and seal
are free of lint and dirt that could damage the seal surface
or prevent sealing.
[TI
rn
SEAL
J 23128-A
J 9553-01
0-RING
[!)
(!]
J 33011
J 34614
Fig. 20 Removing and Installing Shaft Seal and 0-Ring
1.
Dip the new seal seat 0-ring in clean 525 viscosity

refrigerant oil and assemble onto 0-ring installer
J 33011, Figure 20.
2.
Insert the 0-ring installer J 33011 into the compressor

neck until the installer "bottoms". Lower the moveable
slide of the 0-ring installer to release the 0-ring into the
seal 0-ring lower groove. (The compressor neck top
groove is for the shaft seal retainer ring.) Rotate the
installer to seat the 0-ring and remove the installer.
3.
Dip the new seal in clean 525 viscosity refrigerant oil and
assemble seal to Seal Installer J 23128-A, by turning
handle clockwise. The stamped steel case side of the
lip seal must be engaged with knurled tangs of installer
so that flared-out side of lip seal is facing and
installed towards the compressor. Install seal protector
J 34614, in the seal lip and place over the compressor
shaft, Figure 22, and push the seal in place with a
rotary motion or place the seal protector J 34014 over
end of compressor shaft, Figure 22, and slide the new
Q]
J 5403
SNAP RING
PLIERS
[Ij
4.
Install the new seal retainer ring with its flat side against
the Seal, using Snap-Ring Pliers J 5403. See Figure 21.
Use the sleeve from 0-ring installer J 33011 to press in on
the seal retainer ring so that it snaps into its groove.
5.
To leak test, install compressor leak test fixture

J 39893 on rear head of compressor and connect gage
charging lines and J 39500-GM Refrigerant Recovery
System. Pressurize suction and high-side of compressor
with R-134a Refrigerant. Temporarily install (M9 x 1.25
thread on shaft) nut and, with the compressor in
horizontal position, rotate the compressor shaft in
normal direction of rotation several turns by hand. Leak
test the seal area and correct and leak found. Recover the
refrigerant. Remove shaft nut.
6.
Remove any excess oil resulting from installing the new

seal parts from the shaft and inside the compressor neck.
7.
Install the clutch plate and hub assembly as described in

minor repair procedures.
8.
Reinstall compressor belt and tighten bracket.
9.
Evacuate and charge the refrigerant system.
COMPRESSOR PRESSURE RELIEF VALVE
SEAL SEAT
RETAINER
RING
!+ +! Remove or Disconnect
G60060-1D2-C-R1
Fig. 21 Removing or Installing Shaft Seal

Retaining Ring
1.
Recover the refrigerant using J 39500-GM.
2.
Remove old pressure relief valve (Fig. 19).
!+ +! Install or Connect
seal onto the shaft with a rotary motion until it stops.
Take care not to dislodge the 0-ring. Be sure the seal
makes good contact with the 0-ring. Disengage the
installer from the seal and remove the installer
J 23128-A and the seal protector J 34614.
NOTICE: Handling and care of seal protector is

important. If seal protector is nicked or the bottom
flared, the new seal may be damaged during installation.
IT)
ONE-PIECE SEAL
[!)
J 23128-A
(l]
1.
Clean valve seat area on rear head.
2.
Lubricate 0-ring of new pressure relief valve and 0-ring

assembly with new 525 viscosity refrigerant oil. Install
new valve and torque in place, 9.0 Nm (6.1 lbs.-ft.)
3.
Evacuate and recharge the system.
4.
Leak test system.
J 34614 SHAFT SEAL
PROTECTOR
G60250--1 D2-C-R1
Fig. 22 Removing or Installing Shaft Seal

CONTROL SWITCHES
6.
If an external leak is present, perform the necessary

corrective measures and recheck for leaks to make
certain the leak has been corrected.
7.
Recover the refrigerant.
8.
Disconnect both hoses from the test plate J 39893.
9.
Add 90 ml (3 oz.) new PAG lubricant to the compressor

assembly. Rotate the complete compressor assembly
(not the crankshaft or drive plate hub) slowly several
turns to distribute oil to all cylinder and piston areas.
I 0.
Install a M9 x 1.25 threaded nut on the compressor

crankshaft if the drive plate and clutch assembly are not
installed.
11.
Using a box-end wrench or socket and handle, rotate the

compressor crankshaft or clutch drive plate on the
crankshaft several turns to insure piston assembly to
cylinder wall lubrication.
12.
Using J 39500-GM Refrigerant Recovery System,

connect the charging station high-pressure line to the
high-side pressure port of the test plate J 39893.
13.
Using J 39500-GM Refrigerant Recovery System,

connect the charging station low-pressure line to the low
pressure port of the test plate J 39893. Oil will drain out
of the compressor suction port if the compressor is
positioned with the suction port downward.
14.
Attach the compressor to the J 33026 holding fixture and

mount the compressor in a vise so that the compressor
will be in a horizontal position and the shaft can be
turned with a wrench.
15.
Using a wrench, rotate the compressor crankshaft or

drive plate hub ten complete revolutions at a speed of
approximately one-revolution per second. Turning the
compressor at less than one-revolution per second can
result in a lower pump-up pressure and disqualify a good
pumping compressor.
16.
Observe the reading on high-pressure gage at the

completion of the tenth revolution of the compressor.
The pressure reading for a good pumping compressor
should be 690 kPa (100 psi) or above. A pressure reading
of less than 620 kPa (90 psi) would indicate one or more
suction and/or discharge valves leaking an internal leak,
or an inoperative valve, and the refrigerant must be
recovered and the compressor disassembled and
checked for cause of leak. Repair as needed, reassemble
and repeat the pump-up test. Externally leak test.
17.
When the pressure pump-up test is completed, recover

the refrigerant from the high-side and remove the test
plate J 39893.
18.
Tilt the compressor so that the compressor suction and

discharge ports are down. Drain the PAG lubricant from
the compressor.
19.
Allow the compressor to drain for 10 minutes, then refill

with the proper amount of PAG lubricant, per oil balance
procedure in section 1B of the service manual. The PAG
lubricant may be poured into the suction port. If further
assembly or processing is required, a shipping plate or
test plate J 39893 should be installed to keep out air, dirt
and moisture until the compressor is installed.
Figure 20
I+ +! Remove or Disconnect
1.
Recover the refrigerant.
2.
Disconnect the electrical connector from the switch in

the rear head of compressor.
3.
Remove the switch retaining ring using J 5403 internal

snap ring pliers.
4.
Remove the switch from the compressor.
5.
Remove old 0-ring seal from the switch cavity using

J 9553-01 0-ring removal tool.
If existing control switch is reinstalled in the compressor,

a new 0-ring seal must be used and preferably a new retainer
ring should also be used. A new switch kit has the 0-ring and
retainer ring included.
I++! Install or Connect

1.
Check switch cavity and 0-ring groove in the rear head

for dirt or foreign material and clean as necessary. Install
a new 0-ring coated with clean refrigerant oil into
groove in switch cavity.
2.
Lubricate the control switch housing with clean

refrigerant oil and carefully insert switch into switch
cavity until switch bottoms in cavity.
3.
Using J 9533-1 snap ring pliers install switch retaining

ring with high point of curved sides adjacent to switch
housing. Be sure retaining ring is properly seated in
switch cavity retaining groove. Leak test according to
bench test procedure.
COMPRESSOR LEAK TESTING

(EXTERNAL AND INTERNAL)
Bench-Check Procedure
1.
Install test plate J 39893 on rear head of compressor.
2.
Using J 39500-GM Refrigerant Recovery System, attach

center hose of manifold gage set on charging station to a
refrigerant drum standing in an upright drum.
3.
Connect charging station high and low pressure lines to

corresponding fittings on test plate J 39893. Suction port
(low-side) of compressor has large internal opening.
Discharge port (high-side) has smaller internal opening
into compressor and deeper recess.
4.
Open low pressure control, high pressure control and

refrigerant control on charging station to allow
refrigerant vapor to flow into compressor.
5.
Using a leak detector, check for leaks at pressure relief

valve, rear head switch location, compressor front and
rear head seals, center cylinder seal, through bolt head
gaskets and compressor shaft seal. After checking, shut
off low pressure control and high-pressure control on
charging station.
@:)
1 - J5403
SNAP RING PLIERS
2-J6083
SNAP RING PLIERS
3 - J 29886
DRIVER HANDLE
4 - J 8433-1
PULLER BAR
5 - J 8433-3
FORCING SCREW
6 - J 9398-A
BEARING REMOVER
13 -
J 33013
HUB & DRIVE PLATE REMOVER

& INSTALLER
14 -
J 39500-GM
R134a NC REFRIGERANT RECOVERY,

RECYCLING AND RECHARGING
SYSTEM (ACR4)
15- J 33017
PULLEY & BEARING ASSEMBLY

INSTALLER
16- J 33019
BEARING STAKING TOOL
17- J 33020
PULLEY PULLER
18- J 34614
SHAFT SEAL PROTECTOR
7 - J 9481-A
BEARING INSTALLER
8 - J 9553-01
"O" RING REMOVER
19- J 33023
PULLER PILOT
9 - J 39893
PRESSURE TESTING CONNECTOR
20- J 33024
CLUTCH COIL INSTALLER ADAPTER
SEAL SEAT REMOVER &

INSTALLER
21 -
CLUTCH COIL PULLER LEGS
10 -
11 -
J 23128-A
J 21352-A
12- J 33011
J 33025
22- J 34992
COMPRESSOR HOLDING FIXTURE
SUPPORT BLOCK
23- J 39400
LEAK DETECTOR
"O" RING INSTALLER
24- J 39037
HIGH-SIDE CHARGE VALVE SOCKET
Fig. 23 Compressor Overhaul -
Special Tools
STEERING, SUSPENSION, TIRES AND WHEELS DIAGNOSIS 3-1

AND WHEELS
CONTENTS
Steering, Suspension, Tires and Wheels Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section 3
Wheel Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section 3A
Power Steering Gear and Pump On-Vehicle Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section 3B
Power Steering Gear Unit Repair ........................................... Section 3B1A
Power Steering Pump Unit Repair .......................................... Section 3B1B
Front Suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section 3C
Rear Suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section 3D
Tires and Wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section 3E
Steering Wheel and Column On-Vehicle Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section 3F
Supplemental Inflatable Restraint (SIR) Tilt Steering Column Unit Repair .......... Section 3F5B
SECTION 3

AND WHEELS DIAGNOSIS
CAUTION: This vehicle is equieped with Supplemental Inflatable Restraint (SIR). Refer to
CAUTIONS in Section 9J under 'ON-VEHICLE SERVICE" and the SIR Component and Wiring
result.
CONTENTS
General Description .......................... 3-2
General Diagnosis ........................... 3-2
Power Steering Gear Assembly Diagnosis ........ 3-5
Steering Linkage Diagnosis .................... 3-6
Power Steering Pump Assembly Diagnosis ........ 3-6
Steering Column Assembly Diagnosis ........... 3-7
Lock System ............................. 3-7
Steering Column Assembly .................. 3-8
Tum Signal Switch Assembly ................ 3-9
Ignition Switch ........................... 3-11
Key Reminder ........................... 3-12
Column-Mounted Dimmer Switch ........... 3-14
Pivot and Switch Assembly ................. 3-15
Power Steering Gear and Pump
Assemblies Leak ......................... 3-15
General Procedure ........................ 3-15
. External Leakage Check ................... 3-15
Seal Replacement Recommendations ........... 3-15
Power Steering System Test Procedure ..........

Shock Absorber Assemblies ..................
Tires .....................................
Irregular or Premature Wear ................
Tread Wear Indicators .....................
Tire Waddle Complaint ....................
Radial Tire Lead/Pull ......................
Vibration .................................
Road Test ...............................
Tire and Wheel Assembly Balance ...........
Runout Check ...........................
Tire Force Variation Check .................
Substitution Method .......................
Tapered Roller Bearing Diagnosis ..............
Trim Height ...............................
Specifications ..............................
Fastener Tightening Specifications ...........
Special Tools ..............................
3-15
3-17
3-18
3-18
3-19
3-19
3-19
3-19
3-22
3-22
3-22
3-23
3-23
3-23
3-24
3-27
3-27
3-27
3-2 STEERING, SUSPENSION, TIRES AND WHEELS DIAGNOSIS
GENERAL DESCRIPTION
Since the problems in steering, suspension, tire and
wheel assemblies involve several systems, they must all
be considered when diagnosing a complaint. To avoid
using the wrong symptom, always road test the vehicle
first. Proceed with the following preliminary checks and
correct any substandard conditions which are found.
ll'l'I Inspect
Wrong pressure and uneven wear on tires.
Loose connections or wear on joints from the steering column assembly to the steering gear assembly.
Loose or damaged parts on the front and rear suspension or steering gear assembly.
Out-of-round or out-of-balance tires, bent wheel
assemblies and loose and/or rough wheel bearing
assemblies.
Leaks in power steering system. Also check the
power steering fluid level and the accessory drive
belt condition and tension. Refer to "Power Steering
Pump Assembly Diagnosis" in this section.
The following symptom diagnosis tables may help
you find the cause of a problem. The tables list a number
of symptoms, along with associated possible causes. More
information on any particular listing can be found in the
sections referenced in the "Refer To" column.
GENERAL DIAGNOSIS
SYMPTOM
POSSIBLE CAUSE
REFER TO (SECTION)
Misaligned front tire and wheel

assembly.
Mismatched or uneven tires.
Broken or sagging spring.
Radial tire lead/pull.
Unbalanced steering gear valve spool.
Dragging front brake assembly.
3A
BODY/CHASSIS - GENERAL
Vehicle Pulls or Leads
Shimmy, Shake or Vibration
Abnormal Noise at Front End
Bent tire and wheel assembly rim.

Excessive tire and wheel assembly
run out.
Out-of-balance tire or wheel assembly.
Excessive wheel bolt runout.
Excessive brake drum assembly or brake
rotor assembly imbalance.
Worn steering linkage components.
Worn lower control arm ball stud
assembly.
Excessive loaded radial runout of tire.
Worn suspension bushings.
Blister or bump on tire.
Out-of-balance propeller shaft assembly.
Foreign material lodged in wheel rim.
Damaged suspension components.
Worn control arm bushings or steering
linkage.
Loose stabilizer shaft assembly or
broken stabilizer shaft links.
Loose wheel nuts.
Loose suspension bolts/screws.
Misadjusted steering gear assembly.
Worn shock absorber assemblies or
mountings.
Improperly positioned spring.
Scuffed tires.
3E
3C, 30
3E
3B, 3BlA
5
3E
3E
3E
3E
5
3B1A
3C
3E
3C, 30
4A
3C, 30
3B1A, 3C, 30
3C, 30
3E
3C, 30
3B, 3BlA
3C, 30
3C, 30

SYMPTOM
POSSIBLE CAUSE
REFER TO (SECTION)
Low or Uneven Trim Height
Broken, incorrect, or sagging spring.

Overloaded vehicle.
3C,3D
Body Leans or Sways in Corners
Loose stabilizer shaft assembly or

broken stabilizer shaft links.
Worn shock absorber assemblies or
mountings.
Broken or sagging spring.
Overloaded ve.hicle.
3C, 30
Suspension Bottoms
"Dog" Tracking
Overloaded vehicle.
Worn shock absorber assemblies.
Incorrect, broken or sagging spring.
Damaged rear control arm or worn
control arm bushing assembly.
Bent rear axle assembly.
3C, 30
3C,3D
3C, 30
3C, 30
30
4B
TIRES/WHEELS - GENERAL
Misaligned tire and wheel assembly.
Excessive toe.
Sagging or broken spring.
Hard driving.
Overloaded vehicle.
Tires not rotated.
Low or excessive inflation pressure.
Bent suspension components.
3A, 3E
3A
3C, 30
3E
3C,3D
Wheel Assembly Tramp

Improper shock absorber assembly
action.
Blister or bump on tires.
3E
3C, 30
Cupped Tires
3A
3C,3D
3C
3E
3C
3B, 3B1A
Abnormal or Excessive Tire Wear

Weak shock absorber assemblies.
Worn wheel bearing assembly.
Excessive tire or wheel assembly runout.
Worn control arm ball stud assembly.
Loose steering gear assembly
adjustment.
3E
3E
3C, 30
STEERING/STEERING WHEEL
ASSEMBLY - GENERAL
Poor Returnability
Incorrect caster setting.

Lack of lubrication at control arm ball
stud assembly or tie rod ends.
Bind in control arm ball stud assembly.
Bind in steering column assembly.
Incorrect steering gear valve spool.
Intermediate steering shaft joints
binding.
3A
OB
3C
3F,3F5B
3B, 3B1A
3B, 3B1A
3B

SYMPTOM
POSSIBLE CAUSE
REFER TO (SECTION)
Hard Steering
Hydraulic system- Perform test as

outlined in "Power Steering System Test
Procedure" in this section.
Bind or catch in steering gear assembly.
Loose steering gear assembly mounting.
Faulty pipe fitting seat.
3B,
3B,
3B,
3B,
Too Much Play in Steering
Wander or Poor Steering Stability
Erratic Steering When Braking
Loose steering gear assembly mounting.

Loose or worn joints from steering
column assembly to steering gear
assembly.
Mismatched or uneven tires.

Loose stabilizer shaft assembly.
Broken or sagging spring assembly.

Broken or sagging spring assembly.
Warped brake rotor assembly.
Sticking brake caliper piston.
Leaking wheel cylinder or brake caliper
assembly.
Incorrect or uneven caster.
3B1A
3B1A
3B1A
3B1A
3B, 3B1A
3B, 3B1A, 3F
3B, 3B1A
3C, 3D
3C, 3D
3C, 3D
3B, 3B1A
3A, 3E
3C
3C, 3D
5
5
5
3A
Steering Wheel Assembly

Kickback
3B
Air in power steering system.
Loose steering gear assembly mounting. 3B, 3B1A
3B, 3B1A, 3F
Loose or worn joints from steering
column assembly to steering gear
assembly.
3B1A
Loose tie rod ends.
3B, 3B1A
Worn or missing pipe fitting seat.
3C
See "Too Much Play in Steering" for
other possible causes.
Steering Wheel Assembly Surges

or Jerks
Bad or defective tire.

Sluggish steering gear valve spool.
Loose or oil soaked accessory drive belt.
3B, 3B1A
3B, 3B1B
3B
RIDE
Too Soft
(Vehicles with FEl suspension are
designed for soft ride.)
Too Harsh
Incorrect shock absorber assemblies.

Incorrect or sagging spring assembly.
3C, 3D
3C, 3D
Incorrect shock absorber assemblies.

Incorrect spring assembly.
Incorrect tires or tire pressure.
3C, 3D
3C,3D
3E
STEERING, SUSPENSION, TIRES AND WHEELS DIAGNOSIS 3.5
POWER STEERING GEAR ASSEMBLY DIAGNOSIS

SYMPTOM
POSSIBLE CAUSE
REFER TO (SECTION)
Hissing Noise
This is commonly heard when steering

wheel assembly is turned and vehicle
is not moving, and especially so if
brakes are applied. If noise is very
objectionable, replace the gear with
a partial service gear assembly.
(A replacement gear will also have a
slight noise, and is not always a cure
for the condition.)
Loose intermediate steering shaft
universal joints.
3B, 3BlA
Rattle or Chucking Noise
Outlet (pressure) hose assembly contacting frame.

Loose tie rod ends.
Loose steering gear assembly attachment.
Loose pinion shaft assembly.
3B
3B, 3B1A
3BlA
3B, 3B1A
3B,3B1A
If a rattle occurs when driving over bumps, check front brake linings for loose fit and missing antirattle clips.
Poor Return of Steering Wheel
Assembly to Center
Momentary Increase in Effort When

Turning Steering Wheel Assembly
Fast to Right or Left
Steering Wheel Assembly Surges or

Jerks When Turning with Engine
Running, Especially During Parking
Excessive Steering Wheel Assembly
Kickback or Loose Steering
Misaligned front tire and wheel

3A
assembly.
3C
Binding tie rod ends.
3B1A
Binding control arm ball stud assembly.
3C
Steering wheel assembly rubbing against 3F
tum signal switch housing.
3B, 3B1A
Tight or frozen steering gear coupling
3F
shaft assembly.
Sticky or plugged steering gear valve
3B, 3B1A
spool.
3B, 3BlA, 3B1B
High internal leakage.
Sticking or damaged steering gear valve 3B, 3B1A
spool.
Insufficient pump assembly pressure.
3B,3B1B
3B,3B1B
Low fluid level.
Sticky flow control valve.
3B, 3B1B
3B,3B1B

Loose steering gear assembly adjustment.
Loose tie rod ends.
Coupling assembly loose on stabilizer
shaft assembly.
Loose thrust bearing preload adjustment.
Worn pipe fitting seat.
3B
3B, 3B1A
3B1A
3C
3B, 3C
3B, 3B1A
3B, 3B1A

SYMPTOM
Hard Steering or Lack of Assist,
Especially During Parking
POSSIBLE CAUSE
Brake assemblies applied while turning
steering wheel assembly.
Damaged or worn steering gear coupling
shaft assembly.
Sticky flow control valve.
Excessive internal pump assembly
leakage.
Excessive internal steering gear
assembly leakage.
REFER TO (SECTION)
3F
3B,3B1B
3B,3B1B
3B,3B1B
3B, 3B1A
STEERING LINKAGE DIAGNOSIS

SYMPTOM
Excessive Play or Looseness in
Power Steering System
Excessive Looseness in Tie Rod
Assemblies
Hard Steering
POSSIBLE CAUSE
Worn control arm ball stud assembly.
Worn tie rod sockets.
Damaged and leaking seal resulting in
loss of lubricant, corrosion and excessive
wear.
Tight or frozen tie rod assemblies
Steering gear assembly adjusted too
tight.
REFER TO (SECTION)
3C
3B1A
3B1A
3B1A
3B, 3B1A
POWER STEERING PUMP ASSEMBLY DIAGNOSIS

SYMPTOM
Foamy, Milky Fluid, Low Fluid
Level, Low Pressure
Low Pressure Due to Pump

Assembly
Low Pressure Due to Steering Gear

Assembly
POSSIBLE CAUSE
Air in fluid.
Internal pump assembly leakage.
Extremely cold temperatures will cause
air bubbles if fluid level is low.
If fluid level is correct and pump assembly still foams, remove pump assembly;
then remove reservoir assembly from
pump assembly on 3.4L L32 engine.
On 5.7L LTl engine, remove pump
assembly and remote reservoir assembly.
Check soft plug and housing for cracks.
If cracked, replace housing on 3.4L L32
engine or remote reservoir assembly on
5.7L LTl engine.
Stuck or inoperative flow control valve.
Pressure plate not flat against ring.
Extremely worn ring.
Scored pressure plate, thrust plate or
rotor.
Vanes sticking in rotor slots.
Cracked or broken thrust plate or
pressure plate.
High internal leakage.
Scored housing bore.
Leakage at valve rings or seals.
REFER TO SECTION 38, 3E1 B

SYMPTOM
POSSIBLE CAUSE
Growling Noise in Pump Assembly
Restricted hoses or steering gear assembly causing excessive back pressure.

Scored pressure plates, thrust plate or
rotor.
Womring.
Groaning Noise in Pump Assembly
Air in fluid.
Low fluid level.
Loose pump assembly mounting.
Rattling Noise in Pump Assembly
Vanes sticking in rotor slots.

Improperly installed vane.
Damaged pump bearings.
Swishing Noise in Pump Assembly
Damaged flow control valve.
Whining Noise in Pump Assembly
Scored pump shaft bushing.

Scored pressure plates and vanes.
REFER TO SECTION 38, 381 B
STEERING COLUMN ASSEMBLY DIAGNOSIS

SYMPTOM
POSSIBLE CAUSE
LOCK SYSTEM
Will Not Unlock
Will Not Lock
Collapsed shear flange on sector shaft.

Damaged lock bolt.
Damaged lock cylinder.
Damaged housing.
Damaged sector.
Damaged rack.
Damaged or incorrectly cut key.
Broken or worn lock bolt spring.

Damaged sector.
Burr on lock bolt.
Damaged housing.
Damaged rack.
Interference between bowl and rack
coupling.
Stuck ignition switch.
Restricted actuator rod.
Incorrectly installed sector.
REFER TO SECTION 3F, 3F5B

(except where noted)

SYMPTOM
POSSIBLE CAUSE
High Lock Effort


Damaged ignition switch.
Broken or deformed rack preload spring.
Burrs on sector, rack, housing, support or
actuator rod coupling.
Bent sector shaft.
Damaged rack.
Park lock cable damaged or misadjusted.
Extreme misalignment of housing to
cover.
Distorted coupling slot in rack.
Bent actuator rod.
Bent ignition switch mounting bracket.
Restricted actuator rod.
Worn or damaged key.
Will Stick in "START"
Deformed actuator rod.

Check items under "High Lock Effort."
Key Cannot Be Removed in

"OFF-LOCK"
Incorrectly set ignition switch.

Lock Cylinder Can Be Removed
Missing lock cylinder retaining screw.
High Effort in Lock Cylinder

Distorted rack.
Between "OFF" and "OFF-LOCK"
Lock Bolt Hits Shaft Lock in "OFF" Incorrectly set ignition switch.
and "PARK"
STEERING COLUMN ASSEMBLY
Noise in Steering Column Assembly
High Steering Shaft Assembly

Effort
Loose joints from steering column

assembly to steering gear assembly.
Incorrectly aligned steering column
assembly.
Unlubricated horn contact ring.
Lack of grease on bearings.
Loose sight shields.
Worn or broken upper or lower steering
shaft bearing assembly.
Unseated lock plate retainer ring.
Unlubricated spherical joint.
Misaligned steering column assembly.
Improperly installed or deformed dust
seal.
Damaged upper or lower steering shaft
bearing assembly.
Flash on inside diameter of shift tube.
Tight universal joint.
3B, 3B1A
OB
OB
OB
4A

SYMPTOM
POSSIBLE CAUSE
Lash in Steering Column Assembly
Loose IP-to-steering column assembly

upper and lower bracket mounting
bolts/screws.
Broken weld nuts on jacket.
Sheared IP upper bracket capsule.
Loose shoes in housing.
Loose pivot pins.
Loose lock pin in housing support.
Loose housing support bolts/screws.
Loose steering column assembly upper
and lower bracket-to-jacket bolts/screws.
Loose lower bracket-to-adapter and
bearing assembly mounting bolts/screws.
Bent bowl or bowl not concentric with
hub.
Improperly installed cover and housing
end cap.
Excessive clearance between holes in
housing support or housing and pivot pin
diameters.
Damaged or missing anti-lash spring in
spheres.
Steering shaft upper bearing assembly
not seated in housing.
Missing steering shaft upper bearing
inner race.
Loose housing support bolts/screws.
Missing or broken bearing preload
spring.
Loose fit between shoe and pivot pins.
Shoe not free in slot.
Housing Scraping Bowl
Loose Steering Wheel Assembly
Loose Steering Wheel Assembly

(Every Other Tilt Position)
Steering Column Assembly Not
Locking in Any Tilt Position
Shoe seized on pivot pin.

Burrs or dirt on shoe grooves.
Weak or broken shoe lock spring.
Steering Wheel Assembly Fails to

Return to Top Tilt Position
Bound up pivot pins.

Broken or weak wheel tilt spring.
Tight turn signal switch assembly wires.
Noise When Tilting Steering

Column Assembly
Worn upper tilt bumpers.

Shoe lock spring rubbing in housing.
TURN SIGNAL SWITCH ASSEMBLY
rn
Important
This diagnosis covers mechanical problems only.

Refer to SECTION 8A for turn signal switch
electrical diagnosis.
Turn Signal Will Not Stay in Turn
Position
Foreign material or loose parts impeding

movement of yoke.
Broken or missing detent or canceling
spring.
None of the above; replace switch.
REFER TO SECTION 3F, 3FSB


SYMPTOM
POSSIBLE CAUSE
Tum Signal Will Not Cancel
Loose switch mounting screws.

Broken switch or anchor bosses.
Broken, missing or out-of-position
detent, return or canceling spring.
Worn canceling cam.
Tum Signal Difficult to Operate
Tum Signal Will Not Indicate Lane

Change
Hazard Switch Cannot Be Turned

"OFF"
Hazard Switch Will Not Stay "ON"

or Difficult to Turn "OFF"
No Tum Signal Lamps
Turn Indicator Lamps "ON," But

Not Flashing
Loose tum signal switch arm.

Broken or distorted yoke; replace switch.
Loose or misplaced springs.
Foreign parts and/or material.
Loose tum signal switch mounting
screws.
Broken lane change pressure pad or
spring hanger.
Broken, missing or misplaced lane
change spring.
Jammed base or wires.
Foreign material between hazard support
canceling leg and yoke.
If no foreign material is found, replace
turn signal switch.
Loose turn signal switch.
Interference with other components.
Foreign material interference.
None of the above; replace turn signal
switch.
Electrical failure in chassis harness.
Inoperative turn signal flasher.
Loose chassis~to-column connector. Disconnect chassis-to-column connector and
connect new turn signal switch to chassis
and operate switch by hand.
- If vehicle lamps now operate
normally, turn signal switch is
inoperative.
- If vehicle lamps do not operate,
refer to SECTION 8A.
Inoperative turn signal flasher.
Loose chassis-to-column connection.
Inoperative tum signal switch.
To determine if turn signal switch is
inoperative, substitute new turn signal
switch into circuit and operate switch by
hand. If vehicle lamps operate normally,
turn signal switch is inoperative.

(except where noted}

SYMPTOM
POSSIBLE CAUSE
Front or Rear Tum Signal Lamps

Not Flashing
Burned-out or damaged turn signal bulb.

High resistance connection to ground at
bulb socket.
Loose chassis-to-column connector.
Disconnect chassis-to-column connector
and connect new tum signal switch into
system and operate switch by hand.
- If tum signal lamps are now "ON"
and flashing, tum signal switch is
inoperative.
- If vehicle lamps do not operate, refer
to SECTION 8A.
Burned out bulbs or opens, grounds in
wiring harness from front tum signal
bulb socket to indicator lights. Refer to
SECTION 8A.
- If brake lamps work when switch is
in tum position, tum signal switch is
inoperative.
- If lamps flash at a normal rate, tum
signal switch is inoperative.
- If lamps still flash very slowly, refer
to SECTION 8A.
No Tum Indicator Panel Lamps
Stoplamp Not "ON" When Tum

Indicated
Tum Signal Lamps Flash Very

Slowly
Hazard Signal Lamps Will Not

Flash - Tum Signal Functions
Normally
Blown fuse.
Inoperative hazard warning flasher.
Disconnect column-to-chassis connector
system, then press in hazard warning
button and watch hazard warning lights.
- If lamps now work normally, tum
signal switch is inoperative.
- If lamps do not flash, check wiring
harness. Refer to SECTION 8A.
IGNITION SWITCH
Electrical System Will Not Function

Improperly adjusted ignition switch.
Loose connector at ignition switch.
Switch Will Not Tum
Switch Cannot Be Set Correctly

Deformed switch actuator rod.
Sector to rack engaged in wrong tooth.

KEY REMINDER
Reminder Continues to Operate with Key Out,
but Stops When Driver's Door is Closed
!ll
1nspect
Chips, foreign material in lock cylinder bore.

Sticky lock cylinder actuator tip.
Damaged or broken reminder switch (3).
A TESTLEADS
2 CONNECTOR, COLUMN
Reminder Does Not Sound with Key Fully

Inserted in Lock Cylinder and the Driver's Door
Open
!ll
PC6002-3-D-RP
1nspect
Figure 2 - Checking Reminder at Column Connector
NOTICE: If you are using a multimeter to check

continuity with voltage present in circuits, be sure to
use a voltage setting. A multimeter set on a resistance scale will be damaged by the voltage from live
circuits.
1. Reminder to see if power is available. Refer to
SECTION 8A.
2. Chassis wiring for open circuit.
A. Separate chassis connector ( 1) from column
connector (2).
B. Connect female contacts of terminals "E" and
"F" on chassis connector (1). A bent paper
clip will work as a jumper.
If reminder sounds, repair chassis wiring.

If reminder does not sound, go to step 3.
A TEST LEADS
B PADS, REMINDER SWITCH
PC6003-3-D-RP
Figure 3 - Checking Reminder Switch Pads
A BENT PAPER CLIP

B CONTACTS
1 CONNECTOR, CHASSIS
PC00033-F-RP
Figure 1 - Checking Reminder at Chassis Connector
3. Continuity between male "E" and "F" column

connector contacts with a multimeter (or test light).
Push key all the way into lock cylinder (4).
- If there is continuity when key is in, and
off when key is out, function is normal.
- If there is no continuity, fault is in column. Go to step 4.
4. Probes of reminder switch (3) to ensure good contact
with pads on signal switch.
A. Disassemble upper end of column assembly
until turn signal switch mounting bolts/screws
have been removed.
B. Lift turn signal switch to gain access to probes.
C. Bend probes, if needed, then replace turn
signal switch and tighten three bolts/screws.
D. Check function as in step 3.
A ACTUATOR TIP EXTENDED

4 CYLINDER, LOCK
PC6006-3-D-RP
Figure 6 - Lock Cylinder Actuator - Key in Place
B
A TESTLEADS
3 SWITCH, REMINDER
PC6004-3-0-RP
Figure 4 - Checking Reminder Switch
A
B
C
3
TESTLEADS
SCREWDRIVER
PAD, ACTUATOR
SWITCH, REMINDER
3
PC6007-3-D-RP
Figure 7 - Checking Key Reminder Switch Continuity

4
A ACTUATOR TIP RETRACTED

4 CYLINDER, LOCK
PC6005-3-0-RP
Figure 5 - Lock Cylinder Actuator - Key Removed
5. Tum signal switch wiring for short or fault.

A. Connect male contacts of terminals "E" and
"F" of column connector (2) with a jumper.
B. Check key reminder switch pads on tum signal
switch with multimeter.
If there is continuity, function is normal.
If there is no continuity, replace tum
signal switch.
6. Continuity of check key reminder switch probes, if
problem has not been found.
A. Connect a multimeter to probes on reminder
switch (3).
B. Fully insert and remove key from lock cylinder
(4).
If there is continuity when key is in lock
cylinder (4) and no continuity when key
is out, function is normal. Retrace diagnostic steps starting at step 3.
If there is no continuity, fault is in lock
cylinder (4) or reminder switch (3).
A
B
C
3
TESTLEADS
STRAIGHT EDGE
GAGE, PLUG
SWITCH, REMINDER
PC6008-3-0-RP
Figure 8 - Checking Contact Gap
7. Lock cylinder (4) for chips, burrs, or foreign

material that may prevent actuator tip function.
A. Key must be removed, or lock cylinder (4)
must be in "RUN" position, before lock cylinder can be removed.
B. Remove chips, burrs or foreign material.
C. Reassemble and recheck (step 6).

8. Lock cylinder for damage.
With lock cylinder removed, push key all the
way in, turn to "RUN" position and then
remove it.
A. The lock cylinder actuator tip should
extend and retract smoothly. Total extension of tip should be 1.27 mm (0.050
inch).
B. If not, rep lee lock cylinder (4 ). Reassemble and recheck per step 4.
9. Reminder switch (3) if it appears good but will not

operate.
A. Connect multimeter leads to reminder switch
probes on reminder switch (3).
B. Press on actuator pad until switch points touch.
C. If there is no continuity, replace reminder

switch (3).
10. Reminder switch contact gap.
A. Connect multimeter leads to reminder switch
probes on reminder switch (3).
B. Press a 0.76 mm (0.030-inch) wire type plug
gage with a flat piece of stock onto actuator
pad.
If reminder stops when key is in "RUN"

position or when it is turned past "RUN"
toward "START," problem is a sticky
lock cylinder actuator.
For further diagnosis of key reminder, refer to
SECTION 8A.
COLUMN-MOUNTED DIMMER SWITCH

No "LOW" or "HIGH" Beam
IL'l'I Inspect
1. Loose connector at dimmer switch.
2. Improper adjustment.
3. Internally damaged or worn switch. Refer to SECTION 8A.
Check continuity on switch at light green and
tan switch terminals by pushing in plunger all
the way. A click should be heard.
- If there is no continuity, replace dimmer
switch.
- If there is continuity, refer to SECTION
8A.
If contact is not made (no continuity),

decrease switch contact gap until positive
contact is made.
11. Reminder switch contact gap, with positive contact

gap set at 0. 76 mm (0.030 inch) as outlined above.
A. Use a 0.63 mm (0.025-inch) plug gap wire
beneath flat stock.
If contact is made (continuity), increase
switch contact gap.
B. Reminder switch (3) is set properly when

switch contact will touch 0.76 mm (0.030-inch)
wire but not 0.63 mm (0.025-inch) wire.
--~-A SCREWDRIVER
3 SWITCH, REMINDER
PC6009-3-0-RP
Figure 9 - Decreasing Switch Contact Gap
Reminder Keeps Operating with Key in Lock

Cylinder, Driver's Door Open or Closed; Ceases
When Key is Removed
IL'l'I Inspect
Misadjusted or inoperative door jamb switch on
driver's side.
Shorted wire from signal switch to door jamb
switch.
A. This condition indicates lock cylinder (4) or
reminder switch (3) is at fault. To verify, check
for continuity at "E" and "F" male column
connector contacts, with key removed from
lock cylinder (4).
If continuity exists, fault is in column.
B. Insert key into lock, then turn lock toward

"START" position.
A
A SCREWDRIVER
3 SWITCH, REMINDER
PC6010-3-D-RP
Figure 10 - Increasing Switch Contact Gap
PIVOT AND SWITCH ASSEMBLY

Switch Inoperative: No "LOW," "HIGH" and/or
"WASH"
lll 1nspect
1. Loose body-to-switch connector.
2. Broken or damaged switch.
3. Internally damaged or worn switch.
Connect a new switch without removing old
one.
- If system functions, replace switch.
- If system doesn't function, refer to
SECTION SA.
POWER STEERING GEAR AND PUMP

ASSEMBLIES LEAK
GENERAL PROCEDURE
lll 1nspect
For these common complaints about the power
steering system:
- Fluid leakage on garage floor.
- Fluid leaks visible on steering gear assembly
or pump assembly.
- Growling noise, especially when parking or
when engine is cold.
- Loss of power steering when parking.
- Excessive steering effort required.
For an overfilled reservoir assembly.
For fluid aeration and overflow.
Hose connections.
Identify exact point of leakage. Refer to "External
Leakage Check" in this section.
- Point from which fluid is dripping is not
necessarily point where system is leaking. It is
important to identify exact point of leakage.
EXTERNAL LEAKAGE CHECK

Figure 11
This procedure will help identify exact location of
leak. Some leaks can easily be located but seepage type
leaks may be more difficult. To locate seepage leaks, use
the following method:
1. With engine off, wipe dry complete power steering
system.
2. Check fluid level. Adjust fluid level as necessary.
3. Start engine, then turn steering wheel assembly from
stop to stop several times.
Do not hold it at a stop for any length of time as
this can damage pump assembly (5).
It is easier for someone else to operate steering
wheel assembly while you search for seepage.
4. Find exact location of leak and repair.
SEAL REPLACEMENT
RECOMMENDATIONS
Lip Seals
Lip seals, which seal rotating shafts, require special
treatment. This type of seal is used on the hydraulic pump
shaft and the pinion shaft of the steering gear assembly.
When leakage occurs in this area, always replace the seal
or seals, after inspecting and throroughly cleaning the
sealing surfaces. Replace the shaft if pitting is found. If
corrosion in the lip seal contact zone is slight, clean
the surface of the shaft with crocus cloth. Replace the
hydraulic pump shaft or complete gear assembly only if
the leakage cannot be stopped by smoothing with crocus
cloth first.
0-Ring Seals
Whenever a part which forms a sealing surface for
an 0-ring is removed, the 0-ring seal should also be
removed and replaced with a new 0-ring seal. Lubricate
all new 0-ring seals with power steering fluid to ease
assembly.
POWER STEERING SYSTEM TEST

PROCEDURE
Tools Required:
J 5176-D Power Steering Pressure Tester
0-2000 PSI and
J 5176-92 18 mm Power Steering Gauge
Adapter
J 25323-A Power Steering System Analyzer
J 29525-92 Power Steering Analyzer 18 mm
Adapter
If a hydraulic or mechanical malfunction of the
pump assembly or power steering gear assembly is suspected, perform the following procedure to determine the
cause.
NOTICE: See "Notice" on page 3-1 of this section.
1. Disconnect outlet hose assembly at pump assembly
on 3.4L L32 engine or remote reservoir assembly on
5.7L LTl engine.
2. Place drain pan under pump assembly on 3.4L L32
eng~ne or remote reservoir assembly on 5.7L LTl
engme.
3. Connect spare pressure hose to pump assembly on
3.4L L32 engine or remote reservoir assembly on
5.7L LTl engine.
rn
Important
The power steering system may be tested

using J 5176-D or J 25323-A. Testing with
J 25323-A will measure flow rate as well as
pressure.
4. Connect J 5176-D and J 5176-92 or J 25323-A
and J 29525-92 to outlet hose assembly and spare
pressure hose.
5. Open valve on J 5176-D or J 25323-A.
6. Start engine and allow engine to reach normal
operating temperature.
A 3.4L L32 ENGINE

B 5.7L LTl ENGINE
REPLACE DRIVESHAFT SEAL. MAKE CERTAIN THAT
DRIVESHAFT IS CLEAN AND FREE OF PITTING
IN AREA.
D REPLACE HYDRAULIC PUMP FLOW CONTROL VALVE
SEAL (0-RING).
E TORQUE HYDRAULIC PUMP HOSE FITTING NUT TO
28 Nm (21 LB. FT.). IF LEAKAGE PERSISTS, REPLACE
HYDRAULIC PUMP SEAL (0-RING).
F TORQUE HYDRAULIC PUMP FITTING TO 75 Nm
(55 LB. FT.). IF LEAKAGE PERSISTS, REPLACE
G CHECK FLUID LEVEL. IF LEAKAGE PERSISTS WITH THE
LEVEL CORRECT AND HYDRAULIC PUMP RESERVOIR
CAP TIGHT, REPLACE HYDRAULIC PUMP RESERVOIR
CAP.
H IF A CRACKED OR BENT HYDRAULIC PUMP FLUID
RESERVOIR IS DETECTED, REPLACE HYDRAULIC
PUMP FLUID RESERVOIR.
TORQUE STEERING GEAR PIPE FITTING SEAT TO
28 Nm (21 LB. FT.). IF LEAKAGE PERSISTS, REPLACE
STEERING GEAR PIPE SEAL (0-RING).
J REPLACE GEAR WITH PARTIAL STEERING GEAR

ASSEMBLY.
K IF LEAKAGE IS OBSERVED BETWEEN TORSION BAR
AND STEERING GEAR PINION SHAFT ASSEMBLY,
REPLACE WITH PARTIAL STEERING GEAR ASSEMBLY.
L IF LEAKAGE IS OBSERVED AT DRIVER SIDE AND IS
NOT AFFECTED BY DIRECTION OF TURN, REPLACE
WITH PARTIAL STEERING GEAR ASSEMBLY.
M IF LEAKAGE IS OBSERVED AT STEERING GEAR
HOUSING END AND SPURTS WHEN BOTTOMED IN
LEFT TURN, REPLACE WITH PARTIAL STEERING
GEAR ASSEMBLY.
N IF LEAKAGE IS OBSERVED AT THESE POINTS,
REPLACE WITH PARTIAL STEERING GEAR ASSEMBLY.
p TORQUE HYDRAULIC PUMP FITTING TO 75 Nm
(55 LB. FT.) AND HYDRAULIC PUMP HOSE FITTING NUT
TO 28 Nm (21 LB. FT.). IF LEAKAGE PERSISTS, REPLACE
5 PUMP ASSEMBLY, POWER STEERING
6 RESERVOIR ASSEMBLY, POWER STEERING FLUID
7 HOSE ASSEMBLY, POWER STEERING FLUID OUTLET
8 GEAR ASSEMBLY, POWER STEERING
PC0001-3F-RP
Figure 11 - Power Steering Gear and Pump Assemblies Leak Diagnosis
STEERING, SUSPENSION, TIRES AND WHEELS DIAGNOSIS 317

7. With engine at idle and valve open on J 5176-D
or J 25323-A, pressure should be no more than
1 050 kPa (150 psi).
rn
Important
If pressure is more than 1 050 kPa (150 psi),

check the hoses for restrictions and poppet
valve on steering gear assembly for proper
assembly.
NOTICE: Do not leave the valve fully closed for

more than 5 seconds as the pump assembly could be
damaged.
8. Fully close valve on J 5176-D or J 25323-A three
times and record pressure reading each time. Each
reading should show at least 6 895 kPa (1,000 psi).
The three readings should be within 345 kPa (50 psi)
of each other.
If pressure readings are high enough and are

within 345 kPa (50 psi) of each other, pump
assembly is functioning properly.
If pressure readings are high enough but are
not within 345 kPa (50 psi) of each other,
control valve in pump assembly is sticking.
A. Remove valve, clean it and remove any

burrs using crocus cloth or fine hone.
B. If system contains some contamination,
flush it.
If pressure readings are less than 6 895 kPa

(1,000 psi), replace flow control valve and
recheck.
- If pressures are still low, replace rotor and
vanes.
9. If pump assembly checks to specification, leave
valve open and tum steering wheel assembly (or
have someone else tum it) to both stops.
Record highest pressures and compare with
highest pump assembly pressure recorded
earlier.
- If pressure at both stops is not same as

maximum pressure, steering gear assembly is leaking internally and must be
repaired.
10. Turn off engine.
11. Remove J 5176-D and J 5176-92 or J 25323-A
and J 29525-92
12. Connect outlet hose assembly to pump assembly on
3.4L L32 engine or remote reservoir assembly on
5.7L LTl engine.
!~I
Tighten
Hydraulic pump hose fitting nut to 28 Nm

(21 lb. ft.).
3B.
SHOCK ABSORBER ASSEMBLIES

The following procedure includes both on-vehicle
and bench checks to be done when evaluating performance of shock absorber assemblies.
rn
Important
The single-tubed shock absorber assemblies are

highly gas pressurized and require a force of 445 N
( 100 pounds) to initiate shock absorber rod movement. Be careful not to dent or puncture the shock
absorber assemblies, or they must be replaced.
Weak
1. Check and adjust tire pressures to pressures shown
on tire placard.
2. Note load conditions under which vehicle is normally driven.
3. If practical, ride with owner to be sure you understand complaint before proceeding to next step.
4. Test each shock absorber assembly in turn by
quickly pushing down, then lifting up, corner of the
bumper nearest the shock absorber assembly being
checked.
A. Use same amount of effort on each test and
note resistance on compression and rebound.
B. Compare this with a similar vehicle having
acceptable ride quality.
Shock absorber assemblies on both
vehicles should provide the same feeling
of resistance. If there is much difference
between the two vehicles, go to next step.
5. Support vehicle to expose shock mounts.
6. Remove shock absorber assemblies. Refer to SECTION 3C.
CAUTION: The shock absorber assemblies are highly pressurized. Be sure

to properly disassemble module or
personal injury could result.
7. Disassemble plastic dust tube.
8. Remove shock absorber rod washer.
(I] Important
Do not fully compress shock absorber assembly. Shock absorber assemblies are highly gas
charged and will extend when released.
9. Turn shock absorber assembly so lower mount is up
and upper mount is down.
Compress shock absorber assembly against
ground at various rates of speed through
approximately one-half the length of the
exposed chromed shock absorber rod (75 mm
(3 inches) - rear; 50 mm (2 inches) - front).
10. Compare right and left shock absorber assemblies
for compression resistance and rebound speed.
Right and left shock absorber assemblies should
feel comparable.
318 STEERING, SUSPENSION, TIRES AND WHEELS DIAGNOSIS
HU
Differences between front and rear shock

absorber assemblies are normal.
If in doubt about condition, compare with a
shock absorber assembly known to be good.
Noisy
1. Check all mountings for proper tightening.
A loose mounting will cause a noise.
2. If all mountings are intact,jounce vehicle as in step 4
in "Weak" above to isolate suspected unit.
3. If practical, ride with owner to be sure you understand complaint, before proceeding to next step.
4. Remove suspected shock absorber assembly. Refer
to SECTION 3C.
5. Shake shock absorber assembly and listen for loose
metallic parts inside shock absorber body.
If suspicious noise is heard, replace shock
absorber assembly.
6. Turn shock absorber assembly so lower mount is up
and upper mount and rod is down.
Slowly compress shock absorber assembly. Do
not allow chromed portion of shock absorber
rod to pass below black seal cover.
7. Replace shock absorber assembly if seize is encountered with more than 25 mm (1 inch) of chromed
portion of shock absorber rod exposed above seal
cover.
Leaks
1. Fully extend shock absorber assemblies (tire and
wheel assemblies unsupported) to expose seal cover
area for inspection.
2. Look for signs of leaks at top of shock absorber
assembly.
A small amount of fluid is not cause for
replacement. The seal permits some seepage to
lubricate the shock absorber rod.
A leaking shock absorber assembly can easily
be found because there will be an excessive
amount of fluid on shock absorber assembly.
3. A leaking shock absorber assembly must be
replaced.
1i11 (\~~
WEAR INDICATORS
KC0013-3-B-RP
Figure 12 - Tread Wear Indicators
TIRES
IRREGULAR OR PREMATURE WEAR
Figures 12 and 13
Irregular or premature tire wear has many causes.
Some of them are: incorrect inflation pressures, lack of
regular rotation, driving habits, or improper tire and wheel
assembly alignment. If tire and wheel assembly alignment
is reset due to a tire wear condition, always reset toe as
close to zero degrees as the specification allows.
A HARD CORNERING, UNDER INFLATION OR LACK OF

ROTATION
B EXCESSIVE TOE ON THE NON-DRIVE AXLE ASSEMBLY
OR LACK OF ROTATION
C HEAVY ACCELERATION ON DRIVE AXLE ASSEMBLY,
EXCESSIVE TOE ON DRIVE AXLE ASSEMBLY OR LACK
OF ROTATION
PC8013-3-D-RP
Figure 13 - Tire Wear Diagnosis

Rotate tires if following conditions are noted:
Front and rear tire wear is unequal.
Uneven wear exists across tread of any tire.
Left and right front tire wear is unequal.
Left and right rear tire wear is unequal.
Check tire and wheel assembly alignment if following conditions are noted:
Left and right front tire wear is unequal.
Wear is uneven across tread of any front tire.
Front tire treads have a scuffed appearance with
"feather" edges on one side of tread ribs or blocks.
TREAD WEAR INDICATORS

Figure 12
The original equipment tires have built-in tread wear
indicators to show when the tires should be replaced.
These indicators will appear as 12.7 mm (1/2-inch) wide
bands when the tire tread depth becomes 1.6 mm (l/16
inch). When the indicators appear in 2 or more grooves at
3 locations, replace the tire.
TIRE WADDLE COMPLAINT

Figure 14
Tire waddle is side-to-side movement at the front
and/or rear of the vehicle. It can be caused by the steel belt
not being straight within the tire; or by excessive lateral
runout of the tire or wheel assembly. It is most noticeable
at low speed, about 8 to 48 km/h (5 to 30 mph). It may
also appear as a ride roughness at 80 to 113 km/h (50 to
70mph).
The vehicle can be road tested to see which end of
the vehicle has the faulty tire. If the tire causing the tire
waddle is on the rear, the rear end of the vehicle will
"waddle." From the driver's seat, it feels as if someone is
pushing on the side of the vehicle.
If the faulty tire is on the front, the tire waddle is
more easily seen. The front sheet metal appears to be
moving back and forth. It feels as if the driver's seat is the
pivot point in the vehicle.
PC20033-F-RP
Figure 14 - Tire Waddle
A more time-consuming method of determining the

faulty tire is substituting tire and wheel assemblies that are
known to be good. Follow these steps:
1. Drive vehicle to determine if tire waddle is corning
from front or rear.
2. Install tire and wheel assemblies known to be good
from a similar vehicle in place of those on end of
vehicle which is vibrating.
If tire waddle cannot be isolated to front or
rear, start with rear tires.
3. Road test again.
If improvement is noted, install original tire
and wheel assemblies one at a time until faulty
tire is found.
If no improvement is noted, install tires known
to be good in place of all four. Then, install
originals one at a time until faulty tire is found.
RADIAL TIRE LEAD/PULL

Figure 15
Lead/pull is the deviation of the vehicle from a
straight path on a level road with no pressure on the
steering wheel assembly.
Lead is usually caused by:
Poor tire construction.
Uneven brake assembly adjustment.
Improper tire and wheel assembly alignment.
The way in which a tire is built can produce lead in a
vehicle. An example of this is placement of the belt. Offcenter belts on radial tires can cause the tire to develop a
side force while rolling straight down the road and the tire
will tend to roll like a cone.
The lead/pull correction chart should be used to
make sure that the front tire and wheel assembly alignment is not mistaken for tire lead (Figure 15). Refer to
SECTION 3A.
Rear tires will not cause lead.
VIBRATION
Figures 16 and 17
!l'l'I Inspect
Improper tire inflation pressure.
Bent rims from chuckhole or curb impact.
Faulty tires, such as tread distortions, separations, or
bulges.
- Slight sidewall indentations are normal and
will not affect ride.
- Sidewall bulges are not normal and indicate
impact damage.
Mud or tar build-up on tire or wheel assembly.
Replacement tire and wheel assembly does not
conform to original part, or is of lesser quality or
substitute design.
Loose or missing balance weights or wheel nuts.
Irregular or excessive tire wear.
Bent or faulty drive axle assembly.
RADIAL TIRE LEAD/PULL CORRECTION CHART

Adjust the pressure to
specifications (on Tire Placard).
Road Test
Check for proper trim heights.

Vehicle Lead/Pulls
Check brake assemblies for drag.
Cross switch front tire and wheel
assemblies.
Road Test
Vehicle leads/pulls opposite

direction.
Vehicle leads/pulls same

direction.
Probable cause is front tire and
wheel assembly alignment. Check
caster-camber-toe.
Probable cause is tires.
Swap left front tire and wheel

assembly with left rear tire and
wheel assembly.
Alignment not within specifications.
Vehicle Still Leads
Adjust front tire and wheel assembly

alignment to specifications.
Swap right front tire and wheel

assembly with right rear tire
and wheel assembly.
Replace left rear tire.
Road Test
Alignment Within Specifications
Vehicle still leads.
Replace right rear tire.
Change caster setting.
Leads Right
Leads Left
Set right caster at top spec. set

left caster 1 less.
Set left caster at top spec. set

right caster 1 less.
OK
Road Test
Still Leads Left

Continue decreasing right caster
until pull is eliminated.
Still Leads Right

Continue decreasing left caster
until pull is eliminated.
DO NOT exceed 2 cross caster.
PC6014-3-D-RP
Figure 15 - Radial Tire Lead/Pull Diagnosis
VIBRATION COMPLAINT DIAGNOSIS
Visual inspection
Road test to verify

complaint.
OK
Low speed below 64

km/h (40 mph)
High speed above 64

km/h (40 mph)
On-vehicle
runout check
Off-vehicle dynamic
balance
Not OK
Not OK
Off-vehicle
runout check
On-vehicle dynamic
balance
Not OK
Not OK
OK
OK
Match mount tire

on wheel assembly
Index assemblies on
wheel studs.
Not OK
Replace
tire.
OK
Not OK
Measure and
replace wheel assembly.
OK
Measure axle assembly or

brake rotor runout.
OK
Not OK
Replace brake rotor or

axle shaft.
OK
Off-vehicle dynamic
balance
Not OK
On-vehicle finish
balance
Not OK
Check for engine drive

line imbalance.
PC6015-3-D-RP
Figure 16 - Wheel and Tire Vibration
TIREOUTOFROUND
TIRE STIFFNESS VARIATION
RIM BENT OR OUT OF ROUND

KC0017-3-B-RP
Figure 17 - Causes of Vibration/Runout
ROAD TEST
Before performing any work or testing, always road
test the vehicle. Warming up the tires is necessary to
eliminate any flat spotting. For vibrations that appear to
be engine related, refer to SECTION 6. A road test is also
necessary to determine the speed at which the vibration
occurs. Low-speed vibration at speeds less than 64 krn/h
(40 rnph) is usually related to runout. High-speed vibration at speeds greater than 64 krn/h (40 rnph) is usually the
result of imbalance, but rnay be a product of both runout
and imbalance.
TIRE AND WHEEL ASSEMBLY BALANCE

Before removing the tire and wheel assembly frorn
the vehicle, rnark the wheel bolt nearest the valve stern
for future reference. Also rnark the vehicle position
(left front, etc.) on each tire.
Balance is the easiest procedure to perform and
should be done first if the vibration occurs at highway
speeds. An off-vehicle, two-plane dynamic balance
~hould be performed first. This will correct any imbalance
m the tire and wheel assembly. An on-vehicle finish
balance rnay also be required. This rnay offset brake
drurn, rotor, drive axle, or wheel cover imbalance.
If balance does not correct the highway speed vibration, or if the vibration occurs at low speeds, runout rnay
be the probable cause. Runout is the terrn used when components are checked for syrnrnetry. Runout can be caused
by the drive axle assembly, tire, the wheel assembly, the
bearing assembly, or the way the wheel assembly attaches
to the vehicle.
2.
3.
4.
5.
6.
7.
8.
9.
10.
RUNOUT CHECK
This procedure rnay be stopped at whatever point the
acceptable level of runout is reached.
1. Measure free runout of tire and wheel assembly on
vehicle using a dial indicator with a roller wheel.
Lateral runout (side to side) should be
measured on tire's sidewall as close to tread
shoulder as possible.
Radial runout (up and down) should be
measured on center tread rib.
11.
- Sorne tread designs rnay require wrapping a piece of tape tightly around center
tread circurnference for better dial indicator contact.
Disregard any instantaneous indicator needle jumps
due to sidewall depressions, tread blocks, etc.
Record total indicator reading, and location of high
point of runout.
If radial or lateral runout exceeds 1.52 rnrn (0.060
inch), mount tire and wheel assembly on a dynamic
balance machine and remeasure runout.
Make sure wheel is centered on machine by
wheel center pilot hole.
Record total indicator reading, and location of the
high point of runout.
If radial or lateral runout exceeds 1.27 rnrn (0.050
inch), break down assembly and rotate tire on rirn
180 degrees.
In rnany cases, rotating tire on wheel assembly
will bring runout to an acceptable range.
Whenever a tire is rotated on the wheel
assembly, in this way, the assembly rnust be
rebalanced.
Reinflate, mount on dynamic balance machine and
remeasure runout.
Record total indicator reading and location of high
point of runout.
If radial or lateral run out still exceeds 1.27 rnrn
(0.050 inch) and high point has moved approximately 180 degrees, following tire around rirn, tire is
faulty and should be replaced.
If second high point still exceeds 1.27 rnrn (0.050
inch) and is close to original high point, relative to
the rim, wheel is faulty and should be replaced.
A. Before replacing tire and wheel assembly,
break down assembly and measure wheel separately.
B. Replace wheel if radial runout exceeds 1.02
rnrn (0.040 inch), or lateral runout exceeds
1.14 rnrn (0.045 inch).
If runout of tire and wheel assembly is within limits
when measured off the vehicle, yet exceeds the
limits when measured on the vehicle, the attachment
of tire and wheel assembly to hub is probable cause.

12. Rotate assembly two wheel bolts and recheck
run out.
Several positions may have to be tried to find
best location.
13. If runout can not be reduced to an acceptable level,
remove tire and wheel assembly and measure hub
stud runout.
14. If runout exceeds 0.76 mm (0.030 inch), replace hub
or drive axle shaft.
TIRE FORCE VARIATION CHECK

Tire stiffness variation, or loaded radial runout can
also cause a vibration. However, this is difficult to
measure without a tire problem detector or a loaded radial
runout buffer.
The tire problem detector is simply a roller drum
that slowly rotates the tire, while under load, (mounted on
the vehicle) measuring spindle movement.
The loaded radial runout buffer is a more automated
machine that slowly rotates the tire under load with a
roller drum off the vehicle and measures the tire's
stiffness. It will then "match" the tire to the wheel by
buffing off small amounts of rubber from the outer tread
rows at the stiff spot. This procedure is usually effective,
especially when used as a measuring device and for fine
buffing only. This equipment requires careful use. Do not

remove too much rubber.
Because this equipment is not always available, the
most basic procedure of measuring free runout with a dial
indicator, as previously detailed, is usually more practical.
The free runout of the tire will usually correspond with the
tire's stiff spot.
SUBSTITUTION METHOD
Install a known good set of tire and wheel assemblies. If these correct the vibration, the original tire and
wheel assemblies should be reinstalled one at a time until
the vibration returns.
TAPERED ROLLER BEARING

DIAGNOSIS
Figure 18
When diagnosing a bearing condition:
1. Consider general condition of all parts during disassembly and inspection.
2. Identify bearing problem (Figure 18).
3. After identifying bearing problem, refer to diagnostic chart to identify cause and appropriate repair
procedures.
TAPERED ROLLER BEARING DIAGNOSIS

CONDITION
CAUSE
REPAIR PROCEDURE
Bent Cage
Damage due to improper handling or

tool usage.
Replace bearing.
Galling
Metal smears on roller ends due to

overheating. Lubricant failure or
overload.
Replace bearing. Check inner bearing

seals and for proper lubrication.
Abrasive Step Wear
Pattern on roller ends caused by fine

abrasives.
Clean all parts and housing. Check inner

bearing seals and bearings. Replace if
leaking, rough, or noisy.
Etching
Bearing surfaces appear gray or grayish Replace bearings. Check inner bearing
black in color with related etching away seals for proper lubrication.
of material usually at roller spacing.
Misalignment
Outer race misalignment due to a

foreign object.
Clean related parts and replace bearing.

Make sure races are properly seated.
Indentations
Surface depressions on race and rollers

caused by hard particles of foreign
material.
Clean all parts and housings. Check

inner bearing seals and replace bearings
if rough or noisy.
Fattgue Spalling
Flaking of surface metal resulting from

fatigue.
Replace bearing. Clean all related parts.
Brirrelling
Surface indentations in raceway caused

by rollers either under impact loading
or vibration while bearing is not
rotating.
Replace bearing if rough or noisy.
Cage Wear
Wear around outside diameter of cage

and roller pockets caused by abrasive
material and insufficient lubrication.
Replace bearings. Check inner bearing

seals and for proper lubrication.
Abrasive Roller Wear
Pattern on races and rollers caused by

fine abrasives.
Clean all parts and housings. Check

inner bearing seals and bearings.
Replace if leaking, rough, or noisy.

CONDITION
CAUSE
REPAIR PROCEDURE
Cracked Inner Race
Race cracked due to improper fit,

cocking, or poor bearing seats.
Replace inner race.
Smears
Smearing of metal due to slippage.

Slippage can be caused by poor fits,
poor lubrication, overheating, overloads, or handling damage.
Replace bearings. Clean related parts

and check for proper fit and lubrication.
Replace shaft if damaged.
Frettage
Corrosion set up by small relative

movement of parts with no lubrication.
Heat Discoloration
Discoloration can range from faint

yellow to dark blue and can result from
overload or incorrect lubricant, and
overheating.
Excessive heat can cause softening of
the races on rollers.
To check for heat tempering on races or
rollers a file test can be done. A file
drawn over a tempered part will grab
and cut metal.
A file drawn over a hard part will glide
easily without cutting the metal.
Replace bearing. Clean related parts.

Check inner bearing seals and for proper
lubrication.
Replace bearings if overheating damage
is indicated. Check inner bearing seals
and for proper lubrication.
Stain Discoloration
Discoloration can range from light

brown to black and can be caused by
incorrect lubricant or moisture.
TRIM HEIGHT
Figure 19
Incorrect trim heights can produce symptoms similar to those produced when there is a problem with the
tire and wheel assembly alignment. Trim heights should
be checked when diagnosing steering and vibration
complaints (Figure 19).
In order to measure trim height accurately, make
sure:
Tires are at correct pressure as shown on tire placard
"up to vehicle capacity."
Fuel tank assembly is full.
Vehicle has no additional weight or passengers.
Seat assemblies are in full back position.
Reuse bearings if stains can be removed

by light polishing and if there is no
evidence of overheating. Check inner
bearing seals and related parts for
damage. Check for proper lubrication.
Measuring "Z," "J" and "A" Dimensions
1. Lift front bumper of vehicle up approximately

38 mm (1 1/2 inches). Gently remove hands and let
vehicle settle.
A. Repeat operation for a total of 2 times.
B. After second time, measure "Z," "J" and "A"
dimensions.
2. Push front bumper down approximately 38 mm

(11/2 inches). Gently remove hands and let vehicle
rise on its own.
A. Repeat operation for a total of 2 times.
B. Measure "Z," "J" and "A" dimensions.
3. Calculate trim heights.

Trim heights are average of high and low
measurements.
Rear compartment is empty except for spare tire and

jack assembly and simulated fuel load if required.
4. Verify trim heights with Figure 19.
Vehicle is on a known level floor.
5. Correct trim heights as necessary.
All door assemblies, hood assembly and rear

compartment lid assembly are closed.
All dimensions shown on Figure 19 are measured
vertical to the ground. Trim heights should be within
10 mm (0.4 inch) to be considered correct.
Measuring "D," "K" and "B" Dimensions
Repeat procedure as described for "Measuring "Z,"

"J" and "A" Dimensions" using the rear bumper and
measuring "D," "K" and "B" at the appropriate times.
ll
' 1 ll
~
+
'J)
\l
fmJrn~,
E
ll4;J,:lt.ill
;l .. 'ii
@][ffl
~~~ ~ ~
-~,,,
ll[JIBI '1fI8 ll~IB~)

L
.: . '. ... ;
' .f..,'. t-~ ',..

~. ' . .
'" :.
-- .
J
:'
~r '1
~,
'
arn,
Q
GOOD BEARING
ETCHING
CAGE WEAR
HEAT DISCOLORATION
BENTCAGE
MISALIGNMENT
ABRASIVE ROLLER WEAR
STAIN DISCOLORATION
BENTCAGE
INDENTATIONS
CRACKEDINNERRACE
GALLING
FATIGUE SPALLING
SMEARS
ABRASIVE STEPWEAR
BRINELLING
FRETT AGE
Figure 18 - Tapered Roller Bearing Diagnosis
KC0018-3-8-RP
CENTERLINE
CENTERLINE
828mm
(32.59")
FRONT AXLE
ASSEMBLY
(17.24")
REAR AXLE
ASSEMBLY
ROCKER
OUTER
PANEL
REAR BUMPER
BRACKET BOLT/SCREW
ROCKER
11----- INNER
PANEL
DISTANCE
TO
GROUND
LOWEST
POINT OF
ROCKER PANEL
TOP OF REAR AXLE

ASSEMBLY BRACKET
(J &K)
.L_GROUND
SECTION A-A
REAR AXLE
ASSEMBLY
jv1EwA
CENTER OF FRONT LOWER

CONTROL ARM - FRONT
LOWER CONTROL ARM
BUSHING BOLT/SCREW HEAD
jv1Ewe
LOWEST POINT ON
FRONT LOWER CONTROL
ARM BALL STUD
ASSEMBLY (EXCLUDING
GREASE FITTING)
(LEFT-HAND SHOWN)
SUSPENSION
mm inch
mm inch
mm inch
mm inch
mm inch
mm inch
TIRE
F41
215-60
235-55
420
420
16.5
16.5
367
367
14.4
14.4
32
30
1.3
1.2
121
118
4.8
4.6
204
204
8.0
8.0
208
208
8.2
8.4
FE2
235-55
245-50
420
420
16.5
16.5
367
367
14.4
14.4
31
37
1.2
1.5
118
125
4.6
4.9
204
204
8.0
8.0
208
208
8.4
8.4
NOTE: Trim heights should be within 10 mm (0.4 inch).

PC1004-3-FRP
Figure 19 - Trim Height Diagnosis
SPECIFICATIONS
Hydraulic Pump Fitting ............................................... 75 Nm (55 lb. ft.)
Hydraulic Pump Hose Fitting Nut ...................................... 28 Nm (21 lb. ft.)
Power Steering Gear Pipe Fitting Seat ................................... 28 Nm (21 lb. ft.)
SPECIAL TOOLS
1.
~J5176-D
3.
r~J5176-92
2.
J 29525-92
1.
2.
3.
4.
POWER STEERING
POWER STEERING
POWER STEERING
POWER STEERING
PRESSURE TESTER 0- 2000 PSI

SYSTEM ANALYZER
PRESSURE TESTER ADAPTER
ANALYZER 18 mm ADAPTER
4.
NC4005-3-BRP
WHEEL ALIGNMENT 3A 1
SECTION 3A
WHEEL ALIGNMENT
result.
CONTENTS
General Description ........................ 3A-1
Caster ................................. 3A-1
Camber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-1
Toe ................................... 3A-1
Thrust Angle ........................... 3A-1
Preliminary Inspections ................... 3A-2
Diagnosis ...................... Refer to Section 3
On-Vehicle Service . . . . . . . . . . . . . . . . . . . . . . . . 3A-3
Measuring Front Alignment Angles . . . . . . . . . 3A-3
GENERAL DESCRIPTION
Tire and wheel assembly alignment refers to the
angular relationship between the tire and wheel assemblies, the suspension attaching parts and the ground.
CASTER
Figures 1 and 2
Caster is the tilting of the front steering axis (at the
top) either forward or backward from the vertical. A backward tilt is positive(+) and a forward tilt is negative(-).
Caster influences directional control of the steering but
does not affect tire wear and is adjustable only at the front
tire and wheel assemblies.
Caster is affected by vehicle height; therefore, it is
important to keep the body at its designated trim height.
Overloading the vehicle or a weak or sagging rear spring
will affect caster. When the rear of the vehicle is lower
than its designated trim height, the front suspension
moves to a more positive caster. If the rear of the vehicle is
higher than its designated trim height, the front suspension moves to a less positive caster. For trim height
information, refer to SECTION 3.
CAMBER
Figures 1 and 3
Camber is the tilting of the front tire and wheel
assemblies from the vertical when viewed from the front
of the vehicle. When the tire and wheel assemblies tilt
outward at the top, the camber is positive (+). When the
tire and wheel assemblies tilt inward at the top, the camber
is negative (-). The amount of tilt is measured in degrees
from the vertical and is called the camber angle. Camber
setting influences directional control and tire wear.
Front Caster and Camber Adjustment . . . . . . . .

Front Toe Adjustment . . . . . . . . . . . . . . . . . . . .
Measuring Rear Alignment Angles ..........
Rear Thrust Angle Adjustment . . . . . . . . . . . . .
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tire and Wheel Assembly
Alignment Specifications . . . . . . . . . . . . . . . .
Fastener Tightening Specifications . . . . . . . . . .
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3A-4
3A-4
3A-5
3A-6
3A-6
3A-6
3A-6
3A-6
When tire and wheel assemblies are set to a positive

camber angle, they will tend to roll in a path away from
the vehicle's true path. The effect of each tire and wheel
assembly tends to cancel the other. The suspension geometry and camber setting are designed to keep the tire tread
flat on the road through bumps or dips.
TOE
Figures 1 and 4
Toe is a measurement of how much the front tire and
wheel assemblies are turned in or out from a straightahead position. When the tire and wheel assemblies are
turned in, toe is positive (+ ). When the tire and wheel
assemblies are turned out, toe is negative (-). The actual
amount of toe is normally only a fraction of a degree. The
purpose of toe is to ensure that the tire and wheel assemblies roll parallel.
Toe also serves to offset the small deflections of the
tire and wheel assembly support system which occur
when the vehicle is rolling forward. In other words, even
when the tire and wheel assemblies are set to toe in or out
slightly when the vehicle is standing still, they tend to roll
parallel on the road when the vehicle is moving. Toe
affects tire wear.
THRUST ANGLE
Figure 5
The front tire and wheel assemblies aim or steer the
vehicle, but the rear tire and wheel assemblies control
tracking. This tracking action is relative to thrust angle.
Thrust angle is defined as the path that the rear tire and
wheel assemblies will take. Ideally, the thrust angle is
geometrically aligned with the body centerline.
3A-2 WHEEL ALIGNMENT

K
M
~E
A
B
C
D
E
F
G
H
CASTER
CAMBER
TOE
VERTICAL
NEGATIVE CASTER ANGLE
POSITIVE CASTER ANGLE
CENTERLINE OF TIRE AND WHEEL ASSEMBLY
LOWER INBOARD CORNER OF LOWER CONTROL ARM
BALL STUD ASSEMBLY
J POSITIVE CAMBER ANGLE
K
L
M
N
p
Q
1
2
3
CENTERLINE OF VEHICLE
CENTERLINE OF BOLT/SCREW HEAD
TRIM HEIGHT
CENTERLINE OF FRONT TIRE AND WHEEL ASSEMBLIES
POSITIVE WHEEL TOE-IN ANGLE (ONE TIRE AND
WHEEL ASSEMBLY)
NEGATIVE CAMBER ANGLE
FRAME ASSEMBLY
CROSSMEMBER ASSEMBLY, FRONT
ARM ASSEMBLY, FRONT LOWER CONTROL
PC0001-3A-F-RP
Figure 1 - Caster, Camber and Toe
A CASTER IS POSITIVE WHEN LOWER CONTROL BALL

STUD ASSEMBLY IS AHEAD OR PULLING THE SPINDLE
B CASTER IS NEGATIVE WHEN THE LOWER CONTROL
BALL STUD ASSEMBLY IS BEHIND OR PUSHING THE
SPINDLE
C SPINDLE
D VERTICAL
4 STUD ASSEMBLY, FRONT LOWER CONTROL ARM BALL
PC00023A-F-RP
Figure 2 - Caster
PRELIMINARY INSPECTIONS
Stee.ring and vib.ration complaints are not always the
result of improper alignment. Another possibility is tire
"lead" due to worn or improperly manufactured tires.
"Lead" is the vehicle deviation from a straight path on a
level road without pressure on the steering wheel assembly. To determine if the vehicle has a tire lead problem,
refer to SECTION 3.
Before making any adjustment affecting tire and
wheel assembly alignment, make the following inspec-
WHEEL ALIGNMENT 3A3
P..,
---- --- ----
'w
B
A
B
C
D
E
THRUST ANGLE
THRUST LINE - OFF CENTER
GEOMETRIC CENTERLINE
REAR TOE-OUT CONDITION
REAR TOE-IN CONDITION
PC0004-3AFRP
Figure 5 - Thrust Angle
c
A A CYLINDER WILL ROLL STRAIGHT AHEAD
B A CONE WILL ROLL IN A CIRCLE TOWARD THE SMALL
END
C TIRE CONTACTS THE ROAD SURFACE
D POSITIVE CAMBER ANGLE
E VERTICAL
PC00033AFRP
Figure 3 - Camber
- - - - - - - - ''A''
-------~1
FRT
- - - - - - - - "B" - - - - - - -
DIMENSION "A" SHOULD BE LESS THAN "B"
KC0004-3AFRP
Figure 4 - Toe
tions to ensure correct alignment readings and alignment

adjustments.
ll'l'I
Inspect
All tires for proper inflation pressures. Also check

that all tires have about the same tread wear.
Control arm ball stud assemblies. If they are loose,
correct them before adjusting tire and wheel assembly alignment. Refer to SECTION 3C.
Tie rod ends. If they are loose, correct them before

adjusting tire and wheel assembly alignment. Refer
to SECTION 3B.
Runout of tire and wheel assemblies. Refer to SECTION 3.
Vehicle trim height. If out of limits and a correction
is to be made, do so before adjusting alignment.
Refer to SECTION 3 for trim height chart.
Steering gear assembly for looseness at frame
assembly.
Control arm assemblies for loose bushing assemblies.
Stabilizer shaft for loose or missing parts.
Improperly operating shock absorber and spring
assemblies.
Suspension and steering components for damage.
Replace parts as necessary.
Vehicle for stability. The fuel tank assembly should
be full, or the vehicle should have compensating ballast.
Jounce vehicle lightly three times rear and three
times front.
Consideration must be given to excess loads, such as
tool boxes, sample cases, etc. If these items are normally
carried in the vehicle, they should remain in the vehicle
during alignment adjustments.
Consideration should also be given to the condition
of the equipment being used to adjust alignment. Be sure
to follow the equipment manufacturer's instructions.
Regardless of the equipment used to adjust alignment, the
vehicle must be on a level surface, both front-to-rear and
side-to-side.
ON-VEHICLE SERVICE
MEASURING FRONT ALIGNMENT ANGLES
Satisfactory vehicle operation may occur over a
wide range of alignment settings. However, should the
settings vary beyond the specifications shown at the end
of this section, the alignment angles should be corrected.
I'll Measure
Front alignment angles.
A. Install alignment equipment according to the
manufacturer's instructions.
B. Jounce the front and rear bumper assemblies

lightly three times to normalize suspension
prior to measuring angles.
C. Measure alignment angles and record the readings. If adjustments are required, make them in
the following order: caster, camber and toe.
FRONT CASTER AND CAMBER

ADJUSTMENT
Figures 6 and 7
2 CROSSMEMBER ASSEMBLY, FRONT

3 ARM ASSEMBLY, FRONT LOWER CONTROL
Tool Required:
PC0005-3A-F-RP
Figure 6 - Front Caster Adjustment
J 38658 Camber/Caster Adjuster
[e) Adjust
l. Jounce front bumper assembly three times to allow
vehicle to return to normal height before making any
adjustments in caster.
3. Loosen front lower control arm nuts. Refer to SECTION 3C.
4. Install J 38658 to slot holes in lower control arm
assembly (3) and front crossmember assembly (2)
(Figure 6).
5. Caster by rotating turnbuckle on J 38658.

Rotating turnbuckle clockwise will increase
caster.
Rotating turnbuckle counterclockwise will
decrease caster.

~A-f..RP
Figure 7 - Front Camber Adjustment
6. Install J 38658 to slot holes in lower control arm

assembly (3) and front crossmember assembly (2)
(Figure 7).
7. Camber by rotating turnbuckle on J 38658.
Rotating turnbuckle clockwise will increase
camber.
Rotating turnbuckle counterclockwise will

decrease camber.
8. Remove J 38658 from slot holes.
9. Tighten front lower control arm nuts. Refer to SECTION 3C.
10. Lower vehicle.
FRONT TOE ADJUSTMENT

Figure 8
[e) Adjust
NOTICE: See "Notice" on page 3A-1 of this section.
Toe
4
1 KNUCKLE ASSEMBLY, STEERING
2 ROD, STEERING LINKAGE OUTER TIE
3 ROD, STEERING LINKAGE INNER TIE
4 NUT, STEERING LINKAGE TIE ROD ADJUST,
47 Nm (35 LB. FT.)
5 BOOT, STEERING GEAR
PC0007-3AF-RP
Figure 8 - Front Toe Adjustment
WHEEL ALIGNMENT 3A-5

A. Make sure steering wheel assembly is set in a
straight-ahead position within 3.5 degrees.
MEASURING REAR ALIGNMENT ANGLES

Figure 9
After front tire and wheel assembly alignment has
been completed, the rear alignment angles should be
checked if there is excessive rear tire wear or tire and
wheel assemblies do not track properly. Rear tire and
wheel assemblies (14) should be parallel to and the same
distance from the vehicle's centerline ..
If tires do not track correctly after a front tire and
wheel assembly alignment, no amount of adjustment will
correct the problem. Poor tracking or excessive rear tire
wear after a front tire and wheel assembly alignment usually indicates that the axle housing assembly, frame
assembly or suspension arms have been bent.
Rear alignment angles can be checked as follows:
B. Toe adjustments are made separately at each

individual tire and wheel assembly.
C. Loosen nut (4) on inner tie rod (3).
D. Toe to specification by turning inner tie rod

(3). Refer to "Alignment Specifications" in
this section.
- Left and right toe adjustment should be
equal within 0.2 degrees.
E. Check steering gear boot seal is not twisted.
l~I
l@I
Tighten
Nut (3) to 47 Nm (35 lb. ft.).
Rear alignment angles.

A. Back vehicle squarely
machine.
F. Check specifications for adjustment. Readjust
by repeating steps if necessary.
E
G
13
E
G
E
G
13
Measure
onto
alignment
E
G
13
14
14
A RIGHT SIDE OF REAR AXLE ASSEMBLY IS FORWARD

(TOE-OUT OF LEFT TIRE AND WHEEL ASSEMBLY AND
TOE-IN OF RIGHT TIRE AND WHEEL ASSEMBLY)
B RIGHT SPINDLE IS NOT PERPENDICULAR TO
CENTERLINE OF VEHICLE
C REAR VIEW OF REAR AXLE ASSEMBLY SAG
D TOPVIEW
E CENTERLINE OF TIRE AND WHEEL ASSEMBLY
F PERPENDICULAR TO CENTERLINE OF VEHICLE
G PARALLEL TO CENTERLINE OF VEHICLE
H DEVIATION OF TOE FROM CENTERLINE OF VEHICLE
J NEGATIVE CAMBER ANGLE
13 FRONT TIRE AND WHEEL ASSEMBLY
14 REAR TIRE AND WHEEL ASSEMBLY
Figure 9 - Rear Tire and Wheel Assemblies
PC0008-3A-F-RP

B. Compensate for tire and wheel assembly runout the same as for checking front tire and
wheel assembly toe-in.
When checking toe-in with a tram gage,

the measurement will read correctly as
toe-out. However, when using a tram
gage, it will still be necessary to perform
steps A and B to check camber
C. Check camber reading which should be 0.0

degrees 0.6 degrees.
D. Check amount of toe which should be 0.0
degrees 0.3 degrees.
When using an alignment machine to
measure toe-out, the measurement will
read as toe-in on the scale.
REAR THRUST ANGLE ADJUSTMENT

If the thrust angle is not within specifications,
inspect the upper and lower control arm assemblies for
damage. If the control arm assemblies are not damaged,
then check the frame dimensions. Refer to SECTION
10-3.
SPECIFICATIONS
TIRE AND WHEEL ASSEMBLY ALIGNMENT SPECIFICATIONS
SET
Front
Caster ................................................. 4.4 0.5
Cross Caster ............................................ 0.0 0.7
CHECK
4.4 1.0
0.0 0.7
Camber ................................................ 0.4 0.5

Cross Camber ........................................... 0.0 0.7
0.4 1.0
0.0 0.7
Individual Toe ........................................... 0.0 0.1

Total Toe ............................................... 0.0 0.2
0.0 0.1
0.0 0.2
Steering Wheel Angle ..................................... 0.0 3.5
0.0 3.5
Rear
Camber ................................................ 0.0 0.6
Cross Camber ........................................... 0.0 0.6
0.0 0.6
0.0 0.6
Total Toe ............................................... 0.0 0.3

Thrust Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.0 0.15
0.0 0.3
0.0 0.15

Steering Linkage Tie Rod Adjust Nut .................................... 47 Nm (35 lb. ft.)
SPECIAL TOOLS
1.
J 38658
1. CAMBER/CASTER ADJUSTER
PC0009-3A-F-RP
POWER STEERING GEAR AND PUMP ON-VEHICLE SERVICE 38-1
SECTION 38
POWER STEERING GEAR AND PUMP

ON-VEHICLE SERVICE
result.
NOTICE: Do not start the vehicle with any power steering gear inlet or outlet hoses disconnected. When disconnected, cap or plug all openings of components. Failure to do so could result in contamination or loss of power
steering fluid and damage to the system.
CONTENTS
General Description . . . . . . . . . . . . . . . . . . . . . . . . 3B- l
Power Steering Gear Assembly . . . . . . . . . . . . . 3B- l
Power Steering Pump Assembly . . . . . . . . . . . . 3B~ 1
Seal Replacement ........................ 3B-2
On-Vehicle Service . . . . . . . . . . . . . . . . . . . . . . . . 3B-4
Checking and Adding Power Steering Fluid . . . 3B-4
Power Steering Fluid Replacement . . . . . . . . . . 3B 4
Flushing the Power Steering System . . . . . . . 3B-4
Bleeding the Power Steering System . . . . . . . 3B-4
Power Steering Pump Belt (Serpentine Belt) .. 3B-5
Power Steering Pump Pulley Assembly . . . . . . 3B-5
Power Steering Gear Assembly . . . . . . . . . . . . . 3B-5
Power Steering Gear Inlet and Outlet

Hose Assemblies ...................... 3B-6
Hydraulic Pump Flow Control Valve . . . . . . . . . 3B-8
Power Steering Pump Support . . . . . . . . . . . . . . 3B-9
Power Steering Pump Assembly . . . . . . . . . . . 3B-10
Power Steering Fluid Reservoir Assembly . 3B-12
Power Steering Fluid Reservoir
Hose Assembly .................... 3B-12
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3B- l 3
Power Steering Fluid Recommendations . . . . . 3B-13
Fitting Tightening Specifications . . . . . . . . . . . 3 B-13
Fastener Tightening Specifications ......... 3B-13
Special Tools ............................ 3B-14
GENERAL DESCRIPTION
routes pressurized fluid to the left side of the piston, while

allowing fluid to escape from the right side and return to
the valve area. The pressure of the fluid is converted to a
mechanical force applied to the piston and the difference
in force across the piston causes the rack to move to the
right. The opposite occurs when the gear assembly (1) is
turned to the left. Whenever the pump assembly (4 or 32)
provides pressurized fluid to the gear assembly ( 1) and the
valve is operating correctly, the effort to steer the vehicle
is created by this pressure difference at the piston. For
information on power steering gear assembly unit repair,
refer to SECTION 3B1A.
POWER STEERING GEAR ASSEMBLY

Figures 1 and 2
The major internal components of the steering gear
assembly (1) are the power steering gear pinion and valve
shaft assembly, steering gear rack and piston assembly
and steering linkage tie rod assemblies (inner and outer tie
rods). The steering gear rack and piston assembly is supported at its ends in the steering gear housing and sealed to
prevent both external and internal leakage across the
piston. The pinion and valve assembly intersects and
meshes directly with the teeth of the rack and piston
assembly. Manual steering is always available at times
when the engine is not running or in the event of power
steering pump assembly (4 or 32) or serpentine belt
failure. Steering effort is increased under such conditions.
The movement of the steering gear assembly
components, when either parked or moving, is aided by
hydraulic pressure and fluid flow supplied by the power
steering pump assembly (4 or 32). Pressurized fluid is
directed by the steering gear valve during a steer
manuever and travels through external steel cylinder lines
to act on the rack and piston assembly. When the vehicle
is turned right, the steering gear valve is opened and
POWER STEERING PUMP ASSEMBLY

Figures 1 and 2
A constant displacement vane-type pump assembly
provides hydraulic pressure and flow for the power steering system. The pump assembly (4 or 32) is located on the
engine and is belt driven by the power steering pulley
assembly (3 or 31 ).
The major components of the pump assembly (4 or
32) are the fluid reservoir, pump shaft, pump housing,
pump fitting, flow control valve and spring, thrust and
pressure plates, pump ring, pump rotor and pump vanes.
The housing and component parts are "submerged"
in the fluid reservoir in the 3.4L L32 engine. The 5.7L
38-2 POWER STEERING GEAR AND PUMP ON-VEHICLE SERVICE

2 HOSE ASSEMBLY, POWER STEERING GEAR INLET,
28 Nm (21 LB. FT.)
3 PULLEY ASSEMBLY, POWER STEERING PUMP

5 HOSE ASSEMBLY, POWER STEERING GEAR OUTLET,
6
7
8
9
28 Nm (21 LB. FT.)

BOOT, STEERING GEAR
SHAFT ASSEMBLY, STEERING GEAR COUPLING
KNUCKLE ASSEMBLY, STEERING
CLAMP, STEERING GEAR COUPLING SHIELD
PC0001-3B-FRP
Figure 1 - Power Steering System (3.4L L32 Engine)
LTl engine has a remote reservoir assembly (10). The reservoir cap assembly (24) has a fluid level indicator
attached to show the fluid level in the reservoir.
For the 3.4L L32 engine pump assembly (4), there
are two bore openings at the rear of the housing. The
larger opening contains all of the pump ~ssembly comp?nents, except the flow control valve, sprmg and PUn:1P. fitting, which are in the small bore. The pum~ f~ttmg,
working with the flow control valve and spnng, hmits the
maximum flow of the pump assembly (4). The pressure
relief valve, inside the flow control valve, limits the maximum pump assembly (4) pressure.
For the 5.7L LTl engine pump assembly (32), the
bore at the rear of the housing contains the same set of
components as the 3.4L L32 engine pump asse!ll?lY (4).
The flow control valve, spring and pump fittmg are
located in the top of the pump housing, in the casting boss
that runs across the housing. For information on power
steering pump assembly unit repair, refer to SECTION
3BlB.
SEAL REPLACEMENT
Lip Seals
Lip seals, which seal rotating shafts, requir~ special
treatment. This type of seal is used on the hydraulic pump
shaft of the pump assembly. When leakage occurs in this
area, always replace the seal or seals, after inspecting and
thoroughly cleaning the sealin~ s~rfaces: Replace the
shaft if pitting is found. If corros10n m the hp se_al contact
zone is slight, clean the surface of the shaft with crocus
cloth. Replace the shaft only if the leakage cannot be
stopped by smoothing with crocus cloth first.
0-Ring Seals
Whenever a part which forms a sealing surface for
an 0-ring is removed, the 0-ring seal should als? be
removed and replaced "".ith a new 0-ri~g seal.. Lubncate
all new 0-ring seals with power steenng flmd to ease
assembly.
1
6
7
8
9
10
11
24
30
31
32
33
GEAR ASSEMBLY, POWER STEERING

BOOT, STEERING GEAR
SHAFT ASSEMBLY, STEERING GEAR COUPLING
RESERVOIR ASSEMBLY, POWER STEERING FLUID
HOSE ASSEMBLY, POWER STEERING FLUID
RESERVIOR
CAP ASSEMBLY, POWER STEERING FLUID RESERVOIR
HOSE ASSEMBLY, POWER STEERING GEAR INLET,
28 Nm (21 LB. FT.)
PULLEY ASSEMBLY, POWER STEERING PUMP
PUMP ASSEMBLY, POWER STEERING
HOSE ASSEMBLY, POWER STEERING GEAR OUTLET,
28 Nm (21 LB. FT.)
PC00023BF-RP
Figure 2 - Power Steering System (5.7L LT1 Engine)
ON-VEHICLE SERVICE
CHECKING AND ADDING POWER
STEERING FLUID
Fluid level is indicated by marks on a fluid level
indicator on the reservoir cap assembly.
NOTICE: When adding fluid or making a complete
fluid change, always use the proper fluid. Failure to
use the proper fluid will cause hose and seal damage
and fluid leaks. Refer to "Power Steering Fluid Recommendations" in this section.
If the fluid is about 77C (170F), the fluid level
should be at the "H" mark.
If the fluid is about 21 C (70F), the fluid level
should be at the "C" mark.
POWER STEERING FLUID REPLACEMENT

The fluid replacement procedure is a two-stage process: first, flushing the old fluid from the system with new
fluid; and second, bleeding the system to remove trapped
air. The following two sequences outline the steps in each
procedure.
Flushing the Power Steering System

1. Raise and suitably support front of vehicle off
ground until tire and wheel assemblies are free to
turn. Refer to SECTION OA.
2. Remove inlet hose assembly on 3.4L L32 engine or
reservoir hose assembly on 5. 7L LTl engine at fluid
reservoir inlet connector and plug fluid inlet connector port on fluid reservoir assembly.
rn
Important
Position inlet or reservoir hose assembly

toward large container to catch draining fluid.
3. While an assistant is filling fluid reservoir assembly
with fluid, start and run engine at idle.
NOTICE: Do not hold the steering wheel assembly
against tire and wheel assembly stops while flushing
system. Holding steering wheel assembly against
stops will cause high power steering system pressure, overheating, and damage to the pump assembly and/or steering gear assembly.
4. Turn steering wheel assembly from stop to stop.
5. Continue draining until all old fluid is cleared from
power steering system. Addition of approximately
0.94 liters (1 quart) of new fluid will be required to
flush system.
ll"'I
Inspect
Draining fluid while refilling fluid reservoir

assembly.
- If necessary, replace all lines and disassemble, and clean or replace system components.
- Do not reuse any drained fluid.
6. Unplug fluid inlet connector port on fluid reservoir
assembly and reconnect inlet hose assembly on 3.4L
L32 engine and reservoir hose assembly on 5. 7L
LTl engine at fluid reservoir inlet connector.
7. Turn engine off and fill fluid reservoir on 3.4L L32
engine or remote fluid reservoir assembly on 5.7L
LTI engine to "C" mark on fluid level indicator.
Continue with following procedure "Bleeding the
Power Steering System."
Bleeding the Power Steering System

NOTICE: If the system has been serviced, an accurate fluid level reading cannot be obtained unless air
is bled from the system. The air in the fluid may
cause pump assembly cavitation noise and may
cause pump assembly damage over a period of time.
After replacing the fluid or servicing the system, you
must bleed air from the system. Air in the system prevents
an accurate fluid level reading, causes pump assembly
cavitation noise and over time could damage the pump
assembly. To bleed the system proceed as follows:
1. Begin with engine off, front tire and wheel assemblies off ground and turned all the way to left. Refer
to SECTION OA.
2. Add either standard fluid or optional cold climate
fluid to "C" mark on fluid level indicator.
3. Bleed system by turning tire and wheel assemblies
from side to side without hitting stops.
rn
Important
It may be necessary to turn tire and wheel

assemblies from side to side several times.
Keep fluid level at "C" mark on fluid level
indicator. Fluid with air in it has light tan
appearance. This air must be eliminated from
fluid before normal steering action can be
obtained.
4. Start engine. With engine idling, recheck fluid level.
If necessary, add fluid to bring level to "C" mark on
fluid level indicator.
5. Return tire and wheel assemblies to center position.
Lower front tire and wheel assemblies to ground.
Continue running engine for two or three minutes.
6. Test vehicle to be sure steering functions normally
and is free from noise.
ll'l'I
Inspect
For fluid leakage at connection points along

system.
7. Recheck fluid level as described in steps 3 and 4
except fluid level should now be up to "H" mark on
POWER STEERING GEAR AND PUMP ON-VEHICLE SERVICE 385

fluid level indicator after system has stabilized at its
normal operating temperature.
POWER STEERING PUMP BELT

(SERPENTINE BELT)
The pump assembly is driven by a serpentine belt.
No adjustment of the serpentine belt is required.
To remove or install the serpentine belt, refer to
SECTION 6A2A or 6A3A.
2.
3.
POWER STEERING PUMP PULLEY

ASSEMBLY
4.
Figure 3
5.
Tools Required:
J 25034-B Pump Pulley Remover
J 25033-B Pump Pulley Installer

1. Raise and suitably support vehicle on 5.7L LTl
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
engine only. Refer to SECTION OA.

Drain engine coolant on 5. 7L LTl engine only. Refer
to SECTION 6B.
Serpentine belt. Refer to SECTION 6A2A or 6A3A.
Lower vehicle on 5.7L LTl engine only.
Front air intake duct. Refer to SECTION lA.
Generator assembly on 5.7L LTl engine only. Refer
to SECTION 603.
Radiator outlet hose assembly from engine assembly
on 5.7L LTl engine only. Refer to SECTION 6B.
Heater inlet and outlet hose assemblies from water
pump assembly on 5.7L LTl engine only. Refer to
SECTION lA.
Throttle body heater return hose from heater outlet
hose assembly on 5.7L LTl engine only. Refer to
SECTION lA.
Power steering pump bolts/screws on 5.7L LTl
engine only. Refer to "Power Steering Pump
Assembly" in this section.
Inlet and reservoir hose assemblies from pump
assembly on 5.7L LTl engine only. Refer to "Power
Steering Gear Inlet and Outlet Hose Assemblies"
and "Power Steering Fluid Reservoir Assembly" in
this section.
Pulley assembly (3 or 31) from pump assembly (4 or
32) using J 25034-B.

1. Pulley assembly (3 or 31) to pump assembly (4 or
32) using J 25033-B.
[ ] ] Important
Face of pulley assembly hub must be flush

with end of pump shaft before applying load to
pulley assembly hub.
6.
7.
8.
9.
10.
11.
12.
13.
Load required to press pulley assembly hub

onto pump shaft must be greater than 6 672 N
(1,500 lbs.) but less than 31 136 N (7,000 lbs.).
Inlet and reservoir hose assemblies to pump assembly on 5.7L LTl engine only. Refer to "Power Steering Gear Inlet and Outlet Hose Assemblies" and
"Power Steering Fluid Reservoir Assembly" in this
section.
Power steering pump bolts/screws on 5.7L LTl
Throttle body heater return hose to heater outlet hose
assembly on 5.7L LTl engine only. Refer to SECTION lA.
Heater inlet and outlet hose assemblies to water
SECTION lA.
Radiator outlet hose assembly to engine assembly on
5.7L LTl engine only. Refer to SECTION 6B.
to SECTION 603.
Front air intake duct. Refer to SECTION lA.
Raise and suitably support vehicle on 5.7L LTl
Serpentine belt. Refer to SECTION 6A2A or SECTION 6A3A.
Lower vehicle on 5. 7L LTl engine only.
Refill and bleed engine coolant on 5.7L LTl engine
only. Refer to SECTION 6B.
Refill and bleed power steering system on 5.7L LTl
engine only. Refer to "Bleeding the Power Steering
System" in this section.
POWER STEERING GEAR ASSEMBLY

Figure 4

2. Special security wheel lock nuts, if equipped. Refer
to SECTION 3E.
3. Tire and wheel assemblies. Refer to SECTION 3E.
4. Place drain pan under steering gear assembly ( 1).
5. Inlet and outlet hose assemblies from steering gear
assembly. Refer to "Power Steering Gear Inlet and
Outlet Hose Assemblies" in this section.
6. Steering linkage outer tie rod assembly from steering knuckle assembly. Refer to SECTION 3B1A.
7. Steering gear coupling shaft assembly from steering
gear assembly. Refer to SECTION 3F.
8. Nuts (26) and bolts/screws (27).
9. Steering gear assembly (1).

NOTICE: See "Notice" on page 3B-1 of this section.
A
J 25034-8
J 25033-8
32
32
B
A
B
3
4
31
32
3.4L L32 ENGINE

5.7L LT1 ENGINE
PC0003-3Bf-RP
Figure 3 - Power Steering Pump Pulley Assembly
1. Position steering gear assembly (1) to crossmember

assembly (34).
[el Adjust
Steering gear assembly (1) so it aligns as
straight as possible with steering gear coupling
shaft assembly.
2. Hand start bolts/screws (27) and nuts (26).
3. Position back-up wrench to nuts (26).
l~I
Tighten

4. Steering gear assembly to steering gear coupling
shaft assembly. Refer to SECTION 3F.
5. Steering linkage outer tie rod assemblies to steering
knuckle assemblies. Refer to SECTION 3BIA.
6. Inlet and outlet hose assemblies to steering gear
assembly. Refer to "Power Steering Gear Inlet and
Outlet Hose Assemblies" in this section.

to SECTION 3E.
9. Lower vehicle.
10. Refill and bleed power steering system. Refer to
"Bleeding the Power Steering System" in this
section.
POWER STEERING GEAR INLET AND

OUTLET HOSE ASSEMBLIES
Figures 5 and 6

1. Place drain pan under steering gear assembly (1) and
pump assembly (4 or 32).
2. Outlet hose assembly (5) from pump assembly (4)
on 3.4L L32 engine only.
4. Inlet and outlet hose assemblies (2 and 5 or 30 and
33) from steering gear assembly (1).
-------'
1
8
26
27
34
GEAR ASSEMBLY, POWER STEERING

NUT, STEERING GEAR
BOLT/SCREW, STEERING GEAR, 85 Nm (63 LB. FT.)
CROSSMEMBER ASSEMBLY, FRONT
PC0011-3BF-RP
Figure 4 - Power Steering Gear Assembly
5. Inlet hose assembly (2) from pump assembly (4) on

3.4L L32 engine only.
6. Drain engine coolant on 5. 7L LTl engine only. Refer
to SECTION 6B.
7. Serpentine belt on 5.7L LTl engine only. Refer to
SECTION 6A3A.
8. Lower vehicle on 5.7L LTI engine only.
9. Front air intake duct on 5.7L LTl engine only. Refer
to SECTION IA.
10. Generator assembly on 5.7L LTl engine only. Refer
to SECTION 6D3.
11. Radiator outlet hose assembly from engine assembly
12. Heater inlet and outlet hose assemblies from water
SECTION IA.
13. Throttle body heater return hose from heater outlet
assembly on 5.7L LTl engine only. Refer to SECTION IA.
14. Power steering pump bolts/screws on 5.7L LTl
15. Inlet hose assembly (30) from pump assembly (32)
on 5. 7L LTl engine only.
16. Power steering fluid reservoir bolt/screw and power
steering fluid reservoir retainer on 5.7L LTl engine
only. Refer to "Power Steering Fluid Reservoir
17. Outlet hose assembly (33) from reservoir assembly

(10) on 5.7L LTl engine only.
l++I
Install or Connect
NOTICE: See "Notice" on page 3B-1 of this

section.
NOTICE: Inlet and outlet hose assemblies must be
installed to clear each other and all surrounding
parts to prevent chafing. Use minimum clearance of
12 mm (0.47 inch). The outlet hose assembly must
not be twisted during installation. Do not bend or
distort inlet and outlet hose assemblies to make
installation easier. Failure to follow these procedures could result in component damage.
1. Outlet hose assembly (33) to reservoir assembly
(10) using clamp on 5.7L LTl engine only. Lubricate as required.
steering fluid reservoir retainer on 5.7L LTl engine
only. Refer to "Power Steering Fluid Reservoir
3. Inlet hose assembly (30) to pump assembly (32) on
5.7L LTl engine only.
l~I
Tighten
Inlet hose assembly (30) to 28 Nm (21 lb. ft.).

4. Power steering pump bolts/screws on 5.7 LTl
,0
,f~"t
4
2
5
IVIEWA I

28 Nm (21 LB. FT.)

3 PULLEY ASSEMBLY, POWER STEERING PUMP
28 Nm (21 LB. FT.)
PC00053B F-RP
Figure 5 - Power Steering Gear Inlet and Outlet Hose Assemblies (3.4L L32 Engine)
5. Throttle body heater return hose to heater outlet hose

assembly on 5.7L LTI engine only. Refer to SECTION lA.
6. Heater inlet and outlet hose assemblies to water
pump assembly on 5.7L LTI engine only. Refer to
SECTION lA.
. 7. Radiator outlet hose assembly to engine assembly on
5. 7L LTI engine only. Refer to SECTION 6B.
to SECTION 6D3.
9. Front air intake duct on 5. 7L LTI engine only. Refer
to SECTION lA.
10. Raise and suitably support vehicle on 5. 7L LTl
11. Serpentine belt on 5.7L LTl engine only. Refer to
SECTION 6A3A.
12. Inlet hose assembly (2) to pump assembly (4) on
rn
Important
Maintain at least 5 mm (0.20 inch) clearance

between the inlet hose assembly (2) and the
power steering pump support on the 3.4L L32
engine only.
l~I
Tighten
Inlet hose assembly (2) to 28 Nm (21 lb.

ft.).
13. Inlet and outlet hose assemblies (2 and 30 or 5 and

33) to steering gear assembly (1).
l~I
Tighten
Inlet hose assembly (2 or 30) to 28 Nm (21 lb.

ft.) .
Outlet hose assembly (5 or 33) to 28 Nm (21
lb. ft.).
14. Outlet hose assembly (5) to pump assembly (4) on
l~I
Tighten
Outlet hose assembly (5) to 28 Nm (21 lb. ft.).

15. Lower vehicle on 5.7L LTl engine only.
16. Refill and bleed engine coolant on 5.7L LTl engine
only. Refer to SECTION 6B.
"Bleeding the Power Steering System" in this section.
HYDRAULIC PUMP FLOW CONTROL VALVE

Figure 7
l++I
1. Place drain pan under pump assembly (4 or 32).

2. Inlet hose assembly (2 or 30) from fitting (15).
3. Fitting (15) and 0-ring seal (14).
32
11
30
,~~~
V-IE_W_A-,1
,-I
30

11 HOSE ASSEMBLY, POWER STEERING FLUID
RESERVIOR
24 CAP ASSEMBLY, POWER STEERING FLUID RESERVOIR
28 Nm (21 LB. FT.)
28 Nm (21 LB. FT.)
40 CLIP, POWER STEERING GEAR PIPE
PC0006-3BFRP
Figure 6- Power Steering Gear Inlet and Outlet Hose Assemblies (5.7L LT1 Engine)
2. New 0-ring seal (14) to fitting (15).
Important
The flow control valve must be installed in the

same position it was in when removed or flow
control and pressure relief will be affected.
4. Flow control valve (13) and valve spring (12) from
pump assembly (4 or 32) using magnet.
[I1 Important
Lubricate 0-ring seal (14) with power steering
fluid.
3. Hand start fitting (15) and 0-ring seal (14) to pump
assembly (4 or 32).
l~I
NOTICE: Do not disassemble the flow control

valve.
ll'l'I
Inspect
Fitting (15) to 75 Nm (55 lb. ft.).

4. Inlet hose assembly (2 or 30) to fitting (15).
l~I
Flow control valve (13) for free movement

within housing bore.
- If sticking occurs, check for burrs and

clean as necessary.
- If necessary, replace flow control valve
(13).
l++I
Install or Connect
[I1 Important
The flow control valve (13) should be installed
face out, away from contact with the valve
spring (12).
1. Valve spring (12) and flow control valve (13) to
pump assembly (4 or 32).
Tighten
Tighten
Inlet hose assembly (2 or 30) to 28 Nm (21 lb.

ft.).
5. Fill reservoir assembly with fluid. Refer to "Checking and Adding Power Steering Fluid" in this section.
6. Bleed system. Refer to "Bleeding the Power Steering System" in this section.
POWER STEERING PUMP SUPPORT

3.4L L32 Engine Only
Figure 8
l++I
1. Place drain pan under pump assembly (4).
30
~-
15'!;
11
32
14
A 3.4L L32 ENGINE

B 5.7L LT1 ENGINE
2 HOSE ASSEMBLY, POWER STEERING GEAR INLET
'
28 Nm (21 LB. FT.)
RESERVOIR
12 SPRING, HYDRAULIC PUMP FLOW CONTROL VALVE
13 VALVE, HYDRAULIC PUMP FLOW CONTROL

14 SEAL, HYDRAULIC PUMP FLOW CONTROL VALVE
(0-RING)
15 FITTING, HYDRAULIC PUMP
28 Nm (21 LB. FT.)
PC0004-3BF-RP
Figure 7 - Hydraulic Pump Flow Control Valve
2. Outlet hose assembly from pump assembly. Refer to

"Power Steering Gear Inlet and Outlet Hose Assemblies" in this section.
3. Bolts/screws (18) and nuts (19).
4. Support (17) from pump assembly (4) and brace
assembly (35).
l++I
Install or Connect

1. Position support (17) to pump assembly (4) and
brace assembly (35).
2. Hand start nuts ( 19).
3. Hand start bolts/screws (18).
l~I
Tighten
Nuts (19) to 50 Nm (37 lb. ft.).

4. Outlet hose assembly to pump assembly. Refer to
"Power Steering Gear Inlet and Outlet Hose Assemblies" in this section.
POWER STEERING PUMP ASSEMBLY

Figures 8 and 9
!++I
1. Place drain pan under pump assembly (4 or 32).

2. Raise and suitably support vehicle on 5.7L LTl
3. Drain engine coolant on 5.7L LTl engine only. Refer
to SECTION 6B.
4. Serpentine belt. Refer to SECTION 6A2A or 6A3A.
5. Lower vehicle on 5.7L LTl engine only.
6. Front air intake duct. Refer to SECTION lA.
to SECTION 603.
8. Radiator outlet hose assembly from engine assembly
pump assembly on 5.7L LTl engine. Refer to SECTION IA.
hose assembly on 5.7L LTl engine only. Refer to
SECTION IA.
11. Bolts/screws (21) on 5. 7L LTl engine only.
12. Inlet and outlet hose assemblies from pump assembly on 3.4L L32 engine only. Refer to "Power Steering Gear Inlet and Outlet Hose Assemblies" in this
section.
~ fR'f
17 SUPPORT, POWER STEERING PUMP

18 BOLT/SCREW, POWER STEERING PUMP REAR
BRACKET, 50 Nm (37 LB. FT.)
19 NUT, POWER STEERING PUMP SUPPORT,
50 Nm (37 LB. FT.)
20 BOLT/SCREW, POWER STEERING PUMP,
50 Nm (37 LB. FT.)
35 BRACE ASSEMBLY, POWER STEERING PUMP REAR
17
PCOOOB-38-F-RP
Figure 8 - Power Steering Pump Assembly (3.4L L32 Engine)
13. Pulley assembly from pump assembly on 3.4L L32

engine only. Refer to "Power Steering Pump Pulley
14. Inlet and reservoir hose assemblies from pump
assembly on 5.7L LTl engine only. Refer to "Power
Steering Gear Inlet and Outlet Hose Assemblies"
and "Power Steering Fluid Reservoir Hose Assembly" in this section.
15. Pump support from pump assembly on 3.4L L32
engine only. Refer to "Power Steering Pump Support" in this section.
17. Pump assembly (4 or 32).

1. Position pump assembly (4) to brace assembly (35)
on 3.4L L32 engine only.
l~I Tighten
3. Pump support to pump assembly on 3.4L L32
engine only. Refer to "Power Steering Pump Support" in this section.
4. Inlet and reservoir hose assemblies to pump assembly on 5.7L LTl engine only. Refer to "Power Steering Gear Inlet and Outlet Hose Assemblies" and

RESERVOIR
21 BOLT/SCREW, POWER STEERING PUMP,

25 Nm (18 LB. FT.)
CONDITIONER COMPRESSOR AND POWER STEERING
PUMP AND DRIVE BELT TENSIONER
PC0009-3B-F-RP
Figure 9 - Power Steering Pump Assembly (5.7L LT1 Engine)
5.
6.
7.
8.
"Power Steering Fluid Reservoir Hose Assembly"

in this section.
Pulley assembly to pump assembly on 3.4L L32
enigne only. Refer to "Power Steering Pump Pulley
Inlet and outlet hose assemblies to pump assembly
on 3.4L L32 engine only. Refer to "Power Steering
Gear Inlet and Outlet Hose Assemblies" in this section.
Position pump assembly (30) to bracket assembly
(36) on 5.7L LTl engine only.
Bolts/screws (21) on 5.7L LTl engine only.
l~I
9.
I 0.
11.
12.
13.
14.
15.
16.
17.
18.
Tighten

Throttle body heater return hose to heater outlet hose
assembly on 5.7L LTl engine only. Refer to SECTION IA.
Heater inlet and outlet hose assemblies to water
SECTION IA.
Radiator outlet hose assembly to engine assembly on
5.7L LTl engine. Refer to SECTION 6B.
to SECTION 6D3.
Front air intake duct. Refer to SECTION IA.
Raise and suitably support vehicle on 5.7L LTl
Serpentine belt. Refer to SECTION 6A2A or 6A3A.
Lower vehicle on 5.7L LTl engine only.
Refill and bleed engine coolant system on 5.7L LTl
engine only. Refer to SECTION 6B.
Refill and bleed power steering system. Refer to
Power Steering Fluid Reservoir Assembly

5.7L LT1 Engine Only
Figure 10

1. Place drain pan under reservoir assembly (10).
2. Cap assembly (24) from reservoir assembly (10).
3. Bolt/screw (22) and retainer (23).
4. Outlet hose assembly and reservoir hose assembly
from reservoir assembly. Refer to "Power Steering
Gear Inlet and Outlet Hose Assemblies" and
"Power Steering Fluid Reservoir Hose Assembly"
in this section.
5. Reservoir assembly (10).

A CLAMP, POWER STEERING HOSE ASSEMBLY

B CLAMP, POWER STEERING RESERVOIR HOSE
ASSEMBLY
28 Nm (21 LB. FT.)
RESERVOIR
22 BOLT/SCREW, POWER STEERING FLUID RESERVOIR,
10 Nm (89 LB. IN.)
23 RETAINER, POWER STEERING FLUID RESERVOIR
24 CAP ASSEMBLY, POWER STEERING FLUID RESERVOIR
PC0010-lB-F-RP
Figure 1O- Power Steering Fluid Reservoir Assembly

(5.7L LT1 Engine)
1. Outlet hose assembly and reservoir hose assembly to

reservoir assembly. Refer to "Power Steering Gear
Inlet and Outlet Hose Assemblies" and "Power
Steering Fluid Reservoir Hose Assembly" in this
section.
2. Position reservoir assembly ( 10) to right front
wheelhouse assembly.
3. Retainer (23) and bolt/screw (22).
!~I Tighten
4. Cap assembly (24) to reservoir assembly (10).
Power Steering Fluid Reservoir Hose

Assembly
5.7 LT1 Engine Only
Figure 6

2. Drain engine coolant. Refer to SECTION 6B.
3. Serpentine belt. Refer to SECTION 6A3A.

4. Lower vehicle.
6. Generator assembly. Refer to SECTION 6D3.
7. Radiator outlet hose assembly from engine assembly. Refer to SECTION 6B.
pump assembly. Refer to SECTION lA.
assembly. Refer to SECTION lA.
10. Power steering pump bolts/screws. Refer to "Power
Steering Pump Assembly" in this section.
11. Reservoir hose assembly (11) from pump assembly
(32).
steering fluid reservoir retainer from reservoir
assembly. Refer to "Power Steering Fluid Reservoir
13. Reservoir hose assembly (11) from reservoir assembly (10).
2. Power steering fluid reservoir retainer and power

steering fluid reservoir bolt/screw. Refer to "Power
Steering Fluid Reservoir Assembly" in this section.
3. Reservoir hose assembly (11) to pump assembly
(32).
4. Power steering pump bolts/screws. Refer to "Power
Steering Pump Assembly" in this section.
5. Throttle body heater return hose to heater outlet hose
assembly. Refer to SECTION lA.
6. Heater inlet and outlet hose assemblies to water
pump assembly. Refer to SECTION lA.
7. Radiator outlet hose assembly from engine assembly. Refer to SECTION 6B.
11. Serpentine belt. Refer to SECTION 6A3A.
12. Lower vehicle.

NOTICE: See "Notice" on page 3Bl of this sec-
13. Refill and bleed engine coolant. Refer to SECTION

6B.
tion.
1. Reservoir hose assembly (11) to reservoir assembly
(10) using clamp. Lubricate as required.

SPECIFICATIONS
POWER STEERING FLUID RECOMMENDATIONS
Temperate Climate
Power Steering Fluid Requirement ................. GM Power Steering Fluid P/N 1050017 or
1052884, or equivalent meeting GM Specification 9985010
Cold Climate
Power Steering Fluid Requirement ................ GM Power Steering Fluid P/N 12345867 or
12345866 (System should be drained and refilled prior to using this fluid.)
FITIING TIGHTENING SPECIFICATIONS

Hydraulic Pump Fitting-to-Power Steering Pump Assembly ..................
Power Steering Gear Inlet Hose Assembly Fitting-to-Power Steering
Gear Assembly ...................................................
Power Steering Gear Inlet Hose Assembly Fitting-to-Power Steering
Pump Assembly ..................................................
Power Steering Gear Outlet Hose Assembly Fitting-to-Power Steering
Gear Assembly ...................................................
75 Nm (55 lb. ft.)

28 Nm (21 lb. ft.)
28 Nm (21 lb. ft.)
28 Nm (21 lb. ft.)

Power Steering Fluid Reservoir Bolt/Screw ...............................
Power Steering Pump Bolt/Screw - 3.4L L32 Engine .......................
Power Steering Pump Bolt/Screw- 5.7L LTl Engine .......................
Power Steering Pump Rear Bracket Bolt/Screw ............................
Power Steering Pump Support Nut ......................................
Steering Gear Bolt/Screw .............................................
10 Nm (89 lb. in.)

50 Nm (37 lb. ft.)
25 Nm (18 lb. ft.)
50 Nm (37 lb. ft.)
50 Nm (37 lb. ft.)
85 Nm (63 lb. ft.)
SPECIAL TOOLS
1.
J25034-B
2.
J 25033-B
1. PUMP PULLEY REMOVER

2. PUMP PULLEY INSTALLER
PC0013-3BF-RP
POWER STEERING GEAR UNIT REPAIR 3B1A-1
SECTION 381A
POWER STEERING GEAR

UNIT REPAIR
NOTICE: When fasteners are removed, always reinstall them at the same location from which they were removed. If
a fastenerneeds to be replaced, use the correct part number fastener for that application. If the correct part number fastener
is not available, a fastener of equal size and strength (or stronger) may be used. Fasteners that are not reused, and those
requiring thread locking compound will be called out. The correct torque value must be used when installing fasteners
that require it. If the above conditions are not followed, parts or system damage could result.
CONTENTS
Power Rack & Pinion Steering Gear Assembly ... 3B1A-2
Outer Tie Rod .................................................. 3B1A-3
Rack Bearing Preload ...................................... 3B 1A-4
Rack & Pinion Boot ......................................... 3B 1A-4
Inner Tie Rod ................................................... 3B 1A-4
Cylinder Line Assembly and 0-Ring Seals ....... 3B 1A-5
Pinion Seal, Dust Seal and Bearing

Annulus Assembly ........................................... 3B 1A-6
Specifications ........................................................ 3B 1A-9
Fluid Capacities ............................................... 3B 1A-9
Fastener Tightening Specifications .................. 3B 1A-9
Special Tools ........................................................ 3B 1A-9
3B1A-2 POWER STEERING GEAR UNIT REPAIR
VIEW A-A
13
~
23
16
17~
201~~
2~
13
Figure 1 Power Rack and Pinion - End Take Off
POWER STEERING GEAR UNIT REPAIR 3B1A-3

Key No.
Part Name
Key No.
1 NUT, HEXAGON SLOTIED

2 PIN, COTIER
3 SEAL, TIE ROD
5 ROD ASM, OUTER TIE
6 FITIING, LUBE (90 DEG ELBOW)
7 NUT, METRIC HEX (M14 X 1.5)
8 CLAMP, TIE ROD END
10 BOOT, RACK & PINION
11 CLAMP, SEAL RETAINING
12 ROD ASM, lf':,INER TIE
13 RING, SHOCK DAMPENER
15 NUT, ADJUSTER PLUG LOCK
16ADAPTER,SEAL
Part Name
17 RING, RETAINING
18 SEAL, STUB SHAFT DUST
20 SEAL, STUB SHAFT
21 BEARING ANNULUS ASM, NEEDLE
23 - SEAL, 0-RING (4.50 1.0.)
25 - LINE ASM, CYLINDER (RT)
26 - LINE ASM, CYLINDER (LT)
30 - GEAR ASM, RACK & PINION (PARTIAL)
32 - NUT, HEX LOCK
33 - COVER, DUST
35 - CLIP, PIPE
36 - BUSHING, STEERING GEAR
37 - SLEEVE, STEERING GEAR BUSHING
Figure 2 Power Rack and Pinion - End Take Off- Legend
OUTER TIE ROD

Figures 1 thru 3
Tool Required:
J 24319-01 Universal Steering Linkage Puller
1.
2.
3.
4.
Cotter pin (2) and hex slotted nut ( 1) from outer tie
rod assembly (5).
Loosen hex nut (7).
Outer tie rod (5) from steering knuckle with
J 24319-01.
Outer tie rod (5) from inner tie rod (12).
(ZI
Toe by turning inner tie rod (12).
rn
Important
Be sure rack and pinion boot (10) is not
twisted or puckered during toe adjustment.
Adjust
Tighten
Hex nut (7) against outer tie rod (5) to
68 Nm (50 lb. ft.).
1.
-2.
Outer tie rod assembly (5) to inner tie rod (12). Do

not tighten hex nut (7).
Outer tie rod (5) to steering knuckle, hex slotted
nut (1) to outer tie rod stud.
3.
Tighten
Hex slotted nut (1) to 47 Nm (35 lb. ft.).
Tighten nut up to 1/6 additional turn, or70 Nm
(52 lb. ft.) maximum, to align cotter pin slot.
Do not back off nut for cotter pin insertion.
Cotter pin (2) into hole in tie rod stud (5).

A-STEERING KNUCKLE
A
-~ ~~--....
1-NUT, HEXAGON SLOTIED
2-PIN, COTIER
1
'u"i, ' / - - ,
5-ROD ASM, OUTER TIE
~.,..2
~
7-NUT, METRIC HEX (M14 X 1.5)
12-ROD ASM, INNER TIE
~-;;~r<}
Figure 3 Outer Tie Rod Replacement
3B1A-4 POWER STEERING GEAR UNIT REPAIR

RACK BEARING PRELOAD
(on vehicle adjustment)
Figure 15
IZJ
1.
2.
3.
1.
Adjust
Make adjustment with front wheels raised and
steering wheel centered. Be sure to check
returnability of the steering wheel to center after
adjustment.
Loosen adjuster plug lock nut (15) and turn adjuster
plug clockwise until it bottoms in gear assembly
(30), then back off 50 to 70 (approximately one
flat).
Lock nut (15) to adjuster plug.
Lock nut (15) to 75 Nm (55 lb. ft.) while

holding adjuster plug stationary.
RACK & PINION BOOT

Tool Required:
J 22610 Service Boot Clamp Installer
2.
3.
4.
5.
2.
3.
New seal retaining clamp (11) onto rack and pinion

boot (10).
Apply grease to inner tie rod (12) and gear assembly
(30) prior to boot installation (see Figure 5).
Boot ( 10) onto inner tie rod assembly ( 12).

Boot (10) onto gear assembly (30) until seated in
gear assembly groove.
rn
Tighten
Figures 1 thru 6
1.
Do all steps of OUTER TIE ROD "Remove or

Disconnect."
Hex nut (7) from inner tie rod assembly (12).
Tie rod end clamp (8).
Seal retaining clamp (11) with side cutters and
discard.
Rack and pinion boot (10).
4.
5.
6.
7.
Important
Boot (10) must not be twisted, puckered or
out of shape in any way. If the boot is not
shaped properly, adjust by hand before
insta11ing seal retaining clamp (11 ).
Seal retaining clamp (11) on boot (10) with tool

J 22610 and crimp as shown (see Figure 6).
Tie rod end clamp (8) with pliers on boot (10).
Hex nut (7) to inner tie rod assembly (12).
Do all steps of OUTER TIE ROD "Install or
Connect."
INNER TIE ROD

Figures 1 thru 9
t.
2.
3.
Rack and pinion assembly from vehicle (see

Section 3B).
Do all steps of RACK & PINION BOOT "Remove
or Disconnect."
Shock dampener (13) from inner tie rod assembly
(12) and slide back on rack (see Figure 7).
APPLY GREASE TO
THESE AREAS
30
7-NUT, METRIC HEX (M14 X 1.5)

8-CLAMP, TIE ROD END
10-BOOT, RACK & PINION
11-CLAMP, SEAL RETAINING
30-GEAR ASM, RACK & PINION (PARTIAL)
Figure 4 Rack and Pinion Boot Replacement
10-BOOT, RACK & PINION

Figure 5 Boot Seal Grease Application
POWER STEERING GEAR UNIT REPAIR 381A-5

Notice: Steering gear rack must be held stationary during
inner tie rod removal to prevent steering gear damage. Use
an appropriate size wrench at the rack teeth to hold the rack
during inner tie rod removal. For right side inner tie rod
removal, it will be necessary to remove the left side boot to
access the rack teeth.
4.
Inner tie rod assembly (12) from rack assembly as

follows: (See Figure 7 .)
Place a wrench on flat of rack assembly.
Place another wrench on flats of inner tie rod

housing.
Rotate inner tie rod housing counterclockwise until inner tie rod (12) separates from
rack.
1.
Remove old Loctite from threads of rack and inner

tie rod.
[I]
2.
3.
Notice: Steering gear must be held stationary during inner

tie rod installation to prevent steering gear damage.
4.
5.
6.
7.
Apply Loctite 262 to inner tie rod threads

(see Figure 8).
If shock damper was removed, slide it onto steering
gear.
Tighten
Inner tie rod (12) to 100 Nm (74 lb. ft.)
Slide shock dampener up against inner tie rod

assembly.
Do all steps of RACK & PINION BOOT "Install
or Connect."
Rack and pinion assembly to vehicle (see
Section 3B).
CYLINDER LINE ASSEMBLY

and 0-RING SEALS
Figures 1 and 2
Tools Required:
12mm Flare Nut Wrench
16mm Flare Nut Wrench
Important
Threads must be clean prior to Loctite application. Be sure Loctite container expiration
date has not passed. Do not use too much
Loctite. Use only enough to evenly coat
threads.
Install inner tie rod assembly onto steering gear

(see Figure 9).
1.
2.
3.
4.
Loosen cylinder line fittings (25) or(26) on cylinder

end of gear assembly (30).
Loosen fittings on cylinder line assemblies (25) or
(26) at valve end of gear assembly (30).
Cylinder line assemblies (25) or (26) from rack and
pinion gear assembly (30).
0-ring seals (23) from valve end oflines (25) or(26)
and discard.
13
10-BOOT, RACK AND PINION

11-CLAMP, SEAL RETAINING
Figure 6 Boot Clamp Installation
A-RACK ASM, PISTON AND STEERING

B-HOUSING, INNER TIE ROD
13-RING, SHOCK DAMPENER
Figure 7 Inner Tie Rod Removal
3B1A-6 POWER STEERING GEAR UNrT REPAIR
ILI
3.
4.
5.
Inspect
6.
Lines for:
Cracks.
Dents.
Damage to threads.
Replace as needed.
1.
2.
Adjuster plug from gear assembly (30).

Adjuster spring and rack bearing.
Retaining ring (17) from valve bore of gear
assembly (30).
Dust cover (33) from bottom of gear assembly (30)
(see Figure 11 ).
Notice: Stub shaft must be held to prevent damage to the

pinion teeth.
7.
New 0-ring seals (23) to valve end of lines (25)

or (26).
Cylinder line assemblies (25) or (26) to gear
assembly (30).
Hex lock nut (32) from lower end of pinion and

valve assembly, while holding stub shaft with
14 mm Crowfoot Wrench (see Figure 11).
Notice: DO NOT hammer or pound on pinion and valve

assembly. This will cause damage or loosen the drive pin.
Notice: Carefully align threads on all fittings and finger

tighten to avoid stripping and cross-threading.
Important
Tighten
Valve end fittings to 16.9 Nm (12.5 lb. ft.).

Cylinder end fittings to 27 .0 Nm (20 lb. ft.).
PINION SEAL, DUST SEAL

and BEARING ANNULUS ASSEMBLY
Figures 1, 2, 10 Thru 15
Tools Required:
J 29810 Stub Shaft Seal Protector
14 mm Crowfoot Wrench
8.
When performing the following procedure,

do not remove pinion and valve assembly
from gear assembly. Press pinion and valve
assembly only far enough to allow removal
of bearing annulus and seal. Pinion and valve
assembly removal is not required.
Use an arbor press (see Figure 12). Press on

threaded end of pinion until it is possible to remove
stub shaft dust seal (18), stub shaft seal (20),
and stub shaft bearing annulus assembly (21) (see
Figure 13).

1.
2.
Rack and pinion steering assembly from vehicle

(see Section 3B).
Adjuster plug lock nut (15) from adjuster plug (see
Figure 10).
APPLY
LOCTITE9

Figure 8 Inner Tie Rod Installation
A-RACK ASM, PISTON AND STEERING

B-HOUSING, INNER TIE ROD
C-TORQUE WRENCH
Figure 9 Inner Tie Rod Tightening
9.
iJ
Notice: If the stub shaft is not held, damage to the pinion

teeth will occur.
l.
2.
3.
4.
5.
6.
7.
8.
Hex lock nut (32) onto pinion, while holding the

valve stub shaft.
iJ
Tighten
Hex lock nut (32) to 30 Nm (22 lb. ft.).
Dust cover (33) to gear assembly (30).

Stub shaft bearing annulus assembly (21) onto valve
stub shaft.
Seal protector J 29810 onto valve stub shaft.
Apply a small quantity of grease between seals (20)
and (18).
Stub shaft seal (20) and stub shaft dust

seal (18) over protector and into gear
assembly (30).
Retaining ring ( 17) into groove in gear
assembly (30).
Lubricate stub shaft and dust seal area with grease.
Coat rack bearing, adjuster spring and adjuster plug
with lithium base grease and install in gear
assembly (30) (see Figure 15).
rzJ
Lock nut (15) to adjuster plug.
10.
Tighten
Lock nut (15) to 75 Nm (55 lb. ft.) while

holding adjuster plug stationary.
Rack and pinion assembly into vehicle.
rn
Important
Flush and bleed power steering system (hoses,

reservoir and cooler lines) with cold climate
power steering fluid - GM Part #12345866
16-oz. or 12345867 32-oz. (see flushing and
bleeding procedures, Section 3B).
Adjust
With rack centered in the gear assembly (30),

turn adjuster plug clockwise until it bottoms
in the gear assembly, then back off 50 to 70
(approximately one flat). Check rotational
torque on pinion. Maximum pinion preload
torque is 1.8 Nm (16 lb. in.) (see Figure 15).
A-SHAFT, STUB
32-NUT, HEX LOCK
33-COVER, DUST
Figure 11 Retaining Ring and Lock Nut Removal
A-ARBOR PRESS
B-THREADED END OF PINION
Figure 1O Rack Bearing Removal
Figure 12 Pressing Pinion
3B1A-8 POWER STEERING GEAR UNrT REPAIR
BACK OFF 50 DEGREES

TO 70 DEGREES
(APPROX. ONE FLAT)
21-BEARING ANNULUS ASM, NEEDLE

Figure 13 Bearing Annulus Installation
17-RING,
18-SEAL,
20-SEAL,
30-GEAR
RETAINING
STUB SHAFT DUST
STUB SHAFT
ASM, RACK & PINION (PARTIAL)
Figure 14 Seal Installation
A-BEARING, RACK
B-SPRING, ADJUSTER
C-PLUG, ADJUSTER
15-NUT, ADJUSTER PLUG LOCK
Figure 15 Rack Bearing Installation and Adustment
SPECIFICATIONS
FLUID CAPACITIES
Lubricant ...................................................................................... Cold Climate Power Steering Fluid 12345866 (16-oz.)
12345867 (32-oz.)
Capacity Complete System .............................................................................................................. 0.75 liter (1-1/2 pints)

(1)
(7)
(l 2)
(15)
(32)
Hexagon Slotted Nut ............................................................................................... 47.0 Nm

Hex Nut .................................................................................................................. 68.0 Nm
Inner Tie Rod .......................................................................................................... 100.0 Nm
Lock Nut.................................................................................................................. 75.0 Nm
Hex Lock Nut .......................................................................................................... 30.0 Nm
Pinion Preload .. ..... .. ..... ... ..... .. ... .... .. ... ....... .. .. ....... .. ... .. ....... .. .... ..... ... ... .. ....... .. .. ... ... . 1.8 Nm
Valve End Fittings ................................................................................................... 16.9Nm
Cylinder End Fittings .............................................................................................. 27.0 Nm
SPECIAL TOOLS
2. J 24319-01
1. J 22610
3. J 29810
1.
2.
3.
SERVICE BOOT CLAMP INSTALLER

UNIVERSAL STEERING LINKAGE PULLER
STUB SHAFT SEAL PROTECTOR
(35 lb. ft.)

(50 lb. ft.)
(74 lb. ft.)
(55 lb. ft.)
(22 lb. ft.)
(16 lb. in.)
(12.5 lb. ft.)
(20 lb. ft.)
POWER STEERING PUMP UNIT REPAIR 381 B-1
SECTION 381 B
POWER STEERING PUMP

UNIT REPAIR
If a fastener needs to be replaced, use the correct part number fastener for that application. If the correct part number
fastener is not available, a fastener of equal size and strength (or stronger) may be used. Fasteners that are not reused and
those requiring thread locking compound will be called out. The correct torque value must be used when installing
fasteners that require it. If the above conditions are not followed, parts or system damage could result.
CONTENTS
Subsection A: P Series Power Steering Pump
Subsection B: Reverse Rotation Power Steering Pump
P Series Power Steering Pump Assembly ............. 3B 1B-2

P Series Power Steering Pump Service ................. 3B 1B-3
Drive Shaft Seal Replacement ......................... 3B1B-3
Pump Reservoir Replacement .......................... 3B 1B-3
End Plate and Rotating Group Replacement .... 3B 1B-4
Reverse Rotation Power Steering

Pump Assembly .................................................... 3B1B-5
Reverse Rotation Power Steering
Pump Service ........................................................ 3B1B-6
Control Valve Assembly .................................. 3BIB-6
Drive Shaft Seal ............................................... 3B 1B-6
Hydraulic Pump Assembly .............................. 3B1B-7
Specifications ....................................................... 3B 1B-9

Fluid Specifications .......................................... 3B 1B-9
Fastener Tightening Specifications .................. 3B 1B-9
Special Tools ........................................................ 3B 1B-9
381 B-2 POWER STEERING PUMP UNIT REPAIR
12
23
21
40
Figure 1 P Series Power Steering Pump
POWER STEERING PUMP UNIT REPAIR 3818-3

Key No.
Key No.
Part Name
Part Name
17- RING, SHAFT RETAINING

18-VANE, PUMP
20 - RING, PUMP
21-PLATE,PRESSURE
22 - SPRING, PRESSURE PLATE
23 - PLATE, END
25- RING, END PLATE RETAINING
33 - FITTING ASM (CONNECTOR &)
35 - SEAL, 0-RING
36 - BOLT, PUMP MOUNTING
37 - RESERVOIR ASM
38 - CAP ASM, RESERVOIR
40 - SEAL, 0-RING (HOUSING TO STUD)
1 - SEAL, 0-RING
2-VALVE ASM, CONTROL
3 - SEAL, 0-RING
5 - SEAL, 0-RING
6 - SPRING, FLOW CONTROL
7-MAGNET
8 - HOUSING ASM, PUMP
10- SEAL, 0-RING (HOUSING)
11 - SEAL, DRIVE SHAFT
12- SHAFT, DRIVE
13 - PIN, DOWEL
15- PLATE, THRUST
16 - ROTOR, PUMP
Figure 2 P Series Power Steering Pump - Legend
DRIVE SHAFT SEAL REPLACEMENT

Figures 1 thru 3
Tool Required:
J 22670 Shaft Oil Seal Insta11er
Power steering pump from vehicle. Refer to "Power

Steering Pump Replacement" in section 3B.
l+!+I Disassemble
Protect drive shaft (12) with shim stock.

Seal (11) by cutting with a chisel.
l+;+I Assemble
Lubricate seal (11) with power steering fluid.

Seal (11) using J 22670.
I+ +! Install or Connect
l+:+I
1.
2.
3.
4.
5.
6.
Disassemble
Drain power steering fluid from pump.
Bolts (36).
Fitting-(33) and 0-ring seal (35).
Control valve assembly (2) and flow control spring
(6) from housing (8) if replacement is required.
Reservoir (37) from housing (8).
0-ring seals (1, 10, and 40).
Magnet (7).
11-ll
ILI
Clean
Magnet (7).
Inspect
Welch plug in housing (8). Do not remove.
If plug is deformed or dislodged, replace
housing (8).
I-
Power steering pump. Refer to "Power Steering

Pump Replacement" in section 3B.
~11
PUMP RESERVOIR REPLACEMENT

Figure 1
f+ +l
J22670
Power steering pump from vehicle. Refer to "Power
Steering Pump Replacement" in section 3B.
A-CHISEL
B-SHIM STOCK
11-SEAL, DRIVE SHAFT
12-SHAFT, DRIVE
Figure 3 Drive Shaft Seal

[ [ ) Important
1+!+1
Use new seals when assembling pump.
Assemble
Lubricate 0-ring seals ( 1, 10, 35 and 40) with power

steering fluid.
1. Flow control spring (6) and control valve assembly
(2) to housing (8). See Figure 1 for proper orientation.
2. 0-ring seals (1, 10, and 40) to housing (8).
3. Magnet (7) to housing (8).
4. Reservoir (37) to housing (8).
5. 0-ring seal (35) and fitting (33).
Notice: See "Notice" on page 3B 1B-1 of this section.
6.
Bolts (36).
!+ +I
Tighten
Bolts (36) to 58 Nm (43 lb. ft.).
Install or Connect
END PLATE AND ROTATING GROUP

REPLACEMENT
Figures 1, 2 and 4
!+ +I
!+!+I
Power steering pump from vehicle. Refer to
"Power Steering Pump Replacement" in section 3B.
Disassemble
t.
Pump reservoir. Refer to "Pump Reservoir

Replacement" in this section.
2. Retaining ring (25).
3. End plate (23) and spring (22).
Notice: Examine exposed portion of pump drive shaft. If
it is corroded, clean with crocus cloth before removing.
This will prevent damage to the shaft bushing which might
require replacement of the entire housing.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
Pressure plate (21) by using a rubber mallet to. tap

lightly on the drive shaft (12).
Pump ring (20).
Pump vanes (18).
Shaft, rotor and thrust plate assembly.
Shaft retaining ring (17).
Pump rotor (16).
Thrust plate ( 15).
Drive shaft (12).
Dowel pins (13).
0-ring seals (3 and 5).
rn
!+!+I
A-IDENTIFICATION ARROW
3-SEAL
5-SEAL
8-HOUSING
12-SHAFT, DRIVE
13-PINS, DOWEL
15-PLATE, THRUST
16-ROTOR, PUMP
17-RING, SHAFT RETAINING
18-VANES, PUMP
20-RING, PUMP
21-PLATE, PRESSURE
Figure 4 Rotating Group
Important
Use new seals and drive shaft retaining ring
when assembling pump.
Assemble
Lubricate 0-ring seals (3 and 5) with power steering

fluid.
1.
2.
3.
0-ring seals (3 and 5) to housing (8).

Dowel pins (13) to housing (8).
Thrust plate (15) and pump rotor (16) to drive shaft
(12) and secure with retaining ring (17).
Shaft, rotor and thrust plate assembly to housing (8).
Pump vanes (18) to pump rotor (16).
Pump ring (20) to housing (8) with identification
arrow on top edge of ring (20) facing outward.
Pressure plate (21).
Spring (22) and end plate (23).
Retaining ring (25).
Pump reservoir (37). Refer to "Pump Reservoir
4.
5.
6.
7.
8.
9.
t O.
!+ +I
Install or Connect
10
'~~:12
-.).,'
~15
~16
37
36
Figure 1 Power Steering Pump - Reverse Rotation

Key No.
Part Name
Key No.
6 PIN, PUMP RING DOWEL

7 - SHAFT, DRIVE
10 - HOUSING ASM, BUSHING &
11 - SEAL, DRIVE SHAFT
12- SPRING, FLOW CONTROL
13 - VALVE ASM, CONTROL
15 - SEAL, 0-RING
16- FITIING, 0-RING UNION
25 - PLATE, THRUST
Part Name
26 RING, PUMP
27-VANE, PUMP
28 - ROTOR, PUMP
30- RING, SHAFT RETAINING
31-PLATE,PRESSURE
32 - SEAL, 0-RING
33- SPRING, PRESSURE PLATE
35 SEAL, 0-RING
36 COVER, END
37- RING, RETAINING
Figure 2 Power Steering Pump - Reverse Rotation - Legend
CONTROL VALVE
DRIVE SHAFT SEAL
Figure 1
(without disassembly of pump)

Figures 3 and 4
I+ +I
1.
2.
3.
4.
I+ +I
1.
2.
3.
4.
Pump assembly from vehicle, if necessary

for access.
0-ring union fitting (16) and 0-ring (15).
Control valve assembly (13).
Flow control spring (12).
I+ +I
1.
2.
Install or Connect
Flow control spring (12).

Lubricate new 0-ring (15) with power steering
fluid.
0-ring (15) on fitting (16).

Fitting (16) into hydraulic pump housing
assembly (10).
~
5.
Tool Required:
J 7728 Shaft Oil Seal lnsta11er
3.
I+ +I
1.
2.
Pump assembly from vehicle, if necessary for access.

Protect drive shaft (7) with shim stock (see
Figure 3).
Seal (11) and discard. (Use sma11 chiselto cut drive
shaft seal.)
Install or Connect
New drive shaft seal (11 ), lubricated with power

steering fluid, using tool J 7728 (see Figure 4).
Pump assembly to vehicle, if removed.
Tighten

Pump assembly to vehicle, if removed.
J 7728
---11
10
A-CHISEL
B-SHIM STOCK
7-SHAFT, DRIVE
10-HOUSING ASM, HYD PUMP
Figure 3 Shaft Seal Removal

Figure 4 Seal Installation

HYDRAULIC PUMP ASSEMBLY
Figures 1, 4 thru 8
l+;+f
Tool Required:
J 7728 Shaft Oil Seal Installer
4.
5.
6.
Disassemble
7.
1.
Retaining ring (37) using punch in access hole (see

Figure 5).
2. Internal components of pump from pump
housing (10) by gently pushing on drive shaft (7).
Components should include pressure plate
sub-assembly consisting of:
End cover (36).
0-ring seal (35).
Pressure plate spring (33).
Pressure plate (31 ).

Drive shaft sub-assembly consisting of:
Pump rotor (28).
Thrust plate (25).
Drive shaft (7).
Shaft retaining ring (30).

Pump ring (26) and vanes (27).
3. 0-ring (32) from pump housing (10).
A-ACCESS HOLE
B-PUNCH
37-RING, RETAINING
Figure 5 Retaining Ring Removal
8.
9.
Dowel pins (6).

Drive shaft seal (11 ).
End cover (36), pressure plate spring (33) and
0-ring (35) from pressure plate (31 ).
Pump ring (26) and vanes (27) from drive shaft subassembly.
Shaft retaining ring (30) from drive shaft (7).
Pump rotor (28) and thrust plate (25) from drive
shaft (7).
!~I
Clean
All parts in power steering fluid.
Dry parts.
(23
Inspect
Pump ring (26).
Rotor (28).
Vanes (27).
Thrust plate (25).
Drive shaft (7).

For scoring, pitting or chatter marks. If noted,
replace appropriate parts.
7-SHAFT, DRIVE
25-PLATE, THRUST
28-AOTOR, PUMP
30-RING, SHAFT RETAINING
Figure 6 Retaining Ring Installation (Shaft)
!+!+I
7.
Assemble
8.
1.
2.
3.
4.
5.
6.
Lubricate new drive shaft seal (11) with power

steering fluid.
Drive shaft seal ( 11) into pump housing ( 10)

with tool J 7728 (see Figure 4).
Pump ring dowel pins (6) into pump housing (10).
Thrust plate (25) and pump rotor (28) to drive
shaft (7) (see Figure 6).
New shaft retaining ring (30) onto drive shaft (7).
Drive shaft sub-assembly into pump housing (10).
Vanes (27) into pump rotor (28).
28
9.
10.
11.
12.
13.
14.
Pump ring (26), with holes positioned correctly onto

dowel pins (6), in pump housing (10) (see Figure 7).
Lubricate new 0-ring (32) with power steering fluid.
0-ring (32) into groove in pump housing (10).

Pressure plate spring (33).
Lubricate new 0-ring (35) with power steering fluid.
0-ring (35) into end cover (36).
Lubricate outer edge of end cover (36) with power

steering fluid.
Press end cover (36) into pump housing (10).
Retaining ring (37) into groove in pump housing
(10), with ring opening near access hole in pump
housing (see Figure 8).
THIS SIDE FACING UP

26
A
A
COUNTERBORE
FACING DRIVE
SHAFT END OF
HOUSING
A-DOWEL PIN HOLE (LARGE)
B-CROSS-OVER SLOT
26-RING, PUMP
28-ROTOR, PUMP
Figure 7 Rotor or Pump Ring Installation
A-ACCESS HOLE
B-PRESS
C-RETAINING RING OPENING
D-BOLT HOLE
37-RING, RETAINING
Figure 8 Retaining Ring Installation (Housing)
POWER STEERING PUMP UNIT REPAIR
381 B-9
SPECIFICATIONS
FLUID CAPACITIES
Lubricant ...................................................................................................... GM Power Steering Fluid Part No. 1050017
or Equivalent meeting GM Specification 9985010
Capacity Complete System .............................................................................................................. 0.75 liter (1-1/2 pints)
Pump Only ................................................................................................................................................. 0.5 liter (1 pint)
FASTENER TORQUES
P Series Power Steering Pump
(33)
Connector and Fitting Assembly ............................................................................. 75.0 Nm
(36)
Pump Mounting Bolt ............................................................................................... 58.0 Nm
(55 lb. ft.)

(43 lb. ft.)
Reverse Rotation Power Steering Pump

(16)
0-ring Union Fitting ................................................................................................ 75.0 Nm
(55 lb. ft.)
SPECIAL TOOLS
1. J 22670
2. J 7728
1. SHAFT OIL SEAL INSTALLER (P SERIES PUMP)

2. SHAFT OIL SEAL INSTALLER (REVERSE ROTATION PUMP)
FRONT SUSPENSION 3C1
SECTION 3C
FRONT SUSPENSION
result.
CONTENTS
General Description . . . . . . . . . . . . . . . . . . . . . . . . 3C-1
On-Vehicle Service . . . . . . . . . . . . . . . . . . . . . . . . 3C-3
Control Arm Ball Stud Assembly
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3C-3
Lower Control Arm Ball Stud Assembly . . 3C-3
Upper Control Arm Ball Stud Assembly . . . 3C-4
Control Arm Ball Stud Assembly
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . 3C-4
Lower Control Arm Ball Stud Assembly . . . 3C-4
Upper Control Arm Ball Stud Assembly ... 3C-5
Wheel Hub Assembly . . . . . . . . . . . . . . . . . . . . . 3C-6
Front Wheel Bolt . . . . . . . . . . . . . . . . . . . . . . . . 3C-7
Lower Control Arm Assembly . . . . . . . . . . . . . . 3C-8

Lower Control Arm Bushing Assembly . . . . . . . 3C-9
Shock Absorber and Spring Assembly ........ 3C-9
Stabilizer Shaft . . . . . . . . . . . . . . . . . . . . . . . . . 3C- l 3
Stabilizer Shaft Link Assembly ............ 3C-14
Steering Knuckle Assembly ............... 3C-14
Upper Control Arm Assembly ............. 3C-15
Upper Control Arm Bushing Assembly ...... 3C-16
Wheel Bearing Assembly ................. 3C-16
Crossmember Assembly .................. 3C-16
Specifications ............................ 3C-18
Fastener Tightening Specifications . . . . . . . . . . 3C- l 8
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3C-19
GENERAL DESCRIPTION
Side roll of the front suspension assembly is controlled by a stabilizer shaft ( 11 ). The stabilizer shaft is
mounted to stabilizer shaft insulators ( 16) that are held to
frame side rails by stabilizer shaft bracket assemblies. The
ends of the stabilizer shaft ( 11) are connected to the lower
control arm assemblies ( 17) by stabilizer shaft link
assemblies (12) and are isolated by complaint bushings.
Figures 1 and 2
The short/long arm (SLA) front suspension assembly is designed to allow each wheel assembly to compensate for changes in the road surface level without
appreciably affecting the opposite wheel assembly. Each
wheel assembly is independently connected to the frame
assembly by a steering knuckle assembly (6) and wheel
hub assembly (44), shock absorber assembly (24) and
spring assembly (23), upper and lower ball stud assemblies (2 and 10) and upper and lower control arm assemblies ( 1 and 17). The steering knuckle and hub assemblies
(6 and 44) move in a prescribed three-dimensional arc.
The front wheel assemblies are held in proper relationship
to each other by two front tie rod axle assemblies. The
front tie rod axle assemblies are connected to steering
arms on the knuckles and to the steering gear assembly.
Spring assemblies (23) are mounted on the lower
control arm assemblies (17). Ride control is provided by
direct acting shock absorber assemblies (24). The upper
portion of the shock absorber assembly is connected to the
front upper shock absorber mount assembly (45). The
upper mount assembly (45) extends through the upper
control arm support (46) and the center wheelhouse
assembly and attaches with l wo shock absorber upper
mount bolts/screws (26) and two shock absorber upper
mount nuts (25).
The inner ends of the lower control arm assembly

(17) have pressed-in bushings. Bolts (passing through the
bushings) attach the lower control arm assembly (17) to
the crossmember assembly (20).
The upper control arm assembly (1) is attached to
the steering knuckle assembly (6) with a nut (4) and cotter
pin (3) and is bolted to the shock absorber assembly (24)
through an upper control arm support (46) which attaches
to the body.
The lower ball stud assembly (10) is a press fit in the
lower control arm assembly (17) and is attached to the
steering knuckle assembly (6) with a nut (8) and cotter pin
(9).
Rubber grease seals are provided at ball socket
assemblies to keep dirt and moisture from entering the
stud assembly and damaging bearing surfaces.
The upper ball stud' assembly (2) is riveted to the
upper control arm assembly (1) and is attached to the
steering knuckle assembly (6) with a nut (4) and cotter pin
(3);
3C2 FRONT SUSPENSION
------
FFii~gure 1 - -:-=-:-::-;::::-nc,ior
Front Suspension Components
FRONT SUSPENSION 3C-3
1 ARM ASSEMBLY, FRONT UPPER CONTROL

2 STUD ASSEMBLY, FRONT UPPER CONTROL ARM BALL
3 PIN, FRONT UPPER CONTROL ARM COTTER
4 NUT, FRONT UPPER CONTROL ARM, 53 Nm (39 LB. FT.)
5 NUT, FRONT STABILIZER SHAFT LINK ASSEMBLY,

23 Nm (17 LB. FT.)
6 KNUCKLE AND HUB ASSEMBLY, STEERING

7 SLEEVE, FRONT STABILIZER SHAFT LINK ASSEMBLY
8 NUT, FRONT LOWER CONTROL ARM,

110 Nm (81 LB. FT.)
9 PIN, FRONT LOWER CONTROL ARM COTTER

11 STABILIZER SHAFT, FRONT
12 LINK ASSEMBLY, FRONT STABILIZER SHAFT,
23 Nm (17 LB. FT.)
13 BOLT/SCREW, FRONT STABILIZER SHAFT INSULATOR
CLAMP, 55 Nm (41 LB. FT.)
14 CLAMP, FRONT STABILIZER SHAFT INSULATOR
15 BOLT/SCREW, FRONT SHOCK ABSORBER,
65 Nm (48 LB. FT.)
16 INSULATOR, FRONT STABILIZER SHAFT

90 Nm (66 LB. FT.)
19 BOLT/SCREW, FRONT LOWER CONTROL ARM
22 NUT, FRONT SHOCK ABSORBER LOWER BRACKET,
65 Nm (48 LB. FT.)
23 SPRING ASSEMBLY, FRONT
24 ABSORBER ASSEMBLY, FRONT SHOCK
25 NUT, FRONT SHOCK ABSORBER UPPER MOUNT,
43 Nm (32 LB. FT.)
26 BOLT/SCREW, FRONT SHOCK ABSORBER UPPER
MOUNT, 50 Nm (37 LB. FT.)
90 Nm (66 LB. FT.)
44 HUB ASSEMBLY, FRONT WHEEL
45 MOUNT ASSEMBLY, FRONT UPPER SHOCK ABSORBER
46 SUPPORT, FRONT UPPER CONTROL ARM
PC0002-3CfRP
Figure 2 - Front Suspension Components - Legend
c
A
B
C
D
E
F
G
H
WORN
NEW
WEAR SURFACES
SINTERED IRON BEARING
HOUSING SOCKET
H --~
RUBBER PRESSURE RING
1.27 mm (0.050")
WEAR INDICATOR SHOULDER (OUT WHEN NEW)
WHEN LOWER CONTROL ARM BALL STUD ASSEMBLY
WEAR CAUSES WEAR INDICATOR SHOULDER TO BE
BELOW SURFACE, REPLACEMENT IS NEEDED
.:t._
PC0003-3C-F-RP
Figure 3 - Lower Control Arm Ball Stud Assembly Wear Indicator
ON-VEHICLE SERVICE
CONTROL ARM BALL STUD ASSEMBLY
INSPECTION
Figures 3 and 4
ll"'I
Inspect
Ball stud assembly seals should be carefully
inspected for cuts and tears. Whenever cuts or tears
are found, ball stud assembly must be replaced.
Ball studs for wear.
Lower Control Arm Ball Stud Assembly

Figure 3
. The l~we: control ar1!1 ball stud assembly has a
visual wear md1cator. Checkmg the condition of the lower
control arm ball stud assembly is a simple procedure but
must be followed accurately to prevent unnecessary
replacement.
ll'l'I
Inspect
1. Vehicle must be supported by wheel assemblies so

weight of vehicle will properly load ball stud
assemblies.
3C-4 FRONT SUSPENSION

2. Ball stud assembly is inspected for wear by visual
observation alone. Wear is indicated by position of
12.7 mm (0.50 inch) diameter nipple into which
front suspension lubricant fitting is threaded. This
round nipple projects 1.27 mm (0.050 inch) beyond
surface of ball stud assembly cover when new.
Normal wear will result in surface of this nipple
retreating very slowly inward.
3. Wipe front suspension lubricant fitting and nipple
free of dirt and grease. Observe or scrape screwdriver or fingernail across cover. If round nipple is
flush or inside cover surface, replace ball stud
assembly.
CONTROL ARM BALL STUD ASSEMBLY

REPLACEMENT
Lower Control Arm Ball Stud Assembly
Upper Control Arm Ball Stud Assembly

1.
Figure 4
!Ll
2.
1nspect
1. Raise vehicle and position floor stands under both

lower control arm assemblies as near as possible to
each ball stud assembly. Refer to SECTION OA.
rn
3.
4.
Tools Required:
J 39549 Ball Joint/Tie Rod Separator
J 9519-7 Ball Joint Remover
J 9519-9 Ball Joint Installer
J 9519-18 Ball Joint Pressing Screw
J 9519-23 Ball Joint C-Clamp
Raise and suitably support vehicle with floor stands
under frame assembly. Refer to SECTION OA.
Special security wheel lock nut, if equipped. Refer
to SECTION 3E.
Tire and wheel assembly. Refer to SECTION 3E.
Place floor jack under lower control arm assembly
(17).
[I] Important
Important
Vehicle must be stable and should not rock on

floor stands.
2. Position dial indicator against wheel rim.
3. Grasp wheel assembly and push in on bottom of tire
while pulling out at top. Read gage, then reverse
push-pull procedure. Horizontal deflection on dial
indicator should not exceed 3.18 mm (0.125 inch).
If dial indicator reading exceeds 3.18 mm
(0.125 inch), replace ball stud assembly.
4. Anytime ball stud assembly is disconnected from

steering knuckle assembly, check for looseness or if
ball stud assembly can be twisted in its socket with
your fingers. If either of these conditions exist,
replace ball stud assembly.
5. Lower vehicle.
SUPPORT FRONT LOWER

CONTROL ARM ASSEMBLY AS
FAR OUTBOARD AS POSSIBLE
2 POSITION DIAL INDICATOR TO

CHECK MOVEMENT AT THIS
POINT
3 ROCK WHEEL AND TIRE

ASSEMBLY IN AND OUT AT
TOP AND BOTTOM
Floor jack must remain under shock absorber

assembly mounting location on lower control
arm assembly (17) during removal and installation to hold spring assembly and lower
control arm assembly in position.
5. Separate ball stud assembly from steering knuckle
assembly, using J 39549.
6. Lower control arm cotter pin and loosen lower
control arm nut.
7. Press ball stud. assembly out of lower control
arm assembly (17), using J9519-7, J9519-18 and
J 9519-23.

NOTICE: See "Notice" on page 3C-1 of this
section.
1. Position ball stud assembly into lower control
arm assembly (17) and press in, using J 9519-9,
J 9519-18 and J 9519-23, until it bottoms on lower
control arm assembly (17). Ball stud assembly must
firmly press into lower control arm assembly (17). If
it does not, replace lower control arm assembly ( 17).
2. Ball stud assembly to steering knuckle assembly.
3. Hand start lower control arm nut.
rn
Important
Tighten nut enough to align nut slot with stud

hole. Never loosen nut in order to align slot
with hole.
PC6004-3CDRP
Figure 4 - Checking Upper Control Arm Ball Stud Assembly
!~I Tighten
Nut to 110 Nm (81 lb. ft.).
J 9519-18
A REMOVING LOWER BALL STUD ASSEMBLY

B INSTALLING LOWER BALL STUD ASSEMBLY
PC0004-3CFRP
Figure 5 - Removing and Installing Lower Control Arm Ball Stud Assembly
4. Lower control arm cotter pin.

5. Remove floor jack from under shock absorber
assembly mounting location on lower control arm
assembly (17).
6. Tire and wheel assembly. Refer to SECTION 3E.
7. Special security wheel lock nut, if equipped. Refer
to SECTION 3E.
8. Check wheel assembly alignment. Refer to SECTION 3A.
9. Lower vehicle.
Upper Control Arm Ball Stud Assembly

Figures 6 through 1O

1.
2.
3.
4.
Tool Required:
J 39549 Ball Joint{fie Rod Separator
to SECTION 3E.
Place floor jack under shock absorber assembly
mounting location on lower control arm assembly
(17).
rn
Important
Floor jack must remain under the shock

absorber assembly mounting location on lower
control arm assembly ( 17) during removal and
installation to hold the spring assembly and
lower control arm assembly in position.
5. Loosen ball stud assembly (2) from steering knuckle
assembly (6).
6. Cotter pin (3) and nut (4).
7. Support steering knuckle assembly (6) with floor
stands.
8. Separate ball stud assembly (2) from upper control
arm assembly (1), using J 39549.
9. With upper control arm assembly (1) in raised
position, drill out four rivets approximately 6 mm
(0.25 inch) deep, using 1/8-inch drill bit. Refer to
Figure 7.
10. Drill off rivet heads, using 1/2-inch drill bit. Refer to
Figure 8.
11. Punch out rivets, using small punch, and remove ball
stud assembly (2). Refer to Figure 9.
/; I
US ING 112" DR I LL.
DRILL JUST DEEP
ENOUGH TO REMOVE
'..--"- RIVET HEAD
'
\
\\
\ \
-----~
~--
KC0100-3C-B-RP

Figure 8 - Drilling Upper Control Arm Ball Stud Assembly

Rivet Heads
PC0005-3C-F-RP
Figure 6 - Separating Upper Control Arm Ball Stud Assembly
A PUNCH
2 STUD ASSEMBLY, FRONT UPPER
CONTROL ARM BALL
PC6010-3C-D-RP
KC0095-3C-B-RP
Figure 7 - Drilling Upper Control Arm Ball Stud Assembly

Rivet
l++I
Install or Connect
NOTICE: See "Notice" on page 3C-l of this

section.
1. Position new ball stud assembly (2) and install four
service kit bolts/screws (28) and nuts (29). Use
specifications in ball stud assembly kit.
2. Remove temporary support from steering knuckle
assembly (6), then connect ball stud assembly (2) to
steering knuckle assembly (6).
3. Hand start nut (4 ).
Important
Tighten nut enough to align slot with stud hole.

Never loosen nut in order to align slot with
hole.
l~I
Tighten
Nut (4) to 53 Nm (39 lb. ft.).
Figure 9 - Removing Upper Control Arm Ball Stud Assembly
4.
5.
6.
7.
Cotter pin (3).

Remove floor jack from under spring seat.
to SECTION 3E.
8. Lower vehicle.
WHEEL HUB ASSEMBLY

Figure 11
l++I

to SECTION 3E.
4. Brake caliper assembly. Refer to SECTION 581.
5. Brake rotor assembly. Refer to SECTION 581.
29
!~
~
39
39 ROTOR ASSEMBLY, FRONT BRAKE
40
41
42
43
44
CALIPER ASSEMBLY, FRONT BRAKE

BOLT/SCREW, FRONT BRAKE CALIPER
BOLT/SCREW, FRONT WHEEL, 86 Nm (63 LB. FT.)
BRACKET, WHEEL SPEED SENSOR WIRE
HUB ASSEMBLY, FRONT WHEEL
PC0024-3C-F-RP
1
2
3
4
6
28
29
ARM ASSEMBLY, FRONT UPPER CONTROL

STUD ASSEMBLY, FRONT UPPER CONTROL BALL
PIN, FRONT UPPER CONTROL ARM COTTER
NUT, FRONT UPPER CONTROL ARM, 53 Nm (39 LB. FT.)
BOLT/SCREW, SERVICE KIT
NUT, SERVICE KIT
PC00063C-f.RP
Figure 10 - Upper Control Arm Ball Stud Assembly

Attachment
Figure 11 - Front Wheel Hub Assembly
3. Wheel speed sensor electrical connector. Refer to

SECTION 5El.
4. Brake rotor assembly. Refer to SECTION SB 1.
5. Brake caliper assembly. Refer to SECTION SB I.
to SECTION 3E.
8. Lower vehicle.
FRONT WHEEL BOLT

6. Wheel speed sensor electrical connector and move
aside. Refer to SECTION 5El.
7. Bolts/screws (42) from hub assembly (44).
8. Pull hub assembly (44) from spindle.

1. Position hub assembly (44) to spindle.
!~I Tighten
[I] Important
Make sure wheel speed sensor electrical
connector is reconnected to wheel speed sensor
wire bracket (43) and wheel speed sensor or
wires could be damaged.
(Wheel Hub Assembly Removed)

Tools Required:
J 6627-A Wheel Stud Remover
NOTICE: Do not damage wheel assembly mounting surface on hub assembly flange. Brake assembly
disc must be supported before pressing wheel
assembly bolt in or out.
Hub assembly or disc bolts, using J 6627-A.

section.
New serrated bolt into hole in hub assembly. Tap
lightly with hammer to start bolt serration in hole,
making sure that bolt is square with hub flange.

Figure 12
l++I
2. Hand tighten bolts/screws (19 and 21) and nuts

(18 and 27).

to SECTION 3E.
4. Power steering gear assembly from steering knuckle
assembly. Refer to SECTION 3B.
5. Stabilizer shaft link assembly. Refer to "Stabilizer
Shaft Link Assembly" in this section.
6. Shock absorber and spring assembly from lower
control arm assembly. Refer to "Shock Absorber
and Spring Assembly" in this section.
7. Separate lower control arm ball stud assembly from
steering knuckle assembly. Refer to "Control Arm
Ball Stud Assembly Replacement" in this section.
8. Lower control arm assembly (17) from steering
knuckle assembly (6).
9. Bolts/screws (19 and 21) and nuts (27 and 18).
10. Lower control arm assembly ( 17).
l++I
1. Position lower control arm assembly ( 17) to crossmember assembly (20).
l~I
Tighten
Nuts (18 and 27) to 130 Nm (96 lb. ft.).

3. Position lower control arm assembly (17) to steering
4. Hand start nut (8).
rn
Important
Tighten nut enough to align slot with stud hole.

Never loosen nut in order to align slot with
hole.
l~I
Tighten
Nut (8) to 110 Nm (81 lb. ft.).

5. Cotter pin (9).
6. Lower control arm assembly to shock absorber and
spring assembly. Refer to "Shock Absorber and
Spring Assembly" in this section.
Install or Connect


section.
8. Power steering gear assembly to steering knuckle


23 Nm (17 LB. FT.)
110 Nm (81 LB. FT.)
9 COTIER PIN, FRONT LOWER CONTROL ARM
10 BALL STUD ASSEMBLY, FRONT LOWER CONTROL ARM
12 LINK ASSEMBLY, FRONT STABILIZER SHAFT
65 Nm (48 LB. FT.)
90 Nm (66 LB. FT.)
20 CROSSMEMBER ASSEMBLY. FRONT
65 Nm (48 LB. FT.)
90 Nm (66 LB. FT.)
PC00073CFRP
Figure 12 - Lower Control Arm Assembly

to SECTION 3E.
11. Lower vehicle.
12. Align wheel assembly. Refer to SECTION 3A.
LOWER CONTROL ARM BUSHING

ASSEMBLY
The lower control arm bushing assembly cannot be
serviced separately from the lower control arm assembly.
Refer to "Lower Control Arm Assembly" in this section.
SHOCK ABSORBER AND SPRING

ASSEMBLY

Tools Required:
J 34013-B Strut Spring Compresspor
J 34013-114 Modular Shock Assembly Compressor Adapter
J 34013-218 Modular Shock Support
J 34013-88 Strut Compressor Adapter
J 39642 Modular Shock Nut Removal Set,
15 mm (0.60 inch)
J 34013-115 Modular Shock Assembly Alignment Rod
1. Brake master cylinder nuts (driver-side only). Refer
to SECTION SA.
2. Move brake master cylinder assembly aside (driverside only). Refer to SECTION SA.
to SECTION 3E.
8. Nuts (22).
10. Separate lower ball stud assembly from steering
knuckle assembly. Refer to "Control Arm Ball Stud
Assembly Replacement" in this section.
[I] Important
Be sure to mark with chalk or paint (do not
scribe) the lower mount location relative to the
upper mount location before removing the
shock absorber assembly or the assembly cannot be reinstalled.
11. Shock absorber and spring assembly (24 and 23).


110 Nm (81 LB. FT.)
9 PIN, FRONT LOWER CONTROL ARM COTTER


65 Nm (48 LB. FT.)

65 Nm (48 LB. FT.)
43 Nm (32 LB. FT.)
46 SUPPORT, FRONT UPPER CONTROL ARM
PCOOOB-3C-FRP
Figure 13 - Shock Absorber and Spring Assembly
K,n,.ftfnnrr
A~U-11'f'Dnu1m1
SPXCorpnrotiM
1971UUnl<'M,1<r:k
R,.,,.,,ilf,.Mf4S<IM-119Jf
/.!IOfJ ..1-15-12.U
J 34013-B
J 34013-B Strut Spring Compressor

Read Instruction Sheet J 34013-29/29A
Before Using
C-H-E/K
....,
NOVA
..,2
PC00183C-F-RP
Figure 16 - Modular Shock Assembly Compressor Adapter Passenger-Side Position
J-N-L
J 34013-44C
Nova Twin-Cam
PC0016-3CF-RP
Figure 14 - Modular Shock Assembly Compressor Mounting

Hole Location
PC00193CFRP
Figure 17 - Installing Strut Compressor Adapter to Strut

Spring Compressor
J .34013-114
[I] Important
PC0017-3CFRP
Figure 15 - Modular Shock Assembly Compressor Adapter Driver-Side Position
l+!+I Disassemble
1. Install J 34013-114 to J 34013-B. Use wing nuts
to secure tool to mounting holes C-H (lower left
corner) and P (upper right corner) for driver-side
shock absorber assembly and to secure tool to
mounting_ holes A-X-P (upper left corner) and C-H
(lower nght corner) for passenger-side shock
absorber assembly.
Be sure J 34013-218 and J 34013-88 are

aligned so they can open and close together.
If_ the tools are not aligned properly, they
will not open.
2. Install J 34013-218 and J 34013-88.
[I] Important
Be sure the top of the shock absorber assembly
is flat against J 34013-114. The shock absorber
assembly will not be aligned correctly if it does
lay not flat against the tool.
3. Shock absorber assembly to top of J 34013-114.
FRONT SUSPENSION 3C 11
...---J 34013-8
---J 34013-114
24------1

A MATCHING ANGLE BETWEEN SHOCK ABSORBER

ASSEMBLY AND J 34013-114
PC0021-3C-F-RP
PC0020-JC-F-RP
Figure 18 - Installing Shock Absorber Assembly to

Strut Spring Compressor
Figure 19 - Driver-Side Shock Absorber Assembly

Installation
4. Install shock absorber assembly into J 34013-218

and J 34013-88.
5. Close J 34013-218 and J 34013-88 and install
locking pin.
rn
J 34013-
Important
Be sure the mounting ears of the shock

absorber assembly are facing downward
toward the rear of J 34013-B or the shock
absorber assembly will not align properly.
6. Turn screw on J 34013-B counterclockwise to raise
shock absorber assembly up to J 34013-114. Be
sure studs go through guide holes in J 34013-114
and the top of the shock absorber assembly is flat
against the tool.
7. Compress front spring assembly approximately
l3 mm (0.50 inch) or three or four complete turns
of the screw on J 34013-114.
CAUTION: Do not over compress front

spring assembly. Severe overloading
may cause tool failure which could
result in bodily injury.
8. Insert J 39642-1 on shock absorber nut, then insert
J 39642-2 through J 39642-1 to hold shock
absorber rod in place.
9. Remove shock absorber nut with J 39642-1 while
holding shock absorber assembly rod from rotating
with J 39612-2.
10. Discard shock absorber nut.
11. Turn J 34013-B clockwise to fully relieve spring
assembly pressure.
24
A MATCHING ANGLE BETWEEN-SHOCK ABSORBER

ASSEMBLY AND J 34013-114
PC0022-3C-F-RP
Figure 20 - Passenger-Side Shock Absorber Assembly

Installation
l+!+I Assemble
1. Install J 34013-114 to J 34013-B. Use wing nuts to
secure J 34013-114 to J 34013-B mounting holes
C-H (lower left corner) and P (upper right corner)
for driver-side shock absorber assembly and to
secure J 34013-114 to J 34013-B mounting holes
A-X-P (upper left corner) and C-H (lower right
corner) for passenger-side shock absorber assembly
(Figures 15 and 16).
2. Install J 34013-218 and J 34013-88.
[I] Important
Only turn the screw until the shock absorber
assembly is held in J 34013-B by itself. Do not
load the spring assembly.
8. Place J 34013-115 down through top of J 34013-B
through top of shock absorber assembly and onto
shock absorber rod.
[I] Important
J 34013-114
Make sure J 34013-115 is straight with the

shock absorber assembly. If J 34013-115 is
angled, repeat steps 1 through 5 until tool is
straight.
9. Turn operating screw clockwise to compress spring
assembly until threaded portion of the shock
absorber rod is through the top of the shock absorber
assembly.
24
A ROD, FRONT SHOCK ABSORBER

CAUTION: Do not over compress

spring assembly. Severe overloading
may result in tool failure which could
10. Remove J 34013-115.
[I] Important
PC0023-3C-F-RP
Figure 21 - Inserting Modular Shock Assembly Alignment

Rod
3. Install shock absorber assembly to J 34013-218 and

J 34013-88.
11.
[I] Important
Be sure the mounting ears of the shock
absorber assembly are facing downward.
toward the rear of J 34013-B or the shock
absorber assembly will not align properly.
Be sure to mark with chalk or paint (do not
scribe) the lower mount location relative to the
upper mount location before removing the
shock absorber assembly or the assembly
cannot be reinstalled.
4. Close J 34013-218 and J 34013-88 and engage
locking pin.
5. Make sure upper and lower spring seats are positioned correctly.
6. Shock absorber assembly to top of J 34013-114.
[I] Important
Be sure the top of the shock absorber assembly
is flat against J 34013-114. The shock absorber
assembly will not be aligned properly if it does
lay not flat against the tool.
7. Tum screw on J 34013-B counterclockwise to raise
shock absorber assembly up to J 34013-114 without
compressing spring assembly. Be sure studs on
shock absorber assembly go through guide holes in
J 34013-114.
12.
13.
14.
15.
When installing front shock absorber nut,

always replace it with a new one. Never
install the same nut that has been
removed.
Insert new shock absorber nut on shock absorber
rod.
NOTICE: Do not turn the shock absorber rod when
tightening the shock absorber nut or the shock
absorber assembly could be damaged. Keep the
shock absorber rod in a stationary position when
tightening the shock absorber nut.
Place J 39642-1 on shock absorber nut.
Insert J 39642-2 through J 39642-1 and tighten
shock absorber nut.
Tighten shock absorber nut while holding onto
J 39642-2.
Remove shock absorber assembly from J 34013-B.

section.
1. Position shock absorber and spring assembly
(24 and 23) to lower control arm assembly (17).
l~I
Tighten
Nuts (22) to 65 Nm (48 lb. ft.).

3. Lower ball stud assembly to steering knuckle assembly. Refer to "Control Arm Ball Stud Assembly

STABILIZER SHAFT

to SECTION 3E.
Figure22
7. Lower vehicle.

4. Clamps (14).
5. Stabilizer shaft (11 ).
6. Insulators (16).
8. Bracket assemblies (31 ).
8. Hand tighten bolts/screws (26) and nuts (25).
l~I
Tighten

Nuts (25) to 43 Nm (32 lb. ft.).
9. Position brake master cylinder assembly (driver-side
only). Refer to SECTION SA.
to SECTION SA.
16
11
A SIDE RAIL
23 Nm (17 LB. FT.)
12 LINK ASSEMBLY, FRONT STABILIZER SHAFT,
23 Nm (17 LB. FT.)
13 BOLT/SCREW, FRONT STABILIZER SHAFT INSULATOR
CLAMP, 55 Nm (41LB. FT.)
14 CLAMP, FRONT STABILIZER SHAFT INSULATOR
16 INSULATOR, FRONT STABILIZER SHAFT
30 BOLT/SCREW, FRONT STABILIZER SHAFT BRACKET,
55 Nm (41 LB. FT.)
31 BRACKET ASSEMBLY, FRONT STABILIZER SHAFT
44
12
PC0009-3C-FRP
Figure 22 - Stabilizer Shaft
l++I
Install or Connect

section.
1. Position bracket assemblies (31) to side rail.
2. Hand start bolts/screws (30).
l~I
Tighten

44
3. Place insulators (16) over stabilizer shaft (11).
[II Important

23 Nm (17 LB. FT.)
12 LINK ASSEMBLY, FRONT STABILIZER SHAFT
The slit of the insulator must face the front of

the vehicle.
4. Position clamps (14) over insulators (16) and stabilizer shaft (11 ).
l~I
PC0010-3C-F-RP
Figure 23 - Stabilizer Shaft Link Assembly
Tighten

7. Lower vehicle.
STABILIZER SHAFT LINK ASSEMBLY

Figure23
l++I
1. Raise and suitably support vehicle. Refer to SECTION QA.

2. Nut (5).
3. Link assembly (12).
4. Sleeve (7).
l++I
Install or Connect

section.
1. Sleeve (7) between lower control arm assembly ( 17)
and stabilizer shaft ( 11 ).
2. Link assembly (12) through lower control arm
assembly ( 17), sleeve (7) and stabilizer shaft ( 11 ).
3. Nut (5).
l~I
Tighten
Nut (5) to 23 Nm (17 lb. ft.).

4. Lower vehicle.
STEERING KNUCKLE ASSEMBLY

Figure24
l++I

to SECTION 3E.
4. Brake caliper assembly and move aside. Refer to
SECTION SB 1.
5. Brake rotor assembly. Refer to SECTION 5.
6. Wheel speed sensor electrical connector and move
aside. Refer to SECTION 5El.
7. Front wheel hub assembly from steering knuckle
assembly. Refer to "Wheel Hub Assembly" in this
section.
8. Power steering gear assembly from steering knuckle
10. Front shock absorber bolts/screws. Refer to "Shock
Absorber and Spring Assembly" in this section.
11. Separate lower ball stud assembly from steering
12. Lower control arm assembly from steering knuckle
assembly. Refer to "Lower Control Arm Assembly"
in this section.
13. Separate upper ball stud assembly from steering

7. Power steering gear assembly to steering knuckle
8. Front wheel hub assembly to steering knuckle
assembly. Refer to "Wheel Hub Assembly" in this
section.
[I] Important
9.
10.
11.
12.
13.
44

3 PIN, FRONT UPPER CONTROL ARM COTIER
110 Nm (81 LB. FT.)
9 PIN, FRONT LOWER CONTROL ARM COTIER
PC00113CF-RP
Figure 24 - Steering Knuckle Assembly
14. Steering knuckle assembly from upper control arm

assembly. Refer to "Upper Control Arm Assembly"
in this section.
15. Steering knuckle and hub assemblies (6 and 44).

1.
2.
3.
4.

section.
Position steering knuckle and hub assemblies (6 and
44) to upper control arm assembly (1).
Upper ball stud assembly to steering knuckle assembly. Refer to "Control Arm Ball Stud Assembly
Position steering knuckle assembly to lower control
arm assembly. Refer to "Lower Control Arm
Lower ball stud assembly to steering knuckle assembly. Refer to "Control Arm Ball Stud Assembly
14.
15.

wire bracket and wheel speed sensor or wires
could be damaged.
Wheel speed sensor electrical connector. Refer to
SECTION 5El.
Brake rotor assembly. Refer to SECTION 5.
Brake caliper assembly. Refer to SECTION SB 1.
to SECTION 3E.
Lower vehicle.
Check wheel assembly toe alignment. Refer to
SECTION 3A.
UPPER CONTROL ARM ASSEMBLY

Figure25

to SECTION SA.
2. Move brake master cylinder assembly aside (driverside only). Refer to SECTION SA.
to SECTION 3E.
9. Separate upper ball stud assembly from steering
10. Steering knuckle assembly (6) from upper control
arm assembly (1).
11. Upper control arm assembly (1) and shock absorber
assembly (24) from vehicle.
12. Support steering knuckle assembly (6) with floor
stands.
13. Nuts and bolts/screws (37 and 38).
14. Upper control arm assembly (1) from shock
absorber assembly. (24)
3C 16 FRONT SUSPENSION
9. Nuts (25) and bolts/screws (26).
NOTICE: Do not turn the shock absorber assembly
when tightening the upper mount nut or the shock
absorber assembly could be damaged. Keep the
shock absorber assembly in a stationary position
when tightening the nut.
l~I
10.
11.
12.
13.
14.
65 Nm (48 LB. FT.)
43 Nm (32 LB. FT.)
37 BOLT/SCREW, FRONT UPPER CONTROL ARM
46 SUPPORT, FRONT UPPER CONTROL ARM Pcoo, 2.ac-F-RP
Figure 25 - Upper Control Arm Assembly
Install or Connect

section.
1. Position upper control arm assembly (1) to shock
absorber assembly (24).
2. Bolts/screws and nuts (37 and 38).
l~I
Tighten
Nuts (38) to 53 Nm (39 lb. ft.).

3. Upper control arm assembly (1) and shock absorber
assembly (24) to vehicle.
4. Position steering knuckle assembly (6) to upper
control arm assembly (1).
5. Upper ball stud assembly to steering knuckle assembly. Refer to "Control Arm Ball Stud Assembly
Replacment" in this section.
6. Remove floor stands from steering knuckle assembly (6).
Nuts (25) to 43 Nm (32 lb. ft.).

to SECTION 3E.
Lower vehicle.
Position brake master cylinder assembly (driver-side
only). Refer to SECTION SA.
Brake master cylinder nuts (driver-side only). Refer
to SECTION SA.
UPPER CONTROL ARM BUSHING

ASSEMBLY
The upper control arm bushing assembly cannot be
serviced separately from the upper control arm assembly.
Refer to "Upper Control Arm Assembly" in this section.
WHEEL BEARING ASSEMBLY

The maintenance-free wheel bearing assembly does
not need to be serviced separately from the hub assembly.
Refer to "Wheel Hub Assembly" in this section.
CROSSMEMBER ASSEMBLY
Figure26
!++I
l++I
Tighten

to SECTION 3E.
3. Front tire and wheel assemblies. Refer to SECTION
3E.
4. Stabilizer shaft link assemblies. Refer to "Stabilizer
6. Separate lower control arm ball stud assemblies
from steering knuckle assemblies. Refer to "Control
Arm Ball Stud Assembly Replacement" in this
section.
7. Front lower control arm bolts/screws and nuts. Refer
to "Lower Control Arm Assembly" in this section.
8. Lower control arm assemblies ( 17) from crossmember assembly (20).
9. Steering gear bolts/screws from crossmember
A SIDE RAIL
90 Nm (66 LB. FT.)
19 BOLT/SCREW, FRONT LOWER CONTROL ARM,
195 Nm (144 LB. FT.)
21 BOLT/SCREW, FRONT LOWER CONTROL ARM,
130 Nm (96 LB. FT.)
90 Nm (66 LB. FT.)
32 BOLT/SCREW, FRONT CROSSMEMBER,
125 Nm (92 LB. FT.)
33 BOLT/SCREW, FRONT CROSSMEMBER,
100 Nm (74 LB. FT.)
34 NUT, FRONT CROSSMEMBER
PC00133C-F-RP
Figure 26 - Front Crossmember Assembly
10. Engine mount nuts and bolts/screws. Refer to

11. Support front and rear of engine assembly with jack
stands.
12. Front brake pipe assembly. Refer to SECTION 5.
13. Wheel speed sensor electrical connector. Refer to
SECTION 5El.
14. Drivetrain and front suspension frame nut plug.
15. Nuts (34).
16. Bolts/screws (32 and 33).
17. Crossmember assembly (20) and reposition power
steering gear assembly.
!++I
Install or Connect

section.
1. Position crossmember assembly (20) to side rails.
2. Crossmember assembly to power steering gear
!~I
Tighten

4. Nuts (34).
5. Drivetrain and front suspension frame nut plug.
rn
6.
7.
8.
9.
Important

wire bracket and wheel speed sensor or wires
could be damaged.
Wheel speed sensor electrical connector. Refer to
SECTION 5El.
Front brake pipe assembly. Refer to SECTION 5.
Remove jack stands from engine assembly.
Engine mount bolts/screws and nuts. Refer to

I 0. Power steering gear bolts/screws. Refer to SECTION
3B.
11. Position lower control arm assemblies ( I 7) to crossmember assembly (20).

12. Front lower control arm bolts/screws and nuts.
13. Lower control arm ball stud assemblies to steering
knuckle assemblies. Refer to "Control Arm Ball
Stud Assembly Replacement" in this section.

15. Stabilizer shaft link assemblies. Refer to "Stabilizer
to SECTION 3E.
18. Lower vehicle.
19. Align wheel assemblies. Refer to SECTION 3A.
SPECIFICATIONS
Front Crossmember-to-Drivetrain and Front Suspension
Frame Nut Plug Bolt/Screw ........................................ 100 Nm (74
Front Crossmember-to-Side Rail Bolt/Screw ............................. 125 Nm (92
Front Lower Control Arm-to-Front Crossmember Assembly Nut
(Horizontal) ..................................................... 130 Nm (96
Front Lower Control Arm-to-Front Crossmember Assembly Nut
(Vertical) ....................................................... 130 Nm (96
Front Lower Control Arm-to-Front Lower Control Arm Ball Stud
Assembly Nut ................................................... 110 Nm (81
Front Shock Absorber Bolt/Screw ...................................... 65 Nm (48
Front Shock Absorber Lower Bracket Nut ................................ 65 Nm (48
Front Shock Absorber Upper Mount Bolt/Screw ........................... 50 Nm (37
Front Shock Absorber Upper Mount Nut ................................. 43 Nm (32
Front Stabilizer Shaft Bracket Bolt/Screw ................................ 55 Nm (41
Front Stabilizer Shaft Insulator Clamp Bolt/Screw ......................... 55 Nm (41
Front Stabilizer Shaft Link Assembly .................................... 23 Nm (17
Front Stabilizer Shaft Link Assembly Nut ................................ 23 Nm (17
Front Upper Control Arm-to-Front Upper Control Arm Ball Stud
Assembly Nut .................................................... 53 Nm (39
Front Upper Control Arm-to-Front Upper Control Arm Support Nut ............ 98 Nm (72
Front Wheel Hub Assembly ........................................... 86 Nm (63
lb. ft.)
lb. ft.)
lb. ft.)
lb. ft.)
lb.
lb.
lb.
lb.
lb.
lb.
lb.
lb.
lb.
ft.)
ft.)
ft.)
ft.)
ft.)
ft.)
ft.)
ft.)
ft.)
lb. ft.)
lb. ft.)
lb. ft.)
SPECIAL TOOLS
1.
rt
7.
J 39549
J 24292-B
8.
J 34013-B
2.
(j!J
9.
3.
J 34013-88
4.
J 34013-114
10.
J 39642
J 9519-7
[]
J 9519-9
11.
5.
=====
J 9519-18
J34013-115
12.
J 9519-23
6.
1.
2.
3.
4.
5.
6.
7.
J 34013-218
BALL JOINT REMOVER

STRUT SPRING COMPRESSOR
STRUT COMPRESSOR ADAPTER
MODULAR SHOCK ASSEMBLY COMPRESSOR ADAPTER
MODULAR SHOCK ASSEMBLY ALIGNMENT ROD
MODULAR SHOCK SUPPORT
BALL JOINT/TIE ROD SEPARATOR
13.
J 6627-A
8. MODULAR SHOCK NUT REMOVAL SET,

15 mm (0.60 INCH)
9. BALL JOINT REMOVER
10. BALL JOINT INSTALLER
11. BALL JOINT PRESSING SCREW
12. BALL JOINT "C" CLAMP
13. WHEEL STUD REMOVER
PC0014-3C-F-RP
REAR SUSPENSION 30-1
SECTION 30
REAR SUSPENSION
not used, and those requiring thread locking compound will be called out. The correct torque value must be used
result.
CONTENTS
General Description . . . . . . . . . . . . . . . . . . . . . . . . 3D-1
Rear Axle Suspension . . . . . . . . . . . . . . . . . . . . 3D-1
On-Vehicle Service . . . . . . . . . . . . . . . . . . . . . . . . 3D-1
Rear Axle Housing . . . . . . . . . . . Refer to Section 4 B
Jounce Bumper Assembly . . . . . . . . . . . . . . . . . 3D-1
Lower Control Arm Bushing Assembly . . . . . . 3D-1
Rear Springs . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3D-3
Rear Spring Seat . . . . . . . . . . . . . . . . . . . . . . . . 3D-4
GENERAL DESCRIPTION
REAR AXLE SUSPENSION
Figure 1
The rear axle assembly ( 13) is attached to the vehicle
with a link suspension system. The rear axle housing is
connected to the floor panel assembly (7) by two lower
control arm assemblies (6) and a tie rod assembly (11 ). A
single torque arm (8) is used in place of an upper control
arm assembly. It is rigidly mounted to the rear axle
housing at the rear and through a torque arm bushing
assembly to the transmission assembly at the front. On
some vehicles, the torque arm (8) is also mounted to the
propeller shaft assembly (9) with two bolts/screws. Rear
springs (4) are used to support the weight of the vehicle,
and ride control is provided by shock absorber assemblies
(lO)mounted to the rear of the rear axle housing. A stabilizer shaft (5) is also part of the suspension system.
The shock absorber assemblies (10) are mounted at
the bottom with a nut to brackets welded to the rear of
the rear axle housing, and at the top to the floor panel
assembly with a nut. The only service the shock absorber
assemblies require is replacement if they have lost their
resistance, are damaged or are leaking fluid. For shock
absorber assembly diagnosis, refer to SECTION 3.
Tie Rod Assembly . . . . . . . . . . . . . . . . . . . . . . . 3D-4

Lower Control Arm Assembly . . . . . . . . . . . . . 3D-5
Torque Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3D-6
Stabilizer Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . 3D-8
Stabilizer Shaft Bracket and Link Assembly . . . 3D-9
Shock Absorber Assembly . . . . . . . . . . . . . . . . . 3D-9
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3D-10
Fastener Tightening Specifications . . . . . . . . . 3D-10
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3D-11
l+-+I Remove or Disconnect

2. Support rear axle assembly (13).
4. Bumper assembly (1).
1-++I Install or Connect

NOTICE: See "Notice" on page 3D-1 of this
section.
1. Bumper assembly (1) to bumper reinforcement.
l~I Tighten
3. Remove rear axle assembly support.
4. Lower vehicle.
LOWER CONTROL ARM BUSHING

ASSEMBLY
Figures 3 and 4
ON-VEHICLE SERVICE
Important
JOUNCE BUMPER ASSEMBLY

Figure 2
The jounce bumper assembly is located on top of the
rear axle housing.
If both lower control arm assemblies are being

replaced, remove and replace one control arm
assembly at a time to prevent the rear axle assembly
from rolling or slipping sideways, making replacement difficult.
30-2 REAR SUSPENSION
A
B
1
2
3
4
5
6
7
8
9
10
11
12
13
LONGITUDINAL REINFORCEMENT
WITH REAR DISC BRAKES
BUMPER ASSEMBLY, REAR SUSPENSION JOUNCE
BOLT/SCREW, REAR AXLE BUMPER, 27 Nm (20 LB. FT.)
INSULATOR ASSEMBLY, REAR SPRING UPPER
SPRING, REAR
SHAFT, REAR STABILIZER
ARM ASSEMBLY, REAR AXLE LOWER CONTROL
PANEL ASSEMBLY, FLOOR
ARM, REAR AXLE TORQUE
SHAFT ASSEMBLY, PROPELLER
ABSORBER ASSEMBLY, REAR SHOCK
ROD ASSEMBLY, REAR AXLE TIE
BRACE ASSEMBLY, REAR AXLE TIE ROD BRACKET
AXLE ASSEMBLY, REAR
Figure 1 - Rear Axle Suspension (Typical)
PC00013D-F-RP
J 21474-23
J 21474-5
A PRESS
PC0003-3DFRP
Figure 3 - Removing Lower Control Arm Bushing Assembly
A PRESS
A LONGITUDINAL REINFORCEMENT
B REINFORCEMENT, REAR SUSPENSION JOUNCE
BUMPER ASSEMBLY
1 BUMPER ASSEMBLY, REAR SUSPENSION JOUNCE
2 BOLT/SCREW, REAR AXLE BUMPER, 27 Nm (20 LB. FT.)
13 AXLE ASSEMBLY, REAR
PC0002-3Df..RP
PC0004-3D-F-RP
Figure 2 - Jounce Bumper Assembly
Figure 4 - Installing Lower Control Arm Bushing Assembly
!++! Remove or Disconnect
1.
2.
3.
4.
5.
Tools Required:
J 21474-5 Receiver
J 21474-20 Installer
J 21474-23 Remover
Support rear axle assembly.
Lower control arm assembly. Refer to "Lower
Control Arm Assembly" in this section.
Place J 21474-5 over flanged side of bushing
assembly.
Use arbor press to force bushing assembly out of
arm, using large OD of driver such as J 21474-23
contacting OD of outer sleeve.

1. Reverse tool. See Figure 4.
2. Place J 21474-5 over flanged side of bushing

assembly.
3. Bushing assembly into position with J 21474-20.
4. Lower control arm assembly. Refer to "Lower
Control Arm Assembly" in this section.
6. Lower vehicle.
REAR SPRINGS
Figure5

Important
When raising vehicle, do not use twin post type

hoist.

2. Support rear axle assembly (13) with adjustable
lifting device.
3. Shock absorber nuts from rear axle assembly. Refer
to "Shock Absorber Assembly" in this section.
4. Lower rear axle assembly (13).
NOTICE: Do not suspend rear axle assembly by
brake hose assembly. Damage to hose assembly
could result.
5. Upper insulator assembly (15).
6. Rear spring (4 ).
~~6.3mm+6.3mm
II
(0.25" 0.25")
( ,~ If:...
-1V-IE_W_A
....I
4
15

1. Rear spring (4) to rear axle assembly (13).
rn
2.
3.
4.
5.
6.
Important
It is important not to chip or damage the corrosion protection coating on the rear spring.
Avoid contact with hard steel. If coating has
been chipped or damaged, do not use rear
spring until it has been replaced.
Upper insulator assembly (15) to rear spring (4).
Raise rear axle assembly (13).
Shock absorber nuts to rear axle assembly. Refer to
"Shock Absorber Assembly" in this section.
Remove rear axle assembly support.
Lower vehicle.
REAR SPRING SEAT

Figure 5

rn
2.
3.
4.
5.
6.
4
13
14
15
SPRING, REAR
AXLE ASSEMBLY, REAR
SEAT, REAR SPRING
INSULATOR ASSEMBLY, REAR SPRING UPPER
PC0005-3DF-RP
Figure 5 - Rear Spring and Upper Insulator Assembly
Important

hoist.
Support rear axle assembly (13) with an adjustable
lifting device.
Shock absorber nuts from rear axle assembly Refer
to "Shock Absorber Assembly" in this section.
Lower rear axle assembly (13).
NOTICE: Do not suspend rear axle assembly by
brake hose assembly. Damage to hose assembly
could result.
Upper insulator assembly and rear spring. Refer to
"Rear Spring" in this section.
Spring seat (14).

1. Position spring seat (14).
2. Rear spring and upper insulator assembly. Refer to
"Rear Spring" in this section.
3. Raise rear axle assembly (13).
4. Shock absorber nut to rear axle assembly. Refer to

"Shock Absorber Assembly" in this section.
6. Lower vehicle.
TIE ROD ASSEMBLY

Figure 6

3. Bolt/screw ( 17) and nut (49).
4. Bolts/screws (16 and 18) and nuts (19).
5. Tie rod assembly (11).
6. Brace assembly (12).
REAR SUSPENSION 305
A
B
11
12
13
16
17
18
19
49
UNDERBODY BRACE BRACKET (LEFT-HAND SIDE)

UNDERBODY BRACE BRACKET (RIGHT-HAND SIDE)
ROD ASSEMBLY, REAR AXLE TIE
BRACE ASSEMBLY, REAR AXLE TIE ROD BRACKET
AXLE ASSEMBLY, REAR
BOLT/SCREW, REAR AXLE TIE ROD BRACKET,
47 Nm (35 LB. FT.)
BOLT/SCREW, REAR AXLE TIE ROD
BOLT/SCREW, REAR AXLE TIE ROD BRACKET
NUT, REAR AXLE TIE ROD, 102 Nm (75 LB. FT.)
NUT, REAR AXLE TIE ROD, 102 Nm (75 LB. FT.)
PC0006-3D-F-RP
Figure 6 - Tie Rod Assembly

NOTICE: See "Notice" on page 30-1 of this
section.
1. Position brace assembly (12) to right-hand underbody brace bracket.

2. Hand tighten one bolt/screw (18) and one nut (19).
3. Position tie rod assembly (11) to right-hand underbody brace bracket.
4. Hand tighten other bolt/screw (18) and other nut
(19).
5. Bolts/screws (16 and 18) and nuts (19).
l~I
Tighten

Nuts (19) to 102 Nm (75 lb. ft.).
6. Bolt/screw (17) and nut (49).
l~I
Tighten
Nut (49) to 102 Nm (75 lb. ft.).

7. Rear axle assembly support.
8. Lower vehicle.

Figure 7
[I] Important
If both lower control arm assemblies are being
replaced, remove and replace one arm at a time to
prevent rear axle assembly from rolling or slipping
sideways, making replacement difficult.

22
f FAT
20-
A
A FRONT OF LOWER CONTROL ARM ASSEMBLY
(RIGHT-HAND SHOWN LEFT-HAND OPPOSITE)
B REAR OF LOWER CONTROL ARM ASSEMBLY
(RIGHT-HAND SHOWN LEFT-HAND OPPOSITE)
C PAN ASSEMBLY, UNDERBODY
6 ARM ASSEMBLY, REAR AXLE LOWER CONTROL

20 BOLT/SCREW, REAR AXLE LOWER CONTROL ARM,
108 Nm (80 LB. FT.)
21 WASHER, REAR SUSPENSION CONTROL ARM

22 NUT, REAR AXLE LOWER CONTROL ARM,
82 Nm (60 LB. FT.)
PC0007-3D-FRP
Figure 7 - Lower Control Arm Assembly
3. Bolts/screws (20), nuts (22) and washers (21) from

rear axle assembly (13).
4. Bolts/screws (20), nuts (22) and washers (21) from
underbody pan assembly.
5. Lower control arm assembly (6).
!++f Install or Connect

NOTICE: See "Notice" on page 3D-l of this
section.
TORQUE ARM
!++f Remove or Disconnect

2. Support rear axle assembly (13) with an adjustable
lifting device.
[I] Important
1. Position lower control arm assembly (6) to rear axle

assembly (13) and underbody pan assembly.
[I] Important
3.
Do not tighten bolts/screws (20) and nuts (22)

unless the suspension is at curb height position.
2. Bolts/screws (20), nuts (22) and washers (21) to rear
axle assembly (13) from inboard side out.
l~I
4.
5.
Tighten
6.
Nuts (22) to 82 Nm (60 lb. ft.).
7.
8.
9.

4. Lower vehicle.

hoist.
Torque arm from propeller shaft assembly, if
equipped with split propeller shaft assembly. Refer
to SECTION 4A.
Bolts/screws (23), washers (24) and nuts (25) from
rear axle assembly (13).
Bolts/screws (28, 29 and 30) and nuts (27) from
automatic transmission assembly, if equipped.
Bolts/screws (29 and 30) and nuts (27) from manual
transmission assembly, if equipped.
Outer bracket assembly (31 ).
Inner bracket assembly (32).
Torque arm (8).
23

section.
13
1. Position inner bracket assembly (32) through transmisson assembly.

s~!t===--24
2. Position outer bracket assembly (31) to inner

bracket assembly (32) and loosely install nuts (27),
and bolts/screws (28, 29 and 30).
3. Insert torque arm (8) into bracket assemblies (31 and
32).
4. Nuts (27) and bolts/screws (28, 29 and 30).
24
l~I
Tighten
Nuts (27) to 41 Nm (30 lb. ft.).

Bolts/screws (28 and 30) to 50 Nm (37 lb. ft.).
8 ARM, REAR AXLE TORQUE
23 BOLT/SCREW, REAR AXLE TORQUE ARM,
130 Nm (96 LB. FT.)
24 WASHER, REAR AXLE TORQUE ARM
25 NUT, REAR AXLE TORQUE ARM, 132 Nm (97 LB. FT.)
PC0008-3D-F-RP
Figure 8 - Torque Arm to Rear Axle Assembly
5. Position torque arm (8) to rear axle assembly (13).

6. Bolts/screws (23), washers (24) and nuts (25).
l~I
Tighten

Nuts (25) to 132 Nm (97 lb. ft.).
7. Torque arm to propeller shaft assembly, if equipped
with propeller shaft assembly. Refer to SECTION
4A.
8. Rear axle assembly support.
9. Lower vehicle.
27
A
WITH 700 R4 TRANSMISSION
TRANSMISSION ASSEMBLY, AUTOMATIC
BRACKET ASSEMBLY, CATALYTIC CONVERTER
HANGER
27 NUT, REAR AXLE TORQUE ARM BRACKET,
41 Nm (30 LB. FT.)
28 BOLT/SCREW, REAR AXLE TORQUE ARM INNER
A
B
8
26
29 BOLT/SCREW, REAR AXLE TORQUE ARM OUTER

31 BRACKET ASSEMBLY, REAR AXLE TORQUE ARM
OUTER
32 BRACKET ASSEMBLY, REAR AXLE TORQUE ARM INNER
PC0009-3D-F-RP
Figure 9 - Torque Arm to Automatic Transmission Assembly
A
B
C
8
26
27
29
30
31
32
5-SPEED
6-SPEED
TRANSMISSION ASSEMBLY, MANUAL
BRACKET ASSEMBLY, CATALYTIC CONVERTER
HANGER
NUT, REAR AXLE TORQUE ARM BRACKET,
41 Nm (30 LB. FT.)
BOLT/SCREW, REAR AXLE TORQUE ARM OUTER
BOLT/SCREW, REAR AXLE TORQUE ARM INNER
BRACKET ASSEMBLY, REAR AXLE TORQUE ARM
OUTER
BRACKET ASSEMBLY, REAR AXLE TORQUE ARM INNER
30
PC0010-31>-F-RP
Figure 10 - Torque Arm to Manual Transmission Assembly
STABLIZER SHAFT
Figures 11 and 12

2. Nut (41).
3. Link assembly. Refer to "Stabilizer Shaft Bracket
and Link Assembly" in this section.
5. Clamp (37).
6. Insulator (38).
7. Bracket (34).
8. Stabilizer shaft (35).

section.
Important
The stabilizer shaft must be installed with the

bend of the shaft facing down.
1. Place insulator (38) over stabilizer shaft (35).
Important
The slit of the shaft insulator must face the rear

of the vehicle.
2. Position clamp (37) to insulator (38) and stabilizer
shaft (35).
3. Position bracket (39) to rear axle assembly (13).
l~I Tighten
Nuts (36) to 24 Nm (18 lb. ft.).
5. Stabilizer shaft link nut. Refer to "Stabilizer Shaft
Bracket and Link Assembly" in this section.
39
~~
/"" I
40
VIEWA
I
40
39

33 BOLT/SCREW, REAR STABILIZER SHAFT INSULATOR
CLAMP
34 BRACKET, REAR STABILIZER SHAFT ROD
35 SHAFT, REAR STABILIZER
36 NUT, REAR STABILIZER SHAFT INSULATOR CLAMP,
24 Nm (18 LB. FT.)
37 CLAMP, REAR STABILIZER SHAFT INSULATOR
38 INSULATOR, REAR STABILIZER SHAFT
FRTIJ
42
PC00113DFRP
Figure 11 - Stabilizer Shaft
A PAN ASSEMBLY, UNDERBODY
35 SHAFT, REAR STABILIZER
6. Link assembly. Refer to "Stabilizer Shaft Bracket

and Link Assembly" in this section.
7. Lower vehicle.
STABILIZER SHAFT BRACKET AND LINK

ASSEMBLY
39 BRACKET, REAR STABILIZER SHAFT

40 BOLT/SCREW, REAR STABILIZER SHAFT LINK,
23 Nm (17 LB. FT.)
41 NUT, REAR STABILIZER SHAFT LINK, 22 Nm (16 LB. FT.)
42 LINK ASSEMBLY, REAR STABILIZER SHAFT
PC00123DFRP
Figure 12 - Stabilizer Shaft Bracket and Link Assembly
Figure 12

1. Raise and sutiably support vehicle. Refer to SECTION OA.
2. Nut (41).
3. Link assembly (42).
5. Bracket (39).

section.
1. Position bracket (39) to underbody pan assembly.
!~I Tighten
3. Position link assembly (42) to bracket (39).
4. Link assembly (42) and nut (41).
l~I Tighten
Link assembly (42) and nut (41) to 22 Nm
(16 lb. ft.).
5. Lower vehicle.
SHOCK ABSORBER ASSEMBLY

Figure 13

1. Fold down seatback frame assembly.
2. Quarter trim panel assembly. Refer to SECTION
10-6.
3. Pull folding carpet assembly back.

NOTICE: Rear axle assembly must be supported
before removing nut to avoid possible damage to
brake hose lines, tie rod assembly and propeller
shaft assembly.
6. Nut (43).
7. Retainer (44) and upper insulator (45).
8. Retainer (44) and lower insulator (46).
9. Nut (48) from rear axle assembly (13).
10. Shock absorber assembly (4 7).
l++I
Install or Connect

section.
1. Position shock absorber assembly (4 7) to rear axle
assembly (13).
2. Nut (48).
l~I
3.
4.
5.
6.
Tighten
Nut (48) to 90 Nm (66 lb. ft.).

Lower insulator (46) and retainer (44) to shock
Position shock absorber assembly (47) through
underbody pan assembly and seat insulator.
Upper insulator (45) and retainer (44) to shock
Hand start nut (43).
NOTICE: Turning the shock absorber assembly
while tightening the nut could damage the shock
absorber assembly. To prevent damage, keep the
shock asorber assembly stationary when tightening
the nut.
l~I
A
A TYPICAL REAR SHOCK ABSORBER ASSEMBLY
INSTALLATION (RIGHT-HAND SHOWN)
B PAN ASSEMBLY, UNDERBODY
43 NUT, REAR SHOCK ABSORBER, 17 Nm (13 LB. FT.I
44 RETAINER, REAR SHOCK ABSORBER UPPER
INSULATOR
45 INSULATOR, REAR SHOCK ABSORBER UPPER
46 INSULATOR, REAR SHOCK ABSORBER LOWER
47 ABSORBER ASSEMBLY, REAR SHOCK
48 NUT, REAR SHOCK ABSORBER, 90 Nm (66 LB. FT.I
PC0013-3DF-RP
Tighten
Nut (43) to 17 Nm (13 lb. ft.).

8. Lower vehicle.
9. Pull folding carpet assembly down into position.
Figure 13 - Shock Absorber Assembly
10. Quarter trim panel assembly. Refer to SECTION

10-6.
11. Fold seatback frame assembly upright.
SPECIFICATIONS
Rear Axle Bumper Bolt/Screw ......................................... 27 Nm
Rear Axle Lower Control Arm Bolt/Screw .............................. 108 Nm
Rear Axle Lower Control Arm Nut ..................................... 82 Nm
Rear Axle Tie Rod Bracket-to-Left-Hand Brace Bracket Bolt/Screw ........... 47 Nm
Rear Axle Tie Rod-to-Left-Hand Brace Bracket Nut ....................... 102 Nm
Rear Axle Tie Rod-to-Right-Hand Brace Bracket Nut ...................... 102 Nm
Rear Axle Torque Arm Bolt/Screw ..................................... 130 Nm
Rear Axle Torque Arm Bracket Nut ..................................... 41 Nm
Rear Axle Torque Arm Inner Bracket Bolt/Screw (Automatic Transmission
Assembly and Manual Transmission Assembly) ......................... 50 Nm
Rear Axle Torque Arm Inner Bracket Bolt/Screw (Upper)
(Automatic Transmission Assembly Only) .............................. 50 Nm
Rear Axle Torque Arm Nut ........................................... 132 Nm
(20 lb. ft.)
(80 lb.
(60 lb.
(35 lb.
(75 lb.
(75 lb.
(96 lb.
(30 lb.
ft.)
ft.)
ft.)
ft.)
ft.)
ft.)
ft.)
(37 lb. ft.)

(37 lb. ft.)
(97 lb. ft.)

Rear Axle Torque Arm Outer Bracket Bolt/Screw ..........................
Rear Shock Absorber Nut (Lower) ......................................
Rear Shock Absorber Nut (Upper) ......................................
Rear Stabilizer Shaft Insulator Clamp Nut ................................
Rear Stabilizer Shaft Link Bolt/Screw ...................................
Rear Stabilizer Shaft Link Nut .........................................
27 Nm (20 lb.
90 Nm (66 lb.
17 Nm (13 lb.
24 Nm (18 lb.
23 Nm (17 lb.
22 Nm (16 lb.
ft.)
ft.)
ft.)
ft.)
ft.)
ft.)
SPECIAL TOOLS
2.
1.
(lb
9
J 21474-20
J 21474-5
3.
~~
~~
J 21474-23
1. BUSHING RECEIVER
2. BUSHING INSTALLER
3. BUSHING REMOVER
PC0014-3D-F-RP
TIRES AND WHEELS 3E1
SECTION 3E
TIRES AND WHEELS

result.
CONTENTS
General Description . . . . . . . . . . . . . . . . . . . . . . . . 3E-1
Replacement Tires . . . . . . . . . . . . . . . . . . . . . . . 3E-1
All Season Tires ......................... 3E-2
P-Metric Tires . . . . . . . . . . . . . . . . . . . . . . . . . . 3E-2
Tire Chain Usage . . . . . . . . . . . . . . . . . . . . . . . . 3E-2
Tire Placard . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3E-3
Wheel Assemblies . . . . . . . . . . . . . . . . . . . . . . . 3E-3
On-Vehicle Service . . . . . . . . . . . . . . . . . . . . . . . . 3E-4
Wheel Assembly Repair .................. 3E-4
Metric Wheel Nuts and Bolts ............... 3E-4
Wheel Bolt Replacement . . . . . . . . . . . . . . . . . . 3E-4
Front Wheel Bolt . . . . . . . . . Refer to Section 3C
Rear Wheel Bolt . . . . . . . . . . . Refer to Section 4 B
Tire Inflation . . . . . . . . . . . . . . . . . . . . . . . . . . . 3E-4
Wheel Assembly Removal and Installation . . . . 3E-4
Tire and Wheel Assembly Rotation ........ 3E-6
Tire Mounting and Dismounting . . . . . . . . . . . . 3E-6
Steel Wheel Assembly Mounting
Surface Check . . . . . . . . . . . . . . . . . . . . . . 3E-7
Tire Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3E-8

Measuring Wheel Assembly Runout . . . . . . . . . 3E-8
Compact Spare Tire Assembly . . . . . . . . . . . . . 3E-8
Balancing Tire and Wheel Assembly . . . . . . . . 3E-9
General Balance Precautions . . . . . . . . . . . . . 3E-9
Off-Vehicle Balancing . . . . . . . . . . . . . . . . . . 3E-9
On-Vehicle Balancing . . . . . . . . . . . . . . . . . 3E-10
Wheel Balance Weights . . . . . . . . . . . . . . . . 3E-10
Correcting Non-Uniform Tires ........ P,;.. 3E-11
Aluminum Wheel Assemblies ........... ~. 3E-11
Aluminum Wheel Assembly Hub Cap . . . . 3E-11
Aluminum Wheel Assembly Porosity
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3E-11
Aluminum Wheel Assembly
.. Re[inishing . . . . . . . . . . . . . . . . . . . . . . . . 3E-11
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3E-13
Fastener Tightening Specifications . . . . . . . . . 3E-13
Runout Specifications . . . . . . . . . . . . . . . . . . . 3E-13
Tire Pressures ................. ; ........ 3E-13
GENERAL DESCRIPTION
The factory-installed tire and wheel assemblies are
designed to operate satisfactorily with loads up to and
including the full load capacity when inflated to the recommended tire pressures.
Correct tire pressures and driving techniques have
an important influence on tire life. Heavy cornering,
excessively rapid acceleration, and unnecessarily sharp
braking increase tire wear.
REPLACEMENT TIRES
Figure 1
A tire performance criteria (TPC) specification
number is molded in the sidewall near the tire size of all
original equipment tires. This specification number
assures that the tire meets GM's performance standards
for traction, endurance, dimension, noise, handling, rolling resistance, and others. Usually, a specific TPC number is assigned to each tire size.
Replacement tires should be the same size, load
range and construction as the original tires. Replace the
original tires with tires of the same TPC specification
number. Use of any other tire size or type may seriously
affect ride, handling, speedometer/odometer calibration,
KC0001,3E-Y-RC
Figure 1 - Tire Identification
antilock brake system, vehicle ground clearance, and tire

clearance to the body and chassis.
CAUTION: Do not mix different types of
tires on the same vehicle, such as
radial, bias, and bias-belted tires,
3E-2 TIRES AND WHEELS

except in emergencies because vehicle
handling may be seriously affected and
may result in loss of control. This caution does not apply to the compact
spare furnished with the vehicle.
Tires should be replaced when:
They are worn to a point where 1.6 ~m _(1/16 i~ch)
or less tread remains, or cord or fabnc 1s showmg.
To help detect this condition, tires have built-in tread
wear indicators that appear between tread grooves
when tread is worn to 1.6 mm (1/16 inch) or less.
Replace tire when indicators appear in ~wo or more
adjacent grooves at three spots around tire.
Tread or sidewall is cracked, cut or snagged deeply
enough to expose cord or fabric.
Tire has a bump, bulge or split. Slight sid~wall
indentations are normal and should not affect nde.
Tire has a puncture, cut or other d~mage that ~annot
be correctly repaired because of size or location of
damage.
It is recommended that new tires be installed in pairs
on the same axle. If only one tire is replaced, it should be
paired with the tire having the most tread.
ALL SEASON TIRES

Figure 1
Most GM vehicles are now equipped with steel
belted all season radial tires as standard equipment. These
tires qualify as snow tires, with a 37 percent higher av~rage rating for snow traction than non-all season radial
tires used previously. Other perform~nce are~s, sue~ as
wet traction, rolling resistance, tread hfe and air retention,
were also improved slightly. These improvements were
made by changing both tread design and tread compounds_. T~ese tires are i~entified_ by an "M+S"..mol~t:d
in the tire sidewall followmg the size. The suffix MS 1s
also molded in the sidewall after the TPC specification
number.
P-METRIC TIRES
Figure2
All GM vehicles now use passenger-metric (P-metric) sized tires. P-metric tires are available. in tw~ load
ranges: standard load with 210 kPa (30 ps~) max~mum
pressure and extra load with 240 kPa (35 psi) maximum
pressure. Most passenger vehicle tires are standard load.
Most P-metric tire sizes do not have exact corresponding alpha-numeric tire ~ize~. For example,. a
P205/75R15 is not exactly equal m size and load carrymg
capacity to an FR78-15. For this reason, replacement tires
should be of the same TPC specification number (same
size, load range, construction) as those original~y on the
vehicle. If P-metric tires must be replaced with other
sizes a tire dealer should be consulted. Tire companies
can best recommend the closest match of alpha-numeric
to P-metric sizes within their own tire lines.
The metric term for tire pressure is the kilopascal
(kPa). Tire pressure may b_e printed _in both kPa and
pounds per square inch (psi). One psi equals 6.9 kPa.
METRIC TIRE SIZES
TT
P 235
P
T
LT
55
R 16
TIRE TYPE
~ R I MDIAMETER
PASSENGER
ASPECT RATIO
(INCHES)
(SECTION HEIGHT)
14
TEMPORARY
LIGHTTRUCK
(SECTIONWIDTH)
15
SECTION WIDTH
55
16
(MILLIMETERS)
225
235
SECTION
WIDTH
60
65
CONSTRUCTION TYPE
R- RADIAL
B - BIAS - BELTED
D - DIAGONAL (BIAS)
--+-------~
SECTION
HEIGHT
_J
PC0002-3E-F-RP
Figure 2 - Metric Tire Size Format
Refer to the tire placard or "Specifications" in this section for tire pressures.
TIRE CHAIN USAGE

Figure 3
NOTICE: Tire chains should not be used with
P245/50ZR16 or P235/55R16 tires. The chains
could damage the vehicle. Tire chains are only recommended for emergency use or when required by
law.
Due to limited tire-to-body clearance on certain
vehicles, tire chain usage recommendation~ have been
published in the Owner's Manual. When chams are to be
used most current GM vehicles require SAE Class "S"
tire ~hains. These may also be designated as 1100 Series,
Type PL tire chains. These chains are specially designed
to limit the "fly off" effect that occurs when the tire and
wheel assembly rotates.
Manufacturers of tire chains have a specific chain
size for each tire and wheel assembly to ensure proper fit
when installed. Therefore, specific chains should be
obtained for the tire and wheel assemblies on which they
are to be used. Rubber adjusters should not be used to take
up slack or clearance in chains which. are loose due t,o
incorrect size. Always follow the cham manufacturers
installation instructions.
Use of chains may adversely affect vehicle handling.
When tire chains are installed:
Adjust speed to road conditions
Avoid sharp turns
TIRES AND WHEELS 3E-3
ll!I DATE
A~
TYPE "PL"
1100 SERIES, SAE CLASS "S"
TYPE "P"
1200 SERIES, SAE CLASS "U"
r:::=u.a.
KG
c:::::::::JKG
'-
'm
G
LB
GAWARR
.--U..RI
""
---.::::::...,
c:::::::::JKd
THIS VEHICLE CONFORMS TO ALL APPLICABLE

FEDERAL MOTOR VEHICLE SAFE1Y AND
BUMPER STANDARDS IN EFFECT ON THE DATE
OF MANUFACTURE SHOWN ABOVE
MFG BY GENERAL MOTORS CORP

GVRA
GAWRFR
--
...- I
.,HJNTED IN USA
FRT.
......
TIRE-LOADING INFORMATION
OCCUPANTS
VEHICLE CAP. WT.
RR. TOTAL
LBS
KG
CTR.
j.-, .-,
~....----,
L-1
H
_rr
MAX. LOADING@ GVWR SAME AS VEHICLE

PACITY WEIGHT
BBW
COLD TIRE
TIRE SIZE
SPEED
PRESSURE
JT==~
RTG
I ~
I
PSI/KPA
SPAl...=
TYPE "RP"
1800 SERIES, LUG-REINFORCED
G33956-3E-AN
Figure 3 - Examples of Passenger Vehicle Tire Chains
A
B
C
D
E
F
G
H
I
In general, to help prevent chain damage to the

vehicle:
Install chains on rear tire and wheel assemblies as
tightly as possible, then tighten them again after
driving 0.4 to 0.8 km (1/4 to 1/2 mile). Use of chains
on front tire and wheel assemblies is not recommended; chains may contact and possibly damage
vehicle. If chains are to be used on front tire and
wheel assemblies, be sure there is enough clearance.
Do not exceed 70 km/h (45 mph), or chain rnanufacturer 's speed limit, iflower.
Drive in restrained manner and avoid large bumps,
potholes, severe turns and other maneuvers which
could cause tire and wheel assemblies to bounce up
and down.
Follow any other instructions of chain manufacturer
which do not disagree with above.
Additional specific information is published in the
Owner's Manual.
TIRE PLACARD
Figure 4
The tire placard is permanently located on the rear
face of the driver's door, and should be referred to for tire
information. The placard lists the maximum vehicle load,
tire size (including spare), and cold inflation pressure
(including spare).
K
L
M
N
DATE
GROSS VEHICLE WEIGHT RATING
GROSS AXLE WEIGHT RATING FRONT & REAR
CERTIFICATION STATEMENT
VEHICLE IDENTIFICATION NUMBER
VEHICLE CLASS TYPE: "PASSENGER CAR"
MAXIMUM OCCUPANTS
MAXIMUM VEHICLE CAPACITY WEIGHT
MAXIMUM LOADING AT GVWR
TIRE SIZE
SPARE TIRE SIZE
SPEED RATING
TIRE PRESSURE WITH MAXIMUM OCCUPANTS FRONT
&REAR
SPARE TIRE PRESSURE
PC0003-3E-F-RP
Figure 4 - Tire Placard
WHEEL ASSEMBLIES
Wheel assemblies must be replaced if they are bent,
dented, have excessive lateral or radial runout, leak air
through welds, have elongated bolt holes, or if the wheel
nuts will not stay tight. Wheel assemblies with runout
greater than specified may cause objectionable vibrations.
Replacement wheel assemblies must be equivalent
to the original equipment wheel assemblies in load capacity, diameter, rim width, offset, and mounting configuration. A wheel assembly of incorrect size or type may
affect wheel assembly and bearing life, brake cooling,
speedometer/odometer calibration, antilock brake system,
vehicle ground clearance and tire clearance to the body
and chassis.
Steel wheel assemblies can be identified by a two- or
three-letter code stamped into the front side of the rim
near the valve stern assembly. Aluminum wheel assemblies have the code, part number, and manufacturer ID
cast into the inboard side.
3E4 TIRES AND WHEELS
ON-VEHICLE SERVICE
WHEEL ASSEMBLY REPAIR
Wheel assembly repairs that use welding, heating or
peening ~re not appr<?ved. An inner tube is not an acceptable repa1r for leaky t1re and wheel assemblies. Porosity in
aluminum wheel assemblies can be repaired. Refer to
"Aluminum Wheel Assembly Porosity Repair" in this
section.
METRIC WHEEL NUTS AND BOLTS

A metric wheel nut is identified by the word "Metric" stamped on its face. The wheel bolt has the letter
"M" stamped into its end. The thread size of the metric
wheel nuts and bolts are indicated by a code, such as M12
x 1.5.
POUNDS PER SQUARE INCH (psi)

TO KILOPASCALS (kPa)
psi
20
23
24
26
28
29
30
32
35
38
40
41
45
50
kPa
psi
140
55
60
160
170
65
70
180
75
190
80
200
210
85
90
220
240
95
100
260
105
280
110
280
115
310
120
340
CONVERSION: psi x 6.895 = kPa
kPa
380
420
450
480
520
550
590
620
660
690
720
760
790
830
PC00083E-F-RP
WHEEL BOLT REPLACEMENT

CAUTION: If any wheel bolt is damaged
by a loose-running wheel assembly, all
the bolts for that wheel assembly
should be replaced. A loose-running
wheel assembly may break only one
bolt, but the other bolts may be damaged internally. Replacing only the broken bolt and remounting the wheel
assembly may cause further damage
and personal injury.
Front Wheel Bolt

For the front wheel bolt replacement procedure,
refer to SECTION 3C.
Rear Wheel Bolt

For the rear wheel bolt replacement procedure, refer
to SECTION 4B.
TIRE INFLATION
Figure 5
The pressure recommended for all models is carefully calculated to give a comfortable ride, responsive
steering, and maximum tread wear, tire life and resistance
to ~mises. Valve stem assembly caps or extensions should
be mstalled on the valve stem assemblies to keep out dust
and water.
Tire pressure, with tires cold (after vehicle has sat
for three hours or more, or driven less than one mile),
shou~d be checked monthly or before any extended trip.
Set t1re pressure to the specifications on the tire placard
located on the rear face of driver's door or in "Tire Pressures" in this section. Tire pressure will increase about 6.9
kPa (1 psi) for every 5.5C (10F) temperature increase.
For sustained high-speed driving, tires should be set
at the pressures recommended. Sustained driving at high
speeds, where permitted by law, is not advised unless
vehicle has special high-speed tires.
Tire pressure which is higher than that recommended can cause:
Hard ride.
Figure 5 - Inflation Pressure Conversion
Reduced handling.
Tire bruising or carcass damage.
Rapid tread wear at center of tire.
Tire pressure which is lower than that recommended
can cause:
Tire squeal on turns.
Hard steering.
Rapid and uneven wear on edge of tread.
Tire rim bruises and rupture.
Tire cord breakage.
High tire temperatures.
Reduced handling.
High fuel consumption.
Unequal tire pressure on same axle can cause:
Uneven braking.
Steering lead.
Reduced handling.
Swerve on acceleration.
WHEEL ASSEMBLY REMOVAL AND

INSTALLATION
Figures 6 and 7
Penetrating oil has not been found to be effective in
removing tight wheel assemblies. However, if it is used, it
should be applied sparingly to the wheel assembly centerhole area only.
CAUTION: If penetrating oil gets on the
vertical surfaces between the wheel
assembly and the rotor assembly or
brake drum, it could cause the wheel
assembly to work loose as the vehicle
is driven, resulting in a loss of control
and an injury accident. Never use heat
to loosen a tight wheel assembly. It can
shorten the life of the wheel assembly,
studs, or spindle and bearing assemblies. Wheel nuts must be tightened in
sequence and to the proper torque to
10
13
A
10
14
A WHEEL ASSEMBLY, 16 x 7.5 ALUMINUM

B WHEEL ASSEMBLY, 16 x 8 STYLED ALUMINUM
9 BOLT, WHEEL
10 WHEEL ASSEMBLY, TIRE AND
11 NUT, WHEEL, 140 Nm (100 LB. FT.)
12 NUT, SPECIAL SECURITY WHEEL LOCK, 140 Nm
(100 LB. FT.)
13 CAP ASSEMBLY, HUB, 6 Nm (53 LB. IN.)
14 CAP ASSEMBLY, HUB, 6 Nm (53 LB. IN.)
B
PC20093E-F-RP
Figure 6 - Tire and Wheel Assembly
avoid bending the wheel assembly or

rotor assembly.
Sometimes wheel assemblies can be difficult to
remove due to foreign material or a tight fit between the
wheel assembly centerhole and the rotor assembly. Excessive force such as hammering the wheel assembly or tire
can cause damage and is not recommended. Slight tapping
on the tire sidewall using a large rubber mallet is acceptable.
The wheel assembly can be removed without damage as follows:
1. Retighten all wheel nuts on affected wheel assembly. Then loosen each nut two turns. Rock vehicle
from side to side. If this is not effective, go to step 2.
2. Rock vehicle from "DRIVE" to "REVERSE" allowing vehicle to move several feet in each direction. Apply quick, hard jabs on the brake pedal
assembly to loosen wheel assembly. If wheel assembly still does not loosen, then rock vehicle again
from side to side as hard as possible using one or
more person's body weight. If wheel assembly is
still tight, repeat procedure.

2. Wheel nut caps, if equipped.
3. Hub cap assembly (13 or 14).
4. Special security wheel lock nut (12), if equipped.
Use special security wheel lock key, located in

the front floor console assembly.
5. Wheel nuts (11).
Mark location of the tire and wheel assemblies
(10) to the hub assembly.
6. Tire and wheel assembly (10).
l~I Clean
CAUTION: Before installing a wheel
assembly, remove any buildup of corrosion on the wheel assembly mounting
surface and brake drum or rotor assembly by scraping and wire brushing.
Installing wheel assemblies without
good metal-to-metal contact at the
mounting surfaces can cause wheel
nuts to loosen, which may later allow
the wheel assembly to come off while
the vehicle is in motion.
Wheel nuts (11), bolts (9), wheel assembly
(10) and brake drum or rotor assembly mounting surfaces.

NOTICE: See "Notice" on page 3E-1 of this
section.
1. Tire and wheel assembly (10).
CAUTION: Never use oil or grease on
bolts or wheel nuts. Tighten the wheel
nuts with your fingers until they are
....
t-
a:
LL
KC0044-3E-Y-RC
Figure 7 - Five-Hole Wheel Nut Tightening Sequence
snug. Then, tighten the wheel nuts (in

the sequence shown) to the specified
torque. Refer to "Specifications" in this
section. Improperly tightened wheel
nuts could eventually allow the wheel
assembly to come off while the vehicle
is moving, possibly causing loss of
control, personal injury and property
damage.
2. Wheel nuts (11).
l~I
Tighten
Nuts (11) in sequence to 140 Nm (100 lb. ft.)

(Figure 7).
3. Special security wheel lock nut (12), if equipped.
Use special security wheel lock key located in
front floor console assembly.
l~I
t-
a:
LL
lI il
B
A NORMAL FOUR-WHEEL ROTATION PATTERN FOR
TIRES DESIGNED TO ROLL IN EITHER DIRECTION
B SPECIAL FOUR-WHEEL ROTATION PATTERN FOR
DIRECTIONAL TIRES DESIGNED TO ROLL MAINLY IN
ONE DIRECTION
IMPORTANT: DO NOT INCLUDE COMPACT SPARE TIRE
ASSEMBLY IN ROTATION
PC0004-3E-F-RP
Figure 8 - Tire and Wheel Assembly Rotation
Tighten
Nut (12) to 140 Nm (100 lb. ft.).

4. Hub cap assembly (13 or 14).
l~I
....
Tighten
Cap assembly (13 or 14) to 6 Nm (53 lb. in.).

5. Wheel nut caps, if equipped.
6. Lower vehicle.
Tire and Wheel Assembly Rotation

Figures
To equalize wear, rotate tires at intervals specified in
SECTION OB. Whenever uneven tire wear is noticed, the
cause should be investigated. Figure 8 shows the only
methods of tire and wheel assembly rotation recommended.
Due to their design, radial tires tend to wear faster in
the shoulder area, particularly in drive locations. Radial
tires in non-drive locations may develop an irregular wear
pattern that can generate tire noise. This wear makes regular rotation especially important.
Always use a four-wheel rotation. After rotation, be
sure to check wheel nut torque and set tire pressure. Never
use oil or grease on wheel assembly bolts or nuts.
On vehicles with P245/50ZR16 tires, special rotation provisions must be followed because the tires are
directional. See Figure 8 for the recommended rotation.
Rotate the tires. If you have directional tires, be sure
the color-coded arrows on the tires point in the direction
the tires roll. Balance the tire and wheel assemblies using
nylon-coated wheel balance weights. Adjust tire pressures
and tighten wheel nuts to the specified torque. Refer to
"Wheel Assembly Removal and Installation" in this section.
TIRE MOUNTING AND DISMOUNTING

Figure 9
Use a tire changing machine to mount or dismount
tires. Follow the equipment manufacturer's instructions.

rings of the tire to be sure they show around the rim
flanges on both sides of the wheel assembly.
Steel Wheel Assembly Mounting Surface

Check
TIRE LOCATING RING
KC0058-3E-Y-RC
Figure 9 - Tire Locating Ring
Do not use hand tools or tire irons to change a tire as they

may damage the tire beads, wheel assembly rim or
flanges.
NOTICE: Do not lubricate the tire beads or wheel
assembly rim with a lubricant containing silicone.
Silicone will allow the tire to rotate on the wheel
assembly rim, throwing the tire and wheel assembly
out of balance.
NOTICE: Do not attempt to break the tire bead
loose before the tire has completely deflated. It takes
about 70 seconds for the air to completely exhaust
from a large tire. If the valve stem assembly is removed before this amount of time, the bead breaker
on the tire changing machine could put enough force
on the tire to bend the wheel assembly at the mounting surface. This could result in vibration, shimmy
and cracking of the wheel assembly. Completely deflate the tire before attempting to break the tire
bead loose.
Rim bead seats should be cleaned with a wire brush
or coarse steel wool to remove old rubber and light rust or
corrosion. Before mounting or dismounting a tire, the
bead area should be well-lubricated with GM PIN
9985555 (50 percent lubricant and 50 percent water) or
equivalent.
CAUTION: To avoid serious personal
injury, do not stand over the tire when
inflating. The bead may break when it
snaps over safety hump. Do not exceed
280 kPa (40 psi) pressure when inflating any tire if beads are not seated. If
280 kPa (40 psi) pressure will not seat
beads, deflate, relubricate and inflate.
Overinflation may cause the bead to
break and cause serious personal
injury.
After mounting, inflate tire so that beads are completely seated, but never exceed 280 kPa (40 psi).
rn
Important
When mounting blackwall tires, be sure the TPC

specification number faces the outboard side of the
vehicle.
Install the valve stem assembly and inflate to the
pressure specified on the tire placard. Check the locating
Figures 10 and 11
1. Pl~ce straight edge (a~out eight to nine inches long)
with both hands on mboard mounting surface of
wheel assembly.
2. Try to rock straight edge up and down.
The outer ring of mounting surface is normally
raised above everything else inside it. If surface has been bent on a tire changer, it will be
raised above outer ring and straight edge will
rock on this position.
3. Repeat steps 1 and 2 at three or four different positions on inboard mounting surface.
4. If wheel assembly is bent, it must be replaced. Refer
to "Wheel Assembly Removal and Installation" in
this section.
A
B
A STRAIGHT EDGE CHECK
B OUTER RING
PC0006-3E-F-RP
Figure 10 - Steel Wheel Assembly Mounting Surface Check
~. .~.i2~
B
A
B
C
D
ORIGINAL WHEEL MOUNTING SURFACE

BENT WHEEL MOUNTING SURFACE
STRAIGHT EDGE
GAP
PC0007-3E-F-RP
Figure 11 - Steel Wheel Assembly Mounting Surface
3E8 TIRES AND WHEELS
TIRE REPAIR
There are many different materials and techniques
on the market to repair tires, but not all work on some
types of tires. Tire manufacturers have published detailed
instructions on how and when to repair tires. The instructions can be obtained from the tire manufacturer. Repair
of compact spare tire is not recommended.
MEASURING WHEEL ASSEMBLY RUNOUT
INBOARD SIDE
OUTBOARD SIDE
MEASURING WHEEL ASSEMBLY RUNOUT

Figure 12
Wheel assembly runout should be measured with an
accurate dial indicator. Measurements may be taken with
the wheel assembly installed on the vehicle, or off the
vehicle using an accurate mounting surface such as a
wheel balancer. Measurements may be taken with or without the tire mounted on the wheel assembly.
Radial runout and lateral runout should be measured
on both the inboard and outboard rim flanges. With the
dial indicator firmly in position, slowly rotate the wheel
assembly one revolution and record the total indicator
reading. If any measurement exceeds specifications, and
there is a vibration that wheel balancing will not correct,
the wheel assembly should be replaced. Disregard any
indicator readings caused by welds, paint runs, or
scratches.
Steel Wheel Assemblies
- Radial runout 1.01 mm (0.040 inch)
- Lateral runout 1.14 mm (0.045 inch)
Aluminum Wheel Assemblies
- Radial runout 0. 76 mm (0.030 inch)
- Lateral runout 0.76 mm (0.030 inch)
COMPACT SPARE TIRE ASSEMBLY

Figure 13
rn
Important
Use of compact spare may result in activating a

wheel sensor fault code. This will result in "ANTILOCK" warning lamp turning on and deactivation
of antilock brake system. After replacing compact
spare, recycling ignition switch will reset system.
NOTICE: If the compact spare is used as a rear tire,
do not drive faster than 80 km/h (50 mph). Damage
to the .rear .axle assembly may occur if the compact
spare 1s dnven faster than 80 km/h (50 mph). This
speed limitation does not apply when the compact
spare is used as a front tire.
Some vehicles will be equipped with a high-pressure
compact spare. The compact spare uses a narrow 4-inch
wide rim, although the wheel assembly diameter is usually one inch larger than the road wheel assemblies.
NOTICE: The compact spare wheel assembly
should not be used with standard tires, snow tires,
wheel covers or trim rings. If such use is attempted,
damage to these items or other parts of the vehicle
may occur. The compact spare should be used only
on vehicles that offer it as original equipment.
RADIAL RUNOUT
IF WHEEL ASSEMBLY DESIGN MAKES THIS OUTBOARD

MEASUREMENT IMPOSSIBLE, THE INBOARD SIDE
ONLY MAY BE USED.
TIRE REMOVED FROM WHEEL ASSEMBLY

RADIAL RUNOUT
INBOARD SIDE
RADIAL RUNOUT
OUTBOARD SIDE
PC0001-3EB-RP
Figure 12 - Wheel Assembly Runout
Inflation pressure of the compact spare must be periodically checked and maintained at 420 kPa (60 psi). It
can be mounted and dismounted from its wheel assembly
using present tire-changing equipment and procedures.
As with other tires, the beads should completely seat at
280 kPa (40 psi).
CAUTION: To avoid serious personal

injury, do not stand over tire when in
flating. Bead may break when it snaps
over safety hump. Do not exceed 280
kPa (40 psi) pressure when inflating
any tire, including compact spares, if
beads are not seated. If 280 kPa (40 psi)
pressure will not seat beads, deflate,
relubricate and inflate. Overinflation
may cause bead to break and cause
serious personal injury.
The compact spare is designed to weigh less than
standard tires and is easier to handle when need arises.
Check inflation pressure as soon as practical after installing compact spare and adjust to 420 kPa (60 psi).
Replacement of the compact spare should be made only
by an authorized tire dealer.
NOTICE: Do not take the vehicle through an automatic car wash with the compact spare installed. The
vehicle may get caught, which could result in property damage.
1 NUT, SPARE WHEEL STOWAGE

5
ADAPTER, SPARE WHEEL STOWAGE
STEM ASSEMBLY, TIRE VALVE
TIRE ASSEMBLY, COMPACT SPARE
JACK ASSEMBLY
COVER ASSEMBLY, JACK STOWAGE
7 BOLT/SCREW, JACK STOWAGE, 6.5 Nm (58 LB. IN.)
8 BOLT/SCREW, SPARE WHEEL STOWAGE
16 NUT, JACK STOWAGE
2
3
4
5
6
16
PC0005-3E-F-RP
Figure 13 - Compact Spare Tire Assembly
BALANCING TIRE AND WHEEL ASSEMBLY

Figures 14 and 15
There are two methods used to balance tire and
wheel assemblies: static and dynamic. Static balance is
the equal distribution of weight around the wheel assembly. Wheel assemblies that are statically unbalanced cause
a bouncing action called tramp.
Dynamic balance is the equal distribution of weight
on each side of the centerline so that when the tire spins
there is no tendency for the wheel assembly to move from
side to side. Wheel assemblies that are dynamically unbalanced may cause shimmy.
.....- ,
-,
CL
OF SPINDLE
HEAVY
SPOT
WHEEL ASSEMBL V TRAMP
General Balance Precautions

CAUTION: It is recommended that eye
pr_otection be used to prevent personal
1n1ury.
Deposits of foreign material must be cleaned from
the inside of the wheel assembly. Stones should be
removed from the tread in order to avoid operator injury
during spin balancing and to obtain a good balance. The
tire and wheel assembly should be inspected for any damage, then balanced according to the equipment manufacturer's recommendations.
Off-Vehicle Balancing
When balancing tire and wheel assemblies off the
vehicle, use a balancer that pilots the wheel assembly by
ADD WHEEL BALANCE

WEIGHTS HERE
CORRECTIVE WHEEL BALANCE WEIGHTS

PC6006-3EDRP
Figure 14 - Static Unbalance Correction
CL OF SPINDLE
WHEEL ASSEMBLY SHIMMY
ADD WHEEL BALANCE

WEIGHTS HERE
mph) as indicated by the speedometer.

This limit is necessary because the
speedometer indicates only one-half of
the actual wheel speed when one drive
wheel assembly is spinning and the
other drive wheel assembly is stopped.
Personal injury and damage may result
from high-speed spinning.
To distinguish between standard rear axle and limited slip, raise rear of vehicle so both tires are clear of
ground. With the transmission in "PARK" (in gear with a
manual transmission) attempt to turn one wheel assembly
by hand. If the wheel assembly can be turned easily, it is a
standard rear axle: if the wheel assembly cannot be turned
easily, it is a limited slip rear axle. Also, check for limited
slip (G80) on the Service Parts Identification label.
Wheel Balance Weights

Figure 16
CORRECTIVE WHEEL BALANCE WEIGHTS
PC6007-3E-D-RP
Figure 15 - Dynamic Unbalance Correction
the centerhole (not the lug holes) if possible. Always follow the equipment manufacturer's instructions. Some
electronic off-vehicle balancers are more accurate than
the on-vehicle spin balancers, but do not correct for rotor
assembly unbalance. If the vibration is not corrected by
the off-vehicle balance, an on-vehicle balance may also be
needed.
On-Vehicle Balancing
When needed, on-vehicle balancing will help correct vibrations due to brake drum, rotor assembly, and
wheel cover imbalance.
When balancing on-vehicle, do not remove the balance weights from the off-vehicle dynamic balance. If
more than one ounce of additional weight is required, it
should be split between the inboard and outboard rim
flanges.
The driven tire and wheel assemblies should be spun
using the engine. Limit speed as stated in the following
caution.
CAUTION: On vehicles equipped with
limited slip rear axles, do not attempt to
balance a tire on a drive wheel assembly with the other drive wheel assembly
on the ground. The vehicle may drive
through this wheel assembly and
cause the vehicle to move unexpected
ly, resulting in personal injury and
property damage.
CAUTION: Do not spin the drive wheel
assemblies faster than 55 km/h (35
When static balancing, if more than 28 grams (1.0

ounce) are needed, the wheel balance weights should be
split as equally as possible between the inboard and outboard flanges.
Assemblies with factory aluminum wheel assemblies must be balanced using special nylon-coated clip-on
wheel balance weights. These weights are designed to fit
over the thicker inboard and outboard rim flanges of the
aluminum wheel assembly and should be installed with a
nylon-coated hammer.
Adhesive wheel balance weights are also available
for aluminum wheel assemblies. Use the following procedure to install adhesive wheel balance weights.
Adhesive Wheel Balance Weight Installation

1. Clean wheel assembly by sanding to bare aluminum
where wheel balance weight is to be located.
2. Wipe wheel balance weight attachment area with
mixture of half isopropyl alcohol and half water. Use
clean cloth or paper towel for this operation.
3. Dry attachment area with hot air. Surface of wheel
assembly should be warm to touch.
A
B
C
D
E
F
CENTERLINE
INSIDE FLANGE
CLIP-ON WEIGHT
ADHESIVE WEIGHT - DYNAMIC
ADHESIVE WEIGHT - STA TIC ONL y
MOUNTING FACE
PC6008-3E-D-RP
Figure 16 - Aluminum Wheel Balance Weight Placement
TIRES AND WHEELS 3E11

4. Warm adhesive backing on wheel balance weights to
room temperature.
5. Remove tape from back of weights. Do not touch
adhesive surface.
6. Apply wheel balance weight and press on with hand
pressure.
7. Secure wheel balance weight with a 70 to 110 N ( 16
to 25 pound) force applied with a roller.
CORRECTING NON-UNIFORM TIRES

There are two ways to correct tires which cause a
vibration even though they are properly balanced. One
method uses an automatic machine which loads the tire
and buffs small amounts of rubber from the stiff spots on
the outer two tread rows. Correction by this method is
usually permanent and, if done properly, does not significantly affect the appearance or tire tread life. Tire truing
for free runout with a blade-type machine is not recommended as this reduces the tread life substantially and
often does not permanently correct the problem.
Another method is to dismount the tire and rotate it
180 degrees on the rim. It is important that this be done
only on tire and wheel assemblies which are known to be
causing a vibration as it is just as likely to cause good tire
and wheel assemblies to vibrate.
Refer to SECTION 3 for more details.
ALUMINUM WHEEL ASSEMBLIES

Aluminum Wheel Assembly Hub Cap

Hub cap.
- Use flat-bladed tool to pry off hub cap by
inserting tool into slot between rim and hub
cap.

Hub cap.
- Use rubber mallet to fully seat hub cap into
rim.
Aluminum Wheel Assembly Porosity Repair

2. Tire and wheel assembly. Refer to "Wheel Assembly Removal and Installation" in this section.
3. Locate leaking areas by inflating tire to 280 kPa (40
psi) and dipping tire and wheel assembly into water
bath.
4. Mark leak areas.
5. Mark tire at valve stem assembly.
6. Tire from wheel assembly. Refer to "Tire Mounting
and Dismounting" in this section.
7. Scuff inside rim surface at leak area with number 80

grit sandpaper and clean area with general purpose
cleaner such as 3M part number 08984 or equivalent.
8. Apply 3 mm (1/8-inch) thick layer of adhesive/sealant, GM PIN 1052366 or equivalent, to leak test area
and allow six hours of drying time.

1. Tire to wheel assembly. Refer to "Tire Mounting
and Dismounting" in this section.
2. Align matchmark on tire with valve stem assembly.
3. Pressurize to 280 kPa (40 psi) and check for leaks.
4. Adjust tire pressure to meet specifications on tire
placard.
5. Balance tire and wheel assemblies. Refer to "Balancing Tire and Wheel Assembly" in this section.
7. Lower vehicle.
Aluminum Wheel Assembly Refinishing

A protective clearcoat or colorcoat is applied to the
surface of original equipment cast-aluminum wheel
assemblies. A surface break-down condition can begin to
develop if frequent, repeated automatic car wash cleaning
scratches or wears off the factory-applied protective clearcoat. Once the protective clearcoat is damaged, exposure
to caustic cleaners and/or road salt further causes surface
break-down. The service procedures detail how to strip,
clean and recoat aluminum wheel assemblies that are
affected by the above condition. Select and follow only
those procedures for the conditions that apply to the wheel
assemblies you are refinishing.
Required Materials
Amchem Alumi Prep number 33, stock number
DX533, or equivalent - cleaning and conditioning
chemical for aluminum.
Amchem Alodine number 1001, stock number
DX501, or equivalent - coating chemical for aluminum.
Ditzler Declear Acrylic Urethane Clear, stock number DAU-75, or equivalent.
Ditzler Delthane Ultra-Urethane Additive, stock
number DXR-80, or equivalent.
Initial Preparation

Matchmark tire for reinstallation of outboard
wheel balance weights after recoating of wheel
assembly.
2. Tire and wheel assembly from vehicle. Refer to
"Wheel Assembly Removal and Installation" in this
section.

3. Outboard wheel balance weights.
l~I Clean
Wheel assembly inside and out with water base allpurpose cleaner. Remove grease or oil with solvent
cleaner.
Accent Color Preparation
Sand over painted areas that do not require recoloring with number 400-grit wet or dry sandpaper to
promote adhesion of clearcoat.
Surface Damage
CAUTION: Do not use vehicle power to
rotate the wheel assembly while sanding or personal injury may result.
1. Mount wheel assembly on brake lathe and spin
slowly.
NOTICE: Do not use abrasive coarser than 80-grit
or wheel assembly may be damaged.
2. Sand wheel assembly with backing block or pad by
holding abrasive flat to surface of wheel assembly
and moving slowly back and forth from center to
outer edge to remove imperfections.
A. First, sand with number 80-grit sandpaper.
B. Follow with number 150-grit sandpaper.
C. Finish with number 240-grit sandpaper.
Slight Clearcoat Damage on Unpainted Wheel
Assemblies
CAUTION: Use of rubber gloves and
eye protection is necessary to prevent
personal injury.
1. Apply chemical stripper.
A. Allow stripper to penetrate coating.
B. Use a small 1/4-inch detail brush dipped in
stripper to apply material around perimeter and
spoke-like areas.
2. Remove stripper, following manufacturer's recommendations.
CAUTION: Do not use vehicle power to
rotate the wheel assembly while sand
ing or personal injury may result.
3. Sand wheel assembly with number 240-grit sandpaper while rotating wheel assembly on slowly spinning brake lathe or by mounting it on vehicle and
spinning by hand.
This restores machined appearance and promotes adhesion of finish coats.

Recoating Procedure
CAUTION: Use of rubber gloves and
eye protection is necessary to prevent
personal injury.
1. Clean surface of contaminants by washing with soap
and water.
2. Spray wheel assembly with Amchem number 33 or
equivalent.
A. Let wheel assembly soak for 1 to 3 minutes.
B. Rinse with water and blow dry.
3. Spray wheel assembly with Amchem number 1001
or equivalent.
A. Let wheel assembly soak for 1 to 3 minutes.
B. Rinse with water and blow dry.
4. Mask off tire.
CAUTION: When applying any two part
component paint system, wear proper
respiratory protection such as Easi-Air
Respirator, part number 06986, or
equivalent. Follow the specific precautions provided by the paint manufacturer. Failure to follow these precautions
may cause lung irritation and allergic
respiratory reaction.
5. Finish wheel assembly with Ditzler Declear Acrylic
Urethane Clear and Ditzler Ultra Urethane-Additive, or equivalents. Refer to labels for specific
directions.
A. First coat - light mist coat, let flash.
B. Second coat - light, let flash.
C. Third coat - heavy duty, wet coat.
6. Let wheel assembly dry for 24 hours or flash for 30
minutes. Force dry at 60C (140F) for 30 minutes
and allow to cool for 30 minutes before mounting.

1. Balance tire and wheel assembly. Refer to "Balancing Tire and Wheel Assembly" in this section.
Replace original wheel balance weights with
nylon-coated wheel balance weights to avoid
discoloration of wheel assembly.
3. Lower vehicle.
SPECIFICATIONS
Hub Cap Assembly- 16 x 7.5 Aluminum Wheel Assembly ................... 6 Nm (53 lb. in.)
Hub Cap Assembly - 16 x 8 Aluminum Wheel Assembly ................... 6 Nm (53 lb. in.)
Jack Stowage Bolt/Screw ............................................ 6.5 Nm (58 lb. in.)
Special Security Wheel Lock Nut ..................................... 140 Nm (100 lb. ft.)
Wheel Nut- M12 x 1.5 ............................................. 140 Nm (100 lb. ft.)
RUNOUT SPECIFICATIONS
Maximum Radial Runout
Steel Wheel Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Aluminum Wheel Assemblies .......................................
Maximum Lateral Runout
Steel Wheel Assemblies ............................................
Aluminum Wheel Assemblies .......................................
1.01 mm (0.040")
0.76 mm (0.030")
1.14 mm (0.045")
0.76 mm (0.030")
TIRE PRESSURES
Compact Spare ....................................................... 420 kPa (60 psi)
Front ............................................................... 210 kPa (30 psi)
Rear ................................................................ 210 kPa (30 psi)
STEERING WHEEL AND COLUMN ON-VEHICLE SERVICE 3F-1
SECTION 3F
STEERING WHEEL AND COLUMN

ON-VEHICLE SERVICE
CAUTION: The procedures in this section must be followed in the order listed to temporarily
disable the Supplemental Inflatable Restraint (SIR) System and prevent false diagnostic
trouble codes from setting. Failure to follow procedures could result in possible air bag
deployment, personal injury, or otherwise unneeded SIR system repairs.
result.
CONTENTS
General Description ........................ 3F-3
Steering Column Assembly . . . . . . . . . . . . . . . . 3F-3
Ignition Lock Systems . . . . . . . . . . . . . . . . . . . . 3F-3
Brake Transmission Shift Interlock (BTSI) . . . . 3F-3
Supplemental Inflatable Restraint (SIR) . . . . . . 3F-3
Steering Wheel Assembly Controls . . . . . . . . . . 3F-3
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3F-4
Repairs and Inspections Required
after an Accident ........... Refer to Section 9J
Ignition Lock Systems .......... Refer to Section 3
Brake Transmission Shift
Interlock (BTSI) . . . . . . . . . Refer to Section 3F5B
Supplemental Inflatable
Restraint (SIR) ........... Refer to Section 9J-A
Steering Wheel Assembly
Controls .............. Refer to Section SA-150
On-Vehicle Service ........................ 3F-4
Service Precautions . . . . . . . . . . . . . . . . . . . . . . 3F-4
Disabling the SIR System . . . . . . . . . . . . . . . 3F-4
Enabling the SIR System . . . . . . . . . . . . . . . . 3F-4
Live (Undeployed) Inflatable Restraint
Steering Wheel Module Assembly . . . . . . 3F-4
Deployed Inflatable Restraint Steering
Wheel Module Assembly . . . . . . . . . . . . . . 3F-4
Inflatable Restraint Steering Wheel Module
Assembly Shipping Procedures ......... 3F-5
Assembly Scrapping Procedures . . . . . . . . 3F-5
Wiring Repairs .... Refer to Sections 8A-5 and 9J-B

Park Lock System . . . . . . . . . . . Refer to Section 7 A
Brake Transmission Shift Interlock
Solenoid Assembly . . . . . . . . Refer to Section 7 A
Ignition Switch and Dimmer
Switch Assembly . . . . . . . . . . . . . . . . . . . . . . 3F-5
Turn Signal Lever Assembly . . . . . . . . . . . . . . . 3F-7
Hazard Warning Switch . . . . . . . . . . . . . . . . . . . 3F-7
Hazard Warning Switch Knob . . . . . . . . . . . . 3F-7
Steering Column Tilt Wheel Release
Lever Assembly . . . . . . . . . . . . . . . . . . . . . . . 3F-7
Inflatable Restraint Steering Wheel
Module Assembly ..................... 3F-7
Steering Wheel Hom Switch Contact Plate
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3F-8
Radio Control Switch Assembly . . . . . . . . . . . . 3F-8
Steering Wheel Assembly . . . . . . . . . . . . . . . . . 3F-9
Centering the SIR Coil
Assembly . . . . . . . . . . . . . . Refer to Section 3F5B
PASS Key Lock Cylinder . . . Refer to Section 3F5B
Steering Gear Coupling Shaft
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 3F-10
Steering Column Assembly Removal . . . . . . . 3F- l 1
Checking Steering Column Assembly
for Accident Damage . . . . Refer to Section 3F5B
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3F-14
Fastener Tightening Specifications . . . . . . . . . 3F-14
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3F-14
3F-2 STEERING WHEEL AND COLUMN ON-VEHICLE SERVICE
1
OR
46
A CONNECTOR, RADIO ASSEMBLY ELECTRICAL

B CONNECTOR, SIR COIL ASSEMBLY ELECTRICAL
c LEAD, HORN
D BUTION, STEERING GEAR COUPLING HEAT SHIELD
1 MODULE ASSEMBLY, INFLATABLE RESTRAINT
STEERING WHEEL
2 WHEEL ASSEMBLY, STEERING
3 BOLT/SCREW, STEERING WHEEL, 2.8 Nm (25 LB. IN.)
4 NUT, STEERING COLUMN UPPER SUPPORT
'
25 Nm (18 LB. FT.)
5 LEVER ASSEMBLY, TURN SIGNAL AND HEADLAMP
DIMMER SWITCH AND CRUISE CONTROL ACTUATOR
AND WINDSHIELD WIPER AND WINDSHIELD WASHER
6 LEVER ASSEMBLY, STEERING COLUMN TILT WHEEL
RELEASE
7 BOLT/SCREW, STEERING COLUMN, 10 Nm (89 LB. IN.)
8 BOLT/SCREW, INTERMEDIATE STEERING SHAFT,
47 Nm (35 LB. FT.)
9 SHAFT ASSEMBLY, STEERING GEAR COUPLING
10 BOLT/SCREW, INTERMEDIATE STEERING SHAFT
47 Nm (35 LB. FT.)
'
11
12
13
14
15
16
17
18
19
20
21
22
23
31
46

BOOT, STEERING GEAR
SHIELD, STEERING GEAR COUPLING HEAT
COVER ASSEMBLY, STEERING COLUMN DASH PANEL
COLUMN ASSEMBLY, STEERING
BOLT/SCREW, STEERING COLUMN GUIDE,
25 Nm (18 LB. FT.)
GUIDE, STEERING COLUMN
BOLT/SCREW, HAZARD WARNING SWITCH KNOB
0.7 Nm (6 LB. IN.)
BUTION, HAZARD WARNING SWITCH
SPRING, HAZARD WARNING SWITCH KNOB
KNOB, HAZARD WARNING SWITCH
NUT, STEERING WHEEL, 43 Nm (32 LB. FT.)
SEALER, STEERING COLUMN
LEVER ASSEMBLY, TURN SIGNAL AND HEADLAMP
DIMMER SWITCH AND WINDSHIELD WIPER AND
WINDSHIELD WASHER
MODULE ASSEMBLY, INFLATABLE RETRAINT
STEERING WHEEL
PC2001-3F-F-RP
Figure 1 - Steering Column Assembly with SIR
STEERING WHEEL AND COLUMN ON-VEHICLE SERVICE 3f3
GENERAL DESCRIPTION
STEERING COLUMN ASSEMBLY
Figure 1
The locking, energy-absorbing column assembly
( 15) includes three important features in addition to the
steering function.
1. In a front-end collision, the energy-absorbing column assembly (15) is designed to collapse, minimizing the possibility of driver injury.
2. The steering column lock and ignition cylinder assembly are conveniently mounted on the column
assembly (15).
3. When locked, the column-mounted lock acts as a
theft deterrent by preventing the operation of both
ignition and steering.
The turn signal lever assembly (5 or 31) (multifunction turn signal lever) controls the turn signals, headlamp
high beam, windshield washer and wipers, and, if
equipped, cruise control.
To ensure the energy-absorbing action, use only the
specified bolts/screws and nuts and tighten them to their
specified torques. Apply a thin coat of lithium grease to
all friction points during reassembly.
When the column assembly (15) is removed from
the vehicle, handle it with special care. Using a steering
wheel puller other than the one recommended in this
manual, hitting the end of the steering gear coupling shaft
assembly (9) sharply, leaning on the column assembly
(15), or dropping the column assembly (15) could shear or
loosen the plastic fasteners that keep the column assembly
(15) rigid.
IGNITION LOCK SYSTEMS

The automatic transmission assembly uses a park
lock system. This system uses a flexible automatic transmission park lock cable assembly which is attached at one
end to the automatic transmission control lever assembly
and at the other end to the ignition switch mounted to the
column assembly where it actuates a locking pin. This
locking pin engages an ignition switch sliding contact
when the lever assembly is in "REVERSE" and does not
allow the ignition switch to move to the "LOCK" position. With the lever assembly in "PARK" and the ignition
switch slider in "LOCK," the locking pin engages a cam
on the cable assembly and prevents the lever assembly
from being moved into another position.
A steering column key release lever assembly is
used on vehicles with a manual transmission assembly. A
manual transmission clutch start switch assembly is used
so the manual transmission clutch pedal assembly must
be depressed before the engine assembly will crank.
When pressure is applied to the brake pedal assembly, the BTSI solenoid assembly is de-energized and releases the automatic transmission control lever assembly.

(SIR)
The supplemental inflatable restraint (SIR) helps
supplement the protection offered by the driver's seat belt
assembly by deploying an air bag from the center of the
steering wheel assembly during certain frontal crashes.
The air bag deploys when the vehicle is involved in a
frontal crash of sufficient force up to 30 degrees off the
centerline of the vehicle. The steering column assembly is
collapsible and should be inspected after an accident
whether or not a deployment has occurred.
The SIR system components in the steering wheel
and steering column assemblies are the inflatable restraint
steering wheel module assembly and the SIR coil assembly. To obtain a detailed description of these components,
refer to SECTION 9J.
STEERING WHEEL ASSEMBLY CONTROLS

Figure2
Steering wheel assembly controls enable remote
control of the following functions, if equipped:
PWR (Power) - Turns radio assembly on or
off.
VOL (Volume) - Adjusts volume of AM/FM
stereo, cassette tape player or compact disc
player.
PRESET - Selects preset stations.
AM/FM - Switches between AM and FM
bands.
SEEK - Seeks the next station, either up or
down.
RCL (Recall) - Toggles the display between
frequency and time.
BRAKE TRANSMISSION SHIFT INTERLOCK

(BTSI)
The brake transmission shift interlock (BTSI) system prevents the driver from shifting out of "PARK"
without simultaneously pressing the brake pedal assembly. When energized, the BTSI solenoid assembly locks
the automatic transmission control lever assembly.
PC20093fF-RP
Figure 2 Steering Wheel Assembly Controls
LUBRICATION
Apply a thin coat of lithium grease to all friction
points when reassembling components.
ON-VEHICLE SERVICE
SERVICE PRECAUTIONS
CAUTION: When performing service on
or around SIR components or SIR wiring, follow the procedures listed below
to temporarily disable the SIR system.
Failure to follow procedures could result in possible air bag deployment,
personal injury or otherwise unneeded
SIR system repairs.
The diagnostic energy reserve module (DERM) can
maintain sufficient voltage to cause a deployment for up
to ten minutes after the ignition switch is turned "OFF"
or the storage battery assembly is disconnected. Many of
the service procedures require disconnection of the "AIR
BAG" fuse and the inflator module circuits from the
deployment loops to avoid an accidental deployment.
Disabling the SIR System

1. Tum steering wheel assembly so vehicle tire and
wheel assemblies are pointing straight ahead.
2. Tum ignition switch to "LOCK."
3. "AIR BAG" fuse from instrument panel fuse block.
4. Left-hand instrument panel sound insulator assembly. Refer to SECTION 8C.
5. Connector position assurance (CPA) and yellow
two-way SIR connector at base of steering column
assembly.
6. Instrument panel compartment door assembly.
7. Connector position assurance (CPA) and yellow
two-way SIR connector located near yellow 24-way
DERM connector on instrument panel wiring harness assembly.
[I] Important
With "AIR BAG" fuse removed and ignition switch
in "RUN," "AIR BAG" warning/indicator lamp on
instrument panel cluster assembly will light. This is
normal operation and does not indicate SIR system
fault.
Enabling the SIR System

2. Yellow two-way SIR connector and connector position assurance (CPA) located near yellow 24-way
3. Instrument panel compartment door assembly, refer

to SECTION 8C.
4. Yellow two-way SIR connector and connector position assurance (CPA) at base of steering column
assembly.
5. Left-hand instrument panel sound insulator assembly, refer to SECTION 8C.
6. "AIR BAG" fuse to instrument panel fuse block.
7. Turn ignition switch to "RUN" and verify "AIR
BAG" warning/indicator lamp flashes seven times
and then turns off. If "AIR BAG" warning/indicator
lamp does not respond as described, refer to SECTION 9J-A.
Live (Undeployed) Inflatable Restraint

Steering Wheel Module Assembly
Special care is necessary when handling and storing
a live (undeployed) inflatable restraint steering wheel
module assembly. The rapid gas generation produced during deployment of the air bag could cause the inflatable
restraint steering wheel module assembly, or another
object placed in front of it, to be thrown through the air in
the unlikely event of an accidental deployment.
CAUTION: When carrying a live inflat
able restraint steering wheel module
assembly, make sure the bag opening
is pointed away from you. Never carry
the inflatable restraint steering wheel
module assembly by the wires or electrical connector on the underside of it.
In case of an accidental deployment,
the bag will then deploy with minimal
chance of injury. When placing a live
inflatable restraint steering wheel mod
ule assembly on a bench or other surface, always face the bag and trim
cover up, away from the surface. Never
rest a steering column assembly on the
steering wheel assembly with the
inflatable restraint steering wheel mod
ule assembly face down and steering
column assembly vertical. This is necessary so that a free space is provided
to allow the air bag to expand in the
unlikely event of accidental deployment.
Deployed Inflatable Restraint Steering

Wheel Module Assembly
After the inflatable restraint steering wheel module
assembly has been deployed, the surface of the air bag
may contain a powdery residue. This powder consists primarily of com starch (used to lubricate the bag as it
inflates) and by-products of the chemical reaction.
Sodium hydroxide dust (similar to lye soap) is produced
as a by-product of the deployment reaction. The sodium
hydroxide then quickly reacts with atmospheric moisture
and is converted to sodium carbonate and sodium bicarbonate (baking soda). Therefore, it is unlikely that sodium
hydroxide will be present after deployment. As with
many service procedures, you should wear gloves and
safety glasses.
STEERING WHEEL AND COLUMN ON-VEHICLE SERVICE 3F5

Assembly Shipping Procedures
IGNITION SWITCH AND DIMMER SWITCH

ASSEMBLY
Service personnel should refer to the latest service

bulletins for proper SIR inflatable restraint steering wheel
module assembly shipping procedures.
Figures 3 and 4

Assembly Scrapping Procedures
During the course of a vehicle's useful life, certain
situations may arise which will necessitate the disposal of
a live (undeployed) inflatable restraint steering wheel
module assembly. This information covers proper procedures for disposing of a live inflatable restraint steering
wheel module assembly.
Before a live inflatable restraint steering wheel module assembly can be disposed of, it must be deployed.
Live inflatable restraint steering wheel module assemblies must not be disposed of through normal refuse channels.
CAUTION: Failure to follow proper supplemental inflatable restraint (SIR)
inflatable restraint steering wheel module assembly disposal procedures can
result in air bag deployment which may
cause personal injury. Undeployed
inflatable restraint steering wheel module assemblies must not be disposed
of through normal refuse channels.
The undeployed inflatable restraint
steering wheel module assembly contains substances that can cause
severe illness or personal injury if the
sealed container is damaged during
disposal. Disposal in any manner
inconsistent with proper procedures
may be a violation of federal, state and/
or local laws.
If a vehicle is the subject of a Product Liability
Report related to the SIR system and is subject to a Preliminary Investigation (GM-1241), DO NOT DEPLOY
the inflatable restraint steering wheel module assembly
and DO NOT ALTER the SIR system in any manner.
Refer to the applicable service bulletin on SIR shipping
procedures for details on handling SIR systems involved
with GM-1241. If a vehicle is the subject of a campaign
affecting inflatable restraint steering wheel module
assemblies, DO NOT DEPLOY the inflatable restraint
steering wheel module assembly. Follow instructions in
the campaign service bulletin for proper disposition of the
inflatable restraint steering wheel module assembly.
If an inflatable restraint steering wheel module
assembly is replaced under warranty, DO NOT DEPLOY
the air bag. The inflatable restraint steering wheel module
assembly may need to be returned, undeployed, to Inland
Fisher Guide. Refer to procedures shown in the appropriate service bulletin regarding SIR shipping procedures.
In situations which require deployment of a live
(undeployed) inflatable restraint steering wheel module
assembly, deployment may be accomplished inside or
outside the vehicle. The method employed depends upon
the final disposition of the particular vehicle. Refer to
SECTION9J.

2. Instrument panel driver knee bolster assembly and
deflector. Refer to SECTION 8C.
3. Disable SIR system. Refer to "Disabling the SIR
4. Ensure steering column lock and ignition cylinder
assembly is in "LOCK" position.
30
COLUMN ASSEMBLY, STEERING

SWITCH, IGNITION
SWITCH ASSEMBLY, DIMMER
BOLT/SCREW, IGNITION SWITCH, 2.5 Nm (22 LB. IN.)
ROD, DIMMER SWITCH ACTUATOR
BOLT/SCREW, DIMMER AND IGNITION SWITCH,
4 Nm (35 LB. IN.)
29 ROD, IGNITION SWITCH ACTUATOR
30 JACKET, STEERING COLUMN
15
24
25
26
27
28
PC0003-3F-F-RP
Figure 3 - Ignition Switch and Dimmer Switch Assembly
24
A LOCK POSITION
24 SWITCH, IGNITION
PC0004-3F-F-RP
Figure 4 - Ignition Switch Adjustment

5. Steering column upper support nuts from steering
column support. Refer to "Steering Column Assembly Removal" in this section.
6. Lower column assembly (15).
7. Electrical connectors from dimmer switch assembly
(25) and ignition switch (24 ).
8. Dimmer switch actuator rod (27).
10. Dimmer switch assembly (25).
12. Ignition switch actuator rod (29).
13. Ignition switch (24).
14. Automatic transmission park lock cable assembly, if
equipped. Refer to SECTION 7A.
l++I
1.
2.
3.
4.
5.
6. Bolt/screw (26).
l~I
Bolt/screw (26) to 2.5 Nm (22 lb. in.).

7. Position dimmer switch assembly (25) to ignition
switch (24).
(el Adjust
Dimmer switch assembly (25).
- Press switch mechanism slightly to insert
3/32-inch drill bit.
- Move dimmer switch assembly (25) to
remove tool.
Install or Connect
NOTICE: See "Notice" on page 3F-1 of this section.
Automatic transmission park lock cable assembly, if
equipped. Refer to SECTION 7A.
Ensure ignition switch (24) is in "LOCK" position.
Move switch slider to extreme right position
and then move slider one detent left.
Ensure steering column lock and ignition cylinder
assembly is in "LOCK" position.
Ignition switch (24) to jacket (30).
Ignition switch actuator rod (29) to ignition switch
(24).
Tighten
l~I
Tighten

9. Dimmer switch actuator rod (27).
10. Electrical connectors to dimmer switch assembly
(25) and ignition switch (24).
11. Raise column assembly (15).
12. Steering column upper support nuts to steering column support. Refer to "Steering Column Assembly
Removal" in this section.
13. Enable SIR system. Refer to "Enabling the SIR System" in this section.
15
15
31
A
A
B
C
D
E
F
5
WITHOUT CRUISE CONTROL

WITH CRUISE CONTROL
TANG
NOTCH
CONNECTOR, LEVER ASSEMBLY ELECTRICAL
CONNECTOR, COLUMN ASSEMBLY ELECTRICAL
15 COLUMN ASSEMBLY, STEERING
WINDSHIELD WASHER
Figure 5 - Turn Signal Lever Assembly
PC0005-3F-F-RP

TURN SIGNAL LEVER ASSEMBLY

Figure 5

1. Steering column tilt wheel release lever assembly, if
equipped with cruise control. Refer to "Steering
Column Tilt Wheel Release Lever Assembly" in
this section.
2. Access cover, if equipped with cruise control.
3. Electrical connectors, if equipped with cruise control.
4. Turn signal lever assembly (5 or 31) by grasping
firmly and pulling straight out.
rn
Important
Important
Be sure the lever assembly (5 or 31) is fully

seated.
3. Electrical connectors, if equipped with cruise control.
4. Access cover, if equipped with cruise control.
5. Steering column tilt wheel release lever assembly, if
equipped with cruise control. Refer to "Steering
Column Tilt Wheel Release Lever Assembly" in
this section.
HAZARD WARNING SWITCH

The hazard warning switch does not require removal
of the steering column assembly for replacement. For service information, refer to SECTION 3F5B.
Hazard Warning Switch Knob

Figure 6

1. Bolt/screw (18).
2. Button (19), spring (20) and knob (21).

PC0006-3F-F-RP
Figure 6 - Removing Hazard Warning Switch Knob
Be sure the wiper switch is in the "OFF" position before installing the turn signal lever
assembly (5 or 31).
1. Position tang on turn signal lever assembly (5 or 31)
to notch in column assembly (15).
2 Turn signal lever assembly (5 or 31) to column
assembly (15).
rn
18 BOLT/SCREW, HAZARD WARNING SWITCH KNOB,

0.7 Nm (6 LB. IN.)
19 BUTTON, HAZARD WARNING SWITCH
20 SPRING, HAZARD WARNING SWITCH KNOB
21 KNOB, HAZARD WARNING SWITCH
1. Knob (21), spring (20) and button (19).

2. Bolt/screw (18).
l~I Tighten
STEERING COLUMN TILT WHEEL RELEASE

LEVER ASSEMBLY
Figure 7

Grip tilt wheel release lever assembly (6) firmly and
twist counterclockwise.

Grip tilt wheel release lever assembly (6) firmly and
twist clockwise.
INFLATABLE RESTRAINT STEERING

WHEEL MODULE ASSEMBLY
Figure 8

2. Loosen bolts/screws (3) from back of steering wheel
assembly (2) using number 30 TORX driver (or
equivalent) until inflatable restraint steering wheel
module assembly (1 or 46) can be released from
steering wheel assembly (2).
3. Inflatable restraint steering wheel module assembly
(1 or 46) from steering wheel assembly (2).
CAUTION: When carrying a live inflatable restraint steering wheel module

assembly, make sure the bag opening

is pointed away from you. Never carry
the inflatable restraint steering wheel
module assembly by the wires or electrical connector on the underside of it.
In case of an accidental deployment,
the bag will then deploy with minimal
chance of injury. When placing a live
inflatable restraint steering wheel module assembly on a bench or other surface, always face the bag and trim
cover up, away from the surface. Never
rest a steering column assembly on the
steering wheel assembly with the
inflatable restraint steering wheel module assembly face down and steering
column assembly vertical. This is necessary so to that a free space is provided to allow the air bag to expand in
the unlikely event of accidental deployment.
4. SIR coil assembly electrical connector and retainer
(32) from inflatable restraint steering wheel module
assembly (1 or 46).
5. Radio control switch electrical connector from inflatable restraint steering wheel module assembly (1
or 46), if equipped.
6. Hom lead from column assembly (15).

1. Hom lead to column assembly (15).
2. Radio control switch electrical connector to inflatable restraint steering wheel module assembly (1 or
46), if equipped.
3. SIR coil assembly electrical connector and retainer

(32) to inflatable restraint steering wheel module
assembly (1 or 46).
4. Secure SIR coil assembly electrical connector to
steering wheel assembly (2) by inserting thick section of wire into existing retainers.
5. Position inflatable restraint steering wheel module
assembly (1 or 46) to steering wheel assembly (2).
rn
Important
Ensure wiring is not exposed or trapped

between inflatable restraint steering wheel
module assembly (1 or 46) and steering wheel
assembly (2).
l~I Tighten
Bolts/screws (3) to 2.8 Nm (25 lb. in.).
7. Enable SIR system. Refer to "Enabling the SIR System" in this section.
STEERING WHEEL HORN SWITCH

CONTACT PLATE ASSEMBLY
Figure9

1. Inflatable restraint steering wheel module assembly.
Refer to "Inflatable Restraint Steering Wheel Module Assembly" in this section.
2. Bolts/screws (37 and 38 or 45).
3. Hom switch contact plate assembly (40 or 44) from
inflatable restraint steering wheel module assembly
(1 or 46).

NOTICE: See "Notice " on page 3F-1 of this section.
1. Position horn switch plate assembly (40 or 44) to
inflatable restraint steering wheel module assembly
(1 or 46).
2. Bolts/screws (37 and 38 or 45).
l~I Tighten
RELEASE
WINDSHIELD WASHER
PC20073FFRP
Figure 7 - Steering Column Tilt Wheel Release Lever

Assembly

RADIO CONTROL SWITCH ASSEMBLY

Figure 9

STEERING WHEEL AND COLUMN ON-VEHICLE SERVICE 3F9
A LEAD, HORN
B CONNECTOR, RADIO ASSEMBLY ELECTRICAL
C CONNECTOR, SIR COIL ASSEMBLY ELECTRICAL
STEERING WHEEL
2 WHEEL ASSEMBLY, STEERING
3 BOLT/SCREW, STEERING WHEEL, 2.8 Nm (25 LB. IN.)
15 COLUMN ASSEMBLY, sr-EERING
32 RETAINER, INFLATABLE RESTRAINT STEERING WHEEL
MODULE WIRING HARNESS ELECTRICAL CONNECTOR
STEERING WHEEL
PC2008-3F-F-RP
Figure 8 - Removing Inflatable Restraint Steering Wheel Module Assembly
2. Steering wheel horn switch contact plate assembly

from inflatable restraint steering wheel module
assembly. See "Steering Wheel Hom Switch Plate
Contact Assembly" in this section.
3. Radio control switch assembly (39) from inflatable
restraint steering wheel module assembly (1).

1. Radio control switch assembly (39) to inflatable
restraint steering wheel module assembly (1).
2. Steering wheel horn switch contact plate assembly
to inflatable restraint steering wheel module assembly. See "Steering Wheel Horn Switch Plate Contact Assembly" in this section.

STEERING WHEEL ASSEMBLY

Figure 10
Tools Required:
J 1859-A Steering Wheel Puller
J 38720 Steering Wheel Puller Bolts (Part of
J 1859-A)

2. Nut (22).
NOTICE: When removing the steering wheel
assembly, use only the specified steering wheel puller. Under no conditions should the end of the steering column shaft be hammered on, as hammering
could loosen the plastic injections which maintain
steering column assembly rigidity
3F10 STEERING WHEEL AND COLUMN ON-VEHICLE SERVICE
2--0
40
38
39
3 - -........@.;,
!
I ~~=----C
41
~ D
A
6
41
44
B
A
B
C
D
1
2
3
37
38
39
WITH RADIO CONTROL SWITCH ASSEMBLY

WITHOUT RADIO CONTROL SWITCH ASSEMBLY
CONNECTOR, RADIO CONTROL SWITCH ELECTRICAL
CONTACT, STEERING WHEEL HORN
MODULE ASSEMBLY, INFLATABLE RESTRAINT
STEERING WHEEL
WHEEL ASSEMBLY, STEERING
BOLT/SCREW, STEERING WHEEL, 2.8 Nm (25 LB. IN.)
BOLT/SCREW, STEERING WHEEL HORN SWITCH
CONTACT PLATE SHOULDER, 2.8 Nm (25 LB. IN.)
BOLT/SCREW, RADIO CONTROL SWITCH,
1.9 Nm (17 LB. IN.)
SWITCH ASSEMBLY, RADIO CONTROL
40 PLATE ASSEMBLY, STEERING WHEEL HORN SWITCH

CONTACT
41 NUT, STEERING WHEEL
42 FILLER, INFLATABLE RESTRAINT STEERING WHEEL
TRIM
43 BOLT/SCREW, INFLATABLE RESTRAINT STEERING
WHEEL MOUNTING PLATE, 1.9 N.m (17 LB. IN.)
44 PLATE ASSEMBLY, STEERING WHEEL HORN SWITCH
CONTACT
45 BOLT/SCREW, STEERING WHEEL HORN SWITCH
CONTACT PLATE SHOULDER, 2.8 Nm (25 LB. IN.)
STEERING WHEEL
PC2014-3f.F-RP
Figure 9 - Steering Wheel Horn Switch Contact Plate Assembly and Radio Control Switch Assembly
NOTICE: When attaching J 1859-A and J 38720

to the steering wheel assembly, use care to prevent
threading J 38720 (bolts) all the way through the
steering wheel hub into the SIR coil assembly and
damaging the SIR coil assembly.
3. Steering wheel assembly (2), using J 1859-A and
J 38720.
4. Steering wheel horn switch contact plate assembly.

See "Steering Wheel Horn Switch Contact Plate Assembly" in this section.
l++I
Install or Connect
NOTICE: See "Notice " on page 3F-1 of this section.
1. Route SIR coil assembly electrical connector to

steering wheel assembly (2).
2. Steering wheel horn switch contact plate assembly.
See "Steering Wheel Horn Switch Contact Plate
3. Steering wheel assembly (2).
rn
Important
Align block tooth on steering wheel assembly

(2) with block tooth on steering column shaft
within one female serration.
4. Nut (22).
l~I
Tighten
Nut (22) to 43 Nm (32 lb. ft.).

Refer to "Inflatable Restraint Steering Wheel Module Assembly" in this section ..
STEERING GEAR COUPLING SHAFT

ASSEMBLY
Figure 11
l++I
NOTICE: Ensure the tire and wheel assemblies are

pointing straight ahead and the steering wheel
I
A
B
C
2
5
CONNECTOR, RADIO ASSEMBLY ELECTRICAL

CONNECTOR, SIR COIL ASSEMBLY ELECTRICAL
LEAD, HORN
WHEEL ASSEMBLY, STEERING
22

RELEASE
22 NUT, STEERING WHEEL, 43 Nm (32 LB. FT.)
WINDSHIELD WASHER
PC2010-3F-F-RP
Figure 10 - Steering Wheel Assembly
1.
2.
3.
4.
5.
6.
7.
l++I
assembly is locked. Failure to do so may cause the

steering wheel assembly to rotate, causing damage
to the SIR coil assembly.
Bolt/screw (10) from gear assembly (33).
Clamp (11) from boot (12).
Shaft assembly (9) from gear assembly (33).
Boot (12) from shaft assembly (9).
Shield (13) from shaft assembly (9) and column
assembly (15) on 5.7L LTl engine only.
Bolt/screw (8) from column assembly (15).
Shaft assembly (9) from column assembly (15).
4. Position shaft assembly (9) to body rail.

5. Remove clamp (11) from boot (12) and place over
steering gear assembly casting.
6. Position shaft assembly (9) to gear assembly (33).
7. Bolt/screw (10).
l~I
Tighten

8. Position shield (13) to shaft assembly (9) and col-
umn assembly (15) on 5.7L LTl engine only.

9. Shield (13) by inserting button into hole in column
assembly (15) on 5. 7L LTl engine only.
Install or Connect

1. Position shaft assembly (9) to column assembly
(15).
2. Bolt/screw (8)
l~I
Tighten

3. Position boot (12) to shaft assembly (9) and secure
with clamp (11). Do not close clamp (11).
STEERING COLUMN ASSEMBLY REMOVAL

Figures 12 and 13
NOTICE: The tire and wheel assemblies must be
straight ahead and the steering column assembly
locked before disconnecting the steering column
assembly or steering gear coupling shaft assembly
from the steering gear assembly. Failure to do so
will cause the SIR coil assembly to become uncentered, which will cause damage to the SIR coil
assembly.
11
A BUTION, STEERING GEAR COUPLING HEAT SHIELD

B CASTING, STEERING GEAR ASSEMBLY
47 Nm (35 LB. FT.)
9 SHAFT ASSEMBLY, STEERING GEAR COUPLING
47 Nm (35 LB. FT.)
11 CLAMP, STEERING GEAR COUPLING SHIELD
12 BOOT, STEERING GEAR
13 SHIELD, STEERING GEAR COUPLING HEAT
14 COVER ASSEMBLY, STEERING COLUMN DASH PANEL
33 GEAR ASSEMBLY, ~TEE RING
PC0011-3F-F-RP
Figure 11 - Steering Gear Coupling Shaft Assembly

NOTICE: When the steering column assembly is
removed from the vehicle, it is extremely susceptible to damage. Dropping the column assembly on its
end could collapse the steering shaft assembly or
loosen plastic injections that keep the column
assembly rigid. Leaning on the column assembly
could cause steering column jacket to bend or deform. Any of the above conditions could impair column assembly's collapsible design. If the steering
wheel assembly must be removed, use only the specified steering wheel puller and steering wheel puller bolts. Never hammer on the end of the steering
shaft because hammering could loosen plastic injections that keep the column assembly rigid.

4. Steering wheel assembly, if column assembly is to
be replaced. Refer to "Steering Wheel Assembly"
in this section.
5. Intermediate steering shaft bolt/screw from steering
gear coupling shaft assembly and column assembly.
Refer to "Steering Gear Coupling Shaft Assembly"
in this section.
A NUT, WELD
4 NUT, STEERING COLUMN UPPER SUPPORT,
25 Nm (18 LB. FT.)
7 BOLT/SCREW, STEERING COLUMN, 10 Nm (89 LB. IN.)
14 COVER ASSEMBLY, STEERING COLUMN DASH PANEL
17 GUIDE, STEERING COLUMN
36 WASHER, STEERING COLUMN
6. Bolts/screws (7) attaching cover assembly (14) to

dash panel assembly.
7. Cover assembly (14) from dash panel assembly.
8. Electrical connectors.
9. Nuts (4) from steering column support.
10. Automatic transmission park lock cable assembly
from ignition switch, if equipped. Refer to SECTION 7A.
11. Column assembly (15) from vehicle.

NOTICE: If a service replacement steering column
assembly is being installed, do not remove the antirotation pin until after the column assembly has
been connected to the steering gear assembly.
Removing the antirotation pin before the column
assembly is connected to the steering gear assembly
may damage the SIR coil assembly.
1. Position column assembly (15) into vehicle.
2. Automatic transmission park lock cable assembly to
ignition switch, if equipped. Refer to SECTION
7A.
3. Nuts (4) to steering column support.
l~.J Tighten
Nuts (4) to 25 Nm (18 lb. ft.).
14
Figure 12 - Removing Steering Column Assembly
PC0012-3F-F-RP

4. Intermediate steering shaft bolt/screw to steering
gear coupling shaft assembly. Refer to "Steering
Gear Coupling Shaft Assembly" in this section.
rn
Important
When installing the cover assembly (14) to the

dash panel assembly, the lower bolt/screw (7)
must be installed first followed in order by the
outboard bolt/screw (7) and inboard bolt/screw
(7) (Figure 13).
5. Position cover assembly (14) to dash panel assembly.
A
B
C
14
l~I
Tighten

8. Steering wheel assembly, if column assembly is
replaced. Refer to "Steering Wheel Assembly" in
this section.
9. Enable SIR system. Refer to "Enabling the SIR
LOWER
OUTBOARD
INBOARD
COVER ASSEMBLY, STEERING COLUMN DASH PANEL
PC0013-3FfRP
Figure 13 - Steering Column Bolt/Screw Installation

Sequence

SPECIFICATIONS
Dimmer and Ignition Switch Bolt/Screw .................................. 4 Nm (35 lb. in.)
Hazard Warning Switch Knob Bolt/Screw ................................ 0.7 Nm (6 lb. in.)
Ignition Switch Bolt/Screw ........................................... 2.5 Nm (22 lb. in.)
Inflatable Restraint Steering Wheel Mounting Plate Bolt/Screw .............. 1.9 Nm (17 lb. in.)
Intermediate Steering Shaft-to-Steering Column Assembly Bolt/Screw ......... 47 Nm (35 lb. ft.)
Intermediate Steering Shaft-to-Steering Gear Assembly Bolt/Screw ............ 47 Nm (35 lb. ft.)
Radio Control Switch Bolt/Screw ...................................... 1.9 Nm (17 lb. in.)
Steering Column Bolt/Screw .......................................... 10 Nm (89 lb. in.)
Steering Column Guide Bolt/Screw ..................................... 25 Nm (18 lb. ft.)
Steering Column Upper Support Nut .................................... 25 Nm (18 lb. ft.)
Steering Wheel Bolt/Screw ........................................... 2.8 Nm (25 lb. in.)
Steering Wheel Horn Switch Contact Plate Shoulder Bolt/Screw ............. 2.8 Nm (25 lb. in.)
Steering Wheel Nut .................................................. 43 Nm (32 lb. ft.)
SPECIAL TOOLS
~OIIIIIIIIIIOIIIIOIIO
J 1859-A
J 38720
~OillllllllliOOIIIOO
STEERING WHEEL PULLER

STEERING WHEEL PULLER BOLTS (PART OF J 1859-A)
NC1003-3F-B-RP
TILT STRG COL UNIT REPAIR (SIR,FLR SHFT) 3F5B1
SECTION 3F5B

{SIR) TILT STEERING COLUMN
FLOOR SHIFT
UNIT REPAIR
CAUTION: The procedures in this section must be followed in the order listed to temporarily disable
the Supplemental Inflatable Restraint (SIR) System and prevent false diagnostic codes from setting.
Failure to follow procedures could result in possible air bag deployment, personal injury, or
otherwise unneeded SIR system repairs.
CAUTION: Before removing or installing any electrical unit or when a tool or equipment could easily
come in contact with 11 1ive 11 exposed electrical terminals, disconnect the negative battery cable to
help prevent personal injury and/or damage to the vehicle or components. Unless instructed
otherwise, the ignition switch must be in the 11 off 11 or "lock" position.
NOTICE: When fasteners are removed, always reinstall them at the same location from which they were removed. If
a fastener needs to be replaced, use the correct part number fastener for that application. If the correct part number fastener
is not available, a fastener of equal size and strength (or stronger) may be used. Fasteners that are not reused, and those
requiring thread locking compound will be called out. The correct torque value must be used when installing fasteners
that require it. If the above conditions are not followed, parts or system damage could result.
CONTENTS
Steering Column, Parts . . . . . . . . . . . . . . . . . 3F5B-2
Sub Section A - Upper Column . . . . . . . . . . . 3F5B-4
Disabling The SIR System
Enabling The SIR System
lnfl Restraint Coil Assembly
Shaft Lock
Tum Signal Cancelling Cam Asm
Upper Bearing Spring
Upper Bearing Inner Race Seat
Inner Race
Tum Signal Switch Assembly
Buzzer Switch Assembly
Strg Col Pass Key Lock Cylinder Set
Centering Infl Restraint Coil
Sub Section B - Housing Cover . . . . . . . . . . . 3F5B-9
Lock Housing Cover Assembly
Col Hsg Cover End Cap
Pivot & (Pulse) Switch Assembly
Dimmer Switch Rod Actuator
Tilt Spring Assembly
Sub Section C - Mid Column ............

Steering Column Housing Assembly
Steering Wheel Lock Shoe
Switch Actuator Sector
Switch Actuator Rack
Bearing Assembly
Lock Bolt
Strg Column Housing Support Asm
Steering Shaft Assembly
Sub Section D - Lower Column ..........
Dimmer Switch Assembly
Dimmer Switch Adjustment
Ignition Switch Assembly
Ignition Switch Adjustment
Adapter & Bearing Assembly
Accident Damage .....................
Specifications . . . . . . . . . . . . . . . . . . . . . . .
Fastener Torques . . . . . . . . . . . . . . . . . .
Special Tools. . . . . . . . . . . . . . . . . . . . . . . .
3F5B-11
3F5B-15
3F5B-18
3F5B-18
3F5B-18
3F5B-19
3F5B2 TILT STRG COL UNIT REPAIR {SIR,FLR SHFn
C93F01-1
Figure 1 - Tilt Stee nng

. Column
50- GUIDE, SPRING

1- NUT, HEX LOCKING (M14x1 .5)
51- SPRING, WHEEL TILT
2- RING, RETAINING
52- RETAINER, SPRING
3- COIL ASM, INFL RESTRAINT
4- WASHER, WAVE
55- SHAFT ASM, STEERING COLUMN
56- SHAFT ASM, RACE & UPPER
5- RING, RETAINING
57- SPHERE, CENTERING
6- LOCK, SHAFT
58- SPRING, JOINT PRELOAD
7- CAM ASM, TURN SIG CANCEL
59- SHAFT ASM, LOWER STEERING
8- SPRING, UPPER BEARING
61- SCREW, SUPPORT
9- SCREW, BNDG HD CR RECESS
62- SUPPORT ASM, STRG COL HSG
10-SCREW, RD WASH HD (M4.2x1.41)
71- SHROUD, STRG COLUMN HOUSING
11-ARM ASM, SIGNAL SWITCH
72- JACKET ASM, STRG COL
12- SWITCH ASM, TURN SIGNAL
76- ACTUATOR ASM, IGNITION SWITCH
13-SEAT, UPPER BRG INNER RACE
77ROD, DIMMER SWITCH
14- RACE, INNER
78- SCREW, WASH HD (#10-24X.25)
15-SCREW, PAN HD SOC TAP
79- SCREW, HEX WASH HD TAP
16- SWITCH ASM, BUZZER
80- SWITCH ASM, IGNITION
18-SCREW, LOCK RETAINING
82- SCREW, FLT HD (#10-24X.31)
19- COVER ASM, LOCK HOUSING
83- SWITCH ASM, DIMMER
20- LOCK CYLINDER SET, STRG COL
86-ADAPTER, LOWER BEARING
PASS KEY
87- BEARING ASM
21-ACTUATOR, DIMMER SW ROD
88- RETAINER, BEARING ADAPTER
22- PIN, SWITCH ACTUATOR PIVOT
89- CLIP, LOWER BEARING ADAPTER
23- SWITCH ASM, PIVOT & (PULSE)
24- BASE PLATE, COL HSG CVR END
Service Kits
25- CAP, COL HSG COVER END
26- PROTECTOR, WIRING
201- RACK SERV KIT, COL SECTOR &
27- SHROUD, CONNECTOR
-INCLUDES: 14,31,33,44,47,48
30- HOUSING ASM, STRG COLUMN
202- SPRING SERV KIT, TILT COLUMN
31- BEARING ASM
-INCLUDES: 13, 14,39,50,51,52
32- BOLT, LOCK
203- COIL SERV KIT, INFL RESTRAINT
33- SPRING, LOCK B.OLT
-INCLUDES: 3,4,27
34- SHOE, STEERING WHEEL LOCK
204- SPHERE SERV KIT, TILT COLUMN
35- SHOE, STEERING WHEEL LOCK
-INCLUDES: 57,58
36- SHIELD, WIRE PROTECTOR
37- SHAFT, DRIVE
205- GREASE SERV KIT, (SYNTHETIC)
38- PIN, DOWEL
39-PIN, PIVOT
40- SPRING, SHOE
41- SPRING, RELEASE LEVER
42- PIN, RELEASE LEVER
43- LEVER, SHOE RELEASE
44- RACK, SWITCH ACTUATOR
45- SPRING, RACK PRELOAD
46- HOUSING, STRG COLUMN
47-SECTOR, SWITCH ACTUATOR
48- SCREW HEX WASHER HEAD
Figure 2 - Tilt Steering Column - Legend
3F5B-4 TILT STRG COL UNIT REPAIR (SIR,FLR SHFT)

SUB SECTION A UPPER COLUMN
INCLUDES:
DISABLING THE SIR SYSTEM
ENABLING THE SIR SYSTEM
INFL RESTRAINT COIL ASSEMBLY
SHAFT LOCK
TURN SIGNAL CANCELLING CAM ASM
UPPER BEARING SPRING
UPPER BEARING INNER RACE SEAT
INNER RACE
TURN SIGNAL SWITCH ASSEMBLY
BUZZER SWITCH ASSEMBLY
STRG COL PASS KEY LOCK CYL SET
CENTERING INFL RESTRAINT COIL
Tools Required:
J 23653-C Lock Plate Compressor
ENABLING THE SIR SYSTEM
!++-! Install or Connect
1.
2.
3.
4.
5.
SERVICE PRECAUTIONS
CAUTION: When performing service on or
around SIR components or SIR wiring, follow
the procedures llsted below to temporarlly
disable the SIR system. Fallure to follow
procedures could result In possible air bag
deployment, personal Injury or otherwise
unneeded SIR system repairs.
rn
DISABLING THE SIR SYSTEM
1.
2.
3.
4.
5.
rn
Turn the steering wheel so that the vehicle's

wheels are pointing straight ahead.
Turn the ignition switch to "LOCK" and remove
key.
"AIR BAG" fuse from 1/P fuse block.
Lowersondinsulatorpanel-LH. Refer to SECTION
SC.
Connector Position Assurance (CPA) retainer and
yellow 2-way SIR connector at base of steering
column.
IIP compartment door assembly, refer to SECTION SC.
Connector Position Assurance (CPA) retainer and
yellow 2-way SIR connector located near the yellow
24-way DERM harness connector.
Yellow 2-way SIR connector and CPA retainer

located near the yellow 24-way DERM harness
connector.
1/P compartment door assembly, refer to SECTION
SC.
Yellow 2-way SIR connector and CPA retainer at
base of steering column.
Lower sound insulator panel-LH, refer to SECTION
8C.
"AIR BAG" fuse to I/P fuse block.
Turn ignition switch to "RUN" and verify that
the "AIR BAG" warning lamp flashes 7 times
and then turns "OFF". If it does not operate as
described, perform the "SIR Diagnostic System
Check" in SECTION 9J-A.
Important
Before doing any service procedures in this section,
disabling the SIR system and removal of Inflator
Module and Steering Wheel is needed. Columns
equipped with Supplemental Inflatable Restraint
(SIR) and Redundant Steering Wheel Control
(RSWC) will have Inflatable Restraint coils with
two wire leads. (SIR) wire leads are yellow with a
yellow connector shroud. (RSWC) wire leads are
grey with black connectors. (Refer to "Disabling
the SIR System" in this section and service
procedures in section 3F).
The DERM can maintain sufficient voltage to

cause a deployment for up to 2 minutes after the
ignition switch is turned "OFF" or the battery is
disconnected. Many of the service procedures require
disconnection of the "AIR BAG" fuse and the inflator
module circuits from the deployment loops to avoid an
accidental deployment.
!+-+! Remove or Disconnect
Turn ignition switch to "LOCK" and remove key.
!+-+!
Figures 1 through 9 and 13
NOTICE: Place ignition to "LOCK" position to prevent

uncentering coil assembly (3).
1. Disable the SIR system; Refer to "Disabling the
SIR System" in this Section.
2. Negative (-) battery cable.
Important
With the "AIR BAG" fuse removed and ignition
switch "ON", the "AIRBAG"waminglampwillbe
"ON". This is normal operation and does not indicate
an SIR system malfunction.
2 RING, RETAINING
3 COIL ASM, INFL RESTRAINT
4 WASHER, WAVE
Figure 3 - Removing Coil Assembly Off Shaft
TILT STRG COL UNIT REPAIR (SIR,FLR SHFT} 3F5B5

3.
4.
5.
6.
7.
8.
9.
Coil assembly retaining ring (2).

Inflatable restraint coil assembly (3).
Let switch hang freely if removal is not needed.
To remove coil (3), do steps 5 through 17 in this
section.
Wave washer (4).
Shaft lock retaining ring (5) using J 23653-C to push
down shaft lock (6).
Dispose of ring (5).
Shaft lock (6).
Turn signal cancelling cam assembly (7).
Upper bearing spring (8).
10
12
MULTI
FUNCTION
LEVER
9 SCREW, BINDING HD CROSS RECESS

10SCREW, RD WASH HD (M4.2X1.41)
11 ARM ASM, SIGNAL SWITCH
12 SWITCH ASM, TURN SIGNAL
Figure 6 - Turn Signal Switch Removal Preparation

16. Turn signal switch assembly (12).
EXTRA
RETAINING
RINGS

To remove switch (12):
A. Turn signal switch connector from bulkhead

connector.
B. Wiring protector (26).
C. Gently pull wire harness through column.
J 23653-C
5 RING, RETAINING
6 LOCK, SHAFT
Figure 4 - Removing Shaft Lock Retaining Ring
14
13~~
7
'
8
6 LOCK, SHAFT
7 CAM ASM, TURN SIG CANCELLING
8 SPRING, UPPER BEARING
13 SEAT, UPPER BEARING INNER RACE
14 RACE, INNER
TURN SIGNAL
SWITCH CONNECTOR
Figure 5 - Removing Components from Upper Shaft

26 PROTECTOR, WIRING
10.
11.
12.
13.
Upper bearing inner race seat (13).

Inner race (14).
Turn signal to "RIGHT TURN" position (up).
Multi-function lever and hazard knob assembly.
(See Section 3F)
14. Screw (10) and signal switch arm (11).
15. Turn signal switch screws (9).
Figure 7 - Removing Turn Signal Switch
NOTICE: Coil assembly (3) will become uncentered if:

1) Steering column is separated from steering gear
and is allowed to rotate, or
2) Centering spring is pushed down, letting hub
rotate while coil (3) is removed from steering
column. (If this occurs, see Figure 13)
3F5B6 TILT STRG COL UNIT REPAIR (SIR,FLR SHFT)

21.
22.
Lock retaining screw (18).

Pass key lock cylinder (20) and harness.
To remove lock cylinder (20):
A. Terminal connector from bulkhead

connector.
B. Wiring protector (26).
C. Attach a length of mechanics wire to
terminal to aid in reassembly.
D. Retaining clip from housing cover (19)
and gently pull wire harness through
column.
YELLOW
CONNECTOR
SHROUD
BLACK TERMINAL CONNECTOR
26 PROTECTOR, WIRING
27SHROUD,CONNECTOR
Figure 8 - Removing Coil Assembly Switch
!-++!
Install or Connect
Figures 1, 1O through 15 and 26
17.
Inflatable restraint coil assembly (3)with wire harness

from column assembly.
A. Wiring protector (26).

B. Attach a length of mechanics wire to coil
terminal connector to aid in reassembly.
C. Gently pull wire through column.
NOTICE: See "Notice" on page 3F5B-1 of this section.
NOTICE: Ensure all fasteners are securely seated before

applying needed torque. Failure to do may result in
component damage or malfunctioning of steering column.
NOTICE: Route wire from pass key lock cylinder as

shown and snap retaining clip into hole in housing (19).
(See Figures 10 and 11) Failure to do so may result in
component damage of malfunction of pass key lock
cylinder.
20
16 SWITCH ASM, BUZZER

RETAINING
CLIP
Figure 9 - Removing Buzzer Switch
18.
19.
20.
Key from pass key lock cylinder set (20).

Buzzer switch assembly (16).
Reinsert key in pass key lock cylinder (20).
Key in "LOCK" position.
18 SCREW, LOCK RETAINING

20 LOCK CYLINDER SET, STAG COL
(PASS KEY)
Figure 10 - Installing Pass Key Lock Cylinder Set
TILT STRG COL UNIT REPAIR (SIR,FLR SHFT) 3F587
RETAINING
CLIP
INFL RESTRAINT COIL ASM AND

TURN SIGNAL SWITCH WIRE HARNESSES
THROUGH HERE. 5 O'CLOCK POSITION.
20 LOCK CYLINDER SET, STRG COL

(PASS KEY)
Figure 12 - Wire Harnesses through Column
Figure 11 - Routing Pass Key Wire Harness
8.
1.
Pass key lock cylinder (20).

A. Wire terminal through column and snap
retaining clip into hole in housing.
B. Lock cylinder (20) connector to vehicle wire
harness.
2.
Turn signal switch assembly (12) and screws (9).
~Tighten
9.
Tighten screws (9) to 3.4 Nm (30 lb.in.).
Signal switch arm (11) with screw (10).
~Tighten
Lock retaining screw (18).
Tighten screw (10) to 2.3 Nm (20 lb.in.).
!~!Tighten
10.
3.
4.
5.
6.
7.
Key from pass key lock cylinder set (20).

Buzzer switch assembly (16).
Reinstall key in pass key lock cylinder set (20).
Key in "OFF-LOCK" position.
Turn signal switch assembly (12) wire harness

through steering column.
A. Let switch hang freely.
B. Switch connector to bulkhead connector.
Coil assembly (3) wire harness through column.

Let coil hang freely.
11.
12.
13.
14.
15.
16.
Hazard knob assembly and multi-function lever.

(See Section 3F)
Inner race (14).
Upper bearing inner race seat (13).
Upper bearing spring (8).
Turn signal cancelling cam assembly (7).
Lubricate with grease, synthetic (service kit).
Shaft lock (6).
New shaft lock retaining ring (5) using J 23653-C to
push down shaft lock (6).
Ring (5) must be firmly seated in groove on
shaft.
NOTICE: Set steering shaft so that block tooth on upper

steering shaft (56) is at the 12 o'clock position, wheels on
vehicle should be straight ahead, then set ignition switch
to "LOCK" position, to ensure no damage to coil assembly
(3). (See Figure 26 for steering shaft orientation)
17. Wavewasher(4).
3FSBB TILT STRG COL UNIT REPAIR {SIR,FLR SHFT)

NOTICE: Coil assembly (3) will become uncentered if:
1)
Steering column is separated from steering gear

and is allowed to rotate, or
Centering spring is pushed down, letting hub
rotate while coil is removed from column. (If
this occurs, see Figure 13)
2)
--= ..
KEEP LOWER WIRE TIGHT WHILE

SEATING SIR COIL ASM HEAD IN
STEERING COLUMN.
3 COIL ASM, INFL RESTRAINT
6 LOCK, SHAFT
STYLE
A
Figure 14 - Routing Coil Assembly Wire
LOCKING
TAB
SPRING
LOCK
NOTICE: Sir coil assembly wire must be kept tight with

no slack while installing SIR coil assembly. Failure to do
so may cause wire to be kinked near shaft lock area and cut
when steering wheel is turned.
COIL
HUB
18.
19.
STYLE
B
LOCKING
TAB
SPRING
LOCK
COIL
HUB
PERFORM THE FOLLOWING STEPS TO CENTER COIL ASSEMBLY
A WHEELS STRAIGHT AHEAD.
B REMOVE COIL ASSEMBLY.
C HOLD COIL ASSEMBLY WITH CLEAR BOTIOM UP TO SEE COIL
RIBBON.
D NOTE: THERE ARE TWO DIFFERENT STYLES OF COILS. ONE
ROTATES CLOCKWISE AND THE OTHER ROTATES COUNTER
CLOCKWISE.
E WHILE HOLDING COIL ASSEMBLY, DEPRESS SPRING LOCK TO
ROTATE HUB IN DIRECTION OF ARROW UNTIL IT STOPS.
F THE COIL RIBBON SHOULD BE WOUND UP SNUG AGAINST
CENTER HUB.
G ROTATE COIL HUB IN OPPOSITE DIRECTION APPROXIMATELY
TWO AND A HALF (21/2) TURNS. RELEASE SPRING LOCK
BETWEEN LOCKING TABS IN FRONT OF ARROW.
Figure 13 - Centering Coil Assembly
NOTICE: If a new coil assembly (3) is being installed,

assemble pre-centered coil assembly (3) to steering column.
Remove centering tab and dispose. (See Figure 13)
Ensure coil assembly (3) hub is centered.

Coil assembly (3).
A. Pull wire tight while positioning SIR coil to
steering shaft.
B. Align opening in coil with horn tower and
"locating bump" between two tabs on housing
cover.
C. Seat coil assembly into steering column.
PROJECTIONS ON
HOUSING COVER
USED FOR ALIGNMENT
OF COIL ASSEMBLY
INSTALL COIL
ASSEMBLY OVER
SHAFT AND
HORN TOWER.
2 RING, RETAINING
3 COIL ASSEMBLY
7 CAM ASM, TURN SIG CANCEL
Figure 15 - Coil Assembly Installed
20.
Coil assembly retaining ring (2).

Ring (2) must be firmly seated in groove on
shaft.
NOTICE: Gently pull lower coil assembly, turn signal,

pass key ,and pivot & (pulse) wires to remove any wire
kinks that may be inside steering column assembly.
Failure to do so may cause damage to wire harness.
TILT STRG COL UNIT REPAIR (SIR,FLR SHFT) 3F589

21.
22.
Wiring protector (26).

Refer to Section 3F to complete remaining steering
column assembly.
23. Negative(-) battery cable.
24. 1f all service operations are completed, enable the
SIR system; refer to "Enabling the SIR System" in
this Section.
CRUISE CONTROL
WIRE CONNECTIONS
24 BASE PLATE, COL HSG CVR END
SUB SECTION B HOUSING COVER

Figures 1,2, 16 through 20
INCLUDES:
LOCK HOUSING COVER ASS EMBLY
COL HSG COVER END CAP
PIVOT & (PULSE) SWITCH ASS EMBLY
DIMMER SWITCH ROD ACTUATOR
TILT SPRING ASS EMBLY
Figure 16 - Cruise Control Equipped

Steering Columns
[1J
Important
Remove cruise control and multi-function lever
connectors from base plate (24) and disconnect.
Remove multi-function lever. (See Section 3F)
Tools Required:
15
12 O'CLOCK
IY! Important
15
80'CLOCK
rn

removal of Inflator Module and Steering Wheel is
needed. (Refer to service procedures in Section 3F)
Important
Remove only those components necessary to do

repairs.
15 SCREW, PAN HD SOC TAP
Figure 17 - Lock Housing Cover Screw Positions
:i
~' I
24~
............~
!+--+!
25
19 COVER ASM, LOCK HOUSING
CRUISE
CONTROL
PLUG
21 ACTUATOR, DIMMER SW ROD
1.
2.
Do all steps, "Remove or Disconnect", Sub Section A.

Housing cover end cap (25).
24 BASE PLATE, COL HSG CVR END

25 CAP, COL HSG COVER END
77 ROD, DIMMER SWITCH
Figure 18 - Removing Lock Housing Cover
3F5B10 TILT STRG COL UNIT REPAIR (SIR,FLR SHFn

3.
4.
5.
6.
Cover screws (15).

Tilt lever. (See Section 3F)
Lock housing cover assembly (19).
Base plate (24) and dimmer switch rod actuator
(21).
Wire protector shield (36).
7.
!-++!

applying needed torque. Failure to do so may result in
1.
Spring guide (50) and spring (51).

Lubricate with lithium grease.
2.
Spring retainer (52).

Using a cross recess screwdriver push retainer
down and turn clockwise to lock in place.
3.
Pivot & (pulse) switch assembly (23) to lock housing

cover assembly (19).
Switch actuator pivot pin (22) to switch (23) and
cover (19).
Pivot & (pulse) switch wire harness through steering
column.
Switch connector to bulkhead connector.
Wire protector shield (36).
---CRUISE
CONTROL
CONNECTOR
19 COVER ASM, LOCK HOUSING

22 PIN, SWITCH ACTUATOR PIVOT
23 SWITCH ASM, PIVOT & (PULSE)
Figure 19 - Removing Pivot & (Pulse) Switch
4.
5.
50 GUIDE, SPRING
51 SPRING, WHEEL TILT
52 RETAINER, SPRING
6.
Dimmer switch rod actuator (21) to base plate(24).

7.
Base plate (24) to lock housing cover assembly(19).

Bottom edge of dimmer switch rod actuator
(21) must rest on bend in dimmer switch rod
(77).
8.
9.
Lock housing cover assembly (19).

Screws (15). Tighten screw in 12 o'clock position
first, screw in 8 o'clock position second, and screw
in 3 o'clock position third.
Figure 20 - Removing Tilt Spring Assembly
8.
9.
Switch actuator pivot pin (22).

Pivot & (pulse) switch assembly (23).
Install or Connect

To remove switch (23):
!~!Tighten
A.
B.
10.
Tighten screws (15) in same order to 9.0 Nm

(80 lb.in.).
Spring retainer (52).
11.
Pivot & (pulse) switch connector from

bulkhead connector.
Gently pull wire harness through column.
Using a cross recess head screwdriver, push

retainer down and turn counterclockwise to
release.
Spring (51) and spring guide (50).
10.
11.
12.
13.
Install multi-function lever. (See Section 3F)

Plug multi-function lever and cruise control
connectors together and mount on base plate (24).
Housing cover end cap (25).
Do all steps, "Install or Connect", Sub Section A.
TILT STRG COL UNIT REPAIR (SIR,FLR SHFn 3F5811
ll'BI Inspect
SUB SECTION C - MID COLUMN

INCLUDES:
STEERING COLUMN HOUSING ASM
STEERING WHEEL LOCK SHOE
SWITCH ACTUATOR SECTOR
SWITCH ACTUATOR RACK
BEARING ASS EMBLY
LOCK BOLT
STEERING COL HSG SUPPORT ASM
STEERING SHAFT ASSEMBLY
Tools Required:
J 21854-01 Pivot Pin Remover
J 22635 Lock Shoe and Release Lever Pin
Remover and Installer
J 8092 Driver Handle
J 38639 Strg Col Housing Bearing Installer
rn
4.
5.
Steering column for accident damage. (See

Figure 34)
Do steps 3 through 22, "Remove or Disconnect",

Sub Section A.
Do steps 2 through 10, "Remove or Disconnect",
Sub Section B.
39 PIN, PIVOT
Figure 21 - Removing Pivot Pin
Important
6.

removal of Inflator. Module and Steering Wheel is
needed. (Refer to service procedures in Section 3F)
7.
l+..I Remove or Disconnect
rn
Pivot pins (39) using J 21854-01.

Reinstall tilt lever. (See Section 3F)
Steering column housing assembly (30).
Pull back on tilt lever and pull steering column
housing assembly (30) down and away from
column.
Important
Figures 1 through 28,30 and 34
1.
2.
3.
Disable the SIR system; refer to "Disabling the

Negative (-) battery cable.
Steering column from vehicle. (See Section 3F)
NOTICE: Once steering column is removed from vehicle,

the column is extremely susceptible to damage. Dropping
steering column assembly on its end could collapse
steering shaft or loosen plastic injections which maintain
column rigidity. Leaning on steering column assembly
could cause jacket to bend or deform. Any of the above
damage could impair steering column's collapsible design.
If it is necessary to remove steering wheel, use only the
specified steering wheel puller. Under no conditions
should the end of shaft be hammered on as hammering
could loosen plastic injections which maintain steering
column rigidity.

repairs.
46
32 BOLT, LOCK
37 SHAFT, DRIVE
38 PIN, DOWEL
44 RACK, SWITCH ACTUATOR
46 HOUSING, STRG COLUMN
48 SCREW, HEX WASHER HEAD
Figure 22 - Lock Housing Cover Components, Exterior

Release lever pin (42) using J 22635.
Switch actuator sector (47).
Drive shaft (37).
Rack preload spring (45).
Switch actuator rack (44) to actuator sector
(47).
K. Bearing assembly (31) lubricated with
lithium grease to column housing (46)
using J 38639 and J 8092.
L. Lock bolt (32).
M. Lock bolt spring (33). (See Figure 30)
N. Hex head screw (48).
F.
G.
H.
I.
J.
J 22635
34
43
36
31 BEARING ASM
34 SHOE, STEERING WHEEL LOCK
35 SHOE, STEERING WHEEL LOCK
36 SHIELD, WIRE PROTECTOR
42 PIN, RELEASE LEVER
43 LEVER, SHOE RELEASE
!~!Tighten
31
Figure 23 - Lock Housing Cover

Components, Interior
!+!-+! Disassemble
J 8092

J 38639
A.
B.
C.
D.
E.
Bearing assembly (31).

Hex head screw (48).
Lock bolt spring (33).
Lock bolt (32).
Switch actuator rack (44) and rack preload
spring (45).
F. Drive shaft (37).
G. Switch actuator sector (47).
I. Release lever pin (42) using J 22635.
J. Shoe release lever (43).
K. Release lever spring (41).
L. Dowel pin (38) using J 22635.
M. Lock shoes (34) and (35).
N. Shoe springs (40).
!-+;+! Assemble
31
46
31 BEARING ASM
Figure 24 - Installing Bearings
8.
9.
10.
11.
Lower bearing adapter clip (89).

Bearing adapter retainer (88).
Lower bearing adapter (86) and bearing assembly
(87).
Steering column shaft assembly (55).

A. Shoe springs (40).
B. Lock shoes (34) and (35).
C. Dowel pin (38) using J 22635.
D. Release lever spring (41).
E. Shoe release lever (43).
!l.1'! Inspect
Steering column shaft assembly (55) for accident

damage. (See Figure 34)
[I]
Important
BLOCK TOOTH
120'CLOCK
POSITION
Mark upper shaft assembly (56) and lower steering

shaft asm (59) to ensure proper assembly. Failure to
assemble properly will cause steering wheel to be
turned 180 degrees. (See Figures 25 and 26)
7
57~\1(5
NOTCHES
56
BOLT
HOLE
12 O'CLOCK
POSITION
59
56 SHAFT ASM, RACE & UPPER
57 SPHERE, CENTERING
59 SHAFT ASM, LOWER STEERING
TILT90
AND SEPARATE
ALIGNMENT
MARK
LIFT
56
56 SHAFT ASM, RACE &UPPER

57 SPHERE, CENTERING
58 SPRING, JOINT PRELOAD
59 SHAFT ASM, LOWER STEERING
Figure 25 - Removing Steering Shaft Components
[I]
Important
repairs.
!(-+! Disassemble
BOTIOM
END VIEW
Figure 26 - Correct Upper to Lower Shaft Orientation
!-+f+! Assemble
Steering Column Shaft Assembly
A. Joint preload spring (58) to two centering
sphere (57).
B. Centering sphere (57).
Lubricate with lithium grease, slip

into upper shaft assembly (56), and
rotate sphere 90 degrees.
C. Upper shaft assembly (56) to lower steering
shaft assembly (59).
Line up marks and tilt assemblies 90

degrees to each other.
62
Steering Column Shaft Assembly

A. Upper shaft assembly (56), lower steering
shaft assembly (59).
Tilt 90 degrees to each other and

disengage.
B. Centering sphere (57) from upper shaft
assembly (56).
Rotate sphere 90 degrees and slip

out.
C. Joint preload spring (58) from centering
sphere (57).
61 SCREW, SUPPORT
62 SUPPORT ASM, STRG COL HSG
71 SHROUD, STRG COLUMN HSG
77 ROD, DIMMER SWITCH
Figure 27 - Removing Column Housing Support

3.
12.
13.
14.
Support screws (61).

Column housing support assembly (62) with dimmer
switch rod (77) from steering column jacket assembly
(72).
Rod (77) from support (62).
Steering column housing shroud (71).
Four support screws (61).
!~!Tighten
4.
5.
Tighten screws (61) to 8.8 Nm (77 lb.in.)
Dimmer switch rod (77) to housing support (62).

Actuator assembly (76) to housing support (62).
34
72 JACKET ASM, STRG COL

78 SCREW, WASH HD (#10-24X.25)
79 SCREW, HEX WASH HD TAP
80 SWITCH ASM, IGNITION
82 SCREW, FLT HD (#10-24X.31)
83 SWITCH ASM, DIMMER
Figure 28 - Removing Ignition and Dimmer Switches
15.
16.
17.
18.
!-++!
Hex head tapping screw (79).

Washer head screw (78).
Dimmer switch (83) from vehicle wire harness.
34 SHOE, STRG WHEEL LOCK

35 SHOE, STRG WHEEL LOCK
39 PIN, PIVOT
62 SUPPORT ASM, STRG COL HSG
76 ACTUATOR ASM, IGN SWITCH
Figure 29 - Installing Column Housing

to Housing Support
6.
Steering shaft assembly (55) to jacket assembly

(72).
7.
8.
Tilt lever. (See Section 3F)

Column housing assembly (30) to column.
Position column housing assembly (30) and
align switch actuator rack (44) with pin on end
of ignition switch actuator assembly (76).
Pull back on tilt lever, pushing column housing
assembly (30) onto column housing support
assembly (62).
Release tilt lever to lock shoes (34) and (35)
onto dowel pins.
Remove tilt lever. (See Section 3F)
Install or Connect

1.
SHOE MUST ENGAGE

WITH DOWEL PINS
Flat head screw (82).

Ignition switch assembly (80) from ignition
switch actuator assembly (76).
2.
39
Steering column housing shroud (71).

Column housing support (62) to jacket assembly
(72).
TILT STRG COL UNIT REPAIR (SIR,FLR SHFn 3F5B15

32 BOLT, LOCK
33 SPRING, LOCK BOLT
76
47 SECTOR, SWITCH ACTUATOR
76 ACTUATOR ASM, IGN SWITCH
Figure 30 - Actuator Assembly to Actuator Rack

Installed
NOTICE: Once steering column is removed from vehicle,

the column is extremely susceptible to damage. Dropping
steering column assembly on its end could collapse
steering shaft or loosen plastic injections which maintain
column rigidity. Leaning on steering column assembly
could cause jacket to bend or deform. Any of the above
damage could impair steering column's collapsible design.
If it is necessary to remove steering wheel, use only the
specified steering wheel puller. Under no conditions
should the end of shaft be hammered on as hammering
could loosen plastic injections which maintain steering
column rigidity.
ll..1'! Inspect
9.
Pivot pins (39).

Press pin until firmly seated, two places.
10. Lower bearing adapter (86) and bearing assembly

(87).
Lubricated with lithium grease.
Steering column for accident damage. (See

Figure 34)
l+-+!
Figures 1,2,28 and 34
11. Bearing adapter retainer (88).

12. Lower bearing adapter clip (89).
13. Do steps 1 through 12, "Install or Connect", Sub
Section B.
14. Do steps, 1 through 21 "Install or Connect", Sub
Section A
15. To install ignition and dimmer switch assemblies,
do all steps Ignition Switch Assembly, "Install or
Connect", Sub Section D.
2.
3.
4.
5.
6.
SUB SECTION D LOWER COLUMN
!-++!
1.

Dimmer switch assembly (83) from rod (77).
Vehicle wire harness from dimmer switch (83).
Install or Connect
INCLUDES:
DIMMER SWITCH ASSEMBLY
DIMMER SWITCH ADJUSTMENT
IGNITION SWITCH ASSEMBLY
IGNITION SWITCH ADJUSTMENT
ADAPTER & BEARING ASS EMBLY

applying required torque. Failure to do so may result in

1.
2.

Hex head tapping screw (79) and washer head screw
(78).
Tighten finger tight.
Ignition Switch Assembly
f+-+!
1.

SIR System" in this section.
Negative(-) battery cable.
Dimmer switch assembly (83) from rod (77).
Ignition switch assembly (80) from ignition switch
actuator assembly (76).
Vehicle wire harness from ignition switch
assembly (80).
2.
3.
4.
5.
6.
7.
8.
83 SWITCH ASM, DIMMER
Figure 31 -Adjusting Dimmer Switch
~Adjust
Dimmer switch (83). (See Figure 31)
A. Place 3/32-inch drill bit in hole on switch

to limit travel.
B. Position switch on column and push against
dimmer switch rod (77) to remove all lash.
C. Remove drill bit.
I-++!
Tighten screw (79) to 2.5 Nm (22 lb.in.)
~Tighten
Figures 1,2,28,31 and 32

1.
~Tighten
Install or Connect
Lock cylinder (20) to "OFF-LOCK" position.
NOTICE: Install ignition switch (80) to jacket (72) with

switch in "OFF-LOCK" position. (See Figure 32) New
ignition switch will be pinned in "OFF-LOCK" position.
Remove plastic pin after switch is assembled to column.
Failure to do so may cause switch damage.
MOVE SWITCH SLIDER TO EXTREME RIGHT POSITION
AND THEN MOVE SLIDER ONE DETENT TO THE LEFT
"OFFLOCK'

80
3.
4.
5.
6.
Vehicle wire harness to dimmer switch (83).

Steering column to vehicle. (See Section 3F)
If all service operations are completed, enable the
this section.
80 SWITCH ASM, IGNITION
Figure 32 - Adjusting Ignition Switch
TILT STRG COL UNIT REPAIR (SIR,FLR SHFn 3F5B17

~Adjust
Adapter & Bearing Assembly
Ignition switch assembly (80).
A. Move switch slider to extreme right

position.
B. Move switch slider one de tent to left "OFFLOCK" position.
2.
3.
Ignition switch assembly (80) to actuator assembly

(76).
1.
2.
3.
4.
5.
6.

SIR System" in this section.
(87).
~Tighten
4.
5.
Dimmer switch assembly (83) to rod (77).

Hex head tapping screw (79) and washer head screw
(78).
Tighten finger tight.
Ill Adjust
Dimmer switch (83). (See Figure 31)

A. Place 3/32-inch drill bit in hole on switch
to limit travel.
B. Position switch on column and push against
dimmer switch rod (77) to remove all lash.
C. Remove drill bit.
72 JACKET ASM, STAG COL

86 ADAPTER, LOWER BEARING
87 BEARING ASM
88 RETAINER, BEARING ADAPTER
89 CLIP, LOWER BEARING ADAPTER
Figure 33 - Removing Lower Bearing Assembly

Figures 1,2 and 33
~Tighten
Tighten screw (79) to 2.5 Nm (22 lb.in.)
~Tighten

Vehicle wire harness to dimmer switch assembly
(83).
8. Vehicle wire harness to ignition switch assembly
(80).
9. Negative(-) battery cable.
10. If all service operations are completed, enable the
this Section.

1.

(87).
Lubricate inner surface with lithium grease.
2.
3.
4.
5.
6.

If all service operations are completed, enable the
this Section.
6.
7.

CHECKING STEERING COLUMN FOR ACCIDENT DAMAGE
NOTICE: Vehicles Involved In accidents resulting In frame damage,
major body or sheet metal damage, or where the steering column has
been Impacted, or where supplemental Inflatable restraints systems
deployed may also have a damaged or misaligned steering column.
CHECKING PROCEDURE
I
I
JACKET ASM, STEERING COLUMN
Check capsules on steering column bracket assembly; all must be

securely seated In bracket slots and checked for any loose
conditions when pushed or pulled by hand (View A). If not, bracket
should be replaced If bracket Is bolted to the jacket assembly or the
Jacket assembly should be replaced If bracket Is welded to jacket
assembly.
Check for jacket assembly collapse by measuring the distance
from the lower edge of upper jacket to a defined point on the lower
Jacket (View C). If measured dimensions are not within
specifications, a new Jacket must be Installed.
STEERING SHAFT ASM
Visually Inspect steering shaft for sheared Injected plastic (View 8).
If steering shaft shows sheared plastic, a new steering shaft must
be Installed.
Any frame damage that could cause a bent steering shaft must
have steering shaft runout checked In the following manner: Using
a dial Indicator at lower end of steering shaft, have steering wheel
rotated. Runout must not exceed 1.59mm.
NOTICE: Inflatable restraint coll assembly must be removed from
steering column and allowed to hang freely before shaft Is rotated. Failure
to do so could damage coll assembly.
I
I
VIEWA
(CAPSULES)
CHECK FOR ANY LOOSE CONDITION WHEN
PUSHED OR PULLED BY HAND.
~CHECK FOR SHEARED INJECTED
I
VIEWB
I
I
I
I
I
I
I
I VIEW c
PLASTIC AT THESE LOCATIONS.
(STEERING SHAFT)
(METHOD TO DETERMINE COLUMN COLLAPSE)

WITH LOWER BEARING REMOVED
MEASURE DISTANCE BETWEEN ARROWS.
Figure 34 - Checking Steering Column for Accident Damage
SPECIFICATIONS
FASTENER TORQUES
1 Steering Wheel-to-Shaft Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41.0 Nm (30 lb.ft.)
9 Turn Signal Switch Connecting Screws ......................................... 3.4 Nm (30 lb.in.)
10 Turn Signal Switch Actuator Assembly Screw ................................... 2.3 Nm (20 lb.in.)
15 Lock Housing Cover Screws ................................................. 9.0 Nm (80 lb.in.)
18 Lock Retaining Screw ...................................................... 2.5 Nm (22 lb.in.)
48 Lock Bolt Spring Screw .................................................... 4.0 Nm (35 lb.in.)
61 Support-to-Jacket Screws ................................................... 8.8 Nm (77 lb.in.)
78 Upper dimmer Switch Mounting Screw ......................................... 4.0 Nm (35 lb.in.)
79 Lower dimmer Switch Mounting Screw ........................................ 2.5 Nm (22 lb.in.)
82 Ignition Switch Mounting Screw .............................................. 3.7 Nm (33 lb.in.)
J 23653-C
1 PIVOT PIN REMOVER

2 LOCK SHOE AND RELEASE LEVER PIN REMOVER AND INSTALLER
3 DRIVER HANDLE
4 STEERING COLUMN HOUSING BEARING INSTALLER
5 LOCK PLATE COMPRESSOR
Figure 35 - Special Tools
PROPELLER SHAFT 4A-1
SECTION 4A
PROPELLER SHAFT
result.
CONTENTS
Propeller Shaft Assemblies ................
Center Support Bearing ...................
Universal Joint ..........................
.Prope~ler Shaft Joint. .....................
Diagnosis ................................
Road Test ..............................
Coast Test ..............................
Diagnosis of Propeller Shaft Assembly and
Universal Joint ........................
On-Vehicle Service ........................
Propeller Shaft Assembly Runout
Measurement .........................
Differential Drive Pinion Gear Yoke
Runout Measurement ...................
Propeller Shaft Assembly Balance Check .....
4A-1
4A-1
4A-1
4A-1
4A-3
4A-3
4A-3
4A-3
4A-5
4A-5
4A-5
4A-5
4A-7
Propeller Shaft Assembly Balancing ......... 4A-7

Hose Clamp Method . . . . . . . . . . . . . . . . . . . 4A-7
Strobe Light Method ................... 4A-8
One and Two-Piece Propeller Shaft Assembly
Replacement .......................... 4A-9
Unit Repair .............................. 4A-12
Two-Piece Propeller Shaft Assembly ....... 4A-12
Center Support Bearing Replacement ....... 4A-12
Universal Joints ........................ 4A-13
Nylon Injected Ring Type . . . . . . . . . . . . . . 4A-13
Snap Ring Type ...................... 4A-13
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-15
General Specifications ................... 4A-15
Fastener Tightening Specifications . . . . . . . . . 4A-15
Special Tools ............................ 4A-15
GENERAL DESCRIPTION
PROPELLER SHAFT ASSEMBLIES
Figure 1
Torque is transmitted from the transmission assembly to the rear axle assembly through one or more of the
propeller shaft assemblies (5, 6 and 10) and universal joint
assemblies. The 3.4L L32 engine utilizes a two-piece
propeller shaft assembly (6 and 10), while the 5.7L LTl
engine utilizes a one-piece propeller shaft assembly (5).
All propeller shaft assemblies (5, 6 and 10) have universal joints to accommodate angle variations between the
transmission assembly and the rear axle assembly and/or
the rear axle assembly position caused by suspension
motion. The propeller shaft assemblies (5, 6 and 10) are
connected to the transmission assembly with a splined slip
yoke assembly ( 1 or 24) and to the rear axle assembly with
a companion flange (fixed yoke). On the two-piece propeller shaft assembly (6 and 10), the rear portion of the
front propeller shaft assembly ( 6) contains the center support bearing (7) and spline coupling. The spline coupling
has i11ternal splines which accept the rear propeller shaft
assembly (10). The center support bearing (7) is pressed
onto the OD of the coupling. On the front of the rear propeller shaft assembly (10) there is a propeller shaft joint
(9) (sometimes called a constant velocity (CV) joint) that
fits i11to the spline coupling of the front propeller shaft
assembly (6).
rn
NOTICE: If a vehicle is to be undercoated, the

propeller shaft assembly must be kept free of
undercoating material. Undercoating material
or any other foreign material will upset the
propeller shaft balance and produce serious
vibration.
Important
Before propeller shaft assembly removal, reference

mark the propeller shaft assembly to ensure phased
installation alignment. Some propeller shaft assemblies have alignment marks or arrows stamped on
the shaft at the time of production.
CENTER SUPPORT BEARING

Figure 1
The center support bearing (7) supports the driveline
when the two-piece propeller shaft assembly (6 and 10)
are used. The center support bearing (7) is a ball-type
bearing mounted in a rubber cushion that is mounted to
the torque arm assembly. The center support bearing (7) is
pre-lubricated and sealed by the manufacturer.
UNIVERSAL JOINT
Figure 1
The universal joint is basically two Y-shaped yokes
connected by a crossmember called a spider (2). The spider (2) is shaped like a cross having arms of equal length
4A-2 PROPELLER SHAFT
A
B
C
D
E
1
2
3
4
5
6
7
8
9
10
24
SHAFT ASSEMBLY, ONE-PIECE PROPELLER

SHAFT ASSEMBLY, lWO-PIECE PROPELLER
TRUNNIONS
COUPLING, SPLINE
DAMPER, PROPELLER SHAFT SLIP YOKE ASSEMBLY
YOKE ASSEMBLY, PROPELLER SHAFT DAMPER AND
SLIP
SPIDER, PROPELLER SHAFT UNIVERSAL JOINT
BEARING, PROPELLER SHAFT UNIVERSAL JOINT
SPIDER
RING, PROPELLER SHAFT UNIVERSAL JOINT SPIDER
BEARING RETAINER
SHAFT ASSEMBLY, FRONT PROPELLER
BEARING, PROPELLER SHAFT CENTER SUPPORT
SEAL, REAR PROPELLER SHAFT
JOINT, PROPELLER SHAFT
SHAFT ASSEMBLY, REAR PROPELLER
YOKE ASSEMBLY, PROPELLER SHAFT FRONT SLIP
PC0001-4A-F-RP
Figure 1 - Propeller Shaft Assembly Components

called trunnions. The spider (2) allows the two yoke shafts
to operate at any angle to each other. Universal joints are
lubricated for life.
When torque is transmitted through any ordinary
universal joint, the drive pinion gear yoke fluctuates
slightly in speed. In other words, although the propeller
shaft slip yoke assembly (1 or 24) rotates at a constant
speed, the differential drive pinion gear yoke speeds up
and slows down twice per revolution. This fluctuation of
the pinion gear yoke is in direct proportion to the angle
through which the universal joint is operating; the greater
the angle, the greater the fluctuation.
Whenever two universal joints are used, this fluctuation effect can be eliminated by staggering the joints so
that the two yokes are 90 degrees apart, provided the two
joints are transmitting torque through the same angle.
Therefore, when two universal joints are used, the
angles through which they operate must be very nearly the
same. This allows the alternate acceleration and deceleration of one joint to be offset by the alternate deceleration
and acceleration of the second joint. When the two joints
do not run at approximately the same angle, operation is
rough and an objectionable vibration is produced.
Universal joints are designed to handle the effects of
various loadings and rear axle windup during acceleration. Within the designed angle variations the universal
joint will operate efficiently and safely. When the design
angle is changed or exceeded, the operational life of the
joint may decrease.
The universal joint spider bearings (3) used are the
needle roller type. The needle roller bearings are held in
place on the trunnions by round bearing caps. Production
universal joint spider bearings (3) are retained by nylon
injected rings instead of conventional retainer (snap) rings
(4). All service replacement universal joints use retainer
(snap) rings (4 ).
If it becomes necessary to replace a universal joint,
the entire propeller shaft assembly (5, 6 or 10) must be
removed from the vehicle. Care should be taken to avoid
jamming or bending any parts of the assembly.
PROPELLER SHAFT JOINT

Figure 1
The propeller shaft joint (9) (sometimes called a
constant velocity (CV) joint) is used on the two-piece propeller shaft assembly (6 and 10). The propeller shaft joint
(9) allows the driveline angle to be adjusted according to
the up and down movement of the vehicle without disturbing the power flow.
DIAGNOSIS
The following major component groups are usually
the cause of or are related to vibration:
Engine assembly and mounts.
Transmission assembly.
Tires, wheels and brake drum assemblies.
Propeller shaft assemblies and universal joints.
Before road testing a vehicle, check the following:
All fasteners for tightness at universal joint, wheel

nuts and engine mounts.
Tire air pressure.
Load conditions.
ROAD TEST
Figure2
Road test the vehicle to verify the complaint. Record
the speed and rpm at which the greatest vibration occurs.
The vibration is likely to be in the steering wheel or in the
seat bottom. The road test can be helpful in locating the
vibration source.
COAST TEST
Figure2
NOTICE: When performing a "Coast Test" on a
vehicle equipped with an automatic transmission
assembly, caution must be taken when returning
selector lever from "NEUTRAL" to "DRIVE" to
avoid transmission damage. When shifting from
"NEUTRAL" to "DRIVE," remember to:
1. Maintain engine speed at 1500 rpm.
2. Brake to 40 km/h (25 mph).
3. Return selector to "DRIVE."
Drive the vehicle past the vibration speed, shift into
"NEUTRAL" and coast back through the vibration
speed. During a coast test, two kinds of vibration normally
occur: a shaking or a buzzing. A shaking vibration is usually a problem with the tires or a wheel and brake drum or
brake rotor assembly. A buzzing vibration is usually a
driveline problem.
To determine whether a propeller shaft assembly is
causing the problem, drive the vehicle through the speed
range and note at which speed (vehicle and/or engine) the
problem is most pronounced. A tachometer may be used.
Shift the transmission assembly into a lower gear range
and drive the vehicle at the same engine speed as when the
problem was most pronounced in direct drive. Note the
effect on the problem.
To determine the engine speed if a tachometer is not
used, divide vehicle speed by the transmission gear ratio
in which the problem occurs.
Example: With the HYDRA-MATIC 4L60 automatic transmission in 2 range, divide by 1.63. If the problem is most pronounced in direct drive at 88 km/h (55
mph) the same engine speed would be produced in 2 range
at 55 km/h (55/1.63 = 34 mph).
If the problem is still present at the same engine
speed whether in direct drive or in the lower gear range, a
propeller shaft assembly cannot be at fault since a propeller shaft speed varies. If the problem decreases or is eliminated in a different gear range at the same engine speed, a
propeller shaft assembly may be at fault. Refer to "Propeller Shaft Assembly Runout Measurement," "Diagnosis of Propeller Shaft Assembly and Universal Joint" and
Figure 2.
.I:,,
)>
PROPELLER SHAFT ASSEMBLY DIAGNOSIS
.;,..
"ti
:a
DRIVE VEHICLE TO DETERMINE

PROBLEM & SPEED
(ACCELERATION - ROAD - ENGINE)
0
"ti
m
I"""
I"""
DRIVE AT ROAD SPEED ON

SMOOTH ROAD
m
:a
en
:::c
IMPACT BOOM
ROUGH ROAD
)>
RIDE AND EVALUATE AT 345 kPa (50 PSI) TIRE PRESSURE

CHECK TIRES, SUSPENSION
AND/OR BODY COMPARTMENT
PROBLEM NOT IMPROVED
"Tl
<O.
c:
...
PROBLEM IMPROVED
PLACE VEHICLE ON HOIST,

REMOVE REAR TIRE AND
WHEEL ASSEMBLIES AND
VERIFY PROBLEM SPEED
(D
I\)
I
"U
"O
~
SEE TIRE CHECK
.----------'------,
IPROBLEM IMPROVED I
CHECK AND/OR BALANCE TIRE AND WHEEL ASSEMBLIES
U)
:T
VISUAL EXAMINATION
40-72 KM/H (25-45 MPH)
)>
(/)
(/)
DAMAGED PROPELLER
SHAFT ASSEMBLY
(D
0-
TIGHT JOINTS
-<"
0
::::l
0
~
11 MISSING BALANCE
WEIGHT
BURRS OR NICKS ON
SUPPORT YOKE AND/OR PINION YOKE
IMPACT YOKE WITH

HAMMER OR REPLACE
PROBLEM NOT IMPROVED 1 - - - -.....
Ill
' - - - - - - - 1 PROBLEM IMPROVED
;::i.
ROAD TEST
88 KM/H (55 MPH)

ROTATE SHAFT 180 DEGREES AT PINION YOKE
PROBLEM NOT IMPROVED I

WORN UNIVERSAL JOINT
..,.
"'...
AT SLIP YOKE SPLINE
EVALUATE ON HOIST
()
:T
i$
11 EXCESSIVE LOOSENESS
REPLACE NECESSARY
PARTS
REPLACE PROPELLER SHAFT 11 CLEAN PROPELLER SHAFT I !BALANCE PROPELLER SHAFTI I REWORK OR REPLACE
ASSEMBLY
ASSEMBLY
ASSEMBLY
5)'
co
UNDERCOATING
ON PROPELLER SHAFT
ASSEMBLY
REPLACE UNIVERSAL JOINT
I EVALUATE
I PROBLEM IMPROVED
1------.
OUT OF BALANCE DRIVELINE, EXCESSIVE

PINION YOKE OR PROPELLER SHAFT ASSEMBLY RUNOUT
BALANCE PROPELLER SHAFT ASSEMBLY IN VEHICLE
'-------------------------1
ROADTEST
I ROAD TEST
PROPELLER SHAFT 4A5
DIAGNOSIS OF PROPELLER SHAFT ASSEMBLY AND UNIVERSAL JOINT

PROBLEM
POSSIBLE CAUSE
CORRECTION
Leak at front propeller shaft (An 1. Rough outside surface on propeller

shaft slip yoke.
occasional drop of lubricant
leaking from the slip yoke is
normal and requires no
attention.)
2. Fault rear transmission oil seal.
1. Replace transmission seal if cut by

burrs on slip yoke. Minor burrs can
be smoothed by careful use of
crocus cloth or honing with a fine
stone. Replace slip yoke if outside
surface is rough or burred badly.
2. Replace the rear transmission oil
seal. Bring transmission fluid up to
proper level after correction.
Knock in driveline; clunking

1. Worn or damaged universal joints.
noise when vehicle is operated
2. Differential side gears worn.
under float condition at 16 km/h
(lOmph) in high gear or
"NEUTRAL."
1. Replace universal joints.

2. Replace differential side gears as
required.
Ping, snap, or clinking noise in

drive line.
1.
Loose rear axle upper or lower

control arm bolt/screw.
2. Worn or damaged universal joints.
1. Tighten bolt/screw to specified

torque.
2. Replace universal joints.
Scraping noise
1. Slinger rubbing on rear axle

assembly.
2. Brake drum assembly, if equipped,
contacting backing plate.
1. Straighten slinger to remove

interference.
2. Replace brake drum assembly or
backing plate.
ON-VEHICLE SERVICE
[I] Important
The driveline components in this vehicle have been
factory system balanced. System balance provides a
smoother running driveline operation. However, it is
essential that the positions of all driveline components relative to the propeller shaft assembly and
rear axle assembly be observed and ACCURATELY REFERENCE MARKED PRIOR TO
DISASSEMBLY. These components include the
propeller shaft assemblies, rear axle assemblies,
differential drive pinion gear yoke, output shaft, etc.
ALL COMPONENTS MUST BE REASSEMBLED INTO THE EXACT RELATIONSHIP TO EACH OTHER AS THEY WERE
WHEN REMOVED. Additionally, the published
specifications and torque values, as well as any
measurements made prior to disassembly must be
followed to maintain the factory balance.
PROPELLER SHAFT ASSEMBLY RUNOUT

MEASUREMENT
Figure 3
Tool Required:
J 8001 Dial Indicator Set
Noise or vibration at high speed could be caused by
a bent propeller shaft assembly. The propeller shaft
assembly could have been damaged by rough handling or
a cDllision. Check for propeller shaft assembly straightness.
1. Raise vehicle on a twin post hoist so that the rear is

supported on the rear axle housing assembly and the
wheels can spin. Refer to SECTION OA.
2. Mount J 8001 on a movable support that is high
enough to permit contact of the indicator button with
the propeller shaft assembly (5, 6 or 10), or mount
J 8001 to a magnetic base and attach to a smooth
place on the vehicle underbody. Readings are to be
taken at points indicated in Figure 3.
3. With transmission in "NEUTRAL," check for runout by turning a rear wheel to rotate the propeller
shaft assembly (5 or 6 and 10).
4. If runout exceeds 1.40 mm (0.055 inch), disconnect
propeller shaft assembly (5 or 10) at differential
drive pinion gear yoke and rotate the propeller shaft
assembly (5 or 10) 180 degrees. Reinstall propeller
shaft assembly (5 or 10). Check runout again.
5. If runout is still over specifications at the differential
drive pinion gear yoke end, differential drive pinion
gear yoke runout should be measured. Refer to "Differential Drive Pinion Gear Yoke Runout Measurement" in the following procedure. If run-out is still
over specifications, replace the propeller shaft
assembly (5, 6 or 10), but only after checking for
vibration or noise.
6. Lower vehicle.
DIFFERENTIAL DRIVE PINION GEAR YOKE

RUNOUT MEASUREMENT
Figure 4
Tools Required:
J 35819 Runout Gage
H
A ONE-PIECE PROPELLER SHAFT ASSEMBLY RUNOUT
CHECK
B ONE-PIECE PROPELLER SHAFT ASSEMBLY FRONT
RUNOUT MEASUREMENT POINT
c ONE-PIECE PROPELLER SHAFT ASSEMBLY CENTER
D ONE-PIECE PROPELLER SHAFT ASSEMBLY REAR
E TWO-PIECE PROPELLER SHAFT ASSEMBLY RUNOUT
CHECK
F TWO-PIECE PROPELLER SHAFT ASSEMBLY CENTER
G TWO-PIECE PROPELLER SHAFT ASSEMBLY FRONT

H TWO-PIECE PROPELLER SHAFT ASSEMBLY REAR
J DAMPER, PROPELLER SHAFT SLIP YOKE ASSEMBLY
1 YOKE ASSEMBLY, PROPELLER SHAFT DAMPER AND
SLIP
5 SHAFT ASSEMBLY, PROPELLER
6 SHAFT ASSEMBLY, FRONT PROPELLER
7 BEARING, PROPELLER SHAFT CENTER SUPPORT
9 JOINT, PROPELLER SHAFT
10 SHAFT ASSEMBLY, REAR PROPELLER
24 YOKE ASSEMBLY, PROPELLER SHAFT FRONT SLIP PC00034A-F-RP
Figure 3 - Checking Propeller Shaft Assembly Runout
1. Raise the vehicle on a twin post hoist so the rear is

supported on the rear axle housing and the wheels
can spin. Refer to SECTION OA.
2. Remove propeller shaft assembly. Refer to "One
and Two-Piece Propeller Shaft Replacement" in this
section.
3. Measure pinion gear yoke runout using J 35819 and
J 8001. Record run out and mark high and low points
of pinion gear yoke.
4. If pinion gear yoke runout is 0.15 mm (0.006 inch)
or less, remove the pinion gear yoke balance weight,
if used. No further action is required.
5. If pinion gear yoke runout is greater than 0.15 mm
(0.006 inch), but less than 0.28 mm (0.011 inch) and
the balance weight is at or near the low point of pinion gear yoke runnout, no further action is required.
If balance weight is not at or near the low point of
pinion gear yoke runout, remove the weight.
6. If pinion gear runout is over 0.28 mm (0.011 inch),
but no greater than 0.38 mm (0.015 inch) and the
balance weight is at or near the low point of pinion
gear yoke runout, no further action is required.
7. If the balance weight is not at or near the low point
of pinion gear runout, remove the weight and rotate
the pinion gear yoke until runnout is 0.25 mm (0.010
inch) or less.
8.If impossible to achieve 0.25 mm (0.010 inch) or
less runout, install a new pinion gear yoke and
recheck for 0.25 mm (0.010 inch) or less runout.
MAXIMUM INDICATOR READING
PC0004-4AfRP
Figure 4 - Differential Drive Pinion Gear Yoke Runout

Refer to SECTION 4B for pinion gear yoke replacement.
Service replacement pinion gear yoke may be
equipped with balance weights. These weights
should not be removed.
9. Install propeller shaft assembly. Refer to "One and
Two-Piece Propeller Shaft Assembly Replacement"
in this section.
10. Lower vehicle.
PROPELLER SHAFT ASSEMBLY BALANCE

CHECK
l++I
Rotate propeller shaft assembly 180 degrees

from original position.
l++I
Install or Connect
1. Propeller shaft to pinion gear yoke. Refer to "One

and Two-Piece Propeller Shaft Assembly Replacement" in this section.
2. Remove wheel nuts.
4. Determine position that gives best driveline
response by road testing vehicle for final check of
propeller shaft balance.
5. If balance is unacceptable, refer to "Propeller Shaft
Assembly Balancing" in this section.
NOTICE: See "Notice" on page 4A-l of this section.

1. Raise vehicle on twin post hoist so wheels can spin.
Refer to SECTION OA.
2. Both rear tire and wheel assemblies. Refer to SECTION 3E.

3. Install wheel nuts with flat sides against rear brake
drum or rotor assemblies.
!l'l'I Inspect
A. Propeller shaft assembly, universal joint, and
attachments for mud, undercoating or loose
fasteners.
Clean
Propeller shaft assembly, universal joint,

and attachments.
l~I
Tighten
PROPELLER SHAFT ASSEMBLY

BALANCING
Hose Clamp Method
Figures 5 through 7
1. Place vehicle on twin post hoist so that rear of
vehicle is supported on rear axle housing and rear
wheels are free to rotate. Refer to SECTION OA.
2. Remove both rear tire and wheel assemblies. Refer
to SECTION 3E. Install wheel nuts with flat sides
next to rear brake drum or rotor assemblies.
3. Mark and number propeller shaft assembly (5) at
four points, 90 degrees apart, at rear of propeller
shaft assembly (5) just forward of balance weight.
4. Install two clamps ( 11) on rear of propeller shaft
assembly (5) and slide them rearward until clamps
( 11) stop at nearest balance weight welded to tube.
Align both clamps ( 11) at any one of four
marks made on propeller shaft assembly (5) in
step 3 and tighten.
Any loose attachments or fasteners to

specifications. Refer to "Specifications"
in this section.
CAUTION: Do not run the vehicle faster

than 88 km/h (55 mph). Stay clear of the
universal joint and balance weight
areas to avoid possible personal injury.
Do not run the vehicle on the hoist for
extended periods due to the danger of
overheating the transmission assem
bly or engine assembly.
B. Run vehicle in gear at speed where disturbance
peaks. Observe intensity of dis.turbance.
NOTICE: On vehicles with an automatic transmission assembly, allow the driveline components to
stop rotating with the transmission assembly in
"NEUTRAL" before placing the transmission
assembly in "PARK" or parts may be damaged.
C. Stop engine assembly.
4. Propeller shaft assembly from pinion gear yoke

only. Refer to "One and Two-Piece Propeller Shaft
PC6005-4A-D-RP
Figure 5 - Propeller Shaft Assembly Reference Marks

(One-Piece Propeller Shaft Assembly Shown, Two-Piece
Propeller Shaft Assembly Similar)

overheating the transmission assembly or engine assembly.
5. Run vehicle through speed range to 81-88 km/h
(50-55 mph). Note amount of imbalance felt at front
of rear axle housing assembly.
6. Loosen clamps ( 11) and rotate clamp heads 90
degrees to next mark on propeller shaft assembly
(5). Tighten clamps (11) and repeat step 5.
7. Repeat step 6 until vehicle has been run with clamp
heads located at all four marks on propeller shaft
assembly (5).
A REFERENCE MARK - 180 FROM HOSE CLAMP HEADS

5 SHAFT ASSEMBLY, PROPELLER
11 CLAMP, HOSE
A
PC0007 -4A-F-RP
Figure 6 - Balance Hose Clamps (One-Piece Propeller Shaft

Assembly Shown, Two-Piece Propeller Shaft Assembly
Similar)
5 SHAFT ASSEMBLY PROPELLER

11 CLAMP, HOSE
PC0008-4A-F-RP
Figure 7 - Rotating Balance Hose Clamps (One-Piece

Propeller Shaft Assembly Shown, Two-Piece Propeller Shaft
Assembly Similar)
8. Position clamps (11) at point of least imbalance.

Rotate clamp heads away from each other 45
degrees, one on each side of the position.
A. Run vehicle and note if balance has improved.
B. In some cases it may be necessary to use one
clamp (11) or possibly three clamps (11) in
order to obtain good balance.
C. Replace propeller shaft assembly (5) if three
clamps ( 11) do not improve balance.
9. Continue to rotate clamps (11) apart in smaller angular increments until imbalance is at its minimum.
10. Remove wheel nuts.
11. Install tire and wheel assemblies. Refer to SECTION 3E.
12. Lower vehicle.
13. Road test vehicle to check final balance.
A small vibration felt while vehicle is on hoist
may not be noticed on road test.
Strobe Light Method

Figures 5 through 9
If a strobe-light type wheel balancer is used, it will
help in the balancing of the propeller shaft assembly. The
balance pick-up unit should be placed directly under the
nose of the rear axle housing assembly and as far forward
as possible. Make up an extension for the balance pick-up
unit by using 3/8-inch tube and compression fittings (Figure 8).
1. Place vehicle on twin post hoist so rear of vehicle is
supported on rear axle housing assembly and rear
wheels are free to rotate. Lower rear hoist and allow
rear axle assembly to rest on jackstands.
2. Remove both rear tire and wheel assemblies. Refer
to SECTION 3E. Install wheel nuts with flat sides
next to rear brake drum or rotor assemblies. System
is now released and free to respond to propeller shaft
assembly (5).
3. Mark and number propeller shaft assembly (5) at
four points, 90 degrees apart, at rear of propeller
shaft assembly (5) just forward of balance weights.
4. Place strobe light wheel balancer pick-up under pinion gear yoke in contact with rear axle housing
assembly and as far forward as possible.
overheating the transmission or the
engine assemblies.
5. Run vehicle in gear at speed where disturbance is at
its peak.
6. Allow driveline to stabilize by holding at steady
speed.
7. Point strobe light up at spinning propeller shaft
assembly (5) and note position of one of the reference numbers.
\
\
11. Run vehicle through speed range 81-88 km/h (50-55

mph).
A. If disturbance is not gone and strobe light
shows clamp heads at bottom (6 o'clock) of
propeller shaft assembly (5), go to step 12.
B. If strobe light shows two clamp heads at top of
propeller shaft assembly (5), add one more
clamp ( 11) and check.
C. If strobe light shows three clamp heads at top
of propeller shaft assembly (5), remove propeller shaft assembly (5) and rotate 180 degrees
on pinion gear yoke ( 14 ). Check again, without
clamps ( 11 ).
D. Repeat balancing, starting with step 10.
LOCALLY
FABRICATED
TOOL
Important
12.
NOTE: LOCALLY FABRICATED EXTENSION FOR BALANCER

PICK-UP CONSISTS OF 3/8" TUBE AND
COMPRESSION FITTINGS
LC0008-4A-F-RP
Figure 8 - Pick-Up Unit at Differential Drive Pinion Gear Yoke
NOTICE: On vehicles with an automatic transmission assembly, allow the driveline components to
stop rotating with the transmission assembly in
"NEUTRAL" before placing the transmission
assembly in "PARK" or parts may be damaged.
8. Shut off engine assembly.
9. Position propeller shaft assembly (5) so reference
numbers will be in same position as was noted while
propeller shaft assembly (5) was rotating.
When strobe light flashed, heaviest point of
propeller shaft assembly (5) was at bottom (6
o'clock). To balance propeller shaft assembly
(5), it would be necessary to apply balancing
weights (hose clamps) 180 degrees away from
heaviest point or at top of propeller shaft
assembly (5) (12 o'clock).
10. Install two screw-type clamps ( 11) on propeller shaft
assembly (5) as close to rear as possible. Position
both clamp heads 180 degrees from heaviest point of
propeller shaft assembly (5) as indicated by strobe
light. Tighten clamps ( 11 ).
13.
14.
15.
16.
Do not use more than three clamps ( 11) to

balance propeller shaft assembly (5).
E. If propeller shaft assembly (5) still needs more
than three clamps ( 11) at same clock position,
replace propeller shaft assembly (5).
F. If clamps ( 11) are also 180 degrees from their
original position after rotating propeller shaft
assembly (5) 180 degrees, pinion gear yoke
( 14) is out of balance and must be replaced.
G. If strobe light shows clamps (11) at bottom of
propeller shaft assembly (5), but disturbance
still exists, go to step 12.
Rotate two of clamps (11) equally away from each
other toward top (one on each side of the position) in
small increments until best balance is achieved. In
some cases it may be necessary to use one clamp
( 11) or possibly three clamps ( 11) in order to obtain
good balance. Replace propeller shaft assembly (5)
if three clamps ( 11) do not correct problem.
Remove wheel nuts.
Install tire and wheel assemblies. Refer to SECTION 3E.
Remove strobe light and lower vehicle.
Road test vehicle to check final balance.
A small vibration felt while vehicle is on hoist,
may not be noticed on road test.
ONE AND TWO-PIECE PROPELLER SHAFT

ASSEMBLY REPLACEMENT
Figure 10

NOTICE: Do not strike or drop the propeller shaft
assembly, or allow the universal joints to bend to
extreme angles, as this might fracture a joint internally.
l. Raise and suitably support vehicle. Refer to SECTION OA.
2. Mark relationship of propeller shaft assembly (5 or
10) to pinion gear yoke (14).
3. Bolts/screws (16) from center support bearing (7), if
removing two-piece propeller shaft assembly.
A DETERMINE POINT OF IMBALANCE

B ADD HOSE CLAMPS 180 FROM POINT OF IMBALANCE
UNTIL THEY BECOME HEAVY SPOT
C ROTATE TWO CLAMPS EQUALLY AWAY FROM EACH
OTHER UNTIL BEST BALANCE IS ACHIEVED
D HEAVY SPOT
11 CLAMP, HOSE
PC0009-4AfRP
Figure 9 - Positioning Hose Clamps to Achieve Best Balance
4. Center support bearing (7) and washers ( 17) from

torque arm assembly (18), if removing two-piece
propeller shaft assembly.
5. Four bolts/screws (12).
6. Two retainers (13 ).
NOTICE: To prevent transmission seal damage, do

not place any tool between the propeller shaft slip
yoke and splines.
1. Assemble two-piece propeller shaft assembly. Refer
to "Two-Piece Propeller Shaft Assembly" in this
section.
7. Propeller shaft assembly (5 or 6 and 10) by withdrawing slip yoke assembly (1 or 24) from transmission assembly, moving propeller shaft assembly (5
or 6 and 10) rearward and passing it under housing
assembly (15).
2. Slip yoke assembly (1 or 24) onto transmission output shaft after lubricating spline with approximately
18 gm (0.6 ounce) of propeller shaft slip yoke lubricant GM P/N 1050169, or equivalent.
Support propeller shaft assembly (5 or 6 and

10) during removal.
3. Rear of propeller shaft assembly (5 or 10) to pinion

gear yoke ( 14).
If bearing caps are loose, tape them together to

prevent dropping and losing needle roller bearmgs.
8. Separate two-piece propeller shaft assembly, if necessary. Refer to "Two-Piece Propeller Shaft Assembly" in this section.
ll'l'I
Inspect
[I] Important
When making the rear propeller shaft assembly
connection, be sure to align the mark on pinion
gear yoke ( 14) with the mark on propeller shaft
assembly (5 or 10).
4. Rear universal joint to pinion gear yoke (14), making sure bearing caps are properly seated.
1. Transmission output shaft splines for burrs.
5. Two retainers (13).
2. Outer diameter of slip yoke assembly (1 or 24) for

burrs.
3. Splines of slip yoke assembly (1 or 24) for damage,

twisting or wear. They should agree in number and
fit with transmission output shaft splines.
4. Pinion gear yoke (14) at universal joint cap connecting surface for burrs or foreign material.
Tighten
l++I
Install or Connect

NOTICE: The propeller shaft assemblies must be
supported carefully during handling to avoid jamming or bending any of the parts.
l~I
Bolts/screws (12) evenly to 22 Nm (16 lb. ft.).

7. Washers (17) and center support bearing (7) to
torque arm assembly (18), if installing two-piece
propeller shaft assembly.
8. Bolts/screws (16) to center support bearing (7), if
installing two-piece propeller shaft assembly.
l~I
Tighten

9. Lower vehicle.
15
15
A
B
C
1
5
6
7
9
10
12
13
14
15
16
17
18
24
SHAFT ASSEMBLY, ONE-PIECE PROPELLER

SHAFT ASSEMBLY, TWO-PIECE PROPELLER
DAMPER, PROPELLER SHAFT SLIP YOKE ASSEMBLY
YOKE ASSEMBLY, PROPELLER SHAFT DAMPER AND
SLIP
BOLT/SCREW, PROPELLER SHAFT
RETAINER, PROPELLER SHAFT
YOKE, DIFFERENTIAL DRIVE PINION GEAR
HOUSING ASSEMBLY, REAR AXLE
BOLT/SCREW, PROPELLER SHAFT
WASHER, PROPELLER SHAFT
ARM ASSEMBLY, REAR AXLE TORQUE
YOKE ASSEMBLY, PROPELLER SHAFT FRONT SLIP
PC0010-4AF-RP
Figure 10 - Propeller Shaft Assemblies
UNIT REPAIR
TWO-PIECE PROPELLER SHAFT
ASSEMBLY
Figures 1 and 11
Tools Required:
J 33008 Axle Shaft Remover
J 2619-01 Slide Hammer
l+!+I Disassemble
has not engaged into groove in propeller shaft

assembly (6). Again, align propeller shaft
assemblies (6 and 10) and push them together
by hand.
3. Remove propeller shaft assembly (6) from vise.
CENTER SUPPORT BEARING

REPLACEMENT
Figure 11
1. Place propeller shaft assembly (6) horizontally in a
vise.
2. Propeller shaft assembly (6) from propeller shaft
assembly (10).
A. Screw J 33008 onto J 2619-01.
B. Place J 33008 on propeller shaft joint (9)
between propeller shaft joint bell area and propeller shaft assembly (6).
C. Using J 2619-01, drive propeller shaft assembly (10) from propeller shaft assembly (6).
3. Shaft seal (8) from rear propeller shaft assembly
(10).
Discard shaft seal (8).
l+!+I Assemble
1. New shaft seal (8) to rear propeller shaft assembly
(10).
2. Propeller shaft assembly (6) to propeller shaft
assembly ( 10).
Align propeller shaft assemblies (6 and 10) and
push them together by hand. If propeller shaft
assemblies (6 and 10) can be separated by
hand, then snap ring on propeller shaft joint (9)
6
7
9
10
1. Two-piece propeller shaft assembly. Refer to "One

and Two-Piece Propeller Shaft Assembly Replacement" in this section.
2. Front propeller shaft assembly from rear propeller
shaft assembly. Refer to "Two-Piece Propeller Shaft
3. Center support bearing (7).
Stand propeller shaft assembly (6) on end in
press with center support bearing (7) supported
by press bars.
Press propeller shaft assembly (6) down and
Qff center support bearing (7).

1. Center support bearing (7).
Press center support bearing (7) onto propeller
shaft assembly (6) using press.
2. Front propeller shaft assembly to rear propeller shaft
assembly. Refer to "Two-Piece Propeller Shaft
3. Two-piece propeller shaft assembly. Refer to "One
and Two-piece Propeller Shaft Assembly Replacement" in this section.

PC0011-4A-F-RP
Figure 11 - Separating the Two-Piece Propeller Shaft Assembly
PROPELLER SHAFT 4A 13
UNIVERSAL JOINTS
When taking apart a propeller shaft assembly, two
types of universal joints may be found: nylon injected ring
and snap ring.
NOTICE: Never clamp propeller shaft tubing in a
vise, as the tube may be dented. Always clamp on
one of the yokes and support the shaft horizontally.
Avoid damaging the propeller shaft slip yoke sealing
surface. Nicks may damage the bushing or cut the
transmission extension housing seal. Mark the slip
joint and propeller shaft to ensure correct reassembly.
Nylon Injected Ring Type

Tools Required:
J 9522-3 U-Joint Bearing Separator
J 9522-5 U-Joint Bearing Spacer Remover
A TRUNNION
2 SPIDER. PROPELLER SHAFT UNIVERSAL JOINT
19 CAP, BEARING
PC0013-4A-F-RP
l+!+I Disassemble
Figure 13 - Installing Universal Joint Bearing Spacer

Remover
l. Support propeller shaft assembly in a horizontal

position in line with base plate of a press.
2. Place universal joint so that lower ear of shaft yoke
is supported on a l l/8-inch socket.
3. Lower bearing cap ( 19) out of yoke ear by placing
J 9522-3 on open horizontal bearing caps (19) and
pressing lower bearing cap ( 19) out of yoke ear. This
shears nylon injected ring on lower bearing cap ( 19).
If bearing cap ( 19) is not completely removed, lift
J 9522-3 and insert J 9522-5 between seal (23) and
bearing cap (19). Complete removal of bearing cap
( 19) by pressing it out of yoke.
4. Rotate propeller shaft assembly. Shear opposite
nylon injected ring.
5. Opposite bearing cap (19) out of yoke.
6. Spider (2) from yoke.
There are no bearing retainer grooves in production bearing caps ( 19), therefore, they cannot be reused.
If front universal joint is being replaced,
remove pair of bearing caps (19) from propeller shaft slip yoke in same manner.
li,I Clean
Yoke in area locating retainer ring (4) to insure
proper assembly.
All sheared nylon from universal joint cup
bore
[I] Important
Production universal joints of this type cannot
be reassembled. Nylon injected ring types are
replaced by external snap ring types.
When reassembling a propeller shaft assembly,
always install a complete universal joint service kit. This
kit includes one pregreased spider (2), four service bearing cap assemblies with seals (23), needle roller bearings
(21), delrin round washers (20), delrin flat washers (22),
grease and four retainer rings (4 ). Make sure that the seals
(23) are in place on the service bearing caps ( 19) to hold
the needle roller bearings (21) in place during handling.
J 9522-3
l+!+I Assemble
For universal joint assembly procedure, refer to
"Snap Ring Type" in the following procedure.
A 11 /e SOCKET
TO SUPPORT YOKE
EAR (MUST CLEAR
BEARING CAP)
2 SPIDER, PROPELLER SHAFT---UNIVERSAL JOINT
Snap Ring Type

PC00124AF-RP
Figure 12 - Pressing Out Universal Joint Bearing
Tools Required:
J 9522-3 U-Joint Bearing Separator
23
A TRUNNION
2 SPIDER, PROPELLER SHAFT UNIVERSAL JOINT
4 RING, PROPELLER SHAFT UNIVERSAL JOINT SPIDER
BEARING RETAINER
19 CAP, BEARING
20 WASHER, DELRIN ROUND
21 BEARING, NEEDLE ROLLER
22 WASHER, DELRIN FLAT
23 SEAL
PC0014-4A-F-RP
Figure 14 - Service Universal Joint
J 9522-5 U-Joint Bearing Spacer Remover

NOTICE: Use care not to loosen or damage dust
seals. If dust seals are loose or damaged, replace the
entire universal joint.
These universal joints are designed for extended life
and do not require periodic inspections or lubrication.
Wh~n these joint_s are taken apart, repack bearings and
lubncant reservotr at the end of trunnions with chassis
lubricant GM P/N 1052356 or GM P/N 1052497 or
equivalent.
'
l+!+I Disassemble
1. Reta_iner rings (4 ). If retainer ring (4) does not
readily snap out ~f grooves, tap end of bearing cap
(19) lightly to relieve pressure against retainer ring
(4).
4 RING, PROPELLER SHAFT UNIVERSAL JOINT SPIDER

BEARING RETAINER
PC0016-4A-F-RP
Figure 16 - Installing Propeller Shaft Universal Joint Spider

Bearing Retainer Ring
2. Support propeller shaft assembly in a horirontal

position in line with base plate of a press.
3. Place universal joint so lower ear of yoke i~ supported on a 1 1/8-inch socket.
4. Lower bearing cap (19) out of yoke ear. Place
J 9522-3 on open horizontal bearing cap (19). If
bearing cap ( 19) is not completely removed, lift
J 9522-3 and insert J 9522-5 between seal (23) and
bearing cap ( 19) being removed. Complete removal
of bearing cap ( 19) by pressing it out of yoke.
5. Rotate propeller shaft assembly and press opposite
bearing cap ( 19) out of yoke.
6. Spider (2) from yoke.
l+!+I Assemble
1. One bearing cap (19) part way into one side of yoke.
Turn this yoke ear to the bottom.
Insert J 9522-3 seating trunnion in bearing cap

(19).
2. Opposite bearing cap (19) part way.
ll'l'I
Inspect
Both trunnions to ensure positioning is straight

and true into bearing caps ( 19).
A TRUNNION
2 SPIDER, PROPELLER SHAFT UNIVERSAL JOINT
19 CAP, BEARING
PC0015-4A-F-RP
Figure 15 - Partially Inserted Bearing Cap
1'
STRIKE TUBE YOKE
EAR IN THIS AREA
KC0210-4A-B-RP
Figure 17 - Seating Propeller Shaft Universal Joint Spider

Bearing Retainer Ring

clears inside of yoke.
3. Press against opposite bearing caps ( 19), working

spider (2) all of the time to ensure free movement of
trunnions in bearings.
!ll
5. Retainer ring (4) by pressing into place.

Continue pressing until opposite side can be
s!lapped .into place. If nee?ed, strike yoke
firmly with a hammer to aid in seating the
retainer rings (4 ). This springs yoke ears
slightly.
1nspect
Needle roller bearings (21) for binding. If

binding, one or more needle roller bearings
(21) has probably tipped under end of trunnion.
4. Stop pressing when one bearing retainer groove
6. Repeat steps 1 through 5 for other half of universal

joint.
SPECIFICATIONS
One-Piece Propeller Shaft Assembly Runout
Front Propeller Shaft Assembly Runout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Center Propeller Shaft Assembly Runout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rear Propeller Shaft Assembly Runout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Two-Piece Propeller Shaft Assembly Runout
Front Propeller Shaft Assembly Center Runout . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rear Propeller Shaft Assembly Front Runout . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. Rear Propeller Shaft Assembly Rear Runout . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.40 mm (0.055")
1.40 mm (0.055")
1.40 mm (0.055")
1.40 mm (0.055")
1.40 mm (0.055 ")
1.40 mm (0.055")

Propeller Shaft-to-Center Support Bearing Bolt/Screw ...................... 50 Nm (37 lb. ft.)
Propeller Shaft-to-Differential Yoke Bolt/Screw ........................... 22 Nm (16 lb. ft.)
SPECIAL TOOLS
2.
1.
4.
J 9522-3
(fffjj/
/.
I
I
J 9522-5
J 8001
~~
5.
~9-01
6.
J 33008
1.
2.
3.
4.
5.
6.
U-JOINT BEARING SE PARA TOR

U-JOINT BEARING SPACER REMOVER
RUNOUT GAGE
DIAL INDICATOR SET
SLIDE HAMMER
AXLE SHAFT REMOVER
PC0017-4Af-RP
REAR AXLE 48 1
SECTION 48
REAR AXLE
If a fastener needs to be replaced, use the correct part number for that application. If the correct part number
fastener is not available, a fastener of equal size and strength (or stronger) may be used. Fasteners that are not
reused, and those requiring thread locking compound will be called out. The correct torque value must be used
result.
CONTENTS
General Description ........................ 4B-1
Standard Rear Axle Assembly . . . . . . . . . . . . . . 4B-l
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4B-3
Limited Slip Rear Axle Assembly . . . . . . . . . . . 4B-3
Rear Axle Assembly Identification .......... 4B-4
Maintenance and Lubrication .............. 4B-4
Diagnosis ................................ 4B-4
Rear Axle Noises ........................ 4B-5
Gear Noise ........................... 4B-5
Bearing Noise . . . . . . . . . . . . . . . . . . . . . . . . 4B-5
Rear Axle Shaft Bearing Noise ........... 4B-5
Knock at Low Speeds . . . . . . . . . . . . . . . . . . 4B-5
Backlash Clunk ....................... 4B-5
Limited Slip Rear Axle Assembly . . . . . . . . . . . 4B-5
Checking Limited Slip Operation ......... 4B-6
Rear Axle Standard and Limited Slip
Diagnosis ............................ 4B-6
Inspection and Diagnosis .................. 4B-7
Differential Ring Gear Tooth
Nomenclature ....................... 4B-7
Tooth Contact Pattern Test ................ 4B-7
Effects of Increasing Load on
Tooth Contact Pattern ................ 4B-8
Adjustments Affecting Tooth Contact ...... 4B-8
Effects of Differential Drive Pinion
Gear Position on Tooth Pattern ......... 4B-8
On-Vehicle Service ........................ 4B-8
Rear Axle Lubricant Fill and Check ........ 4B-10
Rear Axle Housing Cover and Gasket ....... 4B-10
GENERAL DESCRIPTION
STANDARD REAR AXLE ASSEMBLY
Figures 1 and 2
The rear axle assembly is the semi-floating hypoid
type in which the vehicle weight is carried on the housing
assembly (16). The rear axle assembly is designed for use
with an open driveline and coil spring assemblies. The
rear axle assembly has a hypoid type ring gear (20) with
the centerline of the drive pinion gear (23) below the
centerline of the ring gear (20).
All parts necessary to transmit power from the
propeller shaft to the rear tire and wheel assemblies are
enclosed in the housing assembly (16). A removable steel
cover (43) bolted to the rear of the housing assembly (16)
Rear Axle Shaft . . . . . . . . . . . . . . . . . . . . . . . .

Rear Axle Shaft Bearing Assembly
and/or Bearing Seal ...................
Differential Drive Pinion Gear
Yoke and Seal ........................
Rear Axle Assembly ....................
Rear Wheel Bolt/Screw ..................
Unit Repair ..............................
Differential Case . . . . . . . . . . . . . . . . . . . . . . .
Speed Sensor Reluctor Wheel .............
Differential Ring Gear-to-Differential
Drive Pinion Gear Backlash ............
Differential Bearing Assembly
Preload Adjustment ...................
Differential Drive Pinion Gear ............
Outer Bearing Assembly .............
Inner Bearing Assembly .............
Differential Drive Pinion Gear Depth .......
Differential Case (Limited Slip) ...........
Rear Axle Housing Replacement ...........
Rear Axle Assembly with Disc Brakes . . . . . .
Specifications ............................
Limits for Fitting and Adjusting ...........
Rear Axle Assembly Usage ...............
Special Tools ............................
4B-11
4B-12
4B-13
4B-14
4B-15
4B-15
4 B-16
4B-18
4B-18
4B-19
4B-20
4B-21
4B-22
4B-22
4B-24
4B-24
4B-25
4B-26
4B-26
4 B-26
4B-27
4B-27
4B-27
permits service of the rear axle assembly without removing the entire assembly from the vehicle.
A universal joint connects the rear end of the propeller shaft to the yoke (3). The yoke (3) has a splined end
which fits over and drives the drive pinion gear (23). Two
preloaded tapered roller bearing assemblies support the
drive pinion gear (23) in the housing assembly (16). The
races of the inner bearing assembly (18) and the outer
bearing assembly (7) are a tight press fit in the housing
assembly (16). The inner bearing assembly (18) is a tight
press fit onto the drive pinion gear (23). The outer bearing
assembly (7) combines a light press fit to a close sliding
fit on the yoke end of the pinion gear stem. The races of
the inner and outer bearing assemblies (18 and 7) are
pressed against shoulders recessed in the housing assembly (16).
48-2 REAR AXLE
L .. - - - -- - --- -- - .... ..J

Figure 1 - Standard Rear Axle Assembly
PC0001-4BF-RP
REAR AXLE 48-3
A
B
1
2
3
5
6
7
9
15
16
17
18
19
20
22
23
24
25
26
28
29
32
33
34
35
DIFFERENTIAL ASSEMBLY
OPTIONAL DISC BRAKE ASSEMBLY
NUT, DIFFERENTIAL DRIVE PINION GEAR
WASHER, DIFFERENTIAL DRIVE PINION GEAR
YOKE, DIFFERENTIAL DRIVE PINION GEAR
DEFLECTOR, DIFFERENTIAL DRIVE PINION GEAR DIRT
SEAL, DIFFERENTIAL DRIVE PINION GEAR
BEARING ASSEMBLY, DIFFERENTIAL DRIVE PINION
GEAR OUTER
PLUG, REAR AXLE HOUSING DRAIN
SPACER, DIFFERENTIAL DRIVE PINION GEAR BEARING
HOUSING, ASSEMBLY, REAR AXLE
VENT, REAR AXLE
BEARING ASSEMBLY, DIFFERENTIAL DRIVE PINION
GEAR INNER
SHIM, DIFFERENTIAL DRIVE PINION GEAR
GEAR, DIFFERENTIAL RING
CAP, DIFFERENTIAL CARRIER BEARING
GEAR, DIFFERENTIAL DRIVE PINION
SHIM, DIFFERENTIAL BEARING
SPACER, DIFFERENTIAL BEARING
BOLT/SCREW, DIFFERENTIAL BEARING CAP
BOLT/SCREW, DIFFERENTIAL RING GEAR
BOLT/SCREW, DIFFERENTIAL PINION GEAR SHAFT
LOCK
BEARING ASSEMBLY, DIFFERENTIAL
CASE, DIFFERENTIAL
MAGNET, REAR AXLE HOUSING CHIP COLLECTING
SHAFT, DIFFERENTIAL PINION GEAR
36
37
38
39
40
41
43
44
45
46
48
49
54
58
59
61
63
64
65
66
67
68
69
70
71
72
73
75
GEAR, DIFFERENTIAL PINION

WASHER, DIFFERENTIAL PINION GEAR THRUST
WASHER, DIFFERENTIAL SIDE GEAR THRUST
WHEEL, REAR WHEEL SPEED SENSOR RELUCTOR
GEAR, DIFFERENTIAL SIDE
BOLT/SCREW, REAR AXLE HOUSING
COVER, REAR AXLE HOUSING
BEARING ASSEMBLY, REAR AXLE SHAFT
GASKET, REAR AXLE HOUSING COVER
PLATE, REAR BRAKE BACKING
BOLT/SCREW, REAR BRAKE BACKING
SEAL, REAR AXLE SHAFT BEARING
LOCK, REAR AXLE SHAFT
DRUM ASSEMBLY, REAR BRAKE
BRAKE ASSEMBLY, REAR
BOLT/SCREW, REAR WHEEL
SHAFT REAR AXLE (DRUM BRAKE ASSEMBLIES)
NUT, REAR BRAKE BACKING PLATE
PLATE, REAR BRAKE CALIPER ASSEMBLY MOUNTING
BOLT/SCREW, CALIPER ASSEMBLY MOUNTING
SHIM, AXLE TUBE FLANGE
NUT, REAR BRAKE CALIPER MOUNTING PLATE
CALIPER ASSEMBLY, REAR BRAKE
SHAFT, REAR AXLE (DISC BRAKE ASSEMBLIES)
ROTOR ASSEMBLY, REAR BRAKE
BOLT/SCREW, REAR BRAKE BACKING PLATE
BOLT/SCREW, SENSOR PLUG MOUNTING
SENSOR ASSEMBLY, WHEEL SPEED
PC0002-4B-F-RP
Figure 2 - Standard Rear Axle Assembly - Legend
Tightening nut (1) compresses a collapsible spacer

( 15) that bears against the outer bearing assembly (7) and
a shoulder on the pinion stem. This spacer ( 15) is used to
enable automatic bearing preload adjustment and maintain a preload on both inner and outer bearing assemblies
( 18 and 7). Adjustment of the fore-and-aft position of the
drive pinion gear (23) is obtained by placing selective
shims (19) between the head of the drive pinion gear (23)
and the inner bearing assembly (18).
The case (33) is one piece and is supported in the
housing assembly (16) by two tapered roller side bearing
assemblies (32). These are preloaded by inserting shims
(24) between the bearing assemblies (32) and the housing
assembly (16). The case (33) is positioned for proper differential ring gear-to-differential drive pinion gear backlash by varying the shim thickness from side to side. The
ring gear (20) is bolted to the case (33). A speed sensor
reluctor wheel (39) is press fit to the case (33). A wheel
speed sensor assembly (75) is mounted to the housing
assembly (16). This sensor provides wheel speed
information to the electronic brake control module
(EBCM) assembly. For further information, refer to SECTION 5El.
Two side gears (40) have splined bores for driving
the axle shafts (63 or 70). They are positioned to turn in
counterbored cavities in the case (33). The pinion gears
(36) have smooth bores and are held in position by a solid
pinion gear shaft (35), mounted and locked in the case
(33). All four gears are in mesh with each other. The pinion gears (36) turn freely on the pinion gear shaft (35),
acting as idler gears when the rear wheel assemblies are

turning at different speeds. The pinion gears (36) and side
gears (40) are backed by steel thrust washers (37 and 38).
Operation
When the vehicle turns a corner, the differential
assembly allows the outer rear tire and wheel assembly to
turn faster than the inner tire and wheel assembly. The
inner tire and wheel assembly, turning slower with respect
to the outer tire and wheel assembly, slows its differential
side gear (as the axle shaft is splined to the side gear). The
differential pinion gears roll around the slowed differential side gear, driving the other differential side gear tire
and wheel assembly faster.
LIMITED SLIP REAR AXLE ASSEMBLY

Limited slip rear axle assemblies have several definite operating characteristics. An understanding of these
characteristics is necessary to aid diagnosis.
The energizing force comes from the thrust side of
the gears. Consequently, a free spinning tire and wheel
assembly may not have enough resistance to driving
torque to apply the clutch packs or cones. If this occurs,
applying the parking brake a few notches will provide
enough resistance to energize the cones.
Energizing the cones is independent of acceleration;
therefore, a very slow application of the throttle on starting is recommended to provide maximum traction by preventing "break away" of either rear tire and wheel
assembly.
48-4 REAR AXLE

All rear axle parts of vehicles with the limited slip
rear axle assembly are interchangeable with those
equipped with the standard rear axle assembly, except for
the differential case. It is similar in all respects to the standard differential case, with the addition of cone clutches
splined to each side gear. The Auburn limited slip differential case is non-serviceable and must be replaced.
(7,500 miles). Limited slip differential assemblies also

use GM PIN 1052271 axle lubricant or SAE 80W-90
GL-5 gear lubricant or equivalent.
If the vehicle is used to pull a trailer, change lubricant every 12 500 km (7,500 miles) in either type differential assembly.
DIAGNOSIS
REAR AXLE ASSEMBLY IDENTIFICATION

Figure3
The rear axle assembly identification code and
manufacturer's code must be known before attempting to
adjust or repair axle shafts or the differential assembly.
Rear axle ratio, differential type, manufacturer, and build
date information is stamped on the right axle tube on the
forward side or on a metal tag on the housing cover (43).
The service parts identification label also has RPO codes
for the rear axle assembly printed on it.
MAINTENANCE AND LUBRICATION

Figures 1 and 2
To check or add lubricant, hoist vehicle at suspension contact points. Refer to SECTION OA. Keep vehicle
level. Clean dirt or foreign material from around plug
opening before removing the plug (9). Maintain lubricant
level from flush with bottom of opening to no lower than
15 mm (9/16 inch) below opening. Always replace plug
(9). Tighten to 35 Nm (26 lb. ft.). Use GM PIN 1052271
axle lubricant or SAE 80W-90 GL-5 gear lubricant or
equivalent.
Limited slip differential assemblies should have
lubricant drained and refilled at the first 12 500 km
Many noises reported as coming from the rear axle

assembly actually originate from other sources such as
tire and wheel assemblies, road surfaces, wheel bearing
assemblies, engine assembly, transmission assembly,
muffler or body. A thorough and careful check should be
made to determine the source of the noise before taking
apart the rear axle assembly. Noise which originates in
other places cannot be corrected by adjustment or replacement of parts in the rear axle assembly. Rear axle differential gears, like any other mechanical device, are not
absolutely quiet and should be accepted as being commercially quiet unless some abnormal noise is present.
To make a systematic check for axle noise under
standard conditions, observe the following:
1. Check rear axle lubricant to ensure correct level,
then drive vehicle far enough to thoroughly warm up
rear axle lubricant.
2. Select a level asphalt road to reduce tire noise and
body drumming.
3. Note speed at which noise occurs. Then stop vehic~e
and with the transmission assembly control lever m
"NEUTRAL," run engine slowly up and down
through engine speeds, corresponding to vehicle
speed at which noise was most pronounced, to determine if it is caused by exhaust, muffler roar or other
engine conditions.
2 ABK 103 2
II\\
A
B
C
D
E
F
G
H
43
AXLE CODE
MANUFACTURER
DAY BUILT
SHIFT
LIMITED SLIP TAG
AXI-E CODE TAG
FRONTVIEW
REARVIEW
COVER, REAR AXLE HOUSING
PC0003-4B-FRP
Figure 3 - Rear Axle Assembly Identification
REAR AXLE 48-5

4. Tire noise changes with different road surfaces, but
rear axle noise does not. Temporarily inflating all
tires to approximately 345 Kpa (50 psi) for test purposes only, will alter noise caused by the tires, but
will not affect noise caused by the rear axle assembly. Rear axle noise usually stops when coasting at
speeds under 48 km/h (30 mph). Tire noise continues, but with a lower tone as vehicle speed is
reduced. Rear axle noise usually changes when
comparing drive and coast, but tire noise remains
about the same.
Distinguish between tire noise and rear axle
noise by noting if noise varies with various
speeds or sudden acceleration and deceleration. Exhaust and axle assembly noises show
variations under these conditions while tire
noise remains constant and is more noticeable
at speeds of 32 to 48 km/h (20 to 30 mph).
Check for tire noise by driving vehicle over
smooth pavements or dirt roads (not gravel)
with tires at normal pressure. If noise is caused
by tires, it will noticeably change or disappear
and appear again with changes in the road surface.
5. Loose or rough front wheel inner or outer bearing
assemblies will cause a noise which may be confused with rear axle noise. Front wheel inner or
outer bearing noise does not change when comparing drive and coast. Light application of the brake
pedal assembly while holding the vehicle speed
steady will often cause front wheel inner and outer
bearing noise to diminish, as this takes some weight
off the bearing assembly. Front wheel inner and
outer bearing assemblies may be easily checked for
noise by jacking up the tire and wheel assemblies
and spinning them or by shaking the tire and wheel
assemblies to determine if bearing assemblies are
loose.
6. Rear suspension rubber bushings and spring insulators dampen out rear axle assembly noise when correctly installed. Check that no metallic contact
exists between the spring and spring opening in the
underbody or between lower control arm bushings
and underbody or axle housing brackets. Metalto-metal contact at those points may result in telegraphing road noise and normal axle noise which
would not be objectionable if dampened by bushings.
REAR AXLE NOISES

Gear Noise
After the noise has been determined as being in the
rear axle assembly, the type of noise should be established
to help in making repairs if necessary.
Gear noise (whine) is audible from 32 to 89 km/h
(20 to 55 mph) under four driving conditions:
1. Drive - Acceleration or heavy pull.
2. Road Load- Vehicle driving load or constant speed.
3. Float - Using enough throttle to keep the vehicle
from driving the engine assembly, the vehicle slows
down gradually but the engine assembly still pulls

slightly.
4. Coast - Throttle closed and vehicle in gear. Gear
noise most frequently has periods where noise is
more noticeable, usually 48 to 64 km/h (30 to 40
mph) and 80 to 89 km/h (50 to 55 mph).
Bearing Noise
Bad bearing assemblies generally produce more of a
rough growl or grating sound, rather than the whine typical of gear noise. Bearing noise frequently "wow-wows"
at constant bearing rpm, indicating a faulty differential
drive pinion gear or side bearing assembly. This noise
could easily be confused with rear axle shaft bearing
noise. Inspect and replace as required.
Rear Axle Shaft Bearing Noise

A rough rear axle shaft bearing assembly produces a
noise that continues with the vehicle coasting at low
speed and transmission assembly control lever in "NEUTRAL." Noise may diminish by gentle braking. With rear
tire and wheel assemblies jacked up, spin rear tire and
wheel assemblies by hand while listening at hub assemblies for evidence of rough (noisy) rear axle shaft bearing
assembly.
Knock at Low Speeds

Low speed knock can be caused by a worn universal
joint or a side gear hub counterbore in the differential case
worn oversize. Inspect and replace universal joint or the
differential case and side gear as required.
Backlash Clunk
Excessive clunk with acceleration and deceleration
is caused by worn differential drive pinion gear shaft,
worn differential case, excessive clearance between the
rear axle shaft and side gear splines, excessive clearance
between side gear hub and counterbore in case, worn differential drive pinion gear and side gear teeth, worn differential pinion gear thrust washers and excessive
differential ring gear-to-differential drive pinion gear
backlash. Remove worn parts and replace as required,
selecting close fitting parts when possible. Adjust differential ring gear-to-differential drive pinion gear backlash.
Refer to "Differential Ring Gear-to-Differential Drive
Pinion Gear Backlash'' in this section.
LIMITED SLIP REAR AXLE ASSEMBLY

Improper operation is generally indicated by clutch
slippage or grabbing. Sometimes this produces a chatter
or whirring sound. These sounds are not always indicative
of failure as they could be produced from lack of proper
lubrication. For example, under certain conditions where
one tire and wheel assembly is on a very slippery surface
and the other on dry pavement, wheel spin can occur if
hard acceleration is attempted. Continued spinning may
cause audible noise, such as a whirring sound, due to the
cones lacking sufficient lubric,mt. This does not necessarily indicate a failure of the unit.
During regular operation (straight ahead driving)
when both tire and wheel assemblies rotate at equal
speeds, there is an equal driving force delivered to each
tire and wheel assembly. When cornering, the inside tire
48-6 REAR AXLE

and wheel assembly requires extra driving force causing
slippage in the clutch cone. Consequently, the operational
life of the limited slip unit is dependent upon equal rotation of both tire and wheel assemblies during straight
ahead operation. If wheel rotation for both rear tire and
wheel assemblies is not equal during straight ahead operation, the limited slip unit will constantly be functioning as
if the vehicle were cornering. This will impose constant
slippage on the clutch and will eventually lead to abnormal wear on clutch cone.
Checking Limited Slip Operation
6. Place transmission assembly control lever in "NEUTRAL'' position and lower one rear tire and wheel
assembly to ground.
7. Measure torque required to rotate raised tire and
wheel assembly. Torque should be between 58 and
91 Nm (43 and 67 lb. ft.).
8. Install tire and wheel assembly. Refer to
SECTION 3E.
The differential case must be replaced as an assembly if any of the above checks do not fall within specifications.
Figure 4
Tools Required:
J 2619-01 Slide Hammer
with 1/2 x 13Adapter
J 21579 Axle Shaft Remover
1. Place transmission assembly control lever in
"PARK" position, or in gear if manual transmission
assembly, parking brake lever assembly released.
2. Raise both rear tire and assemblies off the floor.
3. Remove one tire and wheel assembly. Refer to
SECTION 3E.
4. Install J 21579, 1/2 x 13 adapter from J 2619-01 and

a torque wrench.
1/2 x 13 ADAPTER FROM J 2619-01

TORQUE WRENCH
A
B
NC4004-4B-B-RP
5. Measure torque required to rotate one tire and wheel

assembly. Torque should be between 169 and
305 Nm (125 and 225 lb. ft.).
Figure 4 - Measuring Limited Slip Rotating Torque
REAR AXLE STANDARD AND LIMITED SLIP DIAGNOSIS

CONDITION
CAUSE
1.
Noise is the same in "DRIVE" or when coasting.
a.
b.
c.
d.
2.
Noise changes on a different type of road.
a. Tire noise.
b. Road noise.
3.
Noise tone lower as vehicle speed is lowered.
a.
4.
Noise is produced with vehicle standing and driving.
a. Engine noise.
b. Transmission noise.
5.
Vibration.
a. Rough rear axle shaft bearing assembly.

b. Unbalanced or damaged propeller shaft assembly.
c. Tire unbalance.
d. Worn universal joint in propeller shaft assembly.
e. Incorrect driveline angles.
f. Mis-indexed propeller shaft assembly at drive pinion
gear yoke.
g. Drive pinion gear yoke runout too great.
6.
A knock or click approximately every two

revolutions of rear wheel assembly.
a.
Road noise.
Tire noise.
Front wheel bearing noise.
Incorrect driveline angles.
Tire noise.
Rear axle shaft bearing assembly.
REAR AXLE 48-7
CONDITION
CAUSE
a.
Differential side gear and pinion gear noise.
8. Continuous low pitch whirring or scraping noise

starting at relatively low speed.
a.
Drive pinion gear inner or outer bearing noise.
9. Drive noise, coast noise or float noise.
a.
Ring and drive pinion gear noise.
10. Clunk on acceleration or deceleration.
a.
Worn differential pinion gear shaft in case or side

gear hub counterbore in case worn oversize.
b. Worn universal joint on propeller shaft assembly.
c. Differential drive pinion gear yoke lubrication
insufficient.
11. Groan in forward or reverse.
a.
12. Chatter on turns.
a. Wrong lubricant in rear axle assembly.

b. Clutch cones worn (limited slip).
13. Clunk or knock on rough road operation.
Excessive end play of rear axle shafts.
7.
Noise most pronounced on turns.
Wrong lubricant in rear axle assembly.
INSPECTION AND DIAGNOSIS

A close examination of the rear axle assembly prior
to taking it apart will often reveal valuable information as
to the extent and type of repairs or adjustments necessary.
This information and the report of the malfunction provides a basis for determining the degree of tearing down
required. Frequent causes of rear axle noise are improper
backlash, differential drive pinion gear inner or outer
bearing preload, differential side bearing preload, or a
combination of these items. A few simple adjustments
may be all that are necessary to correct the problem.
Before removing the differential case from the housing assembly, these items should be checked and the
results recorded and analyzed: (1) backlash; (2) total differential assembly preload; and (3) tooth contact pattern.
Use care at all times to keep dirt and other foreign
matter, such as grinder dust, soot, or sand, away from the
rear axle assembly to prevent the possibility of subsequent failure.
Variations in the differential assembly or differential

drive pinion gear inner bearing assembly may cause
the differential drive pinion gear to be too far away
from, or close to, the differential ring gear. Thus, the
tooth contact must be tested and corrected, if necessary, or the gears may be noisy.
t:JOTICE: See "Notice" on page 4B-l of this section.
l~I
Clean
1. All dirt from area of cover (43) before removing

cover (43).
2. Remove housing cover. Refer to "Rear Axle Housing Cover and Gasket" in this section.
Differential Ring Gear Tooth Nomenclature

Figure 5
The side of the differential ring gear tooth which
curves outward, or is convex, is referred to as the "drive"
side. The concave side is the "coast" side. The end of the
tooth nearest center of the differential ring gear is referred
to as the "toe" end. The end of the tooth farthest away
from the center is the "heel" end. The toe end of the tooth
is smaller than the heel end.
Tooth Contact Pattern Test

Tool Required:
J 39446 ABS Exciter Ring Protector Kit
NOTICE: It is very important that tooth contact be
tested before the differential assembly is taken apart.
A
B
C
D
E
TOE
HEEL
CONVEX SIDE (DRIVE)
CONCAVE SIDE (COAST)
CORRECT PATTERN
NC4005-4B-B-RP
Figure 5 - Differential Ring Gear Tooth Nomenclature
48-8 REAR AXLE

3. Wipe oil out of the housing assembly (16) and carefully clean each tooth of the ring gear (20).
4. Select correct exciter ring protector from J 39446
and attach to speed sensor reluctor wheel (39).
5. Use gear marking compound GM P/N 1052351 or
equivalent and apply this mixture sparingly to all
ring gear teeth, using a medium stiff brush. When
properly used, the area of differential drive pinion
gear tooth contact will be visible when hand load is
applied.
l~I
Tighten

6. Apply parking brake until a torque of 54 to 70 Nm
(40 to 52 lb. ft.) is required to turn drive pinion
gear (23).
A test made without loading the gears will not give a
satisfactory pattern. Turn yoke (3) with a wrench so
that ring gear (20) rotates one full revolution.
Reverse rotation so that ring gear (20) rotates one
revolution in the opposite direction.
7. Observe pattern on the ring gear teeth and compare
with Figure 6.
8. If pattern is acceptable, remove J 39446.
9. Install housing cover. Refer to "Rear Axle Housing
Cover and Gasket" in this section.
Effects of Increasing Load on Tooth

Contact Pattern
When the "load" on the differential ring and drive
pinion gears is increased, such as when the vehicle is
accelerated forward from standstill or from normal drive,
the tooth contact will tend to spread out and, under very
heavy load, will extend from near toe to near heel on the
drive side. The entire contact also tends to shift toward the
heel under increasingly heavier loads and will become
somewhat broader with respect to tops and bottoms of
teeth. The patterns obtained by this tooth contact pattern
test approximate a light load and, for this reason, they will
extend only about halfway.
The important thing to note is that the contact pattern is centrally located up and down on the face of the
differential ring gear teeth.
Insufficiently preloaded drive pinion gear and differential bearing assemblies will also cause a change in tooth
contact pattern under load.
Adjustments Affecting Tooth Contact

Figure 7
Two adjustments can be made which will affect the
tooth contact pattern: backlash and position of drive pinion gear (23) in the housing assembly. The effects of bearing preloads are not readily apparent on hand-loaded
tooth contact pattern tests.
Backlash is adjusted by means of shims (24). They
move the entire differential assembly closer to or farther
from the drive pinion gear (23). Shims (24) are also used
to set differential bearing preload. If the thickness of the
right shim (24) is increased, along with decreasing the left
shim thickness, backlash will increase. The backlash will

decrease if the left shim thickness is increased, along with
a decrease in right shim thickness.
The position of the drive pinion gear (23) is adjusted
by increasing or decreasing the shim thickness between
the drive pinion gear head and race of the differential
drive pinion gear inner bearing assembly. The shim (19) is
used in the rear axle assembly to compensate for
manufacturing tolerances. Increasing shim thickness
moves the drive pinion gear (23) closer to the centerline
of the ring gear (20). Decreasing shim thickness moves
the drive pinion gear (23) farther away from the centerline
of the ring gear (20).
Effects of Differential Drive Pinion Gear

Position on Tooth Pattern
FigureB
When the differential drive pinion gear is too far
away from the centerline of the differential ring gear, the
pattern will be a high heel contact on the drive side and
high toe contact on the coast side. Moving the differential
drive pinion gear closer to the centerline of the differential
ring gear by decreasing backlash will cause the high heel
contact on the drive side to move down and toward the
toe: the high toe contact on the coast side will move down
and toward the heel.
When the differential drive pinion gear is too close
to the centerline of the differential ring gear, the pattern
will be a low toe contact on the drive side, and a low heal
contact on the coast side. Moving the differential drive
pinion gear farther away from the differential ring gear by
increasing backlash will cause low toe contact on the
drive side to move up and toward the heel: the low heel
contact on the coast side will move up and toward the toe.
ON-VEHICLE SERVICE
Before attempting any service procedures, the technician must know what type rear axle assembly is to be
serviced. Refer to "Rear Axle Assembly Usage" in this
section to identify codes, differential ring gear size, and
ratios. Also, refer to the service parts identification label
on the vehicle.
Most rear axle assembly service repairs can be made
with the vehicle properly supported and the rear axle
housing assembly lowered to its lowest travel. On some
vehicles, it may be necessary to disconnect shock
absorber assemblies to obtain additional clearance. When
doing this, do not allow the rear brake hose assemblies to
become kinked or stretched.
Lubricant may be drained by removing all rear axle
housing bolts/screws and breaking the rear axle housing
cover loose at the bottom.
If the rear axle housing assembly is removed for any
reason, rear axle assembly service can be performed on
the bench.
When a new differential ring gear and differential
drive pinion gear are installed, the owner should be
advised not to accelerate rapidly or exceed 80 km/h
(50 mph) for the first 80 km (50 miles) of driving.
REAR AXLE 48-9
A LOW FLANK CONTACT: DECREASE DIFFERENTIAL DRIVE PINION GEAR BEARING SHIM THICKNESS - MOVES SMALLER DIAMETER OF DIFFERENTIAL DRIVE PINION GEAR OUT TOWARD DIFFERENTIAL RING GEAR CENTER LINE
B HEEL CONTACT: DECREASE BACKLASH - MOVES AREA OF DIFFERENTIAL DRIVE PINION GEAR CONTACT TOWARD TOE
C HIGH FACE CONTACT: INCREASE DIFFERENTIAL DRIVE PINION GEAR BEARING SHIM THICKNESS - MOVES LARGER DIAMETER
OF DIFFERENTIAL DRIVE PINION GEAR IN TOWARD CENTER OF DIFFERENTIAL RING GEAR
D TOE CONTACT: INCREASE BACKLASH - MOVES AREA OF DIFFERENTIAL DRIVE PINION GEAR CONTACT TOWARD HEEL
E DESIRED PATTERN: IN CENTER OF DIFFERENTIAL RING GEAR TOOTH
PC6006-4B-D-RP
Figure 6 - Differential Ring Gear Tooth Contact Pattern Diagnosis Chart
48-10 REAR AXLE
REAR AXLE LUBRICANT FILL AND CHECK

Figures 1 and 2
NOTICE: See "Notice" on 4B-1 of this section.
1. Raise and suitably support vehicle. Refer to
SECTIONOA.
Keep vehicle level.
2. Clean dirt or foreign material from around plug
opening before removing plug (9).
3. Remove plug (9).
4. Maintain axle lubricant level from flush with bottom
of plug opening to no lower than 15 mm (9/16 inch)
below ,Plug opening.
5. Add or replace axle lubricant using GM P/N
1052271 axle lubricant or SAE 80W-90 GL-5 gear
lubricant or equivalent.
6. Install plug (9).
l~I Tighten
A DIFFERENTIAL DRIVE PINION GEAR DEPTH
ADJUSTMENT
B BACKLASH ADJUSTMENT
19 SHIM, DIFFERENTIAL DRIVE PINION GEAR
20 GEAR, DIFFERENTIAL RING
23 GEAR, DIFFERENTIAL DRIVE PINION
24 SHIM, DIFFERENTIAL BEARING
Plug (9) to 35 Nm (26 lb. ft.).

7. Lower vehicle.
REAR AXLE HOUSING COVER AND

GASKET
Figures 1 and 2
PC0004-4B-F-RP
Figure 7 - Tooth Contact Adjustments

1. Raise and suitably support vehicle. Refer, to
SECTION OA.
E
A DIFFERENTIAL DRIVE PINION GEAR TOO FAR AWAY FROM DIFFERENTIAL RING GEAR
(INSUFFICIENT DIFFERENTIAL BEARING SHIM THICKNESS)
B EFFECT ON PATTERN AS DIFFERENTIAL BEARING SHIM THICKNESS IS INCREASED
C DIFFERENTIAL DRIVE PINION GEAR TOO CLOSE TO DIFFERENTIAL RING GEAR
(.EXCESSIVE DIFFERENTIAL BEARING SHIM THICKNESS)
D EFFECT ON PATTERN AS DIFFERENTIAL BEARING SHIM THICKNESS IS DECREASED
E TOE
F HEEL, COAST SIDE (CONCAVE)
G HEEL, DRIVE SIDE (CONVEX)
PC6008-4S-D-RP
Figure 8 - Differential Bearing Shim Thickness Effect on Tooth Pattern
REAR AXLE 4811

2. Bolts/screws (41 ), parking brake cable guides and
pry cover (43) loose.
15!1 Clean
All dirt from area of cover (43) before removing cover (43).
3. Drain lubricant.
4. Gasket (45).
Ill
Clean
Both gasket sealing surfaces.
l++I
Install or Connect

39
1. New gasket (45) and cover (43).
2. Parking brake cable guides and bolts/screws (41).
l~I
Tighten
Bolts/screws (41) in a crosswise pattern to

30 Nm (22 lb. ft.).
3. Lubricant. Refer to "Rear Axle Lubricant Fill and
Check" in this section.
16 HOUSING ASSEMBLY, REAR AXLE

22 CAP, DIFFERENTIAL CARRIER BEARING
26 BOLT/SCREW, DIFFERENTIAL BEARING CAP
29 BOLT/SCREW, DIFFERENTIAL PINION GEAR SHAFT
LOCK
39 WHEEL, REAR WHEEL SPEED SENSOR RELUCTOR
54 LOCK, REAR AXLE SHAFT
PC0005-4B-F-RP
Figure 9 - Internal View of Rear Axle Housing Assembly
4. Lower vehicle.
REAR AXLE SHAFT
Figures 1, 2 and 9
Tool Required:
1.

1. Rear
tire and
SECTION 3E.
wheel
assembly.
Refer
to
2. Rear brake drum assembly and components, if

equipped. Refer to SECTION 5C2.
2.
3.
3. Rear brake rotor assembly, if equipped. Refer to

SECTION 5B2.
4. Rear axle housing cover. Refer to "Rear Axle Housing Cover and Gasket" in this section.
5. Install J 39446 to speed sensor reluctor wheel (39).
6. Bolt/screw (29) from case (33).
7. Pinion gear shaft (35) from case (33).
8. Shaft lock (54).
Access by pushing flanged end of axle shaft
(63 or 70) into housing assembly (16).
9. Axle shaft (63 or 70) from housing assembly (16),
being careful not to damage seal (49).
4.

Axle shaft (63 or 70) into place, taking care that
splines on end of axle shaft (63 or 70) do not damage
seal (49) and that they engage with splines of side
gear (40).
Shaft lock (54).
Push axle shaft (63 or 70) outward so that shaft
lock (54) seats in counterbore of side gear (40).
Pinion gear shaft (35) through case (33), thrust
washers (37) and pinion gears (36), aligning hole in
pinion gear shaft (35) with lock bolt/screw hole in
case (33).
Bolt/screw (29).
l~I
Tighten

5. Remove J 39446 from speed sensor reluctor wheel
(39). If new speed sensor reluctor wheel (39) was
installed, remove protective covering and throw
away.
6. Rear axle housing cover. Refer to "Rear Axle Housing Cover and Gasket" in this section.
SECTION 5B2.
48-12 REAR AXLE

8. Rear brake drum assembly and components, if
equipped. Refer to SECTION 5C2.
9. Rear tire and wheel assembly. Refer to
SECTION 3E.
REAR AXLE SHAFT BEARING ASSEMBLY

AND/OR BEARING SEAL
Tools Required:
J 2619-01 Slide Hammer with 1/2 x 13
Adapter
J 22813-01 Axle Bearing Remover
J 23765 Axle Bearing Installer
J 23771 Axle Oil Seal Installer

1. Rear axle shaft. Refer to "Rear Axle Shaft" in this
section.
2. Rear brake backing plate, if equipped. Refer to
SECTION 5C2.
3. Rear brake caliper anchor bracket and mounting
plate, if equipped. Refer to SECTION 5B2.
4. Seal (49) from housing assembly (16) with a pry bar
behind steel case of seal (49), being careful not to
damage housing assembly (16).
PC0007-4B-F-RP
Figure 11 - Removing Rear Axle Shaft Bearing Assembly
5. Insert J 22813-01 into bore and position it behind

shaft bearing assembly (44) so tangs on tool engage
bearing outer race.
6. Shaft bearing assembly (44), using J 2619-01.
l++l tnstall or Connect

1. Lubricate new shaft bearing assembly (44) with GM
PIN 1052271 axle lubricant or SAE 80W-90 GL-5
gear lubricant or equivalent.
2. Shaft bearing assembly (44) so that tool bottoms
against shoulder in housing assembly (16), using
J 23765 and J 8092.
3. Lubricate sealing lips with GM P/N 1052271 axle
lubricant or SAE 80W-90 GL-5 gear lubricant or
equivalent.
4. Position seal (49) on J 23771 and direct seal (49)
into housing bore.
5. Seal (49) into place, flush with axle tube.
6. Rear brake backing plate, if equipped. Refer to
SECTION 5C2.
J8092 /
16
44
49
63
70

BEARING ASSEMBLY, REAR AXLE SHAFT
SEAL, REAR AXLE SHAFT BEARING
SHAFT, REAR AXLE (DRUM BRAKE ASSEMBLYI
SHAFT, REAR AXLE (DISC BRAKE ASSEMBLY)
44 BEARING ASSEMBLY, REAR AXLE SHAFT

PCOOOS-411-F-RP
PCOCJ06.4B-F-RP
Figure 10 - Rear Axle Shaft
Figure 12 - Installing Rear Axle Shaft Bearing Assembly
REAR AXLE 48-13
PC0009-4B-F-RP
Figure 13 - Installing Rear Axle Shaft Bearing Seal
7. Rear brake caliper anchor bracket and mounting

plate, if equipped. Refer to SECTION 5B2.
section.
ll'l'I Inspect
Operation of rear axle assembly.
DIFFERENTIAL DRIVE PINION GEAR YOKE

AND SEAL
Figures 1, 2 and 14 through 17
Tools Required:
J 8614-2 Pinion Flange Remover Adapter
J 8614-3 Pinion Flange Remover Screw
J 8614-10 Pinion Flange Remover
J 23911 Pinion Oil Seal Installer
A TORQUE WRENCH
3 YOKE, DIFFERENTIAL DRIVE PINION GEAR
PC0010-4B-F-RP
Figure 14 - Checking Differential Drive Pinion Gear Preload
9. Yoke (3), using J 8614-2, J 8614-3 and J 8614-10.

10. Seal (6) by driving it out of housing assembly (16)
with a blunt chisel. Do not damage housing assembly (16).
ll"'I Inspect
Differential drive pinion gear seal surface of yoke
(3) for tool marks, nicks, or damage, such as a
groove worn by seal (6). If damaged, replace
yoke (3).
Housing assembly bore and remove any burrs that
might cause leaks around outer diameter (OD) of
seal (6).

1. Both tire and wheel assemblies. Refer to
SECTION 3E.
2. Rear brake drum assemblies, if equipped. Refer to
SECTION 5C2.
3. Rear brake rotor assemblies, if equipped. Refer to
SECTION 5B2.
4. Propeller shaft assembly from differential drive pinion gear yoke. Refer to SECTION 4A.
5. Mark position of yoke (3), drive pinion gear (23)
and nut (1) so proper drive pinion gear inner and
outer bearing assembly preload can be maintained.
6. If joint bearing assemblies are not retained by a
retainer strap, use a piece of tape to hold bearing
assemblies on their journals.
7. Check preload with a pound-inch torque wrench and
record. This will give combined drive pinion gear
inner and outer bearing, axle shaft bearing and differential bearing preload.
8. Nut (1) and washer (2), using J 8614-10.
Use a suitable container to hold any fluid that
may drain from rear axle assembly
\
----
A WRENCH
PC0011-4B-F-RP
Figure 15 - Removing Differential Drive Pinion Gear Nut
48-14 REAR AXLE
J 8614-2
--------=:;
6 SEAL, DIFFERENTIAL DRIVE PINION GEAR


PC00134B-F-~P
PC0012-4BF-RP
Figure 16 - Removing Differential Drive Pinion Gear Yoke

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.

New seal (6), using J 23911.
Apply pinion gear seal lubricant, GM P/N 1050169
or equivalent, to the OD of yoke (3) and sealing lip
of new seal (6).
Yoke (3).
Washer (2) and nut (1) finger tight.
While holding yoke (3), using J 8614-10, tighten nut
gradually and turn drive pinion gear (23) several
revolutions after each tightening to set the bearing
assemblies. Check preload of bearing assemblies
each time with a pound-inch torque wrench until
preload is 0.3 to 0.6 Nm (3 to 5 lb. in.) more than
reading obtained in removal procedure.
Propeller shaft assembly to differential drive pinion
gear yoke. Refer to SECTION 4A.
Rear brake drum assemblies, if equipped. Refer to
SECTION 5C2.
Rear brake rotor assemblies, if equipped. Refer to
SECTION 5B2.
Tire and wheel assemblies. Refer to SECTION 3E.
Lubricant. Refer to "Rear Axle Lubricant Fill and
Check" in this section.
Lower vehicle.
IL'l'I Inspect
Operation of rear axle assembly.
REAR AXLE ASSEMBLY

Figures 1 and 2

1. Rear tire and wheel assemblies. Refer to
SECTION 3E.
2. Mark propeller shaft assembly and yoke (3).
3. Propeller shaft assembly. Refer to SECTION 4A.
4. Rear stabilizer shaft. Refer to SECTION 30.
5. Support housing assembly (16) with adjustable lifting device.
Figure 17 - Installing Differential Drive Pinion Gear Seal
6. Shock absorber assemblies from housing assembly.

Refer to SECTION 30.
7. Rear axle tie rod assembly. Refer to SECTION 30.
8. Rear brake (center) hose assembly from rear brake
(center) hose assembly junction block. Refer to
SECTION 5.
9. Rear spring assemblies. Refer to SECTION 3D.
10. Parking brake cable assemblies from housing
assembly. Refer to SECTION SF.
11. Electrical connector from wheel speed sensor
assembly (75).
12. Rear axle torque arm from housing assembly. Refer
to SECTION 30.
13. Rear axle lower control arm assemblies from housing assembly. Refer to SECTION 30.
14. Housing assembly (16) with aid of helper.

1. Housing assembly ( 16), with aid of helper.
2. Rear axle lower control arm assemblies to housing
assembly. Refer to SECTION 30.
3. Rear axle torque arm to housing assembly. Refer to
SECTION 30.
4. Electrical connector to wheel speed sensor assembly (75).
5. Parking brake cable assemblies to housing assembly. Refer to SECTION 5F.
6. Rear spring assemblies. Refer to SECTION 3D.
7. Rear brake (center) hose assembly to rear brake
(center) hose assembly junction block. Refer to
SECTION 5.
8. Rear axle tie rod assembly. Refer to SECTION 30.
9. Shock absorber assemblies to housing assembly.
10. Remove adjustable lifting device from housing
assembly (16).
11. Rear stabilizer shaft. Refer to SECTION 30.
13. Bleed hydraulic brake system. Refer to
SECTION 5El.
14. Rear tire and wheel assemblies. Refer to
SECTION 3E.
REAR AXLE 48-15
REAR WHEEL BOLT/SCREW
Figures 18 and 19
Tool Required:
J 6627-A Wheel Stud Remover
When replacing wheel bolts (hub studs), use the following guide:
Stripped bolts/screws - Replace bolts/screws
involved.
One loose bolt/screw - Replace all bolts/
screws.
One broken bolt/screw - Replace all bolts/
screws.
Wheel .bolt/screw hole elongated - Replace
axle shaft.
B
51
A
B
51
61
REAR AXLE SHAFT FLANGE

WASHER
NUT, REAR WHEEL
BOLT/SCREW, REAR WHEEL
PC0015-48-F-RP

1. Rear tire and
SECTION 3E.
2. Rear brake drum
SECTION 5C2.
3. Rear brake rotor
SECTION 5B2.
4. Wheel bolt/screw
J 6627-A.
wheel
Figure 19 - Installing Rear Wheel Bolt/Screw
assembly.
Refer
to
assembly, if equipped. Refer to
6. Rear tire and

SECTION 3E.
wheel
assembly.
Refer
to
assembly, if equipped. Refer to
UNIT REPAIR
(61) from axle shaft flange using

NOTICE: See "Notice" on page 4B-l of this section.
1. Wheel bolt/screw (61 ), four washers and wheel nut
(51) to axle shaft flange.
2. Wheel nut (51) until wheel bolt/screw (61) is completely seated against axle shaft flange.
l~I Tighten
Wheel nut (51) to 140 Nm (100 lb. ft.).
3. Remove wheel nut (51) and four washers.
4. Rear brake drum assembly, if equipped. Refer to
SECTION 5C2.
SECTION 5B2.
J 6627-A
A REAR AXLE SHAFT FLANGE

61 BOLT/SCREW, REAR WHEEL
NOTICE: Any time components are removed or

replaced within the rear axle housing assembly, use
J 39446 to prevent damage to the rear wheel speed
sensor reluctor wheel.
Important
The driveline components in this vehicle have been

factory system balanced. System balance provides a
smoother running driveline operation. However, it is
essential that the positions of all driveline components relative to the propeller shaft and rear axle
assembly be observed and ACCURATELY REFERENCE MARKED PRIOR TO DISASSEMBLY. These components include the propeller shaft
assemblies, rear axle assemblies, differential drive
!)inion gear yoke, output shaft, etc. ALL COMPONENTS MUST BE REASSEMBLED IN
THE EXACT RELATIONSHIP TO EACH
OTHER AS THEY WERE WHEN REMOVED.
Additionally, the published specifications and
torque values, as well as any measurements made
prior to disassembly must be followed to maintain
the factory balance.
When a new differential ring gear and drive pinion
gear are installed, the original differential drive pinion
gear yoke should be replaced with a service differential
drive pinion gear yoke. The owner should be advised not
to accelerate rapidly or exceed 80 km/h (50 mph) for the
first 80 km (50 miles) of driving.
Any time the rear axle assembly is taken apart for
service, the following cleaning and inspecting procedures
should be followed:
PC0014-4B-F-RP
Figure 18 - Removing Rear Wheel Bolt/Screw
Select correct ABS exciter ring protector from

J 39446 and attach to speed sensor reluctor wheel.
48-16 REAR AXLE
1.,1 Clean
All differential bearing assemblies thoroughly m
clean solvent.
ll'l'I Inspect
Bearing assemblies visually and by feel. Bearing
assemblies should feel smooth when oiled and
rotated while applying as much hand pressure as
possible. Minute scratches and pits that appear on
rollers and races at low mileage,are due to the initial
preload, and bearing assemblies having these marks
should not be replaced.
Sealing surface of differential drive pinion gear yoke
for nicks, burrs, or rough tool marks which would
cause damage to the differential drive pinion gear
seal and result in an oil leak. Replace if damaged.

Figures 1, 2 and 20
Important
Before removing the differential case from the rear

axle housing assembly, differential ring gear-to-differential drive pinion gear backlash must be checked.
Refer to "Differential Ring Gear-to-Differential
Drive Pinion Gear Backlash" in this section. This
will indicate gear or bearing wear or an error in
backlash or preload setting which will help in determining the cause of axle noise.
1. Rear axle shafts. Refer to "Rear Axle Shaft" in this
section.
2. Bolt/screw (73) from wheel speed sensor assembly (75).
H~msing assembly bore and remove any burrs that

might cause leaks around the OD of the drive pinion
gear seal.
3. Wheel speed sensor assembly (75).
Differential ring gear and drive pinion gear teeth for

excessive wear and scoring. If any of these conditions exist, replacement of the gears as a set will be
required.
Differential drive pinion gear shaft for unusual wear.

Also, check the differential pinion and side gears
and differential pinion gear thrust washers.
Press fit of the differential bearing assembly inner
race on the differential case hub by prying against
the shoulder at the puller recess in the case. Differential bearing assemblies must be press fit on the
hub.
Carefully place wheel speed sensor assembly (75) along side of housing assembly (16).
rn
Important
A. Bearing caps (22) should be marked "R" and

"L" to make sure they will be assembled in
their original locations.
B. Place right and left bearing outer.races of bearing assemblies (32) and shims (24) in sets with
marked bearing caps (22) so that they can be
reinstalled in their original positions.
Rear axle assembly failures such as chipped bearing

assemblies, loose (lapped-in) bearing assemblies,
chipped gears, etc. are indications that foreign material is present. The rear axle housing assembly must
be cleaned.
5. Shims (24).
Speed sensor reluctor wheel for chipped or missing

teeth; also check for looseness or wobble. Replace
speed sensor reluctor wheel if damaged.
6. Case (33) from housing assembly (16).
NOTICE: Exercise caution in prying on rear axle

housing assembly so gasket sealing surface is not
damaged.
J 39446
DIFFERENTIAL CASE
Tools Required:
J 22888-20 Differential Side
Bearing Remover
J 8107-2 Differential Side
Bearing Remover Plug

J 21465-13 Driver Handle Extension
J 25299 Differential Side Bearing Installer
J 25588 Side Bearing Shim Installer

A PRY BAR
33 CASE, DIFFERENTIAL
PC0016-48-F-RP
Figure 20 - Removing Differential Case
REAR AXLE 48-17
l+)I
Important
Disassemble
Figures 1, 2 and 21
Before assembling the differential assembly,

lubricate all parts with GM P/N 1052271 axle
lubricant or SAE 80W-90 GL-5 gear lubricant
or equivalent.
l. Differential bearing assembly (32) from case (33),

if replacing, using J 22888-20 and J 8107-2. If
removing an Auburn type limited slip differential
case; skip step 2.
2. Pinion gears (36), thrust washers (37), side gears

(40) and thrust washers (38) from case (33).
Mark side gears (40) and case (33) so side
gears (40) can be reinstalled in their original
position.
3. All bolts/screws (28) from case (33), if replacing
ring gear (20) or speed sensor reluctor wheel(39).
Bolts/screws (28) are left-hand thread type.
Discard bolts/screws (28).
4. Ring gear (20) from case (33).
Do not pry between ring gear (20), speed
sensor reluctor wheel (39) and case (33), if ring
gear (20) is on tight.
rn
- Drive ring gear (20) from case (33) using

brass drift and hammer.
Important
Speed sensor reluctor wheel must be replaced if

removed.
5. Speed sensor reluctor wheel (39) only if necessary,
using brass hammer.
IOI
Connecting surfaces of ring gear (20) and

case (33), if replacing ring gear (20).
CAUTION: Once the speed sensor
reluctor wheel has been removed from
the differential case, a new speed sensor reluctor wheel must be installed.
The press fit may be lost if the speed
sensor reluctor wheel is used more
than once. This would allow the speed
sensor reluctor wheel to rotate freely
on the differential case causing a
significant reduction in performance of
the antilock brake system, which could
1. Speed sensor reluctor wheel (39), if removed.
Carefully place speed sensor reluctor wheel
(39) over case (33) on ring gear side.
2. Ring gear (20) over speed sensor reluctor wheel
(39), if removed.
3. Two bolts/screws (28) into opposite sides of ring
gear (20). If converting to an Auburn type limited
slip differential case, skip step 4.
Install remaining new bolts/screws (28) until
just snug.
Discard speed sensor reluctor wheel (39).
l!+I
Assemble
NOTICE: See "Notice" on page 4B-l of this

section.
J 22888-20
32
l~I
PC0017-4B-F-RP
Figure 21 - Removing Differential Bearing Assembly
Tighten
New bolts/screws (28) alternately in progressive stages to 120 Nm (89 lb. ft.).
4. Thrust washers (38), side gears (40), pinion gears
(36) and thrust washers (37) into case (33).
A. Position thrust washers (38) over side gear
hubs and install side gears (40) in case (33). If
same parts are reused, install in original sides.
B. Position one pinion gear (36), (without thrust
washer (37), between side gears (40) and rotate
side gears (40) until pinion gear (36) is directly
opposite loading opening in case (33). Place
other pinion gear (36) between side gears (40)
so that pinion gear shaft holes are in line: then
rotate gears, lining up holes in pinion gears
(36) with holes in case (33).
C. Rotate pinion gears (36) back toward loading
opening just enough to permit sliding in thrust
washers (37).
5. Differential bearing assemblies (32) to case (33), if
removed, using J 8092, J 25299 and J 21465-13.
l++I
32 BEARING ASSEMBLY, DIFFERENTIAL
Clean
Install or Connect
Figures 1, 2 and 24
section.
48-18 REAR AXLE

28 BOLT/SCREW, DIFFERENTIAL RING GEAR (LEFT-HAND
THREAD)
33 CASE. DIFFERENTIAL
PC0018-4BF-RF

22 CAP, DIFFERENTIAL CARRIER BEARING
PC0020-4B-F-RP
Figure 24 - Installing Differential Bearing Shims
Figure 22 - Differential Ring Gear-to-Differential Case
1. Case (33) into housing assembly (16). Refer to

"Differential Case" in this section.
2. Shims (24).
rn
Important
Do not attempt to reinstall the production

shims as they may break when tapped into
place.
If service shims were previously installed, they
can be reused, but whether using new or old
differential bearing assemblies (32), adhere to
the following procedure in all cases. If differential bearing assemblies (32) are used again,
they must have original outer races in place.
Refer to "Differential Bearing Assembly Preload Adjustment" in this section.
Keep shim packs in their respective position,
right or left side.
A. Select a shim 0.10 mm (0.004 inch) thicker
than the one removed from the left side, then
insert left side shim pack between the spacer

and the left bearing race.
B. Loosely install bearing cap (22).
C. Select a shim 0.10 mm (0.004 inch) thicker
than the one removed from the right side and
insert between the spacer (25) and the right
bearing assembly race.
D. It will be necessary to drive the right shim into
position using J 25588.
l~I
Tighten

4. Check backlash and correct if necessary. Refer to
"Differential Ring Gear-to-Differential Drive Pinion Gear Backlash" in this section.
5. Rear axle shafts (63 or 70). Refer to "Rear Axle
Shaft" in this section.
6. Wheel speed sensor assembly (75) and bolt/
screw (73).
l~I
Tighten
SPEED SENSOR RELUCTOR WHEEL

J 21465-13
J 25299
Refer to "Differential Case" above, for removal and

installation of the speed sensor reluctor wheel.
DIFFERENTIAL RING GEAR-TODIFFERENTIAL DRIVE PINION GEAR

BACKLASH
Figure25
Tool Required:
l++I
32 BEARING ASSEMBLY, DIFFERENTIAL
PC0019-4BF-RP
Figure 23 - Installing Differential Bearing Assembly
Rear axle housing cover. Refer to "Rear Axle Housing Cover and Gasket" in this section.
REAR AXLE 48-19

Refer to "Differential Bearing Assembly Preload Adjustment" in the following procedure
for further information.
l@I Measure
1. Rotate case (33) several times to seat bearing assemblies. Mount J 8001.
A. Use a small button on indicator stem so that
contact can be made near heel end of tooth.
B. Set J 8001 so that stem is in line with gear rotation and perpendicular to tooth angle for accurate backlash reading.
2. Check backlash at three or four points around ring
gear (20).
A. Lash must not vary over 0.05 mm (0.002 inch)
around ring gear (20).
B. Drive pinion gear must be held stationary
when checking backlash.
[I] lmportant
1
If variation is over 0.05 mm (0.002 inch),
check for burrs, uneven bolting conditions or

distorted case flange and make corrections as
necessary.
11 Adjust
1. Backlash at the point of minimum lash should be
between 0.13 mm and 0.23 mm (0.005 inch and
0.009 inch) for all new gears.
2. Backlash by increasing thickness of one shim and
decreasing thickness of other shim the same amount.
For each 0.03 mm (0.001 inch) change in backlash desired, transfer 0.05 mm (0.002 inch) in
shim thickness.
To decrease backlash 0.03 mm (0.001 inch),
decrease thickness of right shim 0.05 mm
(0.002 inch) and increase thickness of left shim
0.05 mm (0.002 inch). To increase backlash
0.05 mm (0.002 inch), increase thickness of
right shim 0.10 mm (0.004 inch) and decrease
thickness of left shim 0.10 mm (0.004 inch).

33 CASE, DIFFERENTIAL
PC00214BFRP
Figure 25 - Checking Differential Ring Gear-to-Differential

Drive Pinion Gear Backlash
1++1 Install or Connect

Rear axle housing cover. Refer to "Rear Axle Housing Cover and Gasket" in this section.
DIFFERENTIAL BEARING ASSEMBLY

PRELOAD ADJUSTMENT
Figures 1, 2 and 26
The differential bearing assembly preload adjustment is to be made before installing the drive pinion
gear (23). If drive pinion gear (23) is installed, remove
ring gear (20). Refer to "Differential Case" in this section.
Differential bearing assembly preload is adjusted by
changing the thickness of both the right and left
shims (24) by an equal amount.
By changing the thickness of both shims (24)
equally, the original backlash will be maintained.
Production shims (24) are cast iron and vary in
thickness from 5.33 mm to 6.91 mm (0.210 inch to
0.272 inch) in increments of 0.05 mm (0.002 inch).
Standard service spacers (25) are 4.32 mm
(0.170 inch) thick and steel service shims (24) are available from 1.02 mm to 2.08 mm (0.040 inch to 0.082 inch)
in increments of 0.05 mm (0.002 inch).
Important
Do not attempt to reinstall the production shims (24)

as they may break when tapped into place.
If service shims (24) were previously installed, they
can be reused, but whether using new or old differential bearing assemblies (32), adhere to the following procedure in all cases. If differential bearing
assemblies (32) are used again, they must have original outer races in place.
1. Determine the approximate thickness of shims (24)
needed by measuring each production shim (24) or
each service spacer (25) and shim pack.
In addition to the service spacer (25), service
shims (24) will be needed. Select a starting
point in service shim thickness. Refer to
Figure 26.
2. Place case (33) with differential bearing assembly
outer races in position in the housing assembly (16).
3. Slip the service spacer (25) between each differential bearing assembly race and housing assembly (16) with chamfered edge against housing
assembly (16).
NOTICE: Install the left side differential bearing
cap loosely so the differential case may be moved
while checking adjustments. Another differential
bearing assembly cap bolt/screw can be added in the
lower right side differential bearing cap hole. This
will prevent the case from dropping while making
shim adjustments.
4. Select one or two shims (24) totalling the amount
shown in the right-hand column of Figure 26 and
48-20 REAR AXLE
4.32 mm (0.170") SERVICE

DIFFERENTIAL BEARING SPACER
TOTAL THICKNESS OF
BOTH PRODUCTION
DIFFERENTIAL BEARING
SHIMS REMOVED
TOTAL THICKNESS OF
SERVICE DIFFERENTIAL
BEARING SHIMS TO BE
USED AS A STARTING POINT
10.57 mm (0.416")
10.92 mm (0.430")
11.18 mm (0.440")
11.43 mm (0.450")
11.68 mm (0.460")
11.94 mm (0.470")
12.19 mm (0.480")
12.45 mm (0.490")
12. 70 mm (0.500")
12.95 mm (0.510")
13.21 mm (0.520")
13.46 mm (0.530")
13.97 mm (0. 550")
1.52 mm (0.060")
1. 78 mm (0.070")
2.03 mm (0.080")
2.29 mm (0.090")
2.54 mm (0.100")
2. 79 mm (0.110")
3.05 mm (0.120")
3.30 mm (0.130")
3.56 mm (0.140")
3.81 mm (0.150")
4.06 mm (0.160")
4.32 mm (0.170")
4.83 mm (0.190")
PC6030-4B-D-RP
Figure 26 D1fferent1al Bearing Shim Thickness
position between the right side differential bearing

assembly race and service spacer (25).
Be sure left side differential bearing assembly
race and spacer (25) are against left side of
housing assembly (16).
5. Insert progressively larger feeler gage sizes
0.25 mm, 0.30 mm, 0.36 mm, etc. (0.010 inch,
0.012 inch, 0.014 inch, etc.) between the right
shim (24) and service spacer (25) until there is
noticeable increase in drag.
6. Push feeler gage downward until end of gage makes
contact with housing assembly bore to obtain a correct reading.
The point just before additional drag begins is
the correct feeler gage thickness.
7. Rotate case (33) while using feeler gage to ensure an
even reading.
The original light drag is caused by weight _of
case (33) against housing assembly (16) while
additional drag is caused by differential bearing assembly preload.
By starting with a thin feeler gage, a sense of
"feel" is obtained so the beginning of pre load
can be recognized to obtain zero clearance.
It will be necessary to work case (33) in and
out and to the left in order to insert feeler gage.
8. Remove left side differential bearing assembly
cap (22) and shim (24) from housing assembly (16).
9. The total shim pack needed, with no preload on differential bearing assemblies (32), is the feeler gage
reading found in step 7 plus the thickness of
shims (24) installed in step 4.
10. Select two shims (24) of approximately equal size
whose total thickness is equal to the value obtained
in step 9.
These shims (24) will be installed between
each differential bearing assembly race and
service spacer (25) when case (33) is installed
in housing assembly (16).
The preload will not be added until case (33) is

installed.
11. If drive pinion gear is in position, install ring gear.
Refer to "Differential Case" in this section.
DIFFERENTIAL DRIVE PINION GEAR

Figures 1, 2, 14, 17, 27 and 28
Tools Required:
J 22536 Pinion Driver
J 23911 Pinion Oil Seal Installer

I. Differential case. Refer to "Differential Case" in
this section.
2. Check differential drive pinion gear inner and outer
bearing assembly preload. If ther~ is ~o. preload
reading, check for looseness of dnve pm1on gear
(23) by shaking. Looseness. could be ~aused by
defective inner and outer beanng assemblies ( 18 and
7) or worn yoke (3). If the rear axle assembly was
operated for an ext~nded peri~d with very lo?se
inner and outer bearmg assemblies (18 and 7), nng
gear (20) and drive pinion gear (23) will also require
replacement.
3. Differential drive pinion gear yoke. Refer to "Differential Drive Pinion Gear Yoke and Seal" in this
section.
4. Drive pinion gear (23), using J 22536. Apply heavy
hand pressure on J 22536 toward housing assembly
(16) to keep outer bearing assembly (7) seated to
avoid damage to outer race.

I. If installing new ring gear and drive pinion gear,
measure differential drive pinion gear depth. Refer
to "Differential Drive Pinion Gear Depth" in this
section.
23
A
B
16
23
CHANNEL LOCKING PLIERS

WRENCH
GEAR, DIFFERENTIAL DRIVE PINION
PC0022-4B-F-RP
Figure 27 - Installing Differential Drive Pinion Gear Driver
REAR AXLE 4821

After preload has been checked, final tightening should be done very carefully.
Additional tightening of nut (1) can add many
additional pound inches of torque.
16
23

PC0023-4B-F-RP
Figure 28 - Removing Differential Drive Pinion Gear
2. Drive pinion gear (23) into housing assembly (16).

3. Differential drive pinion gear yoke.
A. Install new seal (6) using J 23911.
B. Apply pinion gear seal lubricant GM P/N
1050169 or equivalent to yoke (3) and sealing
lip of new seal (6).
C. Yoke (3).
D. Washer (2) and nut (1) finger tight.
E. Hold yoke (3).
F. While intermittently rotating drive pm1on
gear (23) to seat inner and outer bearing assemblies ( 18 and 7), tighten nut ( 1) until end play
begins to be taken up.
[I] Important
When no further end play is detectable and
when holder will no longer pivot freely as
drive pinion gear (23) is rotated, preload specifications are being approached.
No further tightening should be attempted
until preload has been checked.
Nut (1) should be further tightened only

slightly and preload should be checked after
each tightening.
Exceeding preload specifications will compress the collapsible spacer (15) too far and
require installation of a new collapsible spacer
(15).
4. Set preload at 1.7 Nm to 3.4 Nm (15 lb. in. to 30
lb. in.) on new inner and outer bearing assemblies
(18 and 7) or 1.0 Nm to 1.7 Nm (10 lb. in. to 15 lb.
in.) on used inner and outer bearing assemblies (18
and 7).
5. Rotate drive pinion gear (23) several times to ensure
that inner and outer bearing assemblies ( 18 and 7)
have been seated.
A. Check preload again.
B. If preload has been reduced by rotating drive
pinion gear (23), reset preload to specifications.
6. Differential case. Refer to "Differential Case" in
this section.

Outer Bearing Assembly
Figures 1, 2 and 29
Tools Required:
J 781 7 Front Pinion Bearing Cup Installer

1. Differential drive pinion gear from rear axle housing
assembly. Refer to "Differential Drive Pinion
Gear" in this section.
2. Differential drive pinion gear seal from rear axle
housing assembly. Refer to "Differential Drive Pinion Gear Yoke and Seal" in this section.
3. Outer bearing assembly (7) from housing assembly
(16).
4. Outer bearing assembly race from housing assembly ( 16), if replacing outer bearing assembly (7).
Drive race from housing assembly (16), using
a punch in slots provided for this purpose.

PC0024-48-f.RP
Figure 29 - Installing Differential Drive Pinion Gear Outer

Bearing Assembly Race
1. Outer bearing assembly race into housing assembly

(16), if removed, using J 8092 and J 7817.
2. Outer bearing assembly (7) into housing assembly
(16).
3. Differential drive pinion gear seal. Refer to "Differential Drive Pinion Gear Yoke and Seal" in this section.
48-22 REAR AXLE

4. Differential drive pinion gear. Refer to "Differential
Drive Pinion Gear" in this section.

Inner Bearing Assembly
Tools Required:
J 22912-01 Rear Pinion Bearing Remover
J 29609 Rear Pinion Bearing Cup Installer
J 5590 Rear Pinion Bearing Cone Installer

1. Differential drive pinion gear. Refer to ''Differential
2. Spacer (15) from drive pinion gear (23).
Discard spacer (15).
3. Drive pinion gear inner bearing assembly race from
housing assembly (16), if replacing inner bearing
assembly ( 18).
Drive race from housing assembly (16) using a
punch in slots provided for this purpose.
4. Drive inner bearing assembly (18) from drive pinion
gear (23) using J 22912-01.
18 BEARING ASSEMBLY, DIFFERENTIAL DRIVE PINION

GEAR INNER
PC002648f.RP
Figure 31 - Installing Differential Drive Pinion Gear Inner

Bearing Assembly

1. Inner bearing assembly (18) onto drive pinion
gear (23) using J 5590.
2. Drive inner bearing assembly race into housing
assembly (16) using J 8092 and J 29609, if inner
bearing assembly (18) was replaced.
3. New spacer (15) onto drive pinion gear (23).
A RACE, DIFFERENTIAL DRIVE PINION GEAR INNER

BEARING ASSEMBLY
PC0027-4B-F-RP
Figure 32 - Installing Differential Drive Pinion Gear Inner

Bearing Assembly Race
DIFFERENTIAL DRIVE PINION GEAR DEPTH

Tools Required:
J 23597-1 Pinion Setting Gage - Arbor
J 23597-11 Pinion Setting Gage - Gage Plate
J 21777-40 Pinion Setting Gage
- Rear Pilot Washer
- Front Pilot Washer
- Stud Assembly-Bolt
- Side Bearing Discs
Differential drive pinion gear depth is measured
with a pinion setting gage. The gage provides a "nominal" or "zero" pinion as a gaging reference.
\ A
A OPENING IN TOOL MUST BE SUPPORTED
PC0025-4BFRP
Figure 30 - Removing Differential Drive Pinion Gear Inner

Bearing Assembly
l!+I Disassemble
Differential case. Refer to "Differential Case" in
this section.
REAR AXLE 48-23
J 23597-1
J 8001
Differential drive pinion gear inner bearing assembly. Refer to "Differential Drive Pinion Gear Inner
Bearing Assembly" in this section.
l,:WI Clean
1.
2.
3.
4.
J 23597-11
All parts of gage.

Differential bearing assembly bore.
Inner and outer bearing assembly cups.
Lubricate inner and outer bearing assemblies (18
and 7) with GM P/N 1052271 axle lubricant or SAE
80W-90 GL-5 gear lubricant or equivalent.
J 21777-43

1. J 21777-40 through J 21777-43.
2. J 23597-11.
3. J 21777-42 and nut in housing assembly (16).
l~I Tighten
4.
5.
6.
7.
Nut to 2.3 Nm (20 lb. in.).

Rotate J 23597-11 to seat inner and outer bearing
assemblies ( 18 and 7).
Mount J 8001 on J 23597-1 and preload indicator
against plunger about 1.27 mm (0.050 inch).
J 21777-45 on J 23597-1 and position unit in housing assembly (16).
Bearing caps (22) and bolts/screws (26).
l~I Tighten
l@I Measure
Differential drive pinion gear depth.
A. Rotate J 23597-1 slowly back and forth until
J 8001 reads the greatest deflection (the point
where the needle changes direction). At that
point, set J 8001 to zero.
B. Repeat rocking action to verify zero setting.
C. After zero setting is obtained, rotate J 23597-1
just until plunger no longer touches
J 23597-11. This provides the gaging reference
of a "zero" or "nominal" drive pinion
gear (23).
D. Record J 8001 reading at pointer position. This
indicates the proper shim to use. Example: if
pointer moved counterclockwise 1. 70 mm
(0.067 inch) to a dial reading of 0.84 mm
(0.033 inch), this indicates a shim thickness of
0.84 mm (0.033 inch).
E. Required shim thickness is EQUAL to J 8001
reading.
J 21777-42
GEAR OUTER
GEAR INNER
PC0028-4B-F-RP
Figure 33 - Pinion Gage Plate Installed in Rear Axle Housing

Assembly
F. Shims are available in 0.03 mm to 0.94 mm

(0.001 inch to 0.037 inch). Shim thickness is
etched on the flat surface for easy identification.

1. Loosen J 21777-43 and remove special tools and
inner and outer bearing assemblies ( 18 and 7) from
2. Correct shim (19) on drive pinion gear (23).
rn
Important
Proper drive pinion gear depth setting is a twostep procedure.

a. The set-up dimension arrived at using
J 8001 is to be considered a starting
point.
b. A ring gear tooth pattern check is necessary to fine tune the drive pinion gear
depth and may indicate additional shim
changes to the drive pinion gear stem.
Refer to "Tooth Contact Pattern Test" in
this section.
Both procedures must be performed to ensure
proper rear axle assembly performance.
3. Differential drive pinion gear inner and outer bearing assemblies. Refer to "Differential Drive Pinion
Gear Inner Bearing Assembly" and "Differential
Drive Pinion Gear Outer Bearing Assembly" in this
section.
l+!+I Assemble
Differential case. Refer to "Differential Case" in
this section.
4824 REAR AXLE
A
B
22
26
OFF GAGE BLOCK

ON GAGE BLOCK
CAP, DIFFERENTIAL CARRIER BEARING
BOLT/SCREW, DIFFERENTIAL BEARING CAP
PC0029-4B-F-RP
Figure 34 - Checking Differential Drive Pinion Gear Depth
l@I Measure
Preload of the total assembly at the drive pinion gear
nut. With new inner and outer bearing assemblies
(18 and 7), preload is 3.6 Nm to 6.2 Nm (32 lb. in.
to 55 lb. in.) rotating torque with a new seal (6).
With used inner and outer bearing assemblies (18
and 7), preload is 1.8 Nm to 3.1 Nm (16 lb. in. to
28 lb. in.) rotating torque with a new seal (6).
DIFFERENTIAL CASE (LIMITED SLIP)

Figure35
The Auburn limited slip differential assembly
case (80) is non-serviceable and must be replaced as an
assembly. Removal and replacement of the differential
case and service on the side bearings and ring gear is the
same as for the standard rear axle assembly.
REAR AXLE HOUSING REPLACEMENT

It is not necessary to remove the rear axle housing
assembly for any normal repairs. However, if the rear axle
housing assembly is damaged, it may be removed and
installed using the following procedures:
Rear Axle Housing Assembly with Drum Brakes

1. Rear axle assembly. Refer to "Rear Axle Assembly" in this section.
29 BOLT/SCREW, DIFFERENTIAL PINION GEAR SHAFT

LOCK
80 CASE, AUBURN DIFFERENTIAL (NON-SERVICEABLE)
PC00304B-F-RP
Figure 35 - Limited Slip Rear Axle Assembly-Auburn-Type
2. Rear brake pipe assemblies from rear wheel brake

cylinders. Refer to SECTION 5.
3. Rear brake pipe assemblies from rear brake (center)
hose assembly junction block. Refer to SECTION 5.
4. Rear brake (center) hose assembly junction block
from housing assembly. Refer to SECTION 5.
REAR AXLE 48-25

5. Rear brake pipe assemblies from housing assembly.
Refer to SECTION 5.
6. Rear axle shaft bearing assemblies and seals. Refer
to "Rear Axle Shaft Bearing Assembly and/or
Bearing Seal" in this section.
7. Rear brake backing plates. Refer to SECTION 5C2.
this section.

Drive Pinion Gear " in this section.
this section.
3. Rear brake backing plates. Refer to SECTION 5C2.
4. Rear axle shaft bearing assemblies and seals. Refer
5. Rear brake pipe assemblies to housing assembly.
Refer to SECTION 5.
6. Rear brake pipe assemblies to rear wheel brake
cylinders. Refer to SECTION 5.
8. Rear brake pipe assemblies to rear brake (center)
9. Rear axle assembly. Refer to "Rear Axle Assembly" in this section.
REAR AXLE ASSEMBLY WITH DISC BRAKES
Figures 1, 2 and 36
A shim (67) may be installed between the rear brake
caliper assembly mounting plate (65) and the axle shaft
tube flange on the housing assembly (16). This shim (67)
centers the rear brake caliper and pad assemblies over the
brake rotor assembly (71), ensuring even brake pad
assembly pressure during braking. This shim (67) may
have to be changed when the housing assembly (16) is
replaced.
I++! Remove or Disconnect

Rear axle assembly. Refer to "Rear Axle Assembly" in this section.
l+)I Disassemble
1. Rear brake pipe assemblies from brake hose
assemblies. Refer to SECTION 5.
2. Rear brake pipe assemblies from rear brake (center)
4. Rear brake pipe assemblies from housing assembly.
Refer to SECTION 5.
5. Rear brake hose assemblies from housing assembly.

Refer to SECTION 5.
6. Rear brake shaft bearing assemblies and seals. Refer

7. Rear brake caliper anchor brackets and mounting
plates. Refer to SECTION 5B2.
8. Shim (67), if installed.
this section.
!+!+I Assemble
this section.
4. Rear axle shaft bearing assemblies and seals, but do
not tighten lock bolt/screw at this time. Leave lock
bolt/screw finger tight. Refer to "Rear Axle Shaft
Bearing Assembly and/or Bearing Seal" in this
section.
l@I Measure
1. Distance from rear face of rear brake caliper
assembly mounting plate (65) (tube flange mounting surface) to front face of machined axle shaft tube
flange, using a caliper.
2. Select shim (67). Refer to Figure 36.
l+!+I Disassemble
section.
l+!+I Assemble
1. Shim (67), if necessary.
3. Rear brake hose assemblies to housing assembly.
Refer to SECTION 5.
4. Rear brake pipe assemblies to housing assembly.
Refer to SECTION 5.
5. Rear brake (center) hose assembly junction block to
housing assembly. Refer to SECTION 5.
6. Rear brake pipe assemblies to rear brake (center)
brake assembly junction block. Refer to SECTION 5.
7. Rear brake pipe assemblies to brake hose assemblies. Refer to SECTION 5.

Rear axle assembly. Refer to "Rear Axle Assembly" in this section.
48-26 REAR AXLE
65
71
DISTANCE "A"
SHIM THICKNESS REQUIRED*
GM PART NUMBER
68.625-69.79 mm (2.70"-2.74")
69.800-70.955 mm (2.75"-2.79")
NO SHIM REQUIRED
0.60 mm (0.024")
26034667
* ORIGINAL SHIM, IF INCLUDED, MAY BE PROPER THICKNESS TO REUSE.
A DIMENSION USED TO DETERMINE SHIM

65 PLATE, REAR BRAKE CALIPER ASSEMBLY MOUNTING
71 ROTOR ASSEMBLY, REAR BRAKE
PC0031-4B-F-RP
Figure 36 - Brake Caliper Assembly Mounting Plate Shim Selection
SPECIFICATIONS
Use a reliable torque wrench to tighten the parts listed to make sure the parts are properly tightened without straining
or distorting parts. These specifications are for clean and lightly-lubricated threads only; dry or dirty threads produce
increased friction which prevents measurement of tightness.
Differential Bearing Cap Bolt/Screw .................................... 75 Nm (55 lb. ft.)
Differential Drive Pinion Gear Setting Gage Nut .......................... 2.3 Nm (20 lb. in.)
Differential Pinion Gear Shaft Lock Bolt/Screw ........................... 36 Nm (27 lb. ft.)
Differential Ring Gear (Left-Hand Thread) Bolt/Screw ..................... 120 Nm (89 lb. ft.)
Rear Axle Housing Bolt/Screw ......................................... 30 Nm (22 lb. ft.)
Rear Axle Housing Drain (Fill) Plug .................................... 35 Nm (26 lb. ft.)
Sensor Plug Mounting Bolt/Screw ...................................... 10 Nm (89 lb. in.)
Wheel Nut ....................................................... 140 Nm (100 lb. ft.)
Rear Axle Type .................................................. Semi-Floating Hypoid
Drive and Torque ..................................................... Through 4 Arms
Ring and Drive Pinion Gear Set Type ............................................. Hypoid
Rear Axle Lubricant Capacity ........................................... 1.65 L (2.90 pt.)
Rear Axle Lubricant ................................... GM PIN 1052271 Axle Lubricant or
SAE 80W-90 GL-5 Gear Lubricant or equivalent
Pinion Gear Seal Lubricant .................................. GM P/N 1050169 or equivalent
Gear Marking Compound ................................... GM PIN 1052351 or equivalent
REAR AXLE 48-27
LIMITS FOR FITTING AND ADJUSTING

Differential Drive Pinion Gear Inner and Outer Bearing Preload
(Measured at Drive Pinion Gear Nut)
New Bearing Assemblies ........ 1.7 - 3.4 Nm (15 - 30 lb. in.) Rotating Torque with New Seal
Used Bearing Assemblies ........ 1.0- 1.7 Nm (10- 15 lb. in.) Rotating Torque with New Seal
Total Assembly Preload
(Measured at Drive Pinion Gear Nut)
New Bearing Assemblies ........ 3.6- 6.2 Nm (32 - 55 lb. in.) Rotating Torque with New Seal
Used Bearing Assemblies ........ 1.8- 3.1 Nm (16- 28 lb. in.) Rotating Torque with New Seal
Differential Ring Gear-to-Differential
Drive Pinion Gear Backlash ............................ 0.13 -0.23 mm (0.005" - 0.009")
REAR AXLE ASSEMBLY USAGE
RING GEAR
DIAMETER
REAR BRAKE
DRUM DISC
AXLE GEAR
RATIO
TEETH
RING GEAR: PINION
AXLE
RATIO
41:15
GU2
42:13
GU5
2.73
DISC
7.62"
CAST IRON DRUM
3.23
DISC
PC0032-4B-F-RP
SPECIAL TOOLS
J 6627-A
[2J
WHEEL STUD REMOVER

MC1001-3E-B-RP
J 8614-01 SET
0~====;::111;..;;lt::::======~)
J8614-10
J 8614-2
J 8614-01 SET,
<IPIOIOIIOUPE
J 8614-3
0
0
0
PINION FLANGE REMOVER ADAPTER

PINION FLANGE REMOVER SCREW
PINION FLANGE REMOVER
LC0027-48-F-RP
48-28 REAR AXLE
3.
J 23597-1
1.
4.
2.
J 21777-40
J 23597-11
J 21777-42
@
5.
1111111111~
GIIIIIIIIII
J 21777-43
7 1/2" AND 7 5/8" RING GEAR REAR AXLE

1.
2.
3.
4.
5.
6.
PINION
PINION
PINION
PINION
PINION
PINION
SETIING GAGE-ARBOR
SETIING GAGE - GAGE PLATE
SETIING GAGE - REAR PILOT WASHER
SETIING GAGE - FRONT PILOT WASHER
SETIING GAGE - STUD ASM-BOLT
SETIING GAGE - SIDE BEARING DISCS
6.
J 21777-45
PC0034-4B-FRP
REAR AXLE 48-29
1.
~
J 2619-01
2.
((8
12.
7.
J 22536
J 23771
13.
8.
J 23911
J 7817
J 22813-01
3.
~,~
J80ff;i1'(
14.
J 25299
9.
4 . ~
J 22888-20
15.
J 8092
J 25588
5.
10.
~
J 22912-01
J 8107-2
16.
J 29609
6.
11.
J 21579
17.
J 23765
J 5590
7 1/2" AND 7 5/8" RING GEAR REAR AXLE

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
SLIDE HAMMER WITH 1/2 X 13 ADAPTER

FRONT PINION BEARING CUP INSTALLER
DIAL INDICATOR SET
DRIVER HANDLE
DIFFERENTIAL SIDE BEARING REMOVER PLUG
AXLE SHAFT REMOVER
PINION DRIVER
AXLE BEARING REMOVER
DIFFERENTIAL SIDE BEARING REMOVER
REAR PINION BEARING REMOVER
AXLE BEARING INSTALLER
AXLE OIL SEAL INSTALLER
PINION OIL SEAL INSTALLER
DIFFERENTIAL SIDE BEARING INSTALLER
SIDE BEARING SHIM INSTALLER
REAR PINION BEARING CUP INSTALLER
17. REAR PINION BEARING CONE INSTALLER
18. ABS EXCITER RING PROTECTOR KIT
19. DRIVER HANDLE EXTENSION
'
{)
18.
J 39446
19.
[JD
<
J 21465-13
PC0035-4B-FRP
BRAKES 51
BRAKES
CONTENTS
Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section 5
Master Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section 5A
Front Disc Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section 5B 1
Rear Disc Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section 5B2
Duo-Servo Drum Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section 5C2
Vacuum Booster System ................................................... Section 5Dl
Antilock Brake System .................................................... Section 5El
Parking Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section 5F
SECTION 5
BRAKES
CAUTION: Certain components in the Antilock Brake System are not intended to be serviced
individually. Attempting to remove or disconnect certain system components may result in
personal injury and/or improper system operation. Only those components with approved
removal and installation procedures in Sections 5 and 5E1 should be serviced.
CAUTION: When servicing brake parts, do not create dust by grinding, sanding brake linin9s, or by cleaning brake parts with a dry brush or compressed air. Many brake parts contain asbestos fibers which can become airborne if dust is created during servicing.
Breathing dust containing asbestos fibers may cause serious bodily harm. A water dampened cloth or water based solution should be used to remove any dust on brake parts.
Equipment is commercially available to perform this washing function. These wet methods
will prevent asbestos fibers from becoming airborne.
CAUTION: Brake fluid may irritate eyes and skin. In case of contact, take the following
actions:
Eye contact - rinse thoroughly with water.
Skin contact - wash with soap and water.
NOTICE: The use of rubber hoses or parts other than those specified for the Antilock Brake System may lead to
functional problems requiring major overhaul. Replace all components included in repair kits used to service this
system. Lubricate rubber parts with clean, fresh brake fluid to ease assembly. Do not use lubricated shop air on
brake parts as damage to rubber components may result. If any hydraulic component is removed or brake pipe or
hose assembly disconnected, it will be necessary to bleed the entire brake hydraulic system. The torque values
specified are for dry, unlubricated fasteners.
result.
NOTICE: Avoid spilling brake fluid on any of the vehicle's painted surfaces, wiring cables or electrical connectors. Brake fluid will damage paint and electrical connections. If any fluid is spilled on the vehicle, flush the area
with water to lessen damage.
CONTENTS
General Description ..........................
Brake Fluid and Fluid Handling ..............
Substandard or Contaminated Brake Fluid ....
Flushing Brake Hydraulic System ...........
5-2
5-2
5-2
5-2
Combination Valve Assembly ................

Brake Pressure Differential Warning Switch ...
Brake Proportion Valve ...................
Warning/Indicator Lamp Operation ............
5-2
5-2
5-2
5-4
5-2 BRAKES
Brake ................................. 5-4
Antilock ............................... 5-4
Diagnosis .................................. 5-4
Brake System Testing ...................... 5-4
External Conditions
That Affect Brake Performance ........... 5-4
Brake System ............................. 5-4
Brake Pedal Assembly Travel ................ 5-4
Brake Fluid Leaks ......................... 5-5
Brake Hose and Pipe Assembly
Inspection ............................ 5-5
Brake Fluid .............................. 5-5
Brake Indicator
Diagnostic Charts ........ Refer to Section 8A-41
On-Vehicle Service .......................... 5-5
Filling Master
Cylinder Reservoir . . . . . . . . . Refer to Section 5A
Brake Pedal Assembly with Bracket ........... 5-5
Brake Pedal Assembly ...................... 5-8

Stoplamp and Cruise Control Switch
Assemblies ............................. 5-9
Brake Pipe Assembly ...................... 5-11
Double Lap Flare ....................... 5-15
ISO Flare ............................. 5-16
Combination Valve Assembly ............... 5-17
Brake Hose Assembly ..................... 5-18
Front Brake Hose Assembly .............. 5-18
Rear Brake (Center) Hose Assembly ........ 5-19
Rear Brake Hose Assembly ............... 5-19
Bleeding Brake
Hydraulic System ......... Refer to Section 5El
Flushing Brake Hydraulic System ............ 5-20
Specifications .............................. 5-20
General Specifications ..................... 5-20
Fastener Tightening Specifications ........... 5-21
Special Tools .............................. 5-21
GENERAL DESCRIPTION
or mineral oil based fluids. Approximately 1.5 liters

(1.5 quarts) of hydraulic brake fluid is required to flush
the brake hydraulic system. Refer to "Flushing Brake
Hydraulic System" under "On-Vehicle Service" in this
section for more information.
BRAKE FLUID AND FLUID HANDLING

CAUTION: Brake fluid may irritate eyes
and skin. In case of contact, take the
following actions:
Eye contact rinse thoroughly with
water.
Skin contact - wash with soap and
water.
NOTICE: Avoid spilling brake fluid on any of the
vehicle's painted surfaces, wiring, cables or electrical connectors. Brake fluid will damage paint and
electrical connections. If any fluid is spilled on the
vehicle, flush the area with water to lessen the damage.
Important
Do not re-use fluid accumulated during brake

hydraulic system bleeding.
Always store brake fluid in a closed container.
Reseal brake fluid containers immediately after use.
Do not use fluid left in an open or improperly sealed
container as it absorbs moisture or can become contaminated.
Substandard or Contaminated Brake Fluid

Use only hydraulic brake fluid GM PIN 1052535 or
an equivalent DOT-3 fluid. DO NOT use power steering
fluid, automatic transmission fluid or DOT-5 silicone
hydraulic brake fluid.
Use of an improper fluid or one contaminated with
mineral oil or water may cause the fluid to boil or the
r~bber components in the brake hydraulic system to detenorate.
Flushing Brake Hydraulic System

The system must be flushed if there is any doubt
about the condition of the fluid in the system or if fluid has
been used which contains the slightest trace of petroleum
COMBINATION VALVE ASSEMBLY

The non-serviceable brake combination valve
assembly is located under the hood, mounted to the ABS
modulator assembly on the left engine compartment side
inner rail assembly. The brake combination valve assembly incorporates the following functions into a single
component:
Brake Pressure Differential Warning Switch

The brake pressure differential warning switch monitors the front and rear brake systems to measure any difference in hydraulic pressure between the two systems. If
a sufficient pressure differential exists between the systems, an electrical ground is made energizing the red
"BRAKE" warning lamp if the ignition is on. The brake
combination valve assembly and brake pressure differential warning switch are also designed so the warning
switch will latch in the warning position once a malfunction has occurred. The "BRAKE" warning lamp will turn
off only after the malfunction is repaired and a pedal force
sufficient to develop approximately 3 100 kPa (450 psi)
hydraulic brake pressure is applied.
Brake Proportion Valve

The brake proportion valve improves front-to-rear
brake balance under severe brake application. Severe
brake application transfers part of the vehicle's rear
weight to the front wheels. The resulting decrease in
weight at the rear wheels can cause reduced brake efficiency. The brake proportion valve limits the pressure to
the rear brakes to reduce the tendency for reduced brake
efficiency. The proportion valve also has a by-pass feature
which assures full system pressure to the rear brakes in the
event of a front system brake failure. Full front system
pressure is retained in the event of rear brake system malfunction.
BRAKES 5-3
Leaking Brake Line or Conn.

Leaking Piston or Axle Seal
Leaking Master Cylinder (Internal)
A)r in Brake System
xxx
Contaminated or Improper Brake

Fluid
Leaking Vac. or Booster Sys.
X
X
XX
xx
xx
x x
Restricted Passage in Vacuum

Booster
Damaged Vacuum Booster
Worn Out Brake Lining
Uneven Brake Lining Wear
Glazed Brake Lining
Incorrect Lining Material
Contaminated Brake Lining
x
x
x
x
x x x x x
XX
XX
xxx
x
x
xx
501
xx x
501
x x
xx
xx
x x
x
x xx
x
x
x x x
x x x
x x
x x
xxxxx
x x x
x x
x xx
x x
x x
xx
x x
x x
x x xx
xx
x x
Restricted Brake Fluid Passage

Improperly Adj. Stop Lamp Switch
or Cruise Control Vacuum Dump
Excessive Vehicle Loading

Improperly Torqued Wheel Nuts
Poor Drum Surface Finish
Park. Brake Cables Frozen
Park. Brake Cables Corroded
x
X
X
X
x
x x
x xx xx
xx
xx
x
x x
xx
xx x
x
xx
x
xx
58
58
501
x
x
xx
xx
x
x
3A
3A
3C
3E
58
BA
5F
5
58
5F
x
x
xx
x
x
x
x
x
x
XX-INDICATES MORE PROBABLE CAUSE(Sl
58, 5C
58
x
xx
X
X
X
x
xxxxxx
X
X
X
501
58, 5C
58, 5C
58, 5C
5B,5C
5B,5C
5B,5C
58
x x x x x
x
x x x x
58
5A
Restricted Hydraulic Line to

Booster
Improper Thickness Variation in

Rotor
Excessive Laterial Run-out in Rotor X
Brake Pedal Linkage Interference

or Binding
Incorrect Vacuum Booster
Pushrod Length
Incorrect Front Wheel Align.
Incorrect Tire Pressure
Loose Front Suspension Parts
Out-of-balance Wheel Assm.
Operator Riding Brake Pedal
Sticking Caliper or Caliper Pistons
Park. Brake Switch Ckt. Gnd.
Park. Brake Not Releasing
Low Brake Fluid
Caliper to Knuckle Clearance
Improper Rear Brake Adj.
Low Engine Vacuum
x x x x x xx
Lining Damaged by Abusive Use

Improper Rotor Surface Finish
Scored Rotor
Brake Asm. Attachments Loose

(Incl. Splash Shield)
xx
3E
5C
5F
5F
X-INDICATES OTHER CAUSE(S)

PC0001-5-F-RP
Figure 1 - Brake System Diagnosis
5-4 BRAKES
WARNING/INDICATOR LAMP OPERATION

Brake
The brake system uses a single red "BRAKE"
warning lamp located in the instrument cluster assembly.
When the ignition switch is in the "START" position, the
"BRAKE" warning lamp should come on. It should go
~ff when the ignition switch returns to the "RUN" position.
The following conditions will activate the
"BRAKE" warning lamp:
1. Parking brake applied. Lamp should be on when
parking brake is applied and ignition switch is
"ON."
2. Brake pressure differential warning switch detects
failure. Refer to SECTION SA for diagnosis.
3. During engine cranking "BRAKE" warning lamp
should remain on. This notifies driver that warning
circuit is operating properly.
Anti lock
The antilock brake system (ABS) uses three indicator lamps: the red "BRAKE" warning lamp, an amber
"ABS INOP" indicator lamp and an amber "LOW
TRAC" indicator lamp, all located in the instrument cluster assembly. Under normal conditions, these lamps
should operate as follows:
1. When ignition is turned to "RUN" position, prior to
starting engine, amber "ABS INOP" indicator lamp
should go on and red "BRAKE" warning lamp
should flash.
2. As engine is cranked, both red "BRAKE" warning
lamp and amber "ABS INOP" indicator lamp
should come on and "LOW TRAC" indicator lamp
may come on and off.
3. When engine is started, amber "ABS INOP" and
red "BRAKE" lamps should go out and "LOW
TRAC" indicator lamp may come on and off.
.
The operation of these three indicator lamps is an
1i:nportant part of the antilock brake system (ABS) diagnosis. If the warning/indicator lamps turn on while driving
the vehicle, this indicates a malfunction. If the warning/
indicator lamps don't turn on under normal conditions as
described above, service the lamps as soon as possible.
For further information regarding warning/indicator lamp
operation for the antilock brake system (ABS), refer to
SECTION 5El.
Test brakes at different vehicle speeds with both

light and heavy brake pedal force.
External Conditions That Affect Brake

Performance
Tires
Tires having unequal contact and grip on the road
will cause unequal braking. Tires must be equally inflated,
and the tread pattern of right and left tires must be approximately equal.
Vehicle Loading
A heavily loaded vehicle requires more braking
effort. When a vehicle has unequal loading, the most
heavily loaded wheels require more braking power than
others.
Wheel Alignment
Misalignment of the wheels, particularly excessive
camber and caster, will cause the brakes to pull to one
side.
BRAKE SYSTEM
Figure 1
For diagnosis of the brake hydraulic system, refer to
Figure 1.
BRAKE PEDAL ASSEMBLY TRAVEL

Most low brake pedal assembly problems are caused
by air in the brake system or misadjusted rear drum
brakes. Bleed the system until air is purged and check rear
brake adjustment. Refer to SECTION 5El. Other less frequent causes of excessive brake pedal assembly travel are
incorrect pushrod assembly length, rear brake shoe adjusters not operating, linings excessively worn, and brake
hydraulic system leakage.
High brake pedal assembly force problems are usually caused by low engine assembly vacuum, a vacuum
leak, or an improperly functioning vacuum booster
assembly. These conditions would also result in higher
than normal brake pedal assembly efforts.
!@I Measure
1.
2.
DIAGNOSIS
BRAKE SYSTEM TESTING
Brakes should be tested on a dry, clean, reasonably
smooth and level roadway. A true test of brake performance cannot be made if the roadway is wet, greasy or
covered with loose dirt so that all tires do not grip the road
equally. Testing will also be affected if the roadway is
crowned, which would throw the weight of the vehicle
toward the wheels on one side. If the roadway is too
rough, the wheels will tend to bounce.
3.
4.
Tool Required:
J 28662 Brake Pedal Effort Gage
Install J 28662 onto pedal assembly.
Hook end of tape measure over top edge of pedal
assembly and measure the distance to rim of steering
wheel assembly.
With engine running at idle and the shift lever in
"NEUTRAL" and the wheel and tire assemblies
blocked, apply brake pedal assembly with 445 N
(100 lb.) force and remeasure. The difference between both readings is actual brake pedal assembly
travel and should be between 51 to 89 mm (2.0 to 3.5
inches).
If brake pedal assembly travel is more than specifications, refer to Figure 1.
BRAKES 55
BRAKE FLUID LEAKS
With engine running at idle and the shift lever in
"NEUTRAL," depress the brake pedal assembly and
hold constant foot pressure. If the pedal assembly grad~ally falls away with constant pressure, the brake hydra~hc
system may be leaking. Perform visual check to conflfm
any suspected leak.
Check the master cylinder assembly fluid levels.
While a slight drop in master cylinder reservoir level do~s
result from normal lining wear, an abnormally low level m
either reservoir indicates a leak in the system. The brake
hydraulic system may be leaking either internally or
externally. Refer to SECTION 5A. Also, the system may
appear to pass this test but still have slight leakage.
Check for possible brake fluid leaks at the brake pipe
assembly and brake hose assembly connections. If any
signs of leakage are found, replace the brake pipe or hose
assembly. Also, inspect the connecting brake component
to determine if it is damaged and should be rebuilt or
replaced. Check the brake caliper boots and rear wheel
cylinder boots for leaks. If any brake fluid appears to be
leaking, rebuild or replace the assembly. Refer to
SECTION 5Bl, SECTION 5B2 or SECTION 5C2.
When checking the brake fluid levels, the master
cylinder rear reservoir may be as low as 25.4 mm (1 inch)
from the top if the linings are worn. This is not abnormal.
Brake Hose and Pipe Assembly Inspection

NOTICE: Do not allow brake components to hang
from the flexible hose assemblies as damage to the
hoses may occur. Some brake hose assemblies have
protective rings or covers to prevent direct contact of
the hose with other chassis parts. Besides causing
possible structural damage to the hose, excessive
tension could cause the hose rings to move out of
their proper locations.
ll'l'l inspect
1. Flexible hydraulic brake hose assemblies, wh~ch
transmit hydraulic pressure from steel brake pipe
assembly on body to steel brake pipe assemblies on
rear axle assembly and to brake caliper assemblies,
at least twice a year when vehicle is on lift for
lubrication.
2. Brake hose assemblies for road hazard damage,
cracks, and chafing of outer cover, and for leaks and
blisters.
A light and mirror may be needed for adequate
inspection.
If any of the above conditions are observed on
brake hose assembly, it will be necessary to
replace it.
BRAKE FLUID
NOTICE: Improper brake fluid, mineral oil or wat~r
in the brake fluid may cause rubber components m
the brake hydraulic system to deteriorate.If brake
master cylinder primary or secondary piston seals
are swollen, the rubber parts have deteriorated. This
deterioration may also be seen by swollen brake

master cylinder reservoir seals, rear wheel cylinder
piston boots or brake caliper piston boots.
If rubber deterioration is evident, disassemble all
hydraulic parts and wash with alcohol. Dry parts with
compressed air before assembly to keep alcohol out of the
system. Replace all rubber parts in the system, including
brake hose assemblies, master cylinder assembly rubber
parts, and brake caliper assembly and wheel cylinder
assembly boots and seals. Also replace the combination
valve assembly and brake pressure modulator valve
assembly, since they have rubber components inside
which are not serviceable. Check for brake fluid on the
linings. If excessive brake fluid is found, replace the
linings.
The system must be flushed if there is any doubt as
to the condition of brake fluid in the system or if a fluid
has been used which contains the slightest trace of petroleum or mineral oil based fluids. Refer to SECTION 5El
for complete brake hydraulic system flush and bleed procedures.
ON-VEHICLE SERVICE
BRAKE PEDAL ASSEMBLY WITH BRACKET
Figures 2 through 4

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.

Battery negative cable assembly.
Left-hand instrument panel sound insulator assembly. Refer to SECTION 8C.
Electronic brake control module assembly. Refer to
SECTION 5El.
Release switch assembly, stoplamp and TCC switch
assembly, and clutch switch assembly or clutch anticipate switch assembly if equipped, from pedal
assembly with bracket. Refer to "Stoplamp and
Cruise Control Switch Assemblies" in this section.
Clutch start switch assembly (29) from brake pedal
assembly with bracket (5) on vehicle with manual
transmission assembly.
Accelerator lever pedal assembly. Refer to
SECTION 6C.
Retainer (16), brake pedal pushrod (15) and washer
(14) from brake pedal assembly pin.
Retainer (20) and clutch pushrod (19) from clutch
pedal assembly pin on vehicle with manual transmission assembly.
Nuts (3 and 7) and bolts/screws (4 and 8).
Nuts (11), on vehicle with manual transmission
assembly.
Brake pedal assembly with bracket (5 or 6).

56 BRAKES
A PANEL ASSEMBLY, DASH

B PIN, BRAKE PEDAL ASSEMBLY
C PIN, CLUTCH PEDAL ASSEMBLY
1 BOOSTER ASSEMBLY, POWER BRAKE
2 VALVE, POWER BRAKE BOOSTER VACUUM CHECK
3 NUT, BRAKE PEDAL, 25 Nm (18 LB. FT.)
4 BOLT/SCREW, BRAKE PEDAL BRACKET,
25 Nm (18 LB. FT.)
5 PEDAL ASSEMBLY, BRAKE AND ACCELERATOR AND
CLUTCH (WITH BRACKET)
7 NUT, BRAKE PEDAL BRACKET, 25 Nm (18 LB. FT.T
25 Nm (18 LB. FT.)
9 BOLT/SCREW, BRAKE PEDAL PIVOT
10 NUT, BRAKE PEDAL PIVOT
11 NUT, CLUTCH MASTER CYLINDER,
27 Nm (20 LB. FT.)
12 BUSHING, BRAKE PEDAL PIVOT
13 PEDAL ASSEMBLY, BRAKE
14 WASHER, BRAKE PEDAL PUSHROD
15 PUSHROD, BRAKE PEDAL
16 RETAINER, BRAKE PEDAL PUSHROD PIN
17 BUSHING, CLUTCH PEDAL PIVOT
18 PEDAL ASSEMBLY, CLUTCH
19 PUSHROD, CLUTCH MASTER CYLINDER
20 RETAINER, CLUTCH PEDAL LEVER PIN
24 PEDAL ASSEMBLY, ACCELERATOR LEVER
18
,,~,20
PC0002-5F-RP
Figure 2 - Manual Transmission Brake Pedal Assembly
BRAKES 5-7
22
<.
24
16
A PANEL ASSEMBLY, DASH

B PIN, BRAKE PEDAL ASSEMBLY
25 Nm (18 LB. FT.)
6 PEDAL ASSEMBLY, BRAKE AND ACCELERATOR
(WITH BRACKET)
7 NUT, BRAKE PEDAL BRACKET, 25 Nm (18 LB. FT.)
25 Nm (18 LB. FT.)
12 BUSHING, BRAKE PEDAL PIVOT
13 PEDAL ASSEMBLY, BRAKE
15 PUSHROD,BRAKEPEDAL
16 RETAINER, BRAKE PEDAL PUSHROD PIN
22 NUT, BRAKE PEDAL PIVOT
23 SPACER, BRAKE PEDAL PIVOT
24 PEDAL ASSEMBLY, ACCELERATOR LEVER
PC0003-5-fRP
Figure 3 - Automatic Transmission Brake Pedal Assembly
5-8 BRAKES
rn
Important
When installing brake pedal assembly with

bracket, make sure that dash panel insulator
material does not get pinched between brake
pedal assembly with bracket and dash panel.
l. Brake pedal assembly with bracket (5 or 6).
2. Nuts (11), on vehicle with manual transmission.
3. Nuts (3 and 7) and bolts/screws (4 and 8).
1~1 Tighten
4.
5.
6.
7.
8.
9.
10.
Nuts (7) to 25 Nm (18 lb. ft.) in sequence:

inboard upper, outboard lower, outboard
upper, inboard lower.
Nuts (3) and bolts/screws (4 and 8) to 25 Nm
(18 lb. ft.).
Nuts (11) to 27 Nm (20 lb. ft.) on vehicle with
manual transmission assembly.
Accelerator lever pedal assembly. Refer to
SECTION 6C.
Retainer (20) and clutch pushrod ( 19) to clutch pedal
assembly pin on vehicle with manual transmission
assembly.
Lubricate clutch pedal assembly pin with chassis lubricant, GM PIN 1052497 or equivalent.
Retainer (16), brake pedal pushrod (15) and washer
(14) to brake pedal assembly pin.
Lubricate brake pedal assembly pin with chassis lubricant, GM PIN 1052497 or equivalent.
assembly, and clutch switch assembly or clutch
anticipate switch assembly if equipped, to pedal
ass~mbly with bracket. Refer to "Stoplamp and
Crmse Control Switch Assemblies" in this section.
Electronic brake control module assembly. Refer to
SECTION 5El.
Clutch start switch assembly (29) to brake pedal
assembly with bracket (5), on vehicle with manual
[el Adjust
assembly, and clutch switch assembly or clutch
anticipate switch assembly on vehicle with manual
tran~mission assembly. Refer to "Stoplamp and
Crmse Control Switch Assemblies" in this section.
BRAKE PEDAL ASSEMBLY

Figures 2 and 3

1. Battery negative cable assembly.
2. Electronic brake control module assembly. Refer to

SECTION 5El.
3. Retainer (16), brake pedal pushrod (15) and washer
(14) from brake pedal assembly pin.
4. Nut (10) and bolt/screw (9) on vehicle with manual
Slide out bolt/screw (9) part way, giving just
enough clearance to remove brake pedal
assembly (13).
5. Nut (22) and bolt/screw (21) on vehicle with automatic transmission assembly.
6. Brake pedal assembly (13).
7. Bushings (12) from brake pedal assembly (13), if
necessary.
8. Spacer (23) from brake pedal assembly (13) on
vehicle with automatic transmission assembly, if
necessary.
li,I Clean
All parts with suitable solvent.
lll
1nspect
All parts for wear. Repair or replace as needed.

l. Spacer (23) to brake pedal assembly (13), if
2.
3.
4.
5.
6.
removed.
Bushings (12) to brake pedal assembly (13), if
removed.
Lubricate bolt/screw (9) with chassis lubricant, GM
PIN 1052497 or equivalent on vehicle with manual
Brake pedal assembly (13).
Bolt/screw (9) and nut (10) on vehicle with manual
Bolt/screw (21) and nut (22) on vehicle with automatic transmission assembly.
l~I Tighten
Nut (10 or 22) to 54 Nm (40 lb. ft.).
7. Retainer (16), brake pedal pushrod (15) and washer
(14) to brake pedal assembly pin.
Lubricate brake pedal assembly pin with chassis lubricant, GM P/N 1052497 or equivalent.
8. Electronic brake control module assembly. Refer to
SECTION 5El.
[el Adjust
Release switch assembly, and stoplamp and TCC
switch assembly, and clutch switch assembly or
clutch anticipate switch assembly if equipped. Refer
to "Stoplamp and Cruise Control Switch Assemblies" in the following procedure.
BRAKES 5-9
STOPLAMP AND CRUISE CONTROL

SWITCH ASSEMBLIES
bracket (5 or 6) until retainer on release switch

assembly (27), stoplamp and TCC switch assembly
(26), or clutch switch assembly (25) or clutch anticipate switch assembly (28) is fully seated.
Figure 4
NOTICE: Make sure to apply the proper amount of

force to the brake pedal assembly during adjustment.
Too much force could damage the vacuum booster
assembly. Too little could cause dragging brakes.
Adjustment
The release switch assembly (27) must be adjusted
at the same time the stoplamp and torque converter clutch
(TCC) switch is adjusted. The clutch switch assembly
(25) or clutch anticipate switch assembly (28) cannot be
adjusted until after the clutch pedal assembly is installed.
NOTICE: Proper stoplamp switch assembly adjustment is essential. Improper stoplamp switch assembly adjustment will cause brake drag and excessive
brake lining wear.
11
Adjust
1. To adjust, depress brake pedal assembly or clutch

pedal assembly and insert release switch assembly
(27), stoplamp and TCC switch assembly (26) and
clutch switch assembly (25) or clutch anticipate
switch assembly (28) into pedal assembly with
2. Slowly pull brake or clutch pedal assembly rearward

with a force of 222 N (50 pounds) until "click"
sounds can no longer be heard. At this point, release
switch assembly (27), stoplamp and TCC switch
assembly (26), and clutch switch assembly (25) or
clutch anticipate switch assembly (28) will have
moved retainers to their adjusted position.
l@I
Measure
Release switch assembly and stoplamp and TCC

switch assembly contacts should be open at 25.4 mm
( 1 inch) or less of pedal assembly travel, and occur at
the same time or before the onset of braking. The
26
29
A
B
C
D
E
F
G
H
J
5
6
25
26
27
28
29
MANUAL TRANSMISSION
AUTOMATIC TRANSMISSION
CONNECTOR, ELECTRICAL
H
WITH 3.4L L32 ENGINE
WITH 5.7L LT1 ENGINE
PEDAL ASSEMBLY, BRAKE AND ACCELERATOR AND
PEDAL ASSEMBLY, BRAKE AND ACCELERATOR (WITH
BRACKET)
SWITCH ASSEMBLY, CRUISE CONTROL CLUTCH
SWITCH ASSEMBLY, STOPLAMP AND TORQUE
CONVERTER CLUTCH
SWITCH ASSEMBLY, CRUISE CONTROL RELEASE
SWITCH ASSEMBLY, CRUISE CONTROL CLUTCH
ANTICIPATE
SWITCH ASSEMBLY, CLUTCH START
PCOCJ04.5-F-RP
Figure 4 - Stoplamp and Cruise Control Switch Assemblies
5-10 BRAKES
31
,f~~
36
0,
33
39
44
30
/:',,.,..
'
33
31
jv1Ewc
A CROSSMEMBER ASSEMBLY, FRONT
30 CYLINDER ASSEMBLY, BRAKE MASTER

31
32
33
34
35
PIPE ASSEMBLY, FRONT BRAKE COMBINATION VALVE

PIPE ASSEMBLY, REAR BRAKE COMBINATION VALVE
VALVE ASSEMBLY, BRAKE PRESSURE MODULATOR
PIPE ASSEMBLY, LEFT-HAND FRONT BRAKE
PIPE ASSEMBLY, RIGHT-HAND FRONT BRAKE
36 PIPE ASSEMBLY, REAR BRAKE FRONT,
15 Nm (11 LB. FT.)
I
37 CLIP, BRAKE PIPE
38 CLIP, BRAKE PIPE
39 CLIP, BRAKE PIPE
40 CLIP, BRAKE PIPE
41 CLIP, BRAKE PIPE
42 BOLT/SCREW, BRAKE PIPE CLIP, 6 Nm (53 LB. IN.)
43 BOLT/SCREW, FRONT BRAKE FRONT PIPE CLIP,
6 Nm (53 LB. IN.)
44 CLIP, BRAKE PIPE
PC00055fRP
Figure 5 - Routing Front Brake Pipe Assemblies
BRAKES 511
BRAKE PIPE ASSEMBLIES-TO-BRAKE MASTER CYLINDER ASSEMBLY

CALLOUT
NUMBER
CIRCUIT
NUT
SIZE
PIPE ASSEMBLY
DIAMETER
APPROXIMATE BRAKE PIPE

LINEAR LENGTH
NUT TIGHTENING
SPECIFICATION
31
PRIMARY
Mll x 1.5
4.76 mm
427.96 mm (16.848'1
32 Nm (24 LB. FT.)
32
SECONDARY
Mll x 1.5
4.76mm
530.74 mm (20.895')
32 Norn (24 LB. FT.)
BRAKE PIPE ASSEMBLIES-TO-COMBINATION VALVE ASSEMBLY

CALLOUT
NUMBER
CIRCUIT
NUT
SIZE
PIPE ASSEMBLY
DIAMETER

LINEAR LENGTH
NUT TIGHTENING
SPECIFICATION
31
PRIMARY
M10x 1.5
4.76mm
427.96 mm (16.848')
18 Nm (13 LB. FT.)
32
SECONDARY
MlOx 1.5
4.76 mm
530.74 mm (20.895')
18 Nm (13 LB. FT.)
BRAKE PIPE ASSEMBLIES-TO-BRAKE PRESSURE MODULATOR VALVE ASSEMBLY

CALLOUT
NUMBER
CIRCUIT
NUT
SIZE
PIPE ASSEMBLY
DIAMETER

LINEAR LENGTH
NUT TIGHTENING
SPECIFICATION
34
LEFT -HANO FRONT
MlOx 1.0
4.76mm
2321.50 mm (91.379')
35
RIGHT-HAND FRONT
MlOx 1.0
4.76 mm
1398.84 mm (55.072')
32 Nm (24 LB. FT.)
36
REAR
M12x 1.5
6.00mm
3813.95 mm (150.155')
32 Nm (24 LB. FT.)
BRAKE PIPE ASSEMBLIES-TO-BRAKE HOSE ASSEMBLIES

PIPE ASSEMBLY
DIAMETER

LINEAR LENGTH
NUTTIGHTENING
SPECIFICATION
MlOx 1.0
4.76 mm
2321.50 mm (91.379')
15 Nm (11 LB. FT.)
MIO x 1.0
4.76mm
1398.84 mm (55.072')
CALLOUT
NUMBER
CIRCUIT
NUT
SIZE
.34
LEFT-HAND FRONT
RIGHT-HAND FRONT
35
NUT COLOR CODE

SIZE
MlOx 1.0
Mll x 1.5
M12x 1.0
M12x 1.5
3/8-24 UNF
COLOR
OLIVE
ORANGE
YELLOW
BLACK
VIOLET
PC0006-5-F-RP
Figure 6 - Front Brake Pipe Assembly Specifications
brake pedal assembly travel can be up to 25.4 mm

(1 inch) before the cruise control system disengages.
Replacement

1. Left-hand instrument panel sound insulator assem-
bly. Refer to SECTION 8C.

3. Release switch assembly (27), stoplamp and TCC
switch assembly (26), and clutch switch assembly
(25) or clutch anticipate switch assembly (28), if
equipped, from pedal assembly with bracket (5 or 6).

(25) or clutch anticipate switch assembly (28), if
equipped, to pedal assembly with bracket (5 or 6).
11 Adjust
Release switch assembly (27), stoplamp and TCC
(25) or clutch anticipate switch assembly (28), as
outlined above.
BRAKE PIPE ASSEMBLY

Figures 5 through 9
CAUTION: Always use double walled
steel brake pipe when replacing brake
pipe assemblies. The use of any other
pipe is not recommended and may
cause brake system failure. Carefully
route and retain replacement brake
512 BRAKES
36
c
53
36
A AXLE ASSEMBLY, REAR

B CLIP, REAR AXLE RETAINER
C RAIL ASSEMBLY, REAR COMPARTMENT PANEL
LONGITUDINAL
15 Nm (11 LB. FT.)
51 BOLT/SCREW, REAR BRAKE HOSE FITTING,
21 Nm (15 LB. FT.)
52 CLIP, REAR BRAKE PIPE
53 HOSE ASSEMBLY, REAR BRAKE
54 PIPE ASSEMBLY, RIGHT-HAND REAR BRAKE
55 PIPE ASSEMBLY, LEFT-HAND REAR BRAKE
56 RETAINER, REAR BRAKE HOSE
57 BRACKET, REAR BRAKE HOSE
58 BOLT/SCREW, REAR BRAKE HOSE RETAINER,
10 Nm (89 LB. IN.)
67 PIPE ASSEMBLY, RIGHT-HAND REAR BRAKE
68 PIPE ASSEMBLY, LEFT-HAND REAR BRAKE
56
PC0008-5-F-RP
Figure 7 - Routing Rear Brake Pipe and Hose Assemblies
BRAKES 513
cause brake system failure.
Refer to Figures 5 through 9 for brake pipe routing,
tightening specifications and replacement. For information on the brake pressure modulator valve assembly, refer
to SECTION 5El.
pipe assemblies. Always use the correct fasteners and the original location
for replacement brake pipe assemblies.
Failure to properly route and retain
brake pipe assemblies may cause damage to the brake pipe assemblies and
REAR BRAKE PIPE ASSEMBLIES-TO-REAR BRAKE HOSE ASSEMBLIES

NUT TIGHTENING
SPECIFICATIONS
CALLOUT
NUMBER
CIRCUIT
NUT SIZE
@CENTER
HOSE
ASSEMBLY
NUT SIZE
@RIGHT ANO
LEFT HOSE
ASSEMBLIES
PIPE ASSEMBLY
DIAMETER
APPROXIMATE
PIPE LINEAR
LENGTH
@ CENTER HOSE
ASSEMBLY
@RIGHT ANO
LEFT HOSE
ASSEMBLIES
54
RIGHT-HANO
REAR DISC
3/8-24 UNF
MlOx 1.0
4.76mm
890.49 mm (35.058")
24 Nm (18 LB. FT.)
15 Nm (11 LB. FT.)
55
LEFT-HANO
REAR DISC
3/8-24 UNF
MlOx 1.0
4.76mm
541.91 mm (21.335")
24 Nm (18 LB. FT.)
15 Nm (11 LB. FT.)
REAR BRAKE PIPE ASSEMBLIES-TO-REAR WHEEL CYLINDERS

NUT TIGHTENING
SPECIFICATIONS
CALLOUT
NUMBER
CIRCUIT
NUT SIZE
@CENTER
HOSE
ASSEMBLY
NUT SIZE
@WHEEL
CYLINDER
PIPE ASSEMBLY
DIAMETER
APPROXIMATE
PIPE LINEAR
LENGTH
@ CENTER HOSE
ASSEMBLY
@RIGHT AND
LEFT WHEEL
CYLINDERS
67
RIGHT-HAND
REAR DRUM
3/8-24 UNF
3/8-24 UNF
4.76mm
1170.05 mm (46.064")
24 Nm (18 LB. FT.)
17 Nm (13 LB. FT.)
68
LEFT-HANO
REAR DRUM
3/8-24 UNF
3/8-24 UNF
4.76mm
864.30 mm (34.027"')
24 Nm (18 LB. FT.)
17 Nm (13 LB. FT.)
NUT COLOR CODE

SIZE
COLOR
MlOx 1.0
OLIVE
Mllx 1.5
ORANGE
M12x 1.0
YELLOW
M12x 1.5
BLACK
3/8-24 UNF
VIOLET
PC0009-5-F-RP
Figure 8 - Rear Brake Pipe and Hose Assembly Specifications
5-14 BRAKES
36
!VIEWS
36
36
~FRT
49
IVIEWD I
45
IVIEWC I
BRAKE PIPE ASSEMBLYTO BRAKE PRESSURE MODULATOR VALVE ASSEMBLY

CALLOUT
NUMBER
CIRCUIT
NUT
SIZE
PIPE ASSEMBLY
DIAMETER
APPROXIMATE PIPE
LINEAR LENGTH
NUT TIGHTENING
SPECIFICATION
36
REAR
M12 x 1.5
6.00 mm
3813.95 mm 1150.155"1
32 Nm (24 LB. FT.I
BRAKE PIPE ASSEMBLY TO REAR BRAKE (CENTER) HOSE ASSEMBLY

CALLOUT
NUMBER
CIRCUIT
NUT
SIZE
PIPE ASSEMBLY
DIAMETER
APPROXIMATE PIPE
LINEAR LENGTH
NUT TIGHTENING
SPECIFICATION
36
REAR
M12x 1.0
6.00 mm
3813.95 mm (150.155")
15 Nm (11 LB. FT.I

45
46
47
48
49
15 Nm (11 LB. FT.)

CLIP, BRAKE PIPE
CLIP, FUEL LINE RETAINER
NUT COLOR
SIZE
MIO x 1.0
M11x1.5
M12x 1.0
M12x 1.5
3/8-24 UNF
COLOR
OLIVE
ORANGE
YELLOW
BLACK
VIOLET
PC00075F-RP
Figure 9 - Routing Underbody Rear Brake Front Pipe Assembly
BRAKES 5-15
rn
Important
Rear brake front pipe assembly (36) should not be

locally fabricated. This pipe assembly should be
ordered through your GM Parts Dealer.
D. Be sure fitting nut is properly placed on tubing.

Insert end of tube between two blocks until
level with top of gage.
A COMPRESSION SCREW
B SWIVEL CONE
Double Lap Flare

Double lap flares are to be used for rear brake rear
pipe assemblies. All other brake pipe assemblies will use
ISO flare.
Tool Required:
J 23530 Brake Line Flaring Tool (45 Degree
Single and Double)
1. Obtain recommended tubing and steel fitting nuts of
correct size.
(?utside diameter of tubing is used to specify
size.
2. Cut tubing to length.
Correct length may be determined by measuring old brake pipe assembly using string and
adding 3 mm ( 1/8 inch) for each double flare.
3. Cut end square and chamfer inside and outside
diameter of tubing with de-burring tool.
Remove all traces of lubricant from tubing.
NOTICE: Do not use single lap flaring tools.
Double lap flaring tools must be used to produce a
flare strong enough to hold system pressure. Using
single lap flaring tools could cause system damage.
A single lap flare will split tubing while a double lap
flare produces a well-formed, unbroken, reinforced
double walled flare.
PC6010-5-D-RP
Figure 11 - Placing Tubing in Tool
E. Insert proper pin of gage into tubing and swing

strap back in closed position. Tighten compression screw until gage bottoms on tool, then unscrew compression screw and swing strap to
one side. Remove gage.
PC6011-5-D-RP
A SINGLE LAP FLARE

B DOUBLE LAP FLARE
Figure 12 - Preparing for Double Lap F'lare
F.
B
Swing strap back in closed position, then tighten compression screw to flare cone downward
to complete double lap flare.
PC6009-5-D-RP
Figure 10 - Single Lap vs. Double Lap Flares
4. Double lap flare tubing ends using J 23530.

A. Make sure fittings are installed before starting
flare.
B. Unscrew compression screw until swivel cone
is at its highest point.
Swing strap to one side.
C. Open lever handle so it is at right angle to rest
of tool and revolve hexagonal tube lights to
accommodate tubing (selection of six sizes).
PC6012-5-D-RP
Figure 13 - Completing Double Lap Flare
G. Unscrew compression screw and open smaller

lever handle to remove brake pipe assembly.
H. Inspect flared ends for splits, cracks, pits or
excessive out-of-round which may cause leaks.
5-16 BRAKES
I.
Blow out brake pipe assembly with dry compressed air to remove any foreign objects.
5. Bend new brake pipe assembly to match old pipe
assembly using a tubing bender.
rn
Important
Minimum clearance of 19 mm (3/4 inch) must

be maintained from all moving components
and 13 mm (1/2 inch) from all vibrating components, unless brake pipe assembly is clipped
to the component. For armor wrapped pipe,
contact is permissible if there is no relative
movement between pipe assembly and contact
surface.
D. Insert proper forming mandrel into tool body.

While holding mandrel in place with your finger, thread in forcing screw until it makes contact and begins to move forming mandrel.
When contact is made, turn forcing screw back
one complete turn.
E. Slide clamping nut over tubing into correct
collet. Leave approximately 19 mm (3/4 inch)
of tubing extending out collet. Insert assembly
into tool body. Tube end must contact face of
forming mandrel.
ISO Flare
ISO flares are NOT to be used for rear brake rear
pipes.
Tool Required:
J 29803-A ISO Flaring Kit
1. Obtain recommended tubing and steel fitting nuts of
correct size.
(?utside diameter of tubing is used to specify
size.
2. Cut tubing to length.
Correct length may be determined by measuring old brake pipe assembly using string and
adding 3 mm ( 1/8 inch) for each ISO flare.
3. Cut end square and chamfer inside and outside
diameter of tubing with de-burring tool.
Remove all traces of lubricant from tubing.
4. ISO flare tubing ends using J 29803-A.
A. Make sure fittings are installed on tubing
before starting flare.
B. Clamp flaring tool body in vise.
C. Select correct size collet and forming mandrel
for tube size used.
A FORMING MANDREL
B FLARING TOOL BODY
C FORCING SCREW
A CLAMPING NUT
B COLLET
PC6014-5-D-RP
Figure 15 - Clamping Nut and Collet
F. Tighten clamping nut into tool body very tight

or tube may push out.
G. Wrench tighten forcing screw in until it bottoms. Do not tighten forcing screw further or
flare may become over-sized.
H. Back clamping nut out of tool body and disassemble clamping nut and collet assembly.
Flare is now ready for use.
A ISO FLARE
PC6013-5-D-RP
Figure 14 - Forming Mandrel and Forcing Screw
Figure 16 - ISO Flare
PC6015-5-B-RP
BRAKES 5-17
62
33 VALVE ASSEMBLY, BRAKE PRESSURE MODULATOR

59 BOLT/SCREW, BRAKE COMBINATION VALVE,
16 Nm (12 LB. FT.)
60 SEAL, BRAKE COMBINATION VALVE
61 SEAL, BRAKE COMBINATION VALVE
62 VALVE ASSEMBLY, BRAKE COMBINATION
63 SEAL, TRANSFER TUBE
64 TUBE, TRANSFER
65 TUBE.TRANSFER
66 SEAL, TRANSFER TUBE
PC0010-5-F-RP
Figure 17 - Combination Valve Assembly
5. Bend new brake pipe assembly to match old pipe

using a tube bender.
Minimum clearance of 19 mm (3/4 inch) must
be maintained from all moving components
and 13 mm (1/2 inch) from all vibrating components, unless brake pipe assembly is clipped
to the component. For armor wrapped pipe,
contact is permissible if there is no relative
movement between pipe assembly and contact
surface.
COMBINATION VALVE ASSEMBLY
4. Seals (61).
Discard seals (61).
5. Transfer tubes (64 and 65) and seals (63 and 66)
from combination valve assembly (62).
l~I Clean
All parts in clean, denatured alcohol.
- Dry with unlubricated, compressed air.
l~I Clean
All parts for wear. Repair or replace as needed.
Figure 17

1. Brake motor assembly from brake pressure modulator assembly. Refer to SECTION 5El.
2. Bolts/screws (59) and seals (60).
Discard seals (60).
3. Combination valve assembly (62).

1. Transfer tubes (64 and 65) and seals (63 and 66) to
combination valve assembly (62).
Lubricate seals (63 and 66) with clean brake
fluid.
2. New seals (61).
518 BRAKES
Lubricate seals (61) with clean brake fluid.
3. Combination valve assembly (62).
4. New seals (60) and bolts/screws (59).
Lubricate seals (60) with clean brake fluid.
l~I
Clean
Dirt and foreign material from front brake hose

assembly (71) and front brake hose fitting (72).
2. Pipe assembly (34) from hose assembly (71).
Tighten

5. Brake motor assembly to brake pressure modulator
valve assembly. Refer to SECTION 5El.
BRAKE HOSE ASSEMBLY
Use a backup wrench on hose assembly fitting.

Be careful not to bend bracket (75) or pipe
assembly (34).
3. Retainer (76) from hose assembly fitting at bracket
(75).
Front Brake Hose Assembly
4. Hose assembly (71) from bracket (75).
Figure 18
l++I
li,I
5. Fitting (72), hose assembly (71), and two gaskets

(73) from caliper assembly (70).
Discard two gaskets (73).
71
75
76~
341
71
34
70
71
72
73
74
75
76
70
PIPE ASSEMBLY, LEFT-HAND FRONT BRAKE

CALIPER ASSEMBLY, FRONT BRAKE
HOSE ASSEMBLY, FRONT BRAKE
FITTING, FRONT BRAKE HOSE, 44 Nm (32 LB. FT.)
GASKET, FRONT BRAKE HOSE FITTING
BOLT/SCREW, FRONT BRAKE HOSE CLIP
BRACKET, FRONT BRAKE HOSE
RETAINER, FRONT BRAKE HOSE
PC0011-!iF-RP
Figure 18 - Front Brake Hose Assembly (Left Side Shown, Right Side Similar)
BRAKES 5-19

1. Fitting (72), hose assembly (71), and two new gaskets (73) to caliper assembly (70).
Lubricate hose assembly fitting threads with
brake fluid.
Hose assembly fitting flange must engage caliper assembly orientation ledge.
!~I
Tighten

2. Hose assembly (71) into bracket (75).
There should be no kinks in hose assembly
(71).
3. Retainer (76) at bracket (75).
4. Pipe assembly (34) to hose assembly (71).
Use backup wrench on hose assembly fitting.
Make sure that hose assembly (71) does not
make contact with any part of suspension.
Check in extreme right and extreme left turn
conditions.
l~I Tighten
Pipe assembly (34) to hose assembly (71) to
15 Nm (11 lb. ft.).
5. Bleed brake hydraulic system. Refer to SECTION
5El.
Rear Brake (Center) Hose Assembly

Figures 8 and 9

SECTION OA.
IOI
2.
3.
4.
5.
Clean
Dirt and foreign material from hose assembly

and pipe assembly fittings.
Pipe assembly (36) from hose assembly (53).
assembly (36).
Retainer (56) from bracket (57) and hose assembly
(53).
Hose assembly (53).
Left rear pipe assembly (55 or 68) and right rear pipe
assembly (54 or 67) from hose assembly (53).
Be careful not to bend left rear pipe assembly
(55 or 68) and right rear pipe assembly (54 or
67).
6. Bolt/screw (51) and hose assembly (53) from rear

axle assembly.
Note position of hose assembly (53) for proper
location during installation.

1. Hose assembly (53) and bolt/screw (51) to rear axle
assembly.
l~I
Tighten

2. Left rear pipe assembly (55 or 68) and right rear pipe
assembly (54 or 67) to hose assembly (53).
l~I
Tighten
Left rear pipe assembly (55 or 68) and right

rear pipe assembly (54 or 67) at hose assembly
(53) to 24 Nm (18 lb. ft.).
3. Hose assembly (53) into bracket (57).
Be sure hose assembly (53) is seated properly
and not twisted.
4. Retainer (56) to bracket (57) and .hose assembly
(53).
5. Pipe assembly (36) to hose assembly (53).
Use backup wrench on hose assembly (53).
assembly (36).
l~I
Tighten
Pipe assembly (36) to hose assembly (53) to

15 Nm (11 lb. ft.).
5El.
7. Lower vehicle.
Rear Brake Hose Assembly

Figure 19

1. Wheel and tire assembly. Refer to SECTION 3E.
IOI
Clean
Dirt and foreign material from hose assembly

(81) and pipe assembly fitting.
2. Hose assembly (81) from pipe assembly (55).
Be careful not to bend bracket (85) and pipe
assembly (55).
3. Retainer (84) from bracket (85) and hose assembly
(81).
4. Fitting (83), two gaskets (82) and hose assembly
(81) from caliper assembly (80).
Discard two gaskets (82).
5-20 BRAKES
l++I
Install or Connect
l. Fitting (83), two new gaskets (82) and hose assembly (81) to caliper assembly (80).
Lubricate hose assembly fitting threads with
clean brake fluid.
Hose assembly fitting flange must engage
caliper assembly orientation ledge.
l~I
Tighten

2. Retainer (84) to bracket (85) and hose assembly
(81).
3. Hose assembly (81) to pipe assembly (55).
Be careful not to bend bracket (85) and pipe
assembly (55).
l~I
Tighten
Pipe assembly (55) to hose assembly (81)

to 15 Nm (11 lb. ft.).
55
80
81
82
83
84
85
90
PIPE ASSEMBLY, LEFT-HAND REAR BRAKE

HOSE ASSEMBLY, LEFT-HAND REAR BRAKE
GASKET, REAR BRAKE HOSE FITTING
FITTING, REAR BRAKE HOSE, 44 Nm (32 LB. FT.)
RETAINER, REAR BRAKE HOSE
BRACKET, REAR BRAKE HOSE
DAMPENER ASSEMBLY, REAR BRAKE VIBRATION
PC00125F-RP
4. Bleed hydraulic brake system. Refer to SECTION

5El.
Figure 19 - Rear Disc Brake Hose Assembly

(Left Side Shown, Right Side Similar)
5. Wheel and tire assembly. Refer to SECTION 3E.
FLUSHING BRAKE HYDRAULIC SYSTEM

NOTICE: Use only DOT 3 brake fluid from a clean,
sealed container. Do not use any fluid from a container which is wet with water. Do not use DOT 5
silicone brake fluid. Improper brake fluid, mineral
oil or water in the fluid may cause the brake fluid to
boil or the rubber components to deteriorate. Keep
all fluid containers capped to prevent contamination.

about the condition of fluid in the system or if fluid has
been used which contains the slightest trace of petroleum
or mineral oil based fluids. Approximately 1.5 liters

(1.5 quarts) of brake fluid is required to flush the brake
hydraulic system. All rubber parts, including brake hose
assemblies, master cylinder assembly rubber parts, and
brake caliper assembly and wheel cylinder assembly
boots and seals that have been subjected to a contaminated
fluid must be replaced. Also replace the combination
valve assembly and brake pressure modulator assembly,
since they have rubber components inside that are not
serviceable. Refer to SECTION 5El for complete brake
hydraulic system flush and bleed procedures.
SPECIFICATIONS
Brake Pedal Assembly Travel .................................... 51 to 89 mm (2.0 to 3.5")
Brake pedal assembly travel maximum with 445 N (100 lb.) force applied to pedal with engine
running at idle.
Hydraulic Brake (Glycol) Fluid . . . . . . . . . . . . . . . . . . . GM P/N 1052535 or equivalent DOT-3 fluid
Brake Pipe Assembly Clearance (Minimum)
Moving Components ................................................... 19 mm (3/4")
Vibrating Components ................................................. 13 mm (l/2")
Armor-Wrapped Pipe Assemblies .................................. Contact is permitted if
there is no relative movement
between pipe assembly
and contact surface
BRAKES 5-21

Brake Combination Valve Bolt/Screw ................................... 16 Nm (12 lb. ft.)
Brake Pedal Bracket Bolt/Screw ........................................ 25 Nm (18 lb. ft.)
Brake Pedal Bracket Nut .............................................. 25 Nm (18 lb. ft.)
Brake Pedal Nut .................................................... 25 Nm (18 lb. ft.)
Brake Pedal Pivot Nut ................................................ 54 Nm (40 lb. ft.)
Brake Pipe Clip Bolt/Screw ............................................ 6 Nm (53 lb. in.)
Clutch Master Cylinder Nut ........................................... 27 Nm (20 lb. ft.)
Front Brake Combination Valve Pipe Assembly-toBrake Combination Valve Assembly .................................. 18 Nm (13 lb. ft.)
Front Brake Combination Valve Pipe Assembly-toBrake Master Cylinder Assembly ..................................... 32 Nm (24 lb. ft.)
Front Brake Hose Fitting ............................................. 44 Nm (32 lb. ft.)
Front Brake Pipe Assembly-to-Brake Pressure Modulator Valve Assembly ...... 32 Nm (24 lb. ft.)
Front Brake Pipe Assembly-to-Front Brake Hose Assembly .................. 15 Nm (11 lb. ft.)
Front Brake Front Pipe Clip Bolt/Screw ................................... 6 Nm (53 lb. in.)
Rear Brake (Center) Hose Fitting Bolt/Screw ............................. 21 Nm (15 lb. ft.)
Rear Brake Combination Valve Pipe Assembly-toBrake Combination Valve Assembly .................................. 18 Nm (13 lb. ft.)
Rear Brake Combination Valve Pipe Assembly-toBrake Master Cylinder Assembly ..................................... 32 Nm (24 lb. ft.)
Rear Brake Front Pipe Assembly-toBrake Pressure Modulator Valve Assembly ............................. 32 Nm (24 lb. ft.)
Rear Brake Front Pipe Assembly-to-Rear Brake (Center) Hose Assembly ....... 15 Nm (11 lb. ft.)
Rear Brake Hose Fitting .............................................. 44 Nm (32 lb. ft.)
Rear Brake Hose Retainer Bolt/Screw ................................... 10 Nm (89 lb. in.)
Rear Brake Pipe Assembly-to-Rear Brake (Center) Hose Assembly ............ 24 Nm (18 lb. ft.)
Rear Brake Pipe Assembly-to-Rear Brake Hose Assembly ................... 15 Nm (11 lb. ft.)
Rear Brake Pipe Assembly-to-Rear Wheel Cylinder ........................ 17 Nm (13 lb. ft.)
SPECIAL TOOLS
2.
I!@{}
1.
J 28662
J 29803-A
\o
...1
J 23530
1. BRAKE PEDAL EFFORT GAGE

2. ISO FLARING KIT
3. BRAKE LINE FLARING TOOL (45 SINGLE AND DOUBLE)
PC0013-5-F-RP
MASTER CYLINDER 5A-1
SECTION 5A
MASTER CYLINDER
actions:
result.
CONTENTS
General Description . . . . . . . . . . . . . . . . . . . . . . . .
Master Cylinder Assembly ................
Master Cylinder Reservoir . . . . . . . . . . . . . . . . .
Brake Fluid and Fluid Handling . . . . . . . . . . . .
Substandard or Contaminated Brake Fluid . .
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Master Cylinder Assembly Check . . . . . . . . . . .
Master Cylinder Assembly . . . . . . . . . . . . . . . .
On-Vehicle Service ........................
Filling Master Cylinder Reservoir ...........
SA-1
5A-1
SA-1
SA-1
SA-2
SA-2
5A-2
5A-2
SA-2
5A-2
GENERAL DESCRIPTION
MASTER CYLINDER ASSEMBLY
The brake master cylinder assembly is a composite
design (plastic reservoir and aluminum body) incorporating a conventional front-to-rear brake system split. The
brake master cylinder primary piston provides the fluid
pressure to the front disc brakes, while the brake master
cylinder secondary piston provides the fluid pressure to
the rear drum or disc brakes. If pressure is lost from either
system, the remaining system will function to stop the
vehicle.
Master Cylinder Assembly ................ SA-3

Bleeding Brake
Hydraulic System . . . . . . . . . Refer to Section 5El
Unit Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5A-4
Master Cylinder Assembly . . . . . . . . . . . . . . . . SA-4
Master Cylinder Assembly Bench Bleeding ... SA-4
Master Cylinder Reservoir . . . . . . . . . . . . . . . . . SA-5
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SA-6
General Specifications . . . . . . . . . . . . . . . . . . . . SA-6
Fastener Tightening Specifications . . . . . . . . . . SA-6
Eye contact - rinse thoroughly

with water.
water.
MASTER CYLINDER RESERVOIR

Figure 1
The reservoir (5) has a fluid level indicator mark
located inside the neck of the reservoir fill opening. The
reservoir cap must be removed to view the indicator mark.
BRAKE FLUID AND FLUID HANDLING

following actions:
A MAXIMUM FILL LEVEL

5 RESERVOIR, BRAKE MASTER CYLINDER
PC0001-5Af.RP
Figure 1 - Brake Fluid Level Indicator
SA-2 MASTER CYLINDER

vehicle's painted surfaces, wiring cables or electrical connections. Brake fluid will damage paint
and electrical connections. If any fluid is spilled on
the vehicle, flush with water to lessen damage.
(II Important
Do not re-use brake fluid accumulated during brake
hydraulic system bleeding.
Always store fluid in a closed container. Reseal
containers immediately after use. Do not use fluid
left in an open or improperly sealed container as it
absorbs moisture or may be contaminated.
Substandard or Contaminated Brake Fluid

Use only brake fluid GM PIN 1052535 or an equivalent DOT-3 fluid. DO NOT use power steering fluid,
automatic transmission fluid or DOT-5 silicone hydraulic
brake fluid.
This deterioration may be seen by a swollen brake
master cylinder reservoir diaphragm or swollen brake
master cylinder primary or secondary seals. Deterioration
of the rubber components may result in costly damage to
the brake pressure modulator valve assembly, disc brake
caliper assemblies and rear wheel cylinders.
If rubber deterioration is evident, the entire brake
system must be flushed and all rubber components
replaced. Refer to SECTION 5.
DIAGNOSIS
MASTER .CYLINDER ASSEMBLY CHECK
1. Check. for cracked brake master cylinder body or
brake fluid around brake master cylinder assembly.
Leaks are indicated only if there is at least a
drop of fluid.
A damp condition is not abnormal.
2. Check for binding brake pedal assembly linkage and
incorrect power brake booster power piston pushrod
assembly length.
A. If both of these are satisfactory, disassemble
brake master cylinder assembly and check for
swollen or elongated primary or secondary
piston seal(s).
B. If swollen primary or secondary seals are

found, substandard or contaminated brake
fluid should be suspected.
C. If contaminated, all components should be disassembled and cleaned. All rubber components, including those in the combination valve
assembly, brake pressure modulator valve
assembly, disc brake calipers and rear wheel
cylinders, should be replaced and all brake
pipe assemblies flushed.

CONDITION
POSSIBLE CAUSE
CORRECTION
Grabby Brakes
(Apparent On-Off Condition)
1. Insufficient brake fluid in master

cylinder assembly.
1. Fill master cylinder reservoirs with

approved brake fluid and check for
leaks.
2. Repair or replace as necessary.
2. Faulty master cylinder primary or

secondary piston seals.
3. Cracked master cylinder body.
3. Replace.
These checks will not determine all master cylinder assembly malfunctions. Refer to SECTION 5.
ON-VEHICLE SERVICE
NOTICE: Do not use lubricated shop air on brake
parts as damage to rubber components may result.
[Il Important
Replace all components included in repair kits used
to service this brake master cylinder assembly.
Lubricate rubber parts with clean brake fluid to ease
assembly.
If any hydraulic component is removed or disconnected, it may be necessary to bleed all or part of the
brake hydraulic system.
The torque values specified are for dry, unlubricated

fasteners.
Perform service operations on a clean bench, free
from all mineral oil materials.
FILLING MASTER CYLINDER RESERVOIR

The brake master cylinder reservoir must be kept
properly filled to insure adequate reserve and to prevent
air from entering the brake hydraulic system. However,
because of expansion due to heat absorbed from the
brakes and from the engine, the reservoir must not be
overfilled.
MASTER CYLINDER 5A3

2. Brake pipe assemblies (1 and 2).
A drop in brake fluid level is normal as the pads and

linings wear. Filling the master cylinder reservoir before
installing new pads and linings may result in brake fluid
spillage once the new pads and linings are in place. Unless
there is a leak in the brake hydraulic system, or if the
brake hydraulic system has been serviced, topping off the
master cylinder reservoir should not be necessary.
Thoroughly clean the master cylinder reservoir cap
before removal to avoid getting dirt in reservoir. Remove
reservoir cap and reservoir diaphragm.
NOTICE: Use only DOT-3 brake fluid from a clean,
sealed container. Do not use any fluid from a container which is contaminated with water. Do not use
DOT-5 silicone brake fluid. Improper brake fluid,
mineral oil or water in the brake fluid may cause it to
boil or the rubber components to deteriorate. Keep
all containers capped to prevent contamination.
Add brake fluid GM P/N 1052535 or equivalent as
required to bring fluid level to line located inside the neck
of the reservoir fill opening.
Plug brake pipe assemblies (1 and 2) to prevent

fluid loss and contamination.
3. Nuts (18).
4. Master cylinder assembly (15).

NOTICE: See "Notice" on page 5A-1 of this
section.
1. Bench bleed master cylinder assembly. Refer to
"Master Cylinder Assembly Bench Bleeding" in
this section.
2. Master cylinder assembly ( 15).
3. Nuts (18).
l~I Tighten
Nuts (18) to 43 Nm (32 lb. ft.).
4. Fill master cylinder reservoir. Refer to "Filling

Master Cylinder Reservoir" in this section.
Figure 2
5. Brake pipe assemblies (1 and 2) to master cylinder

assembly (15) one at a time.
A. Remove locally fabricated plug.
1. Brake fluid from reservoir (5).

Discard old fluid.
B. Install brake pipe assembly fitting finger tight.
12
18
I
15
1 PIPE ASSEMBLY, FRONT BRAKE COMBINATION VALVE,
32 Nm (24 LB. FT.)
2 PIPE ASSEMBLY, REAR BRAKE COMBINATION VALVE,

32 Nm (24 LB. FT.)
RESERVOIR, BRAKE MASTER CYLINDER

BODY, BRAKE MASTER CYLINDER
CAP, BRAKE MASTER CYLINDER RESERVOIR
CYLINDER ASSEMBLY, BRAKE MASTER
18 NUT, BRAKE MASTER CYLINDER, 43 Nm (32 LB. FT.)
5
8
12
15
PC00025A-F-RP
Figure 2 - Brake Master Cylinder Assembly
SA-4 MASTER CYLINDER

6. Have assistant depress brake pedal assembly to
remove air at loose brake pipe assembly fittings.
l~I
Tighten
Fittings of brake pipe assemblies ( 1 and 2) to

32 Nm (24 lb. ft.).
7. Have assistant quickly release and pump brake pedal
assembly several times.
8. If brake pedal assembly remains high and firm, start
vehicle. If brake pedal assembly still feels firm, test
drive vehicle. If brake pedal assembly feels soft or
spongy, bleed entire brake hydraulic system. Refer
to SECTION 5El.
UNIT REPAIR
l~I
Clean
All parts in clean denatured alcohol.

Dry with unlubricated compressed air.
Abrasives should not be used in brake master cylinder body bore.
l+!+I
Assemble
1. Lubricate rubber parts with clean brake fluid to ease

assembly.
2. Seals (7 and 10) and retainer (6) to secondary piston
(21).
3. Lubricated secondary piston (21) and spring (4) into

brake master cylinder body bore.
4. Lubricated primary piston (20) into brake master
cylinder body bore.
5. Ring (14) while depressing primary piston (20).
Figure3
6. Diaphragm (13) into ca'p (12).
[I] Important
7. Cap (12) onto reservoir (5).
Reservoir cap and reservoir diaphragm can be

inspected and/or serviced without removing the
master cylinder assembly from the vehicle.

Brake master cylinder assembly. Refer to "Master
Cylinder Assembly" under "On-Vehicle Service"
in this section.
l+!+I Disassemble
1. Cap (12) and diaphragm (13) from reservoir (5).
Wipe cap (12) and reservoir (5) clean before
removing.
2. Empty brake fluid from reservoir (5).
NOTICE: Take care not to damage the piston bore

or retainer groove during primary piston retainer
ring removal.
3. Ring (14) while depressing primary piston (20).
4. Primary piston (20), secondary piston (21), retainer
(6) and spring (4).
8. Bench bleed master cylinder assembly. Refer to

"Master Cylinder Assembly Bleeding" in the
following procedure.
MASTER CYLINDER ASSEMBLY BENCH

BLEEDING
Materials necessary for master cylinder assembly
bench bleeding:
One 11 x 1.5 mm tube fitting nut
One 12 x 1.0 mm tube fitting nut
Two pieces of 4.75 mm (3/16 inch) brake pipe
tube approximately 50 mm (2 inches) long
1. Locally fabricate two plugs for plugging master
cylinder assembly outlet ports.
A. Fashion ISO flares on one end of each tube.
Refer to SECTION 5.
B. Install nuts onto flared tubes.
C. One at a time, place approximately 13 mm

(1/2 inch) of unflared tube in vise.
D. Compress tube end with vise so that tube
collapses completely.
To remove parts, apply clean, low pressure dry

compressed air into outlet port near closed end
of bore with other outlet port plugged.
E. With tube still in vise, bend it to a 90 degree

angle.
5. Seals (7 and 10) and retainer (6) from secondary

piston (21 ).
F. Remove tube from vise and reinstall to fold

tube end against itself to form air-tight seal.
IL'l'I
Inspect
2. Plug master cylinder assembly outlet ports with

locally fabricated plugs.
Cap (12) and diaphragm (13) for cuts, cracks, nicks

and deformation.
NOTICE: Do not overtighten vise or damage to the

master cylinder assembly will result.
Brake master cylinder body bore for scoring or

corrosion. If noted, replace cylinder body (8).
3. Place shop towels around master cylinder assembly

to absorb bled fluid and mount master cylinder
assembly in vise with front end tilted slightly down.
Replace damaged parts.
MASTER CYLINDER SA-5
23
20
14
4 SPRING, BRAKE MASTER CYLINDER SECONDARY

PISTON
5 RESERVOIR, BRAKE MASTER CYLINDER
6 RETAINER, BRAKE MASTER CYLINDER SECONDARY
PISTON SPRING
7 SEAL, BRAKE MASTER CYLINDER SECONDARY PISTON
PRIMARY
8 BODY, BRAKE MASTER CYLINDER
10 SEAL, BRAKE MASTER CYLINDER SECONDARY PISTON
SECONDARY
12 CAP, BRAKE MASTER CYLINDER RESERVOIR
13 DIAPHRAGM, BRAKE MASTER CYLINDER RESERVOIR
14 RING, BRAKE MASTER CYLINDER PRIMARY PISTON
RETAINER
20 PISTON, BRAKE MASTER CYLINDER PRIMARY
21 PISTON, BRAKE MASTER CYLINDER SECONDARY
22 0-RING
23 PIN, SPRING
PC0003-5A-F-RP
Figure 3 - Brake Master Cylinder Assembly Components
4. Fill master cylinder assembly with clean brake fluid.

5. Using tool with smooth rounded end, stroke primary
piston about 25 mm (1 inch) several times.
rn
Important
As air is bled from master cylinder assembly,

with outlets plugged, resistance to primary
piston travel will not allow full 25 mm (1 inch)
stroke.
6. Reposition master cylinder assembly in vise with
front end of master cylinder assembly tilted slightly
up. Again, stroke primary piston about 25 mm
(1 inch) several times.
7. Reposition master cylinder assembly in vise to level

position. Loosen two locally fabricated plugs one at
a time and push primary piston into master cylinder
bore to force air out of master cylinder assembly.
rn
Important
To prevent air frnm being sucked back into

master cylinder assembly, tighten locally fabricated plugs before allowing primary piston to
return to its original position. Repeat this step
until no air escapes past locally fabricated
plugs.
8. Install master cylinder assembly into vehicle. Refer
to "Master Cylinder Assembly" under "On-Vehicle
Service" in this section.
MASTER CYLINDER RESERVOIR

Figures 2 and 3

1. Brake master cylinder assembly. Refer to "Master
in this section.
5A-6 MASTER CYLINDER
2.
3.
4.
5.
NOTICE: Do not clamp housing area of master

cylinder body in vise or the part may be damaged.
Clamp flange of cylinder body (8) in a vise.
Drive out spring pins (23) using 1/8-inch punch.
Reservoir (5) by pulling straight up and away from
cylinder body (8).
0-rings (22) from grooves in reservoir (5) and
discard.
IL'l'l tnspect

1. Lubricate new 0-rings (22) and grooves in reservoir
(5) with clean brake fluid.
2. 0-rings (22) into grooves in reservoir (5).
Make sure 0-rings (22) are properly seated.
3. Reservoir (5) to cylinder body (8) by pressing
straight down by hand into cylinder body (8).
Reservoir (5) for cracks or deformation.

Replace reservoir (5), if damaged.
l~I
2. Dry with unlubricated compressed air.
4. Drive in spring pins (23) to retain reservoir (5).
Clean
1. Reservoir (5) with clean denatured alcohol.
5. Brake master cylinder assembly. Refer to "Master

in this section.
SPECIFICATIONS
Brake Master Cylinder Body Bore Diameter ............................... 25.4 mm (1.00")
Hydraulic Brake (Glycol) Fluid ................... GM PIN 1052535 or equivalent DOT-3 fluid

Brake Master Cylinder Nut ............................................ 43 Nm (32 lb. ft.)
Brake Pipe Fittings
Front Brake Combination Valve Pipe Assembly ......................... 32 Nm (24 lb. ft.)
Rear Brake Combination Valve Pipe Assembly .......................... 32 Nm (24 lb. ft.)
FRONT DISC BRAKES 581-1
SECTION 581
FRONT DISC BRAKES

CAUTION: When servicing brake parts, do not create dust by grinding, sanding brake linings, or by cleaning brake parts with a dry brush or compressed air. Many brake parts contain asbestos fibers which can become airborne if dust is created during servicing.
actions:
result.
CONTENTS
General Description . . . . . . . . . . . . . . . . . . . . . . .
Front Brake Rotor Assembly ..............
_Front _Brake Caliper Assembly ............
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Front Disc Brake Inner and Outer
Pad Assemblies Inspection .............
Front Brake Rotor Assembly Inspection .....
Front Brake Rotor Assembly
Tolerance and Surface Finish . . . . . . . . . .
Thickness Variation Check .............
Lateral Runout Check .................
Front Brake Caliper Assembly Inspection . . . .
On-Vehicle Service .......................
Front Brake Caliper Assembly ............
Front Disc Brake Inner and Outer
Pad Assemblies ......................
SB 1-1
SBl-1
SBl-1
SB 1-2
SBl-2
SBl-2
SB 1-2
SBl-2
SBl-2
SB 1-4
SBl-4
SBl-4
Front Brake Rotor Assembly .............. SBl-7

Unit Repair .............................. SBl-7
Refinishing Front Brake Rotor
Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . SB 1-7
On-Vehicle Procedure . . . . . . . . . . . . . . . . . SB 1-7
Off-Vehicle Procedure ................. SBl-7
Non-Directional Finishing .............. SBl-7
Burnishing Front Brake Rotor
Assemblies . . . . . . . . . . . . . . . . . . . . . . . . SB 1-8
Front Brake Caliper Assembly . . . . . . . . . . . . SB 1-8
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . SB 1-10
General Specifications . . . . . . . . . . . . . . . . . . SB 1-10
Rotor Refinishing Specifications . . . . . . . . . . SB 1-1 O
Fastener Tightening Specifications ........ SBl-10
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . SB 1-1 O
SBl-S
GENERAL DESCRIPTION
FRONT BRAKE ROTOR ASSEMBLY
The rotor assembly is a highly machined, cast iron
finned type. It is mounted on top of an integral hub bearing uni~.
FRONT BRAKE CALIPER ASSEMBLY

The caliper assembly has a single bore and is
mounted to the steering knuckle assembly with two bolts/
screws.
When the brakes are applied, fluid pressure behind

the piston increases. Pressure is exerted equally against
the bottom of the piston and also against the bottom of the
caliper.housing bm:e. The pressure applied to the piston is
tra~sm1tted_ to the mner pad assembly forcing the lining
agamst the mner rotor surface. The pressure applied to the
bottom of the caliper housing bore forces the caliper to
slide on the caliper bolts/screws toward the center of the
vehicle. This movement causes the outer section of the
caliper to apply pressure against the back of the outer pad
assembly, forcing the lining against the outer rotor assembly surface. As line pressure builds, the inner and outer
5812 FRONT DISC BRAKES
outer pad assemblies should be replaced when the

thickness of any lining is worn to within 0. 76 mm
(0.030 inch) of the shoe. All inner and outer pad
assemblies should be replaced in axle sets.
All front disc brakes have a wear indicator that
makes a noise when the linings wear to a degree where
replacement is required. The wear indicator is an integral
part of the outer pad assembly. When the lining is worn,
the clip indicator contacts the rotor assembly and produces a warning noise.
I@ I Measure
Flatness of inner and outer pad assembly linings.
Place inner and outer pad assembly surfaces
together and check for gap between surfaces. If
more than 0.13 mm (0.005 inch) gap is measured
midway between attaching lugs, inner and outer pad
assemblies must be replaced.

INSPECTION
Front Brake Rotor Assembly Tolerance and
Surface Finish
A INSPECTION POINTS
A
PC0001-5B1 FRP
Figure 1 - Front Disc Brake Inner and Outer

Pad Assemblies Inspection
pad assemblies are pressed against the rotor assembly surfaces with increased force, bringing the vehicle to a stop.
When the brake pedal assembly is released, line
pressure is released and the piston seal and groove cause
the piston to be slightly retracted, resulting in less drag on
the rotor assembly by the inner and outer pad assemblies.
Outward movement of the piston and inward movement of the caliper assembly automatically compensate
for lining wear. As the linings wear, the increased area
behind the piston is filled with brake fluid from the brake
master cylinder reservoir.
DIAGNOSIS
FRONT DISC BRAKE INNER AND OUTER
PAD ASSEMBLIES INSPECTION
Figure 1
ILl
1nspect
Inner and outer pad assemblies at least twice a year

when the wheels are removed (tire rotation, etc.).
When inspecting front disc brakes, check both ends
of the outer pad assembly by looking in at each end
of the caliper assembly. These are the points at
which the highest rate of wear normally occurs.
Also, check the lining thickness of the inner pad
assembly to make sure that it has not worn prematurely. Look through the hole in the top of the caliper
assembly to view the inner pad assembly. Inner and
In manufacturing the rotor assembly, tolerances of

the braking surfaces for flatness, thickness variation and
lateral runout are very closely held. The maintenance of
close tolerances on the shape of the braking surfaces is
necessary to prevent brake roughness.
In addition to these tolerances, the surface finish
must be held to a specified range of 60 Ra roughness or
less. A new rotor assembly falls into this surface range, as
will a rotor assembly that is refinished exactly as directed
in "Refinishing Front Brake Rotor Assemblies" in this
section. The control of the braking surface finish is necessary to avoid problems of hard pedal-apply, excessive
brake fade, pulls and erratic performance and to extend
lining life.
Light scoring of the rotor assembly surfaces not
exceeding 1.5 mm (0.06 inch) in depth, which may result
from normal use, will not affect brake operation.
Thickness Variation Check

Thickness variation can be checked by measuring
the thickness of the front brake rotor assembly at four or
more points around its circumference. All measurements
must be made at the same distance in from the edge of the
rotor assembly. A rotor assembly that varies by more than
0.013 mm (0.0005 inch) can cause brake pedal assembly
pulsation and/or front end vibration during brake ap~l~cations. A rotor assembly that does not meet these spec1f1cations should be refinished to specifications or replaced.
Lateral Runout Check

Figure2
Tool Required:
1. Clean surface of rotor assembly (1).
2. Install wheel nuts (13).

5. Move rotor assembly (1) one complete revolution,
and observe total indicated runout (TIR).
Total indicated runout (TIR) should not be
more than 0.15 mm (0.006 inch).

13 WHEEL NUT, 140 Nm (100 LB. FT.)
PC0002-5B1-F-RP
Figure 2 - Lateral Runout Check
!~I Tighten
Wheel nuts (13) in a star pattern to 140 Nm
(100 lb. ft.).
3. Fasten J 8001 to steering knuckle assembly (18) so
that indicator button contacts rotor assembly surface
about 13 mm (0.5 inch) from rotor edge.
4. Set J 8001 to zero.
In some cases, excessive lateral runout of rotor

assembly (1) can be improved by indexing
rotor assembly ( 1) on hub one or two bolt positions from original position. Indexing the rotor
assembly (1) requires removal and installation
of the front brake caliper assembly. Refer to
"Front Brake Caliper Assembly" under "OnVehicle Service" in this section. If lateral runout cannot be corrected by indexing rotor
assembly (1), check hub and front wheel bearing assembly for excessive lateral runout or
looseness. If hub and bearing assembly lateral
runout exceeds 0.040 mm (0.0015 inch) then
replace hub and bearing assembly. If lateral
runout of the hub and bearing assembly is
within specifications then refinish or replace
rotor assembly ( 1) as necessary.
NOTICE: Whenever the rotor assembly has been
separated from the wheel bearing flange, clean any
rust or foreign material from the mating surface of
the wheel bearing flange and front brake rotor
assembly. Failure to do this may result in increased
lateral runout of the rotor assembly and brake pulsation.
A rotor assembly that does not meet the lateral
runout specification should be resurfaced or
replaced as necessary.
A WEAR SENSOR
2 BOLT/SCREW WITH SLEEVE, FRONT BRAKE
CALIPER, 51 Nm (38 LB. FT.)
3 BUSHING, FRONT BRAKE CALIPER BOLT
5 PAD ASSEMBLY, FRONT DISC BRAKE OUTER
7 PAD ASSEMBLY, FRONT DISC BRAKE INNER
8 BOOT, FRONT BRAKE CALIPER PISTON
9 PISTON, FRONT BRAKE CALIPER
10 SEAL, FRONT BRAKE CALIPER PISTON
11 VALVE, FRONT BRAKE CALIPER BLEEDER,
13 Nm (115 LB. IN.)
12 HOUSING, FRONT BRAKE CALIPER
20 CAP, FRONT BRAKE CALIPER BLEEDER VALVE
PC0003-5B1 -F-RP
Figure 3 - Front Brake Caliper Assembly
581-4 FRONT DISC BRAKES
16
18
2 BOLT/SCREW WITH SLEEVE, FRONT BRAKE CALIPER,

51 Nm (38 LB. FT.)
12
14
16
18
A C-CLAMP
Figure 5 - Front Brake Caliper Assembly Attachment
PC0004-5B1-F-RP
Figure 4 - Compressing Front Brake Caliper Piston

INSPECTION
The front brake caliper assembly must be disassembled for inspection. Refer to "Front Brake Caliper
Assembly" under "Unit Repair" in this section.
ON-VEHICLE SERVICE
[I] Important
to service this front brake caliper assembly.
assembly.
brake system.
Replace shoe and linings in axle sets only.
fasteners.
Perform service operations on a clean bench free

Figures 3 through 7

1. Two-thirds of brake fluid from master cylinder
assembly.
.
HOUSING, FRONT BRAKE CALIPER

FITIING, FRONT BRAKE HOSE, 44 Nm (32 LB. FT.)
HOSE ASSEMBLY, FRONT BRAKE
PC0005-5B1-F-RP
4. Reinstall wheel nuts to retain rotor assembly (1 ).

5. Push piston (9) into caliper housing bore to provide
clearance between inner and outer pad assemblies
(7 and 5) and rotor assembly (1).
A. Position C-clamp on housing (12) and against
outer pad assembly (5).
B. Tighten clamp slowly to press piston (9) into
caliper housing bore.
[I] Important
If removing caliper assembly only to access
other brake parts, skip step 6.
If fitting (14) is disconnected, caliper assembly
must be bled during installation.
6. Fitting ( 14), two copper gaskets, hose assembly ( 16)
from housing (12), if removing caliper assembly
entirely from vehicle.
A. Plug openings in hose assembly ( 16) and housing (12) to prevent brake fluid loss and contamination.
B. Discard copper gaskets.
7. Front brake caliper bolts/screws with sleeves (2).
8. Caliper assembly from rotor assembly (1) and
If caliper assembly is not being removed from
vehicle for unit repair, suspend it from front
suspension using a locally fabricated wire
hook.
lll
1nspect
1. Bolts/screws with sleeves (2) for corrosion and
bushings (3) for cuts and nicks.
If damage is found, use new parts, when installing caliper assembly.
Do not attempt to polish away corrosion.
2. Fitting (14).
If through-hole in fitting (14) is blocked,
remove blockage or replace fitting ( 14).
FRONT DISC BRAKES 581 -5
12
A ADD SILICONE GREASE TO INNER DIAMETER OF
BUSHING
2 BOLT/SCREW WITH SLEEVE, FRONT BRAKE CALIPER,
51 Nm (38 LB. FT.)
PC0007-5B1-F-RP
A WIRE HOOK
Figure 7 - Lubricating Front Brake Caliper Bolt

Sleeve and Bushing
l~I Tighten
PC0006-5B1F-RP
Figure 6 - Suspending Front Brake Caliper Assembly

NOTICE: See "Notice" on page 5Bl-1 of this section.
1. Lubricate inner diameters of bushings (3) with silicone grease GM PIN 1052863 or equivalent.
2. Bolts/screws with sleeves (2).
ILl 1nspect
A. Bolt/screw with sleeve (2) should slide through
bushing (3) using only hand pressure.
If greater force is required or mechanical
assistance is needed, remove bolt/screw
with sleeve (2) along with bushing (3).
B. Mounting bores for corrosion.
a. If mounting bores show signs of corrosion, remove corrosion using a 1-inch

wheel cylinder housing brush.
b. Clean mounting bores with clean denatured alcohol.
C. Replace bushings. Refer to "Front Brake Caliper Assembly" under "Unit Repair" in this
section.
l~I Tighten
Bolts/screws with sleeves (2) to 51 Nm (38 lb.
ft.).
3. Caliper assembly onto rotor assembly (1) and
4. Fitting ( 14), two new copper gaskets, and hose
assembly ( 16) to housing ( 12), if removed.

5. Wheel nuts securing rotor assembly to steering
knuckle assembly flange.
7. Lower vehicle.
8. Fill master cylinder to proper level. Refer to SECTION 5A.
9. If hose assembly (16) was removed, bleed caliper
assembly. Refer to SECTION 5El.
FRONT DISC BRAKE INNER AND OUTER

PAD ASSEMBLIES

1. Front brake caliper assembly. Refer to "Front Brake
Caliper Assembly" under "On-Vehicle Service" in
this section.
2. Outer pad assembly (5). Use screwdriver to disengage buttons on shoe from holes in caliper housing.
3. Inner pad assembly (7).
11:?I Clean
Wipe outside surface of boot (8).
- Use denatured alcohol.
rn
Important
1. Bottom piston (9) into caliper housing bore.

A. Use a large C-clamp positioned on housing
(12) and inside piston well.
B. Tighten clamp slowly to press piston (9) into
caliper housing bore.
2. With piston (9) bottomed in caliper housing bore, lift
inner edge of boot (8) next to piston (9) and press out
any trapped air.
5816 FRONT DISC BRAKES

A
7
8
12
RETAINER SPRING
PAD ASSEMBLY, FRONT DISC BRAKE INNER
BOOT, FRONT BRAKE CALIPER PISTON
HOUSING, FRONT BRAKE CALIPER
PCOOOB-581-F-RP
Figure 8 - Removing Outer Pad Assembly

7 PAD ASSEMBLY, FRONT DISC BRAKE INNER
PC0009-se,-F-RP
Figure 9 - Front Disc Brake Inner and Outer Pad Assemblies
PC0011-5B1.f-RP
Figure 11 - Installing Front Disc Brake Inner Pad Assembly
A. Inner pad retainer spring into piston (9). The

retainer spring is staked to the inner pad assembly (7).
B. Inner pad assembly (7) must lay flat against
piston (9).
C. Check that boot (8) and inner pad assembly (7)
are not touching. If there is contact, remove
inner pad assembly (7) and reseat or re-position boot (8).
2. Outer pad assembly (5).
Back of outer pad assembly (5) must lay flat
against housing (12).
Wear sensor should be at trailing lower edge of
outer pad assembly (5) during forward wheel
rotation. If not, outer pad assembly (5) is on
wrong side.
3. Front brake caliper assembly. Refer to "Front Brake
this section.
12
8
PC0010-5B1-F-RP
Figure 10 - Lifting Front Brake Caliper Piston Boot
Boot (8) must lay flat.

1. Inner pad assembly (7).
\
A WEAR SENSOR
PC0012-581-F-RP
Figure 12 - Installing Front Disc Brake Outer Pad Assembly

4. Apply approximately 778 N (175 pounds) of force to
brake pedal assembly three times to seat linings.
[I] Important
GM replacement brake lining material is recommended for all GM vehicles to maintain the balance
between front and rear brake performance. GM
replacement brake parts have been carefully selected
to provide the proper brake balance for purposes of
both stopping distance and controllability over the
full range of operating conditions. Installation of
front or rear brake lining material with performance
different from that of the GM replacement parts
recommended for this vehicle can change the
intended brake balance of this vehicle.

The rotor assembly is an integral part of the hub
assembly. For removal procedure, refer to SECTION 3C.
UNIT REPAIR
REFINISHING FRONT BRAKE ROTOR
ASSEMBLIES
[I] Important
DO NOT refinish rotor assemblies when performing routine brake maintenance such as replacing
worn front disc brake inner and outer pad assemblies. Refinish a rotor assembly ONLY under the
following circumstances:
- There is a complaint of brake pulsation.
- There is scoring greater than 1.5 mm (0.06
inch).
All rotor assemblies have a minimum thickness
dimension cast into them. This dimension is the minimum
wear dimension and not a refinish dimension. The minimum refinish dimension is greater than the discard dimension. Do not use a rotor assembly that will not meet
spedfications. Replace with a new rotor assembly. Refer
to "Specifications" in this section.
Since accurate control of the rotor assembly tolerances is necessary for proper performance of the front disc
brakes, the rotor assembly should be machined only with
precision equipment. Equipment should be serviced on a
regular basis following the manufacturer's recommended
maintenance procedure.
When refinishing rotor assemblies, the attaching
adapters, tool holders, vibration dampeners and tool bits
must be in good condition. Always use sharp cutting tools
or bits and use only replacement cutting bits recommended by the equipment manufacturer. Dull or worn
tools leave a poor surface finish which will affect braking
performance. Vibration dampening attachments should
always be used when refinishing braking surfaces. These
attachments eliminate tool chatter and will result in better
surface finish. Make sure these adapters are clean and free
of nicks.
On-Vehicle Procedure
Tool Required:
On-Vehicle Brake Lathe, such as Kent-Moore
J 37704
In the cases where rotors are being refinished to correct a problem with brake pulsation, it is recommended
that an on-vehicle brake lathe be used to achieve best
results. Follow the equipment manufacturer's recommended specifications and procedure.
Off-Vehicle Procedure
[I] Important
Remove rust and scale from rotor assembly and
steering knuckle spindle assembly mating surfaces.
Failure to do so may introduce excessive lateral runout when the rotor assembly is mounted on the brake
lathe, or when the rotor assembly is reinstalled on
the steering knuckle spindle assembly.
Following are two recommended procedures that
achieve adequate results using two different off-vehicle
drum/disc brake lathes. (If any other lathe is used, follow
that lathe's instructions and recommendations.)
Ammco Brake Lathe

{Two-cut refinishing procedure)
Spindle Speed
Depth of Cut
(per side)
Tool Cross Feed
(per rev.)
Vibration Dampener
Sand Front Brake
Rotor Assembly
(Swirl Pattern)
ROUGH CUT
150rpm
0.15 mm to
0.64mm
(0.006 inch to
0.025 inch)
0.25mm
(0.010 inch)
Yes
No
FINISH CUT
150 rpm
O.lOmm to
0.15 mm
(0.004 inch to
0.006 inch)
0.05mm
(0.002 inch)
Yes
Yes
Accuturn Brake Lathe, GM Dealer Equipment

{One-cut refinishing procedure)
Locate the deepest score and turn the rotor micrometer knob until the tool bit bottoms out at the deepest point
of the score. Zero the scale and back out the tool bit
(repeat for opposite side of rotor). Advance the cutter
handwheel .until the bits have cleared the inner edges of
the rotor face. Adjust the micrometer knobs for approximately 0.13 mm (0.005 inch) more than the first reading.
This will ensure resurfacing the rotor in one cut.
Spindle Speed
105 rpm
As necessary
Depth of Cut
Tool Cross Feed
0.08 mm (0.003 inch)
(per revolution)
Tool Bit Nose Radius
1/64
Yes
Vibration Dampener
Non-Directional Finishing
It is very important that the rotor surface be made
non-directional by dressing the rotor surfaces with a sanding disc tool such as Ammco 8750 Safe Swirl Disc Rotor

Grinder, Accuturn 433179 Non-Directional Swirl Finisher, or equivalent, using 120 grit aluminum oxide sandpaper. Sand each rotor surface with moderate pressure for
a minimum of 60 seconds. If the brake lathe is not
equipped with an adequate non-directional finishing tool,
an alternate method is to use a sanding block with 150 grit
aluminum oxide sandpaper. With the rotor turning at the
equipment manufacturer's highest recommended cutting
speed, sand each rotor surface for a minimum of 60
seconds using moderate pressure. After the rotor has
been sanded, clean each surface with denatured alcohol or a suitable brake cleaner.
The finished rotor assembly surface should be as
close to that of a new front brake rotor assembly as possible. Failure to obtain the best possible finish may affect
braking performance.
rn
12

PC00135B1F-RP
Figure 13 - Removing Front Brake Caliper Piston
Important
Front brake rotor assemblies should always be

replaced if turning will result in a front brake rotor
assembly that does not meet manufacturer specifications for minimum thickness. When installing new
brake rotor assemblies, do not refinish the surfaces
of these parts. New brake rotor assemblies have the
correct level of surface finish.
Burnishing Front Brake Rotor Assemblies

After front brake pad assemblies have been replaced
and/or rotors have been refinished, it is very important
that the new braking surface be broken in, or burnished.
This can be accomplished by making 20 stops from 48
km/h (30 mph), using medium to firm brake pedal assembly pressure. Take care to avoid overheating the brakes.

Tool Required:
J 26267 Dust Boot Seal Installer
l+t+I Disassemble
NOTICE: Use clean shop towels to pad interior of
caliper housing during piston removal.
1. Remove caliper assembly from vehicle. Refer to
"Front Brake Caliper Assembly" under "On-Vehicle Service" in this section.
2. Bushings (3).
IL'l'I Inspect
A. Bushings (3) for nicks or cuts. Replace if damaged.
A GROOVE
B BEVEL END FIRST
10 SEAL, FRONT BRAKE CALIPER PISTON
11 VALVE, FRONT BRAKE CALIPER BLEEDER, 13 Nm
(115 LB. IN.)
20 CAP, FRONT BRAKE CALIPER BLEEDER VALVE
PC0014-5B1-F-RP
Figure 14 - Front Brake Caliper Assembly Components
B. Mounting bores for corrosion.

a. If mounting bores show signs of corrosion, remove corrosion using a I-inch
wheel cylinder honing brush.
b. Clean mounting bores with clean denatured alcohol.
CAUTION: Do not place fingers in front

of the piston in an attempt to catch or
protect it when applying compressed
air. This could result in serious injury.
FRONT DISC BRAKES 5819

PC00155B1-FRP

PC0016-5B1fRP
Figure 15 - Removing Front Brake Caliper Piston Boot
Figure 16 - Installing Front Brake Caliper Piston Boot
3. Piston (9) from housing (12).

Apply compressed air to housing inlet hole.
4. Piston seal (10) into bore groove of housing (12).
IL'l'I Inspect
Piston (9) for scoring, nicks, corrosion, and
worn or damaged chrome plating.
- Replace piston if any of above are found.
4. Boot (8) from housing (12).
NOTICE: Do not use a metal tool to remove piston
seal from housing bore. Using a metal tool may
damage caliper bore or seal groove.
5. Piston seal (10) from housing (12).
IL'l'I Inspect
Caliper bore and seal groove for scoring, nicks,
corrosion, and wear.
A (!se crocus cloth to polish out light corrosion.
B. Replace housing (12) if corrosion in and
around seal groove will not clean up with
crocus cloth.
6. Bleeder valve cap (20) and bleeder valve (11) from
housing (12).
!+!+I
Make sure piston seal (10) is not twisted.

5. Boot (8) onto piston (9).
6. Piston (9) with assembled boot (8) into bore of
housing (12).
Push piston (9) to bottom of housing bore.
7. Seat boot (8) into counterbore of housing (12) using
J 26267.
8. Bushings (3).
A Lubricate beveled end of bushing (3) with GM
P/N 1052863 or equivalent.

B. Pinch bushing (3) and install bevel end first.
C. Push bushing (3) through housing mounting
bore.
9. Install caliper assembly. Refer to "Front Brake
this section.
Assemble
NOTICE: See "Notice" on page 5Bl-l of this

section.
!~I
Clean
A All parts in clean denatured alcohol.
B. Dry with unlubricated compressed air.
C. Blow out all passages in housing (12) and
bleeder valve (11 ).
1. Lubricate all rubber parts with clean brake fluid.
2. Bleeder valve (11) into housing (12).
!~I
Tighten
Bleeder valve (11) to 13 Nm (115 lb. in.).

3. Replace bleeder valve cap (20).
12

PC0017-5B1-FRP
Figure 17 - Seating Front Brake Caliper Piston Boot
SPECIFICATIONS
Front Brake Caliper Assembly
Front Brake Caliper Housing Bore Diameter ............................ 63.50 mm (2.500")
Front Brake Rotor Assembly
Rotor Diameter (Nominal) ........................................ 278.00 mm (10.945")
Lateral Runout .................................................... 0.13 mm (0.005")
Thickness Variation ............................................... 0.013 mm (0.0005")
Rotor Thickness (Maximum) ........................................ 32.00 mm (1.260")
Minimum Thickness After Refinish ................................... 31.74 mm (1.250")
Discard Thickness ................................................. 30.70 mm (1.209")
All front brake rotor assemblies have a discard dimension cast into them. This is a wear dimension
and not a refinish dimension. Any front brake rotor assembly which does not meet the specifications should be replaced.
ROTOR REFINISHING SPECIFICATIONS

Ammco Brake Lathe
Rough Cut
Spindle Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150 rpm
Depth of Cut (Per Side) . . . . . . . . . . . . . . . . . . . . . . . . . . 0.15 mm to 0.64 mm (0.006" to 0.025")
Tool Cross Feed (Per Revolution) .................................... 0.25 mm (0.010")
Vibration Dampener ......................................................... Yes
Sand Front Brake Rotor Assembly (Swirl Pattern) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . No
Finish Cut
Depth of Cut (Per Side) . . . . . . . . . . . . . . . . . . . . . . . . . . 0.10 mm to 0.15 mm (0.004" to 0.006")
Tool Cross Feed (Per Revolution) .................................... 0.05 mm (0.002")
Sand Front Brake Rotor Assembly (Swirl Pattern) ................................. Yes
Accuturn Brake Lathe
Spindle Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105 rpm
Depth of Cut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . As necessary
Tool Cross Feed (Per Revolution) ...................................... 0.08 mm (0.003")
Vibration Dampener ........................................................... Yes

Front Brake Caliper Bleeder Valve ..................................... 13 Nm (115 lb. in.)
Front Brake Caliper Bolt/Screw With Sleeve .............................. 51 Nm (38 lb. ft.)
Front Brake Hose Fitting ............................................. 44 Nm (32 lb. ft.)
Wheel Nut ....................................................... 140 Nm (100 lb. ft.)
SPECIAL TOOLS
1.
J26267
J 37704
1. DUST BOOT SEAL INSTALLER

2. ON DISC BRAKE LATHE
3. DIAL INDICATOR SET
PC0020-5B1-F-RP
REAR DISC BRAKES 582-1
SECTION 582
REAR DISC BRAKES

CAUTION: When servicing brake parts, do not create dust by grinding, sanding brake linings, or by cleaning brake parts with a dry brush or c~mpressed air. Many brake parts contain asbestos fibers which can become airborne 1f dust is created during servicing.
actions:
If a fastener needs to be replaced, use the correct p_art number fastener for that application. If the correct part
result.
CONTENTS
G~neral _Description .......................
Diagnosis ...............................
Rear Disc Brake Inner and Outer Pad
Assemblies Inspection . . . . . . . . . . . . . . . . .
Rear Brake Rotor Assembly Inspection ......
Rear Brake Rotor Assembly Tolerance
and Surface Finish . . . . . . . . . . . . . . . . . .
Thickness Variation Check . . . . . . . . . . . . .
Lateral Runout Check .................
Rear Brake Caliper Assembly Inspection ....
Rear Brake Caliper Assembly .............
Rear Disc Brake Inner and Outer Pad
Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . .
Rear Brake Caliper Anchor Bracket
and Mounting Plate . . . . . . . . . . . . . . . . . . .
5B2-1
5B2-2
5B2-2
5B2-2
5B2-2
5B2-2
5B2-2
5B2-3
5B2-3
5B2-3
5B2-6
Rear Brake Rotor Assembly . . . . . . . . . . . . . . 5B2-8

Parking Brake Free-Travel Adjustment ...... 5B2-9
Unit Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5B2-9
Refinishing Rear Brake Rotor Assemblies . . . 5B2-9
On-Vehicle ......................... 5B2-10
Off-Vehicle . . . . . . . . . . . . . . . . . . . . . . . . . 5B2-10
Non-Directional Finishing . . . . . . . . . . . . . 5B2-ll
Burnishing Rear Brake Rotor
Assemblies . . . . . . . . . . . . . . . . . . . . . . . 5B2-11
Rear Brake Caliper Assembly . . . . . . . . . . . . 5B2-11
Specifications ........................... 5B2-14
General Specifications . . . . . . . . . . . . . . . . . . 5B2-14
Rotor Refinishing Specifications . . . . . . . . . . 5B2-14
Fastener Tightening Specifications . . . . . . . . 5B2-15
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . 5B2-15
5B2-8
GENERAL DESCRIPTION
The rear disc brake caliper assembly has a single
piston in an aluminum housing which is suspended in the
anchor bracket on two guide pins. Hydraulic pressure,
created by applying force to the brake pedal assembly,
acts equally against the piston and the bottom of the
caliper bore to move the piston outward and to slide the
caliper inward resulting in a clamping action on the rotor.
This clamping action forces the linings against the rotor
creating friction to stop the vehicle. When the parking

brake is applied, the lever on the caliper causes the
pushrod, the actuating collar and the clamp rod assembly
to be moved outward and the caliper to slide inward,
mechanically forcing the pad assemblies against the rotor
assembly. Parking brake application is completely independent of the hydraulic braking system.
The rear disc brake rotor assembly is a composite
cast iron type vented rotor assembly. It has a stamped
sheet metal flange which is insert cast.
582-2 REAR DISC BRAKES
DIAGNOSIS
REAR DISC BRAKE INNER AND OUTER PAD
ASSEMBLIES INSPECTION
Figure 1
ILl
1nspect
Inner and outer pad assemblies at least twice a year

when the wheels are removed (tire rotation, etc.).
When inspecting rear disc brakes, check both ends
of the outer pad assembly by looking in at each end
of the caliper assembly. These are the points at
which the highest rate of wear normally occurs.
Also, check the lining thickness of the inner pad
assembly to make sure that it has not worn prematurely. Look through the hole in the top of the caliper
assembly to view the inner pad assembly. Inner and
outer pad assemblies should be replaced when the
thickness of any lining is worn to within 0. 76 mm
(0.030 inch) of the shoe. All inner and outer pad
assemblies should be replaced in axle sets.
All rear disc brakes have a wear indicator that makes
a noise when the pad assembly linings wear to a degree
where replacement is required. The wear indicator is an
integral part of the inner pad assembly. When the pad
assembly lining is worn, the clip indicator contacts the
rotor assembly and produces a warning noise.
l@I
A INSPECTION POINTS
PC0001-5112f-RP
Figure 1 - Rear Disc Brake Inner and Outer Pad Assemblies

Inspection
Measure
Flatness of inner and outer pad assembly linings.

Place inner and outer pad assembly surfaces
together and check for gap between surfaces. If
more than 0.13 mm (0.005 inch) gap is measured
midway between attaching lugs, inner and outer pad
assemblies must be replaced.
REAR BRAKE ROTOR ASSEMBLY

INSPECTION
Thickness Variation Check

Thickness variation can be checked by measuring
the thickness of the rear brake rotor assembly at four or
more points around its circumference. All measurements
must be made at the same distance in from the edge of the
rotor assembly. A rotor assembly that varies by more than
0.013 mm (0.0005 inch) can cause brake pedal assembly
pulsation and/or rear end vibration during brake apJ?l~cations. A rotor assembly that does not meet these spec1f1cations should be refinished to specifications or replaced.
Rear Brake Rotor Assembly Tolerance and

Surface Finish
Lateral Runout Check
In manufacturing the rotor assembly, tolerances of

the braking surfaces for flatness, thickness variation and
lateral runout are held very close. The maintenance of
close tolerances on the shape of the braking surfaces is
necessary to prevent brake roughness.
Figure2
Tool Required:
1. Fasten J 8001 to rear brake caliper housing so that
indicator button contacts rotor assembly surface
about 13 mm (0.5 inch) from rotor edge.
2. Set J 8001 to zero.
Push in rear axle assembly while setting J 8001
to eliminate endplay.
3. Turn rotor assembly (39) one complete revolution,
and observe total indicated runout (TIR).
Push in rear axle assembly while turning rotor
assembly to eliminate endplay.
Total indicated runout (TIR) should not be
more than 0.15 mm (0.006 inch).
In addition to these tolerances, the surface finish

must be held to a specified range of 60 Ra roughness or
less. A new rotor assembly falls into this surface range, as
will a rotor assembly that is refinished exactly as directed
in "Refinishing Rear Brake Rotor Assemblies" in this
section. The control of the braking surface finish is necessary to avoid problems of hard pedal-apply, excessive
brake fade, pulls and erratic performance and to extend
lining life.
Light scoring of the rotor assembly surfaces not
exceeding 1.5 mm (0.06 inch) in depth, which may result
from normal use, will not affect brake operation.

4. In some cases, excessive lateral runout of rotor
assembly (39) can be improved by indexing rotor
assembly (39).
A. Remove tire and wheel assembly. Refer to
SECTION 3E.
B. Remove rear brake drum assembly or rear
bfake caliper assembly. Refer to SECTION
5C2 or "Rear Brake Caliper Assembly" under
"On-Vehicle Service" in this section.
C. Index rotor assembly (39) on hub one or two
bolt positions from original position.
5. Check lateral runout of rotor assembly (39).
6. If lateral runout of rotor assembly (39) still exceeds
0.15 mm (0.006 inch), check rear axle shaft flange
for excessive lateral runout or looseness.
A. Reposition J 8001 so button contacts surface of
axle shaft flange.
B. Push axle shaft flange inward while turning the
axle shaft flange one full revolution.
C. Continue pushing in axle shaft flange while
setting J 8001 to zero.
D. While maintaining inward pressure, rotate axle
shaft flange and note lateral runout.
E. If axle shaft flange lateral runout exceeds
0.05 mm (0.002 inch), replace rear axle shaft.
Refer to SECTION 4B.
F. If axle shaft flange lateral runout is within
specifications, refinish or replace rotor assembly (39) as necessary. Refer to "Refinishing
Rear Brake Rotor Assemblies" under "Unit
Repair" in this section.
NOTICE: Whenever the rotor assembly has been
separated from the wheel bearing flange, clean any
rust or foreign material from the mating surface of
the wheel bearing flange and front brake rotor
assembly. Failure to do this may result in increased
lateral runout of the rotor assembly and brake
pulsation.
G. A rotor assembly that does not meet the lateral
runout specification should be resurfaced or
replaced as necessary.
REAR BRAKE CALIPER ASSEMBLY

INSPECTION
The rear brake caliper assembly must be disassembled for inspection. Refer to "Rear Brake Caliper
Assembly" under "Unit Repair" in this section.
ON-VEHICLE SERVICE
NOTICE: Do not use lubricated compressed air on
brake parts as damage to rubber components may
result.
[I] Important
to service this caliper assembly.
assembly.
A JOUNCE PAD
PC0002-5B2-F-RP
Figure 2 - Checking Lateral Runout
Replace pad assemblies in axle sets only.

fasteners.

Figures 3 through 6

2. Parking brake cable assembly at equalizer. Refer to

SECTION SF.
Install wheel nuts to retain rotor assembly (39).
4. Brake hose fitting bolt/screw (32), brake hose fitting
(33) and two gaskets (34) only if caliper assembly is
being removed for overhaul.
A. Discard old gaskets (34).
B. Plug hole in caliper housing (14) and brake
hose fitting (33).
5. Actuator lever return spring (4) only if defective.

Discard actuator lever return spring (4) if coils
are opened.
6. Parking brake cable assembly (35) from parking
brake actuator lever (5) and parking brake cable
bracket (8).

7. Vibration dampener nut (41) and vibration dampener assembly (40) from parking brake cable bracket
(8), if necessary.
8. Upper caliper guide pin bolt/screw (13) and discard.
9. Lower caliper guide pin bolt/screw (9) and discard,
only if removing caliper assembly from vehicle.
10. Caliper housing (14) from rotor assembly (39) and
anchor bracket ( 17).
If caliper overhaul or replacement is not
required, hang caliper housing (14) from suspension to avoid damage to brake hose
assembly.
11. Inner and outer pad assemblies (29 and 30) only if
they are being replaced or if anchor bracket ( 17) is
being removed.
12. Shim ( 10), if inner and outer pad assemblies (29 and
30) were removed.
ll'l'I Inspect
1. Guide pins ( 15) for free movement in anchor bracket
(17). Replace guide pins (15) or guide pin boots (16)
if corroded, worn or damaged.
2. Inner and outer pad assemblies (29 and 30) for wear
and maximum taper of 0.15 mm (0.006 inch).
Replace with new inner and outer pad assemblies (29 and 30) if they are tapered beyond
specification.
- Replace inner and outer pad assemblies
(29 and 30) in sets of four.
3. Brake hose fitting bolt/screw (32).
If through-hole in brake hose fitting bolt/screw
(32) is blocked, remove blockage or replace
brake hose fitting bolt/screw (32).

NOTICE: See "Notice" on page 5B2-1 of this
section.
1. New shim (10), ifremoved.
2. Inner and outer pad assemblies (29 and 30), if
removed.
rn
Important
Whenever rear disc brake inner and outer pad

assemblies are replaced, immediately check
the parking brake free-travel. Adjust as necessary. Refer to "Parking Brake Free-Travel
Adjustment" in this section.
A. Outer pad assembly (30) with insulator is
installed toward caliper housing (14). Inner
pad assembly (29) with wear sensor is installed
nearest to piston (19).
B. Wear sensor must be in leading position with
forward wheel rotation. If not, use other inner
pad assembly (29) in replacement kit.
3. Caliper housing (14) over rotor assembly (39) and
into anchor bracket ( 17).
4. New upper caliper guide pin bolt/screw (13).
l~I
Tighten
Upper caliper guide pin bolt/screw (13) to

37 Nm (27 lb. ft.).
5. New lower caliper guide pin bolt/screw (9), if
removed.
l~I
Tighten
Lower caliper guide pin bolt/screw (9) to

37 Nm (27 lb. ft.).
6. Brake hose fitting (33), two new gaskets (34) and
brake hose fitting bolt/screw (32), if removed.
l~I
Tighten
Brake hose fitting bolt/screw (32) to 30 Nm

(22 lb. ft.).
7. Vibration dampener assembly (40) and vibration
dampener nut (41) to parking brake cable bracket
(8), if removed.
l~I
Tighten
Vibration dampener nut (41) to 50 Nm

(37 lb. ft.).
8. Parking brake cable assembly (35) to parking brake
cable bracket (8) and parking brake actuator lever
(5), and parking brake cable equalizer.
9. Actuator lever return spring (4 ), if removed.

10. Bleed brake hydraulic system, if brake hose fitting
was removed. Refer to SECTION 5El.
11. Lower vehicle.

12. Cycle parking brake assembly.
ll'l'I Inspect
Parking brake actuator levers to make sure
they are againsrstops on caliper housing (14).
If parking brake actuator levers are not on their
stops, make sure actuator lever return spring
(4) is correctly installed, then refer to SECTION 5F for parking brake linkage repairs.
Remove wheel nuts securing rotor assembly
(39).
15. Lower vehicle.
16. With engine running, pump brake pedal assembly
slowly and firmly three times to seat inner and outer
pad assemblies (29 and 30).
17. Check brake hydraulic system for leaks.
REAR DISC BRAKES 5825
13
41~
30
1 SEAL, REAR PARKING BRAKE LEVER PIVOT PIN
2 CLIP, REAR PARKING BRAKE LEVER SPRAG
3 PIN, REAR PARKING BRAKE LEVER PIVOT
4 SPRING, REAR CALIPER PARKING BRAKE ACTUATOR
LEVER RETURN
5 LEVER, REAR PARKING BRAKE ACTUATOR
6 VALVE, REAR BRAKE CALIPER BLEEDER,
11 Nm (97 LB. IN.)
7 CAP, REAR BRAKE CALIPER BLEEDER VALVE
8 BRACKET, PARKING BRAKE CABLE
9 BOLT/SCREW, LOWER CALIPER GUIDE PIN,
37 Nm (27 LB. FT.)
10 SHIM
11 SCREW, PARKING BRAKE LEVER ADJUSTER
12 NUT, REAR PARKING BRAKE LEVER PIVOT PIN,
22 Nm (16 LB. FT.)
13 BOLT/SCREW, UPPER CALIPER GUIDE PIN,
37 Nm (27 LB. FT.)
14 HOUSING, REAR BRAKE CALIPER
15 PIN, REAR BRAKE CALIPER GUIDE
16 BOOT, REAR BRAKE CALIPER GUIDE PIN

17 BRACKET, REAR BRAKE CALIPER ANCHOR
18 SEAL, REAR BRAKE CALIPER PISTON
19 PISTON, REAR BRAKE CALIPER
20 BOOT, ACTUATING COLLAR
21 RETAINER, ACTUATING COLLAR BOOT
22 PUSHROD
23 SPRING, PRELOAD
24 COLLAR, ACTUATING
26 SPRING, REAR CALIPER PARKING BRAKE COLLAR
RETURN
27 BUSHING
28 ROD, CLAMP
29 PAD ASSEMBLY, REAR DISC BRAKE INNER
30 PAD ASSEMBLY, REAR DISC BRAKE OUTER
40 DAMPENER ASSEMBLY, REAR BRAKE VIBRATION
41 .NUT, REAR BRAKE VIBRATION DAMPENER,
50 Nm (37 LB. FT.)
PC0003-5B2-F-RP
Figure 3 - Rear Brake Caliper Assembly Components
30
40
32 BOLT/SCREW, REAR BRAKE HOSE FITIING,
30 Nm (22 LB. FT.)
33 FITIING, REAR BRAKE HOSE
34 GASKET, REAR BRAKE HOSE FITIING
PC0004-5B2-F-RP
Figure 4 - Removing Rear Brake Hose Fitting
A WEAR SENSOR
37 Nm (27 LB. FT.)
10 SHIM
37 Nm (27 LB. FT.)
16 BOOT, REAR BRAKE CALIPER GUIDE PIN
41 NUT, REAR BRAKE VIBRATION DAMPENER,
50 Nm (37 LB. FT.)
PC0006-5BZ-F-RP
Figure 6 - Rear Brake Caliper Assembly
REAR DISC BRAKE INNER AND OUTER PAD

ASSEMBLIES
Figures 3, 7 and 8

LEVER RETURN
35 CABLE ASSEMBLY, PARKING BRAKE REAR
PCOOOS-582-F-RP
Figure 5 - Parking Brake Cable Assembly Attachment
I. Two-thirds of brake fluid from master cylinder

reservoir.
Install wheel nuts to retain rotor assembly.
4. Position a C-clamp and tighten until piston (19) bottoms in base of caliper housing (14).
Make sure one end of C-clamp rests on brake
hose fitting bolt/screw (32) and other end
against outer pad assembly (30).
30
A C-CLAMP.

PC0007-582-F-RP
Figure 7 - Compressing Rear Brake Caliper Piston
Important
It is not necessary to remove the actuator lever

return spring (4) to replace the inner and outer
pad assemblies (29 and 30).
5. Upper caliper guide pin bolt/screw (13).
Discard upper caliper guide pin bolt/screw
(13).
6. Inner and outer pad assemblies (29 and 30).
A. Rotate caliper housing ( 14) about lower caliper
guide pin bolt/screw (9) and guide pin ( 15). Be
careful not to strain hose or cable conduit.
B. Lift out inner and outer pad assemblies (29 and
30).
7. Shim (10).
Discard shim (10).
lt:,I
Clean
All residue from shoe guide surfaces on anchor

bracket (17) and caliper housing (14).
ll'l'l inspect
Guide pins ( 15) for free movement in anchor bracket
(17).
- Replace guide pins (15) or guide pin boots (16)
if corroded or damaged. Refer to "Rear Brake
Caliper Assembly" in this section.

section.
1. New shim (10).
2. New inner and outer pad assemblies (29 and 30).

37 Nm (27 LB. FT.)

15
17
29
30
39
PIN, REAR BRAKE CALIPER GUIDE

BRACKET, REAR BRAKE CALIPER ANCHOR
PAD ASSEMBLY, REAR DISC BRAKE INNER
PAD ASSEMBLV, REAR DISC BRAKE OUTER
ROTOR ASSEMBLY, REAR BRAKE
PCOOOS-582-F-RP
Figure 8 - Rear Disc Brake Inner and Outer Pad Assembly

Replacement
[I] Important
Whenever rear disc brake inner and outer pad
assemblies are replaced, immediately check
the parking brake free-travel. Adjust as necessary. Refer to "Parking Brake Free-Travel
A. Outer pad assembly (30) with insulator is
installed toward caliper housing (14). Inner
pad assembly (29) with wear sensor is installed
nearest the piston ( 19).
B. Wear sensor must be on leading edge of inner
pad assembly (29) with forward wheel rotation. If not, use other inner pad assembly (29)
in replacement kit.
C. Replace inner and outer pad assemblies (29
and 30) in axle sets only.

3. Rotate caliper housing (14) into its operating
position.
Springs on outer pad assembly (30) must not
stick through inspection hole in caliper housing (14). If springs are sticking through inspection hole in caliper housing (14), lift caliper
housing (14) and reposition outer pad assembly (30).
4. New upper caliper guide pin bolt/screw (13).
l~I Tighten
-?~
38
Upper caliper guide pin bolt/screw (13) to

37 Nm (27 lb. ft.).
----
5. With engine running, pump brake pedal assembly

slowly and firmly to seat inner and outer pad assemblies (29 and 30).
IL"l'I Inspect
Parking brake actuator levers (5) to ensure they
are against stops on caliper housing (14).
If parking brake actuator levers are not on
their stops, refer to SECTION 5F for
parking brake linkage repairs.
17

Remove wheel nuts securing rotor assembly
(39).
7. Lower vehicle.
8. Fill master cylinder reservoirs. Refer to SECTION
5A.
REAR BRAKE CALIPER ANCHOR BRACKET

AND MOUNTING PLATE
Figure 9

1. Caliper assembly. Refer to "Rear Brake Caliper
Assembly" under "On-Vehicle Service" in this
section.
rn
Important
Remove anchor bracket (17) only if it is damaged or if rotor assembly (39) is being removed
for refinishing or other service operations.
A CALIPER ASSEMBLY REMOVED FROM

ANCHOR BRACKET
B CALIPER ASSEMBLY AND ANCHOR BRACKET
ASSEMBLED
36 BOLT/SCREW, REAR BRAKE CALIPER MOUNTING PLATE,
100 Nm (74 LB. FT.)
38 PLATE, REAR BRAKE CALIPER MOUNTING
pcooo9-5B2-F-RP
Figure 9 - Rear Brake Rotor Assembly, Caliper Anchor

Bracket, and Mounting Plate
2. Two mounting plate bolts/screws (36).

Discard mounting plate bolts/screws (36).
REAR BRAKE ROTOR ASSEMBLY
3. Anchor bracket (17) from mounting plate (38).

section.
1. Anchor bracket (17) to mounting plate (38).
2. Two new mounting plate bolts/screws (36).
l~I Tighten
Mounting plate bolts/screws (36) to 100 Nm
(74 lb. ft.).
- Check torque on both mounting plate
bolts/screws (36) immediately.
3. Caliper assembly. Refer to "Rear Brake Caliper
Assembly" under "On-Vehicle Service" in this
section.
Figure 9
Rear brake rotor assembly can be removed without
removal of caliper assembly from anchor bracket.

3. Two mounting plate bolts/screws (36).
Discard mounting plate bolts/screws (36).
4. Anchor bracket (17) with assembled caliper assembly from mounting plate (38) and suspend them
from rear suspension out of the way using locally
fabricated wire hook.
5. Rotor assembly (39).
l++I
A. Remove adjuster screw ( 11 ).

Install or Connect
B. Clean thread adhesive residue from threads.
NOTICE: See "Notice" on page 5B2-l of this

section.
1. Rotor assembly (39).
2. Anchor bracket ( 17) with assembled caliper assembly to mounting plate (38).
3. Two new mounting plate bolts/screws (36).
l~I
Tighten
Mounting plate bolts/screws (36) to 100 Nm

(74 lb. ft.).
- Check torque on both mounting plate
bolts/screws (39) immediately.
5. Lower vehicle.
C. Coat threads with adhesive.

D. Screw in adjuster screw (11) far enough to
obtain 0.61 mm to 0.71 mm (0.024 inch to
0.028 inch) free-travel between parking brake
actuator lever (5) and caliper housing (14) at
point B.
5. Have assistant release brake pedal assembly, then
apply brake pedal assembly firmly three times.
6. Recheck free-travel as described in steps 2 and 3 and
adjust as necessary.
7. Install actuator lever return spring (4) and parking
brake cable assembly
UNIT REPAIR
PARKING BRAKE FREE-TRAVEL

ADJUSTMENT
Figure 10
The adjustment process requires a second person to
apply a light brake pedal load. Parking brake lever freetravel is set by the position of the adjuster screw (11 ).
Turning the adjuster screw ( 11) clockwise increases the
free-travel; turning the adjuster screw (11) counterclockwise decreases the free-travel.
NOTICE: Inner and outer pad assemblies must be
new or parallel to within 0.15 mm (0.006 inc~).
Parking brake adjustment is not valid wi~h heavily
tapered pad assemblies and may cause caliper/parking brake binding.
[I] Important
Inspect old inner and outer pad assemblies and
replace with new ones if they are tapered.
Parking brake free-travel should only be
changed if the caliper has been taken apart, or
when the. pad assemblies are replaced.
This adjustment will not correct a co1:dition
where parking brake actuator levers will not
return to their stops.
1. Disconnect parking brake cable assembly and
remove actuator lever return spring (4).
2. Have an assistant apply light brake pedal load,
enough to stop rotor from turning by hand.
This takes up all clearances and ensures that
components are correctly aligned.
3. Apply light pressure to parking brake actuator lever
(5).
l@I
Measure
Free-travel between parking brake actuator

lever (5) and caliper housing (14) at point B.
- Free-travel must be 0.61 mm to 0.71 mm
(0.024 inch to 0.028 inch).
4. If free-travel is incorrect, do the following:
REFINISHING REAR BRAKE ROTOR

ASSEMBLIES
rn
Important
DO NOT refinish rotor assemblies when performing

routine brake maintenance such as replacing worn
rear disc brake inner and outer pad assemblies.
Refinish a rotor assembly ONLY under the following circumstances:
- There is a complaint of brake pulsation.
- There is scoring greater than 1.5 mm (0.06
inch).
All rotor assemblies have a minimum thickness
dimension cast into them. This dimension is the minimum
wear dimension and not a refinish dimension. The minimum refinish dimension is greater than the discard dimension. Do not use a rotor assembly that will not meet
specifications. A rotor assembly that has been refinished
too thin will not have proper heat transfer capabilities.
Replace with a new rotor assembly. Refer to "Specifications" in this section.
Since accurate control of the rotor assembly tolerances is necessary for proper performance of the rear disc
brakes, the rotor assembly should be machined only with
precision equipment. Equipment should be serviced on a
regular basis following the manufacturer's recommended
maintenance procedure.
When refinishing rotor assemblies, the attaching
adapters, tool holders, vibration dampeners and tool bits
must be in good condition. Always use sharp cutting tools
or bits and use only replacement cutting bits recommended by the equipment manufacturer. Dull or worn
tools leave a poor surface finish which will affect braking
performance. Vibration dampening attachments should
always be used when refinishing braking surfaces. These
attachments eliminate tool chatter and will result in better
surface finish. Make sure these adapters are clean and free
of nicks.
14
A APPLY PRESSURE HERE

B MEASURE HERE
LEVER RETURN
PCOOl0-582-fRP
Figure 1O- Parking Brake Free-Travel Adjustment
On-Vehicle
Tool Required:
On-Vehicle Brake Lathe, such as Kent-Moore
J 37704
J 37160-A Brake Rotor Mounting Adapter
In the cases where rotors are being refinished to correct a problem with brake pulsation, it is recommended
that an on-vehicle brake lathe be used to achieve best
results. Follow the equipment manufacturer's recommended specifications and procedure.
Off-Vehicle
Tool Required:
J 37160-A Brake Rotor Mounting Adapter
[I] Important
Remove rust and scale from rotor assembly and rear
axle shaft flange mating surfaces. Failure to do so
may introduce excessive lateral runout when the
rotor assembly is mounted on the brake lathe, or
when the rotor assembly is reinstalled on the rear

axle shaft flange.
Following are two recommended procedures that
achieve adequate results using two different off-vehicle
drum/disc brake lathes. (If any other lathe is used, follow
that lathe's instructions and recommendations.)
Ammco Brake Lathe

(Two-cut refinishing procedure)
ROUGH CUT
150 rpm
0.15 mm to
0.64mm
(0.006 inch to
0.025 inch)
Tool Cross Feed
0.25 mm
(per rev.)
(0.010 inch)
Vibration Dampener Yes
Sand Rear Brake
No
Rotor Assembly
(Swirl Pattern)
Spindle Speed
Depth of Cut
(per side)
FINISH CUT
150 rpm
0.10 mm to
0.15 mm
(0.004 inch to
0.006 inch)
0.05 mm
(0.002 inch)
Yes
Yes

Accuturn Brake Lathe, GM Dealer Equipment
(One-cut refinishing procedure)
Locate the deepest score and tum the rotor micrometer knob until the tool bit bottoms out at the deepest point
of the score. Zero the scale and back out the tool bit
(repeat for opposite side of rotor). Advance the cutter
handwheel until the bits have cleared the inner edges of
the rotor face. Adjust the micrometer knobs for approximately 0.13 mm (0.005 inch) more than the first reading.
This will ensure resurfacing the rotor in one cut.
Spindle Speed
Depth of Cut
Tool Cross Feed
(per revolution)
Tool Bit Nose Radius
Vibration Dampener
105 rpm
As necessary
0.08 mm (0.003 inch)
1/64
Yes
Non-Directional Finishing
It is very important that the rotor surface be made
non-directional by dressing the rotor surfaces with a sanding disc tool such as Ammco 8750 Safe Swirl Disc Rotor
Grinder, Accuturn 433179 Non-Directional Swirl ,Finisher, or equivalent, using 120 grit aluminum oxide sandpaper. Sand each rotor surface with moderate pressure for
a minimum of 60 seconds. If the brake lathe is not
equipped with an adequate non-directional finishing tool,
an alternate method is to use a sanding block with 150 grit
aluminum oxide sandpaper. With the rotor turning at the
equipment manufacturer's highest recommended cutting
speed, sand each rotor surface for a minimum of 60
seconds using moderate pressure. After the rotor has
been sanded, clean each surface with denatured alcohol or a suitable brake cleaner.
The finished rotor assembly surface should be as
close to that of a new rear brake rotor assembly as possible. Failure to obtain the best possible finish may affect
braking performance.
rn
Important
Rear brake rotor assemblies should always be

replaced if turning will result in a rear brake rotor
assembly that does not meet manufacturer specifications for minimum thickness. When installing new
brake rotor assemblies, do not refinish the surfaces
of these parts. New brake rotor assemblies have the
Burnishing Rear Brake Rotor Assemblies

After rear brake pad assemblies have been replaced
and/or rotor assemblies have been refinished, it is very
important that the new braking surface be broken in, or
burnished. This can be accomplished by making 20 stops
from 48 km/h (30 mph), using medium to firm brake
pedal assembly pressure. Allow 0.8 km (0.5 mile) to
1.6 km (1.0 mile) between stops to avoid overheating the
brakes.

l+!+I Disassemble
1. Remove caliper assembly. Refer to "Rear Brake
this section.
2. Two collar return springs (26) from actuating collar
boot retainer (31 ).
3. Actuating collar (24) with assembled parts.
Firmly but gently pull actuating collar (24)
with assembled parts out of caliper housing
( 14) by pulling on both ends of actuating collar
4. Clamp rod (28) and bushing (27) from actuating collar (24).
Discard bushing (27).
5. Actuating collar boot retainers (21 and 31), actuating collar boots (20 and 25) and pushrod (22) from
actuating collar (24).
A. Bend back actuating collar boot retainer tabs
and take apart.
B. Remove preload spring (23) from actuating
collar boot retainer (21).
C. Remove pushrod (22) from actuating collar
boot retainer (21).
D. Remove and discard actuating collar boot
retainers (21 and 31) and actuating collar boots
(20 and 25).
CAUTION: Do not place fingers in front

of the piston in an attempt to catch or
protect it when applying compressed
air. The piston can fly out with force
and could result in serious injury.
rn
Important
Use clean shop towels to pad the inside of the

caliper housing (14) during rear brake caliper
piston removal.
NOTICE: To prevent damage, be careful when handling rear brake caliper piston.
6. Piston (19) by directing dry, filtered compressed air
into brake hose port of caliper housing (14).
lll
1nspect
Piston (19) for scoring, nicks, corrosion and

wear.
- Replace piston ( 19) if necessary.
NOTICE: Do not use a metal tool to remove piston
seal. Metal tools may damage the caliper housing
bore or the piston seal groove.
7. Piston seal (18).
Use small wood or plastic tool.
8. Bleeder valve cap (7) and bleeder valve (6).
Discard bleeder valve cap (7).

9. Parking brake lever pivot pin seal (1), sprag clip (2),
actuator lever return spring (4) and parking brake
actuator lever (5) from parking brake lever pivot pin
(3).
Discard sprag clip (2).
IL..-1 Inspect
Caliper housing bore for scoring and corrosion.
Replace caliper housing ( 14) if badly scored or corroded around seal area.
l+!+I
IL..-1 Inspect
Contact points on parking brake actuator lever
(5) and parking brake lever pivot pin (3) for
wear and corrosion.
1.
- Replace if necessary.
10. Parking brake lever pivot pin (3) and pivot pin nut
(12), if worn.
2.
11. Adjuster screw (11) from caliper housing (14).

Discard if damaged or worn.
3.
IL..-1 Inspect
4.
Caliper anchor bracket ( 17) for wear and

damage.
5.
PC0011-5B2-F-RP
Figure 11 - Removing Rear Brake Caliper Piston
1~1 Clean
6.
Pad assembly contact area on anchor bracket

(17).
12. Two guide pins (15) and guide pin boots (16) from
anchor bracket ( 17).
l~I
Clean
1. All parts not included in repair kit in denatured alcohol.
7.
2. Use dry, filtered compressed air to dry parts.

3. Blow out all passages in caliper housing (14) and
bleeder valve (6).

section.
Lubricate new piston seal (18) and caliper housing
bore seal groove with silicone grease or clean brake
fluid.
New piston seal (18) into caliper housing seal
groove.
Make sure piston seal ( 18) is not twisted.
Lubricate bore of caliper housing (14) and piston
(19) with clean brake fluid.
Piston (19) into bore of caliper housing (14 ).
Push down by hand to bottom of bore.
IL'l'I Inspect
- Replace if necessary. Refer to "Rear

Brake Caliper Anchor Bracket and
Mounting Plate" in this section.
A SHOPTOWEL
Assemble
8.
Actuating collar (24) and clamp rod (28) for

corrosion and excessive wear on working
faces.
- If corrosion or excessive wear is present,
replace actuating collar assembly.
Pushrod (22), new inner and outer actuating collar
boots (20 and 25) and new actuating collar boot
retainers (21 and 31) to actuating collar (24 ).
A. Lightly coat actuating collar (24) with liquid
lubricant provided in repair kit. Do not use any
other fluid or grease.
B. Install preload spring (23) into new actuating
collar boot retainer (21).
C. Install new inner and outer actuating collar
boots (20 and 25) into new actuating collar
boot retainers (21 and 31 ).
D. Install pushrod (22) to new actuating collar
boot retainer (21).
E. Clamp new actuating collar boot retainers (21
and 31) firmly against actuating collar (24 ).
F. Bend tabs on new actuating collar boot retainer
(21) to hold actuating collar assembly together.
Clamp rod (28) to actuating collar (24) and actuating
collar boot (25).
A. Lightly coat clamp rod (28) with liquid lubricant provided in repair kit.
B. Slide clamp rod (28) through holes in actuating
collar boot (25) and actuating collar (24 ).
C. Actuating collar boot (25) must be against
reaction plate on clamp rod (28).
New bushing (27) to clamp rod (28).
Lubricate outside of bushing (27) with provided lubricant.
Clamp rod (28) with assembled parts into connecting hole in piston (19).
14
17
A WEAR SENSOR
3 PIN, REAR PARKING BRAKE LEVER PIVOT
LEVER RETURN
6 VALVE, REAR BRAKE CALIPER BLEEDER,
11 Nm (97 LB. IN.)
7 CAP, REAR BRAKE CALIPER BLEEDER VALVE'
37 Nm (27 LB. FT.)
10 SHIM
37 Nm (27 LB.FT.)
18 SEAL, REAR BRAKE CALIPER PISTON
19 PISTON, REAR BRAKE CALIPER
22 PUSHROD
23 SPRING, PRELOAD
24 COLLAR, ACTUATING
26 SPRING, REAR CALIPER PARKING BRAKE
COLLAR RETURN
27 BUSHING
28 ROD, CLAMP
~FRT
8
28
PC0012-5B2-F-RP
Figure 12 - Rear Brake Caliper Assembly - Cutaway View

A. Lubricate grooved bead of actuating collar
boot (20) and boot groove in caliper housing
(14) with provided lubricant. Use remaining
liquid lubricant to coat actuating collar (24),
especially around center hole.
B. Push clamp rod (28) firmly to bottom of connecting hole in piston (19).
C. Pull on actuating collar (24) and seat actuating
collar boot (20) into boot groove in caliper
housing (14).
D. Make sure that pushrod (22) enters hole in caliper housing (14).
9. Two collar return springs (26) to actuating collar
Actuating collar boot retainer (31) must enter
collar return springs (26) at end of second
spring coil.
10. New bleeder valve cap (7) and bleeder valve (6) into
caliper housing ( 14).
l~I
13. Pivot pin seal (1), parking brake actuator lever (5),
new sprag clip (2) and actuator lever return spring
(4), in that order.
A. Teeth of sprag clip (2) must face away from
parking brake actuator lever (5).
B. Snap pivot pin seal cap over parking brake
lever pivot pin (3).
14. Adjuster screw (11) into caliper housing (14) until
actuating collar (24) is about parallel to piston bore
face of caliper housing (14).
15. New guide pin boots (16) and guide pins (15).
A. Lubricate two guide pins (15) with grease provided in repair kit.
B. Slide guide pin boots (16) on guide pins (15).
C. Fill guide pin boots ( 16) with provided grease.
Tighten

11. Parking brake lever pivot pin (3) and new pivot pin
nut (12) to caliper housing (14), if removed.
l~I
12. Lubricate parking brake actuator lever (5) and parking brake lever pivot pin (3) with grease provided in
repair kit.
Tighten
Pivot pin nut (12) to 22 Nm (16 lb. ft.).
D. Assemble to anchor bracket ( 17).

E. Make sure guide pin boots ( 16) fit into grooves
of guide pins ( 15) and anchor bracket ( 17).
16. Install caliper assembly. Refer to "Rear Brake Caliper Assembly" under "On-Vehicle Service" tn this
section.
SPECIFICATIONS
Rear Brake Caliper Assembly
Rear Brake Caliper Housing Bore Diameter (Nominal) ................... 40.50 mm (1.595")
Rear Brake Rotor Assembly
Rotor Diameter (Nominal) ....................................... 293.00 mm (11.535")
Lateral Runout .
Rear Brake Rotor Assembly (On-Vehicle Condition) ................... 0.15 mm (0.006")
Rear Axle Shaft Flange ........................................... 0.05 mm (0.002")
Thickness Variation .............................................. 0.013 mm (0.0005")
Rotor Thickness (Maximum) ....................................... 20.00 mm (0.787")
Minimum Thickness After Refinish . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.63 mm (0.733")
Discard Thickness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.40 mm (0.724")
All rear brake rotor assemblies have a discard dimension cast into them. This is a wear dimension and not a refinish
dimension. Any rear brake rotor assembly which does not meet the specifications should be replaced.
ROTOR REFINISHING SPECIFICATIONS

Ammco Brake Lathe
Rough Cut
Depth of Cut (Per Side) ......................... 0.15 mm to 0.64 mm (0.006" to 0.025")
Tool Crossfeed (Per Revolution) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.25 mm (0.010")
Sand Front Brake Rotor Assembly (Swirl Pattern) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . No

Finish Cut
Depth of Cut (Per Side).. . . . . . . . . . . . . . . . . . . . . . . . 0.10 mm to 0.15 mm (0.004" to 0.006")
Tool Crossfeed (Per Revolution) .................................... 0.05 mm (0.002")
Sand Front Brake Rotor Assembly (Swirl Pattern) ................................. Yes
Accuturn Brake Lathe
Spindle Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105 rpm
Depth of Cut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . As necessarx
Tool Crossfeed (Per Revolution) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.08 mm (0.003' )
Vibration Dampener ........................................................... Yes

Lower Caliper Guide Pin Bolt/Screw .................................... 37 Nm (27 lb. ft.)
Rear Brake Caliper Bleeder Valve ...................................... 11 Nm (97 lb. in.)
Rear Brake Caliper Mounting Plate Bolt/Screw ........................... 100 Nm (74 lb. ft.)
Rear Brake Hose Fitting Bolt/Screw ..................................... 30 Nm (22 lb. ft.)
Rear Brake Vibration Dampener Nut .................................... 50 Nm (37 lb. ft.)
Rear Parking Brake Lever Pivot Pin Nut ................................. 22 Nm (16 lb. ft.)
Upper Caliper Guide Pin Bolt/Screw .................................... 37 Nm (27 lb. ft.)
SPECIAL TOOLS
~
~
3.
2.
1.
J37160-A
J37704
o~~
J 8001
1. BRAKE ROTOR MOUNTING ADAPTER

2. ON DISC BRAKE LATHE
PC0020-5B2-F-RP
DUO-SERVO DRUM BRAKES 5C21
SECTION 5C2
DUO-SERVO DRUM BRAKES

CAUTION: When servicing brake parts, do not create dust by grinding, sanding brake linin~s or by cleaning brake parts with a dry brush or compressed air. Many brake parts contain asbestos fibers which can become airborne if dust is created during servicing.
actions:
result.
CONTENTS
G~neral _Description . . . . . . . . . . . . . . . . . . . . . . .
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Primary and Secondary Shoes Inspection . . . .
Drum Assembly Inspection . . . . . . . . . . . . . . .
Surface Finish .......................
Inside Diameter Check .................
Out-of-Round or Taper Check ...........
Runout Check .......................
Balance . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Drum Assembly ........................
Primary and Secondary Shoes . . . . . . . . . . . . .
Wheel Cylinder ........................
5C2- l
5C2-1
5C2- l
5C2-1
5C2-2
5C2-2
5C2-2
5C2-2
5C2-2
5C2-2
5C2-2
5C2-4
5C2-5
GENERAL DESCRIPTION
The rear drum brake assembly is a duo-servo design.
In the duo-servo brake, the force which the rear wheel
cylinder applies to the primary shoe is multiplied by the
primary lining friction to provide a very large force
applied to the secondary shoe. Adjustment for both the
primary and secondary shoe and lining assemblies is automatic during reverse brake applications.
The rear brake drum assembly has a honed friction
surface that reduces shoe slap, increases lining life, and
reduces the break-in time.
Backing Plate . . . . . . . . . . . . . . . . . . . . . . . . . .
Rear Drum Brake Adjustment . . . . . . . . . . . . .
Unit Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Drum Assembly . . . . . . . . . . . . . . . . . . . . . . . .
Cracked, Scored or Grooved . . . . . . . . . . . .
Out-of-Round or Tapered . . . . . . . . . . . . . . .
Refinishing . . . . . . . . . . . . . . . . . . . . . . . . . .
Balance . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Wheel Cylinder ........................
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fastener Tightening Specifications . . . . . . . . .
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5C2-6
5C2-7
5C2-7
5C2-7
5C2-7
5C2-7
5C2-7
5C2-8
5C2-8
5C2-9
5C2-9
5C2-9
5C2-9
DIAGNOSIS
PRIMARY AND SECONDARY SHOES
INSPECTION
When the thickness of any lining is worn within O. 76
mm (0.030 inch) of the primary or secondary shoe, the
primary and secondary shoes must be replaced. Replace
shoes in axle sets only.
DRUM ASSEMBLY INSPECTION

Pulsation in the brake pedal assembly is usually corrected by servicing the front brakes. Service the rear
brakes only if the problem persists.
SC2-2 DUO-SERVO DRUM BRAKES

To determine if the front or rear brakes are at fault,
drive the vehicle in an area away from people and moving
traffic (such as a large parking lot), and at a slow speed.
Lightly apply the parking brake assembly, and feel for the
pulsation. Be careful not to lock the brakes and flat-spot
the rear tires. If the pulsation is not noticed, the fault is
probably in the front brakes.
When drum assemblies are removed, thoroughly
clean and inspect them for cracks, scores, deep grooves,
out-of-round and taper.
Surface Finish
Normal light scoring of the drum assembly surfaces

not exceeding 0.51 mm (0.020 inch) in depth will not
affect brake operation.
Inside Diameter Check

The nominal inside diameter of the drum assembly
is 241.30 mm (9.500 inches).
Out-of-Round or Taper Check

An out-of-round or tapered drum assembly makes
accurate primary or secondary shoe adjustment impossible and is likely to cause excessive wear of other parts of
brake mechanism due to its eccentric action. An out-ofround drum assembly can also cause severe and irregular
tire tread wear as well as a pulsating brake pedal assembly. When the drum assembly exceeds the specification
limits in taper and/or out-of-round, refinish drum assembly to true up the braking surface. Out-of-round as well as
taper and wear can be accurately measured with an inside
micrometer fitted with proper extension rods.
When measuring a drum assembly for out-of-round,
taper, and wear, take measurements at the open and closed
edges of machined surface and at right angles (90 degrees)
to each other.
Runout Check
Runout for drum assemblies is not to exceed 0.15
mm (0.006 inch).
Balance
During manufacture, weights are used to balance
drum assemblies. These weights must not be removed.
After drum assemblies have been refinished or if difficulty is experienced in maintaining proper wheel balance, drum assemblies should be checked for balance.
Drum assemblies may be checked for balance on most
off-the-vehicle wheel balancers.
A SCREWDRIVER USED ONLY WHEN BACKING OFF

ADJUSTMENT
B BRAKE ADJUSTING TOOL
C ST AR WHEEL ROT A TION TO RETRACT REAR BRAKE
SHOES
D STAR WHEEL ROTATION TO EXPAND
REAR BRAKE SHOES
7 ACTUATOR, .REAR BRAKE SHOE ADJUST
29 PLATE, REAR BRAKE BACKING
PC6001-5C2-D-RP
Figure 1 - Backing Off Rear Brake Shoe Adjustment
brake system.
Replace shoe and lining assemblies in axle sets only.
fasteners.
DRUM ASSEMBLY
Figure 1
ON-VEHICLE SERVICE
rn

Important

to service this drum brake.
Lubricate parts as specified.

SECTION OA.
Mark relationship of wheel to axle flange.
NOTICE: Be careful not to drop the brake drum
assemblies during handling. Out-of-round can occur
DUO-SERVO DRUM BRAKES 5C23
9
~5
12
29
A
22
14
30
~8
A
B
C
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
SHOEPAD
ANCHOR PIN
REAR AXLE ASSEMBLY FLANGE
SPRING, REAR BRAKE SHOE RETURN
SPRING, REAR BRAKE SHOE RETURN
SPRING, REAR BRAKE SHOE HOLD-DOWN
PIVOT, REAR BRAKE SHOE ADJUST ACTUATOR
PIN, REAR BRAKE SHOE
LINK, REAR BRAKE SHOE ADJUST ACTUATOR
ACTUATOR, REAR BRAKE SHOE ADJUST
SPRING, REAR BRAKE SHOE ADJUST
ACTUATOR RETURN
STRUT, REAR PARKING BRAKE LEVER
SPRING, REAR PARKING BRAKE LEVER STRUT
PIN, REAR PARKING BRAKE LEVER PIVOT
LEVER ASSEMBLY, REAR PARKING BRAKE
SHOE, REAR BRAKE PRIMARY
SHOE, REAR BRAKE SECONDARY
SOCKET, REAR BRAKE SHOE ADJUST
17
18
19
20
21
22
23
24
25
26
28
29
30
31
32
34
35
36
RING, REAR PARKING BRAKE LEVER RETAINER

NUT, REAR BRAKE SHOE ADJUST
ADJUSTER, REAR BRAKE SHOE
VALVE, REAR BRAKE BLEEDER, 6 Nm (53 LB. IN.)
BOLT/SCREW, REAR WHEEL CYLINDER,
13 Nm (115 LB. IN.)
BOOT, REAR WHEEL CYLINDER PISTON
PISTON, REAR WHEEL CYLINDER
SEAL, REAR WHEEL CYLINDER PISTON
SPRING, REAR WHEEL CYLINDER PISTON
BODY, REAR WHEEL CYLINDER
CYLINDER, REAR WHEEL
SPRING, PARKING BRAKE CABLE RETURN
ADJUSTER ASSEMBLY, REAR BRAKE SHOE
GUIDE, REAR BRAKE SHOE
CAP, BLEEDER VALVE
NUT, REAR BRAKE BACKING PLATE, 58 Nm (43 LB. FT.)
BOLT/SCREW, REAR BRAKE BACKING PLATE
PC0002-5C2-F-RP
Figure 2 - Rear Brake Assembly Components
5C2-4 DUO-SERVO DRUM BRAKES

from even the smallest fall, resulting in brake pulsation.
NOTICE: Do not pry against the splash shield that
surrounds the backing plate in an attempt to free the
drum assembly. This will bend the splash shield.
3. Drum assembly.
A. Mark relationship of drum assembly to axle
flange.
B. If you have trouble removing rear brake drum
assembly, try the following:
a. Make sure parking brake assembly is
released.
b. Disconnect parking brake cable assemblies from equalizer. Refer to SECTION
5F.
c. Remove adjusting hole cover or knockout plate from backing plate (29) and
back off adjusting screw, using screwdriver and brake adjusting tool.
d. Use rubber mallet to tap gently on outer
rim of drum and/or around inner drum
diameter by axle flange and/or axle pilot,
while pulling outward on drum assembly.
Take care not to deform drum assembly
by excessive use of force.
29
A
B
12
13
29
30
PC0009-5C2-FRP
l:el
1.
2.
3.
4.
Figure 3 - Removing Parking Brake Cable Assembly
Adjust
Rear drum brake assemblies. Refer to "Rear

Drum Brake Adjustment" in this section.
Drum assembly.
Align locating marks on drum assembly and
axle flange.
Align locating marks on wheel and axle flange.
If knockout plate was removed, an adjusting
hole cover, GM P/N 5464803 must be
installed.
If parking brake cable assemblies were disconnected from equalizer, install to equalizer.
Lower vehicle.
Cycle parking brake lever assembly three times.
2.
3.
4.
5.
6.
7.
8.
9.
10.
PRIMARY AND SECONDARY SHOES

Figures 2 through 4
Tools Required:
J 8049 Brake Spring Remover and Installer
J 8057 Brake Spring Pliers
11.
12.

1. Drum assembly. Refer to "Drum Assembly" under
CAUTION: Keep fingers away from rear
brake shoe return springs to prevent
REAR PARKING BRAKE LEVER NOTCH

REAR PARKING BRAKE CABLE END
LEVER ASSEMBLY, REAR PARKING BRAKE
SPRING, PARKING BRAKE CABLE RETURN
!S:.-1
fingers from being pinched between

rear brake shoe return spring and shoe
web or return spring and backing plate.
Return springs (1 and 2) using J 8049.
Hold-down springs (3) and pins (5) using suitable
pliers.
Actuator pivot (4).
Actuator link (6) while lifting up on actuator (7).
Actuator (7) and actuator return spring (8).
Shoe guide (32), strut (9) and strut spring (10).
Primary shoe (13) and secondary shoe (14) from
backing plate (29) and parking brake rear cable
assembly.
Adjuster assembly (31) and spring (15).
Parking brake cable assembly from parking brake
lever assembly (12) by pushing parking brake lever
assembly (12) into parking brake cable return spring
(30). Disengage cable end from parking brake lever
assembly (12).
Primary shoe (13) with parking brake lever assembly (12) and parking brake cable return spring (30).
Parking brake lever assembly (12).
A. Pry open retainer ring (17), remove and discard.
B. Push out pivot pin (11 ).
Clean
1. Adjuster assembly (31).
DUO-SERVO DRUM BRAKES 5C2-5
B
A
B
13
14
15
16
18
19
31
STARWHEEL
PROPER SPRING INSTALLATION
SOCKET, REAR BRAKE SHOE ADJUST
NUT, REAR BRAKE SHOE ADJUST
ADJUSTER ASSEMBLY, REAR BRAKE SHOE
PC0003-5C2-F-RP
Figure 4 - Rear Brake Shoe Adjuster Assembly
A. Clean adjusting screw threads with wire brush.

B. Wash all components in clean denatured
alcohol.
C. Apply brake lubricant, GM PIN 1052196 or
equivalent, to adjuster threads, inside diameter
of adjust socket (16) and adjust socket face.
Adequate lubrication is achieved when a
continuous bead of lubricant is at open
end of adjust nut (18) and adjust socket
( 16) when threads are fully engaged.
2. Backing plate (29) and lubricate contact surfaces
with brake lubricant, GM PIN 1052196 or equivalent.
ll!
1nspect
1. Threads of adjuster ( 19) for smooth rotation over
full length.
2. All parts.
If any parts are of doubtful strength or quality
due to discoloration from heat, overstress, or
wear, the parts should be replaced.

1.
2.
3.
4.
NOTICE: See "Notice" on page 5C2-1 of this section.

Parking brake lever assembly (12).
A. Insert pivot pin (11) through holes in primary
shoe (13) and parking brake lever assembly
(12).
B. Install and crimp new retainer ring ( 17).
Parking brake cable assembly to parking brake lever
assembly (12) by pulling back parking brake cable
return spring (30). Engage cable end into parking
brake lever assembly (12).
Adjuster assembly (31) and spring (15).
Primary shoe (13) and secondary shoe (14) to backing plate (29) and parking brake rear cable assembly.
5. Strut (9) and strut spring (10) by spreading primary

shoe (13) and secondary shoe (14) apart. For proper
positioning:
A. Strut end without strut spring ( 10) engages
parking brake lever assembly (12) and primary
shoe (13) or secondary shoe (14).
B. Strut end with strut spring (10) engages opposite primary shoe (13) or secondary shoe (14).
6. Shoe guide (32).
7. Actuator (7) and actuator return spring (8).
8. Pins (5), actuator pivot (4) and hold-down springs
(3).
9. Actuator link (6) on anchor pin.
10. Actuator link (6) into actuator (7) while holding up
on actuator (7).
11. Return springs (1 and 2) using J 8057.
12. Drum assembly. Refer to "Drum Assembly" under
WHEEL CYLINDER
Figure 5

SECTION OA.
~
2.
3.
4.
5.
Clean
Dirt and foreign material around wheel cylinder (28) and rear brake rear pipe assembly.
Primary and secondary shoes_ Refer to "Primary
and Secondary Shoes" in this section.
Brake pipe fitting and rear brake rear pipe assembly.
Plug opening in rear brake rear pipe assembly
to prevent brake fluid loss and contamination_
Bolts/screws (21).
Wheel cylinder (28).
33 DRUM ASSEMBLY, REAR BRAKE
PC6005-5C2-D-RP
Figure 6 - Setting Tool to Rear Brake Drum Assembly
21 BOLT/SCREW, REAR WHEEL CYLINDER,

13 Nm (115 LB. IN.)
28 CYLINDER, REAR WHEEL
PC0004-5C2-F-RP
Figure 5 - Rear Wheel Cylinder

NOTICE: See "Notice" on page 5C2-1 of this
section.
1. Wheel cylinder (28).
Hold in place with wooden block between
wheel cylinder (28) and axle flange.
l~I
Tighten

3. Rear brake rear pipe assembly.
l~I
Tighten
Brake pipe fitting to 17 Nm (13 lb. ft.).

4. Primary and secondary shoes. Refer to "Primary
5. Lower vehicle.
5El.
2. Primary and secondary shoes. Refer to "Primary

3. Rear axle shaft. Refer to SECTION 4B.
4. Parking brake cable assembly from rear brake backing plate. Refer to SECTION SF.
5. Brake pipe assembly from wheel cylinder (28).
6. Wheel cylinder. Refer to "Wheel Cylinder" under
7. Backing plate bolts/screws (36) and nuts (35).
8. Backing plate (29) from axle flange.

section.
1. Backing plate (29) to axle flange.
2. Backing plate bolts/screws (36) and nuts (35).
l~I
Backing plate nuts (35) to 58 Nm (43 lb. ft.).

4. Rear brake rear pipe assembly to wheel cylinder
(28).
l~I
5.
6.
7.
BACKING PLATE
Figure2

SECTION OA.
Tighten
8.
Tighten
Brake pipe fitting to 17 Nm (13 lb. ft.).

Parking brake cable assembly to brake backing
plate. Refer to SECTION SF.
Rear axle shaft. Refer to SECTION 4B.
Primary and secondary shoes. Refer to "Primary
Bleed brake hydraulic system. Refer to SECTION
5El.
11
Adjust
Rear drum brake assemblies. Refer to "Rear

Drum Brake Adjustment" in this section.

9. Lower vehicle.
10. Cycle parking brake lever assembly three times.
REAR DRUM BRAKE ADJUSTMENT

Figures 4, 6 and 7
Tool Required:
J 21177~A Drum-to-Brake Shoe Clearance
Gage

SECTION OA.
3. Drum assemblies. Refer to "Drum Assembly"
under "On-Vehicle Service" in this section.
19
[el Adjust
Rear brake assemblies.
A. Set J 21177-A so that it contacts inside diameter of drum assembly (33).
B. Position J 21177-A over primary and secondary shoes (13 and 14).
C. Turn star wheel on adjuster (19) until primary
and secondary shoes (13 and 14) contact
J 21177-A.
Outside diameter of primary shoe ( 13)
and secondary shoe (14) will be approximately 1.27 mm (0.050 inch) less than
inside diameter of drum assembly (33) on
each wheel.

1. Drum assemblies. Refer to "Drum Assembly"
3. Lower vehicle.
4. Make several stops, applying firm force to brake
pedal assembly.
Repeat until ample pedal reserve is built up.
UNIT REPAIR
DRUM ASSEMBLY
Cracked, Scored or Grooved
A cracked drum assembly is unsafe for further service and must be replaced. Do not attempt to weld a
cracked drum assembly.
Smooth up any slight scores. Heavy or extensive
scoring will cause excessive brake lining wear, and it may
be necessary to refinish the drum braking surface.
If the brake linings are slightly worn, but still reusable, and the drum assembly is grooved, polish the drum
assembly with fine emery cloth but do not refinish. Eliminating all grooves in the drum assembly and smoothing
A
13
14
19
STARWHEEL
PC60065C2D-RP
Figure 7 - Setting Rear Brake Primary

and Secondary Shoes to Tool
the ridges on the shoe linings would require removing too

much metal and lining, while if left alone, the grooves and
ridges match and satisfactory service can be obtained.
If brake linings are to be replaced, refinish a grooved
drum assembly. A grooved drum assembly, if used with
new lining, will not only wear the lining, but will make it
difficult, if not impossible, to obtain proper brake performance.
Out-of-Round or Tapered
An out-of-round or tapered drum assembly prevents
accurate rear brake shoe adjustment and is likely to cause
excessive wear of other brake parts due to its eccentric
action. An out-of-round drum assembly can also cause
severe and irregular tire tread wear as well as a pulsating
brake pedal assembly. When the drum assembly exceeds
the specification limits in taper and/or out-of-round, refinish drum assembly to true up the braking surface. Out-ofround as well as taper and wear can be accurately
measured with an inside micrometer and extension rods.
When measuring a drum assembly for out-of-round,
taper, and wear, take measurements at the open and closed
edges of the machined surface and at right angles (90 degrees) to each other.
Refinishing
All drum assemblies have a maximum diameter cast
into them. This diameter is the maximum wear diameter
and not a refinish diameter. Do not refinish a drum assembly that will not meet the specifications. Refer to "Specifications" at the end of this section.

Any drum assembly that does not meet specifications shown should be replaced.
26
When refinishing a drum assembly, resurface the

drum assembly to no more than a dimension of 0.76 mm
(0.030 inch) less than the discard diameter. The refinish
diameter is the maximum diameter the drum assembly
should be refinished to, and still allow safe braking action.
If this dimension is exceeded, the drum assembly will
wear beyond the discard diameter during normal brake
wear.
22
34~\
20~
If a drum assembly must be refinished, remove only

enough metal to obtain a true, smooth braking surface. If a
drum assembly does not clean-up when refinished to a
maximum rebore diameter as shown at the end of this section, replace it. Removal of more metal will affect heat
dissipation and may cause rear brake drum assembly
distortion.
22
When refinishing drum assemblies, always use

sharp cutting tools or bits. Dull or worn tools leave a poor
surface finish which will affect initial braking performance. Vibration dampening attachments should always
be used when refinishing braking surfaces. These attachments eliminate tool chatter and will result in better
surface finish.
The optimum spindle speed for refinishing braking
surfaces is 200 rpm. Crossfeed for rough cutting should
range from 0.15-0.25 mm (0.006-0.010 inch) per revolution. Finish cuts should be made at crossfeeds no greater
than 0.05 mm (0.002 inch) per revolution.
After making the finish cuts, sand the brake drum
friction surface for at least 60 seconds. Use 150 grit aluminum oxide sandpaper on a curved sanding block. Make
smooth in-and-out motions with the block while sanding.
This procedure will simulate the original factory surface
finish.
Replacing Drum Assemblies
When installing new drum assemblies, do not refinish the braking surface. New drum assemblies have the
20 VALVE, REAR BRAKE BLEEDER, 6 Nm (53 LB. IN.)

22
23
24
25
26
34
BOOT, REAR WHEEL CYLINDER PISTON

PISTON, REAR WHEEL CYLINDER
SEAL, REAR WHEEL CYLINDER PISTON
SPRING, REAR WHEEL CYLINDER PISTON
BODY, REAR WHEEL CYLINDER
CAP, BLEEDER VALVE
PC00085C2-F-R~
Figure 8 - Rear Wheel Cylinder Components
WHEEL CYLINDER
Figures
!+!+I Disassemble
1. Wheel cylinder completely from vehicle. Refer to
"Wheel Cylinder" under "On-Vehicle Service" in
this section.
2. Boots (22).
3. Pistons (23) and seals (24).
4. Piston spring (25).
5. Bleeder valve cap (34).
6. Bleeder valve (20) from wheel cylinder body (26).
!Ll 1nspect
Balance
During manufacture, weights are used to balance
drum assemblies. Do not remove these weights.
After drum assemblies have been refinished, or
when maintaining proper wheel balance is difficult, check
the drum assemblies for balance. They can be checked on
most off-the-vehicle balancers. If found to be out of balance, replace drum assembly.
NOTICE: Be careful not to drop the brake drum assemblies during handling. Out-of-round can occur
from even the smallest fall, resulting in brake
pulsation.
Wheel cylinder bore for scoring, nicks, corrosion

and wear.
l~I Clean
1. All parts in clean denatured alcohol.
3. Lubricate new seals (24) with clean brake fluid.
l+!+I Assemble
section.
1. Bleeder valve (20).
!~I
3. Piston spring (25).

Tighten
4. Seals (24), pistons (23) and boots (22).

2. Bleeder valve cap (34).

SPECIFICATIONS
Rear Wheel Cylinder Bore Diameter ..................................... 20.6 mm (0.81 ")
Brake Lubricant ..................................................... GM P/N 1052196
Rear Brake Drum Assembly
Inside Diameter (Nominal) ........................................ 241.30 mm (9.500")
Runout .......................................................... 0.15 mm (0.006")
Maximum Refinish Diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 242.82 mm (9.560")
Discard Diameter ............................................... 243.59 mm (9.590")
All rear brake drum assemblies have a discard dimension cast into them. This is a wear dimension
and not a refinish dimension. Any rear brake drum assembly which does not meet the specification
should be replaced.

Rear Brake Backing Plate Nut ......................................... 58 Nm (43 lb. ft.)
Rear Brake Bleeder Valve .............................................. 6 Nm (53 lb. in.)
Rear Brake Rear Pipe Fitting .......................................... 17 Nm (13 lb. ft.)
Rear Wheel Cylinder Bolt/Screw ...................................... 13 Nm (115 lb.'in.)
SPECIAL TOOLS
1.
2.
~
~
J8049
J8057
3.
J 21177-A
1. BRAKE SPRING REMOVER AND INSTALLER

2. BRAKE SPRING PLIERS
3. DRUM-TO-BRAKE SHOE CLEARANCE GAGE
PC60085C2DRP
VACUUM BOOSTER SYSTEM 501-1
SECTION 501
VACUUM BOOSTER SYSTEM

result.
CONTENTS
General Description . . . . . . . . . . . . . . . . . . . . . . . 5D 1-1
Power Brake Booster Assembly ........... 501-1
On-Vehicle Service ....................... 501-2
Power Brake Booster Assembly ........... 501-2
Power Brake Booster
Vacuum Hose and Routing . . . . . . . . . . . . . 5D 1-4
GENERAL DESCRIPTION
POWER BRAKE BOOSTER ASSEMBLY
The power brake booster assembly is a tandem vacuum suspended unit. In a normal operating mode, with the
Vacuum Check Valve ....................

Pushrod Gaging Procedure . . . . . . . . . . . . . . .
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Special Tools ............................
501-4
SD 1-4
SD 1-5
501-5
501-5
service brakes in the released position, the tandem vacuum suspended booster assembly operates with vacuum
on both sides of its diaphragms. When the brakes are
applied, air at atmospheric pressure is admitted to one side
of each diaphragm. The air is then drawn from the booster
through the vacuum check valve to the vacuum source.
A PIPE, AIR INJECTION REACTION

B
C
D
2
3
J
30
31
32
33
3'
MANIFOLD, EXHAUST
FITIING, EXHAUST MANIFOLD
FITIING, ENGINE
BOOSTER ASSEMBLY, POWER BRAKE
VALVE, POWER BRAKE BOOSTER VACUUM CHECK
HOSE, POWER BRAKE BOOSTER VACUUM
CLAMP, POWER BRAKE BOOSTER VACUUM HOSE
BODY, BRAKE MASTER CYLINDER
Figure 1 - Vacuum Booster Hose Routing (5.7L LT1 Engine)
PC0001-501-F-RP
501-2 VACUUM BOOSTER SYSTEM

NOTICE: Internal components of this booster are
not serviceable. The housing must not be unstaked
and separated. Separating the housing will cause
permanent deformation, preventing the booster
assembly from holding proper volume.
ON-VEHICLE SERVICE
rn

parts as damage to rubber parts may result.
3. Nuts (1) attaching master cylinder assembly (2) to

booster assembly (3).
4. Master cylinder assembly (2).
Move master cylinder assembly (2) forward

and toward driver's side to provide clearance
for booster assembly (3). This will flex brake
pipe assemblies slightly. Take care not to bend
or distort brake pipe assemblies.
5. Lower sound insulator assembly. Refer to SECTION 8C.
Important

to service this booster assembly.
Lubricate rubber parts with silicone grease to ease
assembly.
fasteners.
POWER BRAKE BOOSTER ASSEMBLY

Figures 1 through 3
6. Nuts (5) attaching booster assembly (3) to brake

pedal assembly (20).
7. Loosen nut (40).
8. On vehicle with manual transmission assembly,
loosen nuts (41 ).
9. Pull back on brake pedal assembly (20) to access
nuts (35).
10. Nuts (35) attaching booster assembly (3) to dash
panel assembly.
Discard nuts (35) needed for production purposes only.
11. Pushrod (6) from brake pedal pin.

l. Secondary air injection system (AIR) pipe from fitting on exhaust manifold, if necessary.
Move AIR pipe out of the way.
2. Clamp (31) and vacuum hose (30) from check valve
(4).
A. From inside vehicle, remove retainer ( 16) and

washer (15).
B. Tilt entire booster assembly (3) slightly to

work pushrod (6) off brake pedal pin without
putting undue side pressure on pushrod (6).
12. Booster assembly (3) from vehicle.
A
2
3
4
30
31
32
33
34
FITIING, ENGINE
BOOSTER ASSEMBLY, POWER BRAKE
VALVE, POWER BRAKE BOOSTER VACUUM CHECK
HOSE, POWER BRAKE BOOSTER VACUUM
BODY, MASTER CYLINDER
Figure 2 - Vacuum Booster Hose Routing (3.4L L32 Engine)
PC0002-5D1F-RP
VACUUM BOOSTER SYSTEM 5013
35
40
j_
<."""
15
10
6
16
A POWER BRAKE BOOSTER PUSHROD INSTALLED TO

BRAKE PEDAL LEVER PIN
B PANEL ASSEMBLY, DASH
C PIN, BRAKE PEDAL LEVER
1 NUT, BRAKE MASTER CYLINDER, 43 Nm (32 LB. FT.)
2 CYLINDER ASSEMBLY, BRAKE MASTER
5 NUT, BRAKE PEDAL BRACKET, 25 Nm (18 LB. FT.)
6 PUSHROD, POWER BRAKE BOOSTER
10 BOLT/SCREW, POWER BRAKE BOOSTER MOUNTING

16 RETAINER, BRAKE PEDAL PUSHROD
30 HOSE, POWER BRAKE BOOSTER VACUUM
31 CLAMP, POWER BRAKE BOOSTER VACUUM HOSE
33 BODY, BRAKE MASTER CYLINDER
34 RESERVOIR, BRAKE MASTER CYLINDER (PUSH-ON)
35 NUT, POWER BRAKE BOOSTER ASSEMBLY
41 NUT, CLUTCH MASTER CYLINDER, 27 Nm (20 LB. FT.)
PC0003-5D1-F-RP
Figure 3 - Removing and Installing Power Brake Booster Assembly

(Manual Transmission Shown - Automatic Transmission Similar)
l++I
Nut (40) to 25 Nm (18 lb. ft.).

Install or Connect

section.
1. Booster assembly (3) onto vehicle.
2. Pushrod (6) to brake pedal pin.
A. Tilt entire booster assembly (3) slightly to
work pushrod (6) onto brake pedal pin without
putting undue side pressure on pushrod (6).
B. From inside vehicle, install washer (15) and
retainer (16).
3. Nuts (5).
l~I
Nuts (41) to 27 Nm (20 lb. ft.) on vehicle with

4. Master cylinder assembly (2) to booster assembly
(3) and nuts (1).
l~I
Tighten
Nuts (1) to 43 Nm (32 lb. ft.).

5. Vacuum hose (30) and clamp (31) to check valve (4 ).
6. Lower sound insulator assembly. Refer to SECTION 8C.
7. AIR pipe to fitting on exhaust manifold, if removed.

Tighten
Nuts (5) to 25 Nm (18 lb. ft.) in sequence:

inboard upper, outboard lower, outboard
upper, inboard lower.
l~I
Tighten
AIR pipe-to-exhaust
34 Nm (25 lb. ft.).
manifold
fitting
to
501-4 VACUUM BOOSTER SYSTEM
POWER BRAKE BOOSTER VACUUM HOSE

AND ROUTING
Figures 1 and 2
Refer to Figures I and 2 for routing of the vacuum
hose (30).
VACUUM CHECK VALVE

Figure 4
Vacuum check valve and grommet can be inspected
and/or serviced without removing booster assembly from
vehicle.
l++I
I. Clamp (31) and vacuum hose (30) from check valve

(4).
2. Check valve (4) and grommet (9).
ll'l'I
Inspect
Grommet (9) and vacuum hose (30) for cuts, nicks

and excessive wear.
- Replace grommet (9) or vacuum hose (30) if
damaged.
l~I
Clean
1. All parts in denatured alcohol.

l++I
Install or Connect
1. Lubricate inner and outer diameters of grommet (9)

with thin layer of silicone grease GM PIN 12345579
or equivalent.
2. Grommet (9) and check valve (4).
3. Vacuum hose (30) and clamp (31) to vacuum check
valve (4).

g GROMMET, POWER BRAKE BOOSTER VACUUM CHECK
VALVE
30 HOSE, POWER BRAKE BOOSTER VACUUM
31 CLAMP, POWER BRAKE BOOSTER VACUUM HOSE
PC00055D1-fRP
Figure 4 - Vacuum Check Valve and Grommet
PUSHROD GAGING PROCEDURE

Figure 5
Tool Required:
J 37839 Pushrod Height Gage
l@I
Measure
1. Gage booster assembly with 85.0 kPa (25 in. Hg.)

vacuum or maximum engine vacuum available.
Booster assembly can be gaged without being
installed on vehicle, if a suitable vacuum
source is available.
2. Position J 37839 over pushrod (6).
Check both maximum and minimum rod
length.
3. If pushrod (6) length does not fall between maximum and minimum dimensions, use a serviceadjustable pushrod to obtain correct length.

PC0006-5D1F-RP
Figure 5 - Gaging Power Brake Booster Pushrod
VACUUM BOOSTER SYSTEM 501-5
SPECIFICATIONS
Brake Master Cylinder Nut ............................................
Brake Pedal Bracket Nut ..............................................
Brake Pedal Nut ....................................................
Clutch Master Cylinder Nut ...........................................
Secondary Air Injection System (AIR) Pipe-to-Exhaust Manifold Fitting .......
43 Nm (32 lb.
25 Nm (18 lb.
25 Nm (18 lb.
27 Nm (20 lb.
34 Nm (25 lb.
ft.)
ft.)
ft.)
ft.)
ft.)
SPECIAL TOOLS
1.
J 37839
1. PUSHROD HEIGHT GAGE

PC0010-501-FRP
ANTILOCK BRAKE SYSTEM SE1-1
SECTION SE1
ANTILOCK BRAKE SYSTEM

CAUTION: To help avoid personal injury due to poor braking, DO NOT tap into the
vehicle's brake system to operate a trailer brake system.
NOTICE: When fasteners are removed, always install them at the same location from which they were
removed. If a fastener needs to be replaced, use the correct part number fastener for that application. If
the correct part number fastener is not available, a fastener of equal size and strength (or stronger) may be
used. Fasteners that are not reusable, and those requiring thread-locking compound will be called out.
The correct fastener tightening specification must be used when installing fasteners. If the above
conditions are not followed, system damage could result.
NOTICE: The use of rubber hoses or parts other than those specified for the Anti lock Brake System (ABS)
may lead to functional problems requiring replacement of the hydraulic parts. Replace all components
included in repair kits used to service this system. Lubricate rubber parts with clean, fresh brake fluid to
ease assembly. Do not use lubricated shop air on brake parts as damage to rubber components may result.
If any hydraulic component is removed or brake line disconnected, it may be necessary to bleed all or part
of the brake system. The fastener tightening specifications specified are for dry, unlubricated fasteners.
NOTICE: Use only Supreme 11 (GM 1052542) or equivalent DOT 3 brake fluid. The use of DOT 5
(silicone) brake fluid is not recommended. Reduced braking performance or durability may result.
NOTICE: Avoid spilling brake fluid on any of the vehicle's painted surfaces, wiring, cables or electrical
connectors. Brake fluid will damage paint and electrical connections. If any fluid is spilled on the vehicle,
flush the area with water to lessen the damage.
DELGO CHASSIS ABS VI TECHNICA~ ASSISTANCE

For 1993 model year, Delco Chassis Division has an ABS VI field service plan in place. This plan has
been developed to improve customer satisfaction. The plan is set up to help Delco Chassis understand each
field malfunction and to allow them to obtain all failed components back for detailed analysis. With t his
direct field contact, they are able to continuously improve the ABS components.
The plan consists of a Technical Assistance Hotline, staffed by Delco Chassis personnel, that you must
phone to create a technical assistance case before ordering parts for any ABS VI malfunction (all ABS VI
part are on restriction and can only be ordered through this hotline). Please be prepared to provide specific
diagnostic trouble code information, VIN ;md dealer code when phoning for a part or for assistance. The
phone number is 1-800-523-0203.
CONTENTS
General Description 5E1-2
Abbreviations/Definitions SE 1-2
Basic Knowledge Required 5E1-3
5E1-3
System Operation
Base Braking Mode SE 1-3
Antilock Braking Mode
5E1-4
System - Selflest (Initialization) SE 1-5
Warning/Indicator Lamp Operation 5E1-6
Normal Lamp Operation SE 1-6
Tires and ABS SE 1-6
Spare Tire SEf-6
Replacement Ti res 5E1-6
System Components
Hydraulic Modulator/Motor Pack
Assembly
Electronic Brake Control Module
(EBCM)
Front Wheel Speed Sensors
Front Wheel Speed Sen~or ~ings
Rear Wheel Speed Sensor and Ring
Enable Relay
Brake Combination Valve
Wiring Harness
Wheel Speed Sensor

Jumper Harness
SE 1-6
SEl-6
SEl-7
SE1-7
5E1-7
5E1-7
SE1-8
5E1-8
5E1-8
SEl-8
5E1-2 ANTILOCK BRAKE SYSTEM
Warning/Indicator Lamps SE1-8

Hydraulic Modulator
Fuses and Fusible Links SE1-8
Manual Flush
Component Location Views SE 1-8
Hydraulic Modulator
Diagnosis-Electrical SE 1-8
Bleeding Procedure
Diagnostic Process SE 1-8
Rehome Procedure
Diagnostic Process ( 1 of 3) SEl-9
Pressure Bleeding
Self-Diagnostics SEl-12
Hydraulic Modulator
Displaying Diagnostic Trouble Codes
Brake Pipe Connections
(DTCs) SE 1-12
Wheel Brakes
Clearing Diagnostic Trouble Codes
Manual Bleeding
(DTCs) SE 1-12
Hydraulic Modulator
Tech 1 Method SE 1-12
Wheel Brakes
Ignition Cycle Default SE 1-12
Hydraulic Modulator Bleeder Valves
lntermittents and Poor Connections
SEl-13
Hydraulic Modulator Solenoid
Tech 1 Diagnostics SE 1-13
Hydraulic Modulator/Motor Pack
Enhanced Diagnostics SEl-13
Assembly
Diagnostic Circuit Check SE 1-16
Diagnostic Trouble Code and
(EBCM)
Symptom Table SE 1-18
Front Wheel Bearing and Speed Sensor
Wiring Diagram (1 of 2) SEl-20
Assembly ...
EBCM Connector Face View ( 1 of 2) SE 1-22
Front Wheel Speed Sensor Jumper
Diagnosis- Hydraulic SE 1-158
Harness
Automated Self-Diagnosing
Rear Wheel Speed Sensor
Modulator Test SE 1-158
Rear Wheel Speed Sensor Toothed
Automated Motor Pack
Ring
Diagnosis Test SEl-158
Rear Wheel Speed Sensor Jumper
No Gear Movement SE 1- 158
Harness
Hydraulic Functional Control
SEl-158
Enable Relay
Motor Testing SEl-158
Motor Pack Functional Test
SE1 - 1S9
Warning/Indicator Lamps
Solenoid Test SEl-159
Electrical Connectors
Enable Relay Test SE1-1S9

Fuse and Fusible Links
Voltage Load Test SE1-1S9 Unit Repair
Gear Tension Relief Sequence SE1-1S9
Gear Cover
Lamp Tests SEl-160
Motor Pack
Motor Rehome Function SE 1-160
Gear Replacement
On-Vehicle Service SEl-160
Hydraulic Modulator

Service Precautions SEl-160
Master Cylinder
Checking and Adding Fluid SEl-160 Specifications
Flushing Procedure SEl-162
Fastener Tightening Specifications
Pressure Flush SEl-162 Special Tools
GENERAL DESCRIPTION
This section contains information about the ABS
VI antilock brake system.
ABS Vl provides improved stability and
steerability which allows the vehicle to be steered
around obstacles during a panic stop. ABS operation is
available from approximately 5 km/h (3 mph) to the
maximum vehicle speed. ABS Vl CANNOT
INCREASE BRAKE PRESSURE ABOVE MASTER
CYLINDER PRESSURE APPLlED BY THE DRlVER
AND CANNOT APPLY THE BRAKES BY ITSELF.
SE 1-162
SEl - 163
SEl-163
SEl-164
SEl-164
SEl-164
SE1-164
SE1-164
SE1-165
SEl-166
SEl-166
SE 1-166
SEl-167
SEl-167
SEl-168
SE1-169
SEl-170
SEl-170
SEl-171
SEl-171
SEl-171
SEl-171
SEl-171
SEl-173
SEl-173
SEl-173
SEl-173
SEl-173
SEl-173
SEl-174
SEl-174
SEl-176
SEl-176
SEl-176
SEl-176
ABBREVIATIONS/DEFINITIONS
Several abbreviations are commonly used
throughout this section. They are presented here for
reference.
ABS
B+
CKT
CPA
DLC
DTC
DVM
EBCM
ESB
Infinite
Anti lock Brake System

Battery Voltage
Circu it
Connector Position Assurance
Data Link Connector
Diagnostic Trouble Code

Digital Multimeter
Expansion Spring Brake
Open Circuit/Unmeasurably High Resistance
. A.NTILOCK BRAKE SYSTEM ' SE1-3

BASIC KNOWLEDGE REQUIRED
Before using this section, it is important that you

have a basic knowledge of the following items.
Without this basic knowledge, it will be difficult to use
the diagnostic procedures contained in this section.
If you need a review of basic electrical
troubleshooting knowledge, SECTION BA contains
helpful information in the introduction. Basic use of
circuit testing tools is also covered in SECTION BA.
Basic Electrical Circuits - You should understand

the basic theory of electricity and know the
meaning of voltage, current (amps) and resistance
(ohms). You should understand what happens in a
circuit with an open or shorted wire . You should
be able to read and understand a wiring diagram.
Use of Circuit Testing Tools - You should know

how to use a test light and how to use fused jumper
wires to bypass components to test circuits. You
should be familiar with the High Impedance
Multimeter (DVM) J 39200. You should be able to
measure voltage, resistance and current and be
familiar with the meter controls and how to use
them correctly.
SYSTEM OPERATION
Base Braking Mode

Under normal operating condit ions, the brake
systems will operate using conventional braking by
means of brake pedal force , the vacuum booster and
the compact maste r cylinder. Each front ch~nnel
consists of a motor, solenoid, ESB, ball screw, piston,
and check valve. As illustrated in Figure 1, under
normal operat ing conditions (base brakes), the piston
is held in the . upmost (or "home") position. This is
a ccomplished by turning the screw via the motor to
drive the nut upwards . Once at the upmost (or
" home") position, the piston is held by an Expansion
Spring Brake (ESB). An ESB is ~ spring that is
retained in a housing at a close tolerance. One end of
the spring is in contact with the motor drive dog and
the other end is in contact with the pinion drive dog
(see Figure 2). In normal braking, brake pressure is
present on the top of the piston, applying a downward
force. This for'ce applies a counterclockwise torque to
the _motor pinion which tries to rotate the spring
counterclockwise. The counterclockwise torque
expands the spring outward within the hous ing and
prevents gear ~otation. While at the upmost position,
the piston also unseats the check valve via a
protrusion on the piston. Two (2) paths are then
available to transfer braking press ure to the wheel :
(1) through the modulator, around the check valve,
and out to the ~wheel, (2) through the modulator,
through the nor mally open solenoid, and out to the
wheel. The solenoid in the front circuits provides an
CHECK VALVE CLOSED
SOLENOID ENERGISED
INCREASING PRESSURE FROM COMBO VALVE
SOLENOID VALVE CLOSEQ
FRONT MODULATOR
6 . BALL SCREW SPINDLE TURNED TQ LOWER PISTON

7
PISTON LOWERED TO SEAT ,CHECK VALVE
PRESSURE TO FRONT BRAKE HELD CONSTANT

NS 16301
Figure 1 - Front Base Braking Mode , , . :
alternate brake pressure path to the wheel. With .this

arrangement, if the ABS were to lose powe~ or
malfunction with the piston not in its home position, a
redundant brake fluid path is always available. See
Figure 1.
'
' .
The rear channels operate in a similar manner
except: (1) Both rears are con.troJled together and (2)
no solenoid exists. Both rear channels are controlled
by one motor to simplify the d esign. , Since ABS
operates on a select low principle (if either rear wheel
begins to l,ock, brake pressure to both rear' wheels is
reduced to maximize vehicle stability) both rear
brakes are controlled togeth~r.

There is no rear solenoid due to the nature of the
braking system . The vast majority ' of braking :i's. :
accomplished with the front brakes. If an ABS failu~e
were to occur that affected th~ operation or" the
base brakes, a diagnostic trouble code would be stored
and the EBCM would turn "ON" both the amber "Aiis
INOP" lamp and the red "BRAKE" warning lamp.
~~ar

I
2~
MOTOR DRIVES
CLOCKWISE
4
MOTOR DRIVE DOG RELEASES
SPRING BRAKE AND DRIVES PINION
CIRCLIP
MOTOR PINION
PINION DRIVE DOG
EXPANSION SPRING BRAKE (ESB)
MOTOR DRIVE DOG
MOTOR SHAFT
STEEL SLEEVE
MOTOR DRIVE DOG RELEASES SPRING BRAKE

(SPRING LEG BENEATH PINION DOG)
AND DRIVES PINION
10
PINION DOG EXPANDS SPRING AND

LOCKS AGAINST SLEEVE
MS 12381
Figure 2 - Expansion Spring Brake
Antilock Brakin g Mode

ABS VI has been designed to improve the
controllability and steerability of a vehicle during
braking. ABS VI accomplishes this objective by
controlling the hydraulic pressure applied to each
wheel brake. Antilock braking occurs only when the
brake switch is closed and a microprocessor, located in
the EBCM, determines one or more wheels is about to
lose traction during braking. The EBCM will then
a llow the hydraulic modulator to change the brake
pressures several times each second to kee p the
wheel(s) from locking and provide the driver with
maximum vehicle controllability. ABS VI CANNOT
INCREASE THE BRAKE PRESSURE ABOVE THE
MASTER CYLINDER PRESSURE APPLIED BY
THE DRIVER , AND CANNOT APPLY THE
BRAKES BY ITSELF.
The result is greatly improved braking, enabling
the driver to more easily maintain steerability and to
bring the vehicle to a controlled stop. ABS VI provides
effective braking and directional control over a wide
range of road surfaces and driving conditions.
If any wheel(s)/wheels begins to approach lock-up,
the ABS EBCM will control the three (3) motors and
two (2) solenoids, appropriate ly, to cont r ol brake
pressure to the affected wheel/wheel(s). During front
wheel ABS operation, the solenoids are turned "ON" to
isolate that brake press ure path to the wheel (see
Figure 3). The EBCM then provides controlled current
to the motors to regulate the speed and amount of

movement. When the motor is turned "ON" and tries
to drive the ball screw nut, the end of the ESB in
contact with the motor drive dog rotates inward
causing the spring to contract in its housing allowing
the motor to rotate the modulator gear (see Figure 2).
The most common application of this principle is in
window crank mechanisms, whe re a small amount of
force on the crank handle allows the window to be
lowered or raised, but the weight of the window or
force on the window will not allow the window to move
downward. For the ESB, brake pressure on the top of
the pis~ons corresponds to the weight of the window
and the motor corresponds to the window crank
handle. As the motors move backwards, the piston
follows the nut downward, allowing the check valve to
seat. The brake pressure to the wheel is now a
function of the controlled volume within the piston
chamber. To reduce brake pressure, the motor drives
the nut further downward. To reapply or increase
brake pressure, the motor drives the nut and piston
upward . If ABS was entered during low brake
pressure, such as on ice, and dry pavement is then
encountered during reapply, the piston is driven all
the way to the top. This results in the unseating of the
check valve, and a return to base brakes until
sufficient brake pr essure exists to cause the wheel to
approach lock-up again. At this point, the ABS cycle
would start again.
ANTILOCK BRAKE SYSTEM 5E1-5

INLET FROM COMBO VALVE
CHECK VALVES CLOSED

CHECK VALVE CLOSED
SOLENOID VALVE
2 CLOSED
3 INLE-T FROM COMBO
VALVE
f.?f~ktJION
.,~~1,iiL'
1T10N
POSITION
BALL SCREW IN NMODULATIONH

POSITION
,~:~~u~=)
MODULATED PRESSURE TO REAR BRAKES

PISTON LOWERED TO REDUCE PRESSURE
SPRING
8 FRONT MODULATOR MOTOR
EXPANSION SPRING BRAKE (ESB) LOCATION
g MODULATED ABS PRESSURE
MOTOR PINION
YOKE ON BALL SCREW DRIVES BOTH REAR
CIRCUIT PISTONS
MODULATION CHAMBER
TO FRONT BRAKE
NS
NS 16299
Figure 3 Front ABS Braking Mode
Total brake pressure during ABS is limited to the

brake pressure present .~hen ABS was entered. Also,
any. time wheel brake pressure exceeds the brake
pres!;!ure at' the master cylinder (caused by reduced
force on the brake pedal), the check valve unseats and
a small volume of brake fluid is returned to the master
cylinder to equalize pressure. ln this manner, ABS VI
CANNOT INCREASE BRAKE PRESSURE ABOVE
MASTER CYLINDER PRE~S URE APPLIED BY
THE DRIVER AND CANNOT APPLY THE BRAKES
BY ITSELF. When ABS is no longer required, the
pistons are returned to their upmost (or "home")'
porition and the solenoids on the front channels are
opened to again provide a redundant base braking
path.
'
The rear channel operates in a similar manner
except no solenoid is used (refer to Figure 4). Both rear
brake pressu~es are controlled by t he same motor and
both rear brake pressures are maintained at nearly
equal levels.
16300
Figure 4 Rear ABS Braking Mode
System - Self Test (Initialization)

Upon ignition, the ABS VI system goes through .an
initialization sequence during which the EBCM
performs self-diagnostics ;rnd ABS VI component
diagnostics. The EBCM will verify motor, solenoid,
relay, and lamp operation by using specific component
control schemes to ensure that all component's are
functioning properly. The EBCM also checks the
wheel speed sensor circuitry for shorts to ground or
voltage at this time. If th.e EBCM detects a
malfunction in either itself or other .ABS VI
components, it will store ,a diagnostic trouble code and
turn "ON" the ABS warning lamp ("ABS INOP") if
applicable.
During initialization, the "ABS INOP" lamp, will
be "ON" for about 3 seconds with the key in the "RUN"
position. During cranking, the "ABS INOP" lamp will
be "ON" and remain "ON" for about 3 seconds after the
engine starts.
SE1-6 ANTILOCK BRAKE SYSTEM

The ABS active lamp "LOW TRAC" will turn "ON"
only when the EBCM commands the motors "ON"
briefly for diagnosis after the engine is started. On
3.4L V6 equipped vehicles, the EBCM commands the
motors "ON" shortly after the engine is started. If
your foot is on the brake pedal when the engine starts,
the system will not initialize until your foot is removed
from the brake pedal or the vehicle speed exceeds 5
km/h (3 mph). On 5.7L VS equipped vehicles, the
EBCM commands the motors "ON" when the vehicle
speed exceeds approximately 5 km/h (3 mph). On both
3.4L V6 and 5.7L VS equipped vehicles, the "LOW
TRAC " lamp will remain "ON" for only a short period
of time (about l second). A slight mechanical noise
may be heard during the system initialization and
should be considered normal. If foot pressure on the
brake pedal interrupts the system initialization, a
slight movement in the pedal may be felt .
Warning/Indicator Lamp Operation

Normal Lamp Operation
The standard brake system uses a single red

"BRAKE" warning lamp located in the instrument
panel cluster.
The antilock b rake system uses one amber
warning lamp, one a mber indicator lamp, and one red
warning lamp. The warning lamp is the same red
"BRAKE" warning lamp used for the standard brake
system, while the one amber warning lamp is the
"ABS INOP" lamp, and the one amber indicator lamp
is the "LOW TRAC" lamp.
l. When the ignition is turned to the "RUN" position,
prior to starting the engine, the amber "ABS
INOP" lamp should turn "ON" for about 3 seconds.
The red "BRAKE" warning lamp will quickly flash
"ON" also.
2. As the engine is cranked, both the red ''BRAKE"
warning lamp and the a mber "ABS INOP"
warning lamp will come "ON."
3. After the engine is started, the red " BRAKE"
warning lamp will turn "OFF." On 3.4L V6
equipped vehicles, the amber "LOW TRAC" lamp
will flash briefly "ON" at this time to indicate the
ABS motor movement for initialization. On 5.7L
VS equipped vehicles, the amber "LOW TRAC"
lamp will not flash briefly "ON" until the vehicle
speed exceeds approximately 5 km/h (3 mph).
4. Approximately 3 to 4 seconds after the engine is
started, that amber "ABS INOP" lamp should turn
"OFF."
5. Anytime the EBCM determines that the vehicle
has entered a braking event where ABS is
required, the amber "LOW TRAC" lamp will turn
"ON " to indicate that ABS is active. The amber
" LOW TRAC" lam p will r e main "ON" for
approximately 3 to 4 seconds after the ABS event

is completed.
For further information regarding the warning
and indicator lamp operation, refer to
"Warning/Indicator Lamps" in this section.
Tires and ABS

Spare Tire
Using the compact spare supplied with the vehicle

will not affect the operation of the ABS system.
However, reduced stopping distances may occur due to
reduced tire tread depth.
Replacement Tires
Tire size is important for proper performance of the

ABS system. Replacement tires should be the same
size load range and construction as the original tires.
Replace tires in axle sets and only with tires of the
same TPC (Tire Performance Criteria) specification
number. Use of any other tire size or type may
seriously affect the ABS system operation. For more
information on original equipment and replacement
tires, refer to SECTION 3E.
SYSTEM COMPONENTS
The ABS VI Antilock Braking System (ABS)
consists of a conventional hydraulic brake system plus
antilock components . The conventional brake system
includes a vacuum power booster, master cylinder,
front disc brakes, rear disc or drum brakes,
interconnecting hydraulic brake lines, brake combo
valve and switch, and a red "BRAKE" warning lamp.
The ABS .components include a hydraulic
modulator/motor pack assembly, an Electronic Brake
Control Module (EBCM), a system enable relay, three
(3) wheel speed sensors, interconnect wiring, an amber
"ABS INOP" lamp, and an amber "LOW TRAC" lamp
(refer to Figure 5).
Hydraulic Modulator/Motor Pack Assembly

The basic hydraulic modulator configuration
consists of drive gear subassemblies, ball screws, nuts,
pistons, and hydraulic check valves. The hydraulic
modulator/motor pack assembly controls hydraulic
pressure to the front calipers and rear calipers or
wheel cylinders by modulating hydraulic pressure to
prevent wheel lock-up. For more information, refer to
"Base Braking Mode" and "Anti lock Braking Mode" in
this section.
MODULATOR ASSEMBLY
(REMOTE MOUNTED AT LEFT
FRONT UNDERHOOD)
EBCM
(ABOVE DRIVER'S SIDE KICK PANEL)
LAMP DRIVER MODULE

(INTEGRATED INTO J.P. CLUSTER)
ENABLE RElAY
(IN A RELAY CENTER MOUNTED

TO THE LEFT FRONT FENDER
UNDER HOOD)
INTEGRAL FRONT
SPEED SENSORS
(ONE AT EACH FRONT WHEEL)
NS 16302
. Figure 5 ABS-VI Component Location View
Electronic Brake Control Module (EBCM)

The controlling element of ABS VI is a
microprocessor based Electronic Brake Control
Module, or EBCM. Inputs to the system include three
(3) wheel speed sensors, the brake switch, ignition
switch, and unswitched battery voltage. Outputs
include three (3) bidirectional motor controls, three (3)
lamp controls, two (2) solenoid controls, and the
system enable relay. A bidirectional serial data link,
located in pin "M" of the Data Link Connector (DLC),
is provided for service diagnostic tools and assembly
plant testing.
The EBCM monitors the speed of each wheel. If
any wheel begins to approach lock-up and the brake
switch is "ON," the EBCM controls the motors and
solenoids to reduce brake pressure to the wheel
approaching lock-up. Once the wheel regains traction,
brake pressure is increased until the wheel again
begins to approach lock-up. This cycle repeats until
either the vehicle comes to a stop, the brake is
released, or no wheels approach lock-up. Additionally,
the EBCM monitors itself, each input (except the
serial data link) and each output for proper operation.
If any system malfunction is detected, the EBCM will
store a DTC in nonvolatile memory (DTCs will not
disappear if the battery is disconnected). Refer to
"Self-Diagnosis" in this section for more detailed
information.
NOTICE: There is no serviceable or removable

PROM. The EBCM must be replaced as an
assembly.
'(
Front Wheel Speed Sensors

The front wheel speed sensors consist of a variable
reluctance sensor and interconnect wiring. Each
sensor is attached to the hub and bearing assembly in
close proximity to a toothed ring. The result, as teeth
pass by the sensor, is an AC voltage with a trequency
proportional to the speed of the wheel. The tilagnitude
of the voltage increases with increasing speed. The
sensor is not repairable, nor is the air gap adjustable.
Front Wheel Speed Sensor Rings

The front wheel speed sensor toothed rings are an
integral part of the hub and bearing assembly. Like
the front wheel speed sensors themselves, they are not
serviceable. If a malfunction is detected in either the
sensor or the toothed ring, the entire hub and bearing
assembly must be replaced.
Rear Wheel Speed Sensor and Ring

'
A single rear wheel speed sensor
is used for this
ABS application and is located on the rear differential.
[t operates in the same manner as the front wheel
speed sensors, refer to "Front Wheel Speed Sensors."

However, the toothed ring is located within the rear
differential and contains 106 equally spaced teeth.
The sensor and toothed ring are not serviceable and no
provision for air gap adjustment exists.
Enable Relay
The enable relay is a normally-open contact type,
and has special contact material to handle the high
currents required for ABS VI operation. The relay
allows the battery voltage and current to be supplied
to the EBCM, which supplies power to the motors and
solenoids.

Refer to "Brake Combination Valve" in SECTION
5A.
Wiring Harness
The wiring harness is the mechanism by which the
EBCM is electrically connected to power and ground,
wheel speed sensors, motors, solenoids, fuses, switches,
lamps, the enable relay and the serial communications
port. The components, considered part of the wiring
harness, are the wires that provide electrical
interconnection and connectors (terminals) that
provide an electrical/mechanical interface from the
wire to a system component.
Wheel Speed Sensor Jumper Harness
Between each wheel speed sensor and the main

wiring harness is a jumper harness made up of highly
flexible twisted pair wiring. This wiring exists
because the main harness must connect to the
sus pension of the vehicle, thus the wiring in this area
is subjected to the same motion as a spring or shock
absorber. Consequently, any repair to this section of
wiring will result in stiffening and therefore, eventual
failure due to wire fracture . For this reason, THE
WHEEL SPEED SENSOR JUMPER HARNESSES
ARE NOT REPAIRABLE AND MUST BE
REPLACED. DO NOT ATTEMPT TO SOLDER,
SPLICE, OR CRIMP THESE HARNESSES AS
EVENTUAL FAILURE WILL LIKELY RESULT.
Refer to "On-Vehicle Service" in this section.
Warning/Indicator Lamps
The Electronic Brake Control Module (EBCM)
continuously monitors itself and the other ABS
components. If the EBCM detects a problem with the
system, the amber "ABS INOP" lamp will either flash
or light continuously (solid lamp) to alert the driver of
the problem. The "ABS INOP" lamp will flash if the
problem does not immediately hamper ABS operation.
However, a flashing "ABS INOP" lamp signals the

driver that repairs must be made to the system as soon
as possible.
A solid "ABS INOP" lamp indicates that a problem
has been detected that affects the operation of ABS.
No antilock braking will be available. Normal, base
brake performance will remain. In order to regain
ABS braking ability, the ABS system must be
serviced.
The red "BRAKE" warning lamp will be
illuminated when the brake pressure differential
switch located in the brake combination valve closes,
the parking brake switch is closed, the bulb test switch
section of the ignition switch is closed, or under control
of the EBCM when certain ABS codes are set. This
lamp indicates to the driver a base brake problem may
exist. Refer to SECTION SA for diagnosis of the
"BRAKE" warning lamp system.
The amber "LOW TRAC" indicator lamp is used to
alert the driver when ABS is active. Anytime the
EBCM dete rmines that the vehicle has entered a
braking event where ABS is required, the amber
"LOW TRAC" lamp will turn "ON" to indicate that
ABS is active. The "LOW TRAC" lamp will remain
"ON" for approximately 3 to 4 seconds after the ABS
event is completed.
Fuses and Fusible Links

The vehicle's power distribution system consists of
fuses, fusible links, circuit breakers, and the ignition
switch. Fusible links are short pieces of wire several
sizes smaller than the circuit wire to which they
supply power. They are covered with special high
temperature in s ulation. When co nducting an
improperly high current flow, they will melt and stop
current flow. They are designed to protect the
vehicle's electrical system from electrical shorts in
circuits that are not protected by circuit breakers or
fuses. For fuse and fusible link locations, refer to
SECTIONS 8A-10 and SA-11.
COMPONENT LOCATION VIEWS

Refer to Figure 5.
DIAGNOSIS-ELECTRICAL
DIAGNOSTIC PROCESS
When servicing the ABS system, the following
steps should be followed in order. Failure to follow
these steps may result in the loss of important
diagnostic data and may lead to difficul t and timeconsuming diagnosis procedures:
DIAGNOSTIC PROCESS
(Page 1 of 3)
;.
ABS CARTRIDGE SELECTION
TECH 1 SCREEN DISPLAY
STEP 1 SELECT VEHICLE MODEL YEAR
MODEL YEAR: 191?
STEP 2 SELECT USAGE
rcAR
. :,._ ~ .,
STEP 3 SELECT MODE (FIRST SCREEN)
FRONT WHL SPEEDS

REAR WHL SPEEDS
VEHICLE SPEED
ABS WARNING LAMP
LF MOTOR COMMAND FWD/REV
LF MOTOR FEEDBAC
RF MOTOR COMMAND FWD/REV
RF MOTOR FEEDBAC
REAR MOTOR CMD FWD/REV
REAR MOTOR FDBK
L FRONT SOLENOID
R FRONT SOLENOID
BRAKE SWITCH
ENABLE RELAY CMD
BR.AKE T-TALE CMD
BRAKE TELLTALE
ABS BATT VOLT AGE
ABS IGN VOLTAGE
FO : DATA LIST
r,h
,,
''
INFORMATION ABOUT
PREVIOUS CODES STORED
F1: CODE HISTORY

I
F2 : TROUBLE CODES
SNAPSHOT OPTIONS
FO: REPLAY DATA
F1 : MANUAL TRIG.
F2 : AUTO TRIG.
F3 : ANY CODE
F4: SINGLE CODE
F9: TRIGGER POINT
F3 : SNAPSHOT
F4: ABS TESTS
FS: MOTOR REHOME
..
CODES STORED AND CLEAR

CODES
FO : BEGINNING
F1 : CENTER
F2 : END OF DATA
It
~
I
I
'
CONTINUED ON FOLLOWING -:
I
CHART
I
(PAGE 2 OF3)
1
~----------- - -- - ------J
RE HOMES MOTORS AND
PISTONS PRIOR TO BLEEDING
THE BRAKE SYSTEM.
12-3-92
NS 16326
DiAGNOSTIC PROCESS
(Page 2 of 3)
r-----------------------,
: CONTINUED FROM PREVIOUS CHART :
~
(PAGE 1 OF 3)
~
1- ---------- ------- ----
ABS TEST
r--- .----------------------------,
FO : MANUAL CNTRL
CONTINUED ON FOLLOWING CHART (PAGE 3 OF 3)
F1: MODULATOR
I AUTOMATED MOOULATOR DIAGNOSIS
F2 : HYDRL. CNTRL
F4:
MOTOR TEST
FS: GEAR TEN REL
I MANUAL TEST OF MODULATOR

HYDRAULICS-APPLY/HOLD/RELEASE FUNCTIONS
.)
I
I ABS MOTOR PACK DIAGNOSIS
PREPARE ABS MODULATOR FOR OFF VEHICLE

SERVICE
F6: RELAY TEST
F7:
VOLTAGE LOAD
L--------------------------------J
I
I
I
I TEST OF ENABLE RELAY
TEST FOR ADEQUATE BATTERY CAPACITY FOR ABS

OPERATION
FB: LAMP TEST
F9: ABS VERSION
: ABS VERSION NUMBER
MANUAL CONTROL OF THE "ABS INOP; "LOW

TRAC; ANO RED "BRAKE" LAMPS
I
I
11-23-92
NS 15761
[;>IAGNOSTIC PRO~ ESS

(Page 3 of 3)
,-----------------~
:
CONTINUED FROM
PREVIOUS CHART
(PAGE 2 OF 3)
:
I
--,--------------
MANUAL CONTROL
RELAY. SOLENOIDS AND
MOTORS
I
f
i
=TURN ON
=TURNOFF
ENTER : RELAY ON/OFF

YES TO CONTINUE
I
SELECT
FO : LFAPPLY
F1: LFRELEASE
F2 : LFSOLENOID
F4: RF APPLY
FS: RF RELEASE
F6: RF SOLENOID
, I
<
F8: REAR APPLY

F9: REAR RELEASE
I
MOTOR APPLY
COMMAND: XAMPS
FEEDBACK: XAMPS
Et,,IAB RELAY: ON/OFF
I
MOTOR RELEASE
COMMAND: . X AMPS
FEEDBACK: XAMPS
ENABRELAY: ON/OFF
I
SOLENOID
COMMAND : ON/OFF
ENABRELAY: ON/OFF
'..
..
I '
11 2392
MS 12565

1.
2.
3.
4.
5.
Using the Tech 1 scan tool, read all current

and history diagnostic trouble codes (F2). Be
certain to note whic h codes are current
malfunctions. DO NOT CLEAR CODES
unless directed to do so.
Using the Tech 1, read the CODE HISTORY
(Fl) data. Note the codes stored and their
frequency of failure. Specifically, note the last
failure that occurred and the conditions
present when this failure occurred. This "last
failure" is what brought the customer in for
service, and should be the starting point for
diagnosis and repair.
Perform a vehicle preliminary diagnosis
inspection . This should include:
Inspection of the master cylinder fluid
reservoir for proper brake fluid level and
signs of fluid contamination.
Inspection of the hydraulic modulator for
any leaks or wiring damage.
Inspection of brake components at all four
(4) wheels. Verify no drag exists. Also,
verify proper brake apply operation.
Ins pection for worn or damaged front
wheel bearings that may allow a wheel to
"wobble."
Inspection of the wheel speed sensors and
their wiring. Verify solid sensor
attachment and undamaged wiring,
especially at vehicle attachment points.
Verify tires meet legal tread depth
requirements .
If no codes are present, or no mechanical
component malfunctions are present, perform
the "Modulator Test" in this section using the
Tech 1 or T-100 to isolate the cause of the
problem. If the failure is intermittent and not
reproduceable, test drive the vehicle while
using the automatic snapshot feature of the
Tech 1. Perform normal acceleration,
stopping, and turning maneuvers. If this does
not reproduce the malfunction, perform an
ABS stop, on a low coefficient surface such as
gravel, from approximately 48-80 km/h (30-50
mph) while triggering the snapshot mode on
any code . If the failure is still not
reproduceable, use the enhanced diagnostic
information found in CODE HISTORY to
determine whether or not this malfunction
should be diagnosed further .
Once all system malfunctions have been
corrected, clear the ABS codes.
SELF-DIAGNOSTICS
The EBCM contain s sophis t icated on-board
diagnostics that, when accessed with a Tech 1 scan
tool, are designed t o identify the source of any system
malfunction as specifically as possible, including 1

whether or not the malfunction is intermittent. There
are 53 diagnostic trouble codes to assist with
diagnosis.
When using the Tech 1 with ABS VI, the last
diagnostic trouble code is specifically identified, and
specific ABS data is stored at the time of this
malfunction. Also, in addition to the last code set,
there is information .a bout the first five codes set.
Using the Tech 1, each input and output can be
monitored, thus enabling malfunction confirmation
and repair verification. Manual control of components
and automated functional tests are also available
when using the Tech 1. Details of many of these
functions are contained in the following sections.
DISPLAYING DIAGNOSTIC TROUBLE CODES

(DTCs)
Diagnostic trouble codes can be read through the
use of the Tech 1 scan tool. There are no provisions for
"Flash Code" diagnostics.
CLEARING DIAGNOSTIC TROUBLE CODES

(DTCs)
The codes in EBCM memory are erased in one of
two ways:
1. Tech 1 "C lear Codes" selection.
2. Ignition cycle default.
These two methods are detailed below. Be sure to
verify proper system operation and absence of codes
when the clearing procedure is completed.
The EBCM will not permit code clearing until all
codes have been displayed. Also, codes cannot be
cleared by unplugging the EBCM, disconnecting the
battery cables, or turning the ignition "OFF" (except
on an ignition cycle default).
Tech 1 Method
Select F2 for diagnostic trouble codes. After codes
have been viewed complete ly, Tech 1 will ask,
"CLEAR CODES"?; answer "YES." Tech I will then
read, "HISTORY DATA WILL BE LOST. CLEAR
CODES"? Answer "YES" and codes will be cleared.
Ignition Cycle Default

This method is discussed for informational
purposes only . Do not use this method to clear codes
during diagnosis.
If no diagnostic trouble code occurs for 100 drive
cycles (a drive cycle occurs when the ignition is turned
"ON" and the vehicle is driven faster than 16 km/h (10
mph)), any existing codes are cleared from the EBCM
memory.

INTERMITIENTS AND POOR CONNECTIONS
As with most electronic systems, intermittent
malfunctions may be difficult to accurately diagnose.
The following is a method to try to isolate an
intermittent malfunction , especially wheel speed
circuitry.
If an ABS malfunction occurs, the ABS warning
lamp will be "ON" during the ignition cycle in which
the malfunction was detected. If it is an intermittent
problem which seems to have cor rected itself (ABS
warning lamp "OFF"), a diagnostic trouble code will be
stored.Also stor ed will be the history data of the code
at the time the malfunction occurred. The Tech 1 must
be used to read ABS history data.
Most intermittents are caused by faulty electrical
connections or wiring, although a sticking relay or
so lenoid can occasionally be at fault. Refer to
"Intermittents and Poor Connections" in SECTION
8A-4 for a very detailed explanation of how to locate
and repair intermittent conditions.
TECH 1 DIAGNOSTICS
The Tech 1 (and T-100), when plugged into the
DLC, become part of the vehicle's electronic system.
The Tech 1 (and T-100) can perform the following
functions:
Display ABS data.
Display and clear ABS diagnostic trouble
codes.
Control ABS components.
Perform extensive ABS diagnosis.
Provide diagnostic testing for intermittent
ABS conditions.
Each test mode has specific diagnosis capabilities
which depend upon various keystrokes. In general,
five (5) keys control sequencing: "YES," "NO,"
"EXIT," up arrow and down arrow. The FO through F9
keys select operating modes, perform functions within
a n operating mode, or enter code or model year
designations (refer to Figure 6) .
In general , the Tech 1 has six (6) test modes for
diagnosin g the antilock brake system. The six (6) test
modes are as follows :
MODE FO: DATA LIST - In this test mode, the
Tech 1 continuous ly monitors wheel speed
data, brake switch status and other inputs and
outputs.
MODE F1: CODE HISTORY - In t his mode, code
history data is displayed. This data includes
how many ignition cycles since the code
occurred, along with other ABS information.
The first five (5) and last code set are included
in the ABS history data.
MODE F2: TROUBLE CODES - In t his te s t
mode, diagnostic trouble codes stored by the
Answer questions asked by the

TECH 1 and scroll through data
parameters.
Return to previous step.
Used to control data display and

output parameters.
[] I
[[I
E.1
Function keys (FO -F 9): used to

select the operating mode or
perform functions which are unique
to the operating mode
Or
Numeric keys (0-9) : used for
entering OTC designations.
Print data in DATA LIST or
SNAPSHOT mode (if used with
optional RS232C 1/F cartridge and
printer, or using Tech 1a and
printer).
Used at end of a numeric key
sequence or to inform TECH 1 that a
requested action has been
completed.
5-7-92
MS 8737-SE
Figure 6 - General Tech 1 Key Functions
EBCM, both current ignition cycle and history,

may be displayed or cleared.
MODE F3: ABS SNAPSHOT - In this test mode,
the Tech 1 captures ABS data before and after
a system malfunction (auto trigger) or from a
manual key press.
MODE F4: ABS TESTS - In this test mode, the
Tech l performs hydr aulic modulator
functional tests to assist in problem isolation
during troubleshooting.
MODE FS: MOTOR REHOME - In this mode,
the Tech 1 commands the EBCM to rehome the
motors on the hydraulic modulator. This mode
should ALWA VS be used prior to bleeding the
brake system.
For more information refer to the ABS section of
the Tech I Operators Manual.
Enhanced Diagnostics
Enhanced diagnostic information, found in the
CODE HISTORY function of the Tech l, is designed to
provide the service technician with specific
malfunction occurrence information. For each of the
first five (5) and the very last diagnostic trouble code
stored, data is stored to identify the specific code, the
number of occurrences, a nd the number of drive cycles
since the ma lfunction first and last occurred (a drive
cycle occurs when the ignition is turned "ON" and the
vehicle is driven faster than 10 mph) .

However, if a malfunction is current, the drive cycle
counter will increment by turning the ignition "ON"
and "OFF." These first five (5) diagnostic trouble
codes are also stored in the order of occurrence. The
order in which the first 5 codes occurred can be useful
in determining if a previous malfunction is linked to
the most recent malfunction, such as an intermittent
wheel speed sensor which later becomes completely
open.
During difficult diagnosis situations , this
informa tion can be used to identify malfunction
occurrence trends. Does the malfunction occur more
frequently now than it did during the last customer
visit? Did the malfunction only occur once over a large
number of drive cycles , indicating an unusual
condition present when it occurred? Does the
malfunction occur infrequently over a large number of
drive cycles, indicating that special diagnosis
techniques may be required to identify the source of
the malfunction?
If, for example, a malfunction occurred 1 out of 20
drive cycles, the malfunction is intermittent and has
not recurred for 19 drive cycles. This malfunction may
be difficult or impossible to duplicate and may have
been caused by a severe vehicle impact (large pot hole,
speed bump at high speed, etc.) that momentarily
opened an electrical connector or caused unusual
vehicle suspension movement. Problem resolution is
unlikely, and the problem may never recur (check
diagnostic aids provided for that code). If, for example,
the malfunction occurred 3 out of 15 drive cycles, the
odds of finding the cause are still not good, but you
know how often it occurs and you can determine
whether or not the malfunction is becoming more
frequent based on an additional or past customer visit
if the source of the problem cannot or could not be
found. If the malfunction occurred 10 out of 20 drive
cycles, the odds of finding the cause are very good, as
the malfunction may be easily reproduced.
By using the additional malfunction data, you can
also determine if a malfunction is randomly
intermittent or if it has not recurred for long periods of
time due to weather changes or a repair prior to this
visit. Say a code occurred 10 of 20 drive cycles but has
not recurred for 10 drive cycles. This means the
malfunction occurred 10 of 10 drive cycles but has not
reoccurred since. A significant environmental change
or a repair may have occurred 10 drive cycles ago. A
repair may not be necessary if customer information
can confirm a recent repair. If no repair was made, the
service technician can focus on diagnosis techniques
used to locate difficult-to-recreate problems.
___
__
_______.__
; f
,.
..
,
)'!
..
,,
\,.
BLANK
...
DIAGNOSTIC CIRCUIT CHECK
The Diagnostic Circuit Check is an organized approach to identifying a problem created by anAntilock Brake
System (ABS) malfunction. It must be the starting point for any ABS complaint diagnosis, because it directs the
Service Technician to the next logical step in diagnosing the complaint.
The scan data listed in the table may be used after completing the Diagnostic Circuit Check a nd finding the
on-board, diagnostics functioning properly and no Diagnostic Trouble Codes displayed.
A TECH 1 THAT DISPLAYS FAULTY DATA SHOULD NOT BE USED, AND THE PROBLEM SHOULD BE
REPORTED TO THE MANUFACTURER. THE USE OF A MALFUNCTIONING TECH 1 CAN RESULT IN
MISDIAGNOSIS AND UNNECESSARY PARTS REPLACEMENT.
Only the parameters listed below are used in this manual for diagnosing. [fa scan tool other than Tech l is
used and reads other parameters, the values are not recommended by General Motors for use in diagnosing.
SCAN DATA
SCAN Position
Units Displayed
FRONT WHL SPEEDS

REAR WHL SPEEDS
VEHICLE SPEED
ABS WARNING LAMP
LF MOTOR COMMAND FWD/REV
LF MOTOR FEEDBAC
RF MOTOR COMMAND FWD/REV
RF MOTOR FEEDBAC
REAR MOTOR CMD FWD/REV
REAR MOTOR FDBK
L FRONT SOLENOID
R FRONT SOLENOID
BRAKE SWITCH
ENABLE RELAY CMD
BRAKE T-TALE CMD
BRAKE TELLTALE
ABS BATT VOLTAGE
ABS IGN VOLTAGE
MPH/KPH
MPH/KPH
MPH/KPH
ON/OFF
AMPS
AMPS
AMPS
AMPS
AMPS
AMPS
ON/OFF
ON/OFF
ON/OFF/CIRCUIT OPEN
ON/OFF
ON/OFF
ON/OFF/CIRCUIT OPEN
VOLTS
VOLTS
11-23-92
MS 12604
VERIFY THAT All ABS CONNECTORS ARE

CONNECTED PROPERLY.
INSTALL TECH 1.
IGNITION "ON," ENGINE " OFF."
SELECT DA TA LIST MODE.
IS DATA BEING RECEIVED FROM THE EBCM?
IGNITION "OFF."
DISCONNECT 32-WA Y EBCM
CONNECTOR.
IGNITION "ON ."
USING J 39200, MEASURE
THE VOLTAGE FROM
GROUND TO TERMINAL
"B11H, THEN " 810" OFTHE
32-WA Y EBCM HARNESS
CONNECTOR.
IS VOLTAGE GREATER THAN
10 VOL TS ON EACH
TERMINAL?
DIAGNOSTIC CIRCUIT CHECK
ARE ANY CURRENT DIAGNOSTIC TROUBLE CODES

(DTCs) DISPLAYED?
REFER TO
APPLICABLE
OTC CHART.
REFER TO THE DIAGNOSTIC TROUBLE CODE

AND SYMPTOM TABLE FOR FURTHER
ASSISTANCE. IF ORIGINAL COMPLAINT
WAS POOR ABS PERFORMANCE, USE TECH
1 AND PERFORM AUTOMATED HYDRAULIC
FUNCTION TEST.
IGNITION " OFF.

DISCONNECT 8-WAY EBCM CONNECTOR.
USINGJ 39200, MEASURE THE RESISTANCE BETWEEN
TERMINAL "E" OF THE 8-WA Y EBCM HARNESS
CONNECTOR AND THE NEGATIVE BATTERY TERMINAL.
IS RESISTANCE 2 Q OR LESS?
USING J 39200, MEASURE THE RESISTANCE

BETWEEN TERMINAL "A11" OFTHE
32-WAY EBCM HARNESS CONNECTOR AND
TERMINAL HMH OF THE DATA LINK CONNECTOR.
USING J 39200, MEASURE THE RESISTANCE BETWEEN

GROUND AND TERMINAL" A 11" OF THE 32-WA Y EBCM
HARNESS CONNECTOR.
DOES J 39200 DISPLAY RESISTANCE AS " Ol" (INFINITE)?
IGNITION "ON."
USINGJ39200, MEASURE THE VOLTAGE
BETWEEN GROUND AND TERMINAL" A 11" OF
THE 32-WAY EBCM HARNESS CONNECTOR.
IS VOLTAGE 1 VOLT OR LESS?
INSTALLECMCARTRIDGE IN TECH 1.
IGNITION "ON."
SELECTDATALISTMODE .
IS DATA BEING RECEIVED FROM THE ENGINE ECM?
REVIEW ENHANCED
DIAGNOSTIC
INFORMATION
IN THIS SECTION .
REPAIR OPEN OR SHORT TO GROUND

IN CIRCUIT THAT 0 10 NOT INOICA TE
AT LEAST 10 VOL TS.
PROCEED TO SECTION 6E3 CHART

A-2, FOR FURTHER DIAGNOSIS.
11 -20-92
NS 15700
DIAGNOSTIC TROUBLE CODE AND SYMPTOM TABLE

PAGE#
CHART
SYMPTOM
I
I
A
B
"ABS INOP" Lamp "ON" or "OFF" Constantly, No DTCs Stored

"ABS INOP" Lamp "ON" Intermittently, No DTCs Stored
"Low TRAC" Indicator Lamp "ON" With Ignition "OFF," No DTCs
Stored
Tech 1 Displays Undefined DTCs
'
I
,-
SE 1-24
SE 1-25
SE1-26
SE 1-27
l
1
DIAGNOSTIC
TROUBLE CODE
DESCRIPTION
A011
'
'
'
A014
A01S
A016
A017
A018
A021
A022
A024
A02S
A026
A028
A032
A033
A03S
A036
A037
A038
A041
A042
A044
A04S
A046
ABS Warning or Active Lamp Circuit Failure

Enable Relay Contacts or Fuse Open
Enable Relay Contacts Shorted to Battery
Enable Relay Coil Circuit Open
SE1-28
SE 1-32
SE 1-38
SE 1-40
SE 1-42
5E1-44
Enable Relay Coil Circuit Shorted to Ground

Enable Relay Coil Circuit Shorted to B + or Coil Shorted
Left Front Wheel Speed
0 (1 of 2)
Right Front Wheel Speed
0 (1 of 2)
Rear Wheel Speed
0 (1 of 2)
Left Front Excessive Wheel Speed Variation (1 of 2)
=
=
Right Front Excessive Wheel Speed Variation ( 1 of 2)

Rear Excessive Wheel Speed Variation (1 of 2)
Left Front Wheel Sensor Shorted to Battery or Ground
Right Front Wheel Sensor Shorted to Battery or Ground
Rear Wheel Sensor Shorted to Battery or Ground
Low System Voltage
High System Voltage
Left Front ESB Wi II Not Hold Motor
Right Front ESB Will Not Hold Motor
'Rear Axle ESB Will Not Hold Motor
SE 1-46
5E1-SO
SE 1-54
SE 1-58
'
SE 1-62
SE 1-66
SE1-70
SE 1-72
SEl-74
SE 1-76
SE 1-78
SEl-80
SEl-82
SE 1-84
Left Front Channel Will Not Move

Right Front Channel Will Not Move
SEl-86
SE 1-98
Rear Axle Channel Will Not Move

Left Front Motor Free Spins ( 1 of 2)
Right Front Motor Free Spins (1 of 2)
Rear Axle Motor Free Spins (1 of 2)
SE 1-90
SE 1-92
SEl-96
SEl-100
SE 1-104
SE 1-106
SE 1-108
A047
A048
A051
A052
A053
AOS4
AOSS
A056
A057
Left Front Channel in Release Too Long

Right Front Channel In Release Too Long
Rear Axle Channel in Release Too Long
EBCM Failure
Left Front Motor Circuit Open
Left Front Motor Circu it Shorted to Ground
AOS8
Left Front Motor Circuit Shorted to Battery or Motor Shorted
SEl-110
SEl-112
SEl - 114
SEl-116
I
I
I
I
DIAGNOSTIC TROUBLE CODE AND SYMPTOM TABLE

PAGE#
DESCRIPTION
A061
A062
A063
A064
AOGS
A066
A076
A077
A078
A081
A082
A086
A087
A088
A091
A092
A093
A094
A095
A096
Right Front Motor Circu it Shorted to Ground

Right Front Motor Circuit Shorted to Battery or Motor Shorted
Rear Axle Motor Circuit Open
Rear Axle Motor Circuit Shorted to Ground
Rear Axle Motor Circuit Shorted to Battery or Motor Shorted
Left Front Solenoid Circuit Shorted to Battery or Open
Left Front Solenoid Circuit Shorted to Ground or Driver Open
Right Front Solenoid Circuit Shorted to Battery or Open
Right Front Solenoid Circuit Shorted to Ground or Driver Open
Calibration Memory Failure
Red Brake Warning Lamp Activated by ABS
Red Brake Warning Lamp Circuit Open
Red Brake Warning Lamp Circuit Shorted to Battery
Open Brake Switch Contacts During Deceleration
Open Brake Switch Contacts When ABS Was Required
OTC A091 or A092 Set in Current or Previous Ignition Cycle
Brake Switch Contacts Always Closed
Brake Switch Circuit Open
Brake Lamps Circuit Open
SE1 -118
SE1-120
SE1-122
SE1-124
SEt -126
SE 1-128
SE 1-130
SE1-132
5E1-134
5E1-136
SEl-138
SE 1-140
SEl-142
SE 1-144
SEl-146
SEl -148
SEl -1SO
5E1-1S2
SE1-1S4
5E1-1S6
EBCM
B+
t,._______f--
ABS BAT
FUSE 1
502RED - - - - ~ ~ - - - - - 4 4 0 0 R N
FUSIBLE
LINK K
5 AMP
ABS SOLENOIDS
IGN
. - - - - - - - 1 - - 6 5 1 BLK/WHT
1
_.___
S111
6101
GAGES
FUSE 9
BRAKE
BRAKE
COMBO
WARNING SWITCH
INSTRUMENT
CLUSTER
BRAKE WARNING
LAMP CONTROL
SEE SA-11-4
39~NK
GROUND
~39PNK
S206
867 LTGRN
L---D
r-,
L -
.J
1537 DKBLU
ABS ACTIVE
LAMP CONTROL
867 LTGRN
ABS FAIL
LAMP CONTROL
C200D
C200A
=CAMARO
= FIREBIRD
--------1~A~-----873VEL
900 BLK - - - - 8 3 0 LT BLU
l!Jt--
C120
LF WHEEL SPEED
SIGNAL LOW
LF WHEEL SPEED
SIGNAL HIGH
LF WHEEL SPEED SENSOR
TAN
0t-t-=======-872833DK GRN
901 WHT--------11G]AB
900 BLK
C130
RF WHEEL SPEED
SIGNAL LOW
RF WHEEL SPEED
SIGNAL HIGH
RF WHEEL SPEED SENSOR
ABS JUMPER HARNESS
REAR WHEEL SPEED SENSOR
1810 WHT--8--1810 WHT-E]-1810 WHT
REAR WHEEL SPEED

SIGNAL HIGH
1811 BLK-----6--1811 BRN - g - 1 8 1 1 BRN
REAR WHEEL SPEED

SIGNAL LOW
C405B
C405C
C200A
C200D
114-93
NS 15663
Figure 7 Wiring Diagram (1 of 2)

EBCM
DATA LINK CONNECTOR
{DLC)
DERM
ECM
C200D
C200A
_ L. 800TAN L 8 0 0 T A N
@-8oOTAN
5270
5225
SERIAL DATA LINE
SWITCHED IGNITION
ENABLE RELAY CONTROL
1632 PNK
1633 RED
SWITCHED BATTERY INPUT
1633 RED
5180
l
~ .
CRUISE
CONTROL
CHMSL
B + STOP HAZARD
~
FUSE 6
~1400RN
20AMP
i .E~
.
5272
C200D
~ 020 VEl 5243 C200A
S271 820 VEl
BRAKE SWITCH INPUT
BRAKE SWITCH
651 BLK/WHT
- - - - - 1288 OK GRN
651 BLK/WHT
t------
5111
UF ABS SOLENOID CONTROL
1289 LT BLU
G101
R/F MOTOR HIGH
R/F MOTOR LOW
1280 BLK
6-WAY
MOTOR PACK
CONNECTOR
IJF MOTOR HIGH
IJF MOTOR LOW
- ~ - 1284 DK GRN
REAR MOTOR HIGH
- -- - -- - 1285 ORN
REAR MOTOR LOW
- --
11-23-92
NS 15664
Figure 8 Wiring Diagram (2 of 2)

..
'
---
ro
C"""
~n
I
LI1
~~
rnrnrnrnrnrnrnrnrnmrnrnrnrnmm
,'
A1
el;
A16
).
~~@@@@@~@@@@@@@@@
~@@@@@@@@@@@@@@@~
[] [] [] [] [] [] [] Q] Q] [] [] [] [] [] Q]
.J
81
'
~c I
I__)
OJ
1'
L
816
I
I
EBCM 32-WA Y CONN ECTOR
CONNECTOR
TERMINAL
CIRCUIT NO.
Al
PLUGGED
A2
PLUGGED
A3
833
TAN
R/ F WHEEL SIGNA L LOW
A4
872
DK GRN
R/ F WHEEL SIGNAL HIGH
AS
1811
BRN
REAR WHEEL SIGNAL LOW
A6
1810
WHT
REAR WHEEL SIGNAL HIGH
A7
873
YEL
L/ F WHEEL SIGNAL LOW
AS
830
LTBLU
L/F WHEEL SIGNAL HIGH
LTSLU
R/ F ABS SOLENOID
TAN
SERIAL DATA
A9
1289
A10
PLUGGED
Al 1
800
A 12
COLOR
CIRCUIT DESCRIPTION
NOT USED
NOT USED
~
:
I
NO T USED
l
I
'"
PLUGGED
NOT USED
A13
PLUGGED
NOT USED
A14
PLUGGED
NOT USED
Al 5
PLUGGED
NOT USED
A16
PLUGGED
NOT USED
81
1288
DKGRN
82
867
LTGRN
ABS FAIL LAMP CONTROL
83
1632
PNK
ABS ENABLE RELAY CONTROL
84
33
TAN/WHT
BRAKE WARN ING LAMP CONTROL
BS
1537
DK 8LU
ABS ACTIVE LAMP CONTROL
86
PLUGGED
NOT USED
87
PLUGGED
NOT USED
88
PLUGGED
NOT USED
l
~
L/F ABS SOLENOID
89
PLUGGED
810
440
ORN
BATTERY
811
641
BRN
SWITCHED IGNITION
YEL
BRAKE SWITCH INPU T
l
I
I
:,
NOT USED
812
820
813
PLUGGED
NOT USED
814
PLUGGED
NOT USED
81 5
PLUGGED
NOT USED
816
PLUGGED
NOT USED
I
'
'
I
!
9-16-92
NS 15735
Figure 9 - EBCM Connector Face View (1 of 2)
\I
EBCM 8-WAY CONNECTOR

CIRCUIT
PIN
CIRCUIT NO.
COLOR
1280
BLK
UF MOTOR HIGH
1281
PNK
UFMOTORLOW
1284
DKGRN
REAR MOTOR HIGH
1633
RED
SWITCHED BATTERY
651
BLK/WHT
..
GROUND
.
1285
ORN
REAR MOTOR LOW
1282
PPL
R/F MOTOR HIGH
1283
BLK
R/F MOTOR LOW
9-16-92
NS 15736
Figure 10 - EBCM Connector Face View (2 of 2)
CHART A
II
ABS INOP" LAMP "ON" OR "OFF"

CONSTANTLY, NO DTCs STORED
NOTICE: DIAGNOSTIC CIRCUIT CHECK

MUST BE COMPLETED
THIS CHART.
BEFORE USING
IGNITION "OFF."
INSTALL TECH 1.
IGNITION "ON."
USING TECH 1, SELECT F4: ABS TESTS.
SELECTF8: LAMP TEST AND ATTEMPT TO TURN "ON" THE
"ABS INOP" LAMP.
DID THE "ABS INOP" LAMP TURN "ON" ?
USING TECH 1 LAMP TEST.ATTEMPT

TO "FLASH" THE "ABS INOP" LAMP.
DID THE " ABS INOP" LAMP "FLASH"?
MALFUNCTION IS NOT PRESENT AT THIS TIME. INTERMITTENTS

COULD BE CAUSED BY INCORRECT WIRING HARNESS ROUTING
OR LOOSE CONNECTIONS . INSPECT ALL CONNECTORS AND
TERMINALS FOR POOR TERMINAL CONTACT AND EVIDENCE OF
CORROSION. REPLACE ALL TERMINALS THAT EXHIBIT SIGNS OF
POOR TERMINAL CONTACT OR CORROSION.
INSPECT THE "ABS INOP" BULB

TO VERIFY BULB IS GOOD.
REPLACE ANY BLOWN BULBS. IF
BULB IS GOOD, REFER TO
SECTION SA-81 FOR FURTHER
DIAGNOSIS OF INSTRUMENT
CLUSTER.
1-4-93
NS 16310
CHARif. B
1
ABS INOP' LAMP "ON"

INTERMITTENTLY, NO DTCs STORED
NOTICE : DIAGNOSTIC CIRCUIT CHECK

MUST BE COMPLETED BEFORE USING
THIS CHART.
IGNITION HOFF."
DISCONNECT 32-WAY EBCM CONNECTOR. CONNECT A TEST LIGHT
TO GROUND AND PROBE TERMINAL HB10H OF THE 32-WAY EBCM
HARNESS CONNECTOR. OBSERVE TEST LIGHT WHEN MOVING WIRE
HARNESS AND CONNECTORS.
DOES TEST LIGHT REMAIN uON" STEADY?
CONNECT TEST LIGHT BETWEEN GROUND AND 32-WAY EBCM HARNESS

CONNECTOR TERMINAL " 811 ." TURN IGNITION " ON" ANO OBSERVE TEST
LIGHT WHEN MOVING WIRE HARNESS AND CONNECTORS.
DOES TEST LIGHT REMAIN "ON " STEADY?
MALFUNCTION IS NOT PRESENT AT THIS TIME. INTERMITTENTS

COULD BE CAUSED BY INCORRECT WIRING HARNESS ROUTING
OR LOOSE CONNECTIONS. INSPECT ALL CpNNEc'TORS AND
TERMINALS FOR POOR TERMINAL CONTACt AND EVIDENCE OF
CORROSION. REPLACE ALL TERMiNALS THAT EXHIBIT SIGNS OF
POOR TERMINAL CONTACT OR CORROSION .
CONNECTION IN CKT 440/ 502.
CONNECTION IN CKT 641 .
THIS CHART ASSUMES THAT A CURRENT OTC IS STORED INDICATING THAT THIS MALFUNCTION IS PRESENT.
11 -23 -92
NS 16311
CHART(
''LOW TRAC" INDICATOR LAMP "ON"
WITH IGNITION "OFF," NO DTCs STORED
NOTICE: DIAGNOSTIC CIRCUIT CHECK

MUST BE COMPLETED
THIS CHART.
BEFORE USING
IGNITION " OFF .~

OBSERVE THE "LOW TRAC" INDICATOR LAMP.
IS THE "LOW TRAC" INDICATOR LAMP " ON" ?
MALFUNCTION IS NOT PRESENT AT THIS TIME .

INTERMITTENTS COULD BE CAUSED BY INCORRECT
WIRING HARNESS ROUTING OR LOOSE CONNECTIONS .
INSPECT ALL CONNECTORS AND TERMINALS FOR
POOR TERMINAL CONTACT AND EVIDENCE OF
CORROSION . REPLACE ALL TERMINALS THAT EXHIBIT
SIGNS OF POOR TERMINAL CONTACT OR CORROSION .
11 -20-92
NS 16312
CHARTD
TECH 1 DISPLA VS UNDEFINED OTCs
[I] Important
USE THIS CHART IF ANY OF THE FOLLOWING UNDEFINED DTCs ARE SET A012, A013, A023, A027, A031, A034, A043, A067, A068 , A071, A072,
A073, A075, A083, A084, A085, A097, OR A098.
8 .
IGNITION " ON.

USING TECH 1, CLEAR DTCs.
DOES UNDEFINED OTC RESET?
REPLACE EBCM.
MALFUNCTION IS NOT PRESENT

AT THIS TIME.
9-1-92
NS 15701

IGN
EBCM
GAGES
FUSE9
.-
..
BRAKE
BRAKE
COMBO
WARNING sw11:cH
INSTRUMENT
CLUSTER
BRAKE WARNING
LAMP CONTROL
SEE 8A-11-4
39~NK
~39PNK
1537 OK BLU
ABS ACTIVE
LAMP CONTROL
867 LTGRN
ABS FAIL
LAMP CONTROL
5206
D
r-,
L -
.J
C2000
=(AMARO
C200A
= FIREBIRO
9-18-92
NS 15733
OTC A011
..
(Page 1 of 2)
ABS WARNING OR ACTIVE LAMP CIRCUIT FAILURE

Circuit Description:
This DTC checks the state of both the "ABS INOP" lamp and the "LOW TRAC" lamp to identify a situation in
which the driver could not be alerted to a system malfunction or of possible slippery driving <;oncfitions. Due to an
integral lamp driver module within the instrument pane l cluster, the EBCM must provide a ground to turn the
"ABS INOP" lamp "OFF." The "LOW TRAC" lamp circuit is such that the EBCM provides a ground to turn "ON"
the "LOW TRAC" lamp.
Failure Condition:
OTC AOl l can only be set during the three second bulb check or when eith~r of the lamps are commanded
"ON." If the EBCM cannot control either the "ABS INOP" lamp or-the "LOW TRAC '. ' lamp for two seconds, a
malfunction exists.
Action Taken:
A malfunction OTC is stored; however, ABS is not disabled.
Test Description : N umber(s) below refer to circled
number(s) on the diagnostic chart.
1. Determines if the "ABS INOP " lamp, can be
properly controlled. .
'
'
2. Determines if the lamp is "ON" constantly.
3. Checks for other DTCs which could turn ::ON" the
"ABS INOP" lamp.
4. Determines if the "ABS lNOP" lamp can be turned
"OFF" manually.
. ' .lamp
5. Checks the integrity of the "ABS INOP"
circuitry.
.
6. Checks for a short to voltage on the ''AijS ).NOP"
lamp circuitry.
7. Determines if a malfunctioning EBCM is the cause
ofDTC AOll.
8. Verifies that the other 1/P indicator latp's functiop
properly.
.
9. Determines if the "ABS INOP" lamp can be turned
"ON" manually.
10. Checks for a short to ground in the "ABS lNOP"
lamp circuitry.
11. Verifies condition of the 10 amp "GAGES" Fuse 9.

12. Determines if OTC AOl 1 was set due to an EBCM
malfunction.
Diagno~tic Aids:
An ''.~ntermitteq.t" malfunction may be caused by a
poot connectio~. rubbed through wire insulation, or a
wire that is broken inside the insulation .
The 1amp test function of the Tech 1 may be used to
command the lamp ON" while looking for an
intermittent malfunction in t he "ABS INOP" lamp
circuitry ..
The frequency of the malfunction can be checked
by using th~ enhanced diagnostic function of the Tech
1, as described in "Tech 1 Diagnostics" found in this
section.
Any circuitry that is suspected as causing the
intermittent complaint should be thoroughly checked
for backed out terminals, improper mating, broken
locks, improperly formed or damaged terminals, poor
terminal to wiring connections or physica l damage to
the wiring harness.
ANTll.!'.OCK BRAKE SYSTEM 5E1-29
r.j'\ .
\..:_,/
DTC A011
INSTALL TECH 1.
IGNITION "ON."
USING TECH 1, SELECT F4: ABS TESTS.
SELECT F8: LAMP TEST AND ATTEMPT TO TURN
HON," THEN "FLASH " THE .. ABS INOPH LAMP.
CAN THE "ABS INOPH LAMP BE BOTH TURNED
"ONH AND FLASHED USING THE TECH 1?
(Page 1 of 2)
ABS WARNING OR ACTIVE LAMP

CIRCUIT FAILURE
IGNITION "OFF."
REMOVE TECH 1.
IGNITION "ON."
DOES THE" ABS INOPH LAMP TURN " ON" AND STAY " ON " ?
IGNITION "OFF.
DISCONNECT 32 -WAY EBCM
CONNECTOR.
IGNITION "ON.H
CONNECT A FUSED JUMPER
WIRE, SUCH AS J 36169,
WITH A 3 AMP FUSE
BETWEEN GROUND AND
TERMINAL "82" OF THE 32
WAY EBCM HARNESS
CONNECTOR.
DOES "ABS INOP" LAMP
REMAIN "ON"?
r
I
I
-------------,
DIAGNOSIS CONTINUED I
ON FOLLOWING PAGE. .JI
L---------------
f.t\
IGNITION "OFF.H
\.:_,}
REMOVE JUMPER.
DISCONNECT 1/P
CLUSTER
CONNECTOR.
USINGJ 39200,
MEASURE THE
RESISTANCE
BETWEEN TERMINAL
"82" OF THE 32
WAYEBCM
HARNESS
CONNECTOR AND
TERMINAL
(USE TERMINAL
'817" ON A
FIRE BIRD) OF THE VP
CLUSTER HARNESS
CONNECTOR.
IS RESISTANCE 2ll
OR LESS?
INSPECT TERMINAL
"82" OF THE 32-WAY
EBCM CONNECTOR
FOR POOR TERMINAL
CONTACT.
IGNITION " OFF.
RECONNECT All
CONNECTORS.
IGNITION "ON."
DOES OTC A011
RESET?
, IGNITION " OFF."

DISCONNECT
32-WAYEBCM
CONNECTOR.
IGNITION "ON. "
DOES ~ABS
INOP" LAMP
TURN ..ON"?
REPAIR
OPEN IN
CKT39.
CHECK FOR
SHORT TO
GROUND ON
CKT 39 AND All
OTHER
CIRCUITS FROM
SPLICE 5206.
REPAIR ANY
SHORTS TO
GROUND AND
REPLACE FUSE.
IFNO SHORTS
ARE FOUND,
REPLACE FUSE.
'1Q\
\.:.v
"or
MALFUNCTION
IS NOT PRESENT
AT THIS TIME.
REFER TO
"DIAGNOSTIC
AIDS" ON
FACING PAGE.
IGNITION "ON.H
USING J 39200, MEASURE THE
VOLT AGE BETWEEN GROUND
AND TERMINAL "82" OF THE
32WAY EBCM HARNESS
CONNECTOR.
IS VOLTAGE 2 VOLTS OR LESS?
IGNITION " OFF."

DISCONNECT VP
CLUSTER
CONNECTOR.
USINGJ39200,
MEASURE THE
RESISTANCE
BETWEEN GROUND
AND TERMINAL "82"
OF 32-WAY EBCM
HARNESS
CONNECTOR.
DOESJ39200
DISPLAY
RESISTANCE AS " OL"
(INFINITE)?
,_.....___ _~. r- --------,

REPAIR
I REFER TO
I
SHORT TO I SECTION BA-81 1
GROUND
: FOR FURTHER :
INCKT867. I DIAGNOSIS OF I
..__ _ __, I CLUSTER.
I
IGNITION "OFF."
INSPECT TERMINAL "82"
OF THE 32-WAY EBCM
CONNECTOR FOR BENT
TERMINALS OR FOREIGN
DEBRIS . CORRECT AS
NECESSARY.
RECONNECT ALL
CONNECTORS.
IGNITION HON."
DOES OTC A011 RESET?
MALFUNCTION
ISNOT
PRESENT AT
THIS TIME.
REFER TO
"DIAGNOSTIC
AIDSHON
FACING PAGE.
l - - - - - - - - - - J,
r- --------------------,
REFER TO SECTION SA-81 FOR
I
FURTHER DIAGNOSIS"OF CLUSTER. )
l------- ---------------
1-4 -93
NS 15702

IGN
10
AMP
EBCM
GAGES
FUSE9
BRAKE
BRAKE
COMBO
WARNING SWITCH
INSTRUMENT
CLUSTER
r------,
BMKE WARNING
LAMP CONTROL
SEE BA-11-4
39~NK
L....!,_39PNK
S206
867LT GRN _ _.....,
D
~L -
1537 DK BLU
ABS ACTIVE
LAMP CONTROL
867 LT GRN
ABS FAIL
LAMP CONTROL
C200D
C200A
=(AMARO
'1
.J
= FIREBIRD
9-18-92
NS 15733
DTC A011
(Page 2 of 2)
ABS WARNING OR ACTIVE LAMP CIRCUIT FAILURE

This DTC checks the state of both the "ABS INOP" lamp a nd t he "LOW TRAC" lamp to identify a situation in
which the driver could not be alerted to a system malfunction or of possible s lippery driving conditions. Due to an
integral la mp driver module within t he instrument panel cluster, the EBCM must provide a ground to turn the
"ABS INOP" lamp "OFF." The "LOW TRAC" lamp circuit is such that the EBCM provides a ground to turn "ON"
the "LOW TRAC" la mp.
Failure Condition:
DTC AOl l can only be set during the three second bulb check or when either of t he lamps are commanded
"ON." If the EBCM cannot control either the "ABS INOP" lamp or the "LOW TRAC" lamp for two seconds, a
malfunction exists.
Action Taken:
A malfunction DTC is stored ; however, ABS is not disabled.
Test Description: N umber(s) below refer to circled
Diagnostic Aids:

13. Determines if the " LOW TRAC " lamp can be
properly controlled.
14. Determines if the "LOW TRAC" lamp is "ON"
constantly.
15. Checks for a short to ground in the "LOW TRAC"
lamp circuitry.
16. Determines if DTC AOll was set due to a EBCM
malfunction.
17. Determines if DTC AOll was set due to a EBCM
malfunction.
18. Determines if the "LOW TRAC" lamp can be
contro lled manually.
19. Verifies the integrity of the "LOW TRAC" lamp
circuitry.
20. Determines if there is a short to voltage in the
"LOW TRAC" lamp circuitry.
21. Determines if DTC AOl 1 was set due to a n EBCM
malfunction.
An "Intermittent" malfunction may be caused by a

poor connection, rubbed through wire insulation, or a
wire that is broken inside the insulation.
The lamp test function of the Tech 1 may be used to
command the la mp "ON" while looking for an
intermittent ma lfunction in the "LOW TRAC" la mp
circuitry.
by using the enhanced diagnostic function of the Tech
section.
Any circuitry t hat is s uspected as causing the
intermittent compla int should be thoroughly checked
termina l to wiring connections or physical damage to
the wiring harness.
DTCA011
r----------- ----,
I
I
DIAGNOSIS CONTINUED
FROM PREVIOUS PAGE
(Page 2 of 2)
ABS WARN~NG OR ACTIVE LAMP CIRCUIT FAILURE
----- -------- ~
,.-;'\
STILL USING TECH 1 LAMP TEST, ATTEMPT TO TURN "ON," THEN "OFF" THE "LOW TRAC" LAMP.
C~N THE "LOW TRAC" LAMP BE TURNED BOTH "ON" AND "OFF" USING THE TECH 1?
~ . IGNITION "OFF."
fn\
\:.::.;
\:.:.,,;
REMOVE TECH 1.
IGNITION "ON."
DOES THE "LOW TRAC
LAMP TURN "ON" AND
STAY "ON"?
IGNITION "OFF."
INSPECT All CONNECTORS FOR
POOR TERMINAL CONTACT.
RECONNECT All CONNECTORS.
IGNITION "ON."
MALFUNCTION IS NOT
PRESENT AT THIS TIME.
REFER TO " DIAGNOSTIC
AIDS" ON FACING PAGE .
IGNITION " OFF."

DISCONNECT 32-WAY
EBCM CONNECTOR.
IGNITION "ON."
DOES THE "LOW TRAC"
LAMP TURN "ON"?
IGNITION "OFF."
INSPECT TERMINAL " BS"
OF THE 32-WAY EBCM
CONNECTOR FOR BENT
TERMINALS OR FOREIGN
DEBRIS. CORRECT AS
NECESSARY.
RECONNECT All
CONNECTORS.
IGNITION "ON."
REPAIR SHORT
TO GROUND
ONCKT 1537.
'1g\
'--------' \.:..V
MALFUNCTION
ISNOT
PRESENT AT
THIS TIME.
REFER TO
"DIAGNOSTIC
AIDS" ON
FACING PAGE .
'2o\
~
IGNITION "OFF."
IGNITION "ON."
CONNECT A FUSED JUMPER WIRE, SUCH AS
J 36169, WITH A 3 AMP FUSE BETWEEN
GROUND AND TERMINAL "85" OF THE 32WA Y EBCM HARNESS CONNECTOR.
DOES THE "LOW TRAC" LAMP TURN "ON"?
IGNITION "OFF."
DISCONNECT 1/P CLUSTER
CONNECTOR.
RESISTANCE BETWEEN
TERMINAL "85" OF THE 32WAY EBCM HARNESS
CONNECTOR ANO TERMINAL
" 016" (USE TERMINAL " A16"
ON A FIRE BIRD) OF THE 1/P
CLUSTER HARNESS
CONNECTOR.
IS RESISTANCE 20 OR LESS?
IGNITION "ON."
USING J 39200,
MEASURE THE
VOLTAGE FROM
GROUND TO
TERMINAL " BS"
OF THE 32-WAY
EBCM HARNESS
CONNECTOR.
ISVOLTAGE2
VOLTS OR LESS?
I REFER TO
: SECTION BA-81
I FOR FURTHER
: DIAGNOSIS OF
I CLUSTER.
REPAIR OPEN
OR HIGH
RESISTANCE
IN CKT 1537.
IGNITION "OFF."
INSPECT TERMINAL "BS"
OF THE 32-WAY EBCM
CONNECTOR FOR POOR
TERMINAL CONTACT.
RECONNECT All
CONNECTORS.
IGNITION " ON."
MALFUNCTION
ISNOT
PRESENT AT
THIS TIME.
REFER TO
"DIAGNOSTIC
AIDS" ON
FACING PAGE .
REPAIR
SHORT TO
VOLTAGE IN
CKT 1537.
11 -23-92
NS15760
EBCM
TO
IGN 3
. - - - - - - - - - - - - - 6 4 1 BRN--------t
~l
1632 PNK
B+
SAMP
~302RED
---o
Bl
1633 RED
1633 RED
~302RED
LINKB
S180
S272
11-23-92
NS 15732
DTCA014
(Page 1 of 3)
ENABLE RELAY CONTACTS OR FUSE OPEN

Ignition voltage is supplied through terminal "C2" of the ABS enable relay. The EBCM then is able to
energize the pull-in coil by completing the ground circuit at terminal "8 3" of the EBCM. The magnetic field
created closes the enable relay contacts and allows battery voltage and current to be supplied to the EBCM, which
supplies power to the motors and solenoids.
Failure Condition:
DTC A014 can be set anytime after the EBCM commands t he enab le r elay "ON" (the relay is first
commanded "ON" during the three second bulb check). This test monitors the availa bility of currenUvoltage to
the motors and solenoids. This malfunction indicates voltage is not available and would therefore not a llow ABS
operation if required.
Action Taken:
A malfunction DTC is stored, ABS is disabled and the "ABS INOP" lamp is turned "ON."
Test Description : Number(s) below refer to circled

l. This step checks to see if DTC A016 is a lso set as
current or history. If OTC A016 is a lso set, proceed
to that chart first.
2. This step verifies that the malfunction is currently
present.
3. This step verifies that the relay can be turned
"ON" and provide voltage to the EBCM.
4. This step checks for hig h r es istance in the
switched battery circuit from the relay to the
EBCM.
5. This step checks for high resistance in t h e
switched battery circuit from t he battery to the
relay.
6. This step checks for poor terminal contact or
corrosion at the connectors.
7. This step determines if the EBCM is the cause of
the malfunction.
Diagnostic Aids:
An "Inte rmittent" problem may be caused by a
poor connection, rubbed through wire ins ulation, or a
The frequency of the problem can be checked by
using the enhanced diagnostic function of the Tech 1,
as described in "Tech 1 Diagnostics" fo und in this

section.
Any circuitry t hat is suspected as causing the
"In te rmitte n t" complaint s hould be thoroughly
checked for backed out terminals, improper mating,
broken lock s, imprope rl y formed or damaged
terminals, poor te rmina l to wiring connections or
physical da mage to the wiring harness.
VIBRATION, TEMPERATURE EFFECTS:

Check for vibration effects by performing the relay
test function of t he Tech 1. With t he r elay test
commanded "ON," lightly ta p the top and sides of the
relay while monitoring re lay voltage . If the relay
voltage changes significantly, replace t he relay.
If OTC A01 4 only sets when t he vehicle is initially
started in cold ambient conditions (temperature less
than 32F-0C), replace the relay .
DTCA014
(Page 1 of 3)
ENABLE RELAY CONTACTS

OR FUSE OPEN
ti'
\:._)
0:
'
;.
IGNITION " ON/ ENGINE "OFF."

USING TECH 1, SELECT DATA LIST AND OBSERVE ABS
BATTERY VOLTAGE .
DOES TECH 1 INDICATE THAT ABS BATTERY VOLTAGE
IS GREATER THAN 10 VOLTS?
IGNITION " OFF."

DISCONNECT 32 -WAY AND 8-WAY EBCM CONNECTORS.
CONNECT A FUSED JUMPER, SUCH AS J 36169 WITH A 3 AMP
FUSE BETWEEN GROUND AND TERMINAL "83" OF THE
32-WAY EBCM HARNESS CONNECTOR.
IGNITION " ON."
USING J 39200, MEASURE THE VOLTAGE BETWEEN GROUND
AND TERMINAL " D" OF THE 8-WAY EBCM HARNESS
CONNECTOR.
IS VOLTAGE 10 VOLTS OR GREATER?
IGNITION " OFF."

DISCONNECT JUMPER USED IN STEP 3 .
DISCONNECT ENABLE RELAY .
USING J 39200, MEASURE RESISTANCE
BETWEEN TERMINAL "C4" OF THE ENABLE
RELAY HARNESS CONNECTOR AND TERMINAL
" 0 " OF THE 8-WAY EBCM HARNESS
CONNECTOR.
IS RESISTANCE 20 OR LE SS?
0:
DISCONN ECT NEGATIVE BATTERY CABLE.

DISCONNECT POSITIVE BATTERY CABLE.
USING J 39200, MEASUR E THE RESISTANCE
BETWEEN POSITIVE BATTERY CABLE
TERMINAL AND TERMINAL " C1 " OF THE
ENABLE RELAY HARNESS CONNECTOR.
------ -- - -- --- --------,
t PROCEED TO OTC A016 CHART FIRST.
L--- --------------r -- -- --J
MALFUNCTION IS NOT PRESENT AT THIS TIME .

REFER TO "DIAGNOSTIC AIDS" ON FACING PAGE .
---------,
,I DIAGNOSIS
I
: CONTINUED ON :
I NEXT PAGE .
I
L-----------'
REPAIR HIGH
RESISTANCE
IN CKT 1633 .
INSPECT ALL CONNECTORS FOR POOR TERMINAL CONTACT

AND EVIDENCE OF CORROSION.
REFER TO SECTION 8A-4, "CHECK TERMINAL CONTACT."
DO I\NY TERMINALS EXHIBIT POOR CONTACT OR EVIDENCE
OF CORROSION?
REPAIR HIGH RESISTANCE

IN CKT'302.
REF.ER TO SECTION SA.

IGNITION "ON."
REPLACE TERMINALS THAT

EXHIBIT POOR TERMINAL
CONTACT OR EVIDENCE OF
CORROSION.
MALFUNCTION IS INTERMITTENT.
REFER TO " DIAGNOSTIC AIDS" ON FACING PAGE .
11 -23-92
NS 15703
EBCM
TO
~~~~~~~~~~~~~641BRN~~~~~~~
IGN3
~1
B+
1632 PNK
SAMP
1633 RED
~302RED
1633 RED
~302RED
LINKB
5180
5272
11-23-92
NS 15732
DTCA014
(Page 2 of 3)

Ignition voltage is supplied through terminal "C2" of the ABS enable relay . The EBCM then is able to
energize the pull-in coil by completing the ground circuit at terminal "B3" of the EBCM. The magnetic field
Failure Condition:
DTC A014 can be set anytime after the EBCM commands the enable relay "ON" (the relay is first
commanded "ON" during the three second bulb check). This test monitors the availability of current/voltage to
t he motors and solenoids. This malfunction indicates voltage is not available and would therefore not allow ABS
Action Taken:
Test Description: Number(s) below refer to circled

8. This step checks for high resistance in the entire
relay coil circuit.
9. This step verifies proper battery condition.
10. This step verifies proper voltage is available at the
enable relay.
11. This step checks for an open in the switched
battery circuit from the relay to the EBCM.
12. This step verifies the condition of the enable relay.

test function of the Tech 1. Wi t h the relay test
commanded "ON," lightly tap the top and sides of the
relay while monitoring relay voltage. If the relay
voltage changes significantly, replace the relay.
If OTC A014 only sets when the vehicle is initially
than 32F-0C), replace the relay.
Diagnostic Aids:
An "Intermittent" problem may be caused by a
poor connection, rubbed thro ugh wire insulation, or a
as described in "Tech 1 Diagnostics" found in this
section .
Any circuitry that is suspected as causing the
" Intermittent" complaint shou ld be thoroughly
checked for backed out terminals, improper mating,
broken lock s, improperly formed or damaged
terminals, poor terminal to wiring connections or
physical damage to the wiring harness.
DTCA014
(Page 2 of 3)
r------------- -- -,
DIAGNOSIS CONTINUED
: FROM PREVIOUS PAGE .
I
L-
fs' .
\..::_.)

OR FUSE OPEN
- - - - - - - - - - - - - -~
DISCONNECT NEGATIVE BATTERY CABLE .

DISCONNECT POSITIVE BATTERY CABLE.
WITH BATTERY STILL DISCONNECTED, TURN IGNITION
SWITCH TO " RUN." THIS COMPLETES THE IGNITION CIRCUIT
TO THE ENABLE RELAY .
TERMINAL " 83" OF THE 32-WAY EBCM HARNESS
CONNECTOR AND THE POSITIVE BATTERY CABLE TERMINAL.
IS RESISTANCE 9SU OR LESS WHEN MEASURED AT
APPROXIMATELY 24 C (75F)?
USING J 39200, MEASURE THE VOLTAGE BETWEEN

THE NEGATIVE AND POSITIVE BATTERY TERMINALS.
IGNITION HOFF.ff
RECONNECT POSITIVE BATTERY CABLE .
RECONNECT NEGATIVE BATTERY CABLE .
MEASURE THE VOLTAGE BETWEEN TERMINAL
"C1" OF THE ENABLE RELAY HARNESS
CONNECTOR AND GROUND.
IS VOLTAGE 10VOLTS OR GREATER?
USING J 39200, MEASURE THE RE SISTANCE BETWEEN TERMINAL

"C4" OF THE ENABLE RELAY HARNESS CONNECTOR AND
TERMINAL " D" OF THE 8-WAY EBCM HARNESS CONNECTOR.
------ --- ,
I DIAGNOSIS
'
: CONTINUED ON :
I NEXT PAGE .
1
L----------..J
- -- --- - ------~
: REFER TO SECTION 603 I

:
I TO CORRECT LOW
I VOLTAGE CONDITION. 1
~---------------~
USING A JUMPER WIRE, CONNECT TERMINAL "86" ON THE

ENABLE RELAY TO GROUND.
USING A FUSED JUMPER WIRE, SUCH AS J 36169, WITH A 3 AMP
FUSE, CONNECT TERMINAL "85" ON THE ENABLE RELAY TO B + .
TERMINALS " 30" AND " 87" ON THE ENABLE RELAY.
IS RESISTANCE 2Q OR LESS?
MALFUNCTION WAS DUE TO A POOR

CONNECTION . INSPECT ALL CONNECTORS AND
TERMINALS FOR POOR TERMINAL CONTACT
AND EVIDENCE OF CORROSION. REFER TO
SECTION 8A-4, " CHECKING TERMINAL
CONTACT." REPLACE ALL TERMINALS THAT
EXHIBIT EVIDENCE OF POOR TERMINAL
CONTACT OR CORROSION .
11 -23-92
NS 16313
EBCM
TO
IGN 3
B+
t~
'}~..
SAMP
. - - - - - - - - - - - - - 6 4 1 BRN--------4
641BRN
1632 PNK
Lr--,_____r 302 RED
1633 RED
~302RED
LINKB
1633 RED

S180
S272
11-23-92
NS 15732
DTCA014
(Page 3 of 3)

energize the pull-in coil by completing the ground circuit at terminal "83" of the EBCM . The magnetic field
supplies power to the motors a nd solenoids.
Failure Condition:
OTC A014 can be set anytime after the EBCM commands the enable relay "ON" (the relay is first
commanded "ON" during the three second bulb check). This test monitors the availability of current/voltage to
the motors and solenoids. This malfunction indicates voltage is not available and would therefore not allow ABS
Action Taken:
A malfunction OTC is stored, ABS is disabled and the "ABS INOP" lamp is turned "ON."

13. This step checks for proper resistance of the relay
coil.
14. This step checks for high resistance in the enable
relay control circuit between the r elay and t he
EBCM.
15. This step checks for high resistance in the enable
relay control circuit between the battery and the
relay.

test function of the Tech 1. With the relay test
commanded "ON," lightly tap the top and sides of the
relay while monitoring relay vol tage. If the relay
voltage changes significantly, replace the relay.
If OTC A014 only sets when the vehicle is initially
than 32F-0C), replace the relay.
Diagnostic Aids:
An "Intermittent" problem may be caused by a
as described in "Tech 1 Diagnostics" found in this
section.
Any circuitry that is suspected as caus ing the
"Intermittent" complaint s hould be thoroughly
checked for backed out terminals, imprope r mating,
broken lock s, improperly forme d or damaged
termina ls, poor termina l to wiring connections or
phys ica l da mage to the wiring harness.
ANTIL:OCK BRAKE SY.STEM SE1-37
OTC A014
(Page 3 of 3)

OR FUSE OPEN
r----------------,
--------------J
I DIAGNOSIS CONTINUED I
: FROM PREVIOUS PAGE . :
L-
@:
DISCONNECT ENABLE RELAY.

TERMINALS "85" AND "86" ON THE ENABLE RELAY.
IS RESISTANCE 950 OR LESS WHEN MEASURED AT
APPROXIMATELY 24C(75F)7
MEASURE THE RESISTANCE BETWEEN

TERMINAL " CS" OF THE ENABLE RELAY
HARNESS CONNECTOR ANO TERMINAL " 83" OF
IS RESISTANCE 20 OR LESS'?
'1s\
MEASURE THE RESISTANCE BETWEEN TERMINAL "C2"

OF THE ENABLE RELAY HARNESS CONNECTOR AND THE
POSITIVE BATTERY CABLE TERMINAL.
MALFUNCTION WAS DUE TO A POOR

CONNECTION. INSPECT ALL CONNECTORS AND
TERMINALS FOR POOR TERMINAL CONTACT
AND EVIDENCE OF CORROSION . REFER TO
SECTION SA-4, " CHECKING TERMINAL
CONTACT." REPLACE ALL TERMINALS THAT
EXHIBIT EVIDENCE OF POOR TERMINAL
CONTACT OR CORROSION.
REPAIR OPEN OR HIGH RESISTANCE IN

CKT 641, CKT 300, IGNITION SWITCH,
OR BATTERY FEED CIRCUIT TO
IGNITION SWITCH. REFER TO SECTION
SA FOR FURTHER INFORMATION.
11-23-92
NS 16314
EBCM
TO
-~~~~~~~~~~~~641BRN~~~~~~~
IGN3
~l
B+
1632 PNK
SAMP
1633 RED
~302RED
1633 RED
~302RED
LINK B
5180
5272
11-23-92
NS 15732
DTCA015
ENABLE RELAY CONTACTS SHORTED TO BATTERY
Ignition voltage is s upplied through terminal "C2" of the ABS e nable re lay. The EBCM then is able to
energize the pull-in coil by completing the ground circuit at termina l "83" of t he EBCM . The magnetic field
created closes the enable relay contacts and allows battery voltage and current to be s upplied to the EBCM, which
supplies powe r to the motors and solenoids.
Failure Condition:
OTC A015 can be set only before the EBCM commands the relay "ON." This test determines if the enable
relay is energized when it should not be. This malfunction would not allow the enable relay to remove power to
the ABS system. If a second malfunction were to occur that requires t he enable relay to be turned "OFF," that
malfunction cannot be removed if the relay cannot be controlled. The malfunction must be present for three
consecutive drive cycles before the OTC is set.
Action Taken:
A malfunction OTC is stored. ABS is not disabled; however, the "ABS INOP" lamp will flash to indicate a
malfunction exists.
1. This step indicates that the EBCM is capable of
controlling the enable relay as commanded.
2. This step checks for a possible short to battery
voltage in CKT 1633.
3. This step checks for a possible short to ground in
CKT 1632.
4. This step determines whether the short to B + is in
CKT 1633 or internal to the EBCM .
5. This step checks for a possible intermitte nt in
wiring or connectors.
Diagnostic Aids:
poor connection, rubbed th rough wire insula tion, or a
The frequency of t he ma lfunction can be checked
section.
Any circuitry, that is suspected as causing the
intermitte nt complaint, should be thoroughly checked
for backed out te rminals, improper ma ting, broken
locks, improperly formed or da maged terminals, poor
terminal to wiring connections or physical damage to
the wiring harness.
DTCA015
IGNITION - oN,- ENGINE " OFF."

USING THE RELAY TESTFUNCTION OF THE TECH 1,
COMMAND ENABLE RELAY -off.DOES TECH 1 INDICATE THAT ENABLE RELAY IS "OFF AND BATTERY VOLTAGE IS LESS THAN 5 VOLTS?
IGNITION -OFF.DISCONNECT 32-WAY AND 8-WAY EBCM HARNESS CONNECTORS.

IGNITION "ON.USING J 39200, MEASURE THE VOLTAGE BETWEEN GROUND AND
TERMINA L "D" OF THE EBCM 8-WAY CONNECTOR.
15 VOLTAGE 2 VOLTS OR LESS?
ENABLE RELAY
CONTACTS SHORTED
TO BATTERY
MALFUNCTION IS NOT PRESENT AT THIS TIME.

REFER TO - DIAGNOSTIC AIDS- ON FACING PAGE .
IGNITION"OFF."
RECONNECT 8-WA Y AND 32-WAY EBCM CONNECTORS.
IGNITION "ON."
USING RELAY TEST FUNCTION OF TECH 1, COMMAND ENABLE RELAY -off.DOES TECH 1 INDICATE THAT ENABLE RELAY IS "OFF" ANO BATTERY
VOLTAGE IS LESS THAN 5 VOLTS?
MALFUNCTION IS INTERMITTENT. REFER

TO -DIAGNOSTIC AIDS - ON FACING PAGE.
NO
MEASURE THE VOLTAGE BETWEEN TERMINAL "Br OF
THE 32-WAY EBCM HARNESS CONNECTOR AND B + .
IGNITION " OFF."

MEASURE THE VOLTAGE BETWEEN GROUND AND TERMINAL -D- OF
15 VOLTAGE 2 VOLTS OR LESS?
I
I
AFTER ALL DIAGNOSIS IS COMPLETE, CLEAR DTCs, AND TEST DRIVE VEHICLE FOR 3 DRIVE CYCLES TO
VERIFY THAT OTC DOES NOT RESET. A DRIVE CYCLE CONSISTS OF STARTING THE VEHICLE, DRIVING
ABOVE 16 km/h (10 MPH), AND THEN KEYING DOWN.
11-20-92
NS 15704
EBCM
TO
IGN3
t~
'F~~
L-g--[
B+
. - - - - - - - - - - - - - 6 4 1 BRN--------1
641BRN
FUSIBLE
LINKS
1632 PNK
SAMP
302 RED
1633 RED
302 RED
1633 RED
SWITCHED l~N,TION

5180
5272
11-23-92
NS 15732
DTCA016
ENABLE RELAY COIL CIRCUIT OPEN
Failure Condition:
OTC A016 can be set only after OTC A014 has been set. This test detects a n open in the enable relay coil
circuit. An open in this circuit will not a llow the enable relay to be energized thus preventing voltage/current to
the motors and solenoids. If this malfunction is present and the ignition is turned "OFF" before 5 km/h (3 mph) is
reached, OTC A014 is set alone.
'
Action Taken:
A malfunction OTC is stored, ABS is disabled and t he "ABS INOP" lamp is turned "ON."
Test Description: Number (s) below refer to circled

1. This step indicates the EBCM is capab le of
2. This step checks to insure that voltage is available
to t he pull-in coil of the enable relay.
3. This step insures that there is continuity through
the pull-in coil of the enable relay.
4. This step verifies the integrity of the relay control
circuit.
5. This step checks for a possible intermittent in the
wiring or connectors.
Diagnostic Aids:
An "Intermitten t" malfunction may be cau'sed by a
,
The frequency of t he malfunction can bl! checked
1, as described in "Tech 1 Diagnos tics" founa in t his
section.
If the frequency of t he malfunction is high, but is
currently intermittent , check for high coil resistan&e
by measuring between relay terminals "C4" and "C5"
using a DVM. If resistance shows greater than 100
ohms, replace the relay.
Any circuit ry, that is suspected as causing U:(e
intermittent complaint, should be thorougnly checked
the wiring harness.
I
DTCA016
G)
ENABLE RELAY COIL CIRCUIT OPEN

AND TERMINAL "Cr OF THE ENABLE RELAY CONNECTOR.
IS VOLTAGE 10 VOl:TS OR GREATER?
MALFUNCTION IS NOT PRESENT AT THIS

TIME. REFER TO "DIAGNOSTIC AIDS .. ON
FACING PAGE.
USING THE RELAY TEST FUNCTION OF THE TECH 1, COMMAND THE ENABLE
RELAY"OFF."
MEASURE THE VOLTAGE BETWEEN GROUND AND TERMINAL
OF THE
ENABLE RELAY CONNECTOR.
REPAIR OPEN IN CKT 641

OR
ABS IGN FUSE 5.
IGNITION "OFF."
DISCONNECT 32WAY EBCM CONNECTOR.
IGNITION "ON."
MEASURE THE VOLTAGE BETWEEN GROUND AND TERMINAL "83"
OF THE 32-WAY EBCM HARNESS CONNECTOR.
CHECK FOR INTERMITTENT CONNECTIONS

AT ENABLE RELAY. IF OK, REPLACE RELAY..
cs..
IGNITION "ON," ENGINE "OFF."

USING THE RELAY TEST FUNCTION OF THE
TECH 1,COMMANDTHE ENABLE RELAY "ON."
DOES TECH 1 INDICATE ENABLE RELAY "ON,"
AND BATTERY VOLTAGE ABOVE 10 VOLTS?
IGNITION "OFF."
RECONNECT EBCM 32-WAY CONNECTOR.
TEST DRIVE VEHICLE, REACHING AT LEAST 8 km/h (5 MPH).
MALFUNCTION IS
INTERMITTENT. REFER
TO " DIAGNOSTIC AIDS "
ON FACING PAGE.
AFTER ALL !)IAGNOSIS IS COMPLETE, CLEAR DTCs AND TEST DRIVE VEHICLE
FOR THREE (3) DRIVE CYCLES TO VERIFY THAT OTC DOES NOT RESET. A DRIVE
CYCLE CONSISTS OF STARTING THE VEHICLE, DRIVING OVER 16 km/h (10 MPH},
AND THEN KEYING DOWN .
11-20-92
NS 15705
EBCM
TO
IGN3
-~~~~~~~~~~~~641BRN~~~~~~.....
t~
'Ft.~.
641BRN
B+
SAMP
~302RED
1632 PNK
1633 RED
SWITCHED BAJTERY INPUT

1633 RED
~302RED
LINKS
5180
5272
11-23-92
NS 15732
DTCA017
ENABLE RELAY COIL CIRCUIT SHORTED TO GROUND.
supplies voltage to the motors and solenoids.
Failure Condition:
OTC AOl 7 can be set before the EBCM commands the enable relay "ON." This test qetermines if the enable
relay is energized when it should not be. This malfunction would not allow the enable relay to remove power to
the ABS system. If a second malfunction were to occur that requires the enable relay to be turned "OFF," that
malfunction cannot be removed if the relay cannot be controlled.
Action Taken:
A malfunction OTC is stored. ABS is not disabled; however the "ABS INOP" lamp is flashed to indicate a
malfunction exists.

2. This checks to insure that the enable relay or
control CKT 1632 are not shorted to ground.
3. This step checks to see if the EBCM is internally
shorted to ground. A grounded terminal "83"
would cause th e enable relay to be energized any
time the ignition was in the "ON" position.
4. This step checks for a short to ground in control
CKT 1632 or a defective relay.
Diagnostic Aids:
section.
Any circuitry, that is s uspected as causing the
intermittent complaint, should be thoroughly checked
the wiring harness.
DTCA017
ENABLE RELAY COIL CIRCUIT SHORTED TO GROUND

USING THE RELAY TESTFUNCTION OF THE TECH 1; COMMAND
THE ENABLE RELAY "OFF."
DOES TECH 1 INDICATE THAT ENABLE RELAY IS "OFF" AND
BATTERY VOLTAGE IS LESS THAN 5 VOLTS?
IGNITION "OFF. "

IGNITION "ON."
USING J 39200, MEASURE THE VOLTAGE BETWEEN TERMINAL
" Bl" Of THE 32-WAY EBCM HARNESS CONNECTOR AND B +.
IGNITION "OFF."
INSPECT 32-WAY EBCM CONNECTOR TERMINAL "83"
FOR POOR CONTACT.
RECONNECT 32-WAY EBCM CONNECTOR.
IGNITION "ON."

TIME. REFER TO "DIAGNOSTIC AIDS"
ON FACING PAGE.
IGNITION "OFF."
MEASURE VOLTAGE BETWEEN TERMINAL " CS"
OF THE ENABLE RELAY CONNECTOR AND B + .
MALFUNCTION IS
INTERMlTIENT. REFER TO
" DIAGNOSTIC AIDS" ON
FACING PAGE .
AFTER ALL DIAGNOSIS IS COMPLETE, CLEAR DTCs AND TEST DRIVE VEHICLE FOR THREE (3) DRIVE
CYCLES TO VERIFY THAT OTC DOES NOT RESET. A DRIVE CYCLE CONSISTS OF STARTING THE VEHICLE,
DRIVING OVER 16 k"!lh (10 MPH), AND THEN KEYING DOWN.
THIS CHART ASSUMES THAT A CURRENT OTC IS STORED INDICATING THAT THIS FAULT IS PRESENT.
11 -20-92
NS 15706
EBCM
TO
IGN3
. - - - - - - - - - - - - - 6 4 1 BRN-------1
t~
'lctw;
641BRN
B+
SAMP
~302RED
1632 PNK
~302RED
LINK B
1633 RED
1633 RED
5272
11-23-92
NS 15732
DTCA018
ENABLE RELAY COIL CIRCUIT SHORTED TO B + OR COi[ SHORTED
supplies voltage to the motors and solenoids.
Failure Condition:
DTC A018 can be set after the EBCM commands the enable relay "ON." This test monitors the availability of
current/voltage to the motors and solenoids. A malfunction of this type will not allow voltage to be available to
the motors and solenoids; therefore, ABS operation would not be allowed if required.
Action Taken:

2. This step checks for a short to B + on the relay
control circuit.
3. This step verifies that the relay coil has the
appropriate resistance.
4. This step checks for possible poor terminal contact
at the EBCM.
5. This step checks for additional DTCs present.
Diagnostic Aids:
section.
Any circuitry , that is suspected as causing the
intermittent complaint, shou ld be thoroughly checked
the wiring harness .
DTCA018
IS OTC A011 CURRENT OR IN HISTORY?
IGNITION "OFF."
DISCONNECT ENABLE RELAY.
USINGJ 39200, MEASURE THE VOLTAGE
BETWEEN GROUND AND TERMINAL "Bl"
OF THE 32-WAY EBCM HARNESS
CONNECTOR.
.,
CD
ENABLE RELAY COIL CIRCUIT SHORTED

TO B + OR COIL SHORTED
IGNITION HON," ENGINE " OFF."

USING RELAY TEST FUNCTION OF TECH 1,
COMMAND ENABLE RELAY "ON."
DOES TECH 1 INDICATE ENABLE RELAY oN"
AND BATTERY VOLTAGE ABOVE 10 VOLTS?
MALFUNCTION IS NOT
PRESENT AT THIS TIME . REFER
TO " DIAGNOSTIC AIDSH ON
F~CING PAGE
.:

RESISTANCE BET.WEEN TERMINAL
"C2" AND TERMINAL " CS " OF THE
ENABLE RELAY.
IS RESISTANCE 40Q OR GREATER?
REPAIR SHORT TO B + CKT 1632.
"
REPLACE ENABLE RELAY.
IGNITION "OFF. "

INSPECT TERMINAL HBl" OF 32 -WAY
CONNECTOR FOR POOR CONTACT TO EBCM:
RECONNECT ALL CONNECTORS.
IGNITION " ON."
lJ
MALFUNCTION IS INTERMITTENT, REFER TO

"DIAGNOSTIC AIDS" ON FACING PAGE.
(\
* AFTER ALL DIAGNOSIS IS COMPLETE, CLEAR DTCs AND TEST DRIVE VEHICLE FOR THREE (3) DRIVE CYCLES
TO VERIFY THAT OTC DOES NOT RESET. A DRIVE CYCLE CONSISTS OF STARTING THE VEHICLE, DRIVING OVER
16 km/h (10 MPH), AND THEN KEYING DOWN.
THIS CHART ASSUMES THAT A CURRENT DTC IS STORED INDICATING THAT THIS MALFUNCTION
rs PRESENT.
11 -23-92
NS 15707
EBCM
ABS JUMPER HARNESS
1-1-=====- 873 YEL
901 WHT ------1[!JAB

900BLK
----10
UF WHEEL SIGNAL LOW

----ii
830LTBLU _ _ _....,
UF WHEEL SIGNAL HIGH
(120
UF WHEEL SPEED SENSOR
10-21-92
NS 15728
DTCA021
{Page 1 of 2)
LEFT FRONT WHEEL SPEED = 0

As a toothed ring passes by the wheel speed sensor, changes in the electromagnetic field cause the wheel
speed sensor to produce a sinusoidal (AC) voltage signal whose frequency is proportional to wheel speed. The
magnitude of this signal is directly related to wheel speed and the proximity of the wheel speed sensor to the
toothed ring, often referred to as the air gap.
Failure Condition:
OTC A021 can be set when the vehicle is not in an ABS stop. If the left front wheel speed = 0 and the vehicle's
reference speed is greater than 8 km/h (5 mph), a malfunction exists.
Action Taken:
If the customer's comments reflect that the "ABS
INOP" lamp is "ON" only during moist environmental
1. This determines if OTC A032 is present.
changes (rain, snow, vehicle wash), all wheel speed
2. This test verifies whether the malfunction is
sensor circuitry should be thoroughly inspected for
currently present.
signs of water intrus ion. If OTC is not current, clear
3. This step is designed to identify a wheel speed
DTCs and simulate the effects of water intrusion. Use
the following procedure. Spray down the suspected
sensor or circuitry that is damaged and visibly
apparent.
area with a 5% salt water solution (two teaspoons of
4. This test checks to see that the wheel speed sensor
salt to 12 oz . of water). Start vehicle, allow vehicle to
is within proper resistance values.
run for 10 seconds. If OTC returns immediately,
replace suspected harness.
5. This step verifies that the wheel speed sensor can
generate an appropriate output s igna l.
6. This test checks for proper output voltage from the
EBCM.
for backed out termina ls, improper mating, broken
Diagnostic Aids:
terminal to wir ing connections or physical damage to
the wiring harness.
When meas uring wheel speed sensor resistance,
insure vehicle is a t room temperature (20C or 68F).
Wheel speed sensor resistance will vary with
temperature.
When replacing a wheel speed sensor, inspect the
sensor terminals and harness connector for corrosion
and/or water int rusion. If e vidence of corrosion or
section.
water intrusion exis ts, r eplace wheel s peed sensor
harness. Refer to "On-Vehicle Service" in this section.
IMPORTANT:
WHEEL SPEED SENSOR INTERMITTENT PROBLEMS

MAY BE DIFFICULT TO LOCATE. CARE SHOULD BE TAKEN NOTTO
DISTURB ANY ELECTRICAL CONNECTIONS PRIOR TO AN INDICATED
STEP OF THIS CHART. THIS Will INSURE THAT AN INTERMITTENT
CONNECTION WILL NOT BE CORRECTED BEFORE THE SOURCE OF THE
PROBLEM IS FOUND.
TEST DRIVE VEHICLE.

USING TECH 1, SELECT DATA LIST.
MONITOR WHEEL SPEED ON LEFT FRONT WHEEL WHILE
SLOWLY DECELERATING FROM 35 MPH TOO MPH.
IS LEFT FRONT WHEEL SPEED WITHIN 5 MPH OF REMAINING
WHEEL SPEED INPUTS?
IGNITION "OFF."
PHYSICALLY INSPECT WHEEL SPEED SENSOR,
WIRING AND CONNECTORS FOR DAMAGE .
IS PHYSICAL DAMAGE INDICATED?
r-
DTCA021
(Page 1 of 2)
LEFT FRONT WHEEL SPEED = 0
MALFUNCTION IS NOT PRESENT AT

THIS TIME. REFER TO " DIAGNOSTIC
AIDS " ON FACING PAGE.
DISCONNECT LEFT FRONT WHEEL SPEED SENSOR

DIRECTLY AT SENSOR.
TERMINAL" A" AND TERMINAL "S- OF THE WHEEL SPEED
SENSOR.
IS RESISTANCE BETWEEN 990 AND 12100?
WITH J 39200 STILL CONNECTED, SELECT AC VO~TAGE SCALE .

SPIN WHEEL BY HAND WHILE OBSERVING VOLTAGE.
IS VOLTAGE AT LEAST 100 mV(VOLTAGE WILL INCREASE AS
WHEEL SPEED INCREASES)?
.
REPLACE WHEEL SPEED SENSOR,

CLEAR DTCs AND RECHECK.
IGNITION " ON. "

SELECT D.C. VOLTAGE SCALE ON J 39200.
MEASURE VOLTAGE BETWEEN GROUND AND TERMINAL" A " ,
THEN TERMINAL "S- OF THE LEFT FRONT WHEEL SPEED SENSOR
HARNESS CONNECTOR.
IS VOLTAGE BETWEEN 2.25 AND 2 .75 VOLTS ON EACH TERMINAL?

CLEAR OTCs AND RECHECK.
--- -- ---- -- ---,
: DIAGNOSIS CONTINUED
I ON NEXT PAGE.
:
1
L----------------4
11 -10-92
NS 16188
EBCM
ABS JUMPER HARNESS

UF WHEEL SIGNAL LOW
Uf WHEEL SIGNAL HIGH
(120
10-21-92
NS 15728
DTCA021
(Page 2 of 2)
LEFT FRONT WHEEL SPEED

=0
toothed ring often referred to as the air gap.
Failure Condition:
DTC A021 can be set when the vehicle is not in an ABS stop. If the left front wheel speed = 0 and the vehicle's
Action Taken:

7. This checks for an open in the wheel signal high
circuit.
8. This step insures th~t DTC A021 was not set due to
a poor connection between the 32-way EBCM
connector and the EBCM .
9. This step insures that wheel speed sensor circuitry
is not internally shorted.
10. This checks for an open in the wheel signal low
circuit.
Diagnostic Aids:
1, a s described in "Tech 1 Diagnostics" found in this
section.
sensor circuitry should be thoroug hly inspected for
signs of water intrusion . If DTC is not current, clear

salt to 12 oz. of water). Start vehicle, allow vehicle to
run for 10 seconds. If DTC returns immediately,
the wiring harness.
When measuring wheel speed sensor resistance,
insure vehicle is at room temperature (20C or 68F).
Wheel speed se n sor resistance will vary with
temperature.
and/or water intrusion. If evidence of corrosion or
water intrusion exists, replace wheel speed sensor
DTCA021
(Page 2 of 2)
LEFT FRONT WHEEL SPEED
=0
r---------------,
: DIAGNOSIS CONTINUED :
I FROM PREVIOUS PAGE. 1
L-
-------------~
IGNITION "OFF. "

DISCONNECT 32-WAV EBCM CONNECTOR.
TERMINAL " A7" AND TERMINAL " AS" OF THE 32-WAV
EBCM HARNESS CONNECTOR.
DOES J 39200 DISPLAY RESISTANCE AS "OL" (INFINITE)?
CKT 830/900 AND CKT 873/ 901

SHORTED TOGETHER. REPAIR
SHORT AND RECHECK.
IS VOLTAGE OUT OF RANGE

ON TERMINAL" A"?
IGNITION "OFF."
USING J 39200, MEASURE THE RESISTANCEBETWEEN
TERMINAL" A" OF THE LEFT FRONT WH'EEL SPEED
SENSOR HARNESS CONNECTOR AND TERMINAL" AB"
OF THE 32-WAV EBCM HARNESS CONNECTOR.
INSPECT 32-WAY EBCM CONNECTOR FOR POOR

CONNECTION.
RECONNECT ALL CONNECTORS AND REPEAT STEP 2.
IF OTC RETURNS OR WHEEL SPEED IS NOT WITHIN 5
MPH OF REMAINING WHEEL SPEED INPUTS, REPLACE
EBCM.
IGNITION "OFF."
TERMINAL "B" OF THE LEFT FRONT WHEEL SPEED
SENSOR HARNESS CONNECTOR AND TERMINAL" A7"
OF THE 32-WAV EBCM HARNESS CONNECTOR
IS RESISTANCE ~Q OR LESS?
INSPECT 32-WAV EBCM CONNECTOR TERMINALS FOR POOR

CONNECTION.
RECONNECT ALL CONNECTIONS AND REPEA, T STEP 2.
IF OTC RETURNS OR WHEEL SPEED IS NOT WITHIN 5 MPH OF
REMAINING WHEEL SPEED INPUTS, REP~ACE EBCM.
11-10-92
NS 15708
'I
' '
EBCM
ABS JUMPER HARNESS
- - - ~G::r
---- 8--
901WHT
900 BLK
833TAN
R/F WHEEL SIGNAL LOW
872 DK GRN
R/F WHEEL SIGNAL HIGH
( 130
R/F WHEEL SPEED SENSOR
10-21 -92
NS 15729
DTCA022
(Page 1 of 2)
RIGHT FRONT WH EEL SPEED
=0
As a toothed ring passes by the wheel speed sensor, changes in the electromagn etic field cause the wheel
speed sensor to produce a sinusoidal (AC) volta ge signa l whose freque ncy is proportional to wheel speed. The
toothed ring, often referred to as the a ir ga p.
Failure Condition:
OTC A022 can be set when the vehicle is not in an ABS stop. If the right front wheel speed = 0 and the
vehicle's reference speed is grea ter t han 8 km/h (5 mph), a malfunction exists.
Action Taken:
A malfunction OTC is stored, ABS is disa bled a nd the "ABS INOP" lamp is turned "ON."
If the cu stomer's comments r eflect t ha t the "ABS
INOP" lamp is "ON " only during moist environmental
1. This test determines if OTC A033 is present.
changes (rain, snow, vehicle wash), a ll wheel speed
2. This step verifies whethe r the ma lfunction is
currently present.
signs of wa ter intrusion. If OTC is not current, clear
3. This step is designed to ide ntify a whee l speed
DTCs and s imulate the effects of water intrusion. Use
the following procedure. Spray down t he sus pected
apparent.
salt to 12 oz. of water) . Start vehicle, allow vehicle to
is within proper resistance va lues.
generate an appropriate output signal.
Any circuitry, that is s u spected as causing t he
intermittent complaint, should be t horoughly checked
6. This test checks for proper output volta ge from t he
EBCM.
for backed out terminals, improper m ating, broken
locks, improperly formed or damaged te rminals, poor
Diagnostic Aids:
termina l to wiring connections or physica l damage to
the wiring ha rness.
When measuring wheel speed sensor r esis ta nce,
poor connection, rubbed through wire insulation , or a
Wheel s pe ed se n sor res i stance w i ll va ry with
tempera ture .
When replacing a wheel speed sensor, inspect t he
1, as described in "Tech 1 Diagnos tics" found in this
sensor te rminals and harness connector for corrosion
section.
and/or water intrusion . If e vide nce of corrosion or
water int rusion exists, rep lace whee l s peed sensor
harness . Refer to "On-Veh icle Ser vice " in t his section.
ANTILOCK BRAKE SYSTEM 5E1-5'.I
IMPORTANT: WHEEL SPEED SENSOR INTERMITTENT PROBLEMS

MAY BE DIFFICULT TO LOCATE . CARE SHOULD BE TAKEN NOTTO
STEP OF THIS CHART. THIS WILL INSURE THAT AN INTERMITTENT
PROBLEM IS FOUND.
DTCA022
(Page 1 of 2)
RIGHT FRONT WHEEL SPEED
=0
I,
TEST DRIVE VEHICLE.

MONITOR WHEEL SPEED ON RIGHT FRONT WHEEL WHILE
IS RIGHT FRONT WHEEL SPEED WITHIN 5 MPH OF REMAINING
WHEEL SPEED INPUTS'?
IGNITION "OFF." ,
PHYSICALLY INSPECT WHEEL SPEED SENSOR, WIRING AND
CONNECTORS FOR DAMAGE.

TIME. REFER TO "DIAGNOSTIC AIDS" ON
FACING PAGE.
DISCONNECT RIGHT FRONT WHEEL SPEED SENSOR

DIRECTLY AT SENSOR.
TERMINAL " A" AND TERMINAL "B" OF THE WHEEL SPEED
SENSOR. ,
,
IS RESISTANCE BETWEEN 990 AND 121001
r-
WITH J 39200 STILL CONNECTED, SELECT A.C. VOLTAGE

SCALE.
SPIN WHEEL BY HAND WHILE OBSERVING VOLTAGE .
IS VOLTAGE AT LEAST 100 mV (VOLTAGE WILL INCREASE AS
WHEEL SPEED INCREASES)'?

IGNITION"ON."
MEASURE VOLTAGE BETWEEN GROUND AND TERMINAL" A",
THEN TERMINAL "B" OF THE RIGHT FRONT WHEEL SPEED SENSOR
HARNESS CONNECTOR.
.
IS VOLTAGE BETWEEN 2.2SAND2.75 VOLTS ON EACH TERMINAL?

------- - - -- ---,
I ON NEXT PAGE.
:
1
L----------------J
11 -18-92
NS 16189
EBCM
ABS JUMPER HARNESS

(130
10-21-92
NS.15729
DTCA022
(Page 2 of 2)
=0
Failure Condition:
DTC A022 can be set when the vehicle is not in an ABS stop. If the right front wheel speed=O and the
vehicle's reference speed is greater than 8 km/h (5 mph), a malfunction exists.
Action Taken:
7. This checks for an open in the wheel signal HIGH
circuit.
8. This step insures that DTC A022 was not set due to
connector and the EBCM.
9. This test insures that wheel speed sensor circuitry
10. This checks for an open in the wheel signal LOW
circuit.
Diagnostic Aids:
1, as described in "Tech I Diagnostics" found in this
section.
signs of water intrusion. If DTC is not current, clear

the wiring harness.
temperature.
ANTILOCK BRAKE SYST.EM 5E1-53
DTCA022
(Page 2 of 2)
=0
r---------------,
: DIAGNOSIS,CONTINUED :
L-
-------------~
IGNITION "Off."
TERMINAL "A3" AND TERMINAL" A4 " OF THE 32-WAV
DOESJ 39200 DISPLAY RESISTANCE AS "OLH (INFIN ITE)?
CKT 833/901 AND CKT 872/ 900

SHORT AND RECHECK.
INS~ECT 32-WAV EBCM CONNECTOR FOR POOR

CONNECTION.
RECONNECT ALL CONNECTORS,ANI;) REPEAT STEP 2.
IF OTC RETURNS OR WHEEL SPEED IS NOT WITHIN 5 MPH
OF REMAINING WHEEL SPEED INPUTS, REPLACE EBCM.

ON TERMINAL " A"?
I ,
IGNITION "OFF."
TERMINAL HA" OF THE RIGHT FRONT WHEEL SPEED
SE[',ISOR HARNESS CONNECTOR AND TERMINAL" A4"
IGNITION "OFF."
TERMINAL "B" OF THE RIGHT FRONT WHEEL SPEED
SENSOR HARNESS CONNECTOR AND TERMINAL " Ar
IS RESISTANCE 2Q OR LESS?
INSPECT 32-WAV EBCM CONNECTOR TERMINALS FOR POOR

CONNECTION .
RECONNECT ALL CONNECTIONS AND REPEAT STEP 2.
IF OTC RETURNS OR WHEEL SPEED IS NOT WITHINS MPH OF
REMAINING WHEEL SPEED INPUTS, REPLACE EBCM.
11-10-92
NS 15709
EBCM
ABS JUMPER HARNESS
1810WHT~1810WHT-Q-1a1owHT
REAR WHEEL SPEED

SIGNAL HIGH
1811 BLK--0-1811 BRN --B-1811 BRN
REAR WHEEL SPEED

SIGNAL LOW
(4058
C40SC
C200A
C200D
1-27-93
NS 15730
DTCA024
(Page 1 of 2)
REAR WHEEL SPEED = 0

Failure Condition:
OTC A024 can be set when the vehicle is not in an ABS stop. If the rear wheel speed= 0 and the vehicle's
Action Taken:
1. This test determines if OTC A035 is present.
currently present.
signs of water intrusion. If OTC is not current, clear
3 . This step is designed to identify a wheel speed
DTCs and simuiate the effects of water intrusion. Use
apparent.
EBCM.
Diagnostic Aids:
the wiring harness.
temperature.
section.
ANTILOCK BRAKE SYSTEM 5E1 - 55
IMPORTANf.:

MAY BE DIFFICULTTO LOCATE. CARE SHOULD BE TAKEN NOT TO
CONNECTION W ILL NOT BE CORRECTED BEFORE THE SOURCE OF THE
PROBLEM IS FOUND .
DTCA024
(Page 1 of 2)
REAR WHEEL SPEED
=0
0 ..
i~s~D_T_c_A_o_35_A_L_s_o_c_u_R_R_E_N_TL_Y_s_E_T_
?~
TEST DRIVE VEHICLE.

USINGTECH 1,SELECTDATALIST.
,MONITOR WHEEL SPEED ON REAR WHEELS WHILE SLOWLY
DECELERATING FROM 35 MPH TOO MPH.
ARE REAR WHEEL SPEEDS WITHIN 5 MPH OF REMAINING
WHEEL SPEED INPUTS?
0 .
IGNITION HOFF."
PHYSICALLY INSPECT REAR WHEEL SPEED SENSOR,
WIRING AND CONNECTORS FOR DAMAGE.

THIS TIME . REFER TO "DIAGNOSTIC
AIDS" ON FACING PAGE.
DISCONNECT REAR WHEEL SPEED SENSOR DIRECTLY AT SENSOR.

USING J 39200, MEASURE THE RESISTANCE BETWEEN TERMINAL
"A" AND TERMINAL " B" OF THE WHEEL SPEED SENSOR.
WITH J 39200 STILL CONNECTED, SELECT AC VOLTAGE SCALE.

VEHICLE TRANSMISSION IN NEUTRAL.
IS VOLTAGE AT LEAST 100mV (VOLTAGE WILL INCREASE AS

IGNITION " ON."

SELECT DC VOLTAGE SCALE ON J 39200.
MEASURE VOLTAGE BETWEEN GROUND AND TERMINAL "A",
THEN TERMINAL " B" OF THE REAR WHEEL SPEED SENSOR
HARNESS CONNECTOR.
IS VOLTAGE BETWEEN 2.25 AND 2.75 VOLTS ON EACH TERMINAL?
REPLACE WHEEL SPEED

SENSOR, CLEAR DTCs
AND RECHECK.
r----------------,
I ON NEXT PAGE.
~----------------~
11-18-92
NS15710
EBCM
ABS JUMPER HARNE SS
1810 WHT--GJ--1810 W H T - Q 1810 WHT
REAR WHEEL SPEED

SIGNAL HIGH
1811 BLK-@-1811BRN-81811 BRN
REAR WHEEL SPEED

SIGNAL LOW
C405B
C405C
C200A
C200D
1-27-93
NS 15730
DTCA024
(Page 2 of 2)
REAR WHEEL SPEED
=0
speed sensor to produce a sinusoidal (AC) voltage signal whose freque~cy is proportional to wheel speed. The
Failure Condition:
DTC A024 can be set when the vehicle is not in a n ABS stop. If the rear wheel speed= 0 and the vehicle's
reference speed is greater than 8 km/h (5 mph), a ma lfunction exists.
Action Taken:

circuit.
salt to 12 oz. of water). Start vehicle, a llow vehicle to
circuit.
the wiring harness.
Diagnostic Aids:
Wheel speed sensor resistance wi ll vary with
temperature.
section.
ANTltO.CK BRAKE SYSTEM 5E1-57
DTCA024
(Page 2 of 2)
REAR WHEEL SPEED = 0
r---------------,
~
_ _ PREVIOUS
_ _ _ _ _ _ _PAGE.
____ j 1
I FROM
I I
IGNITION oFF."
TERMINAL "AS" AND TERMINAL "A6" OF THE 32-WAY
DOES J39200 DISPLAY RESISTANCE AS "OL (INFINITE)?
CKT1810ANDCKT1811 ,
SHORT AND RECHECK.

CONNECTION.
RECONNECT ALL CONNECTORS AND REPEAT STEP 2 .
IF OTC RETURNS OR WHEEL SPEED IS NOT WITHINS MPH

ON TERMINAL A 1
IGNITION oFF.
DISCONNECT32-WAY EBCMCONNECTOR.
TERMINAL A OF THE REAR WHEEL SPEED SENSOR
HARNESS CONNECTOR AND TERMINAL As OF THE
32-WAY EBCM HARNESS CONNECTOR
,
IGNITION " OFF."
TERMINAL "B" OF THE REAR WHEEL SPEED SENSOR
HARNESS CONNECTOR AND TERMINAL A6" OF THE
'32-WAY EBCM HARNESS CONNECTOR
INSPECT 32-WAY EBCM CONNECTOR TERMINALS FOR POOR CONNECTION.

IF OTC RETURNS OR WHEEL SPEED IS NOT WITHINS MPH OF REMAINING
WHEEL SPEED INPUTS, REPLACE EBCM.
11-10-92
NS1S711
EBCM
ABS JUMPER HARNESS
0 ====~
901 WHT-----<~AB
900 BLK
873 YEL - - - - - 1
830 LT BLU - - - - - "
UF WHEEL SIGNAL LOW

C120
10-21-92
NS 15728
DTCA025
(Page 1 of 2)
LEFT FRONT EXCESSIVE WHEEL SPEED VARIATION

Failure Condition:
OTC A025 can be set when the brake is "OFF." The purpose of this test is to detect a situation in which the
left front wheel acceleration or deceleration is beyond specified limits.
Action Taken:
1. This test determines if OTC A032 is also set.
currently present.
run for 10 seconds . If OTC returns immediately,
sensor or circuitry . that is damaged and visibly
apparent.
the wiring harness.
EBCM.
insure
vehicle is at room temperature (20C or 68F).
Diagnostic Aids:
temperature.
I, as described in "Tech 1 Diagnostics" found in this
section.

MAY BE DIFFICULT TO LOCATE. CARE SHOULD BE TAKEN NOT TO
PROBLEM IS FOUND.
TEST DRIVE VEHICLE.

USINGTECH 1,SELECT DATALIST.
MONITOR WHEEL SPEED ON LEFT FRONT WHEEL WHILE
IS LEFT FRONT WHEEL SPEED WITHIN 5 MPH OF REMAINING
WHEEL SPEED INPUTS?
IGNITION "OFF."
PHYSICALLY INSPECT WHEEL SPEED SENSOR,
WIRING AND CONNECTORS FOR DAMAGE.
IS PHYSICAL DAMAGE INDICATED'?
r-
DTCA025
(Page 1 of 2)
LEFT FRONT EXCESSIVE

WHEEL SPEED VARIATION

THIS TIME. REFER TO "DIAGNOSTIC

DIRECTLY AT SENSOR.
TERMINAL" A .. AND TERMINAL -B" OF THE WHEEL SPEED
SENSOR.
IS RESISTANCE BETWEEN 990 AND 121007
WITH J 39200 STILL CONNECTED, SELECT AC VOLTAGE SCALE.

IS VOLTAGE AT LEAST 100 mV(VOLTAGE WILL INCREASE AS
,

IGNITION "ON."
MEASURE VOLTAGE BETWEEN GROUND AND TERMINAL - A " ,
THEN TERMIN.AL "B" OF THE LEFT FRONT WHEEL SPEED SENSOR
HARNESS CONNECTOR.
IS VOLTAGE BETWEEN 2.25 AND 2.75 VOL TS ON EACH TERMINAL1

--------------,
ON NEXT PAGE.
:
I
L------------ ----~
11-10-92
NS 16188
EBCM
ABS JUMPER HARNESS
0-:=~::_--
901 WHT----i[!]Ae
900 BLK
873 YEL
-----1
830 LT BLU _ _ ___.,
UF WHEEL SIGNAL LOW

C120
10-21-92
NS 15728
DTCA025
(Page 2 of 2)
LEFT FRONT EXCESSIVE WHEEL SPEED VARIATION
Failure Condition:
DTC A025 can be set when the brake is "OFF." The purpose of this test is to detect a situation in which the
left front wheel acceleration or deceleration is beyond specified limits.
Action Taken:
Use the fo llowing procedure. Spray down the
suspected area with a 5% salt water solution (two
7. This checks for a n open in the wheel signal high
teaspoons of salt to 12 oz. of water). Start vehicle,
circuit.
allow vehicle to run for 10 seconds. If DTC returns
8. This step insures that OTC A025 was not set due to
immediately, replace suspected harness.
Any circuitry, that is suspected as ca using the
9. This step insures t hat wheel speed sensor circuitry
circuit.
the wiring harness.
Diagnostic Aids:
temperature.
a nd/or water intrusion. If evidence of corrosion or
harness. Refer to "On-Vehicle Service" in t his section.
section.
sensor circuitry should be thoroughly in spected for
DTCs and s imulate the effects of water intrusion.
DTCA025
(Page 2 of 2)
LEFT FRONT EXCESSIVE WHEEL

SPEED VARIATION
r---------------,
L-
-------------~
IGNITION "OFF."
TERMINAL" A 7" AND TERMINAL" AB " O F THE 32-WAY
DOES J 39200 DISPLAY RESISTANCE AS " OL" (INFINITE)?
CKT 830/900 AND CKT 873/901

SHORT AND RECHECK.
IS VOLT AGE OUT OF RANGE

ON TERMINAL " A"?
0 .
IGNITION HOFF."
TERMINAL "A" OF THE LEFT FRONT WHEEL SPEED
SENSOR HARNESS CONNECTOR AND TERMINAL" AS"
INSPECT 32-WA Y EBCM CONNECTOR FOR POOR

CONNECTION .
RECONNECT ALL CONNECTORS AND REPEAT STEP 2.
IF OTC RETURNS OR WHEEL SPEED IS NOT WITHIN 5
MPH OF REMAINING WHEEL SPEED INPUTS, REPLACE
EBCM.
IGNITION "OFF."
TERMINAL " B" OF THE LEFT FRONT WHEEL SPEED
SENSOR HARNESS CONNECTOR AND TERMINAL A7""
OF THE 32-WAY EBCM HARNESS CONNECTOR
YES
INSPECT 32-WAY EBCM CONNECTOR TERMINALS FOR POOR

CONNECTION.
IF OTC RETURNS OR WHEEL SPEED IS NOT WITHIN 5 MPH OF
11-10-92
NS 15708
EBCM
ABS JUMPER HARNESS
t-r-====-
901 WHT ----1[!]AB
833 TAN
- - - 900 BLK - - - - 1 0
872 DK GRN

(130
10-21-92
NS 15729
DTCA026
(Page 1 of 2)
RIGHT FRONT EXCESSIVE WHEEL SPEED VARIATION
Failure Condition:
right front wheel acceleration or deceleration is beyond specified limits.
Action Taken:
1. This determines ifDTC A033 is present.
2. This step verifies whether the malfunction is
currently present.
apparent.
the wiring harness.
EBCM.
insure
vehicle is at room temperature (20C or 68F).
Diagnostic Aids:
temperature.
section.
IMPORTANT:

MAY BE DIFFICULT TO LOCATE. CARE SHOULD BE TAKEN NOTTO
PROBLEM 15 FOUND.
TEST DRIVE VEHICLE .

MONITOR WHEEL SPEED ON RIGHT FRONT WHEEL WHILE
15 RIGHT FRONT WHEEL SPEED WITHIN 5 MPH OF REMAINING
WHEEL SPEED INPUTS?
IGNITION " OFF."

PHYSICALLY INSPECT WHEEL SPEED SENSOR, WIRING AND
CONNECTORS FOR DAMAGE.
15 PHYSICAL DAMAGE INDICATED?
DTCA026
(Page 1 of 2)
RIGHT FRONT EXCESSIVE


FACING PAGE .
DISCONNECT RIGHT FRONT WHEEL SPEED SENSOR

DIRECTLY AT SENSOR.
TERMINAL" A " AND TERMINAL "B" OF THE WHEEL SPEED
SENSOR.
WITH J 39200 STILi,. CONNECTED, SELECT A .C. VOLTAGE

SCALE .
IS VOLTAGE AT LEAST 100 mV (VOLTAGE WILL INCREASE AS

IGNITION "ON."
MEASURE VOLTAGE BETWEEN GROUND AND TERMINAL "A",
THEN TERMINAL "B" OF THE RIGHT FRONT WHEEL SPEED SENSOR
HARNESS CONNECTOR.
IS VOLTAGE BETWEEN 2.25 AND 2.75 VOLTS ON EACH TERMINAL?

r- - - - - - - - - - - - - - - ,
I ON NEXT PAGE .
t
L----------------~
11 -18-92
NS 16189
EBCM
ABS JUMPER HARNESS
0 t-====-
901 WHT------1[!]Aa,900 BLK
833 TAN
872 DK GRN
(130
10-21-92
NS 15729
DTCA026
(Page 2 of 2)
RIGHT FRONT EXCESSIVE WHEEL SPEED VARIATION
Failure Condition:
right front wheel acceleration or deceleration is beyond specified limits.
Action Taken:

7. This checks for an open in the wheel signal HIGH
circuit.
10. This checks for an open in the wheel signal LOW
circuit.
Diagnostic Aids:
section.
!NOP" lamp is "ON" only during moist environmental

the wiring harness.
temperature.
DTCA026
(Page 2 of 2)
RIGHT FRONT EXCESSIVE

r---------------,
: DIAGNOSIS CONTINUED:
I FROM PREVIOUS PAGE . 1
L-
--- - ---- -----~
IGNITION " OFF."

TERMINAL " A3" AND TERMINAL" A4" OF THE 32-WAY
EBCNI HARNESS CONNECTOR.
SHORT AND RECHECK.
INSPECT 32-WA Y EBCM CONNECTOR FOR POOR

CONNECTION.
RECONNECT ALL CONNECTORS AND REPEAT STEP 2 .
IF OTC RETURNS OR WHEEL SPEED IS NOT WITHINS MPH

ON TERMINAL " A " ?
IGNITION "OFF."
USING J 39200, MEASURE THE RESISTANCE BETWE EN
TERMINAL " A " OF THE RIGHT FRONT WHEEL SPEED
SENSOR HARNESS CONNECTOR AND TERMINAL" A4"
IGNITION "OFF."
TERMINAL "B" OF THE RIGHT FRONT WHEEL SPEED
SENSOR HARNESS CONNECTOR AND TERMINAL A3"
INSPECT 32-WAY EBCM CONNECTOR TERMINALS FOR POOR

CONNECTION .
IF OTC RETURNS OR WHEEL SPEED IS NOT WITHINS MPH OF
11 -10-92
NS 15709
EBCM
ABS JUMPER HARNESS
1810 WHT--GJ---1810 W H T - Q 1810 WHT
REAR WHEEL SPEED

SIGNAL HIGH
1811 BLK--@]-1811 BRN-81811 BRN
REAR WHEEL SPEED

SIGNAL LOW
C405B
C405C
C200A
(2000
1-27-93
NS 15730
DTCA028
(Page 1 of 2)
REAR EXCESSIVE WHEEL SPEED VARIATION
Failure Condition:
rear wheel acceleration or deceleration is beyond specified limits.
Action Taken:
1. This determines ifDTC A035 is present_
2. This test verifies whether the malfunction 1s
currently present.
apparent.
EBCM.
the wiring harness.
Diagnostic Aids:
temperature.
section.
changes (rain, snow, vehicle wash), a ll wheel speed

MAY BE DIFFICULT TO LOCATE. CARE SHOULD BE TAKEN NOT TO
PROBLEM IS FOUND.
DTCA028
(Page 1 of 2)
REAR EXCESSIVE WHEEL SPEED

VARIATION
(D 1s DTC A035 ALSO CURRENTLY sen
TEST DRIVE VEHICLE.

MONITOR WHEEL SPEED ON REAR WHEELS WHILE SLOWLY
DECELERATING FROM 35 MPH TOO MPH.
ARE REAR WHEEL SPEEDS WITHIN 5 MPH OF REMAINING
WHEEL SPEED INPUTS?
IGNITION off.
PHYSICALLY INSPECT REAR WHEEL SPEED SENSOR,
WIRING AND CONNECTORS FOR DAMAGE .

THIS TIME . REFER TO " DIAGNOSTIC
A IDS ON FACING PAGE.
DISCONNECT REAR WHEEL SPEED SENSOR DIRECTLY AT SENSOR.

USING J 39200, MEASURE THE RESISTANCE BETWEEN TERMINAL
A AND TERMINAL eHOF THE WHEEL SPEED SENSOR.
WITHJ39200STILLCONNECTED,SELECTACVOLTAGESCALE.
VEHICLE TRANSMISSION IN NEUTRAL.
IS VOLTAGE AT LEAST 100mV (VOLTAGE WILL INCREASE AS

CLEAR DTCs ANO RECHECK.
IGNITION oN.
SELECT DC VOLTAGE SCALE ON J 39200.
MEASURE VOLTAGE BETWEEN GROUND ANO TERMINAL A ",
THEN TERMINAL B OF THE REAR WHEEL SPEED SENSOR
HARNESS CONNECTOR.
IS VOLTAGE BETWEEN 2.25 AND2 .75 VOLTS ON EACH TERMINAL?
REPLACE WHEEL SPEED

SENSOR, CLEAR DTCs
ANO RECHECK.
r----------------,
I ON NEXT PAGE.
:
I
L----------------~
THIS CHART ASSUMES THAT A CURR ENT DTC IS STORED INDICATING THAT T HIS MALFUNCTION IS PRESENT.
11 -18-92
NS 15710
EBCM
ABS JUMPER HARNESS

1810 WHT
~ 1810 WHT-Q 1810 WHT
1811 BLK-0--1811BRN-81811 BRN
C405B
C405C
C200A
C200D
REAR WHEEL SPEED

SIGNAL HIGH
REAR WHEEL SPEED
SIGNAL LOW
1-27-93
NS 15730
DTCA028
(Page 2 of 2)

Failure Condition:
DTC A028 can be set when the brake is "OFF ." The purpose of this test is to detect a situation in which the
rear wheel acceleration or deceleration is beyond specified limits.
Action Taken:

circuit.
circuit.
Diagnostic Aids:
section.
signs of water intrusion. If OTC is not current clear

run for 10 seconds . If OTC returns immediately,
the wiring harness.
Wheel speed sen~or resistance will vary with
temperature.
DTCA028
(Page 2 of 2)
r---------------,
L-
-------------~
IGNITION HOFF."
TERMINAL " AS" AND TERMINAL " A6" OF THE 32-WAY
DOESJ 39200 DISPLAY RESISTANCE AS "OL" (INFINITE)?
CKT 1810 AND CKT 1811

SHORT AND RECHECK.

CONNECTION.
RECONNECT All CONNECTORS AND REPEAT STEP 2.
IF OTC RETURNS OR WHEEL SPEED IS NOT WITHIN 5 MPH

ON TERMINAL A"?
0 .
IGNITION "OFF.H
TERMINAL " A " OF THE REAR WHEEL SPEED SENSOR
HARNESS CONNECTOR AND TERMINAL HAS" OF THE
IGNITION HOFF."
TERMINAL "8" OF THE REAR WHEEL SPEED SENSOR
HARNESS CONNECTOR AND TERMINAL" A6" OF THE
INSPECT 32-WAY EBCM CONNECTOR TERMINALS FOR POOR CONNECTION.

RECONNECT All CONNECTIONS AND REPEAT STEP 2.
IF OTC RETURNS OR WHEEL SPEED IS NOT WITHIN 5 MPH OF REMAINING
WHEEL SPEED INPUTS, REPLACE EBCM.
11 -1 0-92
NS 15711
EBCM
ABS JUMPER HARNESS
8
1
::: :: ----i~:=====-8-30 ~: ::~ :======
LJF WHEEL SIGNAL LOW

LJF WHEEL SIGNAL HIGH
C120
LJF WHEEL SPEED SENSOR
10-21-92
NS 15728
DTCA032
LEFT FRONT WHEEL SENSOR SHORTED TO BATTERY OR GROUND
toothed ring often referred to as the air gap.
Failure Condition:
OTC A032 can be set anytime after initialization. If either of the left front wheel speed circuits are shorted to
voltage or ground, a malfunction exists.
Action Taken:

1. This test helps to identify whether the DTC is due
to a short to battery or short to ground.
2. This insures that the wheel speed sensor is not
shorted to ground.
3. This insures that the wheel speed sensor circuitry
has good continuity.
4. This checks for short to ground in wheel speed
sensor wiring.
5. This step checks for a possible intermittent
malfunction.
6. This step checks for a possible intermitte nt
malfunction.
7. This step checks to see if wheel speed senso r
circuitry is shorted to voltage .
8. This checks for short to voltage in wheel s peed
sensor wiring.
malfunction.
Diagnostic Aids:
wire that is broken inside the insu lation.

section.
sensor circuitry should be thoroughly ins pected for
signs of water intrusion. lf DTC is not current, clear
the following procedure. Spray down the s uspected
for backed out termina ls, improper mating, broken
the wiring harness.
water intrus ion ex ists, re place wheel s peed sensor
ANTILOCK BRAKE SYSTEM 5E1-7,1
IMPORTANT: WHEEL SPEED SENSOR INTERMITTENT

PROBLEMS MAY BE DIFFICULT TO LOCATE. CARE SHOULD BE
TAKEN NOT TO DISTURB ANY ELECTRICAL CONNECTIONS
PRIOR TO AN INDICATED STEP OF THIS CHART. THIS WILL
INSURE THAT AN INTERMITTENT CONNECTION WILL NOT BE
CORRECTED BEFORE THE SOURCE OF THE PROBLEM IS FOUND.
DTCA032
LEFT FRONT WHEEL SENSOR
SHORTED TO BATTERY OR GROUND
..
TEST DRIVE VEHICLE.

MONITOR LEFT FRONT WHEEL SPEED WHILE SLOWLY DECELERATING FROM 35 MPH TOO MPH.
DOES WHEEL SPEED MATCH REMAINING WHEEL SPEED INPUTS?
IGNITION "OFF."
DIRECTLY AT SENSOR.
USING J 39200, MEASURE RESISTANCE BETWEE N GROUND
AND TERMINAL" A" ON THE WHEEL SPEED SENSOR.
IGNITION "ON."
VOLTAGE BETWEEN GROUND
AND TERMINAL "A", THEN
TERMINAL "B" 0F'rHE LEFT
FRONT WHEEL SPEED SENSOR
HARNESS CONNECTOR.
WAS VOLTAGE BETWEEN 2.25
AND 2.75 VOLTS ON BOTH
TERMINALS?
REPLACE WHEEL
SPEED SE NSOR,
CLEAR ALL DTCs
~ND RE-CHECK.
IGNITION "OFF."
DISCONNECT 32-WAY
EBCM CONNECTOR.
THE RESISTANCE BETWEEN
GROUND AND TERMINAL
"A7" THEN TERMINAL
"AB" OF THE 32 -WAY
EBCM HARNESS
CONNECTOR.
DOES J 39200 DISPLAY
RESISTANCE AS "OL"
(INFINITE)?
RECONNECT ALL
CONNECTIONS.
CLEAR DTCs.
DOES OTC A032 RESET
IMMEDIATELY?
RECONNECT ALL
CONNEplONS.
CLEAR DTCs.
DO ES OTC A032
RESET IMMEDIATELY?
MALFUNCTION IS
INTERMITTENT.
REFER TO
"DIAGNOSTIC
AIDS" ON
FACING PAGE.
REPAIR SHORT TO
GROUND IN CIRCUIT
THAT DID NOT SHOW
INFINITE RESISTANCE.
IGNITION "OFF."
DIRECTLY AT SENSOR.
IGNITION "ON."
USING J 39200, MEASURE THE VOLTAGE
BETWEEN GROUND AND TERMINAL" A" , TH EN
TERMINAL "B" OF THE LEFT FRONT WHEEL
SPEED SENSOR HARNESS CONNECTOR.
IGNITION "OFF."
DISCONNECT 32-WA Y
EBCM CONNECTOR.
IGNITION " ON."
MEASURE THE VOLTAGE
BETWEEN GROUND AND
TERMINAL HA 7" THEN
TERMINAL" AB" OF THE
32-WAY EBCM HARNESS
CONNECTOR.
WAS VOLTAGE 1 VOLT OR
LESS ON BOTH TERMINALS?
MALFUNCTION IS
INTERMITTENT.
REFER TO
"DIA<iNOSTIC AIDS"
ON FACING PAGE.
RECONNECT ALL
CONNECTIONS.
CLEAR OTCs.
DOES OTC A032
RESET IMMEDIATELY?
REPAIR SHORT
TO VOLTAGE IN
CKT873/901
OR
CKT 830/900.
MALFUNCTION IS
INTERMITTENT. REFER
TO "DIAGNOSTIC AIDS"
ON FACING PAGE.
REFER TO "DIAGNOSTIC AIDS" ON
FACING PAGE.
11-23-92
NS15712
5E172 ANTILOCK BRAKE SYSTEM
EBCM
ABS JUMPER HARNESS

901 WHT
900 BLK
----1~
833TAN
----@---
872 DK GRN
(130
10-21-92
NS 15729
DTCA033
RIGHT FRONT WHEEL SENSOR SHORTED TO BATIERY OR GROUND
magnitude of this signal is directly related to wheel speed and the proximity of the wheel speed sen sor to the
Failure Condition:
OTC A033 can be set anytime after initialization. If either of the right front wheel speed circuits are shorted
to voltage or ground, a malfunction exists.
Action Taken:
1, as described in "Tech 1 Diagnostics" found in t his
section.
1. This test helps identify whether t he OTC is due to
a short to battery or short to ground.
shorted to ground.
OTCs and simulate the effects of water intrusion. Use
sensor wiring.
salt to 12 oz. of water) . Start vehicle, allow vehicle to
malfunction.
malfunction.
7. This step checks to see if wheel speed sensor
circuitry is shorted to voltage.
8. This checks for short to voltage in wheel speed
sensor wiring.
the wiring harness.
malfunction.
Diagnostic Aids:
a nd/or water intrusion. If evidence of corrosion or
IMPORTANT:
WHEEL SPEED SENSOR INTERMITTENT

PROBLEMS MAY BE DIFFICULT TO LOCATE . CARE SHOULD BE
CORRECTED BEFORE THE SOURCE OF THE PROBLEM IS FOUND.
0 .
0 .
0:
RIGHT FRONT WHEEL SENSOR

SHORTED TO BATTERY OR GROUND
TEST DRIVE VEHICLE.

USING TECH 1, SELECT DATA LIST .
MONITOR LEFT FRONT WHEEL SPEED WHILE SLOWLY DE CE LERA TING FROM 35 MPH TOO MPH.
IGNITION "Off."
DIRECTLY AT SENSOR.
USING J 39200, MEASURE RESISTANCE BETWEEN GROUND
AND TERMINAL "A" ON THE WHEEL SPEED SENSOR.
IGNITION "ON.
AND TERMINAL" A", THEN
TERMINAL "8" OF THE LEFT
HARNESS CONNECTOR.
AND 2 .75 VOLTS ON BOTH
TERMINALS?
H
IGNITION "OFF."
DISCONNECT 32WAY
EBCM CONNECTOR.
GROUND AND TERMINAL
" A3" THEN TERMINAL
" A4" OF THE 32-WAY
EBCM HARNESS
CONNECTOR.
DOESJ 39200 DISPLAY
RESISTANCE AS "OL
(INFINITE)?
REPLACE WHEEL
SPEED SENSOR,
CLEAR ALL DTCs
AND RE-CHECK.
RECONNECT ALL
CONNECTIONS.
CLEAR DTCs.
TEST DRIVE VEHICLE.
DOES OTC A033 RESET
IMMEDIATELY?
RECONNECT ALL
CONNECTIONS.
CLEAR DTCs.
TEST DRIVE VEHICLE.
DOES OTC A033
RESET IMMEDIATELY?
MALFUNCTION IS
INTERMITTENT.
REFER TO
"DIAGNOSTIC
AIDS"ON
FACING PAGE .
DTCA033
REPAIR SHORT TO
GROUND IN CIRCUIT
THAT DID NOT SHOW
IGNITION "Off."
DIRECTLY AT SENSOR.
IGNITION "ON."
BETWEEN GROUND AND TERMINAL "A", THEN
TERMINAL "8" OF THE LEFT FRONT WHEEL
IS VOLTAGE 3 VOL TS OR LESS?
IGNITION "OFF."
DISCONNECT 32-WA Y
EBCM CONNECTOR.
IGNITION "ON ."
MEASURE THE VOLTAGE
BETWEEN GROUND AND
TERMINAL" A3" THEN
TERMINAL " A4" OF THE
32-WAY EBCM HARNESS
CONNECTOR.
MALFUNCTION IS
INTERMITTENT.
REFER TO
"DIAGNOSTIC AIDS"
ON FACING PAGE.
RECONNECT All
CONNECTIONS.
CLEAR DTCs.
DOES OTC A033 RESET
IMMEDIATELY?
REPAIR SHORT
TO VOLTAGE IN
CKT833/901
OR
q<T872/900.
MALFUNCTION IS
INTERMITTENT. REFER
TO "DIAGNOSTIC AID~ "
ON FACING PAGE .
FACING PAGE .
1 1-23-92
NS 15713
EBCM
ABS JUMPER HARNESS
1810WHT--G}-1s1owHT-Q1s1owHT
REAR WHEEL SPEED

SIGNAL HIGH
1811 B L K - 8 - - 1811 BRN - 8 1 8 1 1 BRN
REAR WHEEL SPEED

SIGNAL LOW
C405B
C405C
C200A
C200D
1-27-93
NS15730
DTCA035
REAR WHEEL SENSOR SHORTED TO BATTERY OR GROUND
Failure Condition:
DTC A035 can be set anytime after initialization. If either of the rear wheel speed circuits are shorted to
voltage or ground, a malfunction exists.
Action Taken:
I, as described in "Tech I Diagnostics" found in this
section. .
1. This helps to identify whether the DTC is due to a
short to battery or short to ground.
shorted to ground.
sensor wiring.
malfunction.
malfunction.
7. This step checks to see if wheel speed sensor
circuitry is shorted to voltage.
8. This checks for short to voltage in wheel speed
sensor wiring.
the wiring harness.
malfunction.
Diagnostic Aids:
ANTILOCK BRAKE SYSTEM 5E1 -75
IMPORTANT: WHEEL SPEED SENSOR I NTERMITTENT

PROBLEMS MAY BE DIFFICULT TO LOCATE. CARE SHOULD BE
CORRECTED BEFORE TH E SOURCE OF THE PROBLEM IS FOUND.
8 .
0 .
DTCA035
REAR WHEEL SENSOR SHORTED TO
BATTERY OR GROUND
TE ST DRIVE VEHICLE .
MONITOR LEFT FRONT WHEEL SPEED WHILE SLOWLY DECELERATING FROM 35 MPH TOO MPH.
IGNITION " OFF. "

DIRECTLY AT SENSOR.
USING J 39200, MEASURE RESISTANCE BETWEEN GROUND
AND TERMIN AL " A" ON THE WHEEL SPEED SENSOR.
IGNITION "ON. "

AND TERMINAL HA" . THEN
TERMINAL " B" OF THE LEFT
HARNESS CONNECTOR.
AND 2.75 VOLTS ON BOTH
TERMINALS?
IGNITION " OFF."

DISCONNECT 32-WAY
EBCM CONNECTOR.
GROUND AND TERMINAL
"AS" THEN TERMINAL
"A6" OF THE 32-WAY
EBCM HARNE SS
CONNECTOR.
DOES J 39200 DISPLAY
RES ISTANCE AS "OL"
(INFINITE)?
RECONNECT ALL
CONNECTIONS.
CLEAR ores.
DOES OTC A035 RESET
IMMEDIATELY?
REPLACE WHEEL
SPEED SENSOR,
CLEAR ALL DTCs
AND RE -CHECK.
0 .
'6\
~
RECONNECT ALL
CONNECTIONS.
CLEAR ores.
TEST DRIVE VEH ICLE .
DOES OTC A035
RESET IMMEDIATELY1
,;;;:;;;;;:;;;;;:;;;.-----'
MALFUNCTION IS
INTERMITTENT.
REFER TO
" DIAGNOSTIC
AIDS" ON
FACING PAGE.
REPAIR SHORT TO
GROUND IN CIRCUIT
THAT DID NOT SHOW
IGNITION " OFF . ..

DIRECTLY AT SENSOR.
IGNITION "ON."
BETWEEN GROUND AND TERMINAL " A ", THEN
TERMINAL "8" OF THE LEFT FRONT WHEEL
IGNITION " OFF. "

DISCONNECT 32-WAY
EBCM CONNECTOR.
IGNITION "ON ."
MEASURE THE VOLTAGE
BETWEEN GROUND AND
TERMINAL " AS" THEN
TERMINAL" A6" OF THE
32 -WAY EBCM HARNESS
CONNECTOR.
MALFUNCTION IS
INTERMITTENT.
REFER TO
"DIAGNOSTIC AIDS"
ON FACING PAGE.
RECONNECT ALL
CONNECTIONS.
CLEAR ores.
DOES OTC A035 RESET
IMMEDIATELY?
REPAIR SHORT
TO VOLT AGE IN
CKT 1810
OR
CKT 1811 .
MALFUNCTION IS
INTERMITTENT. REFER
TO " DIAGNOSTIC AIDS"
ON FACING PAGE .
FACING PAGE .
11 -23-92
NS15714
1
EBCM
TO
IGN 3
B+
, - - - - - - - - - - - - - 6 4 1 BRN-------11
t~
~~....
SAMP
t ;..____,__
641BRN
1632 PNK
_l 302 RED
1633 RED
~302RED
LINKB
1633 RED

5272
11-23-92
NS 15732
DTCA036
LOW SYSTEM VOLTAGE
This OTC is used to monitor the voltage level available to the EBCM controller. If the voltage drops below
11.5 volts, full performance of the ABS system cannot be guaranteed. During ABS operation, ther.e are several
current requirements that will cause battery voltage to drop. Because of this, voltage is monitored prior to ABS
to indicate good charging system condition and also during ABS when voltage may drop significantly.
Failure Condition:
OTC A036 can only be set if the vehicle's speed is greater than 5 km/h (3 mph). If the switched battery
voltage is less than 11.5 volts non-ABS or less than 9.0 volts ABS, a malfunction exists.
Action Taken:

1. This test checks to see what voltage is readily
available at terminal "O" of the EBCM. If voltage
is representative of good charging system
condition, a malfunction is not present.
2. This step isolates the EBCM to check the condition
of the circuitry and charging system.
3. This step isolates the low voltage condition to high
circuit resistance, or improper charging system
operation.
malfunction.
5. This step checks for adequate voltage at the EBCM
when a load is applied to the system.
6. This step isolates which circuit is the source of the
low voltage condition.
Diagnostic Aids:
section.
intermittent complaint, should be t horoughly checked
the wiring harness.
While performing a voltage load test, if it is noted
that only ignition voltage drops below acceptable
voltage levels, CKT 641 should be checked for high
resistance or an open condition.
ANTILOCK BRAKE SYSTEM SE1 -77
DTCA036
START ENGINE .
WITH ENGINE RUNNING, SELECT DATA LIST
AND MONITOR SYSTEM VOLTAGE.
IS VOLTAGE 11 VOLTS OR ABOVE?
LOW SYSTEM VOLTA.GE
PERFORM VOLTAGE LOAD TEST USING TECH 1.

ARE IGNITION AND BATTERY VOLTAGES
GREATER THAN 10 VOL TS?
IGNITION " OFF ."

JUMPER TERMINAL "83" OF THE 32-WA Y EBCM
HARNESS CONNECTOR TO GROUND.
START ENGINE.
USINGJ 39200, MEASURE THE VOLTAGE BETWEEN
GROUND AND TERMINAL "D" OF THE 8-WAY EBCM
HARNESS CONNECTOR.
,.

A IDSH ON FACING PAGE .
G).
0 .
IGNITION "OFF."
RECONNECT THE 8-WAY AND 32-WA Y EBCM CONNECTORS .
IGNITION " ON.H
CONNECT A TEST LIGHT BETWEEN GROUND AND TERMINAL
" DH OF THE 8-WAY EBCM HARNESS CONNECTOR.
(BACKPROBE TERMINAL "D," CAREFUL NOT TO DAMAGE
TERMINAL.)
OBSERVE TEST LIGHT WHILE USING TECH 1 TO PERFORM
VOLTAGE LOAD TEST.
DID TEST LIGHT TUljN "ON " ?
CHECK FOR POOR CONNECTION AT

TERMINAL "OH OF 8-WA Y EBCM
HARNESS CONNECTOR. IF OK,
REPLACE EBCM.
IGNITION " OFF. H

RECONNECT BOTH EBCM CONNECTORS.
START ENGINE.
PERFORM VOLTAGE LOAD TEST USING TECH 1.
MONITOR BATTERY AND IGNITION VOLTAGE.
BATTERY VOLTAGE ONLY

LESS THAN 10 VOLTS .
IGNITION AND BATTERY VOLTAGES

LESS THAN 10 VOLTS.
INSPECTCONNECTIONSAT32-WAY EBCM
.. CONNECTOR TERMINAL "83" AND 8-WA Y EBCM
CONNECTOR TERMINAL "DH FOR CORROSION OR
POOR CONTACT. IF OK, REFER TO SECTION 603
TO. CORRECT LOW VOLTAGE CONDITION.
WITH J 39200 CONNECTED TO GROUND AND

RELAY TERMINAL "C1" OBSERVE VOLTAGE .
IS VOLTAGE ABOVE 10 VOLTS?

OR
OPEN CKT 1633.
CHECK FOR BLOWN

FUSIBLE LINK " B".
IF OK, REPAIR HIGH
RESISTANCE
OR
OPEN IN CKT 302 .
11-19-92
NS 15715
EBCM
TO
IGN3
t~
'}tWS
~~~~~~~~~~~~~641BRN~~~~~~~
641BRN
B+
SAMP
~302RED
1632 PNK
1633 RED

1633 RED
~302RED
LINK B
5272
11-23-92
NS 15732
DTCA037
HIGH SYSTEM VOLTAGE
This OTC is designed to detect high vehicle voltage levels prio r to any required motor movement
(initialization or ABS). If excessive voltage exists, demagnetization of the motor magnets may occur, which
would eventually affect or eliminate ABS performance.
Failure Condition:
OTC A037 can only be set if the vehicle's speed is greater than 5 km/h (3 mph). If the switched battery
voltage is greater than 17 volts, a malfunction exists.
Action Taken:
A malfunction OTC is stored, ABS is disabled and the "ABS INOP" lamp is t urned "ON ."

1. This step checks the voltage level being received
by the EBCM.
2. This s tep indicates whether t he high voltage
condition is caused by a malfunctioning charging
system or EBCM.
Diagnostic Aids:
section.
for backed out te rminals, improper mating, broken
the wiring harness.
DTCA037
HIGH SYSTEM VOLTAGE
START ENGINE .
USING TECH 1, SELECT DATA LIST "ND
MONITOR SYSTEM VOLTAGE .
ISVOLTAGE LESS THAN 16VOLTS?
CONNECT J 39200 BETWEEN TERMINAL

"(1" OF ENABLE RELAY AND GROUND.
IS VOLTAGE LESS THAN 16 VOLTS?
MALFUNCTION NOT PRESENT AT THIS

FACING PAGE .
REPLAq EBCM
AND RECHECK.
11-19-92
NS 15716
EBCM
~btg0s
MOTOR PACK
6 WAY CONNECTOR
1280BLKJINHT
- - - - - - -
1281 PNK
UF MOTOR HIGH
UFMOTORLOW
6-17-92
MS 12767
DTCA038
LEFT FRONT ESB WILL NOT HOLD MOTOR
This OTC is designed to detect a s lipping left front ESB. During initialization and braking, the left front
motor is re-homed. If the ESB s lips, the motor/piston will move. During the next key "ON" initialization, a rehome of the motor verifies the motor/piston remained at the home position. If motor move ment is detected, the
ESB must be s lipping.
Failure Condition :
OTC A038 can be set during initialization. If the EBCM detects that the ESB could not hold the piston in the
home position, a malfunction exists. OTC A086 is always set with OTC A038.
Action Taken:
If a n ESB cannot hold a piston in the home position, the piston may be backdri ve n when the brake pedal is
applied, causing the brake pedal to drop. A malfunction OTC is stored, ABS is disabled, and the "ABS INOP"
lamp and the red "BRAKE" warning lamp are turned "ON."

1. This step checks the left front ESB. A broken or
defective ESB would result in the left front piston
being backdriven by hydraulic pressure and pedal
movement would result.
2. This step insures that the proper motor circuits are
located in the proper connector cavities.
3. This st ep checks for high resistance in the motor
"HIGH" circuitry.
4. This step checks for high resistance in the motor
" LOW" circuitry.
5. This step checks for proper resistance of the motor
windings.
corros ion in the connectors.
7. This step checks for a malfunctioning EBCM.
Diagnostic Aids:
An "Intermittent" malfunction in this OTC may
res ult from a mechanical part of the system that
sticks, binds, or s lips.
The frequency of t he malfunction can be checked
section.
The static modulator test function of the Tech 1 or
T- 100 may be u sed to locate an intermittent
malfunction associated with the ESB.
ANTILOCK BRAKE SYSTEM 5E181
8 .
G)
G)
G).
G).
G).
IGNITION noN,H ENGINE " OFF. H

PUMP BRAKE PEDAL UNTIL FIRM TO DEPLETE VACUUM RESERVE.
USING TECH 1 ABS TESTS, SELECT MANUAL CONTROL FUNCTION.
SELECT MOTOR APPLY FUNCTION OF THE LEFT FRONT CHANNEL
AND APPLY THE MOTOR.
WAIT 5 SECONDS.
APPLY FIRM PRESSURE ON BRAKE PEDAL.
DID BRAKE PEDAL FALL?
DTCA038
LEFT FRONT ESB WILL NOT HOLD
MOTOR
VISUALLY INSPECT THE 6-WAY MOTOR PACK AND 8-WAY EBCM

CONNECTORS FOR PROPER WIRE COLOR/CONNECTOR CAVITY
COMBINATION .
ARE THE PROPER WIRES LOCATED IN THE PROPER CONNECTOR CAVITIES?
IGNITION "OFF.H
DISCONNECT 6 -WAY MOTOR PACK CONNECTOR AND 8-WAY EBCM CONNECTOR.
USING J 39200, MEASURE THE RESISTANCE BETWEEN TERMINAL "A" OF THE 6WAY MOTOR PACK HARNESS CONNECTOR ANO TERMINAL "A" OF THE 8-WAY
IS RESISTANCE LESS THAN 1.SQ?
USING THE CIRCUIT DIAGRAMS

LOCATED IN THE FRONT OF THIS
SECTION, PLACE THE PROPER
WIRES INTO THE PROPER
CONNECTOR CAVITIES . CLEAR
DTCs ANO RECHECK SYSTEM.
MEASURE THE RESISTANCE BETWEEN TERMINAL HB" OF THE 6-WAY

MOTOR PACK HARNESS CONNECTOR AND TERMINAL "B" OF THE BWAY
IS RESISTANCE LESS THAN 1.50?
MEASURE THE RESISTANCE BETWEEN TERMINAL " A" AND TERMINAL "B"
OF THE MOTOR PACK CONNECTOR.
IS RESISTANCE LESS THAN 1.5 !2?
INSPECT THE 6-WAY MOTOR PACK CONNECTOR AND BWAY EBCM

CONNECTOR FOR POOR TERMINAL CONTACT OR CORROSION. REFER TO
SECTION 8A 4, "CHECKING TERMINAL CONTACT ."
DO ANY TERMINALS EXHIBIT POOR CONTACT OR EVIDENCE OF CORROSION?

START ENGINE AND TEST DRIVE VEHICLE, ACHIEVING AT
LEAST 16 km/h (10 MPH).
TURN IGNITION "OFF."
START ENGINE AND TEST DRIVE VEHICLE A SECOND TIME,
ACHIEVING AT LEAST 16 km/h (10 MPH).
REPLACE TERMINALS THAT EXHIBIT

POOR TERMINAL CONTACT OR
EVIDENCE OF CORROSION.

TO "DIAGNOSTIC AIDS" ON FACING PAGE .
1-4.g3
AFTER DIAGNOSIS IS COMPLETE, CLEAR OTCs ANO TEST DRIVE VEHICLE FOR THREE (3) DRIVE CYCLES TO VERIFY THAT OTC DOES
NOT RESET. A DRIVE CYCLE CONSISTS OF STARTING THE VEHICLE, DRIVING OVER 16 km/h (10 MPH) AND THEN KEYING DOWN . NS 16171
EBCM
0~
~~~~~~~~~~~~~~~~-1282PPL
Wo~g~
M - ~ - -
F-
1283 BLK/PNK
R/F MOTOR HIGH
R/F MOTOR LOW
MOTOR PACK
6 WAY CONNECTOR
6-17-92
MS 12768
DTCA041
RIGHT FRONT ESB WILL NOT HOLD MOTOR
This DTC is designed to detect a slipping right front ESB. During initialization and braking, the right front
motor is re-homed. If the ESB slips, the motor/piston will move. During the next key "ON" initialization, a rehome of the motor verifies the motor/piston remained at the home position. If motor movement is detected, the
ESB must be slipping.
Failure Condition:
DTC A041 can be set during initialization. If the EBCM detects that the ESB could not hold the piston in the
home position, a malfunction exists. DTC A086 is always set with DTC A041.
Action Taken:
If an ESB cannot hold a piston in the home position, the piston may be backdriven when the brake pedal is
applied, causing the brake pedal to drop. A malfunction DTC is stored, ABS is disabled, and the "ABS INOP"

1. This step checks the right front ESB. A broken or
defective ESB would result in the right front
piston being backdriven by hydraulic pressure,
a nd pedal movement would result.
"HIGH" circuitry.
"LOW" circuitry.
windings.
corrosion in the connectors.
Diagnostic Aids:
An "Intermittent" ma lfunction in this DTC may
result from a mechanical part of the system that
sticks, binds, or slips.
1, as described in "Tech 1 Diagnostics" found .i n this
section.
T-100 may be used to locate an intermittent
I
'1
G)
0 .
G).
G).
G)
IGNITION " ONt ENGINE .. OFF."

PUMP BRAKE PEDAL UNTIL FIRM TO DEPLETE VACUUM RESERVE .
SELECT MOTOR APPLY FUNCTION OF THE RIGHT FRONT CHANNEL
AND APPLY THE MOTOR.
WAIT 5 SECONDS.
DTC A041
RIGHT FRONT ESB WILL NOT
HOLD MOTOR
VISUALLY INSPECT THE 6-WAY MOTOR PACK AND 8 -WAY EBCM

CONNECTORS FOR PROPER WIRE COLOR/CONNECTOR CAVITY
COMBINATION.
IGNITION HOFF."
DISCONNECT 6-WAY MOTOR PACK CONNECTOR AND 8-WAY EBCM
CONNECTOR.
USING J 39200, MEASURE THE RESISTANCE BETWEEN TERMINAL "E" OF
THE 6-WAY MOTOR PACK HARNESS CONNECTOR AND TERMINAL "G"
USING THE CIRCUIT DIAGRAMS LOCATED

IN THE FRONT OF THIS SECTION, PLACE
THE PROPER WIRES INTO THE PROPER
CONNECTOR CAVITIES. CLEAR DTCs AND
RECHECK SYSTEM.
MEASURE THE RESISTANCE BETWEEN TERMINAL "f" OF THE 6-WAY

MOTOR PACK HARNESS CONNECTOR AND TERMINAL "H" OF THE 8-WAY
EBCM HARNESS CONN ECTOR.
MEASURE THE RESISTANCE BETWEEN TERMINAL "E " AND TERMINAL "F "
INSPECT THE 6-WAV MOTOR PACK CONNECTOR AND 8-WAY EBCM

SECTION SA-4, "CHECKING TERMINAL CONTACT."

START ENGINE AND TEST DRIVE VEHICLE, ACHIEVING AT LEAST 16 km/h (10 MPH).
START ENGINE AND TEST DRIVE VEHICLE A SECOND TIME, ACHIEVING AT LEAST
16 km/ h (10 MPH).
REPLACE TERMINALS THAT EXHIBIT

POOR TERMINAL CONTACT OR

TO "DIAGNOSTIC AIDS" ON FACING PAGE .
AFTER DIAGNOSIS IS COMPLETE, CLEAR DTCs AND TEST DRIVE VEHICLE FOR THREE (3) DRIVE CYCLES TO VERIFY THAT OTC DOES 1-4 -93
NOT RESET. A DRIVE CYCLE CONSISTS OF STARTING THE VEHICLE , DRIVING OVER 16 KM/H (10 MPH) AND THEN KEYING DOWN. NS 16172
EBCM
R~\s:s/(MD
1284 DK GRN/WHT
-----1
REAR MOTOR HIGH
1285 ORN/8LK
-----1
REAR MOTOR LOW
-~~~~~-
MOTOR PACK
6 WAY CONNECTOR
6-17-92
MS 12769
DTCA042
REAR AXLE ESB WILL NOT HOLD MOTOR
This DTC is designed to detect a slipping rear axle ESB. During initialization and braking, the rear motor is
re-homed. If the ESB slips, the motor/piston will move. During the next key "ON" initialization, a re-home of the
motor verifies the motor/piston remained at the home position. If motor movement is detected, the ESB must be
s lipping.
Failure Condition:
DTC A042 cannot be set during initialization. If the EBCM detects that the ESB could not hold t he piston in
the home position, a malfunction exists. DTC A086 is always set with DTC A042.
Action Taken:
If a n ESB cannot hold a piston in the home position, the piston may be backdriven when the brake pedal is
applied, causing the brake pedal to drop. A malfunction DTC is stored, ABS is disabled , and the "ABS INOP"

1. This step checks the rear axle ESB. A broken or
defective ESB would result in the rear axle pistons
being backdriven by hydraulic pressure and wheel
movement would result.
"HIGH" circuitry.
"LOW" circuitry.
windings .
corrosion in the connectors.
7. This steps checks for a malfunctioning EBCM.
Diagnostic Aids:
An "Intermittent" malfunction in this DTC may
res ult from a mecha nical part of the system that
The frequency of t he malfunction can be checked
section.
T-100 may be u sed to loca te an inter mit te nt
"
G)
RAISE THE VEHICLE SUCH THAT THE REAR WHEELS ARE APPROXIMATELY
SIX INCHES OFF THE FLOOR.
IGNITION HON,H ENGINE HOFF."
APPLY FIRM PRESSURE ON BRAKE PEDAL AND RELEASE.
REAPPLY VERY FIRM PRESSURE ON BRAKE PEDAL ANO HAVE AN ASSISTANT
TRY TO SPIN THE REAR WHEELS BY HANO.
COULD ASSISTANT SPIN THE REAR WHEELS?
0 .
0
0
0
DTCA042
REAR AXLE ESB WILL NOT
HOLD MOTOR
VISUALLYINSPECTTHE6-WAY MOTOR PACK

AND 8 -WAY EBCM CONNECTORS FOR PROPER
WIRE COLOR/CONNECTOR CAVITY COMBINATION .
ARE THE PROPER WIRES LOCATED IN THE PROPER
CONNECTOR CAVITIES?
IGNITION " OFF.H

DISCONNECT 6-WAY MOTOR PACK CONNECTOR AND 8-WA Y EBCM
CONNECTOR.
USING J 39200, MEASURE THE RESISTANCE BETWEEN TERMINAL "C" OF

THE 6-WAY MOTOR PACK HARNESS CONNECTOR AND TERMINAL "C"
USING THE CIRCUIT DIAGRAMS LOCATED

IN THE FRONT OF THIS SECTION, PLACE
THE PROPER WIRES INTO THE PROPER
CONNECTOR CAVITIES. CLEAR OTCs AND
RECHECK SYSTEM.
MEASURE THE RESISTANCE BETWEEN TERMINAL "D" OF THE 6 -WAY MOTOR PACK HARNESS
CONNECTOR AND TERMINAL " F" OF THE 8-WAY EBCM HARNESS CONNECTOR.
MEASURE THE RESISTANCE BETWEEN TERMINA L "C" ANO TERMINAL " D"
IS RESISTANCE LESS THAN 1 .S!H
INSPECT THE 6-WAY MOTOR PACK CONNECTOR AND 8-WAY EBCM

SECTION SA-4, HCHECKING TERMINAL CONTACT."
RECONNECT ALL CONNECTORS .

START ENGINE AND TEST DRIVE VEHICLE, ACHIEVING AT LEAST 16 km/h (10 MPH).
TURN IGNITION " OFF."
START ENGINE AND TEST DRIVE VEHICLE A SECOND TIME , ACHIEVING AT LEAST 16 km/ h (10 MPH).
REPLACE TERMINALS
THAT EXHIBIT POOR
TERMINAL CONTACT
OR EVIDENCE OF
CORROSION.

TO " DIAGNOSTIC AIDS" ON FACING PAGE.
AFTER DIAGNOSIS IS COMPLETE, CLEAR DTCs AND TEST DRIVE VEHICLE FOR THREE (3) DRIVE CYCLES TO VERIFY OTC DOES NOT 01 -04-93
RESET. A DRIVE CYCLE CONSISTS OF STARTING THE VEHICLE , DRIVING OVER 16 km/ h (10 MPH) AND THEN KEYING DOWN .
NS 16173
-0
l/F ABS
MOTO
EBCM
12808LK/WHT
UF MOTOR HIGH
1281PNK
LJF MOTOR LOW
~~~~~~~~~~~~~~~~~
MOTOR PACK
6WAYCONNECTOR
t'
I
I
6-17-92
MS 12767
DTCA044
LEFT FRONT CHANNEL WILL NOT MOVE
This DTC is designed to detect bound-up ESB, a stuck motor, or a seized hydraulic modulator. When the
r elease is commanded during initialization, the ESB should release the motor, resulting in sensed current being
less than commanded current (motor is spinning freely). If the motor is not moving, sensed current will be equal
to stall current.
Failure Condition:
DTC A044 can be set during normal operation. If the EBCM detects a condition in which it cannot move the
motor in either direction, a ma lfunction exists.
Action Taken:
This malfunction indicates the channel cannot be moved properly. A malfunction DTC is stored, ABS is
disabled and the "ABS INOP" lamp is turned "ON."

numbe r(s) on the diagnostic chart.
1. This step insures that proper motor circ uits a r e
located in t he proper connector cavities.
2. This step checks for prope r motor movement
during apply and release commands from the Tech
1.
3. This step compares EBCM com mand current to

motor feedback current.
4. This step check s fo r a short ci rcuit between t he
motor "HIGH" a nd motor "LOW" circuits.
5. This test determines if the malfunction is caused
by a defective EBCM.
6. This step verifies that the motor can actua lly a pply
when commanded.
7. This step checks for proper hydraulic modulator
gear and piston movement.
Diagnostic Aids:
An "Inter mittent" malfunction in this DTC may
result from a mechanica l par t of t he system that
sticks, binds, or sl ips.
1, as described in "Tech l Diagnostics" found in this
section . DTC A044 may set after modulator
disassembly if the modulator pistons are positioned at
the bottom of their bore.
Any circ uitry, t ha t is suspected as causing the
intermittent compla int , should be thoroughly checked
termina l to wiring connections or physical damage to
the wiring harness.
1r
I
G)
VISUALLY INSPECT THE 6-WAY MOTOR PACK AND THE 8-WAY EBCM
CONNECTORS FOR PROPER WIRE COLOR/CONN ECTOR CAVITY COMBINATION.
DTCA044
LEFT FRONT CHANNEL
WILL NOT MOVE
r':"12
\.,V
IGNITION oN. ENGINE oFF.

SELECT LEFT FRONT MOTOR APPLY FUNCTION AND APPLY THE MOTOR.
SELECT LEFT FRONT MOTOR RELEASE FUNCTION AND RELEASE MOTOR.

SECTION, PLACE THE PROPER WIRES
IN THE PROPER CONNECTOR
CAVITIES. CLEAR DTCs AND
RECHECK SYSTEM.
FIRM PRESSURE STILL oN BRAKE PEDAL.

SELECT LEFT FRONT MOTOR APPLY FUNCTION ANO APPLY THE MOTOR.
DID BRAKE PEDAL RISE?
MALFUNCTION IS INTERMITTENT. REFER TO

' ] ' .
\.V
\V
REMOVE FOOT FROM BRAKE PEDAL

SELECT LEFT FRONT MOTOR APPLY FUNCTION AND APPLY THE MOTOR WHILE CAREFULLY OBSERVING
THE COMMANDED CURRENT AND THE FEEDBACK CURRENT ON THE TECH 1.
WAS THE FEEDBACK CURRENT HIGHER THAN THE COMMANDED CURRENT?
IGNITION oFF.
DISCONNECT THE 8-WAY EBCM CONNECTOR ANO THE
6-WAY MOTOR PACK CONNECTOR.
TERMINAL A AND TERMINAL B" OF THE 8-WAY EBCM
HARNESS CONNECTOR.
f7\
\...!_)

START ENGINE AND TEST DRIVE
VEHICLE, ACHIEVING AT LEAST 16 km/h
(10MPH).
TURN IGNITION " OFF."
START ENGINE ANO TEST DRIVE VEHICLE
A SECOND :rlME, ACHIEVING AT LEAST
16 km/h (10 MPH).
DOES OTC A044 RESET1
REPAIR SHORT
BETWEEN CKT
1280ANDCKT
1281 .
USING TECH 1 ABS TESTS, PERFORM GEAR

TENSION RELIEF FUNCTION .
IGNITION off."
REMOVE HYDRAULIC MODULATOR/MOTOR PACK
ASSEMBLY FROM VEHICLE . REFER TO "ON
VEHICLE SERVICE" IN THIS SECTION.
SEPARATE MOTOR PACK FROM HYDRAULIC
MODULATOR.
GRASP THE GEAR ON THE HYDRAULIC
MODULATOR (THE HYDRAULIC MODULA TOR IS
THE UNIT WITH THE THREE LARGE GEARS)
FURTHEST FORWARD WHEN THE UNIT IS
INSTALLED IN THE VEHICLE ANO A TT EMPT TO
MOVE THE GEAR.
CAN THE GEAR BE ROTATED AT LEAST 10 FULL
TURNS LOCK TO LOCK?
INSPECT ALL CONNECTORS FOR
CONTAMINATION AND POOR
TERMINAL CONTACT. REPLACE ANY
TERMINALS THAT EXHIBIT POOR
TERMINAL CONTACT OR EVIDENCE
OF CORROSION .
AFTER ALL DIAGNOSIS IS COMPLETE , CLEAR DTCs AND TEST DRIVE VEHICLE FOR THRE E (3) DRIVE CYCLES TO VERIFY
THAT OTC DOES NOT RESET. A DRIVE CYCLE CONSISTS OF STARTING THE VEHICLE, DRIVING OVER 16 KM/H (10 MPH),
01 -04-93
NS 16174
EBCM
----------------0
~~~g~
F -
- - - - - -
1282 PPL
R/F MOTOR HIGH
1283 BLKJPNK
R/F MOTOR LOW
MOTOR PACK
6 WAY CONNECTOR
6-17-92
MS 12768
DTCA045
RIGHT FRONT CHANNEL WILL NOT MOVE
This OTC is designed to detect bound-up ESB, a stuck motor, or a seized hydraulic modulator. When the
release is commanded during initialization, the ESB should release the motor, resulting in sensed current being
to stall current.
Failure Condition:
OTC A045 can be set during normal operation. If the EBCM detects a condition in which it cannot move the
motor in either direction, a malfunction exists.
Action Taken:
This malfunction indicates the channel cannot be moved properly. A ma lfunction DTC is stored, ABS is
Diagnostic Aids:

1. This step insures that proper motor circuits are
2. This step checks for proper motor moveme nt
1.
3. This step compares EBCM command current to
4. This step checks for a s hort circuit between the
motor "HIGH" and motor "LOW" circuits.
by a defective EBCM .
6. This step verifies that the motor can actually a pply
when commanded.

result from a mechanica l part of the system t h at
sec tion . DTC A045 may set after modulator
the wiring harness.
'1
CONNECTORS FOR PROPER WIRE COLOR/CONNECTOR CAVITY COMBINATION.
ARE THE PROPER WIRES LOCATED IN THE PROPER CONNECTOR CA VITIES7
DTCA045
RIGHT FRONT CHANNEL
WILL NOT MOVE
r':\
IGNITION oN,- ENGINE oFF.PUMP BRAKE PEDAL UNTIL FIRM TO DEPLETE VACUUM RESERVE.
SELECT RIGHT FRONT MOTOR APPLY FUNCTION AND APPLY THE MOTOR.
SELECT RIGHT FRONT MOTOR RELEASE FUNCTION AND RELEASE MOTOR.

CAVITIES. CLEAR DTCs AND
RECHECK SYSTEM.
FIRM PRESSURE STILL oN BRAKE PEDAL.

DID BRAKE PEDAL RISE'?

01AGNOSTIC Atos ON FACING PAGE.
G):
'4'
\V
REMOVE FOOT FROM BRAKE PEDAL.

SELECT RIGHT FRONT MOTOR APPLY FUNCTION AND APPLY THE MOTOR WHILE CAREFULLY OBSERVING
IGNITION off.
DISCONNECT THE 8-WAY EBCM CONNECTOR AND THE
6-WAY MOTOR PACK CONNECTOR.
TERMINAL " G" AND TERMINAL
OF THE 8-WAY EBCM
HARNESS CONNECTOR.
DOES J 39200 DISPLAY RESISTANCE As-oL -(INFINITE)?
G)

(10 MPH).
VEHICLE A SECOND TIME, ACHIEVING
AT LEAST 16 km/h (10 MPH).
REPAIR SHORT
BETWEEN CKT
1282 ANDCKT
1283.

IGNITION "OFF. "
REMOVE HYDRAULIC MODULA TOR/MOTOR PACK
ASSEMBLY FROM VEHICLE. REFER TO oN
VEHICLE SERVICE " IN THIS SECTION.
SEPARATE MOTOR PACK FROM HYDRAULIC
MODULATOR.
GRASPTHEGEARONTHEHYDRAULK
MODULATOR (THE HYDRAULIC MODULA TOR IS
THE UNIT WITH THE THREE LARGE GEARS)
FURTHEST REARWARD WHEN THE UNIT IS
INSTALLED IN THE VEHICLE AND ATTEMPT TO
MOVE THE GEAR.
CAN THE GEAR BE ROTATED A T LEAST 10 FULL
TURNS LOCK TO LOCK?
MALFUNCTION IS
INTERMITTENT. INSPECT ALL
CONNECTORS FOR
CONTAMINATION AND POOR
TERMINAL CONTACT. REPLACE
ANY TERMINALS THAT EXHIBIT
POOR TERMINAL CONT ACT OR
AFTER All DIAGNOSIS IS COMPLETE, CLEAR DTCs AND TEST DRIVE VEHICLE FOR THREE (3) DRIVE CYCLE S
TO VERIFY THAT OTC DOES NOT RESET. A DRIVE CYCLE CONSISTS OF STARTING THE VEHICLE, DRIVING
OVER 16 KM/H (10 MPH), AND THEN KEYING DOWN.
01-04-93
NS 16175
EBCM
- - - - - - - - - --
1284 DK GRN/WHT
REAR MOTOR HIGH
- - - - - - - - - - - - - - 1285 ORNIBLK - - - - - t F
REAR MOTOR LOW
----t
(,
MOTOR PACK
6 WAY CONNECTOR
6-17-92
MS 12769
DTCA046
REAR AXLE CHANNEL WILL NOT MOVE
This OTC is designed to detect bound-up ESB, a stuck motor, or a seized hydraulic modulator. When the
release is commanded during initialization, the ESB should release t he motor, resulting in sensed current being
to stall current.
Failure Condition:
OTC A046 can be set during normal operation. If the EBCM detects a condition in which it cannot move the
motor in either direction, a malfunction exists.
Action Taken:
This malfunction indicates the chan nel cannot be moved properly. A malfunction OTC is stored, ABS is

1. This step insures that proper motor circuits are
located in t he proper connector cavities.
2. This step checks for proper motor movement
1.
3. This step compares EBCM command current to
4. This step checks for a short circuit between the
motor "HIGH" and motor " LOW" circuits.
by a defective EBCM.
6. This step verifies that the motor can actually apply
when commanded.
Diagnostic Aids:
result from a mechanical part of the system that sticks
or binds.
sectio n . OTC A046 may set after modulator
Depending on the frequency of the malfunction, a
physical inspection of t he mechanical pa rts suspected
may be necessary.
intermittent complaint, s hould be thoroughly checked
the wiring harness.
ANTILOCK BRAKE SYSTEM 5E1;.91
G)
CONNECTORS FOR PROPER WIRE COLOR/CONNECTOR CAVITY COMBINATION.
DTCA046
REAR AXLE CHANNEL
WILL NOT MOVE
2
\._V
RAISE AND SUPPORTTHE VEHICLE SUCH THAT THE REAR WHEELS ARE
APPROXIMATELY SIX INCHES OFF THE FLOOR.
IGNITION " ON; ENGINE " OFF. "
SELECT REAR AXLE MOTOR APPLY FUNCTION AND APPLY THE MOTOR.
HAVE AN ASSISTANT TRY TO SPIN THE REAR WHEELS BY HAND.
('";'\
\.V

CAVITIES. CLEAR OTCs AND
RECHECK SYSTEM.
FIRM PRESSURE STILL "ON" BRAKE PEDAL.

SELECT REAR AXLE MOTOR RELEASE FUNCTION AND RELEASE THE MOTOR.
HAVE AN ASSISTANT TRY TO SPIN THE REAR WHEELS BY HAND.

,;-.
\..V

SELECT REAR AXLE MOTOR APPLY FUNCTION AND APPLY THE MOTOR WHILE CAREFULLY OBSERVING
IGNITION "OFF."
DISCONN ECT THE 8-WAY EBCM CONNECTOR AND THE
6 -WAY MOTOR PACK CONNECTOR.
TERMINAL " C" ANO TERMINAL "F" OF THE 8-WAY EBCM
HARNESS CONNECTOR.

START ENGINE ANO TEST DRIVE
(10 MPH).
VEHICLE A SECOND TIME, ACHIEVING

IGNITION " OFF."
REMOVE HYDRAULIC MODULATOR/MOTOR PACK
ASSEMBLY FROM VEHICLE. REFER TO " ON
VEHICLE SERVICE" IN THIS SECTION.
SE PARA TE MOTOR PACK FROM HYDRAULIC
MODULATOR.
GRASP THE MIDDLE GEAR ON THE HYDRAULIC
MODULATOR (THE HYDRAULIC MODULATOR IS
THE UNIT WITH THE THREE LARGE GEARS) ANO
ATTEMPT TO MOVE THE GEAR.
CAN THE GEAR BE ROTATED AT LEAST 7 FULL
TURNS LOCK TO LOCK?
REPAIR SHORT
BETWEEN CKT 1284
AND CKT 1285.
INSPECT ALL CONNECTORS FOR
CONTAMINATION AND POOR TERMINAL
CONTACT. REPLACE ANY TERMINALS
THAT EXHIBIT POOR TERMINAL CONTACT
OR EVIDENCE OF CORROSION.
AFTER ALL DIAGNOSIS IS COMPLETE, CLEAR DTCs AND TEST DRIVE VEHICLE FOR THREE (3) DRIVE CYCLES TO VERIFY
THAT OTC DOES NOT RESET. A DRIVE CYCLE CONSISTS OF STARTING TH E VEHICLE, DRIVING OVER 16 KM/H (10 MPH),
01-04-93
NS 16176
EBCM
UF MOTOR HIGH
UFMOTOR LOW
6-17-92
MS 12767
DTCA047
(Page 1 of 2)
LEFT FRONT MOTOR FREE SPINS

This OTC is designed to detect a stripped nut or gear assembly during initialization. During the homing
sequence, the piston should reach the top of the bore resulting in a stalled motor. If this does not occur, the motor
must be spinning with little or no resistance, indicating a nut/screw or gear malfunction.
Failure Condition:
DTC A047 can only be set during initia lization. If the feedback current is less than the command current for
a specified period of time, a malfunction exists.
Action Taken:
A malfunction DTC is stored, ABS is disabled, and the "ABS INOP" lamp is turned "ON."

1. This step checks to see if the corresponding open
motor DTC is also set.
2. This step verifies that the motor was actually
applied as comma nd by observing feedback
current.
3. This step verifies that the motor can release.
4. This step verifies that the motor can be applied by
observing pedal movement.
5. This step checks for a stripped gear on the motor
pack (unit with three small gears).
6. This step checks for a stripped gear on the
hydraulic modulator (unit with three large gears).
7. This step determines whether the h ydraulic
modulator or the motor pack has an internal
malfunction .
Diagnostic Aids:
section. If the DTC only fails once and DTC A056 also
fails, refer to DTC A056. If intermittent and enhanced
diagnostics shows this DTC fails during ABS, refer to
DTCA056.
physical inspection of the mechanical parts suspected
may be necessary.
DTCA047
(Page 1 of 2)
LEFT FRONT MOTOR

FREE SPINS
'J'
0:
0

SELECT LEFT FRONT MOTOR APPLY FUNCTION ANO APPLY THE
MOTOR WHILE CAREFULLY OBSERVING THE COMMAND
CURRENT AND FEEDBACK CURRENT ON THE TECH 1.
WERE BOTH COMMAND AND FEEDBACK CURRENT 10 AMPS?

SELECT LEFT FRONT MOTOR RELEASE FUNCTION AND RELEASE
THE MOTOR.
DID THE BRAKE PEDAL FALL AND WERE BOTH COMMAND
ANO FEEDBACK CURRENT 6 AMPS?
.
FIRM PRESSURE STILL ON BRAKE PEDAL.

SELECT LEFT MOTOR APPLY FUNCTION AND APPLY THE
MOTOR (THIS MOVES THE PISTON TO THE TOP OF ITS BORE.)
010 BRAKE PEDAL RISE?

TENSION RELIEF FUNCTION.
IGNITION"OFF."
DISCONNECT 6-WAY MOTOR PACK CONNECTOR
AND 2-WAY SOLENOID CONNECTORS .
REMOVE HYDRAULIC MODULATOR/MOTOR
PACK ASSEMBLY FROM VEHICLE. (REFER TO
"ON-VEHICLE SERVICE " IN THIS SECTION.)
REMOVE GEAR COVER.
CHECK FOR STRIPPED GEAR ON MOTOR PACK ;
MOTOR PACK IS THE UNIT WITH THE THREE
SMALL GEARS . THE LEFT FRONT GEAR IS THE
GEAR FURTHEST FORWARD WHEN THE
ASSEMBLY IS INSTALLED IN THE VEHICLE .
IS THE MOTOR PACK GEAR STRIPPED?
WAS THE COMMAND

CURRENT OR FEEDBACK
CURRENf OAMPS?
MALFUNCTION
IS
INTERMITTENT.
REFER TO
"DIAGNOSTIC
AIDS" ON
FACING PAGE .
CHECK FOR A STRIPPED GEAR ON

HYDRAULIC MODULATOR; MODULATOR
IS THE UNIT WITH THE THREE LARGE ,
GEARS. THE LEFT FRONT GEAR IS THE
GEAR FURTHEST FORWARD WHEN THE
UNIT IS INSTALLED IN THE VEHICLE.
IS THE MODULATOR GEAR STRIPPED?
r - ------------------------,
I DIAGNOSIS CONTINUED ON NEXT PAGE. 1
L--------------------------J
RECONNECT ALL
CONNECTORS.
START ENGINE ANO TEST
DRIVE VEHICLE, ACHIEVING
START ENGINE ANO TEST
DRIVE VEHICLE A SECOND
TIME, ACHIEVING AT LEAST
16 km/h (10 MPH).
MALFUNCTION
IS
INTERMITTENT.
INSPECT ALL
CONNECTORS
FOR CONTAMINATION AND
POOR
TERMINAL
CONTACT.
REPLACE ANY
TERMINALS
THAT EXHIBIT
POOR
TERMINAL
CONTACT OR
EVIDENCE OF
CORROSION.
AFTER ALL DIAGNOSIS IS COMPLETE, CLEAR DTCs AND TEST DRIVE VEHICLE FOR THREE
(3) DRIVE CYCLES TO VERIFY THAT OTC DOES NOT RESET. A DRIVE CYCLE CONSISTS OF
STARTING THE VEHICLE, DRIVING OVER 16 km/h (10 MPH), AND THEN KEYING DOWN.
01-04-93
NS 16177
-0
lJF AB
MOTO
EBCM
1280BLK/WHT
lJF MOTOR HIGH
9~~~~~~~~~~~~~~~~~1281PNK
LJF MOTOR LOW
MOTOR PACK
6 WAY CONNECTOR
6-17-92
MS 12767
DTCA047
(Page 2 of 2)
LEFT FRONT MOTOR FREE SPINS

Failure Condition :
OTC A047 can only be set during initialization. If the feedback current is less than the command current for
Action Taken:
A malfunction OTC is stored, ABS is disabled, and the "ABS INOP" lamp is turned "ON."
9. This step verifies that the motor can be applied
under a load situation.
"HIGH" circuitry.
"LOW" circuitry.
windings.
This step verifies that the hydra ulic modulator is
functioning properly.
,3.
Diagnostic Aids:
result from a mechanical part of the system t hat
section. If the OTC only fails once and DTC A056 also
DTC A056.
may be necessary.
DTCA047
: FROM PREVIOUS PAGE. :
(Page 2 of 2)
--------------~
RECONNECT ELECTRICAL CONNECTORS

SECURELY POSITION HYDRAULIC MODULA TOR/MOTOR PACK ASSEMBLY IN
VEHICLE WITH GEAR COVER REMOVED SUCH THAT THE GEAR SET CAN BE
OBSERVED. BE CAREFUL NOT TO DAMAGE GEAR SET OR ALLOW THE HYDRAULIC
MODULATOR TO MOVE WHILE TESTING.
IGNITION " ON."
SELECT LEFT FRONT MOTOR APPLY AND APPLY THE MOTOR WHILE OBSERVING
THE GEAR SET FURTHEST FORWARD WHEN THE UNIT IS INSTALLED IN THE VEHICLE.
SELECT LEFT FRONT MOTOR RELEASE FUNCTION AND RELEASE THE MOTOR WHILE
STILL OBSERVING THE GEAR SET.
SELECT LEFT FRONT MOTOR APPLY FUNCTION AND APPLY THE MOTOR.
DID GEAR SET MOVE IN BOTH DIRECTIONS FOR AT LEAST ONE REVOLUTION?
LEFT FRONT MOTOR

FREE SPINS
IGNITION " OFF."

DISCONNECT 6-WAY MOTOR PACK CONNECTOR AND 8-WAY EBCM CONNECTOR.
USING J 39200, MEASURE THE RESISTANCE BETWEEN TERMINAL " A" OF THE 6WAY MOTOR PACK HARNESS CONNECTOR AND TERMINAL A OFTHE 8-WAY

TERMINAL "B" OF THE 6-WAY MOTOR PACK
HARNESS CONNECTOR AND TERMINAL "B"
MEASURE THE RESISTANCE BETWEEN TERMINAL "A"

AND TERMINAL "B" OF THE MOTOR PACK CONNECTOR.
SEPARATE THE MOTOR PACK FROM THE HYDRAULIC MODULATOR.

GRASP THE GEAR ON THE HYDRAULIC MODULATOR (THE HYDRAULIC
MODULATOR IS THE UNIT WITH THE THREE LARGE GEARS) FURTHEST FORWARD
WHEN THE UNIT IS INSTALLED IN THE VEHICLE AND ATTEMPT TO MOVE THE GEAR.
CAN THE GEAR BE ROTATED APPROXIMATELY 12 FULL TURNS LOCK TO LOCK?
MALFUNCTION WAS CAUSED BY A POOR CONNECTION . INSPECT

ALL CONNECTORS AND TERMINALS FOR POOR TERMINAL CONTACT
AND EVIDENCE OF CORROSION. REFER TO SECTION SA-4,
"CHECKING TERMINAL CONTACT." REPLACE All TERMINALS THAT
EXHIBIT SIGNS OF POOR TERMINAL CONTACT OR CORROSION.
REPLACE THE
HYDRAULIC
MODULATOR.
01-12-93
NS 16044
EBCM
----------------0
~~~8~
1282 PPL
R/F MOTOR HIGH
M - - - - - F1283 BLK/PNK
R/F MOTOR LOW
MOTOR PACK
6WAYCONNECTOR
6-17-92
MS 12768
DTCA048
(Page 1 of 2)
RIGHT FRONT MOTOR FREE SPINS

This DTC is designed to detect a stripped nut or gear assembly during initialization . During the homing
Failure Condition:
DTC A.048 can only be set during initialization. If the feedback current is less than the command current for
Action Taken:
A malfunction DTC is stored, ABS is disabled, and the "ABS INOP" lamp is turned "ON ."

motor OTC is also set.
applied as command by observing feedback
current.
3. This step verifies that the motor ca n release.
pack (unit with three small gears).
7. This step determines whether the hydraulic
malfunction.
Diagnostic Aids :
section. If the DTC only fails once and DTC A061 also
diagnostics shows this OTC fail s during ABS, refer to
orfc Ao61.
may be necessary.
DTCA048
IS OTC A063 ALSO CURRENTLY SET1
(Page 1 of 2)
RIGHT FRONT MOTOR

FREE SPINS
(i'\
\.:J
'J'
~
'4'
\V
IGNITION "ON: ENGINE "OFF."

SELECT RIGHT FRONT MOTOR APPLY FUNCTION AND APPLY THE
MOTOR WHILE CAREFULLY OBSERVING THE COMMAND CURRENT
AND FEEDBACK CURRENT ON THE TECH 1.

SELECT RIGHT FRONT MOTOR RELEASE FUNCTION AND RELEASE
THE MOTOR.
DID THE BRAKE PEDAL FALL AND WERE BOTH COMMAND AND
FEEDBACK CURRENT 6 AMPS?

SELECT RIGHT MOTOR APPLY FUNCTION AND APPLY THE

IGNITION"OFF."
DISCONNECT 6WAY MOTOR PACK
CONNECTOR AND 2WAY SOLENOID
CONNECTORS.
"ON-VEHICLE SERVICE " IN THIS SECTION.)
REMOVE GEAR COVER.
CHECK FOR STRIPPED GEAR ON MOTOR
PACK; MOTOR PACK IS THE UNIT WITH THE
THREE SMALL GEARS. THE RIGHT FRONT
GEAR IS THE FURTHEST REARWARD WHEN
THE ASSEMBLY IS INSTALLED IN THE VEHICLE.
WAS THE COMMAND

CURRENT OR FEEDBACK
CURRENT O AMPS?
MALFUNCTION
IS
INTERMITTENT.
REFER TO
"DIAGNOSTIC
AIDS" ON
FACING PAGE .
CHECK FOR A STRIPPED GEAR ON HYDRAULIC

MODULATOR; MODULATOR IS THE UNIT WITH
THE THREE LARGE GEARS. THE RIGHT FRONT
GEAR IS THE GEAR FURTHEST REARWARD
WHEN THE UNIT IS INSTALLED IN THE VEHICLE.

VEHICLE, ACHIEVING AT LEAST 16
km/h (10 MPH).
VEHICLE A SECOND TIME,
ACHIEVING AT LEAST 16 km/h (10
MPH).
MALFUNCTION IS
INTERMITTENT. INSPECT
ALL CONNECTORS FOR
CONTAMINATION AND
REPLACE ANY TERMINALS
THAT EXHIBIT POOR
TERMINAL CONTACT OR
-----------------------~
~-------------------------~
~
I DIAGNOSIS CONTINUED ON NEXT PAGE. 1
1593
NS 16178
EBCM
----------------0
~~~g~
1282 PPL
R/F MOTOR HIGH
M - - - - - F 1283 BLK/PNK
R/F MOTOR LOW
MOTOR PACK
6WAYCONNECTOR
6-17-92
MS 12768
DTCA048
{Page 2 of 2)

This DTC is designed to detect a stripped nut or gear assembly during initialization. During the homing
Failure Condition:
DTC A048 can only be set during initialization. If the feedback current is less than the command current for
Action Taken:

"HIGH" circuitry.
11. This step checks for- high resistance in the motor
"LOW" circuitry.
windings.
13. This step verifies that the hydraulic modulator in
, I
Diagnostic Aids:
section . If the OTC only fails once and DTC A061 also
fails, refer to OTC A061. If intermittent and enhanced
DTC A061.
Depending on the frequency of t he malfunction, a
may be necessary. .
DTCA048
(Page 2 of 2)
r-----------------,
FROM PREVIOUS PAGE.
L- ---------------J
I
RECONNECT ELECTRICAL CONNECTORS.

SECURELY POSITION HYDRAULIC MODULATOR/MOTOR PACK ASSEMBLY IN VEHICLE WITH GEAR COVER REMOVED
SUCH THAT THE GEAR SET CAN BE OBSERVED. BE CAREFUL NOT TO DAMAGE GEAR SET OR ALLOW THE HYDRAULIC
MODULATOR TO MOVE WHILE TESTING.
IGNITION oN.
SELECT RIGHT FRONT MOTOR APPLY AND APPLY THE MOTOR WHILE OBSERVING THE GEAR SET FURTHEST
REARWARD WHEN THE UNIT IS INSTALLED IN THE VEHICLE.
SELECT RIGHT FRONT MOTOR RELEASE FUNCTION AND RELEASE THE MOTOR WHILE STILL OBSERVING THE GEAR SET.
DID GEAR SET MOVE IN BOTH DIRECTIONS FOR AT LEAST ONE REVOLUTION?
IGNITION off.
DISCONNECT 6-WAY MOTOR PACK CONNECTOR ANO 8-WAY EBCM CONNECTOR.
USING J 39200, MEASURE THE RESISTANCE BETWEEN TERMINAL .E. OF THE
6-WAY MOTOR PACK HARNESS CONN ECTOR AND TERMINAL G OF THE 8-WA Y
I~ RESISTANCE LE SS THAN 1.50?

TERMINAL F OF THE 6-WAYMOTOR PACK
HARNESS CONNECTOR AND TERMINAL " H"
MEASURE THE RESISTANCE BETWEEN TERMINAL .E .. AND

TERMINAL F OF THE MOTOR PACK CONNECTOR.
SEPARATE THE MOTOR PACK FROM THE HYDRAULIC MODULATOR.

GRASP THE GEAR ON THE HYDRAULIC MODULA TOR (THE HYDRAULIC
MODULATOR IS THE UNIT WITH THE THREE LARGE GEARS) FURTHEST REARWARD
WHEN THE UNIT IS INSTALLED IN THE VEHICLE AND A TT EMPT TO MOVE THE GEAR.
MALFUNCTION WAS CAUSED BY A POOR CONNECTION. INSPECT

ALL CONNECTORS AND TERMINALS FOR POOR TERMINAL
CONTACT AND EVIDENCE OF CORROSION. REFER TO SECTION 8A-4,
cHECKING TERMINAL CONTACT. REPLACE ALL TERMINALS THAT
REPLACE THE
HYDRAULIC
MODULATOR.
01-12-93
NS 16045
EBCM
1284 DK GRN/WHT
y -
R~J\~lS /( MD
-------------
REAR MOTOR HIGH
1285 ORN/IILK - - - F
REAR MOTOR LOW
----1
MOTOR PACK
6 WAY CONNECTOR
6-17-92
MS 12769
DTCA051
(Page 1 of 2)
REAR AXLE MOTOR FREE SPINS

Failure Condition :
DTC A051 can be set during initialization. If the feedback current is less than the command current for a
specified period of time, a malfunction exists.
Action Taken:
motor OTC is also set.
applied as command by observing feedback
current.
3. This step verifies that the motor can release.
pack (unit with three small gears) .
7. This step determin es whether the hydraulic
malfunction.
Diagnostic Aids:
section. If the DTC only fails once and DTC A064 a lso
diagnostics show t his OTC fails during ABS, refer to
DTCA064.
may be necessary.
DTCA051
(Page 1 of 2)
REAR AXLE MOTOR

FREE SPINS
\.:.,)
0:
fs\
\V
IGNITION oN," ENGINE oFF."

SELECT REAR AXLE MOTOR APPLY FUNCTION AND APPLY THE
MOTOR WHILE CAREFULLY OBSERVING THE COMMAND
CURRENT AND FEEDBACK CURRENT ON THHECH 1.
APPLY FIRM PRESSURE ON BRAKE PEDAL

SELECT REAR AXLE MOTOR RELEASE
FUNCTION AND RELEASE THE MOTOR.
DID THE BRAKE PEDAL FALL AND WERE BOTH
COMMAND AND FEEDBACK CURRENT 6 AMPS?

SELECT REAR AXLE MOTOR APPLY FUNCTION AND APPLY THE

IGNITION"OFF."
DISCONNECT 6-WAY MOTOR PACK CONNECTOR
AND 2-WA Y SOLENOID CONNECTORS.
"ON-VEHICLE SERVICE" IN THIS SECTION.)
REMOVE GEAR COVER.
CHECK FOR STRIPPED GEAR ON MOTOR PACK;
MOTOR PACK IS THE UNIT WITH THE THREE
SMALL GEARS. THE REAR AXLE GEAR IS THE
MIDDLE GEAR OF THE THREE.
('";'\ WAS THE COMMAND

\.:__) CURRENT OR FEEDBACK
CURRENT O AMPS?
MALFUNCTION
IS
INTERMITIENT.
REFER TO
"DIAGNOSTIC
AIDS"ON
FACING PAGE.
CHECK FOR A STRIPPED GEAR ON HYDRAULIC

MODULATOR; MODULATOR IS THE UNIT WITH
THE THREE LARGE GEARS. THE REAR AXLE
GEAR IS THE MIDDLE GEAR OF THE THREE.

VEHICLE, ACHIEVING AT LEAST 16
km/h(10MPH).
TURN IGNITION "OFF. STARTENGINE AND TEST DRIVE
VEHICLE A SECOND TIME,
ACHIEVING AT LEAST 16 km/h (10
MPH).
MALFUNCTION IS
INTERMITTENT. INSPECT
ALL CONNECTORS FOR
CONTAMINATION AND
REPLACE ANY TERMINALS
THAT EXHIBIT POOR
TERMINALCONTACT OR
r- --- - ------------- - ------,

I
DIAGNOSIS CONTINUED ON NEXT PAGE.
L--------------------------J
*
AFTER AU DIAGNOSIS IS COMPLETE, CLEAR DTCs AND TEST DRIVE VEHICLE FOR THREE
(3)DRIVE CYCLES TO VERIFY THAT OTC DOES NOT RESET. A DRIVE CYCLE CONSISTS OF
STARTING THE VEHICLE DRIVING OVER 16 ki,tlh (10 MPH), AND THEN KEYING DOWN.
THIS CHART A~SUMES THAT A CURRENT OTC IS STORED INDICATING THAT THIS MALFUNCTION IS PRESENT.
1-5-93
NS 16179
EBCM
R~'gT~=S / ( MD
1284 DK GRN/WHT - - - C
- - - - - - - - - - - --
REAR MOTOR HIGH
1285 ORNIBLK - - - - t F
REAR MOTOR LOW
MOTOR PACK
6 WAY CONNECTOR
6-17-92
MS 12769
DTCA051
(Page 2 of 2)

must be s pinning with little or no resistance, indicating a nutiscrew or gear malfunction.
Failure Condition:
OTC A051 can be set during initialization. If the feedback current is less than the command current for a
specified period of time, a malfunction exists.
Action Taken:
A malfunction OTC is stored, ABS is disabled, and the "ABS !NOP" lamp is turned "ON."

"HIGH" circuitry.
11. This step checks for high resista nce in the motor
"LOW" circuitry.
windings.
13. This step verifies that the hydraulic modulator is
Diag nostic Aids:

result from a mechanical pa rt of the system that
section. If the OTC only fails once and OTC A064 a lso
fails, refer to OTC A064. If intermittent and enhanced
diagnostics show this OTC fails during ABS, refer to
DTC A064.
physical inspection of the mechanical parts s uspected
may be necessary.
'.
...
'
'Ii
DTCA051
r----------------,
--------------J
L-
@.
(Page 2 of 2)
RECONNECT ELECTRICAL CONNECTORS.

SECURELY POSITION HYDRAULIC MODULATOR/MOTOR PACK ASSEMBLY IN VEHICLE WITH GEAR COVER REMOVED
SUCH THAT THE GEAR SET CAN BE OBSERVED. BE CAREFUL NOT TO DAMAGE GEAR SET OR ALLOW THE
HYDRAULIC MODULATOR TO MOVE WHILE TESTING.
IGNITION "ON."
SELECT REAR AXLE MOTOR APPLY AND APPLY THE MOTOR WHILE OBSERVING THE MIDDLE GEAR SET.
SELECT REAR AXLE MOTOR RELEASE FUNCTION AND RELEASE THE MOTOR WHILE STILL OBSERVING THE GEAR SET.
SELECT REAR AXLE MOTOR APPLY FUNf" )N AND APPLY THE MOTOR.
DID GEAR SET MOVE IN BOTH DIRECTIC" , FOR AT LEAST ONE REVOLUTION7
IGNITION " OFF."

DISCONNECT 6-WAY MOTOR PACK CONNECTOR AND 8-WAY EBCM CONNECTOR.
USINGJ 39200, MEASURE THE RESISTANCE BETWEEN TERMINAL " C" OF THE
6-WAY MOTOR PACK HARNESS CONNECTOR AND TERMINAL " C" OF THE 8-WAY
EBCM HARNESS CONNECTOR
IS RESISTANCE LESS THAN 1.507

TERMINAL " D" OF THE 6-WAY MOTOR PACK
HARNESS CONNECTOR AND TERMINAL "F " OF
THE 8-WAY EBCM HARNESS CONNECTOR .
MEASURE THE RESISTANCE BETWEEN TERMINAL "C"

AND TERMINAL "D" OF THE MOTOR PACK CONNECTOR.
REPAIR HIGH RESISTANCE IN

CKT 1285.
SE PARATE THE MOTOR PACK FROM THE HYDRAULIC MODULATOR.

GRASP THE MIDDLE GEAR ON THE HYDRAULIC MODULATOR (THE
HYDRAULIC MODULATOR IS THE UNIT WITH THE THREE LARGE GEARS) AND
ATT~MPT TO MOVE THE GEAR.
MALFUNCTION WAS CAUSED BY A POOR CONNECTION. INSPECT

All CONNECTORS AND TERMINALS FOR POOR TERMINAL
CONTACT AND EVIDENCE OF CORROSION . REFER TO SECTION 8A-4,
"CHECKING TERMINAL CONTACT." REPLACE All TERMINALS THAT
REPLACE THE
HYDRAULIC
MODULATOR.
11-24-92
NS 16046
-0~
UFABS
MOTO
MOTOR PACK
6 WAY CONNECTOR
M-
EBCM
1280BLK/WHT
l/F MOTOR HIGH
-~~~~~~~~~~~~~~~~ 1281 PNK
l/F MOTOR LOW
6-17-92
MS 12767
DTCA052
LEFT FRONT CHANNEL IN RELEASE TOO LONG
Circuit Description :
This OTC will diagnose a motor that is energized longer than expected. This could occur if a wheel speed
sensor is malfunctioning, the motor does not turn, the left front solenoid mechanically fails open, or the motor
wires are crossed.
Failure Condition:
DTC A052 can be set only during an ABS stop. If the EBCM commands the left front channel in release for
three seconds, a malfunction exists.
Action Taken:
1. This step identifies a problem in a wheel speed
sensor that may cause the system to be in release
too long.
2. This step identifies a motor as being failed or wired
incorrectly.
3. This step ch ecks for a solenoid that may have
mechanically fai led open.
4. If Step 3 has failed, this serves to isolate the cause
of the hydraulic problem, to either t he solenoid or
the ABS hydraulic modulator assembly.
5. This step prepares the hydraulic modulator/motor
pack assembly for separation.
6. This step determines whether a malfunctioning
motor pack or hydraulic modulator is the reason
for DTC A052 being set.
Diagnostic Aids:
mechanical part of the system that sticks or binds.
section. DTC A052 may fail if on ice and steering
wheel is turned to lock during braking. Using the
Tech 1, perform hydraulic test to ensure total brake
system is functional.
for ' backed out terminals, improper mating, broken
the wiring harness.

IMPORTANT: EXCESSIVE DRAG OR HIGH
RESISTANCE IN THE BASE BRAKE OR
SUSPENSION SYSTEM MUST BE INSPECTED AND
CORRECTED BEFORE PROCEEDING WITH OTC
DIAGNOSIS.
DTCA052
LEFT FRONT CHANNEL IN RELEASE TOO LONG
ARE ANY WHEEL SPEED DTCs CURRENTLY SET?
G)
G)
TEST VEHICLE DURING A STEADY DECEL CONDITION FROM 35 MPH TOO MPH
WHILE MONITORING ALL WHEEL SPEEDS ON TECH 1 DATA LIST.
DO ANY OF THE WHEEL SPEEDS INDICATE ERRATIC OR INTERMITTENT
OPERATION?
IGNITION oN, ENGINE oFF.

USING THE MANUAL CONTROL FUNCTION OF TECH 1, SELECT LEFT FRONT
MOTOR APPLY AND APPLY MOTOR.
SELECT LEFT FRONT MOTOR RELEASE AND COMMAND RELEASE OF MOTOR.

SELECT LEFT FRONT SOLENOID APPLY FUNCTION Of
TECH 1 AND ENERGIZE SOLENOID.
APPLY FIRM PRESSURE TO BRAKE PEDAL.
BRAKE PEDAL ROSE

REPAIR CROSSED WIRES TO
LEFT FRONT ABS MOTOR
CIRCUIT.
G)
FIRM PRESSURE STILL APPLIED TO

BRAKE PEDAL.
USING TECH 1,COMMANDLEFT
FRONT SOLENOID oFF.
DID BRAKE PED~L FALL?
SWITCH LEFT FRONT SOLENOID WITH RIGHT

FRONT SOLENOID ANO REPEAT PREVIOUS
TEST.
CD
PROCEED TO
STEP40F
THIS CHART.
PROCEED TO WHEEL SPEED =0

OTC FOR AFFECTED WHEEL.
USING TECH 1, PERFORM GEAR TENSION RELIEF FUNCTION .

IGNITION " OFF.
REMOVE HYDRAULIC MODULATOR/MOTOR PACK ASSEMBLY
FROM VEHICLE .
SEPARATE MOTOR PACK FROM HYDRAULIC MODULATOR.
GRASP THE GEAR ON THE HYDRAULIC MODULATOR
(HYDRAULIC MODULATOR IS THE UNIT WITH THE THREE
LARGE GEARS) FURTHEST FORWARD WHEN THE UNIT IS
INSTALLED IN THE VEHICLE AND ATTEMPT TO ROTATE THE
GEAR IN EITHER DIRECTION.
CAN TH GEAR BE MOVED BY HANO?

REFER TO .DIAGNOSTIC Atos ON FACING PAGE.
USING TECH 1, PERFORM GEAR TENSION RELIEF FUNCTION.

REPLACE ABS HYDRAULIC MODULATOR.
REPLACE SOLENOID THAT FAILED

STEP 3 OF THIS CHART.
AFTER DIAGNOSIS IS COMPLETE, CLEAR DTCs AND TEST DRIVE VEHICLE FOR THRE E (3) DRIVE CYCLES TO VERIFY OTC
DOES NOT RESET. A DRIVE CYCLE CONSISTS OF STARTING THE VEHICLE , DRIVING OVER 16 km/h (10 MPH) AND THEN
KEYING DOWN.
112092
NS-16180
EBCM
----------------0
:c,~g~
1282 PPL
M - - - - F 1283 BLK/PNK
R/F MOTOR HIGH
l
_{
R/F MOTOR LOW
MOTOR PACK
6 WAY CONNECTOR
6-17-92
MS 12768
DTCA053
RIGHT FRONT CHANNEL IN RELEASE TOO LONG
This DTC will diagnose a motor that is energized longer than expected. This could occur if a wheel speed
sensor is malfunctioning, the motor does not turn, the right front solenoid mechanically fails open, or the motor
wires are crossed.
Failure Condition:
DTC A053 can be set only during an ABS stop. If the EBCM commands the right front channel in release for
Action Taken:
Diagnostic Aids:

1. This step identifies a problem in a wheel s peed
too long.
2. This step identifies a motor as being failed or wired
incorrectly.
3. This step checks for a solenoid that may ha ve
mechanically failed open.
4. If Step 3 has failed, this serves to isolate the cause
of the hydraulic problem, to either the solenoid or
the ABS hydraulic modulator assembly.
5. This step prepares the hydraulic modulator/motor
pack assembly for separation.
6. This step determines whether a malfunction motor
pack or hydraulic modulator is the reason for DTC
A053 being set.

section . DTC A053 may fail on ice if steering wheel is
turned to lock during braking. Using the Tech 1
perform hydraulic test to ensure total brake system is
functional.
the wiring harness.

IMPORTANT: EXCESSIVE DRAG OR H IGH
RESISTANCE IN THE BASE BRAKE OR
SUSPENSION SYSTEM MUST BE INSPECTED AND
CORRECTED BEFORE PROCEEDING WITH OT C
DIAGNOSIS.
OTC A053
RIGHT FRONT CHANNEL IN RELEASE TOO LONG
ARE ANY WHE EL SPEED DTCs CURRENTLY SET?
G)
G)
TEST VEHICLE DURING A STEADY D ECEL CONDITION FROM 35 MPH TOO MPH
WHILE MONITORING ALL WHEEL SPEEDS ON TECH 1 DATA LIST.
OPERATION?
IGNITION oN. ENGINE". OFF

USING THE MANUAL CONTROL FUNCTION OF TECH 1, SELECT RIGHT FRONT
MOTOR APPLY AND APPLY MOTOR.
SELECT RIGHT FRONT MOTOR RELEASE AND COMMAND RELEASE OF MOTOR.
PROCEED TO WHEEL SPEED "'0

11

SELECT RIGHT FRONT SOLENOID APPLY
FUNCTION OF TECH 1 AND ENERGIZE SOLENOID.
APPLY FIRM PRESSURE TO BRAKE PEDAL.
DID BRAKE PEDAL FALL1
BRAKE PEDAL ROSE

REPAIR CROSSED WIRES TO
RIGHT FRONT ABS MOTOR
CIRCUIT.
FIRM PRESSURE STILL APPLIED

TO BRAKE PEDAL.
USING TECH 1,COMMAND
RIGHT FRONT SOLENOID
oFF.
D ID BRAKE PEDAL FALL?
PROCEED TO
STEP40F
THIS CHART.
SWITCH RIGHT FRONT SOLENOID WITH LEFT

FRONT SOLENOID AND REPEAT PREVIOUS
TEST.
f.\
\.V
USING TECH 1, PERFORM GEAR

REPLACE ABS HYDRAULIC MODULATOR.
USING TECH 1, PERFORM GEAR TENSION RELIEF FUNCTION.

IGNITION oFF."
REMOVE HYDRAULIC MODULATOR/MOTOR PACK ASSEMBLY
1
FROM VEHICLE.
SE PARA TE MOTOR PACK FROM HYDRAULIC MODULATOR.
GRASP THE GEAR ON THE HYDRAULIC MODULATOR
(HYDRAULIC MODULA TOR IS THE UNIT WITH THE THREE
LARGE GEARS) FURTHEST REARWARD WHEN THE UNIT IS
INSTALLED IN THE VEHICLE AND ATTEMPT TO ROTATE THE
GEAR IN EITHER DIRECTION.
CAN THE GEAR BE MOVED BY HAND?
MALFUNCTION IS NOT PRESENT AT THIS TIME. REFER

TO 01AGNOSTIC AIDS" ON FACING PAGE.
REPLACE SOLENOID THAT FAILED

STEP 3 OF THIS CHART.
AFTER DIAGNOSIS IS COMPLETE, CLEAR DTCs AND TEST DRIVE VEHICLE FOR THREE (3) DRIVE CYCLES TO VERIFY OTC
DOES NOT RESET. A DRIVE CYCLE CONSISTS OF STARTING THE VEHICLE , DRIVING OVER 16 km/h (10 MPH) AND THEN
KEYING DOWN.
11-20-92
NS-16182
EBCM
1284 DK GRN/WHT
-----1
REAR MOTOR HIGH
Ri~T~18S MD - - - - - - 1285 ORN/8LK
-----1
REAR MOTOR LOW
MOTOR PACK
6WAYCONNECTOR
6-17-92
MS 12769
DTCA054
REAR AXLE CHANNEL IN RELEASE TOO LONG
This OTC will diagnose a motor that is energized longer than expected. This could occur if a wheel speed
sensor is malfunctioning, the motor does not turn, or the motor wires are crossed.
Failure Condition:
OTC A054 can be set only during an ABS stop. If the EBCM commands the rear axle channel in release for
Action Taken :
Diagnostic Aids:

1. This step identifies a problem in a wheel speed
too long.
2. This checks for a wheel that may stick or bind
because of a mechanical fault.
3. This checks to see if the motor is capable of moving
and applying the hydraulic piston for the rear
wheels.
4. This step insures that the motor wiring is not
crossed.
5. This isolates the fault of a "no-apply" situation to
either the motor pack or ABS hydraulic modulator
assembly.

section. Using the Tech 1, perform hydraulic test to
ensure total brake system is functional.
the wiring harness.
,I
DTCA054
REAR AXLE CHANNEL IN RELEASE TOO LONG
IMPORTANT: EXCESSIVE DRAG OR HIGH RESISTANCE IN THE BASE
BRAKE OR SUSPENSION SYSTEM MUST BE INSPECTED AND CORRECTED
BEFORE PROCEEDING WITH OTC DIAGNOSIS.
ARE ANY WHEEL SPEED DTCs CURRENTLY SET?
G)
0 .
TEST VEHICLE DURING A STEADY DECEL CONDITION FROM 35 MPH TO

O MPH WHILE MONITORING ALL WHEEL SPEEDS ON TECH 1 DATA LIST.
OPERATION?
RAISE REAR OF VEHICLE AND SUPPORT AS INDICATED IN SECTION OA.

SPIN BOTH REAR WHEELS AND CONFIRM PHYSICAL CONDITION OF
BASE BRAKE SYSTEM.
COULD BOTH,REARWHEELS BE SPUN FREELY BY HAND?
PROCEED TO WHEEL SPEED 0

IGNITION oN.- ENGINE oFF.

USING MANUAL CONTROL FUNCTION OF TECH 1, SELECT REAR AXLE
MOTOR APPLY.
COMMAND APPLY OF REAR MOTOR AND TRY TO SPIN REAR WHEELS
BY HAND.
COULD REAR WHEELS BE SPUN BY HAND?
REPAIR SOURCE OF RESISTANCE

IN BASE BRAKE SYSTEM.
WITH FIRM PRESSURE ON BRAKE PEDAL STILL APPLIED,

COMMAND A RELEASE OF THE REAR AXLE MOTOR.
CAN WHEELS BE MOVED?

REFE~ TO 01AGNOSTIC AIDS. ON FACING PAGE.
USING TECH 1. PERFORM GEAR TENSION RELIEF FUNCTION .

IGNITION oFF.
REMOVE HYDRAULIC MODULATOR/MOTOR PACK ASSEMBLY FROM VEHICLE .
SEPARATE MOTOR PACK FROM HYDRAULIC MODULA TOR.
CONNECT MOTOR PACK WIRING.
IGNITION oN.
USING TECH 1, PERFORM MOTOR TEST.
DO ALL THREE MOTOR PACK GEARS (SMALL GEARS) SPIN FREELY?
AFTER ALL DIAGNOSIS IS COMPLETE, CLEAR DTCs AND TEST DRIVE VEHICLE FOR THREE (3) DRIVE CYCLES
TO VERIFY THAT OTC DOES NOT RESET. A DRIVE CYCLE CONSISTS OF STARTING THE VEHICLE DRIVING
OVER 16 KM/h (10 MPH), AND THEN KEYING DOWN.
11-20-92
NS 16183
MS 12781
DTCAOSS
EBCM FAILURE
This OTC identifies a malfunction detected by the MDI custom IC. It also insure s the cause of the
malfunction is not a result of a problem with the enable relay under a OTC A055 malfunction.
Action Taken:
1. This checks to see if the malfunction is still
present.
2. This step checks to see if the malfunction is
intermittent.
DTCAOSS
EBCM FAILURE
G)
IGNITION HON," ENGINE "OFF."

USING TECH 1, READ DTCs.
IS DTC A055 CURRENTLY SET?
USING TECH 1,CLEARDTCs.

TEST DRIVE VEHICLE FOR THREE (3) DRIVE
CYCLES . A DRIVE CYCLE CONSISTS OF
KEYON, DRIVE VEHICLE OVER 10 MPH,
THEN KEY DOWN.
DOES OTC AOSS RESET?
REPLACE EBCM.
11 -23-92
NS 15427
EBCM
-0~
L/F ABS
MOTO
12808LKIWHT
L/F MOTOR HIGH
1281PNK
UFMOTORLOW
a~~~~~~~~~~~~~~~~~
MOTOR PACK
6 WAY CONNECTOR
617-92
MS 12767
DTCA056
LEFT FRONT MOTOR CIRCUIT OPEN
This DTC identifies a motor that cannot be energized due to an open in its circuitry.
Failure Condition:
DTC A056 can be set only when the motor is commanded "OFF." If the EBCM detects an out of range voltage
on either of the left front motor circuits indicating an open circuit, a malfunction exists.
Action Taken:
An open motor will not activate when requested. A malfunction DTC is stored, ABS is disabled a nd the ABS
INOP" lamp is turned "ON."

1. This step checks for proper resistance of the motor.
2. This step checks for an open in the motor "HIGH"
circuitry.
3. This step checks for an open in the motor "LOW"
circuitry.
Diagnostic Aids:
Using Tech 1, select manual control function, and
exercise motor movement of affected channel in both
directions while applying light pressure on the brake
pedal.
If erratic or "jumpy" brake pedal movement is
detected while performing an "apply" or "release"
function of the motor, an intermittent malfunction
may be indicated.

If the malfunction is not current, wiggle the wires
of the affected channel and check if the DTC resets.
This will help to pinpoint an intermittent malfunction
in the motor circuitry or connections.
section.
the wiring harness.
ANTILOCK BRAKE 'SYSTEM 5E1-113
DTCA056
LEFT FRONT MOTOR CIRCUIT OPEN
DOES OTC A056 OCCUR INTERMITTENTLY?
G)
1GN1T10N oFF.DISCONNECT6-WAY CONNECTOR AT MOTOR PACK.

USING J 39200, MEASURE RESISTANCE ACROSS
MOTOR PACK TERMINALS .,AH AND "S-.
IS RESISTANCE BELOW 2000 Q?
DISCONNECT 8-WA Y CONN ECTOR AT EBCM.

USING J 39200, MEASURE RESISTANCE BETWEEN TERMINAL" A
OF THE 8-WAY EBCM HARNESS CONNECTOR AND TERMINAL., A
OF THE 6-WAY MOTOR PACK HARNESS CONNECTOR.
IS RESISTANCE 2 0 OR LESS?
USING J 39200, MEASURE RESISTANCE BETWEEN TERMINAL 9 OF

THE 8-WAY EBCM HARNESS CONNECTOR AND TERMINAL "S- OF
THE 6-WAY MOTOR PACK HARNESS CONNECTOR.
CHECK FOR POOR CONTACT OR CORROSION AT EBCM 8-WAY

AND MOTOR PACK 6-WA Y CONNECTORS. IF OK, REPLACE EBCM.
12-3-92
MS 12772
EBCM
UF MOTOR HIGH
UFMOTORLOW
6-17-92
MS 12767
DTCA057
LEFT FRONT MOTOR CIRCUIT SHORTED TO GROUND
This DTC identifies a motor circuit that is shorted to ground. This malfunction will not allow the motor to be
controlled at the commanded current rate or will cause the driver circuit to allow current directly to ground.
Failure Condition :
DTC A057 can be set anytime. If the EBCM detects an out of range voltage on either of the left front motor
circuits indicating a circuit shorted to ground, a malfunction exists.
Action Taken:

1. This step checks for a short to ground in the motor
"HIGH" circuitry.
"LOW" circuitry.
3. This step checks for a motor that is internally
shorted to ground.
Diagnostic Aids:
pedal.
function of the motor, an intermitten t malfunction
may be indicated.

section.
the wiring harness.
Jl
DTCA057
LEFT FRONT MOTOR CIRCUIT SHORTED TO GROUND
DOES DTC AOS7 OCCUR INTERMITTENTLY7
G)
Cv
IGNITION "OFF."
DISCONNECT THE 6-WAY MOTOR PACK CONNECTOR AND THE
8-WAY EBCM CONNECTOR.
USING J 39200, MEASURE THE RESISTANCE BETWEEN GROUND
AND TERMINAL .. A " OF THE 6-WA Y MOTOR PACK HARNESS
CONNECTOR.
DOES J 39200 DISPLAY RESISTANCE AS HOL" {INFINITE)7
MEASURE THE RESISTANCE BETWEEN GROUND AND TERMINAL

"B" OF THE 6 -WAY MOTOR PACK HARNESS CONNECTOR.
DOES J 39200 DISPLAY RESISTANCE AS .. OL" (INFINITE)7
MEASURE THE RESISTANCE BETWEEN GROUND AND

TERMINAL " A" OF THE MOTOR PACK.
DOES J 39200 DISPLAY RESISTANCE AS .. OL" (INFINITE)7
(3) DRIVE CYCLES TO VERIFY THAT DTC DOES NOT RESET. A DRIVE CYCLE CONSISTS OF
THIS CHART ASSUMES THAT A CURRENT DTC IS STORED INDICATING THAT THIS MALFUNCTION IS PRESENT.
12-3 -92
MS 12773
EBCM
lJF MOTOR HIGH
UFMOTORLOW
6-17-92
MS 12767
DTCA058
LEFT FRONT MOTOR CIRCUIT SHORTED TO BAITERY OR MOTOR SHORTED
This OTC identifies a motor circuit that is shorted to battery or a motor that has low or no resistance. This
malfunction will not allow the motor to be controlled at the commanded current rate or will cause the motor to
turn in the opposite direction, or not at all.
Failure Condition:
DTC A058 can be set only when the motor is commanded "OFF." If the EBCM detects an out ofra nge voltage
on either of the left front motor circuits indicating a circuit shorted to battery or a motor shorted, a malfunction
exists.
Action Taken:

1. This step checks for a short to voltage in the motor
"HIGH" circuitry.
"LOW" circuitry .
shorted.
Diagnostic Aids:
pedal.
may be indicated.

of the affected channel and check if the DTC resets .
section.
the wiring harness.
r
DTCA058
LEFT FRONT MOTOR CIRCUIT SHORTED TO BATTERY
OR MOTOR SHORTED
G)
IGNITION oFF.
DISCONNECT THE 6-WAY MOTOR PACK CONNECTOR AND THE 8-WAY
EBCM CONNECTOR.
IGNITION oN.
USING J 39200, MEASURE THE VOLTAGE BETWEEN GROUND AND
TERMINAL A OF THE 6-WAY MOTOR PACK HARNESS CONNECTOR.
MEASURE THE VOLTAGE BETWEEN GROUND AND TERMINAL "B"

OF THE 6-WAY MOTOR PACK HARNESS CONNECTOR.
IS VOLTAGE 1 VOLT OR LE SS?
IGNITION .OFF.
SELECT RESISTANCE (Q) POSITION ON J 39200.
TOUCH THE TWO PROBES OF J 39200 TOGETHER AND zERO" J 39200
USING THE RELATIVE (REL) MODE FUNCTION OF J 39200 (REFER TO
J 39200 USER'S MANUAL).
USING J 39200, MEASURE THE RESISTANCE BETWEEN TERMINAL "A
AND TERMINAL r OF THE MOTOR PACK.
IS RESISTANCE GREATER THAN 0.4 Q1
AFTER ALL DIAGNOSIS IS COMPLETE, CLEAR DTCs ANO TEST DRIVE VEHICLE FOR THREE
12-3-92
MS 12774
11
EBCM
----------------0~
~~~g~
F -
- - - - - - -
1282 PPL
R/F MOTOR HIGH
1283 BLK/PNK
R/F MOTOR LOW
,l
MOTOR PACK
6 WAY CONNECTOR
6-17-92
MS 12768
DTCA061
RIGHT FRONT MOTOR CIRCUIT OPEN
Circuit Description :
This DTC identifies a motor that cannot be energized due to an open in its circuitry. This malfunction will
not allow proper front ABS operation.
Failure Condition:
DTC A061 can be set only when the motor is comma nded "OFF." If the EBCM detects an out of range voltage
on either of the right front motor circuits indicating an open circuit, a malfunction exists.
Action Taken:
An open motor will not activate when requested. A malfunction DTC is stored, ABS is disabled and the "ABS
INOP" lamp is turned "ON."

1. This step checks for proper resistance of the motor.
2. This step checks for an open in the motor "HIGH"
circuitry.
circuitry.
Diagnostic Aids:
pedal.
detected while performing an "app ly" or "rel ease"
may be indicated.

section.
the wiring harness.
ANTll.!OCK BRAKE SYSTEM 5E1-119
DTCA061
RIGHT FRONT MOTOR CIRCUIT OPEN
G)
IGNITION oFF."
DISCONNECT 6 -WA Y CONNECTOR AT MOTOR PACK.
USING J 39200, MEASURE RESISTANCE ACROSS
MOTOR PACK TERMINALS
AND "F" .
IS RESISTANCE BELOW 2000 01
DISCONNECT 8-WAY CONNECTOR AT EBCM.

USING J 39200, MEASURE RESISTANCE BETWEEN TERMINAL "G" OF
THE 8-WAY EBCM HARNESS CONNECTOR AND TERMINAL " E.. OF THE
6-WAY MOTOR PACK HARNESS CONNECTOR.
USING J 39200, MEASURE RESISTANCE BETWEEN TERMINAL " H" OF

THE 8-WAY EBCM HARNESS CONNECTOR AND TERMINAL - F- OF THE
6-WA Y MOTOR PACK HARNESS CONNECTOR.
15 RESISTANCE 2 11 OR LESS?
CHECK FOR POOR CONTACT OR CORROSION AT EBCM8-WAY

AND MOTOR PACK 6-WA Y CONNECTORS. IF OK, REPLACE EBCM.
REPAIR OPEN OR HIGH

RESISTANCE IN CKT 1282.
REPAIR OPEN OR HIGH

RESISTANCE IN CKT 1283.
AFTER All DIAGNOSIS IS COMPLETE.CLEAR DTCs AND TEST DRIVE VEHICLE FOR THREE (3)DRIVE CYCLES TO VERIFY THAT
OTC DOES NOT RESET. A DRIVE CYCLE CONSISTS OF STARTING THE VEHICLE , DRIVING OVER 16 km/h (10 MPH), AND THEN
KEYING DOWN .
12-3 -92
MS 12775
EBCM
0~
::0~8~
~~~~~~~~~~~~~~~~-1282PPL
R/F MOTOR HIGH
F - - - - - - - 1283 BLK/PNK
R/F MOTOR LOW
MOTOR PACK
6WAVCONNECTOR
61792
MS 12768
DTCA062
RIGHT FRONT MOTOR CIRCUIT SHORTED TO GROUND
This DTC identifies a motor circuit that is shorted to ground. This malfunction will not allow the motor to be
controlled at the commanded current rate or will cause the motor driver circuit to allow current directly to
ground.
Failure Condition:
DTC A062 can be set anytime. If the EBCM detects an out of range voltage on either of the right front motor
circuits indicating a circuit shorted to ground, a malfunction exists.
Action Taken:

"HIGH" circuitry.
"LOW" circuitry.
shorted to ground.
Diagnostic Aids:
pedal.
function of t he motor , an intermittent malfunction
may be indicated.
An "Intermittent" ma lfunction may be caused by a

section.
the wiring harness.
T
ANTILOCK BRAKE SYSTE.M SE1-121
DTCA062
RIGHT FRONT MOTOR CIRCUIT SHORTED TO GROUND
DOES DTC A062 OCCUR INTERMIITENTL Y?
IGNITION " OFF."

DISCONNECT 6-WAY MOTOR PACK CONNECTOR AND THE 8-WAY
EBCM CONNECTOR.
AND TERMINAL " E" OF THE 6-WAY MOTOR PACK HARNESS
CONNECTOR.
REFER TO "DIAGNOSTIC AIDS"

ON FACING PAGE.

" F" OF THE 6-WAY MOTOR PACK HARNESS CONNECTOR.

TERMINAL "E" OF THE MOTOR PACK.
REPLACE EBCM AND RE-CHECK ABS SYSTEM.
REPLACE MOTOR PACK.
12-3-92
MS 12776
I
'
EBCM
~~~~~~~~~~~~~~~~-1282PPL
R/F MOTOR HIGH
M - - - F 1283 BLK/PNK
R/F MOTOR LOW
~~g~
,I
MOTOR PACK
6 WAY CONNECTOR
6-17-92
MS 12768
DTCA063
RIGHT FRONT MOTOR CIRCUIT SHORTED TO BATTERY OR MOTOR SHORTED
This OTC identifies a motor circuit that is shorted to battery or a motor that has low or no resistance. This
malfunction will not allow the motor to be controlled at the commahded current rate or will cause the motor to
turn in the opposite direction or not at a ll.
Failure Condition:
OTC A063 can be set only when the motor is commanded "OFF." If the EBCM detects an out of range voltage
on either of the right front motor circuits indicating a circuit shorted to battery or a motor shorted, a malfunction
exists.
Action Taken:
Test Description: Number(s) below r efer to circled

"HIGH" circuitry.
"LOW" circuitry.
shorted.
Diagnostic Aids:
Using Tech 1, select manual control function , and
pedal.
may be indicated.

section.
the wiring harness.
f
ANTILOCK BRAKE SYSTEM 5E1 -123
DTCA063
RIGHT FRONT MOTOR CIRCUIT SHORTED
TO BATTERY OR MOTOR SHORTED
IS OTC A036 ALSO SET?
IGNITION "OFF.
EBCM CONNECTOR.
IGNITION " ON .
TERMINAL " E" OF THE 6 -WAY MOTOR PACK HARNESS CONNECTOR.
PROCEED TO THAT OTC CHART FIRST.

F.. OF THE 6-WAY MOTOR PACK HARNESS CONNECTOR.
REPAIR SHORT TO VOLTAGE IN CKT 1282
IGNITION " OFF."

SELECT RESISTANCE (0) POSITION ON J 39200.
TOUCH THE TWO PROBES OF J 39200 TOGETHER AND " ZERO " J 39200
USING THE " RELATIVE (REL) MODE " FUNCTION OF J 39200 (REFER TO
J 39200 USER' S MANUAL).
USING J 39200, MEASURE THE RESISTANCE BETWEEN TERMINAL " E"
AND TERMINAL "F" OF THE MOTOR PACK.
IS RESISTANCE GREATER THAN 0 .4 07
REPAIR SHORT TO VOLTAGE IN CKT 1283.
REPLACE EBCM.
REPLACE MOTOR PACK.
AFTER ALL DIAGNOSIS IS COMPLETE, CLEAR DTCs AND TEST DRIVE VEHICLE FOR THREE (3) DRIVE CYCLES TO VERIFY
THAT OTC DOES NOT RESET. A DRIVE CYCLE CONSISTS OF STARTING THE VEHICLE, DRIVING OVER 16 km/h (10 MPH),
AND THEN KEYING DOWN.
12-3-92
MS 12777
..
EBCM
I
1284 DK GRN/WHT
REAR MOTOR HIGH
I
J
RiAJrs:s / ( MD - - - - - ;,,, 1285 ORN/8lK
.J
-----1
REAR MOTOR LOW
MOTOR PACK
6WAY CONNECTOR
6-17-92
MS 12769
DTCA064
REAR AXLE MOTOR CIRCUIT OPEN
This OTC identifies a motor that cannot be energized due to an open in its circuitry. This malfunction will
not allow proper rear ABS operation.
Failure Condition:
OTC A064 can be set only when the motor is commanded "OFF." If the EBCM detects an out ofrange voltage
on either of the rear axle motor circuits indicating an open circuit, a malfunction exists.
Action Taken:
An open motor will not activate when requested. A malfunction OTC is stored, ABS is disabled and the "ABS
!NOP" lamp is turned "ON."

1. This checks for proper resistance of the motor.
2 . This step checks for an open in the motor "HIGH"
circuitry.
circuitry.
Diagnostic Aids:
pedal.
detected while performing a n "apply" or "release"
may be indicated.

section.
the wiring harness.
ANTILOCK BRAKE SYSTEM. SE1-125
DTCA064
REAR AXLE MOTOR CIRCUIT OPEN
G)
G)
IGNITION " OFF."

DISCONNECT 6 -WAY CONNECTOR AT MOTOR PACK.
USING J 39200, MEASURE RESISTANCE ACROSS MOTOR PACK
TERMINALS "C" AND "D" .
IS RESISTANCE BELOW 2000 01
REFER TO "DIAGNOSTIC A IDS" 'oN FACING PAGE'.
DISCONNECT 8-WAY CONNECTOR AT EBCM.

USING J 39200, MEASURE RESISTANCE BETWEEN TERMINAL " C" OF
THE 8-WAY EBCM HARNESS CONNECTOR AND TERMINAL " C" OF
THE 6-WAY MOTOR PACK HARNESS CONNECTOR.
USING J 39200, MEASURE RESISTANCE BETWEEN TERMINAL "F"

OF THE 8-WAY EBCM HARNESS CONNECTOR AND TERMINAL " D "
OF THE 6 -WAY MOTOR PACK HARNESS CONNECTOR.
CHECK FOR POOR CONTACT OR CORROSION AT EBCM 8-WAY AND

MOTOR PACK 6-WAY CONNECTORS. IF OK, REPLACE EBCM.
REPAIR OPEN OR HIGH RESISTANCE IN CKT 1284.
REPAIR OPEN OR HIGH RESISTANCE IN CKT 1285.
STARTING THE VEHICLE, DRIVING OVER 16 km/ h (10 MPH), AND THEN KEYING DOWN .
12-3-92
MS 12778
SE:1-126 ANTILOCK BRAKE SYSTEM
EBCM
~~.~~~~~~~~~~~~~~~
1284 DK GRN/WHT
REAR MOTOR HIGH
1285 ORN/BLK
REAR MOTOR LOW
MOTOR PACK
6 WAY CONNECTOR
6-17-92
MS 12769
DTCA065
REAR AXLE MOTOR CIRCUIT SHORTED TO GROUND
This OTC identifies a motor circuit that is shorted to ground. This malfunction will not a llow the motor to be
controlled at the commanded current rate or will cause the driver circuit to allow current directly to ground.
Failure Condition:
OTC A065 can be set anytime. If the EBCM detects an out of range voltage on either of the rear axle motor
circuits indicating a circuit s horted to ground, a malfunction exists.
Action Taken:

"HIGH" circuitry.
"LOW" circuitry.
shorted to ground.
Diagnostic Aids:
Using Tech 1, select manua l control function, and
pedal.
If erratic or "jumpy" bra ke pedal movement is
detected while performing an "apply" or "r e lease"
may be indicated.

of the affected channel and check if the OTC resets.
in the motor circuitry or connections .
section .
intermittent complaint, should be thoro ughly checked
for backed out terminals, improper mating, bro ken
the wiring harness.
./
DTCA065
REAR AXLE MOTOR CIRCUIT SHORTED TO GROUND
DOES OTC A065 OCCUR INTERMITTENTLY1
G)
IGNITION oFF.
DISCONNECT THE 6-WAY MOTOR PACK CONNECTOR AND THE
AND TERMINAL "C" OF THE 6-WAY MOTOR PACK HARNESS
CONNECTOR.
DOES J 39200 DISPLAY RESISTANCE AS oL (INFINITE)?

o OF THE 6-WAY MOTOR PACK HARNESS CONNECTOR.
G)

TERMINAL c OF THE MOTOR PACK.
AFTER All DIAGNOSIS IS COMPLETE, CLEAR DTCs AND TEST DRIVE VEHICLE FOR THREE
(3) DRIVE CYCLES TO VERIFY THAT OTC DOES NOT RESET. A DRIVE CYaE CONSISTS OF
STARTING THE VEHIClE, DRIVING OVER 16 km/h (10 MPH), AND THEN KEYING DOWN.
12-3-92
MS 12779
5E1128 ANTILOCK BRAKE SYSTEM
EBCM
1284 DK GRN!WHT
-----ii
REAR MOTOR HIGH
Rf.~T~tBS MD - - - - - - - 12850RN/BLK
-----ii
REARMOTORLOW
MOTOR PACK
6 WAY CONNECTOR
6-17-92
MS 12769
DTCA066
REAR AXLE MOTOR CIRCUIT SHORTED TO BATTERY OR MOTOR SHORTED
This OTC identifies a motor circuit that is shorted to battery or a motor that has low or zero resistance. This
malfunction will not allow the motor to be controlled at the commanded current rate or will cause the motor to
turn in the opposite direction or not t urn at all.
Failure Condition:
OTC A066 can be set only when t he motor is commanded "OFF." If the EBCM detects an out ofrange voltage
on either of the rear axle motor circuits indicating a circuit shorted to battery or a motor shorted, a malfunction
exists.
Action Taken:
A malfunction OTC is stored, ABS is disa bled a nd the "ABS INOP" lamp is turned "ON."

"HIGH" circuitry.
2. This step checks for ~ short to voltage in the motor
"LOW" circuitry.
shorted.
Diagnostic Aids:
directions while applying light pressure on t he brake
pedal.
If erratic or "j umpy" brake pedal movement is
may be indicated.

wire that is broken inside t he insulation.
of the affected channel and check if the OTC resets
section.
the wiring harness.
.i
DTCA066
REAR AXLE MOTOR CIRCUIT SHORTED TO BAITERY
OR MOTOR SHORTED
DOES DTC A066 OCCUR INTERMITTENTLY?
IS DTC A036 ALSO SET?
REFER TO .DIAGNOSTIC A1os ON FACING PAGE.
IGNITION oFF.
EBCM CONNECTOR.
.
IGNITION oN.
TERMINAL c OF THE 6-WAY MOTOR PACK HARNESS CONNECTOR.
G)
G)

D OF THE 6-WAY MOTOR PACK HARNESS CONNECTOR.
IGNITION "OFF."
SELECT RESISTANCE (il) POSITION ON J 39200.
TOUCH THE TWO PROBES OF J 39200 TOGETHER AND "ZERO.. J 39200
USING THE "RELATIVE (REL) Moor FUNCTION OF J 39200 (REFER TO
J 39200 USER' S MANUAL).
USINGJ 39200,MEASURE THE RESISTANCE BETWEEN TERMINAL "C"
AND TERMINAL D" OF THE MOTOR PACK.
IS RESISTANCE GREATER THAN 0 .4 01
REPLACE EBCM
REPLACE MOTOR PACK
I
*
(3)DRIVE CYCLES TO VERIFY THATDTC DOES NOT RESET. A DRIVE CYCLE CONSISTS OF
STARTING THE VEHICLE, DRIVING OVER 16 km/h (10 MPH}, AND THEN KEYING DOWN.
12-3-92
MS 12780
EBCM
5111
~ 651 BLK - - - - - - - - - - - - - - - - - - - - - 651 BLK
GROUND
lJFABS
SOLENOID
G101
651BLK
1288DKGRNfYEL
L/F ABS SOLENOID

CONTROL
R/F ABS
SOLENOID
6518LK
1289LTBLU/BLK
R/F ABS SOLENOID

CONTROL
9-1-92
NS 15727
DTCA076
LEFT FRONT SOLENOID CIRCUIT SHORTED TO BATTERY OR OPEN
This DTC identifies a solenoid that cannot be energized due to an open in its circuitry, or a solenoid that is
always energized due to a short to battery in its circuitry between the driver and the solenoid. An open will not
allow proper ABS operation, but the short to battery simply turns "ON" the solenoid. A path for base brakes is
still allowed once the motor re-homes and the check ball is lifted off its seat during key "ON" initialization.
Failure Condition:
DTC A076 can be set only when the solenoid is commanded "OFF." If the EBCM detects an excessive voltage
in the left front solenoid control circuit, a malfunction exists.
Action Taken:

1. This checks for a short to voltage in the control
circuitry of the solenoid.
2. This checks for an open in the control circuit of the
solenoid.
3. This step checks the solenoid coil for proper
resistance.
4. This step checks for an open in the solenoid ground
circuit.
malfunction in the solenoid circuitry due to poor
terminal contact.
Diagnostic Aids:
section.
the wiring harness.
DTCA076
LEFT FRONT SOLENOID CIRCUIT
SHORTED TO BATTERY OR OPEN
G)
G)
IGNITION " OFF."

IGNITION "ON" ENGINE "OFF."
AND TERMINAL "81" OF THE 32-WAY EBCM HARNESS
CONNECTOR.
IGNITION " OFF."

DISCONNECT LEFT FRONT SOLENOID CONNECTOR.
TERMINAL "81 " OF THE 32-WAY EBCM HARNESS
CONNECTOR AND TERMINAL A " OF JHE LEFT FRONT
SOLENOID HARNESS CONNECTOR.

AND TERMINAL "B" OF THE LEFT FRONT SOLENOID.
IS RESISTANCE BETWEEN 2 .5 AND 5 n?
REPAIR OPEN OR HIGH

RESISTANCE IN CKT
1288.

GROUND AND TERMINAL "r OF THE
LEFT FRONT SOLENOID HARNESS
CONNECTOR.
RECONNECT SOLENOID CONNECTOR AND 32-WAY EBCM

CONNECTOR.
IGNITION "ON."
REFER TO 01AGNOSTIC AIDS" ON
FACING PAGE .
11-19-92
NS 15717
EBCM
_r:-
S111
651 BLK - - - - - - - - - , , - - - - -- - - - - - --
651 BLK
GROUND
UFABS
SOLENOID
G101
651BLK
1288DKGRN/YEL
UF ABS SOLENOID
CONTROL
.\
(
R/F ABS
SOLENOID
651BLK
1289LTBLU/BLK
R/F ABS SOLENOID

CONTROL
9-1 -92
NS 15727
DTCA077
LEFT FRONT SOLENOID CIRCUIT SHORTED TO GROUND OR DRIVER OPEN
This OTC identifies a solenoid that cannot be energized due to an open in its driver circuitry, or a short to
ground between the solenoid driver and the solenoid. These malfunctions can affect ABS operation since the flow
of brake fluid to the wheel cylinder cannot be stopped, making ABS operation for that channel impossible.
Failure Condition:
OTC A077 can be set only when the solenoid is commanded "ON." If the EBCM detects the left front solenoid
control circuit voltage is out of specification, a malfunction exists.
Action Taken:
A malfunction OTC is stored, ABS is disabled and t he "ABS INOP" lamp is turned "ON."

l. This step checks for a solenoid that is internally
shorted to ground.
2. This step checks for a solenoid t hat is not within
proper resistance values.
3. This step indicates if a short to ground exists in the
solenoid circuitry.
4. This checks for a n open control circuit to the
EBCM.
5. This step checks for a possible in termi tten t
terminal contact.
Diagnostic Aids:
wire that is broken inside the insulation .
section.
the wiring harness.
DTCA077
LEFT FRONT SOLENOID CIRCUIT
SHORTED TO GROUND OR DRIVER OPEN
0 .
IGNITION HOFF."
DISCONNECT LEFT FRONT SOLENOID CONNECTOR.
GROUND AND TERMINAL HA " OF THE LEFT FRONT
SOLENOID.

TERMINAL" A" AND TERMINAL "B" OF THE LEFT FRONT
SOLENOID.
IS RESISTANCE BETWEEN 2.5 AND S.O Q?

TERMINAL "81" OF THE 32-WAV EBCM HARNESS
CONNECTOR.
DOESJ 39200 DISPLAY RESISTANCE AS HOL" (INFINITE)?
REPLACE LEFT FRONT SOLENOID.
REPLACE LEFT FRONT SOLENOID.
MEASURE THE RESISTANCE BETWEEN TERMINAL "81 "OF THE

32-WAV EBCM HARNESS CONNECTOR AND TERMINAL "A" OF
THE LEFT FRONT SOLENOID HARNESS CONNECTOR.
RECONNECT SOLENOID CONNECTOR AND 32-WAV EBCM

CONNECTOR.
IGNITION "ON."
REPLACE EBCM.
REFER TO "DIAGNOSTIC AIDS"
ON FACING PAGE.
1-4-93
NS 15718
,,
EBCM
__r-
651 BLK
G101
S111
GROUND
LJF ABS
SOLENOID
651BLK - 1 2 8 8 D K G R N / Y E L
LJF ABS SOLENOID

CONTROL
R/F ABS
SOLENOID
651BLK
1289LTBLU/BLK
R/F ABS SOLENOID

CONTROL
9-1-92
NS 15727
DTCA078
RIGHT FRONT SOLENOID CIRCUIT SHORTED TO BATTERY OR OPEN
This OTC identifies a solenoid that cannot be energized due to an open in its circuitry, or a solenoid that is
always energized due to a short to battery in its circuitry between the driver and the solenoid. An open will not
allow proper ABS operation, but the short to battery simply turns "ON" the solenoid. A path for base brakes is
still a llowed once the motor re-homes and the check ball is lifted off its seat during key "ON" initialization.
Failure Condition:
OTC A078 can be set only when the solenoid is commanded "OFF." If the EBCM detects an excessive voltage
in the right front solenoid control circuit, a malfunction exists.
Action Taken:
Diagnostic Aids:

1. This checks for a short to voltage in the control
circuitry of the solenoid.
2. This checks for an open in the control circuit of the
solenoid.
3. This step checks the solenoid co il for proper
resistance.
4. This step checks for an open in the solenoid ground . section.
circuit.
5. This step checks for a possible intermittent . intermittent complaint, should be thoroughly checked
terminal contact.
the wiring harness.
II
DTCA078
RIGHT FRONT SOLENOID CIRCUIT
SHORTED TO BATTERY OR OPEN
IGNITION "OFF."
DISCONNECT 32-WA Y EBCM CONNECTOR.
USINGJ 39200, MEASURE THE VOLTAGE BETWEEN GROUND
AND TERMINAL" A9" OF THE 32-WAY EBCM HARNESS
CONNECTOR.
IS VOLTAGE 1 VOLT OR LESS1
IGNITION "OFF."
DISCONNECT RIGHT FRONT SOLENOID CONNECTOR.
TERMINAL" A9" OF THE 32-WAY EBCM HARNESS
CONNECTOR AND TERMINAL n A" OF THE RIGHT FRONT
SOLENOID HARNESS CONNECTOR.
IS RESISTANCE 2 il OR LESS1

AND TERMINAL "B" OF THE RIGHT FRONT SOLENOID.
IS RESISTANCE BETWEEN 2.5 AND 5 Q1
G)
REPAIR OPEN OR HIGH

RESISTANCE IN CKT
1289.

TERMINAL "B" OF THE RIGHT FRONT SOLENOID HARNESS
CONNECTOR.
IS RESISTANCE 2 U OR LESS1
G)
RECONNECT SOLENOID CONNECTOR AND 32-WAY EBCM

CONNECTOR.
IGNITION noN.
H
FACING PAGE.
11-19-92
NS15719
5E1-136 ANTILOCKBRAKE SYSTEM
EBCM
__c-- 651 BLK

G101
S111
GROUND
L/FABS
SOLENOID
651BLK - 1 2 8 8 D K G R N I Y E L
L/F ABS SOLENOID

CONTROL
R/FABS
SOLENOID
651BLK
1289LTBLU/BLK
R/F ABS SOLENOID

CONTROL
9-1-92
NS 15727
DTCA081
RIGHT FRONT SOLENOID CIRCUIT SHORTED TO GROUND OR DRIVER OPEN
This DTC identifies a solenoid that cannot be energized due to an open in its driver circuitry, or a short to
ground between the solenoid driver and the solenoid. These malfunctions can affect ABS operation since the flow
of brake fluid to the wheel cylinder cannot be stopped, making ABS operation for that channel impossible.
Failure Condition:
DTC A081 can be set only when the solenoid is commanded "ON." If the EBCM detects the right front
solenoid control circuit voltage is out of specification, a malfunction exists.
Action Taken :
1. This step checks for a solenoid that is internally
shorted to ground.
2. This step checks for a solenoid that is not within
proper resistance values .
3. This step indicates if a short to ground exists in the
solenoid circuitry.
4. This ch ecks for an open control circuit to the
EBCM.
terminal contact.
Diagnostic Aids:
section.
for backed out terminals,. improper mating, broken
the wiring harness.
A"'TILOCK BRAKE SYSTEM SE1-137
DTC A081
RIGHT FRONT SOLENOID CIRCUIT
SHORTED TO GROUND OR DRIVER OPEN
IGNITION "OFF.
. DISCONNECT RIGHT FRONT SOLENOID CONNECTOR.
GROUND AND TERMINAL "A" OF THE RIGHT FRONT
SOLENOID.
DOES DVM DISPLAY RESISTANCE AS "OL" (INFINITE)7

TERMINAL" A" AND TERMINAL "B" OF THE RIGHT
FRONT SOLENOID.
IS RESISTANCE BETWEEN 2.5 AND 5.0 Q7
. t. ~
DISCONNECT 32-WA Y EBCM CONNECTOR.

. 0
. MEASURE,THE RESISTANCE BETWEEN GROUND AND
TERMINAL "A9" OF THE 32-WAY EBCM HARNESS
CONNECTOR .
DOES J 39200 DISPLAY RESISTANCE AS "OL" (INFINITE)7
MEASURE THE RESISTANCE BETWEEN TERMINAL " A9 "OF THE

32-WAY EBCM HARNESS 'CONNECTOR AND TERMINAL "A" OF
THE RIGHT FRONT SOLENOID HARNESS CONNECTOR.
IS RESISTANCE 2 Q OR LESS7
..
REPAIR SHORT TO GROUND

IN CKT 1289.
RECONNECT SOLENOID CONNECTOR AND 32-WA Y EBCM

CONNECTOR.
IGNITION "ON."
DOES DTCA081 RESET?
FACING PAGE.
1-4-93
NS 15720
SE~-138 ANTILOCK BRAKE SYSTEM
MS 12781
DTCA082
CALIBRATION MEMORY FAILURE
This DTC allows the EBCM to check for a calibration malfunction by comparing the calibration value to a
known value stored in the EEPROM.
This DTC is also used as a security measure to prevent improper use of calibrations or changes to these
calibrations that may a lter the designed function of ABS.
Failure Condition:
DTC A082 can be set at key-up. If the program identifier is incorrect or the memory checks um is incorrect, a
malfunction exists.
Action Taken:

1. This step checks to see if the malfunction is
present during diagnosis. If present, the EBCM is
not functioning correctly and must be replaced.
[I] Important
At the time of printing, 1993 vehicles.with ABS-VI

were not being field reprogrammed to correct this
failure. A service bulletin will be issued when
EEPROM reprogramming is a uthorized.
Diagnostic Aids:
An intermittent DTC A082 may be caused by a bad
cell in the EEPROM that is sensitive to temperature
changes. If DTC A082 failed more than once, but is
intermittent, replace EBCM.
by using the enhanced diagnos tic function of the Tech
1, as described in "Tech I Diagnostics" found in t his
section.
DTCA082
CALIBRATION MEMORY FAILURE
G)
IGNITION "ON. "

REPLACE EBCM AND VERIFY

ABS OPERATION.

THIS TIME. REFER TO 01AGNOSTIC
Atos ON FACING PAGE.
06-11 -92
MS8731 -SE

IGN
EBCM
GAGES
FUSE9
BRAKE
BRAKE
COMBO
WARNING SWITCH
INSTRUMENT
CLUSTER
BRAKE WARNING
LAMP CONTROL
SEE SA- 11-4

39~NK
L..!-39PNK
S206
D
r-.,
L -
.J
1537 DKBLU
ABS ACTIVE
LAMP CONTROL
867LTGRN
ABS FAIL
LAMP CONTROL
C200D
C200A
=CAMARO
9-18-92
NS 15733
= FIREBIRD
DTCA086
RED BRAKE WARNING LAMP ACTIVATED BY ABS
~ircuit Description:
, This DTC is provided as an information only DTC, and reflects the status of the command issued by the ABS
EBCM to illuminate the red brake warning lamp. If another DTC issues a command to illuminate the red brake
warning lamp, DTC A086 will be stored in EEPROM as a history DTC at the conclusion of the ignition cycle .

1. This step serves to identify if a DTC other than
DTC A086 commanded the red brake warning
lamp"ON."
Diagnostic Aids:
Any ABS mechanical DTC that issues a command
to illuminate the red "BRAKE" telltale will also result
in DTC A086 being stored in EEPROM during shut
down. These DTCs are: A038, A041, A042, A046, and
A051. If the motors are not in their home position,
certain electrical DTCs will also command the red
"BRAKE" telltale "ON." These DTC s are: A014,
A016, A018, A055, A056, A057, A058, A061, A062,
A063, A064, A065, a nd A066.
If any of these DTCs are indicated along with DTC
A086, they must be corrected prior to a ddressing a
DTC A086 malfunction.
ANTILOCK BRAKE SYSTEM ,11-141
DTCA086
RED BRAKE WARNING LAMP
ACTIVATED BY ABS
','
ARE ANY DTCs CURRENTLY
SET WITH DTC A086?
DTC A086 SET DUE TO VEHICLE

TRANSIENT VOLTAGES, CLEAR DTC.
PROCEED TO "DIAGNOSTIC.AIDS" ON
FACING PAGE OF THIS CHART.
5-22-92
MS 10093
1,
IGN
EBCM
GAGES
FUSE 9
INSTRUMENT
CLUSTER
BRAKE
BRAKE
COMBO
WARNING SWITCH
BRAKE WARNING
LAMP CONTROL
SEE SA-11-4
39~NK
L_._39PNK
S206
:(AMARO
r - ,
= FIREBIRD
L-.1
1537 DK BLU
ABS ACTIVE
LAMP CONTROL
867 LTGRN
ABS FAIL
LAMP CONTROL
C200D
C200A
9-18-92
NS 15733
DTCA087
RED BRAKE WARNING LAMP CIRCUIT OPEN
This DTC is used to verify the EBCM has continuity to the red brake warning lamp in case the EBCM must
turn it "ON." This will only occur if an ABS malfunction is detected that may degrade base brake operation.
Because ABS is not the only device controlling the red brake warning lamp (parking brake and low fluid
sensor may also turn "ON" the lamp) a short to ground in this circuit cannot be detected.
Failure Condition:
DTC A087 can be set after initialization is completed. If the red brake warning lamp circuit voltage is out of
specification indicating an open circuit, a malfunction exists.
Action Taken:
A malfunction DTC is stored, ABS is not disabled; however, the "ABS INOP" lamp will flash to indicate a
malfunction exists.
Diagnostic Aids:
I . This step identifies if the malfunction is currently
present.
2. This step indicates if the EBCM and circuitry has
the ability to complete the ground to the brake
telltale lamp and illuminate it.
3. Because the red brake warning lamp has current
I, as described in "Tech 1 Diagnostics" found in this
supplied to it through the 10 amp "GAGES" Fuse
section. If a Tech I or T-100 are not available, the
9, this step would indicate if the ignition circuit is
parking brake handle may be lifted to verify proper
complete to the VP cluster.
lamp operation and continuity of CKTs 3 and 39.
4. This step isolates if the open circuit is due to a
EBCM failure or open circuitry to the brake
telltale.
5. This step checks for an open in the park brake
circuitry.
6. This step determines if the malfunction is
the wiring harness.
intermittent.
7. This step verifies the condition of the "GAGES"
fuse.
DTCA087
G)

CIRCUIT OPEN
IGNITION "ON ."

PARK BRAKE " Off."
SELECTDATALISTFUNCTIONOFTECH1.
MONITOR BRAKE WARNING LAMP STATUS.
DOES BRAKE WARNING LAMP INDICATE uCIRCUIT OPEN " ?
SELECT LAMP TEST FUNCTION OF TECH 1.

COMMAND RID sRA KE- LAMP oN_IS RED sRAKE- WARNING LAMP oN-?
G)
G)
IGNITION UOFF. "

IGNITION "ON .u
APPLY PARK BRAKE .
USING J 39200, MEASURE THE VOLTAGE BETWEEN
GROUND AND TERMINAL "84 OF THE 32-WAY EBCM
HARNESS CONNECTOR.
IGNITION "OFF."
RELEASE PARK BRAKE .
RECONNECT 32-WAY EBCM
CONNECTOR.
IGNITION " ON."
CHECK BRAKE FLUID LEVEL AND

REPAIR HIGH RESISTANCE IN
BRAKE PRESSURE DIFFERENTIAL
SWITCH CIRCUITRY. REFER TO
SECTION SA .
(v
IGNITION "OFF."
IGNITION "ON."
WITH JUMPER CONNECTED TO GROUND, PROBE
TERMINAL "84" OF 32-WAY EBCM HARNESS
CONNECTOR.
DOES RED " BRAKE" WARNING LAMP ILLUMINATE?
CHECK FOR POOR TERMINAL CONTACT OF TERMINAL

"84" OF THE 32-WAY EBCM HARNESS CONNECTOR.
IF OK, REPLACE EBCM.
G)
REPAIR HIGH
RESISTANCE IN PARK
BRAKE SWITCH
CIRCUITRY. REFER TO
SECTION SA.
MAlFUNCTION IS NOT
PRESENT AT THIS TIME.
REFER TO "DIAGNOSTIC
AIDS" ON FACING PAGE .
CHECK 10 AMP GAGES FUSE 9.

IS FUSE OPEN?
REPAIR OPEN CKT 33

OR
OPEN " BRAKE " WARNING LAMP BULB
OR
OPEN INSTRUMENT PANEL CIRCUITRY.
REFER TO SECTION SA FOR FURTHER DIAGNOSIS.
2-8-93
NS 15721
/'
IGN
EBCM
GAGES
FUSE9
BRAKE
COMBO
BRAKE
WARNING SWITCH
INSTRUMENT
CLUSTER
BRAKE WARNING
LAMP CONTROL
SEE SA-11-4
39~NK
L_._39PNK
1S37DKBLU
ABS ACTIVE
LAMP CONTROL
867LTGRN
ABS FAIL
LAMP CONTROL
5206
06
D
r-.,
L -
.J
=CAMARO
I "ABS INOP"
817
L..----..J.-J
867LTGRN~~1
C200D
C200A
= FIREBIRD
9-18-92
NS 15733
DTCA088
.
,......
RED BRAKE WARNING LAMP CIRCUIT SHORTED TO BATTERY
This DTC identifies a s~ort to battery between the EBCM and the red brake warning lamp, or an open driver
that does not allow the red brake warning lamp to be illuminated by the EBCM. This will only occur if an ABS
fault is detected that may degrade base brake operation.
Failure Condition:
DTC A088 can be set only at the beginning of the three second bulb check. If the EBCM detects battery
voltage on the red brake warning lamp control.circuit, a malfunction exists.
Action Taken:
A malfunction DTC is stored. ABS is not disabled; however, the "ABS INOP" lamp will flash to indicate a
malfunction exists.
Diagnostic Aids:

1. This step identifies if the ground circuit to the red
brake warning lamp is being completed by a source
other than the EBCM.
2. This step identifies if the malfunction is currently
present.
3. By removing the 10 amp "GAGES" Fuse 9, the
voltage source is eliminated. This test indicates if
section.
voltage is being supplied from a source other than.
the gauge fuse.
intermittent complaint, should be thoroughly checked '
4. This step checks for DTC A086 also being set.
the wiring harness.
.j
DTCA088
CIRCUIT SHORTED TO BATTERY
(~)
IGNITION "ON ...

OBSERVE RED uBRAKE" WARNING LAMP.
IS LAMP "OFF"?
USING TECH 1 LAMP FUNCTION,

COMMAND RED " BRAKE" LAMP ON.
IS LAMP ILLUMINATED?
G)
IGNITION " OFF."

REMOVE 10 AMP GAUGES FUSE 9.
DISCONNECT 32-WAY EBCM
CONNECTOR.
IGNITION "ON."
VOLTAGE BETWEEN GROUND AND
TERMINAL "84" OF THE 32-WA Y
MALFUNCTION IS NOT
PRESENT
ATTHISTIME. REFERTO
"DIAGNOSTIC AIDS"
ON FACING PAGE.
CHECK FOR LOW FLUID LEVEL

OR
PARKING BRAKE SWITCH
CLOSED AND CORRECT AS
NECESSARY.
PROCEED TO b Tc
A086 DIAGNOSTIC
CHART.
REPLACE EBCM AND VERIFY RED "BRAKE"

WARNING LAMP FUNCTIONS PROPERLY.
11-19-92
NS 15722
EBCM
B+
STOP HAZARD
FUSE 6
~1400RN
20AMP
~B
p :3
C2000
~ 820 YEL 5243 C200A11--s.....2...1_1-s20 YEL
BRAKE SWITCH
,I
CRUISE CONTROL
MODULE
9-1-92
NS 15734
DTCA091
OPEN BRAKE SWITCH CONTACTS DURING DECELERATION
This DTC is used to detect an open brake switch in the non-ABS mode. The EBCM looks for deceleration
rates that would indicate braking action and verifies this assumption by requiring several repeats of this
detection method. In each case, ABS will not be available since no brake switch is seen.
Failure Condition:
DTC A091 can be set if three deceleration cycles occur with the brake switch "OFF."
Action Taken:

1. This step indicates if the brake switch signal is
being received by the EBCM.
2. This step indicates if an open circuit exists in the
brake switch or brake lamp circuitry.
3. This step isolates the open circuit to either the
brake switch input circuitry, or the EBCM.
4. This step verifies t hat voltage is available at the
brake switch.
5. This step verifies that the brake switch is
Diagnostic Aids:
section.
the wiring harness.
DTCA091
OPEN BRAKE SWITCH CONTACTS
DURING DECELERATION
IS OTC A095 CURRENTLY SET?
G)
G).
G)
IGNITION "ON. "

USING TECH 1, SELECT ABS DATA LIST.
APPLY LIGHT PRESSURE ON BRAKE PEDAL,
WHILE MONITORING BRAKE SWITCH STATUS ON
TECH 1.
DOES TECH 11No1CATE BRAKE sw1rcH oNH
WITHIN 1 INCH OFTRAVEL?
WITH PRESSURE STILL APPLIED TO BRAKE

PEDAL, OBSERVE REAR BRAKE LAMPS.
ARE BRAKE LAMPS "ONN?

Alos ON FACING PAGE .

BETWEEN GROUND AND TERMINAL "B" OF
THE BRAKE SWITCH.
IGNITION " OFF."

IGNITION " ON .
USING J39200, MEASURE THE VOLTAGE
BETWEEN GROUND AND TERMINAL "B12"
CONNECTOR WHILE APPL YING FIRM
PRESSURE ON BRAKE PEDAL.
CHECK FOR POOR CONTACT

AT TERMINAL "B12" OF THE
MEAS~RE THE VOLTAGE BETWEEN

GROUND AND TERMINAL HAN OF
THE BRAKE SWITCH WHILE
APPL YING FIRM PRESSURE ON
BRAKE PEDAL.
REPAIR OPEN OR
SHORTED CKT 140
AND REPLACE 20
AMP STOP
HAZARD FUSE 6.
MISADJUSTED OR FAULTY BRAKE

SWITCH. ADJUST OR REPLACE
SWITCH AS NECESSARY.
11 -19-92
NS 15723
EBCM
B + STOP HAZARD
.. FUSE 6
~1400RN
20AMP
C200D
J..-Ll--~---L
C200A S271
18 c - ~ C 1820YEL 5243 ----a20YEL
BRAKE SWITCH
,I
CRUISE CONTROL
MODULE
9-1-92
NS 15734
DTCA092
OPEN BRAKE SWITCH CONTACTS WHEN ABS WAS REQUIRED
This DTC is run to determine the proper operation of the brake switch. This is important because ABS is
activated when the brake switch is "ON." If the brake switch is "OFF," ABS will never be activated. Since this
malfunction is difficult to detect under normal braking conditions, this malfunction is only detected when ABS is
required.
Failure Condition:
DTC A092 can be set if the vehicle's speed is greater than 8 km/h (5 mph). If the bra ke was not "ON" and a
release was required on two channels for 0.5 seconds, a malfunction exists.
Action Taken:

4. This step verifies the voltage is available at the
brake switch.
5. This step verifies that the brake switch is
Diagnostic Aids:
section.
the wiring ha rness.
DTCA092
OPEN BRAKE SWITCH CONTACTS
WHEN ABS WAS REQUIRED
IS DTC A095 CURRENTLY SET?
G)
G).
IGNITION "ON."
USING TECH 1, SELECT ABS DATA UST.
APPLY LIGHT PRESSURE ON BRAKE PEDAL,
WHILE MONITORING BRAKE SWITCH STATUS ON
TECH 1.
DOES TECH 1 INOICATE BRAKE SWITCH "ON"
WITHIN 1 INCH OFTRAVEL?
WITH PRESSURE STILL APPLIED TO BRAKE

PEDAL, OBSERVE REAR BRAKE LAMPS.
ARE BRAKE LAMPS "ON"?
IGNITION "OFF."
IGNITION "ON."
BETWEEN GROUND AND TERMINAL "812"
CONNECTOR WHILE APPLYING FIRM
PRESSURE ON BRAKE PEDAL.
IS VOLTAGE 10 VOL TS OR GREATER?
CHECK FOR POOR CONTACT

AT TERMINAL NB1r OFTHE

AIDSN ON FACING PAGE.
G)

BETWEEN GROUND AND TERMINAL "B" OF
THE BRAKE ~WITCH.
MEASURE THE VOLTAGE BETWEEN

GROUND AND TERMINAL " AN OF
THE BRAKE SWITCH WHILE
APPLYING FIRM PRESSURE ON
BRAKE PEDAL.
REPAIR OPEN OR
-SHORTED CKT 140
AND REPLACE 20
AMP STOP
HAZARD FUSE 6.
MISADJUSTED OR FAUL TY BRAKE

SWITCH . ADJUST OR REPLACE
11-19-92
NS 15723
EBCM
B
STOP
~
HAZARD
+
FUSE 6
1400RN
20AMP
i p~
B
C200D
C
~ 820 YEL 5243 C200A.._s.....2._1_1_ 820 YEL
BRAKE SWITCH
CRUISE CONTROL
MODULE
9-1-92
NS 15734
DTCA093
OTC A091 OR A092 SET IN CURRENT OR PREVIOUS IGNITION CYCLE
This DTC is the second portion of DTCs A091 and A092. If DTCs A091 or A092 failed during the last ignition
cycle, DTC A093 becomes a current failure during the next ignition cycle, keeping ABS disabled until a brake
switch "ON" state is seen. When a change is seen during an ignition cycle in which DTC A093 is a current
malfunction, DTC A091 or A092 will clear itself at the end of the current ignition cycle, and ABS will enable
itself at the start of the next ignition cycle. DTC A093 alone indicates A091 or A092 failed previously, but is
intermittent, or has been corrected .

1. This step indicates which DTC (either A091 or
A092) caused DTC A093 to set.
2. This insures that the DTC that set is repaired so
that DTC A093 can be cleared.
Diagnostic Aids:
section.
Any circuitry, t hat is suspected as causing the
the wiring harness.
Also, verify proper brake switch operation using
the data list of the Tech 1. As the brake is applied, the
data list should display the brake switch "ON" within
1 inch of travel.
ANTILOCK BRAKE SYSTEM 5E1-1 S1
DTCA093
OTC A091 OR A092 SET IN CURRENT
OR PREVIOUS IGNITION CYCLE
IGNITION NON.
USING TECH 1, READ DTCs.
IS OTC A091 OR A092 SET IN HISTORY
OR
CURRENT DTCs?
PROCEEDTODTCTHATSET
AND REPAIR AS NECESSARY.
USING ENHANCED DIAGNOSTIC FUNCTION

OF TECH 1, VERIFY MALFUNCTION
FREQUENCY WAS LOW AND CLEAR DTCs.
THIS CHART ASSUMES THAT A CURRENT OTC IS STORED INDICATING THAT THIS MALFUNCTION PRESENT.
6-11-92
MS8721SE
EBCM
8STOP
~
HAZARD
+
FUSE 6
140 ORN
20AMP
i p :3 ~
B
C200D
,,
820 YEL S243 C200A_s....2....

1_1-e20 YEL
BRAKE SWITCH
,l
CRUISE CONTROL
MODULE
9-1-92
NS 15734
DTCA094
BRAKE SWITCH CONTACTS ALWJ!, VS CLOSED
This OTC is run to determine the proper operation of the brake switch. This is important because ABS is
activated when the brake switch is "ON" and turned "OFF" when the brake is "OFF." If the brake switch is
always "ON," ABS operation will always be requested resulting in potential modulator cycling on rough roads.
Additionally, this malfunction will most likely result in a dead battery (due to the brake lights staying "ON") if
the driver is not informed of this malfunction.
Failure Condition:
DTC A094 can be set when the vehicle reaches at least 40 km/h (25 mph). If the brake was never "OFF"
during two consecutive drive cycles, a malfunction exists.
Action Taken:
A malfunction DTC is stored. ABS is not disabled; however, the "ABS INOP" will flash to indicate a
malfunction exists.

1. This checks if the malfunction is currently present.
2. This step isolates the cause of the malfunction to
either a malfunctioning or misadj usted brake
switch, or a short to voltage in the brake switch
circuitry.
3. This step checks for unwanted voltage on the
brake switch input circuit.
malfunction.
5. This step determines if the vehicle has cruise
control.
6. This step verifies proper operation of the CHMSL
lamps.
7. This step checks for unwanted voltage from the
cruise control module.
8. This step checks for an open circuit between the
cruise control module ~,nd the brake switch.
Diagnostic Aids:
section.
the wiring harness.
G)
DTCA094
IGNITION "OFF."
OBSERVE REAR CENTER HIGH
MOUNTED STOP LAMP (CHMSL).
ARE THE CHMSL LAMPS .. OFF"?
BRAKE SWITCH CONTACTS

ALWAYS CLOSED
DISCONNECT 32-WAY EBCM HARNESS CONNECTOR.

IGNITION "ON."
USING DVM MEASURE VOLTAGE BETWEEN TERMINAL
" 812" OF 32-WAY EBCM HARNESS CONNECTOR AND
GROUND.
IGNITION "OFF."
INSPECT 32-WAY EBCM HARNESS
CONNECTOR TERMINAL "812" FOR
POOR CONTACT.
TEST DRIVE VEHICLE FOR TWO
DRIVE CYCLES. A DRIVE CYCLE
CONSISTS OF STARTING VEHICLE,
DRIVING OVER 40 km/h (25 mph),
DOES DTCA094 RESET?
REPAIR SHORT TO
VOLTAGE ON CKT 820.
.._--~~~~~~~~~~--.J~.
THI S TIME,
REFER TO
.. DIAGNOSTIC
AIDS"ON
FACING PAGE.
UNPLUG BRAKE LAMP SWITCH

CONNECTOR.
ARE THE CHMSL LAMPS "ON"?
G)
MISADJUSTED OR
MALFUNCTIONING
BRAKE SWITCH.
ADJUST OR REPLACE
SWITCH AS
NECESSARY.
DEPRESS BRAKE PEDAL WHILE HAVING AN

ASSISTANT OBSERVE THE REAR CHMSL LAMPS.
ARE THE CHMSL LAMPS "ON."
DISCONNECT CRUISE CONTROL MODULE

(REFER TO SECTION 98)
IGNITION " ON."
USING DVM, MEASURE VOLTAGE BETWEEN
TERMINAL " B1r OF THE 32-WAY EBCM
HARNESS CONNECTOR AND GROUND.
REPLACE BLOWN
CHMSL BULBS.
DISCONNECT BRAKE SWITCH CONNECTOR.

USING A DVM, MEASURE THE RESISTANCE
BETWEEN TERMINAL "C" OF THE BRAKE SWITCH
HARNESS CONNECTOR AND TERMINAL " G" OF THE
CRUISE CONTROL MODULE HARNESS CONNECTOR.
REPAIR SHORT TO
VOLTAGE IN CKT 820.
REFER TO SECTION 98 FOR FURTHER

DIAGNOSIS OF CRUISE CONTROL MODULE.
REPAIR OPEN OR HIGH

RESISTANCE IN CKT 820
BETWEEN SPLICE 5271 AND
SPLICE 5243.
11 -23-92
NS 15724
EBCM
B+
STOP HAZARD
FUSE6
~ 1 400RN
20AMP
-j
E:3 ~
c
C2000
s20 YEL s243 c200A1---s.....2...
1_1-s20 YEL
BRAKE SWITCH
CRUISE CONTROL
MODULE
9-1-92
NS 15734
DTCA095
BRAKE SWITCH CIRCUIT OPEN
This DTC is used to identify open brake switch circuitry that prevents the brake switch input to the EBCM
from changing states when the brake is applied. This DTC is used in conjunction with DTCs A091 and A092 to
determine the cause of an open brake switch ma lfunction.
Failure Condition :
OTC A095 can be set after initialization is completed. If the brake switch input voltage is out of specification
for one second indicating an open circuit, a malfunction exists.
Action Taken:

1. This step is used to confirm that an open in the
brake switch circuitry currently exists.
Diagnostic Aids:
by using the enha nced diagnostic function of the Tech
section.
lqcks, improperly formed or damaged terminals, poor
the wiring harness.
DTCA095
BRAKE SWITCH CIRCUIT OPEN
IS OTC A096 CURRENTLY SET?
IGNITION "ON."
USING TECH 1, SELECT ABS DATA LIST AND MONITOR
BRAKE SWITCH STATUS.
DOES TECH 1 INDICATE THAT BRAKE SWITCH IS OPEN?
G)
APPLY LIGHT PRESSURE ON BRAKE PEDAL WHILE

MONITORING BRAKE SWITCH STATUS ON TECH 1.
DOES TECH 1 INOICATE BRAKE SWITCH .ON" WITHIN 1
INCH OF TRAVEL?

TIME. REFER TO "DIAGNOSTIC AIDSn ON
FACING PAGE.
APPLY FIRM PRESSURE TO BRAKE PEDAL

AND OBSERVE CHMSL LAMPS.
ARE ALL CHMSL LAMPS "ON"?
IGNITION nOFF."
IGNITION oN.USING A DVM, MEASURE THE VOLTAGE BETWEEN
GROUND AND TERMINAL "812" OF THE 32-WAY EBCM
HARNESS CONNECTOR WHILE APPLYING FIRM PRESSURE
REPAIR OPEN CHMSL LAMP CIRCUIT AS

DIRECTED IN SECTION BA - 11 O.
ON BRAKE PEDAL.
CHECK FOR POOR TERMINAL

CONTACT AT EBCM .
11-23-92
NS 15725
EBCM
B
STOP
~
HAZARD
+
FUSE6
1400RN
20AMP
i p~
B
C2000
C
~ 820 YEL 5243 C200A..._..,..s2.._7_1_ 820 YEL
BRAKE SWITCH
I
CRUISE CONTROL
MODULE
)
9-1-92
NS 15734
DTCA096
BRAKE LAMPS CIRCUIT OPEN
This DTC is designed to isolate the cause of a DTC A095 malfunction and indicate to the driver ABS is still
available. IfDTC A095 fails with OTC A096, the Center High Mounted Stop Lamp (CHMSL) circuit is open. The
presence of battery voltage at the brake switch input indicates a valid brake switch input is still available.
Failure Condition:
DTC A096 can be set only after OTC A095 has been set. If the EBCM detects battery voltage on the brake
switch input circuit for 0.5 seconds, a malfunction exists.
Action Taken:
A malfunction DTC is stored. ABS is not disabled; however, the "ABS INOP" lamp will flash indicating a
malfunction exists.
1. As a result of a malfunction of a n additional brake
switch circuit DTC , this OTC may be set. To
insure proper diagnosis, any additional brake
switch DTCs must be repaired first.
2. This step identifies if the malfunction is curre ntly
present in the brake circuit.
Diagnostic Aids:
section.
Any circuitry, tha t is suspected as causing the
the wiring harness.
DTCA096
BRAKE LAMPS CIRCUIT OPEN
Ci)
ARE ANY OTHER BRAKE SWITCH DTCs

EXCEPT A095 CURRENTLY SET?
APPLY FIRM PRESSURE TO BRA KE PEDAL AND

OBSERVE REAR CHMSL LAMPS.
ARE ALL CHMSL LAMPS "ONU7
MALFUNCTION IS NOT PRESENT AT THIS TIME. REFER TO

"DIAGNOSTIC AIDS ON FACING PAGE.
REPAIR OPEN CHMSL LAMP CIRCUIT

AS DIRECTED IN SECTION SA.
8 -31-92
NS 15726
DIAGNOSIS-HYDRAULIC
1.
2.
AUTOMATED SELF-DIAGNOSING
MODULATOR TEST
If a mechanical modulator malfunction is
suspected, rough ABS performance is reported, or if
any modulator service has been performed, it is
strongly recommended this test be run to verify the
repair has corrected the identified problem and the
displacement cylinder pistons are returned to their
top-most position. The Tech 1 will prompt you for
replies to changes in the brake pedal position. These
brake pedal changes are a result of modulator
component control in a specific order that allows
component malfunctions to be determined. It is very
important, especially when testing the rear channel,
that each reply to the Tech 1 questions be carefully
cons idered . During rear channel testing, pedal
movement will be felt as a bump, which is much
different than the movement felt in the front channels.
3.
4.
5.
6.
7.
8.
9.
AUTOMATED MOTOR PACK DIAGNOSIS TEST

Using the Tech l, the motor pack diagnosis test
should be performed to identify a potential problem in
the motor pack. If a problem exists, the results of the
motor pack test will be indicated on the Tech 1.
If the motor is indicated to be malfunctioning, the
motor pack is not serviceable and must be replaced as
a n assembly; refer to "Motor Pack" under "Unit
NO GEAR MOVEMENT
If all three motors release at this point, the motor
pack a ppears to function properly. Rotate each gear by
hand on the hydraulic .modulator. The front gears
(non-ce nter gears) s hould be able to be rotated
approximately 12.25 full turns lock to lock. If the gear
does not turn freely or at least 12 turns are not
possible, replace the hydraulic modulator.
The rear gear should rotate approximately 7.25
turns. If the gear does not turn freely or at least 7
turns a re not possible, replace the hydraulic
modulator.
Refer to "Hydraulic Modulator" under "On-Vehicle
Service" in this section if replacement of the modulator
is indicated above.
HYDRAULIC FUNCTIONAL CONTROL

This test is used to verify base brake apply and
ABS release, hold, and apply functions. During
testing, if a problem is encountered, the Tech 1 will
provide information on the problem.
10.
Ignition "OFF."
Raise the vehicle such that all wheels to be tested
are off the ground.
Install Tech 1.
Ignition "ON."
Select a channel to test; left front, right front, or
rear. When testing the rear brakes, both rear
wheels should rotate and not rotate together at the
various points in the test; this is true because both
rear brake pressures are controlled together.
Firmly depress brake pedal. Pedal should remain
high and firm.
Have an assistant attempt to rotate the wheel
being tested. If the wheel does not rotate, base
brake apply is working properly.
With the brake pedal still depressed, press the t
key on the Tech 1 to start t he test. The brake pedal
should remain high and firm . (If the brake pedal
drops toward the floor , verify the solenoid
electrical connectors a re connected to t he correct
solenoids.)
With the brake pedal still depressed, have the
assistant attempt to rotate the wheel. The wheel
should rotate with little or no resistance for the
full 18 seconds of this test.
After 18 seconds, brake pressure will be applied,
and a slight bump may be felt in the pedal. This is
normal. The assistant should not be able to rotate
the wheel at this point.
MOTOR TESTING
Each motor can be manually turned "ON" for up to
5 seconds, at a current of 10 amps forward or 6 amps
reverse. The test below describes how front motors
will operate; the rear motor can be tested in a similar
manner, except there will be only a slight pedal drop
(bump) and rise during the test.
1. Ignition "OFF."
2. Install Tech 1.
3. Ignition "ON," engine "OFF."
4. Pump brake pedal several times to deplete vacuum
reserve.
5. Depress and hold brake pedal.
6. Using the Tech 1, "Release" one of the motors. The
brake pedal s hould move smoothly toward the
floor. As the pedal drops, the feedback current
should momentarily drop to only a few amps
(indicating motor movement) and then become
equal to command current (6 amps). This indicates
the motor is no longer moving since the piston has
bottomed out.
Rough or "jumpy" pedal movement indicates
an intermittent electrical connection within
the motor.

7.
With the brake pedal still depressed a nd at the

floor, "Apply" the same motor. The brake pedal
should now smoothly rise back to the top of its
travel. The feedback current should momentarily
drop to a few a mps, then quickly increase to the
command current (10 amps). This indicates the
motor is no longer moving since the piston has
reached the top of its travel.
If the brake pedal does not move both up and down
as indicated and there are no codes set, monitor the
feedback current close ly while performing the test
again. If the feedback current is only a few amps, the
motor is free-spinning. The motor pack must be
separated from the hydraulic modulator to identify an
ESB, motor, gear, or ball screw problem; refer to
"Motor Pack" under "Unit Repair" in this section.
MOTOR PACK FUNCTIONAL TEST

Once the motor pack has been separated from the
hydraulic modulator, this test will help determine if
the motor pack is operating properly.
The Tech 1 will rotate the motors in one direction,
then the other.
If any motor does not turn in both directions, the
motor pack is malfunct ionin g and must be
replaced. Refer to "Motor Pack" under "Unit
If all three motors rotate, try to rotate each gear on
the hydraulic modulator; refer to "No Gear
Movement" in this section.
SOLENOID TEST
1.
2.
3.
4.
5.
6.
Ignition "OFF."
Install Tech 1.
Ignition "ON," engine "OFF."
Select left front or right front.
"Release" the motor for the channel being tested.
Select the solenoid for the same channel as that
being tested.
7 . With no brake pedal press ure applied, turn the
solenoid "ON."
8. Depress the brake pedal. It should be very high
a nd firm.
If the pedal goes nearly to the floor , the
solenoid is leaking and not closing or the
checkball is leaking.
9. With brake pressure still applied , turn the
solenoid "OFF." The brake pedal should drop
immediately.
If the pedal does not drop and the motor is
moving, the sole noid is stuck "ON" or "OFF."
To verify which:
9A. With brake pressure still applied, "Apply"
the motor for the channel being tested.
If the brake pedal rises, the solenoid is

stuck "OFF" (open) or the checkball is
leaking.
If the pedal drops suddenly, the solenoid is
stuck "ON" (closed).
If, when depressing the pedal it slowly sinks
toward the floor, or if it rises during the "Apply" of the
motor, perform the following:
1. Physically switch the two solenoids.
2. Repeat the test for the channel in question.
If the pedal slowly sinks to the floor, the
check valve is leaking and the hydraulic
modulator must be replaced. Refer to
"Unit Repair" under "On-Vehicle Service"
in this section.
If the test now works properly, test the
opposite channel. If the pedal sinks or
rises, the solenoid must be replaced. Refer
to "Hydraulic Modulator Solenoid" under
ENABLE RELAY TEST

This test a llows monitoring the voltage at the
EBCM while turning the enable relay "ON" and
"OFF."
When the relay is commanded "ON," the voltage
should be equal to battery voltage. When t he relay is
"OFF," the voltage should drop below 5 volts.
NOTICE: Voltage will not drop to zero when the

relay contacts are open due to capacitors in the
EBCM. If voltage drops below 5 volts, the relay is
operating properly.
VOLTAGE LOAD TEST

The ABS VI system can draw significant amounts
of current when operating. This test turns "ON" many
of the system components to load-test t he vehicle's
electrical system .
If low voltage malfunctions or intermittent EBCM
operation are occurring, this test will allow you to
monitor two separate power circuits for ABS: ignition
and battery. If only one of two these inputs drops
below 10 volts during testing, high resistance may be
present in that power feed circuit.
GEAR TENSION RELIEF SEQUENCE

When the displacement cylinder pistons are in
their topmost position, each motor has prevailing
torque due to the force necessary to ensure each piston
is he ld firmly at the top of its travel.
',
This torque results in "gear tension," or force on each
gear that makes motor pack separation difficult. To
avoid injury, or damage to t he gears, the "Gear
Tension Relief Sequence" briefly reverses each motor
to eliminate the prevailing torque.
Always perform the "Gea r Tension Relief
Sequence" prior to removing the hydraulic modulator
from t he vehic le. Each hydraulic modulator gear
(large gears) should be able to be turned in one
direction and then in the opposite direction when the
motor pack is removed. If any gear will not move,
replace the hydraulic modulator; refer to "Hydraulic
Modulator" under "On-Vehicle Service" in this section.
LAMP TESTS
This test a llows a functional test of all ABS
indicator/warning lamps and lamp circuitry. With
this test, the "ABS INOP" la mp can be comma nded
"ON," "OFF," or flashing and the "LOW TRAC" and
red "Brake" lamps can be commanded "ON" or "OFF. "
MOTOR REHOME FUNCTION

The motor rehome function is initiated by pressing
the F5 key from the Tech 1 main ABS VI screen. The
motor rehome function should ALWAYS be used prior
to bleeding t he brake system to eliminate a ny trapped
air within the hydra ulic modulato r cylinders. It
accompl is h es this by returning t h e hy dra ulic
modulator pistons to their "home" position a nd forcing
any trapped air toward the bleeder valves where it can
easily be bled out.
rn
Important
The motor rehome function cannot be performed if

any current codes are present. If current codes are
present, the vehicle must be repaired and codes
cleared before performing t he motor r e home
function.
ON-VEHICLE SERVICE
SERVICE PRECAUTIONS
following actions:
Eye contact - rinse thoroughly with
water.
water.
If ingested - consult a physician
immediately.
CAUTION : To help avoid personal injury

due to poor braking, DO NOT tap into the
vehicle s brake system to operate a trailer
brake system.
NOTICE: When fasteners a re removed, always
install them at the same location from which they
were removed. If a fastener needs to be replaced,
u se the correct pa rt number fastener for t hat
application . If the correct part number fastener is
not available, a fastener of equal size and strength
(or stronger) may be used. Fasteners that a re not
reused, and those requiring th r ead- locking
compound, will be called out. The correct fastene r
t ightening specification must be used wh en
installing fasteners that require it. If t he above
conditions are not followed, parts or system could
be damaged.
NOTICE : The use of rubber hoses or parts other
than those specified for the Antilock Brake System
(ABS) may lead to functional problems requiring
replacement of the hydraulic parts. Replace all
components included in repair kits used to service
this system. Lubricate rubber parts with clean,
fresh brake fluid to ease assembly. Do not use
lubricated s hop ai r on brake parts as damage to
rubber components may result. If any hydraulic
component is removed or brake line disconnected,
it is necessary to bleed all or part of t he brake
system. The fastener tightening specifications
listed are for dry, unlubricated fasteners.
NOTICE: Use only Supreme 11 (GM 1052542) or
equivalent DOT 3 brake fluid. The use of DOT 5
(silicone) brake fl u id is not r ecommended .
Reduced braking performance or durability may
result.
vehicle's pai nted surfaces, wiring, cables or
electrica l connectors. Brake fluid will damage
paint and electrical connections. If any fluid is
spilled on the vehicle, flush the area with water to
lessen the damage.
CHECKING AND ADDING FLUID

HYDRAULIC MODULATOR/MOT.OR PACK ASSEMBLY
LEFT HAND WHEELHOUSE
UNDERHOOO ELECTRICAL CENTER

NS 16308
Figure 11 - ABS Hydraulic Modulator/Motor Pack Assembly
MS 12384
MS 12383
Figure 12 - Gear Removal
Figure 13 - Gear Positioning

FLUSHING PROCEDURE
rn
Important
If evidence of contamination is present in the
vehicle's brake fluid, the entire brake system must
be flushed following one of the procedures outlined
below.
After flushing the entire brake system, all rubber
components must be replaced. Components which
must be replaced include: brake hose assemblies,
master cylinder rubber parts, brake caliper and
wheel cylinder boots and seals, combination valve
assembly, hydraulic modulator, and ABS
solenoids. Refer to the proper "On-Ve hicle
Service" for replacement procedures.
After all rubber components have been replaced,
the entire brake system must be re-flushed
following one of the procedures outlined below.
Once the second flushing procedure has been
performed, a complete system bleed must be
performed, refer to "Bleeding Procedure" in this
section.
NOTICE: Use only DOT 3 brake fluid from a

clean, sealed container. Do not use any fluid from
a container which is wet with water. Do not use
DOT 5 silicone brake fluid. Improper brake fluid,
mineral oil (from such things as engine oil,
transmission fluid, etc.), or wate r in the fluid may
cause the brake fluid to boil or the rubber
components to deteriorate . Keep a ll fluid
containers capped to prevent contamination.

about the condition of fluid in the system or if fluid
has been used which contains the slightest trace of
mineral oil (from such things as engine oil,
transmission fluid, etc.).
Pressure Flush
Tools Required:
J 35589 Bleeding Adapter
NOTICE: Pressure bleeding equipment can be

used to perform the flush procedure. The pressure
bleeding equipment used for flushing must be of
the diaphragm type. It must have a rubber
diaphragm between the air supply a nd the brake
fluid to prevent air, moi st ur e, and other
contaminants from entering the hydra ulic system.
~
l.
Clean
Fluid reservoir cover and surrounding area.

2.
F luid reservoir cover.
3. Any remaining brake fluid in reservoir.
ll'l"I Inspect
4. Refill reservoir with clean DOT 3 brake fluid to
proper level.
l+-1 Install or Connect

5.
6.
Bleeder adaptor J 35589 to brake fluid reservoir.

Bleeder adaptor to pressure bleeding equipment.
Adjust
7. Pressure bleeding equipment to 35-70 kPa (5- 10
psi) and wait for approximately 30 seconds to
insure there is no leakage.
8. Pressure bleed equipment to 205-240 kPa (30-35
psi).
Hydraulic Modulator
9. Proceed as follows with press ure bleeding
equipment connected and pressurized:

A. Attach a clear plastic hose to the rearward
bleeder valve on t he hydraul ic modulator .
Place the other end of the hose in a container to
collect draining brake fluid. Do not submerge
hose end into fluid.
B. Slowly open bleeder valve and allow fluid to
flow until clean brake fluid flows or until at
least 118 ml (4 ounces) of fluid is accumulated.
C. Close valve.
D. Repeat above procedure for the forward
bleeder valve until clean brake fluid flows or
until at least 118 ml (4 ounces) of flu id is
accumulated.
I~! Tighten
Hydraulic modulator bleeder valve to 9 Nm

(80 lb. in.).
10. Raise vehicle and suitably support.
rn
Important
Flush sequence:
Right rear.
Left rear.
Right front.
Left front.
11. Flush wheel brakes in sequence shown above.

A. Attach bleeder hose to bleeder valve at each
wheel and place the other end into a container

to collect draining brake fluid. Do not
submerge hose end in fluid.
B. Slowly open bleeder valve and a llow fluid to
flow.
12.
13.
14.
15.
16.
17.
18.
C. Close valve when clean brake fluid begins to

flow or at least 235 ml (8 ounces) of fluid is
accumulated.
Repeat Step 11 on left rear wheel brake.
Repeat Step 11 on rightfront wheel brake.
Repeat Step 11 on left front wheel brake.
Lower vehicle.
Remove bleeder adapter.
Replace all rubber components listed under
"Flushing Procedure ," refer to the appropriate
"On-Vehicle Service" section.
Repeat flushing procedure one more time.
ILI Inspect
19. Fluid level in reservoir and fill to correct level if
necessary.
E3 Install or Connect
20. Fluid reservoir cap.
21. Bleed the entire brake hydraulic system; refer to
"Bleeding Procedure" in this section.
Manual Flush
rn
Important
In the following steps, use a suitable container

and/or shop rags to catch fluid and prevent it from
contacting any painted surfaces.
~ Clean
1. Fluid reservoir cover and surrounding area.

2. Fluid reservoir cover .
3. Any remaining brake fluid in reservoir.
ILI Inspect
4. Refill reservoir with clean DOT 3 brake fluid to
proper level.
5.
Fluid reservoir cover.
Hydraulic Modulator
6.
Flush hydra ulic modulator as follows :

A. Attach a clear plastic bleeder hose to rearward
bleeder valve on the hydraulic modulator a nd
place the other end of hose in a container to
collect draining brake fluid. Do not submerge
hose end into fluid .
B. Slowly open rearward bleeder valve l/2 to 3/4
turns.
C . Depress brake pedal until fluid begins to flow .
D. Close valve and release brake pedal. Repeat

above steps until clean brake fluid flows or at
least 118 ml (4 ounces) of fluid is accumulated .
E. Repeat above procedure for the forward
bleeder valve until clean brake fluid flows or at
least 118 ml (4 ounces) of brake fluid is
accumulated.
l~I Tighten
Hydraulic modulator bleeder valves to 9 Nm

(80 lb . in.).

7.
ILI Inspect
8.
Fluid level in reservoir and fill to correct level if

necessary.
9. Fluid reservoir cover.
10. Raise vehicle and suita bly s upport .
rn
Important
Flush sequence:
Right rea r .
Left rear.
Right front .
Left front.
11. Flus h wheel brakes in sequence shown above.

A. Attach bleeder hose to bleeder valve at each
wheel and place the other end into a container
to collect draining brake fluid. Do not
submerge hose end in fluid.
B. Open bleeder valve.
C . Slowly depress brake pedal.
D. Close valve and slowly release brake pedal.
E . Repeat above procedure until clea n brake fluid
flows or at least 235 ml (8 ounces) of fluid is
accumulated.
12. Repeat Step 11 on left rear brake.
13. Repeat Step 11 on right front brake.
14. Repeat Step 11 on left front brake.
15. Lower vehicle.
16. Replace a ll rubber components listed unde r
"Flushing Procedure," r efer to t he appropriate
"On-Vehicle Service" section.
17. Repeat flushing procedure one more time.
ILI Inspect
18. Fluid level in reservoir and fill to correct level if
necessary.


20. Bleed the entire brake hydraulic system; refer to
"B leeding Procedure" in this section.
BLEEDING PROCEDURE
NOTICE: If any brake component is repaired or
replaced such that a ir is allowed to enter the brake
system, the entire bleeding procedure MUST be
followed.
5.
Bleeder adaptor to pressure bleeding equipment.
~ Adjust
6.
Pressure bleed equipment to 35-70 kPa (5-10 psi)

and wait for approximately 30 seconds to insure
there is no leakage.
7. Pressure bleed equipment to 205-240 kPa (30-35
psi).
Hydraulic Modulator
NOTICE: Prior to bleeding the brakes, the front

and rear displacement cylinder pistons must be
returned to the topmost position ("home" position).
Use the following procedure to rehome the pistons
and motors.
REHOME PROCEDURE
Using a Tech l or T-100 (CAMS), se lect F5: Motor
Rehome. The motor rehome function cannot be
performed if current DTCs are present. If DTCs
are present, the vehicle must be repaired and
DTCs cleared before performing the motor rehome
function.
2. The entire brake system s hould now be bled
following either "Pressure Bleeding" or "Manua l
Bleeding" outlined below.
1.
8. Proceed as follows with pressure bleeding

A. Attach a clear plastic bleeder hose to t he
rearward bleeder valve on the hydraulic
modulator . Submerge opposite hose end in a
clean container partially filled with clean
brake fluid.
B. Slowly open bleeder valve and allow fluid to
flow until no air is seen in fluid.
C. Close valve when fluid flows without any air
bubbles.
D. Repeat Steps 8B and 8C until no air bubbles
are present.
E. Relocate the bleeder hose on t he forward
hydraulic modulator bleeder valve and repeat
Steps 8A through 80.
l~I Tighten
Pressure Bleeding
Tools Required:
J 35589 Bleeding Adaptor
Hydraulic modulato r bleeder valves to 9 Nm

(80 lb. in.).
Brake Pipe Connections
NOTICE: Use only DOT 3 brake fluid from a

clean, sealed container. Do not use fluid from an
open container that may be contaminated with
water. Do not use DOT 5 brake fluid.
NOTICE: Pressure bleeding equipment must be
of the diaphragm type . It must have a rubber
diaphragm between the air supply and the brake
fluid to prevent air, moisture and other
contaminants from entering the hydraulic system.
~
l.
Clean
Fluid reservoir cover and surrounding ar ea.

2.
ILl lnspect
3.
Fluid to be at proper level. Refer to SECTION 5A.

Add clean brake fluid as required.

4.
Bleeder adaptor J 35589 to brake fluid reser voir.
rn
Important
Use a shop cloth to catch escaping brake fluid.

Take care to prevent fluid from running down
motor pack and entering the motor pack base or
into the electrical connector. Also, do not allow
brake fluid to contact any painted surfaces as
surface damage will occur. If brake fluid does
contact any surface, flush surface with water to
lessen damage.
9. Proceed to bleed the maste r cylinder brake

connections as follows with pressure bleeding
A. Crack (slightly open) the forward brake pipe
tube nut on the master cylinder and check for
air in escaping fluid.
B. When air flow ceases, immediately tighten
tube nut.
!~! Tighten
Master cylinder tube nut to 32 N m (24

lb. ft. ).

C. Repeat Steps 9A and 98 for the rearward
master cylinder brake pipe connection.
10. Proceed to bleed the brake combination valve
connections as follows with pressure bleeding
tube nut on the brake combination valve and
check for air in escaping fluid.
tube nut.
17. Open the bleeder valve and apply the brake until
the red "BRAKE" warning lamp turns "ON." This
shuttles the brake pressure differential warning
valve.
18. Close bleeder valve.
19. Reapply pressure to pressure bleeding equipment.
20. Turn the ignition "OFF."
rn
l~I Tighten
Brake combination valve tube nut to 18

Nm (13 lb. ft.).
C. Repeat Steps lOA and lOB for the rearward
brake combination valve pipe connection.
11. Proceed to bleed the hydraulic modulator brake
connections as follows with press ure bleeding
tube nut on the hydraulic modulator and check
for air in escaping fluid.
tube nut.
l~I Tighten
Hydraulic modulator tube nut to 32 Nm

(24 lb. ft.) .
C. Repeat Steps llA and llB for the remaining
hydraulic modulator brake pipe connections,
moving from front to rear.
Important
Do not reapply the brakes after closing the

bleeder valve.
Lower vehicle.
Repeat t he entire Step 8.
Raise vehicle and suitably support.
Repeat the entire Step 13.
Proceed as follows to bleed the front wheel brakes:
A. Attach a clear plastic bleeder hose to the right
front wheel bleeder valve and subme r ge
opposite hose end in a clean container partially
filled with clean brake fluid.
flow.
C. Close valve when fluid begins to flow without
any air bubbles. Tap lightly on the caliper to
dislodge any trapped air bubbles.
D. Re locate bleeder hose to the left front wheel
bleeder valve and repeat Steps 25A through
25C.
26. Lower vehicle.
27. Remove pressure bleedi ng equipment, including
bleeder adapter J 35589.
21.
22.
23 .
24.
25.
Wheel Brakes
ILI Inspect
12. Raise vehicle and suitably s upport.

13. Proceed as follows to bleed the rear wheel bra kes:
A. Attach a clear plastic bleeder hose to the right
rear wheel bleeder va lve and s ubmerge
filled with clean brake fluid .
flow.
C. Close valve when fluid begins to flow without
any air bubbles. Tap lightly on the caliper or
backing plate to dislodge any trapped air
bubbles.
D. Relocate bleeder hose to the left rear wheel
bleeder valve and repeat Steps 13A through
13C.
14. Remove pressure to the pre ssure bleeding
equipment.
15. Attach a clear plastic bleeder hose to the right
front wheel bleeder valve a nd s ubmerge oppos ite
hose end in a clean container partially filled with
clea n brake fluid.
16. Turn the ignition "ON ."
28. Fluid level in reservoir a nd fill to proper level if

necessary.
l+I Install or Connect

ILI Inspect
30. With ig nition "ON ," apply brake pedal with
moderate force and hold. Note pedal travel and
feel.
If pedal feels firm and constant and pedal
travel is not excessive, start the engine. With
the engine running, re-check the pedal travel.
lfit's still firm and constant and pedal travel is
not excessive, go to Step 31.
If pedal feels soft or has excessive travel either
initially or after engine start, the following
procedure may be used . With the Tech 1,
"Release" then "Apply" each motor 2 to 3 times
a nd cycle each so leno id 5 to 10 times.
rn
When finished, be sure to "Apply" the front

and rear motors to insure the pistons are in the
upmost position . DO NOT DRIVE THE
VEHICLE. Now repeat bleeding procedure
starting at Step 1.
31. Road test the vehicle.
Make several normal (non ABS) stops from a
moderate speed to ensure proper brake system
function . Allow adequate cooling time
between stops.
Manual Bleeding
NOTICE : Use only DOT 3 brake fluid from a
clean, sealed container. Do not use brake fluid
from an open container that may be contaminated
with water. Do not use DOT 5 brake fluid.
rn
1.
Fluid reservoir cover and surrounding area.

2.
6.
L'l'I Inspect
ILI Inspect
7.
~ Clean
Fluid level in reservoir and fill to the correct level

if necessary.
j++f Install or Connect

8.
Wheel Brakes
9.
Raise vehicle and suitable support.
(I] Important
3.
Fluid level in reservoir and fill to the correct level

if necessary.
f-++I
Install or Connect

Hydraulic Modulator
5.
Prime hydraulic modulator as follows:

A. Attach clear plastic bleeder ho se to the
modulator. Submerge opposite hose end in a
brake fluid.
B. Slowly open rearward bleeder valve 1/2 to 3/4
turns.
C. Depress brake pedal and hold until fluid
begins to flow .
D. Close valve and release brake pedal.
E. Repeat Steps 58 and 50 until no air bubbles
are present.
F. Relocate the bleeder hose on the forward
Steps 5A t hrough 5E.
Once fluid is seen to flow from both modulator

bleeder valves, the hydraulic modulator is
sufficiently full of fluid . However, it may not
be completely purged of air. At this point move
to the wheel brakes and bleed them. This
ensures that the lowest points in the system
are completely free of air and then the
hydra ulic modulator can be purged of any
remaining air.
1+-+I Remove or Disconnect
Important
In the following steps, use a suitable container

and/or shop cloths to catch fluid and prevent it
from contacting any painted surfaces.
Important
Bleed sequence:
Right rear.
Left rear.
Right front.
Left front.
10. Bleed wheel brakes in sequence shown above .

A. Attach a clear plastic bleeder hose to the
bleeder valve at each wheel and submer ge
filled with clean brake fluid.
B. Open bleeder valve.
C. Slowly depress brake pedal.
E. Wait 5 seconds.
F. Repeat Steps 108 through IOE until the brake
pedal feels firm and no air bubble s are
observed in the bleeder hose.
To assist in freeing entrapped air, tap
lightly on caliper or backing plate with a
rubber mallet.
11. Repeat Step 10 on left rear wheel brake .
12. Repeat Step 10 on right front wheel brake.
13. Repeat Step 10 on left front wheel brake.
14. Lower vehicle.
j+-+I
ILI Inspect
16. Fluid level in reservoir and fill to the correct le vel
if necessary.
23. Road test the vehicle.

Make several normal (non-ABS) stops from a
moderate speed to ensure proper brake system
func t ion . Allow a dequate cooling t ime
between stops.
Install or Connect

18. Bleed the hydraulic modulator.
A. Attach a clear plastic bleeder hose to the
modulator. Submerge opposite hose end in a
brake fluid.
B. Depress brake pedal with moderate force.
C. Slowly open rearward bleeder valve 1/2 to 3/4
turns and allow fluid to flow .
E. Wait 5 seconds.
F. Repeat Steps 108 through lOE until the no air
bubbles are observed in the bleeder hose.
G. Relocate the bleeder hose on the forward
Steps 18A through 18F.
l~I Tighten
Hydraulic modulator bleeder valves to 9

Nm (80 lb . in.).
l+I Remove or Disconnect
REARWARD BLEEDER VALVE

2
NS 16304
IL'l'I Inspect
20. Fluid level in reservoir and fill to the correct level
if necessary.
21 . Fluid reservoir cover.
IL'l'I Inspect
22. With ignition "ON" apply brake pedal with
moderate force and hold. Note pedal travel and
feel.
If pedal feels firm and constant a nd pedal
travel is not excessive, start the engine. With
the engine running, recheck the pedal trave l.
If it's still firm and cons tant and pedal travel is
not excessive, go to Step 23.
If pedal feels soft or has excessive trilvel either
initially or after engine start, use the Tech 1,
"Release" then "Apply" each motor 2 to 3 times
and cycle each solenoid 5 to 10 times . When
finished, be sure to "Apply" the front a nd rear
motors to insure the pistons are in the upmost
position. DO NOT DRIVE THE VEHICLE
Now repeat the bleeding procedure starting a l
Step l.
FORWARD BLEEDER VALVE
Figure 14 - ABS Hydraulic Modulator Bleeder

Locations
HYDRAULIC MODULATOR BLEEDER VALVES

Figure 14

l~I Tighten
Damaged bleeder valve or valves.
New bleeder valve or valves.
Bleeder valve to 9 N m (80 lb. in. ).
HYDRAULIC MODULATOR SOLENOID

Figure 15

1. Solenoid electrical connector.
2. Torxhead bolts.
3. Solenoid.
,.
SOLENOID LIP SEAL
SOLENOID
TORX HEAD BOLT
HYDRAULIC MODULATOR/MOTOR
PACK ASSEMBLY
NS 16309
Figure 15 Hydraulic Modulator Solenoid Removal
rn
Be sure the seal is still attached to the solenoid

when it is removed. If not, check solenoid bore in
modulator.
Do not attempt to disasse mble solenoid , it is
serviceable only as an assembly.
Lubricate seal on new solenoid with clean brake
fluid.
f+I Install or Connect

1.
2.
f~! Tighten
Important
New solenoid.
Verify that the solenoid lip seal is properly
positi oned before sole noid is installed in
hydra ulic modulator (refer to Figure 15).
Pos ition solenoid so that its e lect ri ca l
connector will face the same direction as the
solenoid that was removed.
By hand, press down fir mly on solenoid until
its fla nge seats on ABS hydraulic modulator .
Torx head bolts.
Bolts to 4.5 Nm (40 lb. in.).

3. Solenoid electrical connector to solenoid.
rn
Important
Make sure the solenoid connectors are installed on

correct solenoids.
It is necessary to bleed the en tir e system. Refer to
"Bleeding System" in this section .
HYDRAULIC MODULATOR/
MOTOR PACK ASSEMBLY
Figure 11
CAUTION: To help avoid personal injury,
due to a retained load on the hydraulic
modulator, the gear tension relief
function of the Tech 1 must be performed
prior to the removal of the ABS hydraulic
modulator.
ANTILOCK BRAKE SY.STEM SE1-169

I.
2.
3.
4.
5.
6.
7.
8.
Using Tech 1, perform "Gear Tension Relief

Sequence," as outlined in this section.
Air cleaner duct assembly.
Two solenoid electrical connectors.
Brake pressure differential warning switch
electrical connector.
6-pin motor pack electrical connector.
Five brake pipes (two to master cylinder, three to
wheel brakes).
Place shop cloth on top of motor pack to catch
any dripping fluid. Take care not to allow any
brake fluid to enter the bottom of the motor
pack or the electrical connectors. Plug open
brake pipes to prevent fluid loss and
contamination.
Bolt attaching front of hydraulic modulator/motor
pack assembly to frame rail .
Hydraulic modulator/motor pack assembly from
vehicle.
EBCM AND BRACKET

2
Hydraulic modulator/ motor pack assembly in
vehicle.
2. Bolt attaching hydraulic modulator/motor pack
assembly to frame rail.
1.
l~I Tighten
Bleed entire brake system as outlines in "Bleeding

l~I Tighten
4.
5.
Figure 16

Fasteners on lower sound insulator panel under
steering column.
2. Lower sound insulator panel from vehicle .
3. Manual transmis sion only: left side kick panel.
1.
MOUNTING STUD AND NUT
Nut attaching EBCM bracket to upper I/P.

Push in retainer ("Christmas Tree") attaching
EBCM bracket to sidewall.
Important
6.
7.
8.
9.
It will be necessary to cut the push in retainer

head off to remove EBCM bracket. Do not
attempt to pry fastener out as damage to the
EBCM bracket may result.
EBCM and EBCM bracket from mounting place.

EBCM electrical connectors.
EBCM from vehicle.
Remaining portion of push in retainer.
Important
Two bra ke combination valve tube nuts to 18

Nm (13 lb. ft.).
Three hydraulic modulator tube nuts to 32 N m
(24 lb. ft.).
ELECTRONIC BRAKE CONTROL MODULE

(EBCM)
LEFT HAND KICK PANEL

PUSH-IN RETAINER
Figure 16- EBCM Location
Bolt to 9.0 Nm (80 lb. "in.).

Five brake pipes to hydraulic modulator/motor
pack assembly.
4. 6-pin motor pack electrical connector.
5. Brake pressure differential warning s witch
6. Two solenoid electrical connectors.
Important
3
4
NS 16187
3.
EBCM HARNESS
It is necessary to remove the destroyed

retainer to insure proper retaining force when
installing the new push in retainer.

1.
2.
3.
EBCM electrical connectors.

EBCM and EBCM bracket into mounting location.
New push in retainer ("C hristmas Tree")
attaching EBCM bracket to sidewall.
4. Nut attaching EBCM bracket to upper 1/P.
!~I Tighten
Nut to 25.0 Nm (18.5 lb. ft.).
5. Manual transmission only: left side kick panel.
6. Lower sound insulator panel and fasteners.
FRONT WHEEL BEARING AND SPEED SENSOR

ASSEMBLY
Figure 17
rn
LEFT SIDE SHOWN

RIGHT SIDE SIMILAR
Important
The front wheel speed sensors a nd rings are

integral with the hub and bearing assemblies.
Should a speed sensor or ring require replacement,
the entire hub a nd bearing assembly must be
replaced . Refer to SECTION 3C .
FRONT WHEEL SPEED SENSOR JUMPER

HARNESS
Figure 18
2
FRONT WHEEL SPEED SENSOR JUMPER HARNESS
LOWER CONTROL ARM

NS 16186
Figure 17 - Front Wheel Bearing and Speed Sensor

Assembly
Raise and support vehicle on a suitable hoist as

indicated in SECTION OA.

1. Connector from wheel speed sensor.
2. Harness from re taining clips.
3. Harness grommets from retainers.
I
I
LH SHOWN
RH SIMILAR
FRONT WHEEL SPEED SENSOR JUMPER HARNESS
BRAKE LINE
HARNESS ROSEBUD RETAINER (PUSH INTO CRADLE HOLE)
WHEEL
HARNESS GROMMET (PUSH INTO GROMMET RETAINER)
CRADLE
Figure 18 Front Wheel Speed Sensor Jumper Harness
NS 16303
rn
4. Upper jumper harness connector attached to inside

of frame r ail.
1. Upper jumper ha rness connector attached to inside

offrame rail.
2. Harness to retaining clips.
3. Harness rubber grommets into retainers.
4. Connector to wheel speed sensor.
Important
Be sur e to lubricate se nsor 0 -r ing with

differential oil before installing sensor into
differential housing.
2. Bolt attaching sensor to differential housing.
l~I Tighten
Bolt to 10 Nm (89 lb. in.).
4. Jumper harness grommet into retainer.
REAR WHEEL SPEED SENSOR TOOTHED RING
rn
Important
The rear wheel speed sensor toothed ring is an

integral pa rt of t he rear differential case. If it has
been determined that t he toothed ring must be
replaced, refer to SECTlON 48 for removal and
installation procedures .
REAR WHEEL SPEED SENSOR JUMPER

.HARNESS
1++1 Remove or Disconnect

2
REAR WHEEL SPEED SENSOR JUMPER HARNESS
REAR AXLE HOUSING
REAR WHEEL SPEED SENSOR MOUNTING BOLT

NS 16185
Figure 19 - Rear Wheel Speed Sensor

Figure 19
Raise and support vehicle on a suitable hoist as
indicated in SECTION OA.

1.
2.
3.
4.
Connector from wheel speed sensor.

Jumper harness grommet from retainer.
Bolt attaching sensor to differential housing.
Sensor from differential housing.

1.
Sensor into differential housing.
1. Connector from wheel s peed sensor.

2. J u mper harness grommet from retainer.
3. Upper jumper harness connector from rear body
pass-thru connector.
Upper jumper harness connector to rear body passthru connector.

3. Jumper harness grommet into retainer.
1.
ENABLE RELAY
Figure 20

1. Enable relay cover.
2. Re lay from connector.

l. Relay to connector.
2. Enable relay cover.
BRAKE COMBINATION VALVE

Refer to SECTlON 5A.
I
. J
UNDERHOOD ELECTRICAL CENTER

(ABS ENABLE RELAY LOCATED INSIDE)
NS 16307
Figure 20 - Enable Relay location
LOCKING PIN
CONNECTOR
LOCKING PIN
SEAL*
CONNECTOR
~NGP~
CONN~
LOCKING PIN
CONNECTOR
CONNECTOR
CONNECTOR
CONNECTOR POSITION ASSURANCE (CPA) TYPICAL
MAKE SURE SEAL IS IN PLACE ON CONNECTOR
Figure 21 - ABS VI Electrical Connectors (Typical)
NS 16190

WARNING/INDICATOR LAMPS
Refer to SECTION SC for replacement procedures
and detailed information.
ELECTRICAL CONNECTORS
Figure 21
Some ABS VI components are equipped with
electrical connectors using a Connector Position
Assurance (CPA) lock. This feature insures that when
the connectors are installed they are aligned properly
and connected securely.
rn
Important
Remove the lock before separating the electrical

connectors.
Take care not to damage the locking pin during
removal.
Make sure that the rubber connector seal is in
place on the connector before and after connection.
Always install the lock after the connection is
made.
1+~3 Assemble
Gear cover to hydraulic modulator/motor pack
assembly.
2. Torx head screws.
1.
l~I Tighten
MOTOR PACK
Figure 22
l+t-+I Disassemble
1.
2.
Remove gear cover.

Four torx head screws attaching motor pack.
rn
FUSE AND FUSIBLE LINKS

Refer to SECTION 8A-1 l for repair or replacement
information.
UNIT REPAIR
3.
NOTICE: The following service procedures shall

be performed .only after the hydraulic
modulator/motor pack assembly has been removed
. from the vehicle. Do not perform these procedures
with the unit installed on the vehicle. Complete
overhaul of the hydraulic modulator/motor pack
assembly is not authorized - only the following
steps. These steps will break the unit down into
major components for replacement purposes .
Important
Use care when handling motor pack to ensure

motor pack connector is not damaged, or
accidental intrusion of brake fluid into the
motor pack does not occur. This may result in
a premature failure of the motor pack.
Take care in handling the motor pack . If
dropped or damaged during handling, the
motor pack must be replaced.
Remove motor pack.
rn
CAUTION: To help avoid personal injury,

due to a retained load on the ABS
hydraulic modulator/motor pack
assembly, the gear tension relief function
of the Tech 1 must be performed prior to
removal of the ABS hydraulic
modulator/motor pack assembly_
Torx bolts to 4 N m (35 lb. in.) .
Important
If disassembly of the hydraulic modulator/motor

pack assembly was due to a ABS hydraulic
functional test that did not pass, the "Automated
Motor Pack Diagnosis Test" described in this
section should be performed at this time to isolate
the motor pack or hydraulic modulator.
No repair of the motor pack is authorized. Replace
as an assembly.
1-+~+I Assemble
With the hydraulic modulator upside down, and
the gears facing you, rotate each hydraulic
modulator gear counterclockwise until movement
stops. This procedure will position the pistqns very
close to the top of the modulator bore, simplifying
the brake bleeding procedure (refer to Figure 13).
2. Motor pack to hydraulic modulator.
1.
rn
GEAR COVER
Figure22
l+t..l Disassemble.
Torx head screws attaching gear cover.

2. Remove gear cover .
1.
3.
Important

dropped or damaged during handling the
Align each of t he three motor pack pinions
with the hydraulic modulator gears.
Four torx head screws.

piston can bottom out in the modulator bore
damaging the piston. Turn the modulator gear to
position the piston in the center of its travel. Place
a screwdriver through the holes in the gears (not
between the gears) into the recessed hole in the
modulator base. This will prevent the gear from
turning, aiding in gear installation (refer to Figure
13).
l~I Tighten
4.
Torx head screws to 4.5 N m (40 lb. in.).

Gear cover to hydraulic modulator/motor pack
assembly.
GEAR REPLACEMENT
Figures 12 and 13
rn
Important
Do not attempt to repair damaged motor packs or

hydraulic modulators. Other than modulator
drive gear replacement, repair of these assemblies
is not authorized. Do not lubricate or oil gears on
motor pack.
CAUTION: The modulator drive gears are

under spring load and will turn during
disassembly. After removing hydraulic
modulator drive gear cover, exercise
extreme care not to place fingers into the
gear set, since fingers can be pinched by
rotating gears.
l+!+I Disassemble
Position hydraulic modulator drive gears onto

hydraulic modulator drive shaft.
2. Three gear retaining nuts.
1.
!~I Tighten
Nuts to 8.5 Nm (76 lb. in.).
3. With the hydraulic modulator upside down, and
the gears facing you, ro tate each hydraulic
modulator gear counterclockwise until movement
stops. This procedure will position the pistons very
close to the top of t he hydraulic modulator bore,
simplifying the brake bleeding procedure (refer to
Figure 13).
4. Position motor pack onto hydraulic modulator,
aligning the three motor pack gears with the
modulator gears .
rn
Hydraulic modulator . Refer to "Hydra ulic

Modulator" in this section.
2. Torxhead screws attaching gear cover.
3. Four motor pack to hydraulic modulator Torx
head screws.
1.
rn
4.
Important
Take care in handling the motor pack. If

dropped or damaged in the handling, the motor
pack must be replaced.
Separate motor pack from hydraulic modulator.
Three modulator drive gear to modulator drive

shaft retaining nuts.
6. Gears from modulator (refer to Figure 12).
5.
F~I Assemble
NOTICE :
Do not a llow gear to turn while

tightening the retaining nut, since the modulator

dropped or damaged during handling, the
5. Four motor pack to hydraulic modulator Torx

head screws.
l~I Tighten
Torxhead screws 4.5 Nm (40 lb . in.).
6. Gear cover onto hydraulic modulator with Torx
head screws.
!~I Tighten
NOTICE:
Do not allow gear to turn while

removing the retaining nut, since the modulator
piston can hit the top of the modulator bore,
damaging the piston. Turn the modulator gear to
position the piston in the center of its travel. Place
a screwdriver through the holes in the gears (not
between t he gears) into the recessed hole in the
modulator base. This will prevent the gear from
turning, a iding in gear removal.
Important
Torxhead screws to 4 Nm (35 lb. in.).

7. Hydraulic modulator . Refer to "Hydraulic
Modulator" in this section.
HYDRAULIC MODULATOR
Figure 22
l+!+I Disassemble
Remove gear cover. Refer to "Gear Cover" in this
section.
2. Remove motor pack. Refer to "Motor Pack" in this
section.
3. Two hydraulic modulator to brake combo valve
banjo bolts; separate hydraulic modulator from
brake combo valve.
1.
i
I
I
NS16306
Figure 22 - ABS Hydraulic Modulator Components
4.
Two transfer tubes with 0-rings from brake combo

valve or hydraulic modulator.
5. Banjo bolt 0-rings from brake combo valve and
hydraulic modulator.
rn
Important
If hydraulic modulator is to be replaced, install the

three gears in the same location on replacement
.Refer to "Gea r
No repair of the hydraulic modulator is authorized.
Replace as an assembly.
Refer to SECTION SA for repair of brake combo
valve.
Use new transfer tub e assemblies when
assembling the hydraulic modulator/brake combo
valve asse mbl y. Make sure two 0-rings are
properly installed on each transfer tube.
l+;+I Assemble
1.
Two transfer assemblies.
Lubricate transfer tube assembly 0-rings with

clean brake fluid.
Install transfer tube assemblies in ports in
hydraulic modulator and push in by hand to
bottom.
2. Lubricate new banjo bolt 0-ring with clean brake
fluid and install into the brake combo valve and
3. Hydraulic modulator to brake combo valve.
Hold brake combo value and rock into position
on hydraulic modulator inserting transfer tube
assemblies into brake combo valve ports.
4. Two hydraulic modulator to brake combo valve
banjo bolts.
l~I Tighten
5.
Banjo bolts to 16 Nm (12 lb. ft.).

With the hydraulic modulator upside down, and
the gears facing you, rotate each hydraulic
modulator gear coun~erclockwise until movement
stops.
4
3
J 35589
7000001
BRAKE BLEEDING ADAPTER
TECH 1 SCAN TOOL
MASS STORAGE CARTRIDGE
J 39200 DIGITAL MULTIMETER

NS 16305
This procedure will position the pistons very close

to the top of the modulator bore simplifying the
brake bleeding procedure (refer to Figure 13).
6. Motor pack to hydra ulic modulator.
7. Gear cover to hydraulic modulator/motor pack
assembly.
MASTER CYLINDER
Refer to SECTION 5A for r e pai r of master
cyl inder.
SPECIFICATIONS
ABS Hydraulic Modulator
Bleeder Valves
Solenoid Torx
Head Bolt
Electronic Brake Control
Module (EBCM) Nut
Mounting Bolt
Three Hydraulic Modulator

Brake Pipe Tube Nuts
Two Brake Combination Valve
Brake Pipe Tube Nuts
Two Master Cy linder Brake
Pipe Tube Nuts
Modulator Drive Gear Nuts
TorxHead Screws
Attaching Gea r Cover
Four Torx Head Scre ws
Attaching Motor Pack
Two Banjo Bolts Attaching
to ABS Hydraulic
Modulator
32 Nm (24 lb. ft.)

18 Nm (13 lb . ft.)
32 Nm (24 lb. ft .)
8.5 Nm (75 lb. in.)
4.0 Nm (35 lb. in.)
4.5 Nm (40 lb. in.)
16 Nm (12 lb. ft.)
SPECIAL TOOLS
9.0 Nm (80 lb . in.)
4.5 Nm (40 lb. in.)

25 Nm (18.5 lb. ft.)
9.0 Nm (80 lb. in.)
The J 39200 High Impedance Multimeter is the

only DVM authorized for use in diagnosing and
servicing the ABS VI system.
PARKING BRAKE 5F1
SECTION 5F
PARKING BRAKE
CAUTION: When servicing brake parts, do not create dust by grinding, sanding brake
linings, or by cleaning brake parts with a dry brush or compressed air. Many brake parts
contain asbestos fibers which can become airborne if dust is created during servicing.
result.
CONTENTS
Parking Brake System . . . . . . . . . . . . . . . . . . . .
Parking Brake Lever Assembly . . . . . . . . . . . . .
Cable Assemblies . . . . . . . . . . . . . . . . . . . . . . . .
"BRAKE" Indicator Lamp . . . . . . . . . . . . . . . .
On-Vehicle Service . . . . . . . . . . . . . . . . . . . . . . . .
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Parking Brake Lever Assembly .............
Cable Assemblies . . . . . . . . . . . . . . . . . . . . . . . .
Front Cable Assembly ..................
5F- l
5F-1
5F-1
5F-1
5F-1
5F-3
5F-3
5F-3
5F-3
5F-3
GENERAL DESCRIPTION
Rear Cable Assembly (Drum Brakes) . . . . . . 5F-5

Rear Cable Assembly (Disc Brakes) . . . . . . . 5F-6
Parking Brake Adjustment . . . . . . . . . . . . . . . . . 5F-7
"BRAKE" Indicator Lamp .... Refer to Section SC
Unit Repair
Rotor Refinishing . . . . . . . . . . . Refer to Section 5B2
Drum Refinishing . . . . . . . . . . Refer to Section 5C2
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5F-7
Fastener Tightening Specifications . . . . . . . . . . 5F-7
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5F-7
mechanical stops when the parking brake lever assembly

is fully released.
PARKING BRAKE SYSTEM

The parking brake system allows the rear brake
assemblies to be mechanically applied by lifting the parking brake lever assembly. On vehicles with rear drum
brakes, this system mechanically forces the rear brake
shoes outward, forcing the rear primary and secondary
shoes against the brake drum assemblies. On vehicles
with rear disc brakes, this system mechanically forces the
rear brake inner and outer pad assemblies against the
brake rotor assembly.
PARKING BRAKE LEVER ASSEMBLY

This vehicle is equipped with a self-adjusting parking brake lever assembly. This mechanism automatically
takes up any slack in the cable assemblies and provides
the correct amount of tension in the cable assemblies
when the system is engaged. The parking brake cable
assemblies cannot be manually adjusted.
When operating correctly, the rear parking brake
actuator levers on the rear disc brake caliper assemblies or
the rear drum brake assemblies will fully return to their
CABLE ASSEMBLIES
Three separate cables are used in the parking brake
system. The left and right rear cable assemblies are joined
to the front cable assembly at the equalizer, with the rear
cable assemblies running to the rear of the vehicle.
This vehicle is equipped with coated parking brake
cable assemblies. The wire strand is coated with a plastic
material which slides over plastic seals inside the conduit
end fittings. This is for corrosion protection and reduced
parking brake effort.
"BRAKE" INDICATOR LAMP

The red "BRAKE" indicator lamp will illuminate
when the ignition switch is in "START" and the parking
brake lever assembly is applied or not fully released. The
parking brake indicator switch assembly, located in the
parking brake lever assembly, will ground the "BRAKE"
indicator lamp circuit and cause the "BRAKE" indicator
lamp to illuminate.
SF-2 PARKING BRAKE
0
B
...
A
B
C
D
E
F
1
4
5
8
9
12
15
16
ARM, ADJUSTER
GRIP, PARKING BRAKE LEVER
BUTION, PARKING BRAKE LEVER RELEASE
PAWL, ADJUST
PIN, ADJUST PAWL
PULLEY, PARKING BRAKE LEVER
LEVER ASSEMBLY, PARKING BRAKE
SWITCH, PARKING BRAKE INDICATOR
BOLT/SCREW, PARKING BRAKE INDICATOR SWITCH,
2.8 Nm (25 LB. IN.)
EQUALIZER, PARKING BRAKE CABLE
GROMMET, PARKING BRAKE CABLE
BOLT/SCREW, PARKING BRAKE LEVER,
10 Nm (89 LB. IN.)
CABLE ASSEMBLY, PARKING BRAKE FRONT
SPRING, PRETENSION
PC0001-5FFRP
Figure 1 - Parking Brake Lever Assembly
PARKING BRAKE SF-3
ON-VEHICLE SERVICE
LUBRICATION
Figure 1
NOTICE: Do not lubricate the parking brake cable
assemblies. Lubrication destroys the plastic coating
on the parking brake cable assemblies.
If the parking brake lever assembly (1) does not
fully return, lubricate the following parts using GM PIN
1052497:
Adjust pawl pin.
Handle ratchet.
Adjusting ratchet.
PARKING BRAKE LEVER ASSEMBLY

Figures 1 and 2
Tool Required:
J 37043 Parking Brake Cable Release Tool

1. Front floor console assembly. Refer to SECTION
8C.
2. Light switch and wiring from parking brake indicator switch (4 ).
3. Bolt/screw (5) and parking brake indicator switch
(4) from parking brake lever assembly (1 ).
4. With parking brake lever assembly (1) in up position, remove pretension spring ( 16).
5. With parking brake lever assembly (1) in down position, rotate adjuster arm toward front of vehicle until
a 3 mm metal pin can be inserted into hole.
A. Remove and discard remaining piece of plastic
shear pin.
B. Insert 3 mm metal pin into hole, locking out
self adjuster.
6. If there is sufficient parking brake cable slack, skip
to step 10.
8. Rear cable assemblies (17 and 18) from equalizer (8).
9. Lower vehicle.
10. Bend back cable retainer tab on pulley.
11. Barrel-shaped front cable end fitting from adjuster
track on pulley.
12. Two bolts/screws (12) and parking brake lever
assembly (1) from floor pan.
13. Front cable assembly (15) and casing from parking
brake lever assembly (1) and bracket, using J 37043.

NOTICE: See "Notice" on page 5F-1 of this
section.
1. Front cable assembly (15) and casing to parking

brake lever assembly ( 1) and bracket.
2. Two bolts/screws (12) and parking brake lever
assembly (1) to floor pan.
l~I
Tighten

3. Bolt/screw (5) and parking brake indicator
switch (4).
l~I
Tighten

4. Light switch and wiring to parking brake indicator
switch (4).
5. Barrel-shaped front cable end fitting to adjuster
track on pulley.
6. Bend cable retainer tab to original position on
pulley.
7. If rear cable assemblies ( 17 and 18) were not disconnected from equalizer, skip to step 11.
9. Rear cable assemblies (17 and 18) to equalizer (8).
10. Lower vehicle.
11. Rotate adjuster arm toward rear of vehicle and fully
raise parking brake lever assembly (1).
12. Pretension spring (16).
13. Remove 3 mm metal pin from hole.
14. Cycle parking brake lever assembly (1) three times.
15. Front floor console assembly. Refer to SECTION 8C.
CABLE ASSEMBLIES
NOTICE: Handling these cables while servicing the
parking brake system requires extra care. Damage to
the plastic coating will reduce corrosion protection
and if the damaged area passes through the seal,
increased parking brake effort could result. Contacting the coating with sharp-edged tools, or with sharp
surfaces of the vehicle underbody, should be
avoided.
Front Cable Assembly

Figures 1 and 2
Tool Required:

1. Front floor console assembly. Refer to SECTION 8C.
2. With parking brake lever assembly (1) in up position, remove pretension spring (16).
3. With parking brake lever assembly (1) in down position, rotate adjuster arm toward front of vehicle until
a 3 mm metal pin can be inserted into hole.
A. Remove remaining piece of plastic shear pin
from hole.
SF-4 PARKING BRAKE
18
10
!VIEWA
I
17
19
B
A
B
C
D
8
10
11
13
17
18
WITH DISC BRAKE ASSEMBLIES

WITH DRUM BRAKE ASSEMBLIES
BRACKET,UNDERBODY
FITTING, PARKING BRAKE REAR CABLE END
DRUM ASSEMBLY, REAR BRAKE
GUIDE, PARKING BRAKE REAR CABLE
CABLE ASSEMBLY, LEFT PARKING BRAKE REAR
CABLE ASSEMBLY, RIGHT PARKING BRAKE REAR
23 GUIDE, PARKING BRAKE REAR CABLE (DRUM BRAKE
ASSEMBLIES ONLY)
PC0002-5F-F-RP
Figure 2 - Parking Brake Cable Routing
PARKING BRAKE 5F-5
18
102 mm (4.0")
1. .
---1
~~.~5~ 1I_________III 5 mm (0.2")

Smm (0.2")
.....
A
B
C
8
17
18
SURFACE OF NOTCHES MUST BE SMOOTH

SPACER, PARKING BRAKE CABLE EQUALIZER
BRACKET, UNDERBODY
CABLE ASSEMBLY, RIGHT PARKING BRAKE REAR
PC0004-5F-F-RP
Figure 3 - Parking Brake Cable Equalizer Spacer (Locally Fabricated)
B. Insert 3 mm metal pin into hole, locking out

4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
self adjuster.
Pull parking brake lever assembly (1) all the way
back.
Left and right rear cable assemblies (17 and 18)
from equalizer (8).
Fitting of front cable assembly (15) from bracket,
using J 37043.
Grommet (9) from slot in underbody assembly.
Lower vehicle.
Bend back cable retainer tab on pulley.
Barrel-shaped front cable end fitting from adjuster
track on pulley.
Front cable assembly (15) and casing from parking
brake lever assembly (1), using J 37043.
Front cable assembly (15) from floor pan.

1. Front cable assembly (15) and grommet (9) into slot
in floor pan.
A. Soapy water can be used as lubricant.
B. Feed forward end of grommet (9) into slot.
C. Use a small, curved, flat-ended pry bar to
gently press rearward end into slot.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
Be sure grommet (9) is properly seated in

slot in floor pan.
Front parking brake cable casing to parking brake
lever assembly (1).
Barrel-shaped front cable end fitting into adjuster
track on pulley.
Bend cable retainer tab to original position on
pulley.
Make sure parking brake lever assembly (1) is in
down position.
Rear cable assemblies (17 and 18) to equalizer (8).
Lower vehicle.
With parking brake lever assembly (1) in up position, install pretension spring ( 16).
Remove 3 mru metal pin from hole.
Cycle parking brake lever assembly (1) three times.
Front floor console assembly. Refer to SECTION 8C.
Rear Cable Assembly (Drum Brakes)

Figures 2, 3 and 4
Tool Required:
This vehicle is equipped with a blind cable system at
the brake drum assembly. The rear parking brake cable
5F-6 PARKING BRAKE

4. Left or right rear cable assembly (17 or 18) and casing from underbody bracket and retainer.
Use J 37043 to compress retainer fingers on
casing and pull left or right rear cable assembly
(17 or 18) from underbody bracket.
5. Pull rear cable assemblies ( 17 and 18) through
guides (13 and 23) installed on rear axle housing
assembly (19).
7. Drum assembly (11).
8. Left or right rear cable assembly (17 or 18) from
backing plate.
Use J 37043 to compress retainer fingers and
pull out left or right rear cable assembly
(17 or 18).
11
11
c
A SPRING, GUIDE
B LEFT PARKING BRAKE REAR CABLE ASSEMBLY PRIOR
TO INSTALLATION
C LEFT PARKING BRAKE REAR CABLE ASSEMBLY
INSTALLED
11 DRUM ASSEMBLY, REAR BRAKE
17 CABLE ASSEMBLY, LEFT PARKING BRAKE REAR
PC0005.5f.f-RP
Figure 4 - Installing Rear Parking Brake Cable Assembly to

Rear Brake Drum Assembly
assembly can be installed to the brake drum assembly

without disassembling the brake drum assembly.

1. Fully disengage parking brake lever assembly. Be
sure handle is down and brake indicator lamp is not
lit. If parking brake lever assembly is partially
engaged, it will not be possible to pull equalizer (8)
rearward in step 3.
equalizer (8).
A. Pull equalizer (8) rearward to gain necessary
cable slack.
B. Insert locally fabricated spacer to hold equalizer (8) in place as shown in Figure 3.
C. Remove left or right rear cable assembly
(17 or 18) from equalizer (8).
1. Left or right rear cable assembly (17 or 18) to backing plate.

Ensure that retainer fingers are seated.
Align previous marks on axle flange and
wheel.
3. Feed left rear cable assembly (17) through guide
(13) or right rear cable assembly (18) through guides
(13 and 23) on rear axle housing assembly (19).
4. Left or right rear cable assembly (17 or 18) into
underbody bracket.
5. Left or right rear cable assembly ( 17 or 18) to equalizer (8).
6. Remove locally fabricated spacer.
7. Lower vehicle.
Rear Cable Assembly (Disc Brakes)

Figures 2, 3 and 5
Tool Required:

1. Fully disengage parking brake lever assembly. Be
sure handle is down and brake indicator lamp is not
lit. If parking brake lever assembly is partially
engaged, it will not be possible to pull equalizer (8)
rearward in step 3.
equalizer (8).
A. Pull equalizer (8) rearward to gain necessary
parking brake cable slack.
B. Insert locally fabricated spacer to hold equalizer (8) in place as shown in Figure 3.
C. Remove left or right rear cable assembly
(17 or 18) from equalizer (8).
PARKING BRAKE SF-7

actuator lever (21) and cable bracket (22).
A. Pull all parking brake cable slack to caliper end

of parking brake cable assembly.
B. Remove left or right rear cable assembly
(17 or 18) from tang on actuator lever (21).
C. Using J 37043, compress retainer fingers on
cable casing and pull from cable bracket (22).

1. Left or right rear cable assembly (17 or 18) to actuator lever (21) and cable bracket (22).
Seat retainer fingers into cable bracket (22).
10
17
21
22
24
3. Feed left or right rear cable assembly (17 or 18)

through guide (13) on rear axle housing
assembly ( 19).

LEVER, REAR PARKING BRAKE ACTUATOR
BRACKET, PARKING BRAKE CABLE
DAMPENER ASSEMBLY, REAR BRAKE VIBRATION
4. Left or right rear cable assembly (17 or 18) into

underbody bracket.
5. Left or right rear cable assembly (17 or 18) to equalizer (8).
PC0006-5F-F-RP
Figure 5 - Installing Rear Parking Brake Cable Assembly to

Rear Disc Brake Caliper Assembly
4. Left or right rear cable assembly ( 17 or 18) and casing from underbody bracket.
Compress retainer fingers on casing using
J 37043 and pull left or right rear cable assembly ( 17 or 18) from underbody bracket.
5. Pull left or right rear cable assembly (17 or 18)
through guide ( 13) installed on rear axle housing
assembly ( 19).
6. Remove locally fabricated spacer.

7. Lower vehicle.
PARKING BRAKE ADJUSTMENT

Adjustments are not normally necessary after
replacing the parking brake cable assemblies or the parking brake lever assembly. Refer to SECTION 5B2 for
parking brake free-travel adjustment procedures and to
SECTION 5C2 for rear drum brake adjustment.
SPECIFICATIONS
Parking Brake Indicator Switch Bolt/Screw .............................. 2.8 Nm (25 lb. in.)
Parking Brake Lever Bolt/Screw ....................................... 10 Nm (89 lb. in.)
SPECIAL TOOLS
1. J 37043
1. PARKING BRAKE CABLE RELEASE TOOL

PC0007-5F-F-RP
ENGINE GENERAL DESCRIPTION 6-1
ENGINE
CONTENTS
Engine General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section 6
3.4 Liter V6 Engine On-Vehicle Service ..................................... Section 6A2A
3.4 Liter V6 Engine Unit Repair ............................................ Section 6A2B
5. 7 Liter V8 Engine On-Vehicle Service ..................................... Section 6A3A
5.7 Liter V8 Engine Unit Repair ............................................ Section 6A3B
Cooling-and Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section 6B
Engine Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section 6C
Engine Electrical .................................................. , . . . . . . . Section 60
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section 601
Cranking System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section 602
Charging System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section 603
Ignition System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section 604
Engine Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section 605
Driveability and Emissions - General Information ............................... Section 6E
Driveability and Emissions - Fuel Injection (Port) (3.4L) .................... Section 6E3 (3.4L)
Driveability and Emissions - Fuel Injection (Port) (5.7L) .................... Section 6E3 (5.7L)
Exhaust System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section 6F
SECTION 6
ENGINE GENERAL DESCRIPTION

CONTENTS
Description of Section 6 ...................... 6-2
Section 6A- Engine Mechanical .............. 6-2
Section 6B - Cooling and Radiator ............ 6-2
Section 6C - Engine Fuel ................... 6-2
Section 60 - Engine Electrical ............... 6-2
Section 6E - Driveability and Emissions General Information ...................... 6-2
Section 6F - Exhaust System ................. 6-2
General Information .......................... 6-2
Cleanliness and Care ....................... 6-2
General Information on Engine Service ........ 6-2
Engine Performance Diagnosis ................. 6-3
Engine Mechanical Diagnosis .................. 6-3
Excessive Oil Loss ......................... 6-3
Oil Leak Diagnosis ........................ 6-3
Finding the Leak ........................ 6-3
Repairing the Leak ....................... 6-3
Low or No Oil Pressure ..................... 6-4

Engine Noise Diagnosis ....................... 6-4
Main Bearing Noise ........................ 6-4
Connecting Rod Bearing Noise ............... 6-4
Timing Gear or Chain and Sprocket Noises ..... 6-4
Piston Noises ............................. 6-4
Valve Mechanism or Valve Train Noises ........ 6-5
Flywheel Noises (Automatic Transmission) ..... 6-5
Engine Knock Diagnosis ...................... 6-5
Knocks Cold and Continues for Two to Three
Minutes and Increases with Torque .......... 6-5
Heavy Knock Hot with Torque Applied ........ 6-5
Light Knock Hot .......................... 6-6
Knocks on Initial Start-Up but Only Lasts
a Few Seconds .......................... 6-6
Knocks at Idle Hot ......................... 6-6
Engine Compression Test ..................... 6-6
ALL NEW GENERAL MOTORS VEHICLES ARE CERTIFIED BY THE UNITED STATES ENVIRONMENTAL PROTECTION AGENCY AS CONFORMING TO THE REQUIREMENTS OF THE REGULATIONS FOR THE CONTROL OF AIR POLLUTION FROM NEW MOTOR VEHICLES. THIS CERTIFICATION
IS CONTINGENT ON CERTAIN ADJUSTMENTS BEING SET TO FACTORY STANDARDS. IN MOST
CASES, THESE ADJUSTMENT POINTS EITHER HAVE BEEN PERMANENTLY SEALED AND/OR MADE
INACCESSIBLE TO PREVENT INDISCRIMINATE OR ROUTINE ADJUSTMENT IN THE FIELD. FOR
THIS REASON, THE FACTORY PROCEDURE FOR TEMPORARILY REMOVING PLUGS, CAPS, ETC.,
FOR PURPOSES OF SERVICING THE PRODUCT MUST BE STRICTLY FOLLOWED AND, WHEREVER
PRACTICABLE, RETURNED TO THE ORIGINAL INTENT OF THE DESIGN.
6-2 ENGINE GENERAL DESCRIPTION
DESCRIPTION OF SECTION 6
SECTION 6A - ENGINE MECHANICAL
This section contains information on the mechanical
parts of the engine, such as the block, crankshaft, pistons,
valve train, and camshaft. Overhaul procedures, removal
and replacement procedures, and specifications are also
covered. The specific subsections are:
6A2A - 3.4 Liter V6 Engine On-Vehicle Service
6A2B - 3.4 Liter V6 Engine Unit Repair
6A3A- 5.7 Liter V8 Engine On-Vehicle Service
6A3B - 5.7 Liter V8 Engine Unit Repair
SECTION 68 - COOLING AND RADIATOR

Engine cooling system components such as the
radiator, water pump, hoses, thermostat, and cooling fan,
are covered in this section.
SECTION 6C - ENGINE FUEL
GENERAL INFORMATION
CLEANLINESS AND CARE
An automobile engine is a combination of many
machined, honed, polished and lapped surfaces with tolerances that are measured in the ten-thousandths of an inch.
When any internal engine parts are serviced, care and
cleanliness are important. A liberal coating of engine oil
should be applied to friction areas during assembly, to
protect and lubricate the surfaces on initial operation.
Throughout this section, it should be understood that
proper cleaning and protection of machined surfaces and
friction areas is part of the repair procedure. This is considered standard shop practice even if not specifically
stated.
Whenever valve train components are removed for
service, they should be kept in order. They should be
installed in the same locations, and with the same mating
surfaces, as when removed.
This section contains information on all the parts of

the fuel system except the Throttle Body Injection (TBI)
unit itself. Items covered are: fuel tank, fuel pump, fuel
filter, and fuel lines.
Battery cables should be disconnected before any

major work is performed on the engine. Failure to disconnect cables may result in damage to wiring harness or
other electrical parts.
SECTION 60 - ENGINE ELECTRICAL
GENERAL INFORMATION ON ENGINE

SERVICE
Items covered in this section are the battery, generator, starter, distributor, engine wire harness, spark plugs
and wires.
Ignition system diagnosis can be found in the
appropriate 6E Section as a "C-4" chart.
Specific subsections are:
60 - Engine Electrical
601 - Battery
602 - Cranking System
603 - Charging System
604 - Ignition System
605 - Engine Wiring
SECTION 6E - DRIVEABILITV AND

EMISSIONS - GENERAL INFORMATION
This section covers emission control systems, general information, and diagnostic procedures which will
lead to repairing performance and driveability related
problems. Emission components are covered, as well as
removal and replacement procedures. Instructions on use
of special tools are also given. Specific subsections are:
6E- Driveability and Emissions - General
Information
6E3 (3.4L) - Driveability and Emissions - Fuel
Injection (Port) (3.4L)
6E3 (5.7L) - Driveability and Emissions - Fuel
Injection (Port) (5.7L)
SECTION 6F - EXHAUST SYSTEM

This section has information on all exhaust system
parts, such as tailpipes, mufflers, and the catalytic
converter.
[I] Important
THE FOLLOWING INFORMATION ON ENGINE
SERVICE SHOULD BE NOTED CAREFULLY, AS IT
IS IMPORTANT IN PREVENTING DAMAGE AND
IN CONTRIBUTING TO RELIABLE ENGINE PERFORMANCE.
When raising or supporting the engine for any reason, do not use a jack under the oil pan. Due to the small
clearance between the oil pan and the oil pump screen,
jacking against the oil pan may cause it to be bent against
the pump screen resulting in a damaged oil pick-up unit.
When working on the engine, remember that the
12-volt electrical system is capable of causing short
circuits. When performing any work where electrical
terminals could possibly be grounded, the ground cable of
the battery should be disconnected at the battery.
Any time the air cleaner is removed, the intake
opening should be covered. This will protect against accidental entrance of foreign material, which could follow
that intake passage into the cylinder and cause extensive
damage when the engine is started.
IN
THE
MECHANICAL
PROCEDURES
DESCRIBED IN THIS SECTION, REFERENCES
WILL BE MADE TO THE REMOVAL OF EQUIPMENT SUCH AS POWER STEERING PUMP, AIR
CONDITIONING COMPRESSOR, ETC.
SHOULD IT BECOME NECESSARY TO
REMOVE ANY SUCH ITEM TO PERFORM OTHER
SERVICES, REFER TO THE APPROPRIATE SECTION OF THIS SERVICE MANUAL FOR SPECIFIC
INFORMATION.
ENGINE PERFORMANCE DIAGNOSIS

Engine performance diagnosis procedures are covered in Section 6E and should be consulted for diagnosis
of any driveability, emissions, or "Service Engine Soon"
light complaint.
Refer to:
SECTION 6E - Driveability and Emissions General Information
SECTION 6E3 (3.4L) - Driveability and
Emissions - Fuel Injection (Port) (3.4L)
SECTION 6E3 (5.7L) - Driveability and
Emissions - Fuel Injection (Port) (5.7L)
ENGINE MECHANICAL DIAGNOSIS

The following diagnostic information covers common problems and possible causes. When the proper
diagnosis is made, the problem should be corrected by
adjustment, repair or part replacement as required. Refer
to the appropriate section of the manual for these procedures.
EXCESSIVE OIL LOSS

Excessive oil consumption, not due to leaks, is the
use of 2 quarts (l.9L) or more of engine oil within 2,000
miles or 3 200 kilometers.
External oil leaks. Tighten bolts and/or replace
gaskets and seals as necessary.
Improper reading of oil level indicator (dipstick).
Check oil with vehicle on a level surface and allow
adequate drain-down time.
Improper oil viscosity. Use recommended SAE
viscosity for prevailing temperatures. Refer to SECTION OB for engine oil specifications.
Continuous high speed driving, and/or severe usage
such as trailer hauling, will normally cause
decreased oil mileage.
Crankcase ventilation system malfunctioning.
Valve guides and/or valve stem seals worn, or seals
omitted. Ream guides and install oversize service
valves and/or new valve stem seals.
Piston rings broken, improperly installed, worn, or
not seated. Allow adequate time for rings to seat.
Replace broken or worn rings as necessary.
Piston improperly installed or misfitted.
2. At what point is the fluid leaking from? After running the vehicle at normal operating temperature,
park the vehicle over a large sheet of paper. After a
few minutes, the approximate location of the leak
should be found by the drippings on the paper.
3. Visually check around the suspected component.
Check around all gasket mating surfaces for leaks. A
mirror is useful for finding leaks in areas that are
hard to reach.
4. If the leak still cannot be found, it may be necessary
to clean the suspected area with a degreaser, steam
or spray solvent. Clean the area well, then dry the
area. Operate the vehicle for several miles at normal
operating temperature and varying speeds. After
operating the vehicle, visually check the suspected
component. If leak still cannot be located, try using
the powder or black light and dye method.
Powder Method
1. Clean the suspected area.
2. Apply an aerosol-type powder (such as foot powder)
to the suspected area.
3. Operate the vehicle under normal operating conditions.
4. Visually inspect the suspected component. The leak
path to the source should be found by tracing the
white powder surface.
Black Light and Dye Method
A dye and light kit is available for finding leaks.
Refer to the manufacturer's directions when using the kit.
1. Pour specified amount of dye into leaking component.
2. Operate the vehicle under normal operating conditions as directed in the kit.
3. Direct the light toward the suspected area. The dyed
fluid will appear as a yellow path leading to the
source.
Repairing the Leak

Once the origin of the leak has been pinpointed and
traced back to its source, the cause of the leak must be
determined in order for it to be repaired properly. If a
gasket is replaced, but the sealing flange is bent, the new
gasket will not repair the leak. The bent flange must be
repaired also. Before attempting to repair a leak, check to
be sure that the following conditions are correct as they
may cause a leak.
Gaskets
OIL LEAK DIAGNOSIS

Most oil leaks are easily located and repaired by
visually finding the leak and replacing or repairing the
necessary parts. On some occasions a fluid leak may be
difficult to locate or repair. The following procedure may
help in locating and repairing most leaks.
Finding the Leak

1. Identify the fluid, determine whether it is engine oil,
automatic transmission fluid, power steering fluid,
etc.
!ll 1nspect
Fluid level/pressure is too high.
Improperly tightened fasteners or dirty/damaged
threads.
Warped flanges or sealing surface.
Scratches, burrs or other damage to the sealing
surface.
Damaged or worn gasket.

Cracking or porosity of the component.
Improper sealant used (where applicable).
Seals
Fluid level/pressure is too high.
Damaged seal bore (scratched, burred or nicked).
Damaged or worn seal.
Improper installation.
Cracks in components.
Shaft surface scratched, nicked or damaged.
Loose or worn bearing causing excess seal wear.
LOW OR NO OIL PRESSURE
Low oil level. Fill to full mark on oil level indicator.

Slow idle speed.
Incorrect or malfunctioning oil pressure switch.
Incorrect or malfunctioning oil pressure gage.
Replace with proper gage.
Improper oil viscosity or diluted oil. Install oil of
proper viscosity for expected temperature, or install
new oil if diluted with moisture or unburned fuel
mixtures.
Oil pump worn or dirty.
Plugged oil filter.
Oil pickup screen loose or plugged.
Hole in oil pickup tube.
Excessive bearing clearance. Replace if necessary.
Cracked, porous or plugged oil galleries. Repair or
replace block.
Gallery plugs missing or misinstalled. Install plugs
or repair as necessary.
Camshaft worn, or poorly machined. Replace camshaft.
ENGINE NOISE DIAGNOSIS

There are four steps to diagnosing engine noise. You
must determine:
1. Type of noise.
2. Under which operating conditions it exists.
3. At what rate, and at what location in the engine.
4. Compare sounds in other engines to make sure the
condition is not normal.
Identify the type of noise, for example, a light rattle
or a low rumble. Determine the exact operating conditions
under which the noise appears.
Remember, engine noises are generally synchronized to either speed (caused by the crankshaft, connecting rods or pistons) or one-half engine speed (valve train
noises). Try to determine the rate at which the noise is
occurring.
MAIN BEARING NOISE

Damaged or worn main bearing noise is revealed by
dull thuds or knocks which happen on every engine revo-
lution, and this noise is loudest when the engine is under

heavy load.
Excessive crankshaft end play is indicated by an
intermittent rap or knock sharper than a worn main bearing. Causes of main bearing noises include:
Low oil pump pressure.
Thin, diluted or dirty oil and/or filter.
Excessive main bearing clearance.
Excessive crankshaft end play.
Out-of-round crankshaft journals.
Excessive belt tension.
Loose crankshaft pulley.
Loose flywheel or torque converter.
Loose main bearing cap.
CONNECTING ROD BEARING NOISE

A damaged or worn connecting rod bearing will produce knock under all speeds. During the early stages of
wear, connecting rod noise may be confused with piston
slap or loose wrist pins. Connecting rod knock noise
increases in volume with engine speed and is at its loudest
on deceleration. Causes of connecting rod bearing noise
include:
Excessive bearing clearance.
Worn crankshaft connecting rod journal.
Thin, diluted or dirty oil and/or filter.
Low oil pressure.
Crankshaft connecting rod journals out-of-round.
Misaligned connecting rod.
Connecting rod bolts not properly torqued.
Wrong bearing inserts or misaligned bearing half.
TIMING GEAR OR CHAIN AND SPROCKET

NOISES
Engines designed with timing gears, or those
equipped with timing chain and sprockets, can produce
different noises. The most common noise is a high frequency, light knocking sound. This sound will generally
be the same in intensity whether the engine is idling, operating at high speeds, or under load. Causes of timing gear
or chain and sprocket noises include:
Worn timing chain and/or gears.
Misaligned gears.
Excessive backlash.
Damaged tooth.
Gear or sprocket loose on shaft.
Too much end play in the camshaft or crankshaft.
PISTON NOISES
Piston pin, piston, and connecting rod noises are
hard to separate. A loose piston pin, for example, causes a
sharp double knock usually heard when the engine is
idling, or during sudden acceleration then deceleration of
the engine. A piston pin that has been improperly fitted
will emit a light ticking noise that is more noticeable with
no load on the engine.

Excessive piston-to-cylinder bore clearance will
cause piston slap noise. The noise is similar to a metallic
knock, as if the piston were "slapping" the cylinder wall
during its stroke. As with most engine noises, understanding the cause of the noise will help you imagine what
the noise sounds like. An indication of piston slap is a
decrease in noise as the engine warms up. When the
engine is cold, the piston-to-bore clearance is greater and
piston slap will be louder. Causes of piston noises include:
Worn or loose piston pin or bushing.
Improper fit of pin.
Excessive piston-to-cylinder bore clearance (piston
slap).
Lack of lubrication.
Carbon deposits on top of piston striking cylinder
head.
Worn or broken piston ring land.
Broken or cracked piston.
Misaligned connecting rods.
Worn or damaged rings.
Worn or out-of-round cylinder walls.
Excessive ring land clearance.
Insufficient ring-end gap clearance.
Piston 180 degrees out of position.
Incorrect piston cam grind.
VALVE MECHANISM OR VALVE TRAIN

NOISES
A light tapping at one-half engine speed, or any
varying frequency, can indicate a valve train problem.
These tapping noises increase with engine speed.
Before attempting to judge valve train noises, thoroughly warm up the engine. This will bring all engine
components to a normal state of expansion. Also, run the
engine at various speeds and listen for engine noise with
the hood closed while sitting in the driver's seat.
If the valve mechanism is abnormally noisy, remove
the rocker arm covers and use an engine stethoscope to
determine which valves or valve train parts are causing
the noise.
CAUTION: This procedure is not recommended on engines with stainless
steel exhaust manifolds because manifold temperature will exceed the flash
point of the oil causing a fire with
possible personal injury.
Causes of valve mechanism noises include:
Broken or weak valve spring(s).
Sticking or warped valves.
Bent pushrods.
Dirty, stuck, worn or defective valve lifters.
Damaged or improperly machined camshaft lobes.
Insufficient or poor oil supply to valve train (low oil
pressure).
Excessive valve stem-to-guide clearance.
Worn valve guides.
Worn rocker arms or pushrods.

Broken rocker arm studs.
Loose or worn rocker arm attachments.
Missing or mispositioned lifter guides (roller lifter
engines).
FLYWHEEL NOISES
(AUTOMATIC TRANSMISSION)
A loose or cracked flywheel will produce an irregular thud or click. To test for a loose or cracked flywheel,
operate the vehicle at approximately 20 mph (32 km/h)
and shut off the engine. If a thud is heard, the flywheel
may be loose or damaged. This type of thud is loudest on
deceleration.
Loose torque converter-to-flywheel or flywheel-tocrankshaft bolts will sound similar to bearing knock. This
condition produces several raps during quick acceleration
on a free running engine. Depending on the idle smoothness, when the transmission is in gear, the noise may or
may not appear. Check the torque converter-to-flywheel
and flywheel-to-crankshaft bolts before attempting to
investigate any bearing-related knock.
NOTICE: Be sure the converter-to-flywheel bolts
are not too long. Converter bolts that are too long
may dimple the torque converter clutch surface
causing a shudder condition.
ENGINE KNOCK DIAGNOSIS

Noises in engines are sometimes characteristic of the
design. Compare the sounds in other engines to make sure
the condition is not normal.
KNOCKS COLD AND CONTINUES FOR TWO

TO THREE MINUTES AND INCREASES WITH
TORQUE
Flywheel contacting splash shield. Reposition
splash shield.
Loose or broken balancer or drive pulleys. Tighten
or replace as necessary.
Excessive piston-to-bore clearance. Replace piston.
Bent connecting rod.
Cold engine piston knock usually disappears when
the cylinder is grounded out. Cold engine piston
knock which disappears in 1.5 minutes should be
considered acceptable.
HEAVY KNOCK HOT WITH TORQUE

APPLIED
Broken balancer or pulley hub. Replace parts as
necessary.
Loose torque converter bolts.
Exhaust system grounded. Reposition as necessary.
Flywheel cracked.
Excessive main bearing clearance. Replace as
necessary.
Excessive rod bearing clearance. Replace as necessary.
LIGHT KNOCK HOT

Detonation or spark knock. Check operation of EST
or ESC. Refer to SECTION 6E3. Check engine
timing and fuel quality.
Loose torque converter bolts. Tighten bolts.
Exhaust leak at manifold. Tighten bolts and/or
replace manifold.
Excessive rod bearing clearance. Replace bearings
as necessary.
2. Turn engine off.

3. Two-wire terminal connector from distributor.
4. Spark plugs from all cylinders.
5. Air duct or air cleaner from throttle body.
Block throttle plate in open position.
l@I Measure
Engine compression.
KNOCKS ON INITIAL START-UP BUT ONLY

LASTS A FEW SECONDS
Improper oil viscosity. Install proper oil viscosity for
expected temperatures. Refer to SECTION OB for
engine oil specifications.
Hydraulic lifter bleed down. Clean, test and replace
as necessary.
- When the engine is stopped, some valves will
be open. Spring pressure against lifters will
tend to bleed lifter down. Attempts to repair
should be made only if the problem is consistent.
- An engine that is operated for only short
periods between start-ups may have lifter noise
that lasts for a few minutes. This is a normal
condition.
Excessive crankshaft end clearance. Replace crankshaft thrust bearing.
Excessive front main bearing clearance. Replace
worn parts.
KNOCKS AT IDLE HOT

A/C compressor or generator bearing. Replace as
necessary.
Valve train. Replace parts as necessary.
Improper oil viscosity. Install proper viscosity oil for
expected temperature. Refer to SECTION OB for
engine oil specifications.
Excessive piston pin clearance. Replace piston and
pin.
Connecting rod alignment. Check and replace rods
as necessary.
Loose crankshaft balancer. Torque and/or replace
worn parts.
Piston pin offset to wrong side. Install correct piston.
ENGINE COMPRESSION TEST

A compression pressure test is performed on the
engine cylinders to determine the condition of the rings,
valves and head gasket.

1. Run engine until it reaches normal operating temperature. Battery must be at or near full charge.
A. Install compression gage firmly to cylinder

spark plug hole.
B. Have a helper crank the engine through at least

four compression strokes in the cylinder being
tested and check the readings on the gage at
each stroke. Record the results.
C. Disconnect gage.
D. Repeat compression test for each cylinder.
lll
1nspect
Record compression readings from all cylinders.

The lowest reading should not be less than 70 percent of the highest and no cylinder reading should be
less than 689 kPa (100 psi).
Problem areas can be identified as follows:
- Normal - Compression builds up quick and
evenly to specified compression on each cylinder.
- Piston Rings - Compression is low on first
stroke and tends to build up on following
strokes, but does not reach normal. Compression improves considerably with the addition
of oil. Use approximately three squirts from a
plunger type oiler.
- Valves - Compression is low on first stroke
and it does not tend to build up in following
strokes. Compression does not improve much
with the addition of oil. Use approximately
three squirts from a plunger type oiler.
- Head Gaskets - Leaking head gaskets give
nearly the same test results as valve problems
but may be recognized by engine coolant in
the crankcase. Head gasket leakage between
two cylinders will give low readings on both
cylinders.

1. Remove block from throttle plate.
2. Air duct or air cleaner to throttle body.
3. Spark plugs.
4. Two-wire terminal connector to distributor.
3.4 LITER V6 ENGINE ON-VEHICLE SERVICE RPO L32 - VIN S 6A2A1
SECTION 6A2A
3.4 LITER V6 ENGINE

ON-VEHICLE SERVICE
RPO L32 - VIN S
CAUTIONS in Section 9J..;B under "On-Vehicle Service" and the SIR Components and Wiring
injury, or unneeded SIR system repairs.
CAUTION: Before removing or installing any electrical unit, or when a tool or equipment
could easily come in contact with "live" or "hot at all times" exposed electrical terminals,
disconnect the battery negative cable to help prevent personal injury and/or damage to the
vehicle or components. Unless instructed otherwise, the ignition switch must be in the
"OFF" or "LOCK" position.
result.
CONTENTS
General Description . . . . . . . . . . Refer to Section 6A2B
On-Vehicle Service ...................... 6A2A- l
Fuel System Pressure Relief ............. 6A2A- l
Serpentine Drive Belt and Tensioner
Assembly .......................... 6A2A-2
Engine Mount Assemblies and Brackets .... 6A2A-4
Oil Level Indicator and Tube Assemblies ... 6A2A-5
Upper Intake Manifold Assembly ......... 6A2A-5
Valve Rocker Arm Cover Assemblies ...... 6A2A-7
Valve Rocker Arms and Pushrod
Assemblies ......................... 6A2A-8
Lower Intake Manifold Assembly ......... 6A2A-9
Valve Lifter Assemblies ................ 6A2A-10
Exhaust Manifold Assemblies ........... 6A2A-l l
Crankshaft Balancer Assembly .......... 6A2A-14
Engine Front Cover Assembly ........... 6A2A-14
Timing Chain Assembly, and Crankshaft
and Camshaft Sprockets .............. 6A2A-15
ON-VEHICLE SERVICE
FUEL SYSTEM PRESSURE RELIEF
CAUTION:
To reduce the risk of fire and personal injury, it is necessary to
relieve the fuel system pressure
before servicing fuel system components.
Camshaft Assembly ...................

Valve Springs and Stem Seals ...........
Cylinder Head Assembly and Gasket .....
Oil Pan Assembly ....................
Oil Pump Assembly ...................
Connecting Rod Bearings ..............
Piston and Connecting Rod Assemblies ...
Crankshaft Bearings ...................
Flywheel Assembly ...................
Crankshaft Rear Oil Seal Assembly ......
Engine Assembly .....................
Thread Repair .......................
Specifications ..........................
Fastener Tightening Specifications .......
Engine Assembly Specifications
(3.4L L32) ........................
Special Tools ..........................
6A2A-18
6A2A- l 9
6A2A-20
6A2A-23
6A2A-23
6A2A-24
6A2A-26
6A2A-27
6A2A-29
6A2A-29
6A2A-30
6A2A-32
6A2A-33
6A2A-33
6A2A-33
6A2A-36
After relieving system pressure, a

small amount of fuel may be
released when servicing fuel lines
or connections. In order to reduce
the chance of personal injury,
cover fuel pipe fittings with a shop
towel before disconnecting, to
catch any fuel that may leak out.
Place the towel in an approved
container when disconnect is
completed.
6A2A2 3.4 LITER V6 ENGINE ON-VEHICLE SERVICE RPO L32 - VIN S
1.
2.
3.
4.
5.
Tool Required:
J 34730-1 Fuel Pressure Gage
Disconnect battery negative cable assembly terminal to avoid possible fuel discharge if an additional
attempt is made to start the engine.
Loosen fuel filler cap to relieve tank vapor pressure.
Connect J 34 730-1 to fuel pressure connection.
Wrap a shop towel around fitting while connecting
J 34730-1 to avoid spilling.
Install bleed hose into an approved container and
open valve to bleed system pressure. Fuel connections are now safe for servicing.
Drain any fuel remaining in J 34730-1 into an
approved container.
SERPENTINE DRIVE BELT AND TENSIONER

ASSEMBLY
Figures 1 and 2
NOTICE: Routine inspection of the belt may reveal
cracks in the belt ribs. These cracks will not impair
belt performance and therefore should not be considered a problem requiring belt replacement. However, the belt should be replaced if belt slip occurs or
if sections of the belt ribs are missing.
A single serpentine drive belt is used to drive all
engine accessories. All belt driven accessories are rigidly
mounted with belt tension maintained by a spring loaded
tensioner assembly.
The indicator on the movable portion of the tensioner assembly must be within the limits of the marks of
the stationary portion of the tensioner assembly. Any
reading outside of these limits indicates either a defective
belt or tensioner assembly.
Drive Belt
ll'l"I Inspect
Belt length scale on drive belt tensioner assembly
for proper installed length. If belt length scale does
not indicate proper installed length, install a new
drive belt.

CAUTION: See "Caution" on page
6A2A1 of this section.
2. Lift drive belt tensioner assembly (145) downward
(clockwise) off drive belt using a socket and handle
on tensioner pulley bolt/screw.
3. Drive belt (148).
l~I Clean
Accessory drive belt surfaces.

1. Drive belt (148) over tensioner pulley by pushing
down on drive belt tensioner assembly (145).
jv1EwA
145
28
A
B
C
D
E
28
50
145
147
148
149
150
229
INDICATOR MARK
READING FOR REPLACING BELT IN SERVICE
DEFECTIVE PARTS CHECK RANGE
MAXIMUM TOLERANCE BELT READING
MINIMUM TOLERANCE BELT READING
PULLEY, CRANKSHAFT
PULLEY, WATER PUMP
TENSIONER ASSEMBLY, DRIVE BELT
GENERATOR ASSEMBLY
BELT, SERPENTINE DRIVE
PULLEY ASSEMBLY, DRIVE BELT IDLER
PULLEY, POWER STEERING PUMP
PC0001-6A2A-F-RP
Figure 1 - Serpentine Drive Belt
3.4 LITER VS ENGINE ON-VEHICLE SERVICE RPO L32- VIN S 6A2A3

- Be sure drive belt (148) is aligned into proper
grooves of accessory drive pulleys.
Drive Belt Tensioner Assembly
++I Remove or Disconnect
1. Drive belt (148) by lifting drive belt tensioner

assembly (145) downward (clockwise) off drive belt
using a socket and handle on tensioner pulley bolt/
screw.
2. Drive belt tensioner bolts/screws (152).
3. Drive belt tensioner assembly (145).

NOTICE: See "Notice" on page 6A2A-l of this
section.
Drive Belt Idler Pulley

The drive belt idler pulley assembly is used in place
of the A/C compressor when the vehicle is not equipped
with air conditioning.

1. Drive belt (148) by lifting drive belt tensioner
assembly (145) downward (clockwise) off drive belt
using a socket and handle on tensioner pulley bolt/
screw.
2. Idler pulley bolts/screws (151 ).

3. Drive belt idler pulley assembly (150).

section.
1. Drive belt idler pulley assembly (150).
2. Idler pulley bolts/screws ( 151 ).
l~I Tighten
l~I Tighten
Drive belt tensioner bolts/screws (152) to
33 Nm (24 lb. ft.).
Idler pulley bolts/screws (151) to 50 Nm

(37 lb. ft.).
- Be sure belt is aligned into proper grooves of
accessory drive pulleys.
151
145
150
151
152

PULLEY ASSEMBLY, DRIVE BELT IDLER
BOLT/SCREW, DRIVE BELT IDLER PULLEY
BOLT/SCREW, DRIVE BELT TENSIONER
PC0002-6A2AF-RP
Figure 2 - Drive Belt Tensioner Assembly and Idler Pulley
6A2A-4 3.4 LITER V6 ENGINE ON-VEHICLE SERVICE RPO L32 - VIN S
ENGINE MOUNT ASSEMBLIES AND

BRACKETS
Figure 3
NOTICE: When raising or supporting the engine for
any reason, do not use a jack under the oil pan,
crankshaft pulley, or any sheet metal. Due to small
clearance between the oil pan and the oil pump
screen, jacking against the oil pan may cause it to be
bent against the pump screen, resulting in a damaged
oil pickup unit.
ll'l'I
Inspect
Engine mounts for damage to rubber portions of

mount.
Rubber surface covered with heat check
cracks.
- Rubber cushion separated from plate of mount.
- Rubber cushion split through center.
1. Raise and suitably support vehicle. Refer to SEC-
TION OA.
2. Exhaust crossover pipe. Refer to SECTION 6F.
3. Engine mount through-bolts/screws (120) and nuts
(117).
4. Raise engine with a jacking fixture.
5. Engine mount bolts/screws (118) and mount assemblies (119).
6. Engine bracket bolts/screws and brackets ( 116).

NOTICE: See "Notice" on page 6A2A-1 of this
section.
1. Engine brackets ( 116) and bolts/screws.
2. Engine mount assemblies (119) and bolts/screws
(118).
A
B
116
117
118
119
120
!VIEW
LEFT-HAND SIDE
RIGHT-HAND SIDE
BRACKET, ENGINE
NUT, ENGINE MOUNT THROUGH-BOLT/SCREW
BOLT/SCREW, ENGINE MOUNT
MOUNT ASSEMBLY, ENGINE
THROUGH-BOLT/SCREW, ENGINE MOUNT
Al
PC0003-6A2A-F-RP
Figure 3 - Engine Mount Assemblies and Brackets
3.4 llTER V6 ENGINE ON-VEHICLE SERVICE RPO L32- VIN S 6A2A5
l~I
Tighten
Engine mount bolts/screws (118) and bracket

bolts/screws to 58 Nm (43 lb. ft.).
3. Lower engine.
(117).
l~I
Tighten
Engine mount through-bolt/screw nuts (117) to

80 Nm (59 lb. ft.).
-or Engine mount through-bolts/screws (120) to
95 Nm (70 lb. ft.).
6. Lower vehicle.
OIL LEVEL INDICATOR AND TUBE

ASSEMBLIES

1. Nut securing tube bracket to left cylinder head stud
bolt/screw.
2. Level indicator and tube assemblies from engine
block.

l'JOTICE: See "Notice" on page 6A2A-1 of this
section.
1. Clean tube assembly and apply sealant, GM P/N
12345493 or equivalent, around tube 12.7 mm
(0.50 inch) below bead.
2. Tube assembly into engine block and rotate into
position.
3. Nut securing tube bracket.
!~I
Tighten
Oil level indicator tube nut to 21 N m

(15 lb. ft.).
4. Level indicator.
UPPER INTAKE MANIFOLD ASSEMBLY

Figures 4 and 5

1.
2.
3.
4.
5.

6A2A-1 of this section.
Drain coolant. Refer to SECTION 6B.
Throttle body air duct.
Fuel rail injector wiring harness connectors.
Wiring harness retaining nut and lay harness aside.
6. Accelerator cable bracket bolts/screws, bracket and

cables from throttle body assembly.
7. Relieve fuel system pressure. Refer to "Fuel System
Pressure Relief" in this section.
8. Fuel pipe connectors.
9. Fuel pipe bracket bolts/screws.
10. Fuel pipe hold down plate bolt/screw (167).
11. Fuel pipe assembly and reposition.
12. Coolant hoses from throttle body assembly.
13. Fuel rail stud (169).
14. Fuel pressure regulator vacuum hose.
15. Wiring harness electrical connectors from the following:
Idle air control
Throttle position sensor
Manifold absolute pressure sensor
Evaporative emissions canister purge solenoid
valve
16. Blow dirt out of injector bores with compressed air.
17. Fuel rail assembly (166).
18. Vacuum harness assembly.
19. Exhaust gas recirculation (EGR) flexible pipe bolts/
screws and reposition EGR flexible pipe assembly
and gasket at upper intake manifold assembly ( 155).
20. Upper intake manifold bolts/screws (156).
21. Upper intake manifold assembly (155) and gasket
(154).
l~I Clean
Upper intake manifold bolts/screws (156).
Upper intake manifold sealing surfaces.

section.
1. Upper intake manifold gasket (154) and manifold
assembly (155).
2. Upper intake manifold bolts/screws ( 156).
l~I
Tighten
Upper intake manifold bolts/screws ( 156) to

25 Nm (18 lb. ft.).
3. EGR flexible pipe gasket, pipe assembly and bolts/
screws at upper intake manifold assembly (155).
A. Apply teflon sealant GM P/N 1052080 to
threads of bolts/screws.
B. Gasket must be installed with text "tube side"
facing the tube.
l~I Tighten
EGR flexible pipe bolts/screws to 26 Nm
(19 lb. ft.).
4. Vacuum harness assembly.
6A2A6 3.4 LITERV6 ENGINE ON-VEHICLE SERVICE RPO L32-VIN S
155
166
167
169
167
MANIFOLD ASSEMBLY, UPPER INTAKE

RAIL ASSEMBLY, FUEL INJECTOR FUEL
BOLT/SCREW, FUEL PIPE HOLD DOWN PLATE
STUD, FUEL INJECTOR FUEL RAIL
PC0006-6A2A-F-RP
Figure 4 - Fuel Rail Assembly
~---156
155
142
154
155
156
MANIFOLD ASSEMBLY, LOWER INTAKE

GASKET, UPPER INTAKE MANIFOLD
MANIFOLD ASSEMBLY, UPPER INTAKE
BOLT/SCREW, UPPER INTAKE MANIFOLD
142
PC00076A2A-FRP
Figure 5 - Upper Intake Manifold Assembly
3.4 LITER VS ENGINE ON-VEHICLE SERVICE RPO L32- VIN S 6A2A-7
rn
VALVE ROCKER ARM COVER ASSEMBLIES

Important
Do not press on the regulator cover or piedmont valve when installing fuel rail assembly.
5. Fuel rail assembly ( 166).
A. Lightly lubricate fuel injector 0-rings using
clean engine oil.
B. Install injectors of fuel rail assembly ( 166) into
bores of manifold.
C. Carefully press on fuel rail assembly (166)
with palms of both hands until injectors are
fully seated.
6. Fuel rail stud ( 169).
l~I
7.
8.
9.
10.
11.
Tighten
Fuel rail stud (169) to 25 Nm (19 lb. ft.).

Wiring harness electrical connectors to the following:
Idle air control
Throttle position sensor
Manifold absolute pressure sensor
Evaporative emissions canister purge solenoid
valve
Fuel pressure regulator vacuum hose.
Fuel rail wiring harness retaining nut.
Fuel pipe assembly to fuel rail assembly (166).
Slide fuel line hold down plate over fuel pipe
assembly.
Fuel pipe hold down plate bolt/screw (167).
Apply teflon sealant GM P/N 1052080 to
threads of bolt/screw (167).
!~I
14.
15.
16.
17.
18.
19.
Right Side
!++I
Tighten
Accelerator cable bracket bolts/screws to 10

Nm (90 lb. in.).
Fuel pipe bracket-to-front brace bolt/screw to
8 Nm (71 lb. in.)
Fuel pipe bracket-to-intake manifold assembly
bolt/screw to 10 Nm (89 lb. ft.).
Fuel pipe connectors.
Fuel rail injector wiring harness connectors.
Coolant hoses to throttle body assembly.
Refill with coolant. Refer to SECTION 6B.
1. Upper intake manifold assembly. Refer to "Upper

Intake Manifold Assembly" in this Section.
2. EGR valve adapter bolt/screw, stud, and adapter
with EGR valve assembly from exhaust manifold
assembly.
3. Crankcase vent pipe.
4. Spark plug wiring harness assembly from clips.
5. Nuts (192) and reinforcements (193).
6. Valve rocker arm cover assembly (194) and gasket
(195).
!.,I
Clean
Rocker cover assembly and cylinder head gasket

surfaces.
!++I
Install or Connect

section.
1. Valve rocker arm cover gasket (195) and cover
assembly (194).
2. Reinforcements (193) and nuts (192).
l~I
Tighten
Nuts (192) to 10 Nm (89 lb. in.).

3. Spark plug wiring harness assembly to clips.
4. Crankcase vent pipe.
5. EGR valve adapter, bolt/screw and stud with EGR
valve assembly to exhaust manifold assembly.
Tighten
Fuel pipe hold down plate bolt/screw (167) to

25 Nm (18 lb. ft.)
12. Fuel pipe bracket bolts/screws.
13. Accelerator cable bracket, bolts/screws and cables.
!~I
Figure 6
l~I
Tighten
EGR valve adapter bolt/screw and stud to

31 Nm (23 lb. ft.).
Intake Manifold Assembly" in this section.
Left Side
l++I

2. PCV valve and hose assembly.
3. Spark plug wire harness assembly from clips.
5. Valve rocker arm cover assembly (194) and gasket
(195).
!++I
Install or Connect

section.
192
194
A APPLY SEALANT AT CYLINDER HEAD TO
INTAKE MANIFOLD MATING SURFACE
113 HEAD ASSEMBLY, CYLINDER
192 NUT, VALVE ROCKER ARM COVER
193 REINFORCEMENT, VALVE ROCKER ARM COVER
194 COVER ASSEMBLY, VALVE ROCKER ARM
195 GASKET, VALVE ROCKER ARM COVER
196 STUD, VALVE ROCKER ARM COVER
193
---195
PCOOOB-6A2A-F-RP
Figure 6 - Valve Rocker Arm Cover Assemblies
1. Valve rocker arm cover gasket (195) and cover
assembly (194).
2. Reinforcements (193) and nuts (192).
l~I Tighten
Nuts (192) to 10 Nm (89 lb. in.).
3. Spark plug wire harness assembly to clips.
4. PCV valve and hose assembly.
VALVE ROCKER ARMS AND PUSHROD

ASSEMBLIES
Figure 7

1. Valve rocker arm cover assemblies. Refer to "Valve
Rocker Arm Cover Assemblies" in this section.
2. Valve rocker arm nuts (124) and balls (123).

3. Valve rocker arms (122) and pushrod assemblies
(93).
Place valve rocker arms (122), balls (123) and
pushrod assemblies (93) in a rack so they can
be reinstalled in same locations from which
they were removed.
rn
Important
Refer to SECTION 6A2B for inspection of the

rocker arms, studs and pushrod assemblies.

section.
rn
Important
When installing valve rocker arms (122), balls

(123) and pushrod assemblies (93), coat their
3.4 LITERV6 ENGINE ON-VEHICLE SERVICE RPO L32-VIN S 6A2A-9

124
113
93
113
121
122
123
124
PUSHROD ASSEMBLY, VALVE

HEAD ASSEMBLY, CYLINDER
STUD, VALVE ROCKER ARM
ARM, VALVE ROCKER
BALL, VALVE ROCKER ARM
NUT, VALVE ROCKER ARM
PC00096A2A-F-RP
Figure 7 - Valve Rocker Arms and Pushrod Assemblies
bearing surfaces with prelube, GM P/N

1052365 or equivalent. Install these components in the locations from which they were
removed.
1. Pushrod assemblies (93). Make sure pushrod assemblies (93) seat in lifter sockets.
2. Valve rocker arms (122).
3. Valve rocker arm balls (123) and nuts (124).
11
Adjust
Valves when lifter is on base circle of camshaft lobe:

A. Engine should be in number 1 firing position.
This may be determined by placing fingers on
number 1 rocker arms as crankshaft assembly
is rotated. If valves are not moving, engine is in
number 1 firing position. If valves move,
engine is in number 4 firing position and
should be rotated one revolution to reach number 1 position.
B. With engine in number 1 firing position, following valves should be adjusted:
Exhaust - 1, 2, 3
Intake - 1, 5, 6
C. Tighten adjusting nut until there is zero lash +
1-1/2 turns.
(This can be determined by rotating pushrod
while turning adjusting nut). When lash has
been removed, turn adjusting nut in 1-1/2 additional turns (to center lifter plunger).
D. Crank engine one revolution. This is number 4
firing position. With engine in this position,
following valves should be adjusted to zero
lash + 1-1/2 turns:
Exhaust - 4, 5, 6
Intake - 2, 3, 4
LOWER INTAKE MANIFOLD ASSEMBLY

Figure 8

3. Upper radiator hose from lower intake manifold
assembly (142).
4. Heater hose from lower intake manifold assembly
(142).
5. Wiring harness ground leads.
6. Manifold bolts/screws (144) and nuts (143).
7. Lower intake manifold assembly (142) and gaskets
(141).
6A2A10 3.4 LITERV6 ENGINE ON-VEHICLE SERVICE RPO L32-VIN S
~FRT
10
A
B
113
140
141
142
143
144
APPLY SEALANT
TIGHTENING SEQUENCE
STUD, CYLINDER HEAD
GASKET, LOWER INTAKE MANIFOLD
MANIFOLD ASSEMBLY, LOWER INTAKE
NUT, LOWER INTAKE MANIFOLD
BOLT/SCREW, LOWER INTAKE MANIFOLD
PC0010-6A2A-FRP
Figure 8 - Lower Intake Manifold Assembly

1. Gaskets (141 ).
2. Apply sealant GM P/N 12345739 at engine block to
manifold mating surface. Bead should be 2.0-3.0
mm (0.08-0.12 inch) wide and 3.0-5.0 mm
(0.12-0.20 inch) thick.
3. Lower intake manifold assembly (142).
4. Manifold bolts/screws (144) and nuts (143).
l~I
5.
6.
7.
8.
Tighten
Manifold bolts/screws (144) and nuts (143) to

30 Nm (22 lb. ft.).
Wiring harness ground leads.
Heater hose.
Upper radiator hose.
Valve rocker arm cover assemblies. Refer to "Valve

VALVE LIFTER ASSEMBLIES

Figures 9 and 10
No service parts are available for valve lifter assemblies. They are replaced as a unit when worn and when a
new camshaft assembly is installed.
Valve lifters should be kept in order so they may be
installed in their original position. Some engines will
have both standard and 0.25 mm (.010 inch) oversize
(0.S.) valve lifters.
Where oversize lifters are used, the cylinder case
will be marked with a daub of white paint and/or "0.25
mm O.S." stamped on the lifter boss.
If the lifters are removed, they must be installed in
their original location. If replacement is necessary, use
lifters with a narrow flat ground along the lower 3/4 of
lifter. These flats provide additional oil to the cam lobe
and lifter surfaces.
3.4 LITER V6 ENGINE ON-VEHICLE SERVICE RPO L32-VIN S 6A2A-11
~UJ)
Figure 9 - Oversize Lifter Marking

I. Upper intake manifold assembly. Refer to "Upper
3. Lower intake manifold assembly. Refer to "Lower
4. Valve rocker arms and pushrod assemblies. Refer to
"Valve Rocker Arms and Pushrod Assemblies" in
this section.
5. Valve lifter assembly (94).
rn
Important
Refer to SECTION 6A2B for cleaning and inspection of the valve lifter assemblies.

1. Coat lifters with prelube, GM P/N 1052365 or
equivalent.
2. Valve lifter assembly (94 ).
this section.
EXHAUST MANIFOLD ASSEMBLIES

Figures 11 and 12
Left Side

A
B
C
D
E
F
93
94
PLUNGER
LIFTER BODY
CHECK BALL SPRING
PLUNGER RETURN SPRING
CHECK BALL (CLOSED)
CHECK BALL (OPEN)
LIFTER ASSEMBLY, VALVE
PC00386A2A-F-RP
Figure 10 - Valve Lifter Assembly Operation

4. Lower vehicle.
5. Oxygen sensor electrical connector.
6. Secondary air injection check valve pipe bracket nut
and reposition pipe (manual transmission only).
7. Exhaust manifold bolts/screws (102).
8. Exhaust manifold assembly (105) and heat shields
(103 and 104).
9. Exhaust manifold gasket (106).
li,I Clean
Exhaust manifold and cylinder head sealing surfaces.

(103 and 104).
l~I
Tighten
Exhaust manifold bolts/screws (102) to 25

Nm (18 lb. ft.).
5. Secondary air injection check valve pipe bracket nut
(manual transmission only).
6A2A12 3.4 LITER VG ENGINE ON-VEHICLE SERVICE RPO l32-VIN S
111
102
'
102
103
104
105
106
111
113
BOLT/SCREW, EXHAUST MANIFOLD

SHIELD, EXHAUST MANIFOLD HEAT
MANIFOLD ASSEMBLY, EXHAUST
GASKET, EXHAUST MANIFOLD
SENSOR ASSEMBLY, OXYGEN
102
102
PC0012-6A2AfRP
Figure 11 - Left Exhaust Manifold Assembly
l~I
6.
7.
8.
9.
Tighten
Secondary air mJection check valve pipe

bracket nut to 25 Nm (18 lb. ft.).
Exhaust crossover pipe. Refer to SECTION 6F.
Lower vehicle.
Right Side

1.
2.
3.
4.

Transmission filler tube. Refer to SECTION 7C.
5. A/C compressor rear bracket bolts/screws. Refer to

SECTION lB.
6. Rear two exhaust manifold bolts/screws (202).
7. Lower vehicle.
8. Serpentine drive belt. Refer to "Serpentine Drive
Belt and Tensioner Assembly" in this section.
10. Generator. Refer to SECTION 6D3.
11. A/C compressor from bracket and reposition. Refer
to SECTION 1B.
12. Generator rear "Y" brace. Refer to SECTION 6D3.
13. EGR valve, adapter, and flexible pipe. Refer to SECTION 6E3.
14. Secondary air injection pipe assembly from exhaust
manifold assembly (215) (manual transmission
only). Refer to SECTION 6E3.
15. Exhaust manifold front and middle bolts/screws
(202).
16. Exhaust manifold assembly (215), heat shields (203
and 205) and gasket (216).
3.4 LITER V6 ENGINE ON-VEHICLE SERVICE RPO L32-VIN S 6A2A13
202
113
202
203
205
215
216
202

PC0011 6A2A-F-RP
Figure 12 - Right Exhaust Manifold Assembly
Iii
Clean
Exhaust manifold and cylinder head sealing

surfaces.
l++I
4. EGR valve adapter, and flexible pipe. Refer to SECTION 6E3.

5. Generator rear "Y" brace. Refer to SECTION 6D3.
6. Generator. Refer to SECTION 6D3.
Install or Connect

section.
(203 and 205).
3. Exhaust manifold front and middle bolts/screws
(202).
l~I
Tighten
Exhaust manifold bolts/screws (202) to 25

Nm (18 lb. ft.).
7. A/C compressor. Refer to SECTION lB.


11. Transmission filler tube. Refer to SECTION 7 A.
12. A/C compressor rear bracket bolts/screws. Refer to
SECTION lB.
6A2A-14 3.4 LITER V6 ENGINE ON-VEHICLE SERVICE RPO L32- VIN S

14. Exhaust manifold rear bolts/screws (202).
l~I
Tighten
Exhaust manifold rear bolts/screws (202) to

25 Nm (18 lb. ft.).
15. Lower vehicle.
17. Refill transmission. Refer to SECTION 7A.
CRANKSHAFT BALANCER ASSEMBLY

Figures 13 and 14
Tools Required:
J 24420-B Torsional Damper Remover
J 29113 Torsional Damper Installer
!++I
l. Raise and suitably support vehicle. Refer to SECTION OA.

27 BALANCER ASSEMBLY, CRANKSHAFT
PC0015-6A2AF-RP
Figure 13 - Removing Crankshaft Balancer Assembly
3. Crankshaft balancer bolt/screw and washer.

4. Crankshaft pulley bolts/screws and pulley.
5. Crankshaft balancer assembly (27) using J 24420-B.
!++I
Install or Connect

section.
l. Crankshaft balancer assembly (27) using J 29113.
2. Remove J 29113.
3. Crankshaft pulley and bolts/screws.
4. Crankshaft balancer washer and bolt/screw.
[I] Important
If balancer assembly is replaced, new balance
weights of the same size must be installed on

the new balancer assembly in the same hole
locations as the old balancer assembly.
!~I
Tighten
Crankshaft balancer bolt/screw to 78 Nm

(58 lb. ft.).
Crankshaft pulley bolts/screws to 50 Nm
(37 lb. ft.).
6. Lower vehicle.
27 BALANCER ASSEMBLY, CRANKSHAFT
Pcooso-&A2A-F-RP
Figure 14 - Installing Crankshaft Balancer Assembly
ENGINE FRONT COVER ASSEMBLY

Figure 15
l++I
1. Throttle body air duct.

3. Water pump assembly. Refer to SECTION 68.
3.4 LITER V6 ENGINE ON-VEHICLE SERVICE RPO L32-VIN S 6A2A15
55
52
53
54
55
58
59
60
61
71
59
58
52
53
BOLT/SCREW, WATER PUMP

PUMP ASSEMBLY, WATER
GASKET, WATER PUMP
SEAL ASSEMBLY, ENGINE FRONT COVER
BOLT/SCREW, ENGINE FRONT COVER
COVER ASSEMBLY, ENGINE FRONT
GASKET, ENGINE FRONT COVER
ENGINE BLOCK
PC0048-6A2A-F-RP
Figure 15 - Engine Front Cover Assembly
4. Crankshaft balancer assembly. Refer to "Crankshaft

Balancer Assembly" in this section.
5. Power steering pump and bracket. Refer to SECTION 3Bl.
6. Oil pan assembly. Refer to "Oil Pan Assembly" in
this section.
7. Lower radiator hose from the front cover assembly.
8. Crankshaft sensor.
9. Engine front cover bolts/screws (59).
10. Engine front cover assembly (60) and gasket (61).
1..,1 Clean
Engine front cover and engine block gasket surfaces.
ll'l'I Inspect
Engine front cover assembly (60) for damage to the
seals or gasket surface. Refer to SECTION 6A2B to
replace front cover seals if necessary.
l++I
Install or Connect

section.
1. Gasket (61) and engine front cover assembly (60).
Coat both sides of lower tabs of gasket (61)
with sealer, GM PIN 1052080.
l~I
3.
4.
5.
6.
7.
8.
9.
10.
11.
Tighten
Engine front cover bolts/screws (59) to 21

Nm (15 lb. ft.).
Oil pan assembly. Refer to "Oil Pan Assembly" in
this section.
Crankshaft sensor.
Lower radiator hose.
Crankshaft balancer assembly. Refer to "Crankshaft
Balancer Assembly" in this section.
Lower vehicle.
Water pump assembly. Refer to SECTION 6B.
Power steering pump and bracket. Refer to SECTION 3Bl.
Serpentine drive belt. Refer to "Serpentine Drive
TIMING CHAIN ASSEMBLY, AND

CRANKSHAFT AND CAMSHAFT
SPROCKETS
Tools Required:
J 23444-A Crankshaft Sprocket Remover
J 38612 Crankshaft Sprocket Installer
6A2A16 3.4 LITER V6 ENGINE ON-VEHICLE SERVICE RPO L32-VIN S
A
25
26
71
97
98
100
ALIGNMENT MARKS
CHAIN ASSEMBLY, TIMING
SPROCKET,CRANKSHAFT
ENGINE BLOCK
BOLT/SCREW, CAMSHAFT SPROCKET
SPROCKET, CAMSHAFT
CAMSHAFT ASSEMBLY
I I
I I
I I
100
25
71
26
PC00466A2AFRP
Figure 16 - Camshaft Assembly, Sprockets and Timing Chain Assembly
KEY, CRANKSHAFT SPROCKET

SPROCKET,CRANKSHAFT
ENGINE BLOCK
J 23444-A
PC0016-6A2AFRP
Figure 17 - Removing Crankshaft Sprocket

1. Engine front cover assembly. Refer to "Engine
Front Cover Assembly" in this section.
2. Rotate crankshaft assembly (22) until timing marks
punched on crankshaft sprocket (26) and camshaft
sprocket (98) are aligned to marks on engine block
3.
4.
5.
6.
(71) or timing chain dampener. See Figure 16. This

is the number 4 piston at top dead center.
Camshaft sprocket bolts/screws (97).
Camshaft sprocket (98) and timing chain assembly
(25).
Crankshaft sprocket (26) using J 23444-A.
Timing chain dampener bolts/screws (62) and
dampener (63).
3.4 LITERV6 ENGINE ON-VEHICLE SERVICE RPO L32-VIN S 6A2A-17
l++I
71
Install or Connect

section.
1. Key (24 ), if previously removed.
2. Crankshaft sprocket (26) using J 38612.
3. Camshaft sprocket (98) and timing chain assembly
(25).
Make sure timing marks on camshaft and

crankshaft sprockets are aligned with marks
cast into engine block.
Coat crankshaft and camshaft sprockets with
engine oil.
62
A
62
63
71
TIMING ALIGNMENT MARKS

BOLT/SCREW, TIMING CHAIN DAMPENER
DAMPENER, TIMING CHAIN
ENGINE BLOCK
PC0047-6A2A-FRP
Figure 18 - Timing Chain Dampener
4. Camshaft sprocket bolts/screws (97).
l~.J
Tighten
Camshaft sprocket bolts/screws (97) to 24

Nm (18 lb. ft.).
5. Timing chain dampener (63) and bolts/screws (62).
l~I
7. Key (24), if necessary.
Tighten
ll'l"I Inspect
Refer to SECTION 6A2B for component inspection.

A
22
24
26
71

CRANKSHAFT ASSEMBLY
KEY, CRANKSHAFT SPROCKET
SPROCKET, CRANKSHAFT
ENGINE BLOCK
26
PC0045-6A2A-F-RP
Figure 19 - Installing Crankshaft Sprocket
6A2A-18 3.4 LITER V6 ENGINE ON-VEHICLE SERVICE RPO L32-VIN S
CAMSHAFT ASSEMBLY
Measuring Camshaft Lobe Lift
Tool Required:
J 8520 Cam Lobe Lift Indicator
Measuring lobe lift procedure is similar to that used
for checking valve timing. If improper valve operation is
indicated, measure lift of each pushrod in consecutive
order and record readings.
1. Remove valve rocker arm. Refer to "Valve Rocker
Arms and Pushrod Assemblies" in this section.
2. Position J 8520 with ball socket adapter on pushrod.
Make sure pushrod is in lifter socket.
3. Rotate crankshaft slowly in direction of rotation
until lifter is on heel of camshaft lobe. At this point,
pushrod is in its lowest position.
4. Set dial indicator on zero, then rotate crankshaft
slowly until pushrod is in fully raised position (Figure 20).
5. Compare total lift recorded from dial indicator with
specifications.
6. If camshaft readings for all lobes are within specifications, remove dial indicator assembly.
7. Install and adjust rocker arms. Refer to "Valve
Rocker Arms and Pushrod Assemblies" in this section.

this section.
Int.tke Manifold Assembly" in this section.
4. Bolt/screw (91), clamp (92) and oil pump drive
assembly (90).
90 DRIVE ASSEMBLY, OIL PUMP

91 BOLT/SCREW, OIL PUMP DRIVE CLAMP
92 CLAMP, OIL PUMP DRIVE
PC0004-6A2A-FRP
Figure 21 - Oil Pump Drive Assembly

6. Camshaft sprocket. Refer to "Timing Chain Assembly, Crankshaft and Camshaft Sprockets" in this
section.
7. Valve lifter assemblies. Refer to "Valve Lifter
Assemblies" in this section.
8. Discharge air conditioning system. Refer to SECTION lB.
9. Air conditioning compressor and condenser hose
from condenser.
10. Air conditioning receiver and dehydrator hose from
condenser.
11. Radiator assembly with air conditioning condenser.
12. Air conditioning condenser support assembly.
NOTICE: All camshaft journals are the same diameter so care must be used in removing the camshaft
to avoid damage to the bearings.
13. Camshaft assembly (100).
A. Install three 5/16-18 x 4-inch bolts/screws in
camshaft bolt/screw holes.
B. Carefully rotate and pull camshaft assembly
(100) out of bearings.
Important
Figure 20 - Measuring Camshaft Lobe Lift
Refer to '' Cleaning, Inspection and Repair'' in SECTION 6A2B for inspection and measurement procedures for camshaft assembly.
3.4 LITER V6 ENGINE ON-VEHICLE SERVICE RPO L32- VIN S 6A2A-19
11. Camshaft sprocket. Refer to "Timing Chain Assembly, Crankshaft and Camshaft Sprockets" in this
section.
13. Oil pump drive assembly (90), clamp (92) and bolt/
screw (91).
Lubricate oil pump drive gear with prelube,
GM PIN 1052365 or equivalent.
Lubricate assembly with engine oil for ease of
installation.
!~I Tighten
Oil pump drive clamp bolt/screw (91) to 34
Nm (25 lb. ft.).
this section.
A BOLTS
100 CAMSHAFT ASSEMBLY
VALVE SPRINGS AND STEM SEALS

PC0044-6A2A-F-RP
Figure 22 - Removing and Installing Camshaft Assembly
!ll
1nspect
Camshaft bearings for scratches, pits, or loose fit in

their bores. Replace camshaft bearings, if necessary.
Refer to SECTION 6A2B.

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
NOTICE: See "Notice" on page 6A2A of this section.

When installing a new camshaft assembly ( 100),
coat camshaft lobes with "Molykote" or its equivalent.
When installing a new camshaft assembly (100),
replace all valve lifter assemblies to ensure durability of camshaft lobes and lifter rollers.
Lubricate all camshaft journals with engine oil.
Camshaft assembly (100).
Air conditioning condenser support assembly.
Radiator assembly with air conditioning condenser.
Air conditioning receiver and dehydrator hose to
condenser.
Air conditioning compressor and condenser hose to
condenser.
Charge air conditioning system. Refer to SECTION
lB.
Valve lifter assemblies. Refer to "Valve Lifter
Figures 23 and 24
Tools Required:
J 23590 Spark Plug Port Adapter
J 5892-C Valve Spring Compressor (Head-On)
J 23738-A Valve Stem Seal Tester

1. Valve rocker arms and pushrod assemblies at cylinder to be serviced. Refer to "Valve Rocker Arms and
Pushrod Assemblies" in this section.
2. Spark plug at cylinder to be serviced.
3. Install J 23590 to spark plug hole and apply compressed air to hold valve (125 or 132) in place.
NOTICE: When using the valve spring compressor,
be careful not to scratch or gouge the valve stem.
4. Compress valve spring (128 or 135) using J 5892-C
(Figure 23).
5. Valve stem key ( 131 or 139).
6. Valve spring cap (130 or 138), and oil shield (137)
on exhaust valves.
7. Valve spring (128 or 135) and dampener (127 or
134).
8. Intake valve stem oil seal (126).
9. Valve stem 0-ring seal (129 or 136).

section.
1. Intake valve stem oil seal (126) and seat seal against
cylinder head, or valve spring shim, if equipped.
2. Valve stem 0-ring seal (129 or 136).

3. Valve spring dampener (127 or 134) and spring (128
or 135).
4. Valve spring oil shield (137) on exhaust valve and
valve cap (130 or 138).
5. Compress valve spring (128 or 135) using J 5892-C.
6. Valve stem key ( 131 or 139).
A. Use grease to hold key in place while disconnecting J 5892-C.
B. Remove J 23590.
C. Make sure key seats properly in upper groove
of valve stem.
D. Tap end of stem with a plastic-faced hammer to
seat key, if necessary.
7. Spark plug.
l~I Tighten
Spark plug to 15 N m (11 lb. ft.).
this section.
I
'
ll'l'I Inspect
I I
PC0018-6A2A-F-RP
Figure 23 - Compressing Valve Spring
Valve stem 0-ring seal (129 or 136) for leaks.

- Place J 23737-A in position over end of valve
stem and against valve spring cap ( 130 or 138).
Operate J 23738-A and make sure no air leaks
past valve stem 0-ring seals (129 or 136).
l@I Measure
@~
131
Valve spring installed height.

- Use a narrow, thin scale and measure from bottom of valve spring (128 or 135) on dampener
lip to bottom inside of oil shield (137) for
exhaust valve (132) and to top of valve spring
cap (130) for intake valve (125). If measurement exceeds specified height, install valve
spring seat shims as necessary. Do not shim so
height is less than specified.
139
~138
130----
129
--137
@---136
128-----!:~-eitl
CYLINDER HEAD ASSEMBLY AND GASKET
&ir'127
125
~126
125
126
127
128
129
130
131
132
134
135
136
137
138
139
132
Figure25
Tool Required:
J 36660 Torque Angle Meter
Left Cylinder Head Assembly
134
VALVE, INTAKE
SEAL, VALVE STEM OIL
DAMPENER, VALVE SPRING
SPRING, VALVE
SEAL, VALVE STEM 0-RING
CAP, VALVE SPRING
KEY, VALVE STEM
VALVE, EXHAUST
DAMPENER, VALVE SPRING
SPRING, VALVE
SEAL, VALVE STEM 0-RING
SHIELD, VALVE STEM OIL
CAP, VALVE SPRING
KEY, VALVE STEM
PC0035-6A2A-F-RP
Figure 24 - Valve Assemblies

2. Drain coolant. Refer to SECTION 6B.
3. Lower vehicle.
3.4 LITERV6 ENGINE ON-VEHICLE SERVICE RPO L32-VIN S 6A2A21

115
~FRT
0
6
02
03
115
112
A
71
112
113
115
71
TIGHTENING SEQUENCE
ENGINE BLOCK
GASKET, CYLINDER HEAD
BOLT/SCREW, CYLINDER HEAD
PC0043-6A2A-F-RP
Figure 25 - Cylinder Head Assembly
7. Left exhaust manifold assembly. Refer to "Exhaust

Manifold Assemblies" in this section.
8. Oil level indicator and tube assemblies. Refer to
"Oil Level Indicator and Tube Assemblies" in this
section.
10. Coolant temperature sensor connector.
11. Spark plug wires from spark plugs.
12. Spark plugs.
13. Engine lift bracket.
14. Wiring harness clip from rear of cylinder head
assembly (113).
15. Secondary air injection pipe bracket bolt/screw.
16. Power steering pump assembly and brackets and lay
aside. Refer to SECTION 3Bl.
17. Loosen rocker arms until pushrod assemblies can be
removed.
18. Cylinder head bolts/screws (115).

19. Cylinder head assembly (113) and gasket (112).
Important
Refer to SECTION 6A2B for cylinder head assembly cleaning, inspection and repair.

section.
1. New cylinder head gasket (112).
2. Cylinder head assembly ( 113) over locator pins and
gasket (112).
3. Coat threads of cylinder head bolts/screws ( 115)
with sealing compound, GM P/N 1052080 or equivalent.
4. Cylinder head bolts/screws (115) finger tight.
l~I
Tighten
Cylinder head bolts/screws ( 115) in sequence

to 55 Nm (41 lb. ft.) (Figure 25).
Turn cylinder head bolts/screws ( 115) in
sequence an additional 90 degrees using
J 36660
5. Pushrod assemblies and rocker arms. Refer to
this section.
6. Power steering pump assembly and brackets. Refer
to SECTION 3Bl.
7. Secondary air injection pipe bracket bolt/screw.
8. Spark plugs.
l~I
Tighten
Spark plugs to 15 Nm (11 lb. ft.).

8. Right exhaust manifold assembly. Refer to "Exhaust
9. Generator and brackets. Refer to SECTION 6D3.
10. Spark plug wires from spark plugs.
11. Spark plugs.
12. Loosen rocker arms until pushrod assemblies can be
removed.
13. Cylinder head bolts/screws (115).
rn
l++I
9. Spark plug wire harness assembly to spark plugs.

10. Wiring harness clip to rear of cylinder head assembly (113).
11. Engine lift bracket.
Important
1.
2.
3.

Install or Connect

section.
New cylinder head gasket (112).
Cylinder head assembly (113) over locator pins and
gasket (112).
Coat threads of cylinder head bolts/screws (115)
with sealing compound, GM P/N 1052080 or equivalent.
Cylinder head bolts/screws ( 115) finger tight.

section.
4.
15. Left exhaust manifold assembly. Refer to "Exhaust

Cylinder head bolts/screws (115) in sequence

to 55 Nm (41 lb. ft.) (Figure 25).
Turn cylinder head bolts/screws (115) in
sequence an additional 90 degrees using
J 36660
5. Pushrod assemblies and rocker arms. Refer to
this section.
6. Spark plugs.

19. Refill with coolant. Refer to SECTION 6B.
l~I
l~I
Right Cylinder Head Assembly
l++I

3. Lower vehicle.
"Serpentine Drive Belt and Tensioner Assembly" in
this section.
7.
8.
9.
10.
11.
12.
13.
Tighten
Tighten

Spark plug wires to spark plugs.
Generator and brackets. Refer to SECTION 6D3.
Right exhaust manifold assembly. Refer to "Exhaust
Lower intake manifold assembly. Refer to "Lower
Valve rocker arm covers. Refer to "Valve Rocker
Arm Covers" in this section.
Upper intake manifold assembly. Refer to "Upper
Serpentine drive belt tensioner assembly. Refer to
"Serpentine Drive Belt and Tensioner Assembly" in
this section.
3.4 LITER V6 ENGINE ON-VEHICLE SERVICE RPO L32- VIN S 6A2A-23

14. Refill with coolant. Refer to SECTION 6B.
OIL PAN ASSEMBLY

Figure26
l++I
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
1-,1
l~I

Air intake duct.
Drain engine oil.
Wiring harness clips from left side of oil pan assembly (1).
Oil level sensor connector.
Oil level sensor assembly.
Exhaust crossover pipes from exhaust manifold
assemblies. Refer to SECTION 6F.
Exhaust pipe hanger bolt/screw and reposition pipe.
Refer to SECTION 6F.
Transmission fluid cooler lines from clip at oil pan
assembly (automatic transmission).
Starter motor assembly. Refer to SECTION 602.
Converter cover bolts/screws and cover (automatic
transmission). Refer to SECTION 7 A.
Engine mount through-bolts/screws.
Raise engine with jacking fixture.
Oil pan bolts/screws (12), studs (13), nuts (11) and
reinforcements (10).
Oil pan assembly (1) and gasket (2).
Rotate crankshaft assembly to reposition counterweights if necessary.
Clean
1. Oil pan and engine block gasket surfaces.

2. Apply a small amount of sealer, GM PIN 12345739
or equivalent, where oil pan gasket tabs seat on rear
crankshaft bearing cap groove.
l++I
Oil pan studs (13) to 6 Nm (53 lb. in.).

3. Lower engine.
4. Engine mount through-bolts/screws.
5. Oil level sensor assembly.
Install or Connect

section.
1. Oil pan gasket (2) and oil pan assembly (1 ).
2. Oil pan nuts (11 ), reinforcements (10), bolts/screws
(12) and studs (13).
l~I
Tighten
Front corner oil pan nuts (11) to 33 Nm

(24 lb. ft.).
Rear corner oil pan bolts/screws to 25 Nm
(18 lb. ft.)
Oil pan side rail bolts/screws (12) to 10 Nm
(89 lb. in.).
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
Tighten
Engine mount through-bolts/screws to 95 Nm

(70 lb. ft.)
Engine oil level sensor assembly to 22 Nm
(16 lb. ft.).
Converter cover and bolts/screws (automatic transmission). Refer to SECTION 7 A.
Transmission fluid cooler lines to clip at oil pan
Exhaust pipe hanger bolt/screw.
Exhaust crossover pipes to exhaust manifold assemblies. Refer to SECTION 6F.
Wiring harness clips to oil pan assembly (1).
Lower vehicle.
Air intake duct.
Refill engine with oil.
OIL PUMP ASSEMBLY

Figure 27
l++I
this section.
2. Bolt/screw (16) attaching oil pump assembly (17) to
rear crankshaft bearing cap.
3. Oil pump assembly (17) and driveshaft (18).
[I] Important
Refer to SECTION 6A2B for oil pump assembly
cleaning, inspection and repair.
l++I
Install or Connect

section.
1. Oil pump assembly (17) and driveshaft (18).
Align slot on end of intermediate shaft ( 18)
with drive tang on oil pump drive assembly.
2. Bolt/screw (16) attaching oil pump assembly (17) to
rear crankshaft bearing cap.
l~I
Tighten

this section.
13
11
12
1
2
3
10
11
12
13
71
PAN ASSEMBLY, OIL

GASKET, OIL PAN
STUD, OIL PAN
REINFORCEMENT, OIL PAN
NUT, OIL PAN
BOLT/SCREW, OIL PAN
STUD, OIL PAN
ENGINE BLOCK
PC0013-6A2A-F-RP
Figure 26 - Oil Pan Assembly
rn
CONNECTING ROD BEARINGS

Connecting rod bearings are the precision insert type
and do not use shims for adjustment. Do not file connecting rods or rod caps. If clearances are found to be excessive, a new bearing will be required. Service bearings are
available in standard size and 0.013 and 0.026 mm undersize for use with new and used standard size crankshafts.

this section.
2. Oil pump assembly. Refer to "Oil Pump Assembly"

in this section.
Important
Place matchmarks or numbers o.n connecting

rod assemblies (83) and connecting rod caps
(81). Connecting rod caps (81) must be
assembled to their original connecting rod
assemblies (83).
3. Connecting rod nuts (80).
4. Connecting rod cap (81) and bearings (82).
Keep bearings (82) with their original connecting rod assembly (83) and cap (81) for reassembly.
Wipe oil from bearings (82) and crankpins.
lll
1nspect
Bearings (82) for excessive wear or damage.
87
85
80
81
82
83
84
NUT, CONNECTING ROD

CAP, CONNECTING ROD
BEARING, CONNECTING ROD
ROD ASSEMBLY, CONNECTING
BOLT, CONNECTING ROD
85 PIN, PISTON
86 PISTON ASSEMBLY
87 RING, PISTON
PC0027-6A2A-F-RP
Figure 28 - Piston and Connecting Rod Assembly
16
17
18
20
71
C. Install connecting rod nuts (80).
BOLT/SCREW, OIL PUMP

PUMP ASSEMBLY, OIL
DRIVESHAFT, OIL PUMP
CAP, CRANKSHAFT BEARING
ENGINE BLOCK
l~I
Connecting rod nuts (80), evenly, to

50 Nm (37 lb. ft.).
NOTICE: Do not turn the crankshaft assembly with
the gaging plastic installed or the accuracy of the
measurement will be affected.
D. Remove connecting rod nuts (80) and cap (81 ).
Gaging plastic will be found adhering to either
connecting rod cap (81) or crankshaft journal
and is measured without removing it.
E. Measure gaging plastic at its widest, using
scale provided with gaging plastic. Refer measurements to "Specifications" in this section.
If clearance is greater than specified,
select an undersize bearing (82) and remeasure clearance.
If clearance cannot be brought to specifications, regrind crankpin. If crankpin is
already at maximum undersize, replace
crankshaft assembly (22).
F. Remove all gaging plastic material after measuring.
PC00176A2A-F-RP
Figure 27 - Oil Pump Assembly
l@I
Measure
1. Crankpin for out-of-round and taper with a micrometer. Refer measurements to "Specifications" in this
section.
If not within specifications, replace or recondition crankshaft assembly.
If installing new bearings (82), determine new
bearing size from the maximum crankpin
diameter.
2. Bearing clearances, using gaging plastic.
A. Place piece of gaging plastic the full width of
bearing (82), (parallel to crankshaft assembly)
onto the crankpin.
Gaging plastic should be positioned in
middle of bearing (82). Bearing (82) is
thickest in center and bearing clearance
must be measured at this location.
B. Install connecting rod cap (81) with bearing
(82) onto connecting rod assembly (83).
Tighten
l++I
Install or Connect

section.
1. Coat inside surface of bearings (82) with engine oil.
PISTON AND CONNECTING ROD

ASSEMBLIES
Figures 28 and 31
Tools Required:
J 5239 Connecting Rod Bolt Guide Set
J 8037 Piston Ring Compressor

Figure 29 - Measuring Bearing Clearance

this section.
in this section.
3. Cylinder head assembly. Refer to "Cylinder Head
Assembly and Gasket" in this section.
4. Ring ridge.
A. Turn crankshaft assembly (22) until piston
assembly (86) is at bottom of its stroke.
B. Place a cloth on top of piston assembly (86).
C. Use a ridge reamer to remove ring ridge.
D. Turn crankshaft assembly (22) so piston
assembly (86) is at top of its stroke.
E. Remove cloth and cutting debris.
rn
Figure 30 - Measuring Connecting Rod Side Clearance

l~I Tighten
Connecting rod nuts (80), evenly, to 50 Nm
(37 lb. ft.).
l@I Measure
Connecting rod side clearance.
A. When all connecting rod bearings (82)
have been installed, tap each connecting
rod assembly (83) lightly parallel to
crankpin to make sure they have clearance.
B. Measure side clearance between connecting rod caps (81) using a feeler gage, or
dial indicator.
C. Rod side clearance should be 0.18 to
0.44 mm (0.007 to 0.017 inch).
in this section.
this section.
Important
Place matchmarks or numbers on connecting

rod assemblies (83) and connecting rod caps
(81 ). Connecting rod caps (81) must be
assemblies (83).
5. Connecting rod nuts (80) and cap (81).
6. Connecting rod assembly (83) and piston assembly
(86) out of top of engine block using J 5239.
rn
Important
Refer to SECTION 6A2B for cleaning, inspection

and repair of piston and connecting rod assembly.
l~I Clean
1. Cylinder bores with hot water and detergent or with
a light honing.
2. Swab bores with engine oil and a clean, dry cloth.

section.
1. Coat piston assembly (86), piston rings, cylinder
bore, and bearing surfaces with engine oil.
2. Piston assembly (86) into its original bore using
J 5239 and J 8037 and lightly tapping top of piston
assembly (86) with a wooden hammer handle.
A. When installing piston assembly (86) and connecting rod assembly (83), stamped arrow on
piston assembly (86) must point to front of
engine while flange on connecting rod assembly (83) must face toward front of piston on
3.4 LITER V6 ENGINE ON-VEHICLE SERVICE RPO L32 - VIN S 6A2A-27

left hand assembly and face toward rear of piston on right hand assembly.
B. Hold J 8037 firmly against engine block until
all piston rings have entered cylinder bore.
3. Connecting rod caps (81) onto their original connecting rod assemblies (83).
Align matchmarks or numbers which were
placed on connecting rod assembly (83) and
connecting rod cap (81) during removal.
!~I Ti.ghten
(37 lb. ft.).
!ll
1nspect
Connecting rod assembly (83) for binding by
prying back and forth with a suitable tool. If
necessary, loosen and retighten connecting rod
cap (81).
!@I Measure
Connecting rod side clearance. Refer to
"Specifications" in this section.
in this section.
this section.
CRANKSHAFT BEARINGS
Figures 31 and 32
Tools Required:
J 8080 Main Bearing Shell Remover and
Installer
Crankshaft bearings are of the precision insert type.
If clearances are found to be excessive, a new bearing,
both upper and lower halves, will be required. Service
bearings are available in both standard size and undersize.
Replace both bearing shells as a set.

this section.
in this section.
3. Spark plugs.
4. Cap (20) and lower crankshaft bearing (23) requiring replacement.
5. Insert J 8080 into oil hole in crankshaft journal.
6. Rotate crankshaft assembly (22) allowing J 8080 to
push against insert's straight (unnotched) side. This
will roll upper crankshaft bearing (23) out of block.
7. Remove J.8080 from crankshaft assembly (22).
A ASSEMBLE WITH ARROWS ON CAP

TOWARD FRONT OF ENGINE
19 BOLT/SCREW, CRANKSHAFT BEARING CAP
20 CAP, CRANKSHAFT BEARING
22 CRANKSHAFT ASSEMBLY
23 BEARING, CRANKSHAFT
71 ENGINE BLOCK
PC0019-6A2A-F-RP
Figure 31 - Crankshaft Assembly
l~I
lll
1nspect
In general, lower half of crankshaft bearing insert
(except number 1 bearing) shows a greater wear and
most distress from fatigue. If upon inspection lower
half is suitable for use, it can be assumed that upper
half is also satisfactory. If lower half shows evidence
of wear or damage, both upper and lower halves
should be replaced. Never replace one half without
replacing other half.
rn
4.
5.
Important
To obtain most accurate results when checking

crankshaft bearing clearances, use gaging plastic.
When engine is in vehicle, crankshaft assembly
must be supported upward to remove any clearance
from upper bearing. Total clearance can then be
measured between lower bearing and journal.
To assure proper seating of crankshaft assembly, all
bearing cap bolts/screws should be at their specified
torque. In addition, prior to checking fit of bearings,
surface of crankshaft journal and bearing should be
wiped clean of oil.
l@I
6.
Measure
1. With oil pan and oil pump assemblies removed, and

starting with rear crankshaft bearing, remove bearing cap and wipe oil from journal and bearing cap.
2. Place a piece of gaging plastic full width of bearing
(parallel to crankshaft assembly) on journal.
7.
l]J Important
Do not rotate crankshaft assembly while gaging plastic is between bearing and journal.
3. Install bearing cap and evenly tighten retaining
bolts/screws to specifications. Bearing cap must be
tightened to specification in order to assure proper
reading. Variations in torque affect compression of
gaging plastic.
KC0047-6A3-F-RP
Figure 32 - Removing Crankshaft Bearing
8.
Tighten
Crankshaft bearing cap bolts/screws (19) to

50 Nm (37 lb. ft.).
Turn crankshaft bearing cap bolts/screws (19)
an additional 77 degrees using J 36660.
Remove bearing caps. Flattened gaging plastic will
be found adhering to either bearing shell or journal.
Without removing gaging plastic, measure its compressed width (at widest point) with graduations on
gaging plastic envelope. Normally crankshaft bearing journals wear evenly and are not out-of-round.
However, if a bearing is being fitted to an out-ofroundjournal 0.005 mm (0.0002 inch maximum), be
sure to fit to maximum diameter of journal. If bearing is fitted to minimum diameter, and journal is outof-round 0.005 mm (0.0002 inch) or more,
interference between bearing and journal will result
in rapid bearing failure. If flattened gaging plastic
tapers toward middle or ends, there is a difference in
clearance indicating taper, low spot or other irregularity of bearing or journal. Be sure to measure journal with a micrometer if flattened gaging plastic
indicates this difference.
If bearing clearance is within specifications, bearing
insert is satisfactory. If clearance is not within specifications, replace insert. Always replace both upper
and lower inserts as a unit. When bearing cap is
installed and clearance is less than 0.032 mm
(0.0012 inch), inspect for burrs or nicks.
An undersize bearing may produce proper clearance. If not, it will be necessary to regrind crankshaft journal for use with next undersize bearing.
After selecting new bearing, recheck clearance.
Proceed to next bearing. When checking number 1
crankshaft bearing, remove serpentine drive belt so
as to prevent tapered reading with gaging plastic.
After all bearings have been checked, rotate crankshaft assembly to see that there is no excessive drag.

section.
1. Crankshaft bearings (23) into engine block (71) and
crankshaft bearing caps (20).
A. Coat crankshaft bearings (23) with oil.
B. Insert plain (unnotched) end between crankshaft assembly and indented or notched side of
block. Rotate bearing into place using J 8080
as previously described, and remove J 8080
from oil hole in crankshaft journal.
2. Crankshaft bearing caps (20) with assembled crankshaft bearings (23) with arrows pointing toward
front of engine.
3. Crankshaft bearing cap bolts/screws (19) .
With crankshaft assembly (22), crankshaft
bearings (23) and crankshaft bearing caps (20)
installed and bolts/screws ( 19) started, thrust
crankshaft assembly (22) rearward to set and
align bearing caps (20). Then force crankshaft

assembly forward to align crankshaft thrust
bearing.
!~I
Tighten
Crankshaft bearing cap bolts/screws (19) to
50 Nm (37 lb. ft.).
Turn crankshaft bearing cap bolts/screws ( 19)

evenly an additional 77 degrees using J 36660.
l@I
l~I
Tighten
Flywheel bolts/screws (36) to 83 Nm (61lb.

ft.).
2. Transmission assembly. Refer to SECTION 7A for
an automatic transmission or SECTION 7B for a
manual transmission and SECTION 7C for the
clutch.
Flywheel Assembly Balancing
Measure
Crankshaft end play, using a dial indicator or feeler

gage. Refer to "Specifications" in this section.
- If using a feeler gage, measure between front
of number 3 crankshaft bearing cap (20) and
crankshaft thrust surface.
FLYWHEEL ASSEMBLY
Figure 33
Flywheel Assembly Replacement

1. Transmission assembly. Refer to SECTION 7A for
clutch.
2. Flywheel bolts/screws (36), retainer (34) and flywheel assembly (33).
Figure 33
ll'l'I Inspect
Flywheel assembly (33) for missing or loose converter-to-flywheel bolts/screws. Tighten or replace
as necessary.
Converter for damage or missing balance weights. If
converter is damaged or bala.nce weights are missing, replace converter.
If flywheel assembly (33) is replaced, new balance
weights of same size must be installed on new flywheel assembly in same hole locations as old flywheel assembly.
CRANKSHAFT REAR OIL SEAL ASSEMBLY

Tool Required:
J 34686 Rear Main Bearing Oil Seal Installer
Figures 34 and 35

1. Flywheel assembly. Refer to "Flywheel Assembly

section.
1. Flywheel assembly (33), retainer (34) and flywheel
bolts/screws (36).

Care should be taken not to nick crankshaft
sealing surface when removing seal.
2. Crankshaft rear oil seal assembly.
33
33 FLYWHEEL ASSEMBLY
34 RETAINER, FLYWHEEL
36 BOLT/SCREW, FLYWHEEL
22
PC00056A2A-F-RP
Figure 33 - Flywheel Assembly

Insert a screwdriver or similar tool through
dust lip at an angle as shown in Figure 34. Pry
seal out by moving handle of tool towards end
of crankshaft. Repeat as necessary around seal.

1. Coat new seal assembly entirely with engine oil.
2. Seal assembly onto J 34686.
3. J 34686 onto rear of crankshaft assembly. Tighten
screws snugly to ensure seal assembly will be
installed squarely over craPkshaft assembly.
4. Crankshaft rear oil seal assembly to crankshaft
assembly.
5. Tighten wing nut on J 34686 until it bottoms.
6. Remove J 34686 from crankshaft assembly.
ENGINE ASSEMBLY

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
DUST LIP
12.
13.
14.
15.
16.
17.
J 10210-6A3-J-RA
Figure 34 - Removing Crankshaft Rear Oil Seal Assembly
ALIGNMENT HOLE
DUST
LIP
18.
19.
20.
21.
22.
23.
MC0019-6A4-A-RA
Figure 35 - Installing Crankshaft Rear Oil Seal Assembly
24.

Wheels and tires. Refer to SECTION 3E.
Drain engine oil.
Exhaust crossover pipe assembly from intermediate
pipe. Refer to SECTION 6F.
Converter cover bolts/screws (automatic transmis.
sion). Refer to SECTION 7A.
Converter bolts/screws (automatic transmission).
Front fascia lower deflectors. Refer to SECTION
10-5.
Stabilizer bar bolts/screws. Refer to SECTION 3C.
Transmission fluid cooler lines from radiator assembly (automatic transmission). Refer to SECTION
6B.
Lower radiator hose from radiator assembly. Refer
to SECTION 6B.
Heater hoses from pipes at engine assembly. Refer to
SECTION lBl.
Electrical ground straps from right side of engine
block.
Electrical connections from starter motor assembly.
Refer to SECTION 6D2.
Electrical connectors from the following sensors:
Knock
Oxygen
Coolant Temperature
Camshaft
Crankshaft
Wheel Speed
Electrical connectors from engine oil level switch
and fuel pump switch/engine oil pressure gage sensor assemblies.
Right front brake line from caliper brake hose. Refer
to SECTION 5.
Wiring harness from transmission assembly.
Shift linkage from transmission assembly. Refer to
SECTION 7A or SECTION 7B.
Propeller shaft assembly after matchmarking. Refer
to SECTION 4A.
Torque arm from transmission assembly. Refer to
SECTION 3D.
Intermediate steering shaft from rack and pinion
assembly. Refer to SECTION 3F4.

25.
26.
27.
28.
29.
30.
31.
32.
33.
34.
35.
36.
37.
38.
39.
40.
41.
42.
43.
44.
45.
46.
47.
48.
49.
50.
51.
Electrical ground straps from left side of frame rail.

Lower vehicle.
Air intake duct.
Fuel pipe assembly. Refer to "Upper Intake Manifold Assembly" in this section.
Cruise and accelerator control cables from throttle
body assembly. Refer to SECTION 6E3.
Upper radiator hose from intake manifold assembly.
Lower radiator hose from front cover assembly.
Radiator fan assembly electrical connections.
Radiator fan assembly. Refer to SECTION 6B.
Brake booster vacuum hose.
"Y" brace from right exhaust manifold assembly.
Generator and air conditioning compressor bracket
and reposition. Refer to SECTION 603.
Engine wiring harness connectors and reposition
wiring harness.
Brake master cylinder and reposition. Refer to SECTION SA.
Upper bolts/screws and nuts from strut assemblies.
Right front brake line from modulator valve assembly and clips. Refer to SECTION 5.
Position lift table under engine and engine frame
assembly.
Engine frame and transmission support bolts/
screws. Refer to SECTION 10-3.
Raise vehicle from engine, transmission and engine
frame assemblies.
Secure strut assemblies to engine frame.
Transmission TV cable from throttle body assembly.
Transmission assembly. Refer to SECTION 7A or
SECTION 7B.
Clutch housing and clutch assembly (manual transmission). Refer to SECTION 7C.
Power steering lines from power steering pump
Engine assembly from engine frame.
f++I Install or Connect

section.
l. Engine assembly to engine frame.
!~I
Tighten
Engine mount through-bolt/screw to 95 Nm

(70 lb. ft.).
3. Power steering lines to power steering pump. Refer

to SECTION 3B.
4. Clutch housing and clutch assembly. Refer to SECTION 7C.
5. Transmission assembly. Refer to SECTION 7A or
SECTION 7B.
6. Transmission TV cable to throttle body assembly.
7. Position engine lift table and strut assemblies and
install engine, transmission and engine frame
assemblies.
8. Engine frame and transmission support bolts/
9. Engine lift table.
10. Lower vehicle.
11. Bolts/screws and nuts to upper strut assemblies.
12. Right front brake line to modulator valve assembly
and clips. Refer to SECTION 5.
13. Brake master cylinder and reposition. Refer to SECTION SA.
14. Engine wiring harness connectors.
15. Generator and air conditioning compressor bracket.
16. "Y" brace to right exhaust manifold assembly.
17. Brake booster vacuum hose.
18. Radiator fan assembly. Refer to SECTION 6B.
19. Radiator fan assembly electrical connections.
20. Lower radiator hose to front cover assembly. Refer
to SECTION 6B.
21. Upper radiator hose to intake manifold assembly.
22. Cruise and accelerator control cables to throttle
body assembly. Refer to SECTION 6E3.
23. Fuel pipe assembly. Refer to "Upper Intake Manifold Assembly" in this section.
25. Electrical ground straps to left side of frame rail.
26. Intermediate steering shaft to rack and pinion
27. Torque arm to transmission assembly. Refer to SECTION 7A or SECTION 7B.
29. Shift linkage to transmission assembly. Refer to
SECTION 7A or 7B.
30. Torque arm to transmission assembly. Refer to SECTION 30.
31. Wiring harness to transmission assembly.
32. Right front brake line to caliper brake hose. Refer to
SECTION 5.
33. Electrical connectors to engine oil level switch and
fuel pump switch/engine oil pressure gage sensor
assemblies.

34. Electrical connectors to the following sensors:
Wheel Speed
Crankshaft
Camshaft
Coolant Temperature
Oxygen
Knock
35. Electrical connections to starter motor assembly.
Refer to SECTION 6D2.
36. Electrical ground straps to right side of engine
block.
37. Heater hoses to pipes at engine assembly. Refer to
SECTION lBl.
38. Lower radiator hose to radiator assembly. Refer to
SECTION 6B.
39. Transmission fluid cooler lines to radiator assembly
(automatic transmission). Refer to SECTION 6B.
41. Stabilizer bar bolts/screws. Refer to SECTION 3C.
42. Front fascia lower deflectors. Refer to SECTION
10-5.
43. Converter bolts/screws (automatic transmission).
44. Converter cover bolts/screws (automatic transmission). Refer to SECTION 7A.
45. Exhaust crossover pipe assembly to intermediate
pipe. Refer to SECTION 6F.
46. Lower vehicle.
47. Refill with engine oil. Refer to SECTION OA.
48. Refill with engine coolant. Refer to SECTION 6B.
49. Wheels and tires. Refer to SECTION 3E.
51. Bleed brake system. Refer to SECTION 5El.
3B.
STEP
STEP
53. Air intake duct.

54. Align wheels. Refer to SECTION 3A.
THREAD REPAIR
Figure 36
Damaged threads may be reconditioned by drilling
out, re-threading and installing a suitable thread insert.
General purpose thread repair kits are available commercially.
CAUTION: Wear safety glasses to avoid
eye damage.
1. Determine size, pitch and depth of damaged thread.
If necessary, adjust stop collars on cutting tool and
tap to required depth.
rn
Important
Refer to kit manufacturer's instructions

regarding size of drill and tap to be used.
2. Drill out damaged thread. Clean out chips.
3. Tap hole.
A. Lubricate tap with light engine oil.
B. Clean thread.
rn
Important
Avoid build-up of chips. Back out tap every

few turns and remove chips.
4. Thread the thread insert onto mandrel of installer.
Engage tang of insert onto end of mandrel.
5. Lubricate insert with light engine oil (except when
installing in aluminum) and install.
[I) Important
When correctly installed, insert should be flush
to one turn below surface.
6. If tang of insert does not break off when backing out
installer, break tang off with a drift pin.
STEP 4
STEP
5
KC0049-6A4B-RP
Figure 36 - Repairing Threaded Holes
3.4 LITERV6 ENGINE ON-VEHICLE SERVICE RPO L32-VIN S 6A2A33
SPECIFICATIONS
Accelerator Control Cable Bracket Bolt/Screw ............................ 10 Nm (90 lb. in.)
Camshaft Sprocket Bolt/Screw ......................................... 24 Nm (18 lb. ft.)
Connecting Rod Nut ................................................. 50 Nm (37 lb. ft.)
Crankshaft Balancer Bolt/Screw ........................................ 78 Nm (58 lb. ft.)
Crankshaft Bearing Cap Bolt/Screw (plus 77 degrees) ...................... 50 Nm (37 lb. ft.)
Crankshaft Pulley Bolt/Screw .......................................... 50 Nm (37 lb. ft.)
Cylinder Head Bolt/Screw (plus 90 degrees) .............................. 55 Nm (41 lb. ft.)
Drive Belt Idler Pulley Bolt/Screw ...................................... 50 Nm (37 lb. ft.)
Drive Belt Tensioner Bolt/Screw ....................................... 33 Nm (24 lb. ft.)
EGR Flexible Pipe Bolt/Screw ......................................... 26 Nm (19 lb. ft.)
EGR Valve Adapter Tube Bolt/Screw ................................... 31 Nm (23 lb. ft.)
Engine Bracket Bolt/Screw ............................................ 58 Nm (43 lb. ft.)
Engine Front Cover Bolt/Screw ........................................ 21 Nm (15 lb. ft.)
Engine Mount Through-Bolt/Screw ..................................... 95 Nm (70 lb. ft.)
Engine Mount Through-Bolt/Screw Nut ................................. 80 Nm (59 lb. ft.)
Engine Mount-to-Frame Bolt/Screw ..................................... 58 Nm (43 lb. ft.)
Engine Oil Level Sensor Assembly ..................................... 22 Nm (16 lb. ft.)
Exhaust Manifold Bolt/Screw .......................................... 25 Nm (18 lb. ft.)
Flywheel Bolt/Screw ................................................. 83 Nm (61 lb. ft.)
Fuel Injector Fuel Rail Stud ........................................... 25 Nm (18 lb. ft.)
Fuel Pipe Bracket-to-Front Brace Bolt/Screw .............................. 8 Nm (71 lb. in.)
Fuel Pipe Bracket-to-Intake Manifold Bolt/Screw .......................... 10 Nm (89 lb. in.)
Fuel Pipe Hold Down Plate Bolt/Screw .................................. 25 Nm (18 lb. ft.)
Lower Intake Manifold Bolt/Screw ..................................... 30 Nm (22 lb. ft.)
Oil Level Indicator Tube Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 N m ( 15 lb. ft.)
Oil Pan
Front Corner Bolt/Screw and Nut ..................................... 33 Nm (24 lb. ft.)
Rear Corner Bolt/Screw ............................................ 25 Nm (18 lb. ft.)
Side Rail Bolt/Screw ............................................... 10 Nm (89 lb. in.)
Stud ............................................................. 6 Nm (53 lb. in.)
Oil Pan Drain Plug .................................................. 25 Nm (18 lb. ft.)
Oil Pump Drive Clamp Bolt/Screw ..................................... 34 Nm (25 lb. ft.)
Oil Pump-to-Crankshaft Bearing Cap Bolt/Screw .......................... 41 Nm (30 lb. ft.)
Secondary Air Injection Check Valve Pipe Bracket Bolt/Screw ............... 25 Nm (18 lb. ft.)
Secondary Air Injection Pipe Fitting .................................... 25 Nm (18 lb. ft.)
Timing Chain Dampener Bolt/Screw .................................... 21 Nm (15 lb. ft.)
Upper Intake Manifold Bolt/Screw ...................................... 25 Nm (18 lb. ft.)
Valve Rocker Arm Cover Nut .......................................... 10 Nm (89 lb. in.)
ENGINE ASSEMBLY SPECIFICATIONS (3.4L L32)

General
Type .......................................................................... V6
Displacement.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.4L (204 CID)
Bore ................................................................ 92 mm (3.622")
Stroke .............................................................. 84 mm (3.312")
Compression Ratio ............................................................. 9.0:1
Firing Order ............................................................. 1-2-3-4-5-6
Oil Pressure (Minimum at operating temperature) .......... 103 kPa (15 psig) at 1,100 engine rpm
Oil Filter Torque .................................................... 16 Nm (12 lb. ft.)
Cylinder Bore
Diameter ........................................... 92.020-92.038 mm (3.6228-3.6235")
Out-of-Round ............................................... 0.007 mm (0.0003") MAX.
6A2A-34 3.4 LITER V6 ENGINE ON-VEHICLE SERVICE RPO L32-VIN S

Piston Assembly
Diameter ........................................... 91.977-91.992 mm (3.6211-3.6217")
Piston Bore Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.028-0.061 mm (0.0011-0.0024")
Piston Rings
Piston Compression Ring
Groove Clearance
Top ................................................ 0.05-0.09 mm (0.002-0.0035")
2nd ................................................. 0.05-0.09 mm (0.002-0.0035")
Gap
Top ................................................. 0.18-0.41 mm (0.007-0.016")
2nd .................................................. 0.48-0.74 mm (0.019-0.029")
Piston Oil Ring
Groove Clearance-MAX ............................................ 0.20 mm (0.008")
Gap ................................................... 0.25-0.76 mm (0.010-0.030")
Piston Pin
Diameter ......................................... 22.9915-22.9964 mm (0.9052-0.9054")
Clearance in Piston Assembly .......................... 0.0116-0.0218 mm (0.0005-0.0009")
Fit In Cm;mecting Rod Assembly ............. 0.0165-0.0464 mm (0.00065-0.0018 ") Interference
Crankshaft Assembly
Main Journal
.
Diameter-All ...................................... 67.239-67.257 mm (2.6473-2.6483")
Taper-Max ................................................ 0.005 mm (0.0002") MAX.
Out-of-Round ............................................. 0.005 mm (0.0002") MAX.
Crankshaft Bearing Clearance ............................ 0.032-0.077 mm (0.0012-0.0030")
Crankshaft Thrust Bearing Clearance ....................... 0.032-0.077 mm (0.0012-0.0030")
Crankshaft Assembly End Play ............................. 0.06-0.21 mm (0.0024-0.0083")
Connecting Rod Assembly
Connecting Rod Journal
Diameter ......................................... 50.768-50.784 mm (1.9987-1.9994")
Taper-Max ..................................................... 0.005 mm (0.0002")
Out-of-Round-Max .............................................. 0.005 mm (0.0002")
Rod Bearing Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.028-0.082 mm (0.0011-0.0032")
Rod Side Clearance ......................................... 0.18-0.44 mm (0.007-0.017")
Camshaft Assembly
Journal Diameter ......................................... 47.44-47.52
Bearing Inside Diameter ................................. 47.523-47.549
Journal Clearance ........................................ 0.026-0.101
Lobe Lift
Intake ..........................................................
Exhaust ........................................................
mm (1.868-1.871 ")
mm (1.871-1.872")
mm (0.001-0.004")
6.67 mm (0.2626")
6.94 mm (0.2732")
Valve System
Lifter Assembly ........................................................... Hydraulic
Rocker Arm Ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.50: 1
Valve Lash ............................................. 1 1/2 turn down from zero lash
Face Angle .................................................................... 45
Seat Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Seat Runout .................................................. 0.025 mm (0.001 ") MAX.
Seat Width
Intake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.55-1.85 mm (0.061-0.073 ")
Exhaust ................................................. 1.70-2.00 mm (0.067-0.079")
Stem Clearance
Intake ........................................ 0.0356 mm-0.0686 mm (0.0014-0.0027")
Exhaust ....................................... 0.0381 mm-0.0737 mm (0.0015-0.0029")
Valve Spring
Free Length ....................................................... 48.5 mm (1.91 ")
Pressure
Closed ........................................... 356 Nat 40.9 mm (80 lb. at 1.61 ")
Open ........................................... 841 Nat 30.5 mm (190 lb. at 1.20")
Installed Height .................................................... 40.9 mm (1.61 ")
Approximate # of Coils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3.4 LITER V6 ENGINE ON-VEHICLE SERVICE RPO L32 - VIN S 6A2A-35

Oil Pump
Gear Lash ............................................ 0.094-0.195 mm (0.0037-0.0077")
Gear Pocket
Depth ................................................ 30.53-30.61 mm (1.202-1.205")
Diameter ............................................ 38.202-38.252 mm (1.504-1.506")
Gear
Length ............................................... 30.45-30.48 mm (1.199-1.200")
Diameter .............................................. 38.05-38.10 mm (1.498-1.500")
Side Clearance ........................................... 0.08-0.10 mm (0.003-0.004")
End Clearance .......................................... 0.05-0.152 mm (0.002-0.006")
Valve-to-Bore Clearance ................................. 0.038-0.089 mm (0.0015-0.0035")
SPECIAL TOOLS
1.
2.
3.
4.
5.
6.
J23444-A
J 29113
~
~
J 8037
J 24420-B
J 8520
8.
9.
10.
J 23590
J 23738-A
11.
J 34686
CD ~
12.
J 34730-1
J 38612
7.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
J 5892-C
CRANKSHAFT SPROCKET REMOVER

TORSIONAL DAMPER INSTALLER
PISTON RING COMPRESSOR
TORSIONAL DAMPER REMOVER
REAR MAIN BEARING OIL SEAL INSTALLER
CRANKSHAFT SPROCKET INSTALLER
VALVE SPRING COMPRESSOR
CAM LOBE LIFT INDICATOR
SPARK PLUG PORT ADAPTER
VALVE STEM SEAL TESTER
TORQUE ANGLE METER
FUEL PRESSURE GAGE
MAIN BEARING SHELL REMOVER & INSTALLER
CONNECTING ROD BOLT GUIDE SET
13.
~t
J8080
14.
Cii;
;;
J5239
PC0014-6A2A-F-RP
3.4 LITER V-6 VIN CODE S 6A2B-1
SECTION 6A2B
3.4 LITER V-6 VIN CODE S

CAUTION: To help avoid personal injury when a vehicle is on a hoist, provide additional support for
the vehicle at the opposite end from which components are being removed. This will reduce the
possibility of the vehicle falling off of the hoist.
NOTICE: When fasteners are removed, always reinstall them at the same location from which they were
removed. If a fastener needs to be replaced, use the correct part number fastener for that application. If the correct
part number fastener is not available, a fastener of equal size and strength (or stronger) may be used. Fasteners
that are not reused, and those requiring thread locking compound will be called out. The correct torque value must
be used when installing fasteners that require it. If the above conditions are not followed, parts or system damage
could result.
CONTENTS
General Description ............................... 6A2B- 6
Engine Construction ............................ 6A2B- 6
Engine Lubrication .............................. 6A2B- 6
Disassembly ......................................... 6A2B- 6
Flywheel. .......................................... 6A2B- 6
Draining the Engine ............................ 6A2B- 6
Upper Intake Manifold ......................... 6A2B-11
Valve Rocker Cover ............................ 6A2B-11
Valve Rocker Arm and Pushrod ............. 6A2B-11
Lower Intake Manifold ......................... 6A2B-13
Valve Lifters ..................................... 6A2B-13
Exhaust Manifold ................................ 6A2B-14
Oil Pan ............................................ 6A2B-15
Electronic Ignition Module .................... 6A2B-16
Coolant Pump .................................... 6A2B-17
Torsional Damper ............................... 6A2B-17
Engine Front Cover ............................. 6A2B-18
Timing Chain and Sprockets .................. 6A2B-18
Camshaft .......................................... 6A2B-18
Cylinder Head .................................... 6A2B-20
Oil Pump .......................................... 6A2B-20
Piston and Connecting Rod ................... 6A2B-21
Crankshaft ........................................ 6A2B-21
Rear Main Seal .................................. 6A2B-22
Camshaft Bearings .............................. 6A2B-22
Cleaning, Inspection and Repair ................ 6A2B-22
Cylinder Block ................................... 6A2B-22
Thread Repair .................................... 6A2B-25
Crankshaft ........................................ 6A2B-25
Pistons and Connecting Rods ................. 6A2B-26
Main Bearing and Rod Bearing Selection .. 6A2B-29
Oil Pump Unit Repair .......................... 6A2B-31
Cylinder Head Reconditioning ................ 6A2B-33
Camshaft Inspection ............................ 6A2B-38

Oil Pan ............................................ 6A2B-39
Coolant Pump .................................... 6A2B-39
Valve Lifters ..................................... 6A2B-39
Valve Rocker Arms and Pushrods ........... 6A2B-40
Assembly ............................................ 6A2B-41
Cylinder Block ................................... 6A2B-41
Camshaft Bearings .............................. 6A2B-41
Crankshaft ........................................ 6A2B-42
Rear Main Oil Seal ............................. 6A2B-43
Pistons and Connecting Rods ................. 6A2B-44
Oil Pump .......................................... 6A2B-45
Cylinder Head .................................... 6A2B-45
Camshaft .......................................... 6A2B-46
Coolant Pump .................................... 6A2B-48
Torsional Damper ............................... 6A2B-49
Electronic Ignition Module .................... 6A2B-49
Oil Pan ............................................ 6A2B-50
Exhaust Manifold ................................ 6A2B-50
Valve Lifters ..................................... 6A2B-50
Valve Rocker Arm and Pushrod ............. 6A2B-50
Flywheel ........................................... 6A2B-52
Specifications ....................................... 6A2B-52
Fastener Tightening Specifications ........... 6A2B-52
Engine Specifications ........................... 6A2B-54
Special Tools ....................................... 6A2B-56
6A2B-2 3.4 LITER V-6 VIN CODE S
--------
101
54
27
?
31/
28
"--i .
17~
16-
-4
3.4 LITER V-6 VIN CODE S 6A2B3
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70
71
PAN, OIL
GASKET, OIL PAN
STUD, OIL PAN
CLIP, WIRING HARNESS
NUT, OIL PAN
CLIP, OIL COOLER PIPE
NUT, OIL PAN
WASHER, OIL DRAIN PLUG
PLUG, OIL DRAIN
NUT, OIL PAN
BOLT, OIL PAN - SMALL
STUD, OIL PAN
BOLT, OIL PAN - LARGE
SENSOR, OIL LEVEL
BOLT, OIL PUMP
PUMP ASSEMBLY, OIL
ROD, OIL PUMP DRIVE
BOLT, MAIN BEARING CAP
CAP, MAIN BEARING
0-RING
72
PUMP, COOLANT
GASKET, COOLANT PUMP
BOLT, CRANKSHAFT POSITION SENSOR
SENSOR, CRANKSHAFT POSITION
SEAL, FRONT COVER OIL
BOLT, ENGINE FRONT COVER
COVER, ENGINE FRONT
BOLT, TIMING CHAIN DAMPER
DAMPER, TIMING CHAIN
PLUG, OIL GALLERY - 1/8"
BOLT, IGNITION TIMING SENSOR
SENSOR, IGNITION TIMING
SENSOR, KNOCK
PLUG,COOLANTJACKET
PLUG, COOLANT JACKET
BLOCK, ENGINE
DOWEL
PLUG, COOLANT JACKET
74
75 GASKET, REAR CAMSHAFT COVER
76 COVER, REAR CAMSHAFT
CRANKSHAFT
BEARING, MAIN
77
KEY, CRANKSHAFT
CHAIN, TIMING
SPROCKET.CRANKSHAFT
DAMPER, TORSIONAL
PULLEY, CRANKSHAFT
WASHER, TORSIONAL DAMPER
BOLT, TORSIONAL DAMPER
BOLT, COOLANT PUMP PULLEY
SEAL, REAR MAIN
FLYWHEEL
REINFORCEMENT, FLYWHEEL
PIN, FLYWHEEL- MANUAL TRANS
BOLT, FLYWHEEL
STUD, BRACKET
BRACKET, POWER STEERING PUMP
NUT, BRACKET
GASKET, OIL FILTER ADAPTER
ADAPTER, OIL FILTER
0-RING
BOLT, OIL FILTER ADAPTER
SENSOR, OIL PRESSURE
FILTER, OIL
TUBE, OIL LEVEL INDICATOR
NUT, OIL LEVEL INDICATOR TUBE
INDICATOR, OIL LEVEL
78
79
80
81
82
83
84
85
86
87
88
89
90
91
92
93
94
95
96
97
98
99
100
101
BOLT, REAR CAMSHAFT COVER

NUT, CONNECTING ROD
CAP, CONNECTING ROD
ROD, CONNECTING
BOLT, CONNECTING ROD
PIN, PISTON
PISTON
RINGS, OIL CONTROL
RING, LOWER COMPRESSION
RING, UPPER COMPRESSION
DRIVE ASSEMBLY, OIL PUMP
BOLT, DRIVE ASSEMBLY CLAMP
CLAMP, OIL PUMP DRIVE ASSEMBLY
PUSH ROD
LIFTER
BOLT, CAMSHAFT POSITION SENSOR
SENSOR, CAMSHAFT POSITION
BOLT, CAMSHAFT SPROCKET
SPROCKET, CAMSHAFT
PIN, DOWEL
CAMSHAFT
BEARING, CAMSHAFT
BOLT, COOLANT PUMP PULLEY

PULLEY, COOLANT PUMP
BOLT, COOLANT PUMP - SMALL
BOLT, COOLANT PUMP - LARGE
BOLT, COOLANT PUMP - MEDIUM
P0002-6A2B-F-RA
Figure 2 Legend View 1
=----
6A2B-4 3.4 LITER V-6 VIN CODES
172
167
1'91 ~
I
168
166
194
195
125-t
223
"'
~ 221
~-_,,-
'
226 '
229
230
Cl
,
\
224
227
Figure
En .
102
gine Disassembled V iew 2 of 2
i02 BOLT, EXHAUST MANIFOLD

103 SHIELD, EXHAUST MANIFOLD
HEAT

HEAT
105
106
111
112
113
114
115
116
117
118
119

SENSOR,OXYGEN
HEAD, CYLINDER
SENSOR, COOLANT TEMPERATURE GAGE
BOLT, CYLINDER HEAD
BRACE, FUEL LINE
BOLT, FUEL LINE BRACE
BRACKET, FRONT ENGINE LIFT
BOLT, FRONT ENGINE LIFT
BRACKET
BRACKET
STUD, ROCKER ARM
155
156
157
158
159
160
161
162
MANIFOLD, UPPER INTAKE
BALL, ROCKER ARM

NUT, ROCKER ARM
VALVE, INTAKE
SEAL, INTAKE VALVE STEM
DAMPER, SPRING
SPRING, VALVE
KEY
VALVE, EXHAUST
SHIM - SELECTIVE
DAMPER, SPRING
SHEDDER, OIL
KEY
MANIFOLD
142 MANIFOLD, LOWER INTAKE

143 NUT, LOWER INTAKE MANIFOLD
144 BOLT, LOWER INTAKE MANIFOLD
145 SENSOR, COOLANT

TEMPERATURE
BOLT, THERMOSTAT HOL)SING
HOUSING, THERMOSTAT
THERMOSTAT
NIPPLE, HEATER INLET
GASKET,UPPERINTAKE
MANIFOLD
SENSOR, MAP
SCREW, MAP SENSOR
BRACKET, ACCELERATOR CABLE
BOLT,ACCELERATOR
CABLE BRACKET
168
169
170
171
172
173
PLATE, FUEL LINE HOLD DOWN
STUD, FUEL RAIL HARNESS

HARNESS, VACUUM
HOSE, FUEL PRESSURE
REGULATOR VACUUM
LINE, FUEL
SCREW, FUEL LINE RETAINING
SCREW, EVAP CANISTER PURGE
CANISTER PURGE, EVAP
HOSE, SECONDARY AIR
INJECTION
180 VALVE, AIR CHECK

181 PIPE, SECONDARY AIR
INJECTION
182 PIPE, SECONDARY AIR

INJECTION
183
184
185
186
187
188
189
190
191
192
193
BOLT, AIR PIPE

NUT, AIR PIPE
GASKET, VALVE ROCKER COVER

STUD, VALVE ROCKER COVER
TUBE, CRANKCASE VENT
FITTING, TUBE
BRACKET, REAR ENGINE LIFT
STUD, REAR ENGINE LIFT
BRACKET
HEAT
204 NUT, EXHAUST MANIFOLD HEAT

SHIELD

HEAT
206
207
208
209
210
211
212
213
STUD, FUEL RAIL ASSEMBLY

HARNESS, FUEL INJECTOR RAIL
COVER, VALVE ROCKER
202 BOLT, EXHAUST MANIFOLD

CLIP, ENGINE WIRING HARNESS
167
175
176
177
178
179
194
195
196
197
199
200
201
BOLT, UPPER INTAKE MANIFOLD

TUBE, VACUUM
BOLT, FUEL LINE HOLD DOWN

PLATE
CAP, SPRING
STUD, LOWER INTAKE
MANIFOLD
HOSE,HEATERINLET
TOR
SPRING, VALVE
0-RING
CLAMP, HOSE
163
164 BODY, THROTTLE
165 BOLT/STUD, THROTTLE BODY
166 RAIL ASSEMBLY, FUEL INJEC-
0-RING
CAP, SPRING
SCREW, HEATER INLET PIPE
GASKET, THROTTLE BODY
ARM, ROCKER
141 GASKET, LOWER INTAKE
146
147
148
149
PIPE, HEATER INLET
MANIFOLD, EXHAUST - LEFT
120 STUD, FRONT ENGINE LIFT

121
122
123
124
125
126
127
128
129
130
131
132
133
134
135
136
137
138
139
140
150
151
152
153
154
214
215
216
217
219
220
221
222
223
224
VALVE, EGR
BOLT, EGR VALVE
GASKET, EGR VALVE
PIPE, EGR ADAPTER
BOLT, EGR ADAPTER PIPE
GASKET, EGR ADAPTER PIPE
PIPE, FLEXIBLE ADAPTER
GASKET, FLEXIBLE ADAPTER
PIPE
BOLT, FLEXIBLE ADAPTER PIPE
MANIFOLD, EXHAUST - RIGHT
SENSOR.OXYGEN
WIRES, SPARK PLUG - RIGHT
WIRES, SPARK PLUG - LEFT
PLUG, SPARK
SYSTEM, ELECTRONIC IGNITION
COIL, ELECTRONIC IGNITION
BRACKET, REAR POWER
STEERING PUMP
225 PUMP, POWER STEERING

226 NUT, ELECTRONIC IGNITION
SYSTEM
227 BRACKET, POWER STEERING

PUMP
228 BOLT, POWER STEERING PUMP

BRACKET
CLAMP, AIR HOSE
229 PULLEY, POWER STEERING
HOSE, SECONDARY AIR

INJECTION
230 BOLT, POWER STEERING PUMP
PUMP
CAP, OIL FILL

TUBE, OIL FILL
SCREW, OIL FILL TUBE
VALVE,PCV
GROMMET
NUT, VALVE ROCKER COVER
REINFORCEMENT, VALVE
ROCKER COVER
P0004-6A2B-F-RA
Figure 4 Legend View 2
GENERAL DESCRIPTION
ENGINE CONSTRUCTION
Figures 1 through 4
Cylinder Block
The cylinder block is made of cast alloy iron and
has six cylmders arranged in a "V" shape with three
cylinders in each bank. The cylinder banks are set at a
60 angle from each other.
The right bank cylinders are (1,3,5) and the left
bank cylinders are (2,4,6).
Four main bearings support the crankshaft
which is retained by bearing caps that are machined
with the block for proper alignment and clearances.
Cylinder Head
The cast iron cylinder heads have individual intake and exhaust ports for each cylinder. Valve guides
are integral, and rocker arms are retained on individual threaded studs with locking nuts.
Crankshaft and Bearings
The crankshaft is cast nodular iron with deep
rolled fillets on all six crankpins and all four main
journals. Four steel-backed aluminum bearings are
used, with the #3 bearing being the end-thrust
bearing.
Camshaft and Drive
The camshaft is cast alloy iron with tapered
13.2 mm wide lobes, offset from the lifters and tapered to provide positive valve lifter rotation. The
camshaft 1s supported by four journals and includes an
oil pump drive gear.
Pistons and Connecting Rods
The pistons are cast aluminum with steel struts
using two compression rings and one oil control ring.
The piston pin is offset 0.8 mm towards the major
thrust side. This allows a gradual change in thrust
pressure against the cylinder wall as the piston travels
its path. Pms are chromium steel and have a floating
fit m the pistons. They are retained in the connecting
rods by a press fit.
Connecting rods are made of forged steel. Full
pressure lubrication is directed to the connecting rods
by drilled oil passages from the adjacent main bearing
journal.
Valve Train
A very simple ball-pivot and rocker type valve
train is used. Motion is transmitted from the camshaft
through the hydraulic lifter and J?Ushrod to the rocker
arm. The rocker arm pivots on its ball and transmits
the camshaft motion to the valve. The rocker arm ball
locates on a stud, threaded into the head, and is retained by a nut. The pushrod is located by a guide
plate held under the rocker arm stud, assuring that the
rocker arm operates in the plane of the valve.
Intake Manifold
The intake manifold is a two-piece cast aluminum unit. It centrally supports a fuel rail with six fuel
injectors.
Exhaust Manifolds
The exhaust manifolds are cast nodular iron.
ENGINE LUBRICATION
Figures 5 through 8
Full pressure lubrication, through a full flow oil

filter is furnished by a gear type oil pump. Oil is
drawn up through the pickup screen and tube, and
passed through the pump to the oil filter.
The oil filter is a full flow paper element unit.
An oil filter bypass is used to ensure adequate oil
supply, should the filter become plugged or develop
excessive pressure drop. The bypass is designed to
open at 69-83 kPa (10-12 psi).
A new priority oil delivery system supplies oil
first to the crankshaft journals. The passages supplying oil to the crankshaft main bearings also supply oil
to the camshaft bearings through intersecting vertical
drilled holes. Oil from the crankshaft main bearings is
supplied to the connecting rod bearings by means of
intersecting passages drilled in the crankshaft. The
front cam bearing has a 0.25 mm deep slot on its
outside diameter to supply oil to the cam sprocket
thrust face, and oil passages from the camshaft journals supply oil to the hydraulic lifters.
The hydraulic lifters pump oil up through the
pushrods to the rocker arms. Oil draimng back from
the rocker arms is directed by cast dams m the crankcase casting to su_eply the camshaft lobes. Oil also
drains past specific hydraulic lifter flats to oil
camshaft lobes directly.
DISASSEMBLV
FLYWHEEL
Figure 9
E3
1. Flywheel retaining bolts (36).

2. Flywheel (33).
DRAINING THE ENGINE
E3
1. Oil drain plug (9) and drain engine oil.

2. Oil filter (45).
3. Coolant drain plugs (69 and 70) and drain
coolant.
3.4 LITER V-6 VIN CODES 6A2B-7
'
'
7
1.U,I
:s:
l
P0101-6A2B-F-RA
Figure 5 Engine Lubrication View 1 of 4
~~
~z
:::<{
om
a:
1-
r
a:a:
<{
w~
~o
I- 1-
z~
Oz
a:<{
u.. al
a:
l-
o u..
u.. w
....J ....J
<{ ~
S2o
a.. a:
~ u..
P0102-6A2BfRA
LUBRICATION ENOS/ ..
154 B.T.D.C.
I ,~'-"
BEGINNING OF
LUBRICATION
:::!!
cc
c:
-,
CD
.......
END OF
:::,
VIEW IN DIRECTION OF
cc
LUBRICATION
ARROW C
:J
FOR CYL'S 2, 4 & 6
CD
c:
C"
-,
c5
Dl
.....
c5
BEGINNING OF
LUBRICATION
:J
<
cii"
:E
190 DURATION
OF LUBRICATION
LUBRICATION ENDS
134 B.T.D.C.
E
.,,II'
:i,
)>
:s:,.
r-
:::j
\
13
:a
<
a,
<
I
END OF
LUBRICATION
FOR CYL'S 1, 3 & 5

VIEWS SHOWING INTERMITIENT OILING OF
CONNECTING ROD BEARING THROUGH GROOVE
ON UPPER HALF OF MAIN BEARINGS.
0
m
0
en
CCI
u,
<
<
z
a
6w
Cl)
P0104-6A2B-F-RA
3.4 LITER V-6 VIN CODES 6A2B11
36
'---..!
22 CRANKSHAFT
33 FLYWHEEL (AUTOMATIC)
34 RETAINER (AUTOMATIC)
36 BOLT, FLYWHEEL
P00056A2B-F-RA
Figure 9 f=lywheel
UPPER INTAKE MANIFOLD

Figure 10 and 11
E3
1. Throttle body heater hose clamps (152) and

hoses (153).
2. Fuel line clamp bolts (176 and 177).
rn
3.
4.
5.
6.
7.
8.
9.
10.
Important
The fuel line hold down plate and pivot bolt are
part of the fuel rail assembly. Do not remove the
pivot bolt.
Fuel line hold down plate bolt (167).
Rotate fuel line hold down plate (168)
counter-clockwise.
Fuel lines (175).
Fuel injector rail wiring harness retaining nut.
Fuel rail stud (169).
Fuel pressure regulator vacuum hose (173).
Coolant sensor electrical connector.
Blow dirt out of injector bores with compressed
air.
Fuel injector rail assembly (166).
Pry carefully on injector rail_ (166).
Remove injectors one side at a time.
11.
12.
PCV valve (190).

EGR flexible tube bolts at upper intake manifold
(155).
13. MAP sensor electrical connector.
14. Upper intake manifold bolts (156).
15. Upper intake manifold (155) and gasket (154).
VALVE ROCKER COVER

Figure 12
E3

2.
Valve rocker cover (194) and gasket (195).
VALVE ROCKER ARM AND PUSHROD

Figure 13
E3
1. Rocker arm nuts (124).

Place valve train parts in a rack so that
they can be installed in the same location
which they were removed.
Rocker arms (122) and balls (123).
Pushrods (93).
2.
3.
167
155 MANIFOLD, UPPER INTAKE

166 RAIL ASSEMBLY, FUEL INJECTOR
167 BOLT, FUEL INJECTOR
169 STUD, FUEL INJECTOR
P0006-6A2B-F-RA
Figure 10 Fuel Injector Rail
156~
~---156
155
142
154
155
156
MANIFOLD, LOWER INTAKE

GASKET, UPPER INTAKE MANIFOLD
BOLT, UPPER INTAKE MANIFOLD
142
P0007 -6A2B-F-RA
Figure 11 Upper Intake Manifold
3.4 LITER V-6 VIN CODE S 6A2B13
192
A
194
APPLY SEALANT AT CYLINDER HEAD TO INTAKE

MANIFOLD MATING SURFACE
113
HEAD, CYLINDER
192
193
NUT, VALVE ROCKER COVER

REINFORCEMENT, VALVE ROCKER COVER
193
194 COVER, VALVE ROCKER

195
GASKET, VALVE ROCKER COVER
196
STUD, VALVE ROCKER COVER
---195
P00086A2BFRA
Figure 12 Valve Rocker Cover
LOWER INTAKE MANIFOLD
VALVE LIFTERS
Figure 14
Figure 13
E3
E3
1. Retaining bolts (144) and nuts (143).

2. Lower intake manifold (142) and gaskets (141).
1. Valve lifters (94).
124
93
113
121
122
123
124
PUSH ROD
HEAD, CYLINDER
STUD, ROCKER ARM
ARM, ROCKER
113
BALL, ROCKER ARM

NUT, ROCKER ARM
P0009-6A2BF-RA
Figure 13 Valve Rocker Arms and Pushrods
EXHAUST MANIFOLD
6.
Figures 15 and 16
7.
E3
8.
1.
2.
3.
4.
5.
Serpentine drive belt.

Rear NC compressor bracket mounting bolts
and bracket.
Generator pencil brace bolts and braces.
A/C compressor and generator mounting
bracket bolts.
A/C compressor and generator mounting
bracket.
9.
10.
11.
AIR pipe fitting from right exhaust manifold, if

equipped.
AIR pipe retaining nut (184) and bolt (183), if
equipped.
.
Secondary air injection pipe assembly, if
equipped.
Exhaust manifold retaining bolts (102 and 202).
Exhaust manifolds (105 and 215) and heat
shields (103, 104, 203 and 205).
Exhaust manifold gaskets (106 and 216).
10
A
B
113
140
141
142
143
144
APPLY SEALANT
TIGHTENING SEQUENCE
HEAD, CYLINDER
STUD, LOWER INTAKE MANIFOLD
GASKET, LOWER INTAKE MANIFOLD
MANIFOLD, LOWER INTAKE
NUT, LOWER INTAKE MANIFOLD
BOLT/STUD, LOWER INTAKE MANIFOLD
113
P00106A2BF-RA
Figure 14 Lower Intake Manifold
OIL PAN
Figure 17
E3
1. Oil pan nuts (11) and reinforcements (10).

2. Oil pan bolts (12) and studs (13).
3. Oil pan (1) and gasket (2).
202
113
202
203
204
205
215
216
202
HEAD, CYLINDER
STUD/BOLT, EXHAUST MANIFOLD
SHIELD, HEAT
NUT, HEAT SHIELD
SHIELD, HEAT
MANIFOLD, EXHAUST
P0011-6A2B-F-RA
Figure 15 Exhaust Manifold - Right
ELECTRONIC IGNITION MODULE
EJ
1. Power steering pump pulley (229) using
Figure 18
Tools Required:
J 25034-B Power Steering Pump Pulley
Remover
J 25034-5 Adapter
2.
3.
4.
J 25034-B and J 25034-5.

Power steering pump bracket retaining bolts.
Power steering pump bolts (228) and pump
(225).
Electronic ignition module nuts (226) and
electronic ignition module (223).
102
103
104
105
106
111
113
BOLT/STUD, EXHAUST MANIFOLD

SHIELD, HEAT
SHIELD, HEAT
MANIFOLD, EXHAUST
102
SENSOR.OXYGEN
HEAD, CYLINDER
102
P0012-6A2B-F-RA
Figure 16 Exhaust Manifold - Left
COOLANT PUMP
TORSIONAL DAMPER
Figure 76
Figure 19
E3
Tool Required:
J 24420-B Torsional Damper Remover
1. Power steering pump m)ounting bracket bolts

(230) and bracket (227 .
2. Coolant pump pulley bolts (49) and pulley (50).
3. Coolant pump bolts (51, 52 and 53).
4. Coolant pump (54) and gasket (55).
E3
1.
2.
3.
Torsional damper bolt (30) and washer (29).

Crankshaft pulley bolts (31) and pulley (28).
Torsional damper (27) using J 24420-B.
6A28-18 3.4 LITER V-6 VIN CODES
13
1
2
3
10
11
12
13
14
71
PAN, OIL
GASKET, OIL PAN
STUD, OIL PAN
NUT, OIL PAN
BOLT, OIL PAN
STUD, OIL PAN
BOLT, OIL PAN
BLOCK, ENGINE
P00136A2B-F-RA
Figure 17 Oil Pan
ENGINE FRONT COVER
4.
Timing chain damper bolts (62) and damper

(63).
Figure 73
E3
1.
2.
CAMSHAFT
Engine front cover bolts (59).

Engine front cover (60) and gasket (61).
Figure 69
!+ +!
TIMING CHAIN AND SPROCKETS
1. Oil pump driven gear hold down clamp bolt (91)
Figure 20
2.
Tool Required:
J 5825 Crankshaft Sprocket Remover
!+ !
1.
2.
3.
Cam sprocket bolts (97).

Cam sprocket (98) and timing chain (25).
Crankshaft sprocket (26) using J 5825.
3.
and clamp (92).

Oil pump driven gear assembly (90).
NOTICE: Camshaft journals are all the same
diameter so care must be used when removing the
camshaft to avoid bearing damage.
Camshaft (100).
Install three 4-inch bolts in the camshaft
bolt holes.
Carefully rotate and pull the camshaft
(100) out of the camshaft bearings.
222
71
71
222
226
226
BLOCK, ENGINE
MODULE, ELECTRONIC IGNITION
NUT, ELECTRONIC IGNITION MODULE
P0014-6A2B-F-RA
Figure 18 Electronic Ignition Module
J24420-B
27
DAMPER, TORSIONAL
P0015-6A2B-F-RA
Figure 19 Torsional Damper Removal
24
24
26
71
J 23444-A
KEY
BLOCK, ENGINE
P0016-6A2B-FRA
Figure 20 Crankshaft Sprocket Removal
CYLINDER HEAD
Right
Figure 68
E3
1.
2.
3.
Pencil brace bracket bolts.

Cylinder head bolts (115).
Cylinder head (113) and gasket (112).
Left
Figure 68
E3
1.
2.
3.
4.
5.
6.
Power steering pump bracket bolts and bracket

(224).
Oil level indicator tube nut (47).
Engine lift bracket bolts (119 and 120) and
bracket (118).
Engine coolant temperature sensor (114).
Cylinder head (113) and gasket (112).
OIL PUMP
Figure 21
E3
1.
2.
Oil pump bolt (16).

Oil pump (17) and drive rod (18).
16 BOLT, OIL PUMP

17 PUMP, OIL
18 ROD, DRIVE
20 CAP, MAIN BEARING
71 BLOCK, ENGINE
P0017-6A2BfRA
Figure 21 Oil Pump

Figure22
E3
1. Mark the piston (86) with the number of the

cylinder from which .it is being removed.
2. Mark the connecting rod (83) and the rod cap
(81) so that they can be assembled ~orrectly.
3. Turn the crankshaft (22) to bottom dead center.
&!}
4.
Clean
Carbon from the top end of the cylinder.
Connecting rod nut (80) and cap (81).
NOTICE: If there is a pronounced ridge at the

top of the piston travel, this ridge must be removed with a rid~e reamer before removing piston and connectmg rod assembly. Do not use
force. Avoid breakmg piston rings and damaging
the piston.
NOTICE: Install thread protector to avoid
damage to the crankshaft journal.
5. Connecting _rod (83) and piston assembly (86).
Push out with a smtable tool.
A USE A SHORT PIECE OF

3/8" HOSE AS A GUIDE
P00186A2B-F-RA
Figure 22 Connecting Rod Protector
CRANKSHAFT
Figure 23
E3
17
19
ASSEMBLE WITH ARROWS ON

CAP TOWARD FRONT OF ENGINE
0-RING
BOLT, MAIN BEARING CAP
20 CAP, MAIN BEARING

22 CRANKSHAFT
23 BEARING, MAIN
71
BLOCK, ENGINE
1. Main bearing cap bolts (19).

2. Main bearing caps (20) and lower bearing
halves (23).
3. Crankshaft (22).
4. Upper bearing halves (23).
P0019-6A2Bf-RA
Figure 23 Crankshaft
REAR MAIN SEAL
E3
1.
CLEANING, INSPECTION AND REPAIR
CYLINDER BLOCK
Rear main seal from crankshaft (32).
Tool Required:
CAMSHAFT BEARINGS
J 8087 Cylinder Bore Checking Gage
Figure 24
11
Tool Required:
Camshaft
J 33049
Remover/Installer
E3
Bearing
1.
Camshaft cover bolts (77), cover (76) and

gasket (75).
Camshaft bearings (101).
2.
A. Select the proper expander assembly and

driving washer.
B. Assemble J 33049. Tighten the expander
assembly snug with the camshaft bearing.
C. Drive out bearings.
[II
1. Oil filter adapter bolt (43).

2.
3.
4.
5.
6.
7.
8.
9.
[II
Important
Camshaft bearings (101) must not be re-used

after they have been removed.
Disassemble
Oil filter adapter (41) and gasket (40).

Knock sensor.
Ignition timing sensor retaining bolt (66) and
sensor (67) .
Camshaft sensor retaining bolt (95).
Camshaft sensor (96).
Coolant jacket plugs (74).
Coolant jacket threaded plugs (69 and 70).
Oil gallery plugs (64, 65, 78 and 79).
Important
Caustic cleaning solution destroys the bearing

material. All bearings must be replaced after
cleaning with a caustic solution. Do not clean
bearing material or aluminum parts with caustic
solutions.
Clean
Sealing material from mating surfaces.

Boil in caustic solution.
-
EXPANDER ASSEMBLY
DRIVE BAR
B
C
BEARING, CAMSHAFT
DRIVING WASHER
E
F
GUIDE CONE
DRIVE BAR HANDLE
ILI
P0019-6A5B-ALNW-RA
Figure 24 Removing/Installing Camshaft Bearings
Flush with clean water or steam.
Oil passages.
All blind holes.
Spray or wipe cylinder bores and machined
surfaces with engme oil.
Inspect
Check surface for flatness. Use a straight edge

and a feeler gage (Figure 26). If the cylinder
head deck flatness exceeds O.lmm (0.004 inch),
the surface should be machined flat. If more than
0.25 mm (0.010 inch) must be removed, replace
the block.
Oil pan rail and timing cover attaching area for
nicks. Minor irregularities may be cleaned up
with a flat mill file.
Head bolt tapped holes.
Transaxle case mating surface.
NOTICE: If this surface is not flat, a broken

flywheel may result.
64
65
\
69_-..l,,J/
71
I VIEWA I
71
64
65
69
70
71
78
79
PLUG, OIL GALLERY

PLUG, OIL GALLERY
71
PLUG, COOLANT DRAIN
78
PLUG, COOLANT DRAIN

BLOCK, ENGINE
79
I VIEW BI
PLUG, OIL GALLERY

PLUG, OIL GALLERY
P0021-6A2B-F-RA
Figure 25 Engine Block
Temporarily install the crankshaft. Measure

crankshaft flange run-out. Refer to "Crankshaft"
in Cleaning, Inspection and Repair of this
section.
STRAIGHT EDGE
FEELER GAGE
P0022-6A2B-F-RA
Figure 26 Measuring Cylinder Block for Flatness
!@!
Measure
Cylinder block flange surface runout at six

mounting hole bosses (Figure 27).
1. Hold gage plate flat against the crankshaft
flange (Figure 27).
2. Place dial indicator stem on the transaxle
mounting bolt hole boss (Figure 28) and
set indicator to 0.
3. Take and record the readings obtained on
the remaining transaxle mounting bolt hole
bosses (Items A-F, Figure 27).
Measurements should not vary more than
0.25 mm (0.010 inch).
4. If the readings vary more than 0.25 mm
(0.010 inch), recheck crankshaft flange
run-out. If the run-out is excessive, replace
the crankshaft.
2.
Camshaft and Crankshaft bearing bores, using

J 8087, measure concentricity and alignment.
3. Cylinder bore, with J 8087 measure for wear,
taper, run-out and ridging (Figures 29 and 30).
rn
P0023-6A2B-F-RA
Figure 27 Transaxle Mounting Surface Checking

Points
If the bore is worn out of specifications, it

may be rebored, honed and fitted with
oversize pistons. The smallest available
oversize should be selected. Refer to
"Pistons and Connecting Rods" in
Cleaning, Inspection and Repair of this
section.
Important
Leave sufficient material to allow finish

honing in conjunction with fitting the
piston.
If the bore is glazed but otherwise
serviceable, break the glaze lightly with a
hone and replace the piston rmgs.
Make sure the honing stones are clean,
sharp and straight. Move the hone slowly
up and down to produce a cross-hatch
pattern. Clean bore thoroughly with soap
and water. Dry and rub in clean engine
oil; then measure.
Figure 28 Measuring Transaxle Mounting Surface
llI
1.
Figure 29 Measuring Cylinder Bore
Inspect
Threaded holes. If necessary, clean with a tap or

drill out and install thread inserts. Refer to
"Thread Repair" in Cleaning, Inspection and
Repair of this section.
II]
Important
The following inspections as well as

reconditioning, if necessary, must be
carried out with the main bearing caps
installed and tightened to specification.
Make sure main bearing caps are installed
correctly, with the arrows pointing toward
the front of the engine.
J10286-6A-W
Figure 30 Cylinder Wear Pattern
THREAD REPAIR
CRANKSHAFT
Figure 31
Figure 23
Damaged threads may be reconditioned by drilling out, rethreading and mstalling a suitable thread
insert.
CAUTION: Wear safety glasses to

avoid eye damage.
1. Determine size, pitch and depth of damaged
thread. If necessary, adjust stop collars on
cutting tool and tap to the required depth.
ILI
II]
Important
Refer to the kit manufacturer's

instructions regarding the size of the drill
and tap to be used.
Refer to Figure 31-A.
3. Tap hole. Lubricate tap with light engine oil.
Clean the thread. Refer to Figure 31-B.
II]
Important
Avoid build-up of chips. Back out the tap

every few turns and remove chips.
4. Thread the thread insert onto the mandrel of the
installer (Figure 31-C). Engage the tang of the
insert onto the end of the mandrel.
5. Lubricate the insert with light engine oil (except
when installing in aluminum) and install. Refer
to Figure 31-D.
[I]
Clean
Oil, sludge and carbon.

Probe oil passages for obstructions.
Inspect
Keyway.
Threads.
Bearing journals and thrust surfaces for:
Cracks.
Chips.
Gouges.
Roughness.
Grooves.
Overheating (discoloration).
Corresponding bearing inserts for embedded
foreign matenal and determine its source.
[l]
Important
If cracks, severe gouges or burned spots

are found, the crankshaft must be
replaced. Slight roughness may be
removed with a fine r.olishing cloth
soaked in clean engine 011. Burrs may be
removed with a fine oil stone.
Important
6.
When correctly installed, the insert should

be flush to one turn below the surface.
If the tang of the insert does not break off when
backing out the installer, break the tang off with
a drift pin.
A
DRILL HOLE TO
PROPER SIZE
TAP HOLE TO
PROPER SIZE
INSTALL INSERT
ON MANDREL
INSTALL INSERT INTO

NEWLY THREADED HOLE
J10289-6A-W
Figure 31 Repairing Threaded Holes
IGI
Measure
Crankshaft journals. With a micrometer measure

taper and run-out. If the readings are within
specifications. Refer to "Engine Specifications"
in this section, note results for later selection of
bearing inserts. If not within limits, the
crankshaft must be replaced.
[I]
Important
Note the location of main bearing high

spots. If they are not in line, the
crankshaft is bent and must be replaced.
PISTONS AND CONNECTING RODS
Clean
Piston (86), piston pin (85) and connecting rod

(83) of:
Sludge.
Carbon.
It is essential that the piston ring

grooves are cleaned of carbon to the
bare metal.
Varnish from the piston pin (85) by
soaking in carburetor cleaning solution.
Do not scrape the piston skirt.
Tool Required:
J 24086-B Piston Pin Remover/Installer
l+;+I
Disassemble
CAUTION: Use care when handling

the piston. Worn piston rings are sharp
and may cause bodily injury.
1.
2.
J 24086-SA
Eiston rings (87, 88 and 89). Use a suitable tool

to expand the rings. Piston rings must not be
re-used.
Place the I?iston (86) and connecting rod (83)
assembly mto J 24086-B and press out the
piston pm. Refer to Figure 32. Be sure the flat
side or inside of piston is up when installing
piston and rod assembly into fork.
[I]
Important
Make sure no load is put on piston (86)

during disassembly.
CAUTION: Avoid inhaling fumes or

exposure of the skin to carburetor
cleaning fluid, as bodily injury may result.
Figure 32 Removing Piston Pin
A GAGING POINT
B SIZING POINT
B
B
A
PISTON GAGING POINTS
BORE GAGING POINTS
P0024-6A2B-F-RA
Figure 33 Cylinder Bore and Piston Gaging Points
!L!
Piston to Bore Clearance
Inspect
1. Connecting rod (83) for:
Bending or twisting.
A. Install the connecting rod cap (81 ).
B. Place the connecting rod assembly
(83) on a checking fixture and check
for bending or twisting.
[I]
Do not attempt to straighten the

connecting rod.
The connecting rods should not
be bent more than 0.007 inch for
every three inches of rod length.
The connecting rods should not
be twisted more then 0.0015 inch
for every inch of rod length. If
bent or twisted, replace.
!(Q!
1.
Check new connecting rods

before using them.
2.
Piston pin (85) for:
3.
Outside of the connecting rod bearing and

the ID of the connecting rod lower end for
wear indicating high spots in the
connecting rod lower end.
Upper end for scoring.
Scoring.
Galling caused by improper installation.
Fit in connecting rod and piston.
Scoring of the skirt.
Cracks.
Broken ring groove lands.
Wear.
When fitting pistons, both piston and cylinder

bore condition must be considered together.
Production and service pistons have the same
nominal weight and can be intermixed without
affecting engine balance. If necessary, used
pistons may be fitted selectively to any cylinder
of the engine, providing they are in good
condition and the same weight.
Do not cut oversize pistons down or engine
balance will be affected.
Measure
Piston diameter. When measuring piston for

size or taper, measurement must be made as
shown with the piston pin removed (Figure 34).
If worn or damaged, replace with a standard or
oversize piston.
[I]
2.
3.
4.
Piston (86) for:
Important
5.
Important
Finish hone when selecting piston.
Cylinder bore (Figure 33), with a telescoping

gage. If "".orn beyond specifications, re bore and
hone to size.
Subtract piston diameter from cylinder bore
diameter to determine piston-to-bore clearance.
Compare piston-to-bore clearance with
specifications in "Engine Specifications" of this
section to determine if clearance is in acceptable
range.
If used piston is not accel?table, check service
piston sizes and determine if a new piston can be
selected. (Service pistons are available in
standard, and several oversizes.)
6.
7.
If cylinder bore must be reconditioned, measure

new piston diameter then hone cylinder bore to
correct clearance.
Select new piston and mark piston to identify
the cylinder for which it was fitted.
A FEELER GAUGE
89 PISTON RING
MEASURE RING GAP CLEARANCE WITH RING
POSITIONED AT BOTTOM RING TRAVEL AS SHOWN
Figure 35 Measuring Piston Ring Gap
Piston Ring Side Clearance
[I]
P01006A2B-F-RA
Do not attempt to cut the ring groove, although

high spots in the ring groove may be cleaned up
by careful use of a point file.
Figure 34 Measuring Piston
Piston Pin Bore-to-Piston Pin Clearance
!@!
1.
2.
3.
4.
5.
Measure
Measure the piston pin bore diameter with an

inside micrometer.
Measure the piston pin diameter with a
micrometer.
Important
!@!
Measure
1. Piston compression ring side clearance.

2. Roll the piston ring around the groove in wh!ch
it is to be installed and measure the side
clearance (Figure 36). If the r_ing is to~ t_hic~, try,
another ring. Refer to "Engme Spec1ficat1ons
in this section for specifications.
Subtract piston pin bore diameter from piston

pin diameter to determine clearance.
Compare clearance with Specifications in
"Engine Specifications" of this section to
determine if clearance is in acceptable range.
If it is not acceptable, replace piston assembly.
Piston Compression Ring End Gap
[I]
!@!
1.
2.
3.
4.
89 TOP COMPRESSION RING

A INSERT FEELER GAUGE AT TOP OF
RING GROOVE TO MEASURE RING SIDE
P0026-6A2B-F-RA
CLEARANCE
Important
Do not reuse piston rings. Fit rings to match the

cylinder they will be used in.
Figure 36 Measuring Piston Ring Side Clearance
Measure
Place piston into the cylinder at the bottom of

the ring travel.
Place a piston ring on top of the piston.
Back off the piston.
Measure the ring gap (Figure 35). If the gap is
below specification, increase the gap by
carefully filing off excess material.
!+!+!
Assemble
[I]
Important
Make sure that the arrow on top of the piston

faces towards the front of the engine.
1. Place piston (86) and connecting rod (83) into

J 24086-B (Figure 37).
2.
3.
Coat the piston pin (85) with clean engine oil.

Press the piston pin (85) into place.
l~I
4.
Oil control ring assembly (87).
Inspect
Piston (86) for freedom of movement.
Expander.
Lower oil control ring.
Upper oil control ring.
NOTICE: Use a piston ring expander to install

the rings. Avoid expanding the rings more than
necessary, which may cause ring damage.
5.
Upper and lower compression ring (88 and 89).

Manufacturer's mark facing up.
IT]
Important
In order to provide an effective

compression seal, the ring gaps must be
staggered (Figure 39).
ENGINE LEFT
ENGINE FRONT
ENGINE RIGHT ~
B---,
MC0015-6A4-A-RA
Figure 37 Installing Piston Pin
c--
--AD
B--A OIL RING SPACER GAP

(TANG IN HOLE OR SLOT WITH ARC}
B OIL RING RAIL GAPS
C 2ND COMPRESSION RING GAP
O TOP COMPRESSION RING GAP P0028-6A2B-F-RA
Figure 39 Piston Ring Gap Locations
86
85
80
MAIN BEARING AND ROD BEARING

SELECTION
83
84
85
86
87
88
89
ROD - CONNECTING
BOLT
PIN - PISTON
PISTON ASM.
RING-OIL CONTROL
RING - PISTON COMP. LWR.
RING - PISTON COMP. UPR.
P0027-6A2B-F-RA
Figure 38 Piston and Rod Assembly
Evaluate bearings as specified in this section. If
the engine is out of the vehicle and upside down, the
crankshaft will rest on the upper bearings and the total
clearance can be measured between the lower bearing
and journal. If the engine is to remain in the vehicle,
the crankshaft must be supported upward to remove
any clearance from the upper bearing. The total clearance can then be measured between the lower bearing
and journal.
Engine bearings are of the precision insert type.
They are available for service use in standard and
various undersizes (Figure 40).
NOTICE: Bearing inserts must not be
shimmed, scraped or filed. Do not touch the bearing surface of the insert with bare fingers. Skin
oil and acids will etch the bearing surface.
I~(,,
A
A AMOUNT UNDERSIZE
STAMPED AT EITHER
END (.016, .032)
o~o
0
P0029-6A2B-F-RA
1.
Inspect
Bearing surfaces for:
2.
3.
Thrust surfaces (main thrust bearing) for:
[I]
4.
!G!
Wear.
Gouges.
Embedded foreign material. If foreign
material is found, determine its nature and
source. Inspect oil pan sludge and
residue.
Uneven side-to-side wear. If uneven wear
is found, check for a bent crankshaft or
tapered bearing journals.
Wear. Surface wear indicates either
movement of the insert or high spots in
the surrounding material (spot wear).
Overheating (discoloration).
Looseness or rotation (flattened tangs and
wear grooves).
Wear.
Grooving. Grooves are caused by
irregulanties of the crankshaft thrust
surface. Refer to "Crankshaft" in
Cleaning, Inspection and Repair of this
section.
Bearing clearance. To determine the correct

replacement insert size, the bearing clearance
must be measured accurately. Either of the
followin~ two methods may be used, however,
method 'A" gives more reliable results and is
preferred.
Important
Method "A" yields measurement from

which the bearing clearance can be
computed. Method "B" yields the
bearing clearance directly. Method "B"
does not give any indication of bearing
run-out.
Do not mix inserts of different nominal
size in the same bearing bore.
Method "A"
1. Measure the journal diameter with a micrometer
in several places, approximately 90 apart, and
average the measurements.
2. Measure taper and run-out. Refer to "Engine
Specifications" for allowable limits.
3. Install bearing inserts and tighten bearing cap
bolts or nuts to specification. Measure ID with
an inside micrometer.
II]
Bearing failure, other than normal wear,

must be investigated carefully. Inspect the
crankshaft or connecting rod and the
bearing bores.
A. Tighten the bearing cap to specifications.

B. Measure the bore for taper and out of
round (Figure 41).
C. No taper or out of round should exist.
Measure
II]
Important
Connecting rods or main bearing bores as

follows:
Figure 41 Measuring Bearing Bore
Outer surfaces for:
P0030-6A2B-F-RA
Figure 40 Main Bearing Insert Markings
!L!
CYLINDER BLOCK
4.
Important
The bearing cap must be tightened to

specification wlien the measurement is
taken.
Measure the connecting rod ID in the
same direction as the length of the rod.
Select a set of bearing inserts that will produce

the desired clearance, refer to "Engine
Specifications" in this section. If the specified
clearances cannot be met, the crankshaft journal
must be re-conditioned and undersized bearing
inserts installed. Replace both bearing shells
as a set.
OIL PUMP UNIT REPAIR
Method "B"
1. Clean and install the used bearing inserts.

2. Place a piece of gaging plastic across the entire
Figure 43 through 48
Tool Required:
bearing width.
NOTICE: In order to prevent the possibility of

cylinder block and/or main bearing cap damage,
the main bearing caps are to be tapped into their
cylinder block cavity using a brass or leather mallet before attaching bolts are installed. Do not use
attaching bolts to pull main bearing caps into
their seats. Failure to observe this mformation
may damage a cylinder block or bearing cap.
3.
4.
Seat the bearing cap carefully by tapping it

lightly with a suitable tool.
Bearing cap bolts or nuts.
l~I
II]
5.
6.
7.
8.
J 21882 Oil Suction Tube Installer
l:I
1. Drain oil from pump.

2.
Do not remove pickup tube from cover

unless loose or broken.
CAUTION: The pressure regulator

valve spring in some models is under
pressure. Exercise caution when removing the retaining pin, as bodily injury
may result.
5. Pressure regulator valve.
Do not rotate the crankshaft.
bearing shells as a set.
Important
3. Pump cover bolts and cover.

4. Pump gears.
Important
Remove the bearing cap, leaving the gaging

plastic in place. It does not matter whether the
gagi!lg plastic adheres to the journal or to the
beanng cap.
Measure the gaging plastic at its widest point
with the scale printed on the gaging plastic
package (Figure 42).
Remov~ all traces of the gaging plastic after
measunng.
Select a set of bearing inserts that will produce
the desired clearance refer to "Engine
Specifications" in this section. Replace both
Drive shaft (18).
(I]
Tighten
Main bearing cap bolts (19) evenly to

50 Nm (37 lb. ft.).
Turn main bearing cap bolts (19) evenly
an additional 77 using J 36660.
Rod cap nuts (80) evenly to 50 Nm
(37 lb. ft.).
Disassemble
Cotter pin.
Spring.
Valve. If the valve is stuck, soak the
pump housing in carburetor cleaning
solvent.
CAUTION: Avoid breathing of fumes

or exposure of the skin to the cleaning
solvent, as bodily injury may result.
llI
Clean
All parts of sludge, oil and varnish.

Varnish may be removed by soaking m
carburetor or cleaning solvent.
Inspect
For foreign material and determine source.

Pump housing and cover for:
Cracks.
Scoring.
Casting imperfections.
Damaged threads.
Do not attempt to repair the pump housing.
If in doubt, replace the spring.
Figure 42 Measuring Bearing Clearance
Idler gear shaft. If loose in the housing, replace

the pump.
Pressure regulator valve for:
Scoring.
Sticking. Burrs may be removed with a
fine oil stone.
Pressure regulator valve spring for:

Loss of tension.
Bending.
Looseness, if permanently pressed into the

pump body. If the suction pipe is loose,
bent or has been removed, the pump body
cover and suction pipe must be replaced.
Broken wire mesh or screen.
Looseness.
Wear.
!@!
Measure
Refer to "Engine Specifications" in this section

for Specifications.
Gear lash. Install gears, and measure in several
places (Figure 44).
Pump housing gear pocket (Figure 45).
Gears (Figure 46).
Gear side clearance (Figure 47).
Gear end clearance (Figure 48).
II]
!+!+!
1.
2.
5.
6.
!L!
1.
Important
Make sure the cotter pm is properly

secured.
Cotter pin.
Apply seal~r GMcf/n 1950026 (or ~quivalent),
to a new pipe, an tap mto place with a plastic
hammer, using J 21882.
[I]
Gears for:
Chipping.
- Galling.
- Wear.
Drive shaft and drive shaft extension for:
Pressure regulator valve and spring.
[I]
Suction pipe and screen assembly for:
4.
Important
Whenever the oil pump is overhauled,

clean the oil pan of oil and sludge; replace
the oil filter; and fill crankcase with clean
oil.
Inspect
Oil pressure as follows:
A.
Prime engine oil galleries by removing

engine oil pump drive unit and rotate 011
pump drive shaft using drill motor and
appropriate socket and extension.
B. Remove the oil pressure sending unit and
install a pressure gage.
NOTICE: If the oil pressure does not build up

almost immediately, remove the oil pan and
check oil pump suction pipe attachment to the
pump. Running the engine without measurable
oil pressure will cause extensive damage.
A PUMP BODY
B IDLER GEAR AND DRIVE GEAR
Important
C PUMP COVER
D PRESSURE REGULATOR VALVE
E PRESSURE REGULATOR SPRING
When deciding pump serviceability based

on end clearance, consider depth of wear
pattern in the pump cover.
Assemble
Lubricate all internal parts with engme oil

during assembly.
Pump gears.
NOTICE: To avoid engine damage, use only

original equipment gaskets. The gasket thickness
is critical to proper functioning of the pump.
3. Cover and gasket.
!~J
Tighten
Pump cover bolts to 10 Nm (89 lb. in.).
F~-c=)
WI
c
P0031-6A2B-F-RA
Figure 43 Oil Pump
Figure 44 Measuring Oil Pump Gear Lash
Figure 47 Measuring Gear Side Clearance
DEPTH OF POCKET
DIAMETER OF POCKET
A
Figure 45 Measuring Oil Pump Gear Pocket
Figure 48 Measuring Oil Pump End Clearance
CYLINDER HEAD RECONDITIONING

A LENGTH OF GEAR
B DIAMETER OF GEAR
P0033-6A28-F-RA
Figure 46 Measuring Oil Pump Gears
Tools Required:
J 8062 Valve Spring Compressor.
J 8101 Valve Guide Cleaner
J 9666 Valve Spring Tester
J 37377 Valve Guide Reamer 0.089 mm
(0.003 inch) OS.
(0.015 inch) OS.
(0.030 inch) OS.
[I]
Ft3
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
Important
Before removing the cylinder head(s) from the

engine and before disassembling the valve
mechanism, perform a compression test and note
the results.
During disassembly of the cylinder head, be sure
that the valve train components are kept together
and identified so that they can be installed in
their original locations.
16.
@----138
130--
128
Spark plugs (221).

Right cylinder head engine lift hook bolts (201 ).
Engine lift hook (200).
Intake manifold mounting stud (140).
Rocker cover studs (196).
Compress the valve springs (128 and 135) using
J 8062.
Valve locks (131 and 139).
Valve caps (130 and 138).
Exhaust valve oil shedders (137).
Valve springs (128 and 135) and dampers
(127 and 134).
Spring shims (133), if equipped.
Intake valve stem oil seals (126).
Valve stem 0-rings (129 and 136).
-137
---
@)
129
Disassemble
NOTICE: Avoid damaging the valve guide. If

the valve stem has mushroomed due to wear from
the rocker arm, remove burrs by chamfering the
valve stem with an oil stone. Do not remove the
valve from the guide with a hammer and punch.
14.
15.
@~139
~
---"""l@l'.n
136
~135
~127
125
132
134
126
EXHAUST
INTAKE
125
126
127
128
129
130
131
INTAKE VALVE
OIL SEAL
132
134
DAMPER
VALVE SPRING
135
0-RING
CAP
136
137
138
KEY
139
EXHAUST VALVE
DAMPER
VALVE SPRING
0-RING
OIL SHEDDER
CAP
KEY
P0035-6A2B-F-RA
Figure 50 Valves and Components
ILI
Inspect
Cylinder head gasket and mating surfaces for

leaks, corrosion and blow-by. If the gasket has
failed, determine the cause:
A. Improper installation.
B. Loose or warped cylinder head.
C. Missing, off location or not fully seated
dowel pins.
D. Low torque on cylinder head bolts.
E. Warped case (block) surface.
F. Scratched surfaces.
G. Excessive inlet manifold torque.
H. Cracked engine block tapped holes.
Valves (125 and 132).

Rocker arm studs (121) and pushrod guide
plates.
Water jacket plugs.
Clean
CAUTION: Safety glasses must be

worn when using a power wire brush to
avoid damage to the eyes.
1.
2.
----
113
CYLINDER HEAD
P0034-6A2B-F-RA
Figure 49 Compressing Valve Spring

Cylinder head (113). Carefully remove all
varnish, soot and carbon to the bare metal. DO
NOT use a motorized wire brush on any gasket
sealing surface.
3. Valve guides as shown in Figure 51.
4.
Valves (125 and 132) of carbon, oil and varnish.
5.
6.
Carbon can be removed with a wire brush.

Remove varnish by soaking in carburetor
cleaning fluid.
Do not scratch the valve stem with the
wire brush.
Threaded holes.
Remains of sealer from plug holes.
4.
5.
6.
7.
/~\'1.
Illll
/<le
VALVE GUIDE
CLEANER
BT-6415
OR
J-8101
J10251-6A-W
Figure 51 Cleaning Valve Guide
!l!
1.
Inspect
Cylinder head bolts (115) for damaged threads

or stretching, and damaged heads caused by
improper use of tools.
[II
2.
3.
Important
Suspect bolts must be replaced.

Cylinder head (113) for cracks, especially
between valve seats and in the exhaust ports.
Cylinder head deck for corrosion, sand particles
in head, and porosity.
[II
Cylinder head deck, intake and exhaust

manifold mating surfaces for flatness as shown
in Figure 52. These surfaces may be
re-conditioned by milling. If the surfaces are
"out of flat" by more than O.lmm (0.004 inch),
the surface should be milled. If more than
0.25 mm (0.010 inch) of metal must be removed
from the head, it should be replaced.
All threaded holes for damage. Threads may be
reconditioned with thread inserts. Refer to
"Thread Repair" in this section.
Cooling jacket plugs seating surfaces.
Valve seats for excessive wear and burned
spots.
Important
Do not attempt to weld the cylinder head,

replace it.
Since the valve guide serves to support

and center the valve grinder, it is essential
that the valve guide is cleaned properly. If
the valve guide requires reaming, measure
valve guide clearance to determine if an
oversized valve will be required. This
procedure must be performed before
valve seats can be reconditioned.
If a burnt valve condition exists, it may be
necessary to recondition the valve seat. At
no time should there be less than 4 mm of
valve seat material remaining after
reconditioning.
Valve seats may be reconditioned by
grinding. Follow the grinder
manufacturer's instructions. Refer to
"Engine Specifications" in this section for
seat angles. If, after grinding, the new
seat is too wide, it may be narrowed by
using a 70 stone. The 70 stone will raise
the seat.
8. Valve stem tip for wear.
9. Valve lock (131 and 139) and oil seal grooves
for chipped or worn lands. Replace the valve if
chipped or worn.
10. Valve face for burning or cracking. If pieces are
broken off, inspect the corresponding piston and
cylinder head area for damage.
11. Valve stem for burrs and scratches. Burrs and
minor scratches may be removed with an oil
stone.
12. Valve stem for straightness and valve head for
bending or distortion. Use "V" blocks. Bent or
distorted valves must be replaced.
13. Valve face for grooving. If the groove is so deep
that refacing would result in a knife edge, the
valve must be replaced.
14. The valve face may be ground to specifications
if it is otherwise in good condition. If the valve
face cannot be grounded within the limits given,
it must be replaced. Refer to "Engine
Specifications" in this section.
15. Valve spring dampers (127 and 134) for broken
pieces or cracks. Replace if damaged.
16.
Valve springs (128 and 135).
17.
Free length.
Spring ends. If they are not parallel, the
spring is bent and must be replaced.
Spring tension (load open and load
closed). If below specification, replace.
For cracks or breaks.
Valve spring seating surface of the spring caps
for wear, cracks or gouging. Replace as
required.
MC0044-6A1-W-RA
Figure 54 Checking Valve Spring Tension
!~!
Figure 52 Checking Cylinder Head Flatness
.-:..:.-..:
:::< ..
. . . . ....
. .~
..
. . .
.. .
..
. ... .
...
. .. ......
/ ~ ..
K37898-6A7-JN
Figure 53 Checking Valve Springs
Measure
1. Valve margin after grinding valves. If the

margin is less than the minimum recommended
margin, replace the valve.
2. Valve seat margin and runout. If the margin is
less than the minimum recommended margin,
replace the cylinder head.
3. Valve guide clearance.
Insert the valve into its guide. Lift it 2 mm
(1/8 inch) off the seat and move it side to
side, measuring the amount of movement
with a dial indicator, or
With a hole gage, measure the valve guide
ID, then measure the valve stem with a
micrometer and compare the clearance.
Refer to "Engine Specifications" in this
section for allowable clearances.
NOTICE: Avoid breaking reamer flutes or jamming the reamer into the valve guide due to packing of chips or carbon. Clean the valve guides
before reaming.
The valve guides may be reamed oversize and an
oversized valve installed (Figure 56).
5.
Intake valve stem oil seals (126).
IT]
MC0010-6A4-A-RA
Figure 55 Measuring Valve Guide Clearance
Clean all traces of Prussian blue. Apply a

dab of Prussian blue on the valve seat and
repeat the check. The traces of Prussian
blue transferred to the valve indicates
valve run-out. Recondition valve seat/face
or replace valves as required.
Important
Push the valve stem seals down as far as

possible. If oversize valves have been
mstalled, oversized valve stem must be
used.
A. Use plastic sleeve provided.

B. Press over valve guide boss.
6.
7.
8.
J 37377, J37378,
OR J 37379
Spring shim (133), if required.

Valve stem 0-rings (129 and 136).
Valve spring dampers (127 and 134) and springs
(128 and 135).
9. Exhaust valve oil shedders (137).
10. Valve caps (123 and 138).
11. Compress the valve springs (128 and 135) using
J 38606.
12. Valve locks (131 and 139).
DrJ[JtJ
14.
!~I
Tighten
Studs (121) to 46 Nm (35 lb. ft.).

4. Valves (125 and 132).
l~I
Measure
Valve run-out. Lift the valve off its seat

and apply a dab of Prussian blue on the
valve face. Seat the valve and carefully
rotate it. The Prussian blue traces
transferred to the valve seat are an
indication of concentricity of the valve
seat.
16.
Tighten
Studs (196) to 12 Nm (106 lb. in.).

Intake manifold mounting studs (140).
l~I
Tighten
Plug to 21 Nm (15 lb. ft.).

3. Pushrod guide plates and rocker arm studs
(121).
l~I
15.
Inspect
Make sure valve locks are seated.

l~I
Assemble
1. Lightly lap the reconditioned valves into the

valve seat.
2. Cooling jacket plugs. Coat plugs with sealer
GM p/n 1050026 (or equivalent).
Release valve springs (128 and 135).
ILI
MC0011-6A4-A-RA
Figure 56 Reaming Valve Guide
liI
13.
If necessary, hold valve locks in place

with grease.
Tighten
Studs (140) to 10 Nm (89 lb. in.).

Right cylinder head engine lift hook (200) and
bolts (201).
l~I
Tighten
Bolts (201) to 32 Nm (24 lb. ft.).

NOTICE: To avoid damage, install spark plugs
(221) after the cylinder head has been installed on
the engine block assembly.
CAMSHAFT INSPECTION
Figure 57 and 58
A CAMSHAFT JOURNALS
B MICROMETER
Tool Required:
J 26900-12 Dial Indicator
J 26900-13 Magnetic Base
!L!
rn
!@!
1.
Inspect
rn
P00366A2BFRA
Figure 57 Measuring Camshaft Journals
Important
Do not attempt to repair the camshaft, replace it

if damaged.
If a new camshaft is installed, all valve lifters
must be replaced.
Measure
Bearing journals.
2.
Sprocket.
Keyway and threads.
Bearing surfaces and lobes for:
Wear.
Galling.
Gouges.
Overheating (Discoloration).
With a micrometer, measure diameter and

run-out. If out of specification, replace
the camshaft.
A
Camshaft lift.
A. Lubricate the camshaft bearings with GM
Camshaft and Lifter Prelube p/n 1052365
(or equivalent).
B. Carefully set the camshaft on "V" blocks
or between camshaft centers.
C. Install J 26900-12 and J 26900-13.
D. Measure camshaft journal run out and lobe
lift (Figure 57 and 58). If out of
specification, replace the camshaft.
Important
If a new camshaft is being installed, add

Camshaft and Lifter Prelube GM p/n 1052365
(or equivalent) to the engine oil.
Coat cam lobes with Camshaft and Lifter
Prelube GM p/n 1052365 (or equivalent).
CAMSHAFT JOURNALS
Figure 58 Measuring Cam Lift and Journal Runout

Figure 71
!L!
Inspect
Camshaft and crankshaft sprockets (98 and 26)

for wear or knicks.
Key and crankshaft keyway for wear or nicks.
Timing chain (25) for wear or binding.
ENGINE FRONT COVER

Figure 73
Tool Required:
J 34995 Oil Seal Installer
!:+!
Disassemble
1. Crankshaft position sensor screws (56).

2. Crankshaft position sensor (57).
3. Front cover oil seal (58).
Pry out carefully with a suitable tool.
ILI
l+t+I
Clean
VALVE LIFTERS
Engine front cover mating surfaces.
Figure 59
Inspect
Front cover oil seal (58) for damage.

Cracks or knicks.
Assemble
1. Front cover oil seal (58) using J 34995.

2. Crankshaft position sensor (57).
3. Crankshaft position sensor screws (56).
l~I
Tighten
Sensor screws (56) to 10 Nm (89 lb. in.).
Valve lifters should be kept in order so they may

be installed in their original position.
If the lifters are removed, they must be installed
in their original location. If replacement is necessary,
use lifters with a narrow flat ground along the lower
3/4 of lifter. These flats provide additional oil to the
cam lobe and lifter surfaces.
ILI
Inspect
Lifter body for wear and scuffing.

Lifter bore for wear.
Lifter pushrod seat for wear.
OIL PAN
[I]
Figure 17
l:+I
Disassemble
Important
Whenever new valve lifters are being

installed, coat foot of valve lifters with
camshaft and lifter I?relube GM p/n
1052365 (or equivalent).
1. Low oil level indicator (15).
ILl
l!+l
Clean
Oil l?an (1) in solvent. Remove all sludge and

varmsh.
Gasket surfaces.
Inspect
Gasket flanges for bending or damage.

Oil pan (1) for cracks or dents.
Assemble
1. Low oil level indicator (15).
l~I
Tighten
Indicator (15) to 22 Nm (16 lb. ft.).
2. Oil drain plug (9) and washer (8).
l~I
Tighten
Oil drain plug (9) to 25 Nm (18 lb. ft.).
COOLANT PUMP
Figure 74
ILI
Clean
Coolant pump (54) mating surface.

Inspect
Coolant pump shaft for looseness.
A
B
C
D
E
F
PLUNGER
LIFTER BODY
CHECK BALL SPRING
PLUNGER RETURN SPRING
CHECK BALL (CLOSED)
CHECK BALL (OPEN)
93
PUSHROD
P0038-6A2B-F-RA
Figure 59 Valve Lifter Operation
VALVE ROCKER ARMS AND PUSHRODS
Figure 13
Figures 11 and 60
!l!
!t3
Inspect
Rocker arms (122) and balls (123) for wear at

rotation surfaces.
_Pushrod (93) ends for wear.
Pushrod (93) for bends.
VALVE ROCKER COVERS
1.
2.
Disassemble
Clean
Inspect
Gasket surfaces.
Manifold bolts and studs.
Assemble
Vacuum tee.
Emission control vacuum harness assembly
3.
4.
Canister purge solenoid (178).

MAP sensor screws (160) and MAP sensor
(158).
5. Throttle body gasket (163), throttle body (164)
and bolts (165).
Rubber grommets.
Oil fill tube (188) and bolt (189).
Clean
(172).
Assemble
!~!
1.
2.
Gasket flanges for damage.

Rubber grommets for deterioration.
!t!
!t!
Valve rocker cover gasket surfaces.
!l!
1.
2.
5. Vacuum tee.
Oil fill tube bolt (189) and oil fill tube (188).
Rubber grommets.
1. Throttle body bolts (165), throttle body (164)

and gasket (163).
2. MAP sensor screws (160) and MAP sensor
(158).
3. Canister purge solenoid (178).
4. Emission control vacuum harness assembly
(172).
Figure 12
!t3
Disassemble
!~!
Tighten
Oil fill tube bolt (189) to 8 Nm

(71 lb. in.).
Tighten
Apply sealer GM p/n 1052080 to threads
of throttle body bolts.
Throttle body bolts (165) to 25 Nm
(18 lb. ft.).
155
163
165
164

BODY, THROTTLE
165
STUD, THROTTLE BODY
165
BOLT, THROTTLE BODY

P00396A2B-F-RA
~165
Figure 60 Throttle Body

Figure 14
lJ
1:
2.
3.
4.
5.
6.
I!+!
Disassemble

Thermostat housing bolts (146).
Thermostat housing (147) and gasket.
Thermostat (148).
Heater inlet pipe nipple (149).
Clean
Intake manifold gasket surfaces.

Injector bores.
Intake manifold bolts and studs.
2.
!~!
Apply teflon sealant GM p/n 1052080 to

threads of plugs.
Coolant drain plugs to 19 Nm(14 lb. ft.).
3. Coolant plugs (74).
Apply sealant GM p/n 12345493 to
outside edge of coolant expansion plugs
(74).
4. Camshaft position sensor (96).
5. Camshaft position sensor retaining bolt (95).
!~!
1. Heater inlet pipe nipple (149).

Tighten
6.
Apply teflon sealant to threads of pipe

nipple (149).
Pipe nipple (149) to 14 Nm (124 lb. in.).
2. Engine coolant temperature sensor (145).
threads of sensor (145).
Sensor (145) to 13 Nm (115 lb. in.).
3. Thermostat (148).
4. Thermostat housing gasket and housing (147).
5. Thermostat housing bolts (146).
!~!
Apply sealer GM p/n 1052080 to threads

of knock sensor.
Knock sensor (68) to 19 Nm (14 lb. ft.).
8. Oil filter adapter (41) and gasket (40).
9. Oil filter adapter bolt (43).
!~I
10.
Studs (196) to 12 Nm (106 lb. in.).
CYLINDER BLOCK
!~!
Tighten

threads of plugs.
Filter (45) to 13 Nm (115 lb. in.).
Figure 61
Tool Required:
J 33049
Camshaft
Remover/Installer
Install or Connect
1. Oil gallery plugs (64 and 65).
Tighten
CAMSHAFT BEARINGS
Figure 1
l+I
Tighten
Bolt (43) to 68 Nm (50 lb. ft.).

Oil filter (45).
!~!
Tighten
ASSEMBLY
Tighten
Tighten
Thermostat housing bolts (146) to 21 Nm

(15 lb. ft.).
6. Rocker cover studs (196).
Tighten
Bolt (66) to 10 Nm (89 lb. in.).

Knock sensor (68).
!~I
Tighten
Bolt (95) to 10 Nm (89 lb. in.).

Ignition timing sensor (67) and retaining bolt
(66).
!~!
7.
!~I .Tighten
Tighten
Assemble
!~I
Front and rear oil gallery plugs (79) to

33 Nm (24 lb. ft.).
Front and rear oil gallery plugs (65 and
78) to 19 Nm (14 lb. ft.).
Lifter valley oil gallery plugs (64) to
15 Nm (11 lb. ft.).
Coolant drain plugs (69 and 70).
!+!
Bearing
Install or Connect
1. New camshaft bearings (101).

A. Select front, rear and intermediate
camshaft bearings.
B. Select the proper expander assembly and

driving washer.
C. Assemble J 33049.
D. Place intermediate camshaft bearing onto
J 33049 and index the oil hole at 4 o'clock
when looking from the front of the engine
block. Drive the intermediate camshaft
bearings into place.
E. Install #4 camshaft bearing with the oil
hole indexed at 4 o'clock when looking
from the front of the engine block, using
J 33049.
F. Install #1 camshaft bearing with the oil
hole indexed at 4 and 7 o'clock when
looking from the front of the engine block,
using J 33049.
ILI
2.
CRANKSHAFT
Figure 62 and 63
lI
Install or Connect
NOTICE: Bearing inserts must not be

shimmed, scraped or filed. Do not touch the bearing surface of the insert with the bare fingers.
Skin oil and acids will etch the bearing surface.
[I]
Important
Make sure the bearing cap bolt holes and

the cap mating surfaces are clean and dry.
1. Dip bearing cap bolts (19) in clean engine oil.

NOTICE: Upper and lower inserts may be different. Do not obstruct any oil passages.
Inspect
2. Place bearing inserts (23) into the bearing cap
With a piece of 3/32 inch brass rod with a 90

bend at the end, probe the bearing oil holes and
verify that they are properly aligned (Figure 61).
(20) and into the engme block (71). Refer to

"Main Bearing and Connecting Rod Bearing
Selection" in this section.
NOTICE: Proper alignment of the oil holes is

critical. Restriction of the oil flow will cause severe engine damage.
[I]
Camshaft cover gasket (75), cover (76) and

bolts (77).
l~I
3.
Tighten
Bolts (77) to 10 Nm (89 lb. in.).

4.
5.
6.
Important
The inserts will project slightly when put

into place. Make sure they project an
equal distance on both sides. Make sure
the insert tangs are engaged.
In the case of a thrust bearing type main bearing

insert, coat the thrust surface with GM EOS p/n
1052368 (or equivalent).
Lubricate the bearing surface with clean engine
oil.
Crankshaft (22).
Oil gallery 0-ring (21) between the engine
block and the rear main bearing cap (20).

cylinder block and/or main bearing cap damage,
the main bearing caps are to be tapped into their
cylinder block cavity using a brass or leather mallet before attaching bolts are installed. Do not use
attaching bolts to pull main bearing caps into
their seats. Failure to observe this mformation
may damage a cylinder block or bearing cap.
A
90 BEND
CHECKING OIL HOLE ALIGNMENT WITH

BRASS ROD. MAKE ROD AS SHOWN
USING 3/32" ROD ABOUT 762mm (30") LONG
7.
P0040-6A2B-F-RA
Figure 61 Checking Camshaft Bearing Oil Hole

Alignment
Bearing cap (20). Tap gently into place with a

suitable tool.
8.
Apply a small amount of sealer GM p/n

1052942 to the rear of rear bearing cap
sealing surface.
With crankshaft bearing and bearing caps

installed and cap bolts started, thrust crankshaft
rearward to set and align bearing caps, then
thrust crankshaft forward to align rear face of
thrust main bearing (Figure 62).
9. Main bearing cap bolts (19).
l~I
IGI
REAR MAIN OIL SEAL
Tool Required:
J 34686 Rear Main Oil Seal Installer
Tighten
Main bearing cap bolts (19) evenly to 50

Nm (37 lb. ft.).
Turn main bearing cap bolts (19) evenly
an additional 77 using J 36660.
Measure
Crankshaft end play (Figure 63).
"
A MAI~ BEARING THRUST FLANGES

B WOOD BLOCK
C BUMP SHAFT REARWARD THEN
FORWARD TO ALIGN THRUST
FLANGES OF CENTER MAIN BEARING
=5'
/C
~
~
P00416A2B-F-RA
Figure 62 Seating the Crankshaft Thrust Bearing
Figures 64 and 65
l+I
Install or Connect
1. Apply engine oil to ID and OD of new seal.

Slide seal over mandrel until back of seal
bottoms sguarely against collar of tool (Figures
64 and 65).
2. Rear main oil seal (32).
A. Align dowel pin of J 34686 with dowel
pin in crankshaft and attach J 34686 to
crankshaft by hand or tighten attaching
screws to 5 Nm (44 lb. in.).
B. Turn "T" handle of J 34686 so the collar
pushes the seal into the bore. Turn handle
until the collar is tight against the cylinder
case, this will ensure the seal is seated
properly.
C. Loosen the "T" handle of J 34686 until it
comes to a stop.
D. Remove J 34686 attaching screws.
ILI
Inspect
Check to ensure seal is seated squarely

in bore.
DUST LIP SIDE
J-34686
SEAL BORE TO SEAL SURFACE

TO BE LUBRICATED
WITH ENGINE OtL BEFORE
ASSEMBLY
Figure 63 Measuring Crankshaft End Play
MC0018-6A4-A-RA
Figure 64 Rear Main Seal and Tool
9.
ALIGNMENT HOLE
Bearing cap nuts (80).
l~I
DUST
LIP
IL!
!C!
Tighten
Cap nuts (80) to 52 Nm (38 lb. ft.).

Inspect
Pry the connecting rod back and forth

with a suitable tool and check for binding.
If necessary, loosen and retighten tlie
bearing cap.
Measure
Connecting rod side clearance

(Figure 67).
MC0019-6A4-A-RA
Figure 65 Installing Rear Main Seal
PISTONS AND CONNECTING RODS

Figures 66 and 67
Tool Required:
l+I
Install or Connect
1.
Lubricate cylinder wall and piston rings with

clean engine oil.
2. Turn crankshaft to bottom dead center.
3. Connecting rod stud thread protector
(Figure 22).
4. J 8037 Piston ring compressor (Figure 66).
NOTICE: Guide the lower connecting rod end
carefully to avoid damaging the crankshaft journal.
5.
A
86
ARROW TOWARDS FRONT OF ENGINE

PISTON
P0042-6A2B-f.RA
Figure 66 Piston Ring Compressor
Piston (86) and connecting rod (83) assembly.
rn
Important
6.
7.
Make sure that the arrow on top of the

piston faces towards the front of the
engine (Figure 66).
Remove thread protectors.
Connecting rod bearings (82). Refer to "Main
Bearing and Connecting Rod Bearing
Selection" in this section.

rod bolt or bearing cap damage, the bearing caps
may need to be tapped into position with a brass
or leather mallet before attaching nuts are installed. Do not use attaching nuts to pull bearing
caps onto rod. Failure to observe this information
may damage a rod bolt or bearing cap.
8.
Seat the bearing caps (81) by pushing on by

hand or by carefully tappmg it lightly with a
suitable tool.
Figure 67 Measuring Connecting Rod Side Clearance
2. Cylinder head (113).

3. Cylinder head bolts (115).
OIL PUMP
Figure 21
lI
l~I
Install or Connect
1. Oil pump (17) and drive rod (18).

2. Oil pump bolt (16).
l~I
Tighten
4.
Bolt (16) to 41 Nm (30 lb. ft.).

CYLINDER HEAD
Tool Required:
Right
Bolts (115) in sequence to 55 Nm

(41 lb. ft.). Figure 68.
Turn bolts (115) in sequence an additional
90 using J 36660. Figure 68'
Pencil brace bracket bolts.
Left
Figure 68
lI
Figure 68
lI
Tighten
Install or Connect
1. Cylinder head gasket (112).

2. Cylinder head (113).
Install or Connect
1. Cylinder head gasket (112).

115
.FRT
06
02
03
07
113
115
112
A
71
71
112
113
115
TIGHTENING SEQUENCE
BLOCK, ENGINE
HEAD, CYLINDER
BOLT/STUD, CYLINDER HEAD
P0043-6A2B-F-RA
Figure 68 Cylinder Head Installation
3.
l~I
Tighten
A BOLTS
100 CAMSHAFT
4.
Bolts (115) in sequence to 55 Nm

(41 lb. ft.). Figure 68.
Turn bolts (115) in se9.uence an additional
90 using 1 36660. Figure 68.
I~!
Tighten
5.

threads of sensor (114).
Coolant temperature sensor (114) to
13 Nm (115 lb. in.).
Engine lift bracket (200) and bolts (201).
I~!
6.
!~!
7.
Tighten
Bolts (201) to 50 Nm (37 lb. ft.).

Oil level indicator tube nut (47).
Tighten
Nut (47) to 21 Nm (15 lb. ft.).

Power steering pump bracket (38), nut (39) and
bolt (37).
I~!
Bolt (37) to 25 Nm (18 lb. ft.).

Nut (39) to 50 Nm (37 lb. ft.).
CAMSHAFT
1.
2.
3.
Figure 69 Installing Camshaft

Figure 70 through 72
Figure 69
I!
P0044-6A2B-F-RA
Tighten
Tool Required:
Install or Connect
NOTICE: Camshaft journals are all the same

diameter so care must be used when installing the
camshaft to avoid bearing damage.
Coat camshaft journals with engine oil or its
equivalent.
Coat camshaft lobes with prelube GM p/n
1052365.
Camshaft (100).
Install three 4-inch bolts in the camshaft
bolt holes.
Carefully rotate and install the camshaft
(100) into the camshaft bearings.
Oil pump driven gear assembly (90).
Lubricate driven gear with prelube GM
p/n 1052365.
Lubricate assembly with engine oil for
ease of installation.
Oil pump driven gear hold down clamp (92) and
bolt (91).
I~!
Tighten
Bolt (91) to 34 Nm (25 lb. ft.).
J 38612 Crankshaft Sprocket Installer
I!
1.
2.
Install or Connect

Remove J 38612.
3.
Camshaft sprocket (98) and timing chain (25).
4.
Coat crankshaft and camshaft sprocket

teeth with engine oil.
Coat rear face of camshaft sprocket with
engine oil.
Align timing marks on crankshaft and
camshaft sprockets with cast timing marks
on engine block or timing marks on
timing chain damper.
Camshaft sprocket bolts (97).
!~!
Tighten
Bolts (97) to 25 Nm (18 lb. ft.).
A
22
24

CRANKSHAFT
KEY, CRANKSHAFT
26
71
BLOCK, ENGINE
P0045-6A2BF-RA
Figure 70 Crankshaft Sprocket Installation
A
25
26
71
ALIGNMENT MARKS
CHAIN, TIMING
\ \
\ \
\ \
SPROCKET,CRANKSHAFT
BLOCK, ENGINE
97 BOLT, CAMSHAFT SPROCKET

98 SPROCKET, CAMSHAFT
100
CAMSHAFT
100
26
71
P0046-6A2B-F-RA
Figure 71 Camshaft sprocket and Timing Chain Installation
5.
Timing chain damper (63) and bolts (62).
ENGINE FRONT COVER
Tighten
Figure 73
Bolts (62) to 25 Nm (18 lb. ft.).
I!
1.
71
2.
3.
Install or Connect
Front cover gasket (61).

Uniformly coat both sides of the lower
tabs of the front cover gasket (61) with
sealer GM p/n 1052080.
Front cover (60).
Front cover bolts (59).
l~I
Tighten
Bolts (59) to 21 Nm (15 lb. ft.).
COOLANT PUMP
Figure 74
!++!
62
A
62
BOLT, TIMING CHAIN DAMPER
63
DAMPER, TIMING CHAIN
71
BLOCK, ENGINE
Install or Connect
1. Coolant pump gasket (55).

Apply sealer GM p/n 1052080 to the threads of
the coolant pump retaining bolts (51, 52 and 53).
P0047-6A2B-F-RA
Figure 72 Timing Chain Damper
APPLY SEALANT
BOLT, COOLANT PUMP (LARGE)
BOLT, COOLANT PUMP (MEDIUM
59
58
53
Figure 73 Engine Front Cover
54
55
58
59
60
61
71
PUMP, COOLANT
GASKET, COOLANT PUMP
SEAL, FRONT COVER OIL
BOLT.COVER
COVER, ENGINE FRONT
BLOCK, ENGINE
P0048-6A2B-F-RA
51 BOLT, COOLANT PUMP (SMALL)

52 BOLT, COOLANT PUMP (LARGE)
53 BOLT, COOLANT PUMP (MEDIUM)
54 PUMP, COOLANT
55 GASKET, COOLANT PUMP
60 COVER, ENGINE FRONT
-53
51
P0049-6A2B-F-RA
Figure 74 Coolant Pump
2.
Coolant pump (54) and retaining bolts (51, 52

and 53).
l~I
3.
Tighten
Large bolts (52) to 47 Nm (35 lb. ft.).
Medium bolts (53) to 21 Nm (15 lb. ft.).
Small bolts (51) to 10 Nm (89 lb. in.).
Coolant pump pulley (50) and retaining bolts
(49).
l~l
4.
Tighten
Bolts (49) to 25 Nm (18 lb. ft.).
Power steerin_g pump mounting bracket (227)
and bolts (22~) .
TORSIONAL DAMPER
Figure 75
Tool Required:
J 29113 Torsional Damper Installer
lI
1.
2.
3.
Install or Connect
Torsional damper (27) using J 29113.
keyway of damper prior to installation.
Remove J 29113.
Crankshaft pulley (28) and retaining bolts (31).
l~I
4.
Tighten
Bolts (31) to 50 Nm (37 lb. ft.).
Torsional damper washer (29) and bolt (30).
l~I
Tighten
Bolt (30) to 79 Nm (58 lb. ft.).
27
DAMPER, TORSIONAL
P0050-6A2B-F-RA
Figure 75 Torsional Damper Installation
ELECTRONIC IGNITION MODULE

Figure 18
Tool Required:
J 25033-B Power Steering Pump Pulley
Installer
lI
Install or Connect
1. Electronic ignition module (222) and retaining

nuts (226).
l~l
Tighten
Nuts (226) to 10 Nm (89 lb. in.)
6A2B-50 3.4 LITER V-6 VIN CODE. S
2.
3.
4.
Power steering pump (225) and retaining bolts

(228).
Power steering pump to rear bracket retaining
bolts.
Power steering pump pulley (229) using
J 25033-B.
Install pulley (229) until fully seated.
OIL PAN
Figure 17
lI
1.
2.
3.
Install or Connect
Oil pan gasket (1).

Apply sealant GM p/n 12345739 where
the oil pan gasket tabs seat on rear main
bearing cap groove.
Oil pan (1).
Oil pan reinforcements (10), nuts (11), bolts
(12 and 14) and studs (13).
l~I
l~I
VALVE LIFTERS
Figure 13
lI
following:
1. Oxygen sensor (111 and 217).
VALVE ROCKER AF M AND PUSHROD

Figure 13
I!
1.
l~I
3.
l~I
4.
I!
1.
2.
Tighten
Bolts (207) to 30 Nm (22 lb. ft.).

Right manifold EGR flexible adapter pipe
gasket (211 ), EGR flexible adapter pipe (212)
and bolts (114).
l~I
2.
Tighten
Studs (210) to 31 Nm (23 lb. ft.).

Right manifold EGR gasket (208), EGR (206)
and bolts (207) .
Tighten
Bolts (214) to 26 Nm (19 lb. ft.).
Install or Connect
Exhaust manifold gasket (106 and 216).

Exhaust manifold (105 and 215) and heat
shields (103, 104 and 205).
Install or Connect
Install lifters in their original locations.

1. Coat lifters with prelube, GM p/n 1052365.
2. Valve lifters (9L ).
Tighten
Oxygen sensor (110 and 218) to 42 Nm

(31 lb. ft.).
Right manifold EGR adapter pipe (209) and
studs (210).
Tighten
Bolts (10 . and 202) to 25 Nm (18 lb. ft.).

4. Secondary air injection pipe assembly, if
equipped.
5. AIR pipe fittin ~ to right exhaust manifold, if
equipped.
6. AIR pipe retair ng nut (184) and bolt (183), if
equipped.
7. A/C compres: or and generator mounting
bracket.
8. A/C compres~ or and generator mounting
bracket bolts.
9. Generator pencil brace bolts and braces.
10. Rear A/C com1 ressor bracket mounting bolts
and bracket.
11. Serpentine drive belt.
Nuts (11) to 10 Nm (89 lb. in.).

Two rear bolts (14) to 25 Nm (18 lb. ft.).
Remaining bolts _and studs (12 and 13) to
10 Nm (89 lb. m.).
Figures 15 and 16
Transfer Parts
If replacing an exhaust manifold, transfer the
2.
Exhaust manifold retaining bolts (102 and 202).
Tighten
EXHAUST MANIFOLD
l~I
3.
3.
Install or Connec1
Pushrods (93).
Install pus 1rods in their original location.
Coat the ends of the pushrods with
prelube G 1 p/n 1052365.
Rocker arms (1: 2) and balls (123).
Install ro< ~er arms and balls in their
original lo ation.
Coat rocke arm balls and friction surfaces
of rocker arms with prelube GM p/n
1052365.
Rocker arm nuts (124).
Adjust
Valves when lifte is on base circle of camshaft

lobe:
A. The engine should be in the # 1 firing
position. 1 1is may be determined by
placing fing rs on the # 1 rocker arms as
the engine , ssembly timing mark on the
torsional dar per aligns witli the crankshaft
position sen or bolt located on the front
cover. If th( valves are not moving, the
engine is in :he #1 firing position. lf the
valves move the engine is in #4 firing
position and should be rotated one
revolution to reach the #1 position.
B. With the engine in the #1 firing position,

the following valves should be adjusted:
Exhaust - 1, 2, 3
Intake - 1, 5, 6
C. Tighten the adjusting nut until there is zero
lash + 1-1/2 turns.
(This can be determined by rotating
pushrod while turning adjusting nut).
When lash has been removed, turn
adjusting nut in 1-1/:', additional turns (to
center hfter plunger).
D. Crank the engine one crankshaft
revolution. This 1s th1 #4 firing position.
With the engine in this position, the
following valves shou d be adjusted to zero
lash + 1-1/2 turns:
Exhaust - 4, 5, 6
Intake - 2, 3, 4
VALVE ROCKER COVER

Figure 12
l+I
1.
2.
l+I
1. Cut lower manifold gasket where it says "Cut

Out".
Upper intake manifold gasket (154) and

manifold (155).
Upper intake manifold bolts (156).
3.
4.
2. Lower intake manifold gasket (141).

3. Apply sealant GM p/n 12345739 at both ends
where the intake manifold mates the engine
block. Bead should be 2.0-3.0 mm wide and
3.0-5.0 mm thick.
4. Lower intake manifold (142).
5. Retaining bolts (144) and nuts (143).
5.
[I)
6.
Tighten
Upper intake manifold bolts (156) to

25 Nm (18 lb. ft.).
MAP sensor electrical connector.

EGR flexible adapter pipe gasket (213), pipe
and bolts (212) at upper manifold (155).
l~I
Tighten
Bolts (144) and nuts (143) in sequence,

refer to Figure 14.
First, bolts (144) and nuts (143) in
sequence, to 5 Nm (44 lb. in.).
Then, bolts (144) and nuts (143) in
sequence, to 20 Nm (15 lb. ft.).
Finally, bolts (144) and nuts (143) in
sequence, to 30 ,Nm (22 lb. ft.).
Install or Connect
l~I
Install or Connect
Nuts (192) to 10 Nm (89 lb. in.).
Figure 10 and 11
2.
l~I
Tighten
Figure 14
This will allow you to put the manifold

gasket on with pushrods already installed.
Apply sealant GM p/n 12345739 at

cylmder head to lower manifold joint.
Reinforcement (193) and nuts (192).
l~I
1.
Valve rocker cover gasket (195) and cover

(194).
lu-1
Install or Connect
Tighten

threads of bolts (212).
Gasket must be installed with text "tube
side" facing the pipe.
EGR flexible adapter pipe bolts to 26 Nm
(19 lb. ft.).
PCV valve (190).

Important
Do not press on the regulator cover or piedmont

valve when installing fuel injector rail assembly.
Fuel injector rail assembly (166).
A. Lightly lubricate fuel injector 0-rings with
engine oil.
B. Install injectors of fuel rail assembly into
bores of manifold.
C. Carefully press on injector rail (166) with
palms of both hands until injectors are
fully seated.
7.
Fuel rail stud (169).
13.
l~I
Tighten
FLYWHEEL
Fuel rail stud (169) to 25 Nm (18 lb. ft.).
Figure 9
8.
9.
10.
11.
Coolant sensor electrical connector.

Fuel pressure regulator vacuum hose ( 173).
Fuel injection harness retaining nut.
Fuel lines (175) to fuel injection rail (166).
12.
Slide fuel line hold down plate (168) over

fuel lines.
Fuel line hold down plate bolt (167).
l~I
lI
1.
2.
Fuel line clamp bolts (176 and 177).
Install or Connect
Flywheel (33).
Flywheel retaining bolts (36).
l~I
Tighten
Bolts (36) to 83 Nm (61 lb. ft.).
Tighten

threads of bolt (167).
Bolt (167) to 25 Nm (18 lb. ft.).
SPECIFICATIONS
AIR Check Valve Assembly .................................................................................. 19 Nm (14 lb.
AIR Pipe Fitting to Manifold ................................................................................. 25 Nm (18 lb.
AIR Pipe Assembly Nut ....................................................................................... 25 Nm (18 lb.
AIR Pipe Assembly Screw .................................................................................... 50 Nm (37 lb.
Camshaft Rear Cover Bolts ................................................................................... 10 Nm (89 lb.
ft.)
ft.)
ft.)
ft.)
in.)
Camshaft Position Sensor Screw ............................................................................ 10 Nm (89 lb.

Camsha~t Sprocket Bolt ........................................................................................ 25 Nm (18 lb.
Connectmg Rod Cap Nut ......................................................................................50 Nm (37 lb.
Coolant Drain Plug ............................................................................................. 19 Nm (14 lb.
Coolant Pump Bolt - Large .................................................................................. .47 Nm (35 lb.
in.)
ft.)
ft.)
ft.)
ft.)
Coolant
Coolant
Coolant
Coolant
Coolant
ft.)
in.)
ft.)
in.)
in.)
Pump Bolt - Medium ................................................................................ 21 Nm (15 lb.

Pump Bolt - Small ................................................................................... 10 Nm (89 lb.
Pump Pulley Bolt.. ................................................................................... 25 Nm (18 lb.
Temperature Sensor ................................................................................ 13 Nm (115 lb.
Temperature Gage Sensor. ........................................................................ 13 Nm (115 lb.
Crankshaft Pulley Bolt ......................................................................................... 50 Nm (37 lb. ft.)

Crankshaft Position Sensor Screw ........................................................................... 10 Nm (89 lb. in.)
Cylinder Head Bolt .......................................................................... 55 Nm + 90 (41 lb. ft. + 90)
Cylinder Head Bolt Tightening Sequence ........................................................................... Refer to A
Cylinder Head Coolant Plug .................................................................................. 23 Nm (17 lb. ft.)
Electronic Ignition Module Retaining Nut ................................................................. 10 Nm (89 lb. in.)
EGR Adapter Pipe to Exhaust Manifold Bolt ............................................................. 31
EGR Flexible Adapter Pipe to
EGR Adapter Pipe Bolt ..................................................................................... 26
EGR Flexible Adapter Pipe to
Upper Intake Manifold Bolt ................................................................................ 26
EGR to Adapter Pipe Bolt ....................................................................................30
Engine Front Cover Bolt.. ...................................................................................... 21
Nm (19 lb. ft.)

Nm (22 lb. ft.)
Nm (15 lb. ft.)
Exhaust Manifold Bolt ......................................................................................... 25

Flywheel Bolt .................................................................................................... 83
Front Engine Lift Bracket Bolt. ..............................................................................50
Fuel Injector Rail Bolt ......................................................................................... 25
Fuel Line Hold Down Plate Bolt ............................................................................ 25
Nm
Nm
Nm
Nm
Nm
Nm (23 lb. ft.)

Nm (19 lb. ft.)
(18
(61
(37
(18
(18
lb.
lb.
lb.
lb.
lb.
ft.)
ft.)
ft.)
ft.)
ft.)
Heater Hose Nipple Assembly .............................................................................. 14 Nm (124 lb. in.l

Ignition Timing Sensor Screw ................................................................................ 10 Nm (89 lb. ft.
Knock Sensor .................................................................................................... 19 Nm (14 lb. ft.
Lower Intake Manifold Mounting Stud ..................................................................... 10 Nm (89 lb. in.)
Lower Intake Manifold Bolt .................................................................................. 30 Nm (22 lb. ft.)
Lower Intake Manifold Tightening Sequence ...................................................................... Refer to B
Lower Intake Manifold Nut ................................................................................... 30 Nm
Main Bearing Cap Bolts .................................................................... 50 Nm + 77 (37 lb.
Oil Drain Plug ................................................................................................... 25 Nm
Oil Gallery Plug - 1!8" ......................................................................................... 15 Nm
Oil Gallery Plug - 1!4" ......................................................................................... 19 Nm
Oil Gallery Plug - 3!8" ........................................................................................ .33 Nm
(22 lb. ft.)

ft. + 77)
!18 lb. ft.)
11 lb. ft.)
14 lb. ft.)
(24 lb. ft.)
Oil
Oil
Oil
Oil
Oil
Fill Tube Retaining Screw ................................................................................ 8 Nm (71 lb.

Filter ........................................................................................................ 13 Nm (115 lb.
Filter Adapter Bolt ......................................................................................... 68 Nm (50 lb.
Level Indicator Nut ........................................................................................ 21 Nm (15 lb.
Level Sensor ................................................................................................ 22 Nm (16 lb.
in.)
in.)
ft.l
ft.
ft.
Oil
O~l
Oil
Oil
Oil
Oil
Pan Bolt (2 Rear) .......................................................................................... 25 Nm (18 lb.

Pan Bolt ..................................................................................................... 10 Nm (89 lb.
Pan Nut ...................................................................................................... 10 Nm (89 lb.
Pan Stud ...................................................................................................... 6 Nm (53 lb.
Pressure Sensor ........................................................................................... 13 Nm (115 lb.
Pump Bolt ................................................................................................... 41 Nm (30 lb.
ft.)
~n.)
1n.)
in.)
in.)
ft.)
Oil Pump Cover Bolt .......................................................................................... 10 Nm (89 lb.

Oil Pump Drive Assembly Bolt .............................................................................. 34 Nm (25 lb.
Oxygen Sensor .................................................................................................. .42 Nm (31 lb.
Power Steering Pump Bracket Assembly Bolt.. ........................................................... 50 Nm (37 lb.
Power Steer~ng Pump Rear Brace Nut ......................................................................50 Nm (37 lb.
Power Steenng Pump Rear Brace Stud ..................................................................... 25 Nm (18 lb.
in.)
ft.)
ft.)
ft.)
ft.)
ft.)
Pressure Plate Bolt ............................................................................ 20 Nm + 45 (15 lb. ft. + 45)

Rear Engine Lift Bracket Bolt ................................................................................ 50 Nm (37 lb. ft.)
Rocker Cover Mounting Stud .................................................................................. 8 Nm (71 lb. in.)
Rocker Cover Retaining Nut ................................................................................. 10 Nm (89 lb. in.)
Rocker Arm Nut ................................. , ......................................................................... Refer to C
Rocker Arm Stud ................................................................................................ 46 Nm (35 lb. ft.)
Spark Plug ................................................. : ...................................................... 31
Thermostat Housing Bolt ...................................................................................... 21
Throttle Body Retaining Bolt ................................................................................. 25
Timing Chain Damper Bolt ................................................................................... 25
Torsional Damper.B.olt ......................................................................................... 79
Upper Intake Mamfold Bolt.. ................................................................................. 25
A) Refer to "Cylinder Head" under Assembly in this section.
B) Refer to "Lower Intake Manifold" under Assembly in this section.
C) Refer to "Rocker Arms and Pushrods" under Assembly in this section.
Nm
Nm
Nm
Nm
Nm
Nm
(23
(15
(18
(18
(58
(18
lb.
lb.
lb.
lb.
lb.
lb.
ft.)
ft.)
ft.)
ft.)
ft.)
ft.)
ENGINE SPECIFICATIONS
General Specifications
Type ............................................................................................................................... 60V-6
Displacement .............................................................................................................. 204 Cu. In.
Liter (VIN) ...................................................................................................................... 3.4 (S)
RPO ................................................................................................................................... L32
Bore ............................................................................................................... 92 mm (3.622 inch)
Stroke ........................................................................................................... 84 mm (3.3122 inch)
Compression Ratio ................................................................................................................ 9.0:1
Firing Order ................................................................................................................ 1-2-3-4-5-6
Oil Pressure @ Operating
Temperature ...................................................................... 103 kPa (15 psi) @ 1100 rpm - minimum
Cylinder Bore
Diameter .............................................................................. 92.020 mm-92.038 mm (3.6228"-3.6235")
Out-of-Round - Max ......................................................................................... 0.007 mm (0.0003 11)
Piston
Diameter .............................................................................. 91.977 mm-91.992 mm (3.6211"-3.6217")
Clearance ................................................................................ 0.028 mm-0.061 mm (0.0011"-0.0024")
Piston Ring
Compression
Groove Clearance
lst ........................................................................................... 0.05 mm-0.09 mm (0.002"-0.0035")
2nd .......................................................................................... 0.05 mm-0.09 mm (0.002"-0.0035")
Gap (at gage dia.)
1st ............................................................................................ 0.18 mm-0.41 mm (0.007"-0.016")
2nd ........................................................................................... 0.48 mm-0.74 mm (0.019"-0.029")
Oil Groove Clearance - Max ................................................................................... 0.20 mm (0.008")
Gap (Segment at gage dia.) ............................................................... 0.25 mm-0. 76 mm (0.010"-0.030")
Piston Pin
Diameter ............................................................................... 22.9915 mm-22.9964 mm (.9052".9054")
Clearance ............................................................................. 0.0116 mm-0.0218 mm (0.0005"-0.0009")
Fit in Rod - Press ................................................................. 0.0165 mm-0.0464 mm (0.00065"-0.0018")
Crankshaft
Main Journal
Diameter - All .................................................................... 67.239 mm-67.257 mm (2.6473"-2.6483")
Taper - Max .................................................................................................. 0.005 mm (0.0002")
Out-of-Round - Max ........................................................................................ 0.005 mm (0.0002")
Main Bearing Clearance .............................................................. 0.032 mm-0.077 mm (0.0012"-0.0030")
Main Thrust Bearing
Clearance ............................................................................. 0.032 mm-0.077 mm (0.0012"-0.0030")
Crankshaft End Play ..................................................................... 0.06 mm-0.21 mm (0.0024"-0.0083")
Crankpin
Diameter .............................................................................. 50.768 mm-50.784 mm (1.9987"-1.9994")
Taper - Max .................................................................................................... 0.005 mm (0.0002")
Out-of-Round - Max .......................................................................................... 0.005 mm (0.0002")
Rod Bearing Clearance ............................................................... 0.028 mm-0.082 mm (0.0011"-0.0032")
Rod Side Clearance ......................................................................... 0.18 mm-0.44 mm (0.007"-0.017")
Camshaft
Lobe Lift
Intake ............................................................................................................ 6.67 mm (0.2626")
Exhaust .......................................................................................................... 6.94 mm (0.2732")
Journal Diameter ......................................................................... .47.44 mm-47.52 mm (1.868"-1.871")
Bearing Inside
Diameter ............................................................................. .47.523 mm-47.549 mm (1.871"-1.872")
Journal Clearance ......................................................................... 0.026 mm-0.101 mm (0.001"-0.004")
Valve System
Lifter ........................................................................................................................... Hydraulic
Rocker Arm Ratio ............................................................................................................... 1.50:1
Face Angle ............................................................................................................................ 45
Seat Angle ............................................................................................................................ 46
Seat Runout - Max .............................................................................................. 0.025 mm (0.001")
Seat Width
Intake ........................................................................................ 1.55 mm-1.85 mm (0.061"-0.073")
Exhaust~ 1.70 mm-2.0 mm (0.067" -0.079")
Stem Clearance
Intake .............................................................................. 0.0356 mm-0.0686 mm (0.0014" -0.0027")
Exhaust ............................................................................ 0.0381 mm-0.0737 mm (0.0015" -0.0029")
Valve Spring
Free Length .......................................................................................................... 48.5 mm (1.91")
Load - Closed ........................................................................... 356 N @ 40.9 mm (80 Lbs. @ 1.61")
Load - Open ........................................................................... 841 N @ 30.5 mm (190 Lbs. @ 1.20")
Installed Height ..................................................................................................... 40.9 mm (1.61")
Approx. # of Coils ................................................................................................................... 4
Oil Pump
Gear Lash ............................................................................... 0.094 mm-0.195 mm (0.0037"-0.0077")
Gear Pocket
Depth ..................................................................................... 30.53 mm-30.61 mm (1.202"-1.205")
Diameter .............................................................................. 38.202 mm-38.252 mm (1.504"-1.506")
Gear
Length .................................................................................... 30.45 mm-30.48 mm (1.199"-1.200")
Diameter ................................................................................. 38.05 mm-38.10 mm (1.498"-1.500")
Side Clearance ............................................................................... 0.08 mm-0.10 mm (0.003"-0.004")
End Clearance .............................................................................. 0.05 mm-0.152 mm (0.002"-0.006")
Valve to Bore Clearance ............................................................. 0.038 mm-0.089 mm (0.0015"-0.0035")
SPECIAL TOOLS
J 9666
J 8037
J 8062
Q\1
J8087 ~ ;
. ..
J 8101
ooc
5
Q,,
J 24086-B
J 21882
\
7
J 24420-B
\\iiW
J 26900-12
J 26900-13
J 5825
~
10
12
11
J 29113
13
1
2
3
4
5
DIAL INDICATOR SET

VALVE SPRING TESTER
CYLINDER BORE CHECKING GAGE
VALVE GUIDE CLEANER
6
7
VALVE SPRING COMPRESSOR

OIL SUCTION PIPE INSTALLER
8
9
10
11
12
13
PISTON PIN REMOVER AND

INSTALLER SET
TORSIONAL DAMPER REMOVER
CRANKSHAFT SPROCKET REMOVER
DIAL INDICATOR
MAGNETIC BASE
TORSIONAL DAMPER INSTALLER
P0051-6A2B-F-RA
SPECIAL TOOLS (CONT.}

J 38612
J 34995
1
2
3
CAMSHAFT BEARING REMOVER

AND INSTALLER
TORQUE ANGLE METER
CRANKSHAFT SPROCKET
INSTALLER
4
5
6
REAR MAIN OIL SEAL INSTALLER

FRONT COVER OIL SEAL
INSTALLER
VALVE GUIDE REAMER
P0052-6A2B-F-RA
5.7 LITER va ENGINE ON-VEHICLE SERVICE RPO LT1 - VIN P 6A3A1
SECTION 6A3A
5.7 LITER VS ENGINE

ON-VEHICLE SERVICE
RPO LT1 - VIN P
CAUTIONS in Section 9J-B under "On-Vehicle Service" and the SIR Components and Wiring
injury, or unneeded SIR system repairs.
could easily come in contact with "live" or "hot at all times" exposed electrical terminals,
disconnect the battery negative cable to help prevent personal injury and/or damage to the
vehicle or components. Unless instructed otherwise, the ignition switch must be in the
"OFF" or "LOCK" position.
result.
CONTENTS
General Description .......... Refer to Section 6A3B
On-Vehicle Service ...................... 6A3A-1
Fuel System Pressure Relief ............. 6A3A-1
Serpentine Drive Belt and Tensioner
Assembly .......................... 6A3A-2
Engine Mount Assemblies and Brackets .... 6A3A-3
Oil Level Indicator and Tube Assemblies ... 6A3A-4
Intake Manifold Assembly ............... 6A3A-5
Exhaust Manifold Assemblies ............ 6A3A-7
Valve Rocker Arm Cover Assemblies ...... 6A3A-9
Assemblies ........................ 6A3A-10
Rocker Arm Studs .................... 6A3A-10
Valve Lifter Assemblies ................ 6A3A-11
Water Pump Assembly ................. 6A3A- l 1
Crankshaft Balancer Assembly and Hub ... 6A3A- l 1
Distributor Assembly .................. 6A3A-12
Engine Front Cover Assembly ........... 6A3A-12
Timing Chain Assembly, Crankshaft and
Camshaft Sprockets, and Water Pump
Driveshaft Assembly ................ 6A3A-13
ON-VEHICLE SERVICE
CAUTION:
To reduce the risk of fire and personal
injury, it is necessary to relieve the fuel
system pressure before servicing fuel
system components.
Camshaft Assembly ................... 6A3A-14

Valve Spring and Stem Seal ............. 6A3A-16
Cylinder Head Assembly and Gasket ..... 6A3A-17
Engine Oil Cooler and Hose Assembly .... 6A3A-19
Oil Pan Assembly .................... 6A3A-20
Oil Pump Assembly ................... 6A3A-21
Connecting Rod Bearings .............. 6A3A-23
Piston and Connecting Rod Assemblies ... 6A3A-24
Crankshaft Bearings ................... 6A3A-25
Flywheel Assembly ................... 6A3A-27
Crankshaft Rear Oil Seal Assembly ...... 6A3A-27
Crankshaft Rear Oil Seal Housing Assembly
and Gasket ........................ 6A3A-28
Engine Assembly ..................... 6A3A-29
Thread Repair ....................... 6A3A-31
Specifications .......................... 6A3A-32
Fastener Tightening Specifications ....... 6A3A-32
5.7L (LTl) ........................ 6A3A-33
Special Tools .......................... 6A3A-35
After relieving system pressure, a small

amount of fuel may be released when
servicing fuel lines or connections. In
order to reduce the chance of personal
injury, cover fuel pipe fittings with a
shop towel before disconnecting, to
catch any fuel that may leak out. Place
the towel in an approved container
when disconnect is completed.
6A3A2 5.7 LITER VS ENGINE ON-VEHICLE SERVICE RPO LT1 -VIN P
1.
2.
3.
4.
5.
Tool Required:
Disconnect battery negative cable assembly terminal to avoid possible fuel discharge if an additional
attempt is made to start the engine.
Connect gage J 34 730-1 to fuel pressure connection.
gage to avoid spilling.
Install bleed hose into an approved container and
open valve to bleed system pressure. Fuel connections are now safe for servicing.
Drain any fuel remaining in gage into an approved
container.
The indicator on the movable portion of the tensioner assembly must be within the limits of the marks of the
stationary portion of the tensioner assembly. Any reading
outside of these limits indicates either a defective belt or
tensioner assembly.
Drive Belt
!Ll
1nspect
Belt length scale on the drive belt tensioner assembly for the proper installed length. If the belt length
scale does not indicate the proper installed length,
install a new drive belt.

SERPENTINE DRIVE BELT AND TENSIONER

ASSEMBLY

2. Lift drive belt tensioner assembly (145) downward
(clockwise) off drive belt (148) using a socket and
handle on tensioner pulley bolt/screw.
Figures 1 and 2
NOTICE: Routine inspection of the belt may reveal
cracks in the belt ribs. These cracks will not impair
belt performance and therefore should not be considered a problem requiring belt replacement. However, the belt should be replaced if belt slip occurs or
if sections of the belt ribs are missing.
A single serpentine drive belt is used to drive all engine accessories. All belt driven accessories are rigidly
mounted with belt tension maintained by a spring loaded
tensioner assembly.
!i,I
Clean
Accessory drive belt surfaces.

147
!VIEWA!
146
148
42
A
149
1501-----!
145
A
B
C
D
E
42
145
146
147
148
149
150
INDICATOR MARK
READING FOR REPLACING BELT IN SERVICE
DEFECTIVE PARTS CHECK RANGE
MAXIMUM TOLERANCE BELT READING
MINIMUM TOLERANCE BELT READING
BALANCER ASSEMBLY, CRANKSHAFT
GENERATOR ASSEMBLY
BELT, SERPENTINE DRIVE
PULLEY, DRIVE BELT IDLER
PC00606A3A-FRP
Figure 1 - Serpentine Drive Belt
5.7 LITER VS ENGINE ON-VEHICLE SERVICE RPO LT1 - VIN P 6A3A-3


2. Idler pulley bolts/screws (151).
Drive Belt Tensioner Assembly
3. Drive belt idler pulley (150).

section.

1. Drive belt idler pulley (150).
2. Idler pulley bolts/screws ( 151 ).
l~I Tighten

section.
Idler pulley bolts/screws ( 151) to 50 N m

(37 lb. ft.).

!~I Tighten
Drive belt tensioner bolts/screws (152) to
33 Nm (24 lb. ft.).
ENGINE MOUNT ASSEMBLIES AND

BRACKETS
Figure 3
NOTICE: When raising or supporting the engine for
any reason, do not use a jack under the oil pan,

crankshaft pulley, or any sheet metal. Due to small
clearance between the oil pan and the oil pump
screen, jacking against the oil pan may cause it to be
bent against the pump screen resulting in a damaged
oil pickup unit.
Drive Belt Idler Pulley

The drive belt idler pulley is used in place of the A/C
compressor when the vehicle is not equipped with air
conditioning.
ll'l'I
Inspect
Engine mounts for damage to the rubber portions of

the mount.
- Rubber surface covered with heat check
cracks.
- Rubber cushion separated from the plate of the
mount.
Rubber cushion split through the center.

(125).
3. Raise engine with a jacking fixture.
4. Engine mount bolts/screws (128) and engine mount
assemblies (127).
152
145
150
151
152

PULLEY, DRIVE BELT IDLER
BOLT/SCREW, DRIVE BELT IDLER PULLEY
BOLT/SCREW, DRIVE BELT TENSIONER
PC00616A3AFRP
Figure 2 - Drive Belt Tensioner Assembly and Idler Pulley
5. Engine bracket bolts/screws (126) and engine brackets (124).

section.
1. Engine brackets (124) and engine bracket bolts/
screws (126).
126
128
124
125
126
127
128
130
BRACKET, ENGINE
NUT, ENGINE MOUNT
BOLT/SCREW, ENGINE BRACKET
MOUNT ASSEMBLY, ENGINE
PC0062-6A3A-F-RP
Figure 3 - Engine Mount Assemblies and Brackets
2. Engine mount assemblies (127) and engine mount

bolts/screws (128).
l~I Tighten
Engine mount and bracket bolts/screws (126
and 128) to 58 Nm (43 lb. ft.).
3. Lower engine.
(125).
l~I Tighten
Engine mount through-bolt/screw nuts (125) to
80 Nm (59 lb. ft.).
-or Engine mount through-bolts/screws ( 130) to
95 Nm (70 lb. ft.).
OIL LEVEL INDICATOR AND TUBE

ASSEMBLIES

1. Nut securing tube bracket to right exhaust manifold
stud bolt.
2. Level indicator and tube assemblies from engine
block.

section.
1. Clean tube assembly and apply sealant, GM PIN
12345493 or equivalent, around tube 12.7 mm (0.50
inch) below bead.
2. Tube assembly into engine block and rotate into
position.
3. Nut securing tube bracket.
5.7 LITER VB ENGINE ON-VEHICLE SERVICE RPO LT1 -VIN P 6A3A5
1
2
3
4
5
6
7
7
BOLT/SCREW, FUEL INJECTION FUEL RAIL

RAIL ASSEMBLY, MULTIPORT FUEL INJECTION FUEL
BODY ASSEMBLY, THROTTLE
BOLT/SCREW, THROTTLE BODY
MANIFOLD ASSEMBLY, INTAKE
TUBE ASSEMBLY, FUEL PRESSURE REGULATOR
VACUUM
..,
/
PC0009-6A3B-F-RP
Figure 4 - Fuel Rail and Throttle Body Assemblies
l~I
Tighten
Oil level indicator tube nut to 34 Nm

(25 lb. ft.).
4. Level indicator.
INTAKE MANIFOLD ASSEMBLY

Figures 4 through 6
l++I
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.

Wiring harness connectors from fuel injectors.
Left and right wiring harnesses and lay aside.
Accelerator cable bracket bolts/screws, bracket and
cables from throttle body assembly (3).
Relieve fuel system pressure. Refer to "Fuel System
Pressure Relief" in this section.
Secondary air injection diverter valve hoses.
Fuel pipe connectors from fuel rail assembly (2).
Fuel rail bolts/screws (1).
Fuel pressure regulator vacuum tube assembly (7).
Fuel rail assembly (2) from intake manifold assembly (6) and lay aside.
Vacuum and crankcase vent hoses.
Exhaust gas recirculation (EGR) control valve relay
nut and control valve relay.
15. Emission canister purge solenoid bracket nut and

solenoid.
16. EGR valve nuts and valve assembly.
17. Secondary air injection pipe fitting, nuts and pipe
assembly from intake and right exhaust manifold
assemblies.
18. Generator rear brace. Refer to SECTION 603.
19. Coolant hoses from throttle body assembly (3).
20. Throttle body bolts/screws (4 ), throttle body assembly (3) and gasket (5).
21. Intake manifold bolts/screws (8) and studs (9).
22. Intake manifold assembly (6) and gaskets (10).
Discard gaskets (10).
li,I
Clean
Intake manifold bolts/screws (8) and studs (9).

Cylinder head assembly, engine block and intake
manifold sealing surfaces.
l++I
Install or Connect
NOTICE: See "NOTICE" on page 6A3A-1 of this

section.
1. Apply a 5 mm (3/16 inch) bead of RTV sealer, GM
P/N 1052366 or equivalent, to the front and rear of
the engine block. Extend the bead 13 mm (1/2 inch)
up each cylinder head assembly to seal and retain the
gaskets.
2. Intake manifold assembly (6) with new gaskets ( 10).
l~I
Tighten
Intake manifold bolts/screws (8) and studs (9)

in a first pass to 8 Nm (71 lb. in.) in sequence
6A3A-6 5.7 LITERV8 ENGINE ON-VEHICLE SERVICE RPO LT1 -VIN P
FRTt
6
3
6 MANIFOLD ASSEMBLY, INTAKE
PC0055-&A3E-F-RP
Figure 6 - Intake Manifold Tightening Sequence
as shown in Figure 6. Tighten in sequence in a

second pass to final specifications of 48 N m
(35 lb. ft.).
4. Throttle body assembly (3), gasket (5) and throttle
body bolts/screws (4).
l~I
Tighten
Throttle body bolts/screws (4) to 26 Nm

(19 lb. ft.).
5. Coolant hoses to throttle body assembly (3).
6. Generator rear brace. Refer to SECTION 603.
7. Accelerator cable bracket, bolts/screws and cables.
l~I
Tighten
Accelerator cable bracket bolts/screws to

10 Nm (90 lb. in.).
8. Secondary air injection pipe assembly and nuts.
l~I
Tighten
Secondary air injection pipe exhaust manifold

fitting to 34 Nm (25 lb. ft.).
Secondary air injection pipe flange nuts to
intake manifold assembly to 25 Nm (19 lb.
ft.).
9. EGR valve assembly and nuts.
10. EGR control valve relay and nut.
l~I
A
6
8
9
10
Tighten
EGR valve nuts to 22 Nm (16 lb. ft.).

EGR control valve relay nut to 22 Nm (16 lb.
ft.).
11. Emission canister purge solenoid and bracket bolt/
screw.
SEALER
BOLT/SCREW, INTAKE MANIFOLD
STUD, INTAKE MANIFOLD
GASKET, INTAKE MANIFOLD
!~I Tighten
PC0010-8A3B-F-RP
Figure 5 - Intake Manifold Assembly
Emission canister purge solenoid bracket bolt/

screw to 6 Nm (53 lb. in.).
12. Vacuum and crankcase vent hoses.
5.7 LITER VS ENGINE ON-VEHICLE SERVICE RPO LT1 -VIN P 6A3A7

13. Fuel rail assembly (2) to intake manifold assembly
(6).
14. Fuel pressure regulator vacuum tube assembly (7).
15. Fuel rail bolts/screws (1 ).
232
l~I Tighten
16.
17.
18.
19.
20.
21.
22.
229
230
Fuel rail bolts/screws (1) to 20 Nm (15 lb. ft.).

Fuel pipe connectors to fuel rail assembly (2).
Secondary air injection diverter valve hoses.
Left and right wiring harnesses.
Wiring harness connectors to fuel injectors.

Figures 7 and 8
Right Exhaust Manifold Assembly

section.
7. Three rear exhaust manifold assembly bolts/screws
(21).
8. Lower vehicle.
9. Secondary air injection pipe fitting from exhaust
manifold assembly (19).
10. Generator and rear lower brace. Refer to SECTION
14
603.
11. Remaining exhaust manifold studs (20) and bolt/
screw (21).
12. Heat shields, exhaust manifold assembly (19) and
exhaust manifold gasket ( 18).
l.::.WI Clean
Exhaust manifold and
surfaces.
cylinder head
sealing

section.
1. Exhaust manifold gasket (18), exhaust manifold
assembly (19) and heat shields.
11
12
13
14
15
22
229
VALVE ASSEMBLY, SECONDARY AIR INJECTION CHECK

PIPE ASSEMBLY, SECONDARY AIR INJECTION
STUD, SECONDARY AIR INJECTION PIPE
NUT, SECONDARY AIR INJECTION PIPE
GASKET, SECONDARY AIR INJECTION PIPE
HOSE ASSEMBLY, SECONDARY AIR INJECTION CHECK
VALVE
230 CLAMP, SECONDARY AIR INJECTION CHECK VALVE
HOSE
232 CONNECTOR, SECONDARY AIR INJECTION CHECK
VALVE HOSE
PC0011-8A3B-F-RP
Figure 7 - Secondary Air Injection Components
6A3A-8 5.7 LITER VB ENGINE ON-VEHICLE SERVICE RPO LT1 -VIN P
16
16
17
18
19
20
21

STUD, EXHAUST MANIFOLD
19
21
PC0012-6A3B-F-RP
Figure 8 - Exhaust Manifold Assemblies
2. Front three exhaust manifold studs (20) and bolt/

screw (21).
3. Generator and rear lower brace. Refer to SECTION
603.
5. Remaining exhaust manifold bolts/screws (21).
l~I
6.
7.
8.
9.
10.
11.
Tighten
Exhaust manifold studs (20) and bolts/screws

(21) to 35 Nm (26 lb. ft.).
Oxygen sensor electrical connector.
Oil level indicator and tube assemblies. Refer to
section.
Lower vehicle.
Secondary air injection pipe assembly fitting to
exhaust manifold assembly ( 19).
l~I
Tighten
Secondary air injection pipe assembly fitting to

34 Nm (25 lb. ft.).
Left Exhaust Manifold Assembly
!++I
CAUTION: See "Caution" on

page

3. Crossover pipe from exhaust manifold assembly.
4. Lower vehicle.
6. Secondary air injection pipe fitting from exhaust
9. Heat shields, exhaust manifold assembly (16) and
exhaust manifold gasket ( 17).
!i,I
Clean
Exhaust manifold and cylinder head sealing surfaces.
!++I
Install or Connect

section.
1. Exhaust manifold gasket ( 17), exhaust manifold
assembly (16) and heat shields.
!~I
Tighten
Exhaust manifold bolts/screws (21) to 35 Nm

(26 lb. ft.).
4. Secondary air injection pipe fitting from e)(haust
5.7 LITER va ENGINE ON-VEHICLE SERVICE RPO LT1 -VIN P 6A3A-9
l~I Tighten
5.
6.
7.
8.
9.
Secondary air injection pipe fitting to 34 Nm

(25 lb. ft.).
Brake booster vacuum hose.
Crossover pipe to exhaust manifold assembly. Refer
to SECTION 6F.
Lower vehicle.

Figure 9
Right Cover Assembly

1.
2.
3.
4.
5.
6.
7.
8.
9.
fi,I

Transmission fluid level indicator tube assembly
bracket from transmission housing (automatic transmission only.)
Lower vehicle.
Crankcase vent hose.
Generator and rear generator brace. Refer to SECTION 603.
Rocker arm cover bolts/screws (24 ).
Rocker arm cover assembly (23) and gasket (25).
Clean
Rocker arm cover assembly and cylinder head gasket surfaces.

section.
1. Gasket (25) and rocker arm cover assembly (23).
2. Rocker arm cover bolts/screws (24 ).
!~I Tighten
Rocker arm cover bolts/screws (24) to 11 N m
(100 lb. in.).
3. Crankcase vent hose.
4. Generator and rear generator brace. Refer to SECTION 603.

24 BOLT/SCREW, VALVE ROCKER ARM COVER
PC0013-6A3B-F-RP
6. Transmission fluid level indicator tube assembly to

transmission housing (automatic transmission only.)

8. Lower vehicle.
Left Cover Assembly

2. Secondary air injection hose from pump to check
valve assembly.
3. Rocker arm cover bolts/screws (24).
4. Rocker arm cover assembly (23) and gasket (25).
fi,I
Clean
Rocker arm cover assembly and cylinder head gasket surfaces.

section.
1. Gasket (25) and rocker arm cover assembly (23).
2. Rocker arm cover bolts/screws (24).
l~I
[I] Important
Tighten
Rocker arm cover bolts/screws (24) to 11 Nm

(100 lb. in.).
3. Secondary air injection hose to pump and check
valve assembly.

ASSEMBLIES
l~I
Figure 10

2. Rocker arm nuts (31) and rocker arm balls (30).
3. Rocker arms (29) and pushrod assemblies (27).
Place the rocker arms (29), rocker arm balls
(30) and pushrod assemblies (27) in a rack so
that they can be reinstalled in the same locations from which they were removed.
[I] Important
Refer to SECTION 6A3B for inspection of the rocker arms, studs and pushrod assemblies.

section.
27
28
29
30
31
When installing rocker arms (29) and mcker

arm balls (30), coat their bearing surfaces with
prelube, GM PIN 1052365 or equivalent.
Install these components and the pushrod
assemblies (27) in the locations from which
they were removed.
2. Rocker arms (29).
3. Rocker arm balls (30) and rocker arm nuts (31).

STUD, VALVE ROCKER ARM BALL
ARM, VALVE ROCKER
Tighten
Rocker arm nuts (31) until all lash is eliminated.
11 Adjust
1. Turn crankshaft assembly until cast arrow on crankshaft hub is in 12 o'clock position and number 1
cylinder is in firing position (top dead center).
Watch number 1 cylinder valves as crankshaft
hub arrow approaches 12 o'clock position. If a
valve moves as the arrow moves to position,
the engine is in number 6 cylinder firing position. Crankshaft assembly must then be turned
one more time to reach number 1 cylinder firing position.
2. With engine in number 1 cylinder firing position, the
following valves can be adjusted:
Exhaust 1, 3, 4, 8
Intake 1, 2, 5, 7
3. Back off rocker arm nut (31) until lash is felt in
pushrod assembly (27). Then tighten rocker arm nut
(31) until all lash is removed. Zero lash can be felt
by rotating pushrod assembly (27) between thumb
and forefinger until there is no more movement.
4. When all free play has been removed, tighten rocker
arm nut (31) one additional turn.
5. Turn crankshaft assembly one revolution until hub
arrow is again at 12 o'clock position. This is number
6 cylinder firing position. The following valves can
now be adjusted:
Exhaust 2, 5, 6, 7
Intake 3, 4, 6, 8
6. Install valve rocker arm cover assemblies. Refer to
"Valve Rocker Arm Cover Assemblies" in this section.
ROCKER ARM STUDS

Figure 10
Rocker arm studs that have damaged threads should
be replaced with new studs.

PC0014-6A3B-F-RP
Figure 10 - Valve Rocker Arms and Push rod Assemblies
1. Valve rocker arm cover assembly. Refer to "Valve

5.7 LITER V8 ENGINE ON-VEHICLE SERVICE RPO LT1 - VIN P 6A3A-11

2. Valve rocker arm. Refer to "Valve Rocker Arms and
3. Rocker arm stud (28).

section.
1. Apply sealer, GM P/N 1052080 or equivalent, to
threads of new rocker arm stud.
2. Rocker arm stud (28).
!~I
Tighten
Rocker arm stud (28) to 68 Nm (50 lb. ft.).

3. Valve rocker arms. Refer to "Valve Rocker Arms
and Pushrod Assemblies" in this section.
4. Valve rocker arm cover assembly. Refer to "Valve

Figure 11
Tools Required:
27
32
33
34
35
36

BOLT/SCREW, VALVE LIFTER GUIDE RETAINER
RETAINER, VALVE LIFTER GUIDE
GUIDE, VALVE LIFTER
J 3049 Hydraulic Valve Lifter Remover (Plier

Type)
PC0015-6A3B-F-RP
Figure 11 - Valve Lifter Assemblies
J 9290-01 Hydraulic Valve Lifter Remover

(Slide Hammer Type)
No service parts are available for valve lifter assemblies. They are replaced as a unit when worn and when a
new camshaft assembly is installed.

1. Intake manifold assembly. Refer to "Intake Manifold Assembly" in this section.
this section.
4. Valve lifter guide retainer (33) and bolts/screws
(32).
5. Valve lifter guide (35) and valve lifter assembly
(36).
Some valve lifter assemblies (36) may be stuck
in their bores because of gum or varnish deposits. These valve lifter assemblies (36) can be
removed using J 3049 or J 9290-01.
[I] Important
Refer to SECTION 6A3B for inspection of the valve
lifter assemblies.

section.
1. Coat valve lifter rollers with prelube, GM PIN

2. Valve lifter assemblies (36) in the same location
from which they were removed.
3. Valve lifter guides (35), valve lifter guide retainer
(33) and bolts/screws (32).
l~I Tighten
this section.
WATER PUMP ASSEMBLY

The water pump assembly is directly driven by the
pump shaft which is coupled to a bearing, gear and shaft
assembly driven by the camshaft sprocket. Refer to SECTION 6B for water pump assembly service procedures.
CRANKSHAFT BALANCER ASSEMBLY AND

HUB
Figure 12
Tool Required:
J 39046 Crankshaft Hub Remover/Installer
6A3A12 5.7 LITER VB ENGINE ON-VEHICLE SERVICE RPO LT1 -VIN P
l++I
[I] Important
If balancer assembly is replaced, new balance

weights of the same size must be installed on
the new balancer assembly in the same hole
locations as the old balancer assembly.

3. Balancer bolts/screws (46) and balancer assembly
(42).
4. Matchmark crankshaft hub (45) to engine front
cover assembly.
Do not crank engine over after match-marking
crankshaft hub and engine front cover assembly. Rotating crankshaft assembly will misalign installation of balancer assembly to
crankshaft assembly possibly resulting in engine imbalance.
5. Crankshaft hub bolt/screw and washer.
6. Crankshaft hub (45) using J 39046.
The crankshaft hub (45) can be installed by a different procedure if the engine should accidentally be cranked
over after matchmarking the hub and engine front cover
assembly.
A. Set number 1 piston assembly to top dead center.

B. Install crankshaft hub (45) with cast arrow on
hub in the 12 o'clock position.
l++I
Install or Connect

section.
1. Crankshaft hub (45) using J 39046.
2. Crankshaft hub washer and bolt/screw.
3. Crankshaft balancer assembly (42) and bolts/screws
(46).
l~I
Tighten
Crankshaft balancer hub bolt/screw to 102

Nm (75 lb. ft.).
Crankshaft balancer bolts/screws (46) to 81
Nm (60 lb. ft.).
5. Lower vehicle.
DISTRIBUTOR ASSEMBLY
The distributor assembly is mounted to the engine
front cover assembly and driven by a splined shaft connected to the camshaft sprocket. Refer to SECTION 604
for the distributor assembly service procedures.

Figure 13
Tool Required:
J 39087 Driven Gear Shaft Front Cover Seal
Protector
l++I
1. Throttle body air duct.

3. Water pump assembly. Refer to SECTION 6E.
4. Crankshaft balancer assembly and hub. Refer to
"Crankshaft Balancer Assembly and Hub" in this
section.
5. Distributor assembly. Refer to SECTION 604.
this section.
8. Engine front cover assembly (50) and gasket (51).
l~I
Clean
Engine front cover and engine block gasket surfaces.
ll'l'I
Inspect
Engine front cover assembly (50) for damage to the

seals or gasket surface. Refer to SECTION 6A3B to
replace front cover seals if necessary.
l++I
42
45
46
77

HUB, CRANKSHAFT BALANCER
BOLT/SCREW, CRANKSHAFT BALANCER
WEIGHT, CRANKSHAFT BALANCER
PC0017-6A38-F-RP
Figure 12 - Crankshaft Balancer Assembly and Hub
Install or Connect

section.
NOTICE: Be careful not to damage the seal when
installing the engine front cover assembly over the
water pump driveshaft assembly.
5.7 LITER VB ENGINE ON-VEHICLE SERVICE RPO LT1 -VIN P 6A3A13
50
50
51
52
74

PIN, ENGINE FRONT COVER LOCATING
PC0019-&A3B-F-RP
1. Gasket (51) and engine front cover assembly (50)

using J 39087 on water pump driveshaft assembly.
l~I
3.
4.
5.
6.
7.
8.
Tighten
Engine front cover bolts/screws (52) to 11

Nm (100 lb. in.).
Oil pan assembly. Refer to "Oil Pan Assembly" in
this section.
Distributor assembly. Refer to SECTION 604.
Crankshaft balancer assembly and hub. Refer to
"Crankshaft Balancer Assembly and Hub" in this
section.
Water pump assembly. Refer to SECTION 6B.
TIMING CHAIN ASSEMBLY, CRANKSHAFT

AND CAMSHAFT SPROCKETS, AND WATER
PUMP DRIVESHAFT ASSEMBLY
Figures 14 and 15
Tools Required:
J 5825-A Crankshaft Gear Remover
J 5590 Crankshaft Gear Installer
J 39243 Driven Gear Assembly Remover
J 39092 Driven Gear Assembly Installer
Protector
J 39089 Driven Gear/Water Pump Shaft Seal
Installer
l++I

2. Rotate crankshaft assembly until timing marks
punched on crankshaft sprocket (62) and camshaft
sprocket (57) are aligned as shown in Figure 14.
(61).
NOTICE: Do not turn the crankshaft assembly after

the timing chain has been removed to prevent damage to piston assemblies or valves.
5. Water pump bearing retainer bolts/screws (64) and
water pump driveshaft assembly (63) using J 39243.
Remove and discard 0-ring from water pump
driveshaft assembly (63).
6. Crankshaft sprocket (62) using J 5825-A.
7. Key, if necessary.
!l'l'I Inspect
Refer to SECTION 6A3B for component inspection.

section.
1. Key, if previously removed.
2. Crankshaft sprocket (62) using J 5590.
3. Water pump driveshaft assembly (63) using J 39092.
4. Water pump bearing retainer bolts/screws (64).
6A3A-14 5.7 LITER va ENGINE ON-VEHICLE SERVICE RPO LT1 -VIN P
A
B
56
57
58
59
60
61
62
63
64
TIMING MARKS
KEYWAY
SPROCKET, CAMSHAFT
BOLT/SCREW, CAMSHAFT RETAINER
RETAINER, CAMSHAFT
CAMSHAFT ASSEMBLY
SPROCKET,CRANKSHAFT
DRIVESHAFT ASSEMBLY, WATER PUMP
BOLT/SCREW, WATER PUMP DRIVESHAFT BEARING
RETAINER
PC0020-6A3BfRP
Figure 14 - Camshaft Assembly, Sprockets and Water Pump Driveshaft Assembly
l~I
Tighten
Water pump bearing retainer bolts/screws (64)

to 12 Nm (105 lb. in.).
(61).
Camshaft sprocket and water pump driveshaft

gears must mesh, or damage to camshaft
retainer (59) could occur.
Make sure that camshaft and crankshaft timing
marks align as shown in Figure 14.
l~I
Tighten
Camshaft sprocket bolts/screws (56) to 28

Nm (21 lb. ft.).
7. New 0-ring to water pump driveshaft assembly
using J 39089.
8. Engine front cover assembly. Refer to "Eflgine

CAMSHAFT ASSEMBLY


this section.
3. Bolt/screw (66) and oil pump driveshaft assembly
(65).
4. Engine front cover assembly. Refer to "Eflgine
65 DRIVESHAFT ASSEMBLY, OIL PUMP

66 BOLT/SCREW, OIL PUMP DRIVESHAFT
PC0022-6A3B-F-RP
Figure 16 - Oil Pump Driveshaft Assembly
62 SPROCKET.CRANKSHAFT
PC0021-6A3B-F-RP
Figure 15 - Crankshaft Sprocket Replacement
5. Camshaft sprocket. Refer to "Timing Chain Assembly, Crankshaft and Camshaft Sprockets, and Water
Pump Driveshaft Assembly" in this section.
8. Air conditioning compressor and condenser hose
from condenser.
condenser.
10. Radiator assembly with air conditioning condenser.
11. Air conditioning condenser support assembly.
12. Camshaft retainer bolts/screws (58) and camshaft
retainer (59).
to avoid damage to the bearings.
rn

camshaft bolt holes.
out of bearings.
Important
Refer to "Cleaning, Inspection and Repair" in SECTION 6A3B for inspection and measurement procedures for the camshaft assembly.
Refer to "Valve Rocker Arms and Pushrod Assemblies" in SECTION 6A3B to measure camshaft lobe
lift.
!l'l'I Inspect
Camshaft bearings for scratches, pits, or loose fit in
their bores. Replace the camshaft bearings, if necessary. Refer to SECTION 6A3B.

1.
2.
3.
4.

section.
When installing a new camshaft assembly (60), coat
camshaft lobes with "Molykote" or its equivalent.
When installing a new camshaft assembly (60),
replace all valve lifter assemblies to ensure durability of the camshaft lobes and lifter rollers.
Lubricate all camshaft journals with e11gine oil.
Camshaft assembly (60).
6A3A-16 5.7 LITER VB ENGINE ON-VEHICLE SERVICE RPO LT1 -VIN P

this section.
VALVE SPRING AND STEM SEAL

Tools Required:
J 22794 Spark Plug Port Adapter
J 5892-C Valve Spring Compressor (Head-On)
l+I
1. Valve rocker arms and pushrod assemblies at cylinder to be serviced. Refer to "Valve Rocker Arms and
2. Spark plug at cylinder to be serviced.
3. Install J 22794 to spark plug hole and apply compressed air to hold valves in place.
4. Compress valve spring (69) using J 5892-C (Figure
18).
5. Valve stem keys (72).
A 5/16-18 x 4" BOLTS

PC0023-6A3B-F-RP
Figure 17 - Removing Camshaft Assembly
6. Valve spring cap (70).

7. Valve spring (69).
8. Valve stem oil seal (73).
5. Camshaft retainer (59) and camshaft retainer bolts/

screws (58).
l~I
6.
7.
8.
9.
Tighten
Camshaft retainer bolts/screws (58) to 12 Nm

(105 lb. in.).
Air conditioning condenser support assembly.
Radiator assembly with air conditioning condenser.
Air conditioning receiver and dehydrator hose to
condenser.
Air conditioning compressor and condenser hose to
condenser.
10. Charge air conditioning system. Refer to SECTION

lB.
12. Camshaft sprocket. Refer to "Timing Chain Assembly, Crankshaft and Camshaft Sprockets, and Water
Pump Driveshaft Assembly" in this section.
14. Oil pump driveshaft assembly (65) and bolt/screw
(66).
l~I
Tighten
31 NUT, VALVE ROCKER ARM

69 SPRING, VALVE
PC0064-6A3AF-RP
5.7 LITER VS ENGINE ON-VEHICLE SERVICE RPO LT1 -VIN P 6A3A-17
CYLINDER HEAD ASSEMBLY AND GASKET

71
Figure20
Left Cylinder Head Assembly
69 SPRING, VALVE
CAP, VALVE SPRING
VALVE, INTAKE
KEY, VALVE STEM
SHIM, VALVE SPRING
70
71
72
73
76
PC0044-6A3B-FRP
Figure 19 - Valve Assembly (Intake Shown, Exhaust Similar)

L Valve stem oil seal (73) and seat seal against valve
spring shim (76).
3. Valve spring cap (70).

4. Compress valve spring (69) using J 5892-C.
A. Use grease to hold keys in place while disconnecting J 5892-C.
B. Remove J 22794.
C. Make sure keys seat properly in upper groove
of valve stem.

3. Crossover pipe from exhaust manifold assembly.
4. Lower vehicle.
6. Secondary air injection hose from check valve
assembly.
7. Coolant air bleed pipe bolt/screw from left cylinder
head assembly using a backup wrench on pipe fitting.
8. Ignition coil bolts/screws and coil assembly. Refer
to SECTION 604.
9. Left exhaust manifold assembly. Refer to"Exhaust
10. Spark plug wire harness assembly from clips.
11. Spark plug wire harness assembly from spark plugs.
12. Spark plugs.
14. Rocker arm cover bolts/screws and cover assembly.
Refer to "Valve Rocker Arm Cover Assemblies" in
this section.
15. Rocker arm nuts, rocker arms, and pushrod assemblies. Refer to "Valve Rocker Arms and Pushrod
16. Cylinder head bolts/screws (81 ).
17. Cylinder head assembly (34) and cylinder head gasket (82).
Discard cylinder head gasket (82).
rn
D. Tap end of stem with plastic-faced hammer to

seat keys, if necessary.
6. Spark plug.
l~.J
Tighten
Important
1.
2.
Spark plug to 15 Nm (11 lb. ft.).
3.

this section.
4.

section.
New cylinder head gasket (82) with yellow tab facing up.
Cylinder head assembly (34) over locator pins and
cylinder head gasket (82).
Coat threads of cylinder head bolts/screws (81) with
sealing compound, GM PIN 1052080 or equivalent.
Cylinder head bolts/screws (81) finger tight.
6A3A18 5.7 LITER V8 ENGINE ON-VEHICLE SERVICE RPO LT1 -VIN P
16 12
A
B
34
67
81
82
GASKET TAB (YELLOW SIDE UP)

BOLT TIGHTENING SEQUENCE
BLOCK, ENGINE
PC0024-8A3BFRP
l~I

and in three passes to 88 Nm (65 lb. ft.) (Figure 20).
5. Pushrod assemblies and valve rocker arms. Refer to
this section.
6. Right valve rocker arm cover assembly and bolts/
screws.
l~I
lJ Tighten
Tighten
14.
15.
16.
17.
Tighten
Valve rocker arm cover bolts/screws to 11 Nm

(100 lb. in.).
18.
19.
Engine coolant air bleed pipe bolt/screw to

41 Nm (30 lb. ft.).
Secondary air injection hose to check valve assembly.
Intake manifold assembly. Refer to "Intake Manifold Assembly" in this section.
Crossover pipe to exhaust manifold assembly. Refer
to SECTION 6F.
Lower vehicle.
Right Cylinder Head Assembly
8. Spark plugs.
l++I
l~I
Tighten

10. Spark plug wire harness assembly to clips.
11. Left exhaust manifold assembly. Refer to"Exhaust
12. Ignition coil bolts/screws and coil assembly.
l~I
Tighten
Ignition coil bolts/screws to 33 Nm (24 lb.

ft.).
13. Engine coolant air bleed pipe and bolt/screw to left
cylinder head assembly using a backup wrench on
pipe fitting.
1. Raise and suit~bly support vehicle. Refer to SECTION OA.

3. Serpentine drive belt and belt tensioner assembly.
Refer to "Serpentine Drive Belt and Tensioner
4. Transmission fluid level indicator tube assembly
bracket from transmission housing.
5. Air conditioning compressor rear brace bolt/screw
from engine block.
6. Air conditioning compressor electrical connector.
7. Air conditioning compressor front mounting bolts/
screws and lay air conditioning compressor aside.
8. Right exhaust manifold assembly. Refer to "Exhaust
9. Lower vehicle.

11. Right valve rocker arm cover assembly. Refer to
13. Coolant air bleed pipe bolt/screw from left cylinder
head assembly.
14. Lower radiator hose from water pump assembly and
reposition.
15. Heater hose from water pump assembly and reposition.
16. Coolant air bleed pipe assembly hose from radiator.
3B.
18. Generator bracket bolts/screws and generator and air
conditioning compressor and power steering pump
bracket assembly.
20. Spark plugs.
this section.
Discard gasket (82).
24. Coolant air bleed pipe bolt/screw and pipe assembly
from cylinder head assembly.
rn
Important

1.
2.
3.
4.
5.

section.
Coolant air bleed pipe assembly and bolt/screw to
cylinder head assembly using backup wrench.
New cylinder head gasket (82) with yellow tab facing up.
Cylinder head assembly (34) over dowel pins and
gasket (82).
Coat threads of cylinder head bolts/screws (81) with
sealing compound, GM PIN 1052080 or equivalent.
l~I Tighten
41 Nm (30 lb. ft.).
6. Pushrod assemblies and valve rocker arms. Refer to
this section.
7. Spark plugs.
l~I
Tighten

9. Generator and air conditioning compressor and
power steering pump bracket assembly and generator bracket bolts/screws.
l~I
10.
11.
12.
13.
14.
15.
16.
Generator bracket bolts/screws to 42 Nm

(31 lb. ft.).
Right valve rocker arm cover assembly. Refer to
Generator assembly. Refer to SECTION 6D3.
Power steering pump assembly. Refer to SECTION
3B.
Coolant air bleed pipe assembly hose to radiator.
Heater hose to water pump assembly and reposition.
Lower radiator hose to water pump assembly.
Coolant air bleed pipe bolt/screw to left cylinder
head assembly using backup wrench.
l~I
17.
18.
19.
20.
21.
22.
24.
25.
26.
Tighten

41 Nm (30 lb. ft.).
Intake manifold assembly. Refer to "Intake Manifold Assembly" in this section.
Right exhaust manifold assembly. Refer to "Exhaust
Air conditioning compressor front mounting bolts/
screws.
Air conditioning compressor electrical connector.
Air conditioning compressor rear brace bolt/screw
to engine block.
l~I
23.
Tighten
Tighten
Air conditioning compressor rear brace bolt/

screw to 33 Nm (24 lb. ft.).
Transmission fluid level indicator tube assembly
bracket to transmission housing.
Serpentine drive belt and belt tensioner assembly.
Refer to "Serpentine Drive Belt and Tensioner
Lower vehicle.
ENGINE OIL COOLER AND HOSE

ASSEMBLY

Figure 21
1. Drain coolant.
2. Oil filter assembly (144).
6A3A-20 5.7 LITER va ENGINE ON-VEHICLE SERVICE RPO LT1 -VIN P

3. Engine oil cooler bolt/screw (140) to engine oil
cooler assembly (141).
l~I
Tighten
Engine oil cooler bolt/screw to 33 Nm (24 lb.

ft.).
4. Engine oil cooler hose bracket nut.
l~I
Tighten
Engine oil cooler hose bracket nut to 17 Nm

(13 lb. ft.).
5. Oil filter assembly (144).
6. Refill coolant. Refer to SECTION 6B.
OIL PAN ASSEMBLY

Figures 22 and 23

1.
2.
3.
129
140
141
142
143
144
HOSE ASSEMBLY, ENGINE OIL COOLER

BOLT/SCREW, ENGINE OIL COOLER
COOLER ASSEMBLY, ENGINE OIL
ADAPTER ASSEMBLY, OIL FILTER
BOLT/SCREW, OIL FILTER ADAPTER
FILTER ASSEMBLY, OIL
4.
5.
6.
7.
8.
9.
10.
PC0063-6A3A-F-RP
Figure 21 - Engine Oil Cooler and Hose Assembly
3. Engine oil cooler bolt/screw (140) from engine oil

cooler hose assembly manifold fitting and oil cooler
assembly (141).
4. Nut from engine oil cooler hose bracket.
5. Engine oil cooler hose assembly clamps from radiator and water pump assemblies.
6. Engine oil cooler hose assembly (129).
7. Engine oil cooler assembly (141) from oil filter
adapter assembly (142).

section.
1. Engine oil cooler assembly ( 141) to oil filter adapter
assembly (142).
l~I
Tighten
Engine oil cooler fitting to 23 Nm (17 lb. ft.).

2. Engine oil cooler hose assembly (129) and clamps to
radiator and water pump assemblies.
11.
12.
13.
14.
15.
16.
17.
18.

Air intake duct.
Drain engine oil.
Oil level sensor assembly ( 178).
Exhaust crossover pipes from exhaust manifold
assemblies. Refer to SECTION 6F.
Exhaust pipe hanger bolt/screw and reposition pipe.
Engine oil cooler hose bracket nut from oil pan assembly.
Engine oil cooler bolt/screw from engine oil cooler
assembly and reposition engine oil cooler hose
assembly.
Transmission fluid cooler lines from clip at oil pan
Starter motor assembly. Refer to SECTION 6D2.
Converter cover bolts/screws and cover (automatic
transmission).
Raise engine with jacking fixture.
Oil pan bolts/screws (84), studs (83) and nuts (85).
Oil pan assembly (54), reinforcements (53) and gasket (55).
Rotate crankshaft assembly to reposition counterweights if necessary.
IW:,I Clean
1. Oil pan and engine block gasket surfaces.
2. Apply a small amount of sealer, GM PIN 105291 ~ or
equivalent, to the front cover assembly and_ er1gme
block junction and to the rear oil seal housm~ and
engine block junction. Apply sealer 25 mm (1 mch)
-.........._.
55
55
A
53
54
55
SEALER
PAN ASSEMBLY, OIL
GASKET, OIL PAN
PC0052-6A3B-FRP
Figure 22 - Oil Pan Sealer
in either direction of the radius cavity of these junctions. See Figure 22.
l~I

section.
1. Oil pan gasket (55), oil pan assembly (54) and reinforcements (53).
2. Oil pan nuts (85), bolts/screws (84) and studs (83).
l~I
Tighten
Corner oil pan bolts/screws (84) or stud (83),

and nuts (85) to 20 Nm (15 lb. ft.).
Remainder of oil pan bolts/screws (84) and
studs (83) to 11 Nm (100 lb. in.).
3. Lower engine.
5. Oil level sensor assembly (178).
l~I
6.
7.
8.
9.
Tighten
Engine mount through-bolts/screws to 95 Nm

(70 lb. ft.).
Engine oil level sensor assembly ( 178) to 22
Nm (16 lb. ft.).
Converter cover and bolts/screws (automatic transmission).
Transmission fluid cooler lines to clip at oil pan
Engine oil cooler bolt/screw to engine oil cooler
assembly.
10.
11.
12.
13.
14.
15.
16.
17.
18.
Tighten
Engine oil cooler bolt/screw to 33 Nm (24 lb.

ft.).
Engine oil cooler hose bracket nut to oil pan assembly.
Exhaust pipe hanger bolt/screw.
Exhaust crossover pipes to exhaust manifold assemblies. Refer to SECTION 6F.
Lower vehicle.
Air intake duct.
Refill engine with oil.
OIL PUMP ASSEMBLY

Figure 24

this section.
2. Oil pan baffle nuts.
3. Bolt/screw (120) attaching oil pump assembly (118)
to rear crankshaft bearing cap.
4. Oil pan baffle (119), oil pump assembly (118) and
driveshaft (89) and retainer (95).
rn
Important
Refer to SECTION 6A3B for oil pump assembly

cleaning, inspection and repair.
120
89
95
118
119
120
53

RETAINER, OIL PUMP DRIVESHAFT
PUMP ASSEMBLY, OIL
BAFFLE, OIL PAN
PC0026-6A3B-FRP

1.
53
54
55
83
84
85
178
190

PAN ASSEMBLY, OIL
GASKET, OIL PAN
STUD, OIL PAN
BOLT/SCREW, OIL PAN
NUT, OIL PAN
SENSOR ASSEMBLY, ENGINE OIL LEVEL SWITCH
BRACKET, ENGINE WIRING HARNESS
PC0053-6A3BFRP
2.
3.
4.

section.
Oil pump assembly (118), and driveshaft (89) with
retainer (95).
Align slot on end of driveshaft (89) with drive
tang on oil pump assembly (118).
Oil pan baffle ( 119).
Bolt/screw ( 120) attaching oil pump assembly (118)
Oil pan baffle nuts.
l~I
Tighten

Oil pan baffle nuts to 34 Nm (25 lb. ft.).
this section.
5.7 LITER VB ENGINE ON-VEHICLE SERVICE RPO LT1 - VIN P 6A3A-23

C. Install connecting rod nuts (100).
Figure25
and do not use shims for adjustment. Do not file connecting rods or rod caps. If clearances are found to be excessive, a new bearing will be required. Service bearings are
available in standard size and 0.001 and 0.002-inch undersize for use with new and used standard size crankshafts,
and in 0.010 and 0.020-inch undersize for use with
reconditioned crankshafts.
When removing a connecting rod cap, you may find
a 0.010-inch undersize bearing. These are used in
manufacturing for selective fitting.
l++I
l~I

61 Nm (45 lb. ft.).
NOTICE: Do not turn the crankshaft assembly with
the gaging plastic installed or the accuracy of the
D. Remove connecting rod nuts (100) and connecting rod cap (99). The gaging plastic will be
found adhering to either the connecting rod cap
(99) or crankshaft journal. Leave the gaging
plastic in place to measure it.
E. Measure gaging plastic at its widest, using
scale provided with gaging plastic. Refer measurements to "Specifications" in this section.

this section.
in this section.

select an undersize bearing (101) and
re-measure clearance.
[I] Important
rod assemblies ( 104) and connecting rod caps
(99). Connecting rod caps (99) must be assembled to their original connecting rod assemblies (104).
3. Connecting rod nuts ( 100).
4. Connecting rod cap (99) and bearings ( 101 ).
Keep bearings (101) with their original connecting rod assembly (104) and connecting rod
cap (99) for reassembly.
Wipe oil from bearings (101) and crankpins.
ll"'I
Inspect
l@I
Measure

section.
section.
If not within specifications, replace or recondition crankshaft assembly (98).
If installing new bearings ( 101 ), determine
new bearing size from maximum crankpin diameter.
2. Bearing clearances, using gaging plastic.
A. Place piece of gaging plastic the full width of
bearing (101), (parallel to crankshaft assembly) onto crankpin.
Plastic gage should be positioned in
Tighten
If clearance cannot be brought to specifications, regrind crankpin. If crankpin is

already at maximum undersize, replace
crankshaft assembly (98).
F. Remove gaging plastic.
l++I
Install or Connect

section.
1. Coat inside surface of bearings (101) with engine
oil.
l~I
Tighten

(45 lb. ft.).
l@I
Measure
Connecting rod side clearance.

A. When all connecting rod bearings (101)
have been installed, tap each connecting
rod assembly (104) lightly parallel to
crankpin to make sure they have clearance.
B. Measure side clearance between connecting rod caps (99) using a feeler gage, or
dial indicator.
C. Rod side clearance should be 0.16 to 0.35
mm (0.006 to 0.014 inch).
in this section.
this section.
6A3A-24 5.7 LITER V8 ENGINE ON-VEHICLE SERVICE RPO LT1 -VIN P

ASSEMBLIES
Figure25
99
\~100
~~~~~~.
1;J,,.1 .7 ----101
I~

Tools Required:

this section.
in this section.
4. Ring ridge.
101

103


assembly ( 103) is at top of its stroke.
[I] Important
98
Place matchmarks or number<; on connecting

assemblies (104).
103
5. Connecting rod nuts (100) and connecting rod cap

(99).
~ FRT

(103) out of top of engine block using J 5239.
[ ] ] Important
IVIEWB I
A FLANGES OF CONNECTING RODS MUST FACE TO THE

FRONT IN THE LEFT BANK AND TO THE REAR IN THE
RIGHT BANK
B ARROW TO BE ORIENTED TO FRONT OF ENGINE
99 CAP, CONNECTING ROD
100 NUT, CONNECTING ROD
101 BEARING, CONNECTING ROD
102 BOLT/SCREW, CONNECTING ROD
103 PISTON ASSEMBLY
104 ROD ASSEMBLY, CONNECTING
Refer to SECTION 6A3B for cleaning, inspection

and repair of the piston and connecting rod assembly.
!i,I Clean
1. Cylinder bores with hot water and detergent or with
a light honing.
2. Swab bores with engine oil and a clean, dry cloth.

section.
PC0027-6A3BF-RP
Figure 25 - Piston and Connecting Rod Assemblies


2. Piston assembly (103) into its original bore using
J 5239 and J 8037 and lightly tapping top of piston
assembly (103) with a wooden hammer handle.
A. When installing piston assembly (103) and
connecting rod assembly (104), stamped arrow
on piston assembly (103) must point to front of
engine while flange on connecting rod assembly ( 104) must face toward front of piston on
left-hand assembly and face toward rear of piston on right-hand assembly. Refer to Figure 25.
B. Hold J 8037 firmly against engine block until
3. Connecting rod caps (99) onto their original connecting rod assemblies (104).
Align matchmarks or numbers which were
placed on connecting rod assembly ( 104) and
connecting rod cap (99) during removal.
l~I
Tighten

(45 lb. ft.).
in this section.
this section.
CRANKSHAFT BEARINGS
Figures 26 and 27
Tool Required:
J 8080 Main Bearing Shell Remover and Installer
Crankshaft bearings are of the precision insert type.
If clearances are found to be excessive, a new bearing,
both upper and lower halves, will be required. Service
bearings are available in both standard size and undersize.
Selective fitting of both connecting rod and crankshaft bearing inserts is necessary in production in order to
obtain close tolerances. For example, on a rear crankshaft
bearing you may find one half of a standard insert with
one half of a 0.001 inch undersize insert which will decrease the clearance 0.0005 inch from using a full standard bearing.
rn
Important
If replacing the rear crankshaft bearing, check for

the correct part number. Some rear crankshaft bearings are 0.20 mm (0.008 inch) wider than standard.
The crankshaft assembly will be identified by
"0.008" stamped on the rear counterweight.

this section.

in this section.
3. Spark plugs.
4. Cap ( 107 or 109) and lower bearing of crankshaft
bearing ( 110 or 111) requiring replacement.
5. Insert J 8080 into oil hole in crankshaft journal.
6. Rotate crankshaft assembly (98) allowing J 8080 to
push against insert's straight (unnotched) side. This
will roll upper bearing out of block.
7. Remove J 8080 from crankshaft assembly (98).
ll'l'! Inspect
In general, the lower half of the crankshaft bearing
insert (except # 1 bearing) shows a greater wear and
the most distress from fatigue. If upon inspection the
lower half is suitable for use, it can be assumed that
the upper half is also satisfactory. If the lower half
shows evidence of wear or damage, both upper and
lower halves should be replaced. Never replace one
half without replacing the other half.
rn
Important
To obtain the most accurate results when checking

crankshaft bearing clearances, use gaging plastic.
If the engine is out of the vehicle and upside down,
the crankshaft assembly will rest on the upper bearings and the total clearance can be measured
between the lower bearing and journal. If the engine
is to remain in the vehicle, the crankshaft assembly
must be supported upward to remove any clearance
from the upper bearing. The total clearance can then
be measured between the lower bearing and journal.
To assure the proper seating of the crankshaft assembly, all bearing cap bolts/screws should be at their
specified torque. In addition, prior to checking fit of
bearings, the surface of the crankshaft journal and
bearing should be wiped clean of oil.
I@! Measure
1. With oil pan and oil pump assemblies removed, and
starting with rear crankshaft bearing, remove bearing cap and wipe oil from journal and bearing cap.
Note location of stud bolts/screws.
2. Place a piece of gaging plastic the full width of bearing (parallel to the crankshaft assembly) on journal.
[I] Important
Do not rotate the crankshaft assembly while
the gaging plastic is between the bearing and
journal.
3. Install bearing cap and evenly tighten retaining
bolts/screws to specifications. Bearing cap must be
tightened to specification in order to assure proper
reading. Variations in torque affect the compression
of the gaging plastic.
115
67
98
107
108
109
110
111
112
113
114
115
116
139
BLOCK, ENGINE
CRANKSHAFT ASSEMBLY
BOLT/SCREW, CRANKSHAFT BEARING CAP
BEARING, CRANKSHAFT
BEARING, CRANKSHAFT
STUD, CRANKSHAFT REAR OIL SEAL RETAINER
GASKET, CRANKSHAFT REAR OIL SEAL HOUSING
HOUSING ASSEMBLY, CRANKSHAFT REAR OIL SEAL
NUT, CRANKSHAFT REAR OIL SEAL HOUSING
BOLT/SCREW, CRANKSHAFT REAR OIL SEAL HOUSING
PIN, CRANKSHAFT REAR OIL SEAL HOUSING LOCATOR
139
PC00286A3BFRP
l~I
Tighten
Crankshaft bearing cap bolts/screws (108) and

studs to 105 Nm (77 lb. ft.).
4. Remove bearing caps. The flattened gaging plastic
will be found adhering to either the bearing shell or
journal.
io
KC0047-6A3-F-RP
Figure 27 - Removing Crankshaft Bearing
5. Without removing gaging plastic, measure its compressed width (at the widest point) with graduations
on gaging plastic envelope. Normally crankshaft
bearing journals wear evenly and are not out-ofround. However, if a bearing is being fitted to an
out-of-round journal (0.001 inch maximum), be sure
to fit to maximum diameter of journal: If bearing is
fitted to minimum diameter, and journal is out-ofround 0.001 inch, interference between bearing and
journal will result in rapid bearing failure. If flattened gaging plastic tapers toward middle or ends,

there is a difference in clearance indicating taper,
low spot or other irregularity of bearing or journal.
Be sure to measure journal with a micrometer if flattened gaging plastic indicates more than 0.001 inch
difference.
6. If bearing clearance is within specifications, bearing
insert is satisfactory. If clearance is not within specifications, replace insert. Always replace both upper
and lower inserts as a unit. When bearing cap is
installed and clearance is less than 0.001 inch,
inspect for burrs or nicks.
7. A standard, 0.001 inch or 0.002 inch undersize bearing may produce proper clearance. If not, it will be
necessary to regrind crankshaft journal for use with
next undersize bearing. After selecting new bearing,
recheck clearance.
8. Proceed to next bearing. When checking #1 crankshaft bearing, loosen accessory drive belt .so as to
prevent tapered reading with gaging plastic. After all
bearings have been checked, rotate crankshaft
assembly to see that there is no excessive drag.

section.
1. Crankshaft bearings ( 110 and 111) into engine block
(67) and crankshaft bearing caps (107) and rear
crankshaft bearing cap (109).
A. Coat crankshaft bearings ( 110 and 111) with
oil.
B. Insert plain (unnotched) end between crankshaft assembly and indented or notched side of
block. Rotate bearing into place using J 8080
as previously described, and remove J 8080
from oil hole in crankshaft journal.
2. Crankshaft bearing caps ( 107) and rear crankshaft
bearing cap (109) with assembled crankshaft bearings ( 110 and 111) with arrows pointing toward front
of engine.
3. Crankshaft bearing cap bolts/screws (108) and
studs.
bearings ( 110 and 111) and crankshaft bearing
caps ( 107) and rear crankshaft bearing cap
( 109) installed and bolts/screws ( 108) and
studs started, thrust crankshaft assembly (98)
rearward to set and align bearing caps ( 107 and
109). Then thrust crankshaft assembly forward
to align rear faces of rear crankshaft bearings
(111 ).
l~I Tighten
studs to 105.Nm (77 lb. ft.).
l@I
Measure
Crankshaft end play, using a dial indicator or

feeler gage. Refer to "Specifications" in this
section.
If using a feeler gage, measure between the

front of the rear crankshaft bearing cap ( 109)
and the crankshaft thrust surface.
FLYWHEEL ASSEMBLY
Figure28
Flywheel Assembly Replacement

1. Transmission assembly. Refer to SECTION 7 A for
clutch.
2. Flywheel bolts/screws (136 or 138) and flywheel assembly (135 or 137).

section.
1. Flywheel assembly (135 or 137) and flywheel bolts/
screws (136 or 138).
l~I Tighten
Flywheel bolts/screws (136 or 138) to 100
Nm (74 lb. ft.).
2. Transmission assembly. Refer to SECTION 7 A for
clutch.
Flywheel Assembly Balancing
Figure 28
ll'l'I
Inspect
Flywheel assembly ( 135 or 137) for missing or loose

converter-to-flywheel bolts/screws. Tighten or
replace as necessary.
Converter for damage or missing balance weights. If
converter is damaged or balance weights are missing, replace converter. Refer to SECTION 7 A.
If flywheel assembly is replaced, new balance
weights (134) of same size must be installed on new
flywheel assembly in same hole locations as old flywheel assembly.
CRANKSHAFT REAR OIL SEAL ASSEMBLY


Tool Required:
J 35621 Rear Main Seal Installer
Care should be taken not to nick crankshaft
sealing surface when removing seal.
6A3A-28 5.7 LITER VS ENGINE ON-VEHICLE SERVICE RPO LT1 -VIN P

133
114
A SEAL REMOVAL NOTCHES

114 HOUSING ASSEMBLY, CRANKSHAFT REAR OIL SEAL
PC00296A3BfRP
Figure 29 - Removing Crankshaft Rear Oil Seal Assembly
CRANKSHAFT REAR OIL SEAL HOUSING

ASSEMBLY AND GASKET
B
A
B
C
98
133
134
135
136
137
138
FOR MANUAL TRANSMISSION

FOR AUTOMATIC TRANSMISSION
LOCATOR HOLE
CRANKSHAFT ASSEMBLY
PIN, FLYWHEEL LOCATOR
WEIGHT, FLYWHEEL
FLYWHEEL ASSEMBLY
BOLT/SCREW, FLYWHEEL
FLYWHEEL ASSEMBLY
Figures 26 and 29
PCOOOS-6A3BFRP
2. Crankshaft rear oil seal assembly.

Using notches provided in crankshaft rear oil
seal housing assembly (114), pry out seal
assembly with a screwdriver.

1. Coat new seal assembly entirely with engine oil.
2. Seal assembly onto J 35621.
3. J 35621 onto rear of crankshaft assembly (98).
Tighten screws snugly to ensure seal assembly will
be installed squarely over crankshaft assembly (98).
4. Crankshaft rear oil seal assembly to crankshaft assembly (98) and crankshaft rear oil seal housing
(114).
5. Tighten wing nut on J 35621 until it bottoms.
6. Remove J 35621 from crankshaft rear oil seal housing assembly (114).

this section.
3. Crankshaft rear oil seal housing nuts ( 115) and bolts/
screws (116).
4. Crankshaft rear oil seal housing assembly (114) with
the assembled seal, and gasket (113).
5. Crankshaft rear oil seal assembly from crankshaft
rear oil seal housing assembly ( 114).
1.,1 Clean
Gasket surfaces.

section.
rn
Important
Always use a new crankshaft rear oil seal

assembly and a new oil seal housing gasket
(113) during the installation of the crankshaft
rear oil seal housing assembly ( 114).
1. New oil seal housing gasket (113) and crankshaft
rear oil seal housing assembly (114) on studs (112).
It is not necessary to use any type of sealant to
hold oil seal housing gasket (113) in place.
5.7 LITER V8 ENGINE ON-VEHICLE SERVICE RPO LT1 -VIN P 6A3A29
LC0012-6A4BRP
Figure 30 - Installing Crankshaft Rear Oil Seal

screws (116).
!~I
Tighten
Crankshaft rear oil seal housing nuts ( 115) and

bolts/screws (116) to 15 Nm (11 lb. ft.).
!ll
1nspect
Oil pan gasket for damage. Replace gasket if

necessary.
this section.
4. New crankshaft rear oil seal assembly. Refer to
"Crankshaft Rear Oil Seal Assembly" in this section.
ENGINE ASSEMBLY

2. Air intake duct.
6. Drain engine oil.
7. Exhaust crossover pipe assembly. Refer to SECTION 6F.
10-5.

13. Secondary air injection pump assembly. Refer to
SECTION 6E3.
14. Air conditioning hose assembly from condenser and
compressor. Refer to SECTION lB.
15. Transmission fluid cooler lines from radiator assembly. Refer to SECTION 6B.
16. Lower radiator hose from radiator assembly. Refer
to SECTION 6B.
17. Lower heater hose from water pump assembly.
18. Electrical ground straps from right side of engine
block.
19. Electrical connections from starter motor assembly.
20. Electrical connectors from knock sensor and oxygen
sensor assemblies.
21. Electrical connectors from engine oil level switch
and fuel pump switch/engine oil pressure gage sensor assemblies.
22. Electrical connector from coolant temperature sensor assembly.
23. Electrical connectors from wheel speed sensor
assemblies.
24. Left front brake line from caliper brake hose. Refer
to SECTION 5B 1.
25. Wiring harness from transmission assembly.
26. Shift linkage from transmission assembly. Refer to
SECTION 7A or 7B.
27. Propeller shaft after matchmarking. Refer to SECTION 4A.
28. Torque arm from transmission assembly. Refer to
SECTION 3D.
29. Intermediate steering shaft from rack and pinion
30. Electrical ground straps from left side of engine
block and frame rail.
31. Lower vehicle.
32. Fuel lines from fuel rail assembly. Refer to SECTION 6C.
33. Cruise and accelerator control cables from throttle
body assembly.
34. Upper radiator hose from water pump assembly.
35. Lower radiator hose from water pump assembly.
36. Upper heater hose from water pump assembly. Refer
to SECTION 6B.
37. Coolant air bleed pipe hose from radiator assembly.
39. Generator. Refer to SECTION 603.
40. Engine wiring harness connectors and reposition
wiring harness.
condenser. Refer to SECTION lB.

42. Air conditioning hose from expansion tube. Refer to
SECTION lB.
43. Power steering reservoir and reposition. Refer to
SECTION 3B.
44. Brake master cylinder and reposition. Refer to SECTION 5A.
45. Upper bolts/screws and nuts from strut assemblies.
46. Right front brake line from modulator valve assembly and clips. Refer to SECTION 5.
48. Position lift table under engine and engine frame
assembly.
50. Raise vehicle from engine, transmission and engine
frame assemblies.
51. Secure strut assemblies to engine frame.
52. Transmission TV cable from throttle body assembly.
7B.
54. Clutch housing and clutch assembly (manual transmission). Refer to SECTION 7C.
55. Hose assemblies from air conditioning compressor.
56. Air conditioning compressor bolts/screws and compressor. Refer to SECTION 1B.
57. Power steering lines from pump. Refer to SECTION
3B.
58. Motor mount through-bolts/screws. Refer to "Engine Mount Assemblies and Brackets" in this section.
59. Engine assembly from engine frame.
[I] Important
Refer to SECTION 6A3B for engine block cleaning,
inspection, and repair.

1. Engine assembly to engine frame.
2. Motor mount through-bolts/screws. Refer to
"Engine Mount Assemblies and Brackets" in this
section.
3. Power steering lines to pump. Refer to SECTION
3B.
4. Air conditioning compressor and bolts/screws.
5. Hose assemblies to air conditioning compressor.
6. Clutch housing and clutch assembly (manual transmission). Refer to SECTION 7C.
7B.
8. Transmission TV cable to throttle body assembly.

9. Position engine lift table and strut assemblies and
install engine, transmission and engine frame
assemblies.
11. Engine lift table.
12. Lower vehicle.
13. Bolts/screws and nuts to upper strut assemblies.
14. Right front brake line to modulator valve assembly
and clips. Refer to SECTION 5.
15. Brake master cylinder and reposition. Refer to SECTION 5A.
16. Power steering reservoir. Refer to SECTION 3B.
17. Air conditioning hose to expansion tube. Refer to
SECTION lB.
18. Air conditioning receiver and dehydrator hose to
condenser. Refer to SECTION 1B.
19. Engine wiring harness and connectors.
20. Generator. Refer to SECTION 603.
22. Coolant air bleed pipe hose to radiator assembly.
23. Upper heater hose to water pump assembly. Refer to
SECTION 6B.
24. Lower radiator hose to water pump assembly. Refer
to SECTION 6B.
25. Upper radiator hose to water pump assembly. Refer
to SECTION 6B.
26. Cruise and accelerator control cables to throttle
body assembly.
27. Fuel lines to fuel rail assembly. Refer to SECTION
6C.
28. Raise and suitably support vehicle.
29. Electrical ground straps to left side of engine block
and frame rail.
30. Electrical connections to starter motor assembly.
31. Intermediate steering shaft to rack and pinion
32. Torque arm to transmission assembly. Refer to SECTION 30.
33. Propeller shaft. Refer to SECTION 4A.
34. Shift linkage to transmission assembly. Refer to
SECTION 7A or 7B.
35. Wiring harness to transmission assembly.
36. Left front brake line to caliper brake hose. Refer to
SECTION 5Bl.
37. Electrical connectors to wheel speed sensor assemblies.
38. Electrical connector to coolant temperature sensor
assembly.
39. Electrical connectors to engine oil level switch and
fuel pump switch/engine oil pressure gage sensor
assemblies.

40. Electrical connectors to knock sensor and oxygen
sensor assemblies.
41. Electrical ground straps to right side of engine
block.
42. Lower heater hose to water pump assembly. Refer to
SECTION 6B.
43. Lower radiator hose from radiator assembly. Refer
to SECTION 6B.
44. Transmission fluid cooler lines to radiator assembly.
45. Air conditioning hose assembly to condenser and
compressor. Refer to SECTION 1B.
46. Secondary air injection pump assembly. Refer to
SECTION 6E3.
10-5.
52. Exhaust crossover pipe assembly. Refer to SECTION 6F.
53. Bleed brake system. Refer to SECTION 5.
55. Lower vehicle.
56. Refill with engine oil. Refer to SECTION OA.
57. Refill with engine coolant. Refer to SECTION 6B.
58. Charge air conditioning system. Refer to SECTION
lB.
3B.
STEP 2
STEP 3
61. Align wheels. Refer to SECTION 3A.
THREAD REPAIR
Figure 31
Damaged threads may be reconditioned by drilling
out, re-threading and installing a suitable thread insert.
General purpose thread repair kits are available commercially.
CAUTION: Wear safety glasses to avoid

eye damage.
1. Determine size, pitch and depth of damaged thread.
If necessary, adjust stop collars on cutting tool and
tap to required depth.
rn
Important
Refer to kit manufacturer's instructions

regarding size of drill and tap to be used.
3. Tap hole.
A. Lubricate tap with light engine oil.
B. Clean thread.
rn
Important
Avoid build-up of chips. Back out tap every

few turns and remove chips.
4. Thread the thread insert onto mandrel of installer.
Engage tang of insert onto end of mandrel.
5. Lubricate insert with light engine oil (except when
installing in aluminum) and install.
[Il Important
When correctly installed, insert should be flush
to one turn below surface.
6. If tang of insert does not break off when backing out
installer, break tang off with drift pin.
STEP 4
STEP 5
KC0049-6A4-BRP
Figure 31 - Repairing Threaded Holes
6A3A-32 5.7 LITER VB ENGINE ON-VEHICLE SERVICE RPO LT1 - VIN P
SPECIFICATIONS
Air Conditioning Compressor Rear Brace-to-Engine Block Bolt/Screw ......... 33 Nm (24 lb. ft.)
Camshaft Retainer Bolt/Screw ........................................ 12 Nm (105 lb. in.)
Camshaft Sprocket Bolt/Screw ......................................... 28 Nm (21.lb. ft.)
Catalytic Converter-to-Exhaust Manifold Nut ............................. 21 Nm (15 lb. ft.)
Crankshaft Balancer Bolt/Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81 N m (60 lb. ft.)
Crankshaft Balancer Hub Bolt/Screw ................................... 102 Nm (75 lb. ft.)
Crankshaft Bearing Cap Bolt/Screw .................................... 105 Nm (77 lb. ft.)
Crankshaft Rear Oil Seal Housing Nut and Bolt/Screw ...................... 15 Nm (11 lb. ft.)
Cylinder Head Bolt/Screw ............................................ 88 Nm (65 lb. ft.)
Distributor Bolt/Screw .............................................. 11 N m (100 lb. in.)
Drive Belt Idler Pulley Bolt/Screw ...................................... 50 Nm (37 lb. ft.)
Drive Belt Tensioner Bolt/Screw ....................................... 33 Nm (24 lb. ft.)
EGR Control Valve Relay Nut ......................................... 22 Nm (16 lb. ft.)
EGR Valve Nut ..................................................... 22 Nm (16 lb. ft.)
Engine Block Oil Gallery Plug ........................................ 24 Nm (18 lb. ft.)
Engine Bracket Bolt/Screw ............................................ 58 Nm (43 lb. ft.)
Engine Coolant Air Bleed Pipe Bolt/Screw ............................... 41 Nm (30 lb. ft.)
Engine Front Cover Bolt/Screw ....................................... 11 Nm ( 100 lb. in.)
Engine Mount Through-Bolt Nut ....................................... 80 Nm (59 lb. ft.)
Engine Mount Through-Bolt/Screw ..................................... 95 Nm (70 lb. ft.)
Engine Mount-to-Frame or Engine Bolt/Screw ............................ 58 Nm (43 lb. ft.)
Engine Oil Cooler Bolt/Screw ......................................... 33 Nm (24 lb. ft.)
Engine Oil Cooler Fitting ............................................. 23 Nm (17 lb. ft.)
Engine Oil Cooler Hose Bracket Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 N m (13 lb. ft.)
Engine Oil Level Sensor Assembly ..................................... 22 Nm (16 lb. ft.)
Evaporative Emission Canister Purge Solenoid Valve Bracket Bolt/Screw ........ 6 Nm (53 lb. in.)
Exhaust Manifold Bolt/Screw and Stud .................................. 35 Nm (26 lb. ft.)
Flywheel Bolt/Screw ................................................ 100 Nm (74 lb. ft.)
Fuel Injection Fuel Rail Bolt/Screw ..................................... 20 Nm (15 lb. ft.)
Fuel Pump Switch and Engine Oil Pressure Gage Sensor Assembly ........... 12 Nm (105 lb. in.)
Ignition Coil Bolt/Screw .............................................. 33 Nm (24 lb. ft.)
Intake Manifold Bolt/Screw and Stud
First Pass ........................................................ 8 Nm (71 lb. in.)
Final Pass ...................................................... 48 Nm (35 lb. ft.)
Knock Sensor Assembly .............................................. 19 Nm (14 lb. ft.)
Oil Filter Adapter Bolt/Screw .......................................... 25 Nm (18 lb. ft.)
Oil Level Indicator Tube Nut .......................................... 34 Nm (25 lb. ft.)
Oil Pan
Corner Bolt/Screw and Nut ......................................... 20 Nm (15 lb. ft.)
Side Rail Bolt/Screw ............................................. 11 N m ( 100 lb. in.)
Oil Pan Baffle Nut ................................................... 34 Nm (25 lb. ft.)
Oil Pump Cover Bolt/Screw ............................................ 9 Nm (80 lb. in.)
Oil Pump Driveshaft Bolt/Screw ....................................... 18 Nm (13 lb. ft.)
Oil Pump-to-Rear Crankshaft Bearing Cap Bolt/Screw ...................... 88 Nm (65 lb. ft.)
Oil Temperature Sensor Assembly ..................................... 12 Nm (108 lb. in.)
Secondary Air Injection Pipe Bracket Bolt/Screw .......................... 34 Nm (25 lb. ft.)
Secondary Air Injection Pipe Fitting-to-Exhaust Manifold Assembly .......... 34 Nm (25 lb. ft.)
Secondary Air Injection Pipe Flange Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Nm (19 lb. ft.)
Secondary Air Injection Pipe Flange Stud ................................ 10 Nm (89 lb. in.)
Spark Plug Bracket Bolt/Screw ....................................... 12 Nm (105 lb. in.)
Starter Motor Bolt/Screw ............................................. 46 Nm (34 lb. ft.)
Throttle Body Bolt/Screw ............................................. 26 Nm (19 lb. ft.)
Valve Lifter Guide Retainer Bolt/Screw .................................. 20 Nm (15 lb. ft.)
Valve Rocker Arm Cover Bolt/Screw ................................... 11 Nm (100 lb. in.)
Valve Rocker Arm Stud .............................................. 68 Nm (50 lb. ft.)
Water Pump Bearing Retainer Bolt/Screw ............................... 12 Nm (105 lb. in.)
Water Pump Bolt/Screw .............................................. 41 Nm (30 lb. ft.)
5.7 LITER VS ENGINE ON-VEHICLE SERVICE RPO LT1 - VIN P 6A3A-33
ENGINE ASSEMBLY SPECIFICATIONS 5.7L (LT1)

GENERAL
TypeV8
Displacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.7L (350 CID)
Bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101.60 mm (4.000")
Stroke .. , ........................................................ 88.39 mm (3.480")
Compression Ratio ............................................................ 10.5:1
Firing Order ......................................................... 1-8-4-3-6-5-7-2
Spark Plugs
Type .................................................................. AC41-906
Gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.27 mm (0.050")
Torque .......................................................... 15 Nm (11 lb. ft.)
Oil Pressure (Minimum) ............................. 41.4 kPa (6.0 psig) at 1,000 engine rpm
124.1 kPa (18.0 psig) at 2,000 engine rpm
Oil Filter Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 N m (14 lb. ft.)
CYLINDER BORE
Out-of-Round
Production .................................................. 0.02 mm (0.001 ") MAX.
Service Limit ................................................ 0.05 mm (0.002") MAX.
Taper
Production
Thrust Side .............................................. 0.012 mm (0.0005") MAX.
Relief Side ............................................... 0.025 mm (0.0010") MAX.
Service Limit .............................................. 0.025 mm (0.0010") MAX.
PISTON ASSEMBLY
Piston Bore Clearance
Production ........................................ 0.025 - 0.068 mm (0.0010 - 0.0027")
PISTON RINGS
Groove Clearance
Production Top ................................... 0.030 - 0.081 mm (0.0012 - 0.0032")
Production 2nd ................................... 0.030 - 0.081 mm (0.0012 - 0.0032")
Service Limit ............................................. 0.107 mm (0.0042") MAX.
Gap
Production Upper ..................................... 0.25 - 0.50 mm (0.010 - 0.020")
Production Lower ............................... 0.46 - 0.66 mm (0.018 - 0.026") MAX.
Service Limit ............................................... 0.88 mm (0.035") MAX.
Piston Oil Ring
Groove Clearance
Production .......................................... 0.051 - 0.17 mm (0.002 - 0.007")
Service Limit ............................................... 0.20 mm (0.008") MAX.
Gap
Production ........................................... 0.25 - 0.76 mm (0.010 - 0.030")
Service Limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.65 mm (0.065") MAX.
PISTON PIN
Diameter ......................................... 23.546 - 23.548 mm (0.9270 - 0.9271 ")
Clearance in Piston Assembly
Production ...................................... 0.0127 - 0.0203 mm (0.0005 - 0.0008 ")
Service Limit ............................................... 0.025 mm (0.001 ") MAX.
Fit In Connecting Rod Assembly .............. 0.021 - 0.040 mm (0.0008 - 0.0016") Interference
CRANKSHAFT ASSEMBLY
Main Journal
Diameter #1 ..................................... 62.189 - 62.212 mm (2.4484 - 2.4493")
Diameter#2, #3, #4 ............................... 62.182-62.205 mm (2.4481 - 2.4490")
Diameter #5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62.177 - 62.120 mm (2.4481 - 2.4488 ")
Taper
Production ............................................... 0.005 mm (0.0002") MAX.
Out-of-Round

Crankshaft Bearing Clearance
Production #1 ...................................... 0.020 - 0.051 mm (0.0008 - 0.0020")
Production #2, #3, #4 ................................ 0.028 - 0.051 mm (0.0011 - 0.0020")
Production #5 ...................................... 0.043 - 0.081 mm (0.0017 - 0.0032")
Service Limit #1 .................................... 0.025 - 0.038 mm (0.0010 - 0.0015")
Service Limit #2, #3, #4 .............................. 0.025 - 0.064 mm (0.0010 - 0.0025")
Service Limit #5 .................................... 0.064 - 0.089 mm (0.0025 - 0.0035")
Crankshaft Assembly End Play ............................. 0.03 - 0.17 mm (0.001 - 0.007")
CONNECTING ROD ASSEMBLY
Diameter ........................................ 53.068 - 53.334 mm (2.0893 - 2.0998 ")
Taper
Out-of-Round
Rod Bearing Clearance
Production ........................................ 0.033 - 0.088 mm (0.0013 - 0.0035")
Rod Side Clearance ....................................... 0.16 - 0.35 mm (0.006 - 0.014")
CAMSHAFT ASSEMBLY
Journal Diameter ................................... 47.452 - 47.477 mm (1.8682 - 1.8692")
End Play ............................................... 0.11 - 0.30 mm (0.004 - 0.012")
Lobe Lift 0.050 mm (0.002")
Intake ........................................................... 7.62 mm (0.300")
Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.62 mm (0.300")
VALVE SYSTEM
Rocker Arm Ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.50: 1
Face Angle .................................................................... 45
Seat Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Seat Runout ................................................... 0.05 mm (0.002") MAX.
Seat Width
Intake ................................................ 0.76 - 1.27 mm (0.030 - 0.050")
Exhaust ............................................... 1.52 - 2.03 mm (0.060 - 0.080")
Stem Clearance
Production
Intake ........................................... 0.027 - 0.069 mm (0.0011 - 0.0027")
Exhaust ......................................... 0.027 - 0.069 mm (0.0011 - 0.0027")
Service
Intake ................................................... 0.093 mm (0.0037") MAX.
Exhaust ................................................. 0.119 mm (0.0047") MAX.
Valve Spring
Free Length ....................................................... 51.1 mm (2.01 ")
Pressure
Closed .................................... 360- 395 Nat 45.2 mm (81 - 89 lb. at 1.78")
Open ................................ 1121 - 1208 Nat 33.1 mm (252 - 272 lb. at 1.305")
Installed Height
Intake ........................................................... 45.2 mm (1.78")
Exhaust ......................................................... 45.2 mm (1.78")
Valve Lift
Intake ......................................................... 11.43 mm (0.450")
Exhaust ....................................................... 11.68 mm (0.460")
SPECIAL TOOLS
J 5590
J 6098-01
J 39087
0~
J 5825-A
J 5892-C
J 39088
ii
J8037
J 9666 or
J 8056
J 8062
J 39089
0
0
0
G
0
CRANKSHAFT GEAR INSTALLER

DRIVEN GEAR SHAFT FRONT COVER SEAL PROTECTOR
CRANKSHAFT GEAR REMOVER
VALVE SPRING COMPRESSOR (HEAD-ON)
DRIVEN GEAR/WATER PUMP SHAFT SEAL INSTALLER
CAMSHAFT BEARING REMOVER AND INSTALLER
DRIVEN GEAR SHAFT FRONT COVER SEAL INSTALLER
PISTON RING COMPRESOR
[!]
VALVE SPRING TESTER
G]
VALVE SPRING COMPRESSOR (HEAD-OFF)

NC1036-8A1A-Y-RP
El
==[JI
~~
~
c::::,
Offg
@@
~'
GJ
,,
e
,,,$
J 8520
@]
be
J 39046
J 22794
CARBON REMOVING BRUSH
CRANKSHAFT HUB REMOVER AND INST ALLER
~
~
~
~
~
~
~
J 24086-8
\l~t<:1)
~e
~
{j
J 35468
J 35621
G]
Q(N
J 21882
t===i
-\
J 23738-A
J8358
SPARK PLUG PORT ADAPTOR

( 14 mm TAPER ED SEAT)
J 39092
VALVE STEM SEAL TESTER (MITY-VAC)

PISTON PIN REMOVER AND INSTALLER SET
FRONT COVER OIL SEAL INSTALLER
REAR MAIN SEAL INSTALLER
J 39090
VALVE GUIDE CLEANER

DRIVEN GEAR ASSEMBLY INSTALLER
DISTRIBUTOR DRIVESHAFT FRONT COVER SEAL INSTALLER
NC1036-6A1AB-RP
5.7 LITER VB ENGINE ON-VEHICLE SERVICE RPO LT1 - VIN P 6A3A-37
J 3049
J7872
J5239
J8001
~~
J9290-01
J 39243
J 34730-1
]
~
~
~
~
~
~
HYDRAULIC VAL VE
LIFTER REMOVER (PLIER TYPE)
MAGNETIC BASE INDICATOR
SET
DIAL INDICATOR SET
FUEL PRESSURE GAGE
MAIN BEARING SHELL
REMOVER & INSTALLER
HYDRAULIC VALVE
LIFTER REMOVER
(SLIDE HAMMER TYPE)
DRIVEN GEAR ASSEMBLY REMOVER
NC1037-8A1A-Y-RP
5.7 LITER VS ENGINE UNIT REPAIR RPO LT1 -VIN P 6A3B-1
SECTION 6A3B
5.7 LITER VS ENGINE

UNIT REPAIR
RPO LT1 - VIN P
[f a fastener needs to be replaced, use the correct part number fastener for that application. If the correct part
result.
CONTENTS
General Description ...................... 6A3B-6
Construction .......................... 6A3B-6
Lubrication ........................... 6A3B-6
Disassembly ........................... 6A3B-10
Flywheel Assembly ................... 6A3B-10
Draining the Engine Assembly .......... 6A3B-10
Intake Manifold Assembly .............. 6A3B-10
Exhaust Manifold Assemblies ........... 6A3B-10
Valve Rocker Arm Cover Assemblies ..... 6A3B-l 1
Assemblies ........................ 6A3B- l 1
Valve Lifter Assemblies ................ 6A3B- l 1
Water Pump Assembly ................. 6A3B- l 1
Crankshaft Balancer Assembly and Hub ... 6A3B-13
Distributor Assembly .................. 6A3B-14
Oil Pan Assembly .................... 6A3B-14
Engine Front Cover Assembly ........... 6A3B-14
Driveshaft Assembly .............. 6A3B-14
Camshaft Assembly ................... 6A3B-14
Cylinder Head Assembly ............... 6A3B-14
Oil Pump Assembly ................... 6A3B-15
Piston and Connecting Rod Assembly ..... 6A3B-16
Crankshaft Rear Oil Seal Housing and
Crankshaft Assembly ................ 6A3B-16
Camshaft Bearings .................... 6A3B-16
Cleaning, Inspection and Repair ........... 6A3B-17
Engine Block ........................ 6A3B-17
Crankshaft Bearing Fitting .............. 6A3B-21
Crankshaft Assembly .................. 6A3B-23
Piston and Connecting Rod Assembly ..... 6A3B-23
Connecting Rod Bearings .............. 6A3B-25
Oil Pump Assembly ................... 6A3B-26
Cylinder Head Assembly ............... 6A3B-27
Camshaft Assembly ................... 6A3B-29
Driveshaft Assembly .............. 6A3B-30
Engine Front Cover Assembly ........... 6A3B~30
Engine Front Cover Oil Seals ...........

Oil Pan Assembly ....................
Water Pump Assembly .................
Valve Lifter Assemblies ................
Assemblies ........................
Valve Rocker Arm Cover Assemblies .....
Intake Manifold Assembly ..............
Assembly .............................
Engine Block ........................
Camshaft Bearings ....................
Crankshaft Assembly ..................
Crankshaft Rear Oil Seal Housing ........
Crankshaft Rear Oil Seal ...............
Piston and Connecting Rod Assembly .....
Connecting Rod Bearings ..............
Oil Pump Assembly ...................
Cylinder Head Assembly ...............
Camshaft Assembly ...................
Driveshaft Assembly ..............
Engine Front Cover Assembly ...........
Distributor Assembly ..................
Oil Pan Assembly ....................
Crankshaft Balancer Assembly and Hub ...
Water Pump Assembly .................
Valve Lifter Assemblies ................
Valve Rocker Arm Ball Studs ...........
Assemblies ........................
Valve Rocker Arm Cover Assemblies .....
Intake Manifold Assembly ..............
Exhaust Manifold Assemblies ...........
Flywheel Assembly ...................
Specifications ..........................
Fastener Tightening Specifications .......
5.7L (LTl) ........................
Special Tools ..........................
6A3B-30
6A3B-30
6A3B-30
6A3B-31
6A3B-31
6A3B-31
6A3B-31
6A3B-31
6A3B-31
6A3B-31
6A3B-32
6A3B-33
6A3B-33
6A3B-33
6A3B-33
6A3B-34
6A3B-34
6A3B-34
6A3B-35
6A3B-35
6A3B-36
6A3B-36
6A3B-36
6A3B-36
6A3B-37
6A3B-37
6A3B-37
6A3B-38
6A3B-38
6A3B-39
6A3B-40
6A3B-40
6A3B-40
6A3B-41
6A3B-45
6A3B-2 5.7 LITER VS ENGINE UNIT REPAIR RPO LT1 -VIN P
196
197
~~~,
195-=--
.. -;:-,,,
192
194
210
~211
199
10
215
cfri
~33
217
~200
st
201
23~-~A
25
235
25 ---l.4P'
81
229
18
227
82
82
17
PC0001 6A3BfRP
Figure 1 - Upper Engine Assembly
5.7 LITER VS ENGINE UNIT REPAIR RPO LT1 - VIN P 6A38-3
2
3
5
6
8
9
10
11
12
15
16
17
18
19
21
23
24
25
27
28
29
30
31
33
34
35
36
69
70
71
72
73
78
79
81
82
192
193

BODY ASSEMBLY, THROTILE
GASKET, THROTILE BODY
COVER ASSEMBLY, VALVE ROCKER ARM
BOLT/SCREW, VALVE ROCKER ARM COVER
GASKET, VALVE ROCKER ARM COVER
ARM, VALVE ROCKER
GUIDE, VALVE LIFTER
SPRING, VALVE
CAP, VALVE SPRING
VALVE, INTAKE
KEY, VALVE STEM
SHIM, VALVE SPRING
VALVE, EXHAUST
PIPE ASSEMBLY, ENGINE FUEL
SOLENOID ASSEMBLY, EGR CONTROL VALVE RELAY
194 NUT, EGR CONTROL VALVE RELAY

195 FITIING, INTAKE MANIFOLD VACUUM
196 VALVE ASSEMBLY, EVAPORATIVE EMISSION
CANISTER PURGE SOLENOID
197 HOSE, EVAPORATIVE EMISSION CANISTER PURGE

SOLENOID VALVE
198 BRACKET, EVAPORATIVE EMISSION CANISTER PURGE

SOLENOID VALVE
199 PIPE ASSEMBLY, EVAPORATIVE EMISSION CANISTER

200
201
202
203
204
205
206
207
208
209
210
211
212
213
215
216
217
218
222
226
227
229
232
235
PURGE SOLENOID VALVE

HOSE, CRANKCASE VENT VALVE
GROJVIMET, CRANKCASE VENT HOSE CONNECTOR
FITIING, POWER BRAKE BOOSTER VACUUM TUBE
GASKET, EGR VALVE
VALVE ASSEMBLY, EGR
BOLT/SCREW, EGR VALVE
GROMMET, CRANKCASE VENT VALVE
VALVE ASSEMBLY, CRANKCASE VENT
CONNECTOR, CRANKCASE VENT VALVE HOSE
HOSE, CRANKCASE VENT VALVE
PIPE, ENGINE COOLANT AIR BLEED
HARNESS ASSEMBLY, EGR VALVE VACUUM
BOLT/SCREW, ACCELERATOR CONTROL CABLE
BRACKET
BRACKET, ACCELERATOR CONTROL CABLE
HOSE, THROTILE BODY HEATER
CLAMP ASSEMBLY, THROTILE BODY HEATER INLET
HOSE
SHIELD, EXHAUST MANIFOLD HEAT OUTER
SHIELD, EXHAUST MANIFOLD HEAT INNER
COIL ASSEMBLY, IGNITION
SPARK PLUG
SUPPORT, SPARK PLUG WIRE
VALVE
CONNECTOR, SECONDARY AIR INJECTION CHECK
VALVE HOSE
HARNESS ASSEMBLY, IGNITION DISTRIBUTOR WIRING
PC0002-6A3B-F-RP
Figure 2 - Upper Engine Assembly - Legend
6A384 5.7 LITER VB ENGINE UNIT REPAIR RPO LT1 -VIN P
154
58
4.
59
174
184
185
,/J
138
42
--~
187
121
137
54
189
..
-190
PC0003-6A3B-F-RP
Figure 3 - Lower Engine Assembly
5.7 LITER VB ENGINE UNIT REPAIR RPO LT1 - VIN P 6A3B5
A
B
37
38
39
40
41
42
43
44
45
46
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
74
77
84
89
95
98
99
100
101
102
103
104
105
106
107
108
109
110
111
112
113

GASKET, WATER PUMP
COUPLING, WATER PUMP DRIVESHAFT
BOLT/SCREW, CRANKSHAFT BALANCER HUB
WASHER, CRANKSHAFT BALANCER HUB
PAN ASSEMBLY, OIL
GASKET, OIL PAN
SPROCKET, CAMSHAFT
RETAINER, CAMSHAFT
CAMSHAFT ASSEMBLY
RETAINER
DRIVESHAFT ASSEMBLY, OIL PUMP
BOLT/SCREW, OIL PUMP DRIVESHAFT
BLOCK, ENGINE
PLUG, CAMSHAFT REAR BEARING HOLE
BOLT/SCREW, OIL PAN
CRANKSHAFT ASSEMBLY
CAP, CONNECTING ROD
NUT, CONNECTING ROD
BOLT/SCREW, CONNECTING ROD
PISTON ASSEMBLY
PIN, PISTON
RING, PISTON
BEARING, CRANKSHAFT
BEARING, CRANKSHAFT
114
115
116
117
118
119
120
121
135
136
137
138
139
141
142
143
144
145
154
155
156
157
158
159
160
161
162
165
167
168
170
171
172
174
175
176
177
178
179
180
181
183
184
185
186
187
188
189
190
191
223

STUD, CRANKSHAFT BEARING CAP
PUMP ASSEMBLY, OIL
BAFFLE, OIL PAN
BRACKET ASSEMBLY, GENERATOR AND AIR
PUMP
FLYWHEEL ASSEMBLY
FLYWHEELASSEMBLY
HARNESS ASSEMBLY, SPARK PLUG WIRE
SENSOR ASSEMBLY, ENGINE COOLANT
TEMPERATURE
SEAL, WATER PUMP DRIVESHAFT
SEAL ASSEMBLY, WATER PUMP BEARING
SEAL, DISTRIBUTOR
SEAL ASSEMBLY, CRANKSHAFT FRONT OIL
INDICATOR ASSEMBLY, OIL LEVEL
TUBE ASSEMBLY, OIL LEVEL INDICATOR
NUT, OIL LEVEL INDICATOR TUBE
SENSOR ASSEMBLY, FUEL PUMP AND ENGINE OIL
PRESSURE INDICATOR SWITCH
PLUG, ENGINE BLOCK OIL GALLERY
PIN, TRANSMISSION
PLUG, ENGINE BLOCK CORE HOLE
SENSOR ASSEMBLY, KNOCK
PLUG, OIL FILTER ADAPTER HOLE
BEARING, CAMSHAFT
BEARING, CLUTCH PILOT
SEAL ASSEMBLY, CRANKSHAFT REAR OIL
SENSOR ASSEMBLY, ENGINE OIL LEVEL SWITCH
PIN, OIL PUMP LOCATOR
KEY, CRANKSHAFT BALANCER
CLIP, TRANSMISSION OIL COOLER PIPE
NUT, CRANKSHAFT OIL DEFLECTOR
SHIM, STARTER MOTOR
MOTOR ASSEMBLY, STARTER
BOLT/SCREW, STARTER MOTOR
STUD, STARTER MOTOR
GASKET, OIL PAN DRAIN PLUG
PLUG, OIL PAN DRAIN
BRACKET, ENGINE WIRING HARNESS
PLUG, ENGINE BLOCK OIL GALLERY
HARNESS ASSEMBLY, IGNITION COIL WIRE
PC00004-6A3B-F-RP
Figure 4 - Lower Engine Assembly - Legend
GENERAL DESCRIPTION
CONSTRUCTION
Figures 1 through 4
Engine Block
The engine block is made of cast iron and has eight
cylinders arranged in a "V" shape with four cylinders in
each bank. It is a one-piece casting with the cylinders
encircled by coolant jackets.
Cylinder Head Assemblies
The cylinder head assemblies are cast aluminum and
have powdered metal valve guides and valve seats pressed
into the intake and exhaust ports. The spark plugs are
located between the intake and exhaust ports.
Crankshaft Assembly
The crankshaft assembly is made of cast nodular
iron. It is supported by five crankshaft bearings that are
retained by bearing caps which are machined with the
block for proper alignment and clearances. The bearing
caps are retained by two bolts/screws each. The number
five bearing at the rear of the engine assembly is the end
thrust bearing. Four connecting rod journals (two rods per
journal) are spaced 90 degrees apart.
Piston and Connecting Rod Assemblies
The pistons are cast aluminum that use two compression rings and one oil control ring assembly. The piston is a low-friction, lightweight design with a flat top and
barrel-shaped skirt. The piston pins are chromium steel.
They have a floating fit in the piston and are retained by a
press fit in the connecting rod assembly.
The connecting rod assemblies are made of forged
steel. They are machined with the rod cap installed for
proper clearances and alignment.
Camshaft Assembly
A steel camshaft assembly is supported by five bearings pressed into the engine block. The timing sprocket
mounted to the front of the camshaft assembly is driven
by the crankshaft sprocket through a timing chain assembly.
The camshaft sprocket also has spur gear teeth
which drive a geared shaft assembly to operate the water
pump assembly.
A spiral gear machined into the camshaft assembly
near the rear journal drives a shaft assembly which operates the oil pump assembly.
The center of the camshaft sprocket has a splined
opening with a keyway (missing tooth) that mates with the
distributor driveshaft. This provides net build timing,
meaning that the ignition timing does not have to be
adjusted.
Valve Train
The valve train is a ball pivot type. Motion is transmitted from the camshaft assembly through hydraulic
roller lifter and tubular pushrod assemblies to the rocker
arms. The rocker arm pivots on a ball to open the valve.

The hydraulic lifter assemblies keep all parts of the valve
train in constant contact.
The rocker arm ball is retained on the rocker arm
stud with a locking nut. The rocker arm stud is threaded
into the cylinder head assembly.
Intake Manifold Assembly
The intake manifold assembly is a one-piece cast

aluminum unit. The intake manifold assembly has exhaust
gas recirculation and crankcase vent passages cast tnto it
but coolant crossover passages have been eliminated.
Exhaust Manifold Assemblies
The two cast-iron exhaust manifold assemblies

direct exhaust gases from the combustion chambers to the
exhaust system. The exhaust manifold assemblies each
have a port for air injection system pipe fittings.
LUBRICATION
Figures 5 through 7
Engine assembly lubrication is supplied by a geartype oil pump assembly. The oil pump assembly is driven
by an intermediate shaft which is connected to a shaft
assembly driven by the camshaft assembly. The pump
gears rotate and draw oil from the oil pan sump through
a pick-up screen and pipe. The oil is pressurized as it
passes through the pump and sent through engine block
oil galleries.
Contained within the oil pump assembly is a pressure relief valve that maintains oil pressure within a specified range.
Pressurized oil is directed to the oil filter where
harmful contaminants are removed. A bypass valve is also
incorporated into the oil filter. The bypass allows oil to
bypass the filter and flow to the engine assembly if the
filter becomes clogged.
The oil is then pumped to the main oil gallery which
is drilled through the length of the engine block just above
the camshaft assembly. At the rear of the engine block, oil
also flows into the right and left lifter oil galleries. From
the main oil gallery, oil is pumped downward to the camshaft bearings, then to the crankshaft bearings. The crankshaft bearing upper inserts are grooved to align with oil
passages drilled from the crankshaft bearing journal to the
connecting rod journal. After lubricating the connecting
rod bearings, the cylinder walls, rings and piston pins are
lubricated by oil which is "slung" from the connecting
rod bearing journals due to the rotation of the crankshaft
assembly. This oil then returns to the oil pan sump. Oil
that has entered the left and right lifter oil galleries pressurizes the hydraulic lifter assemblies and is then pumped
up through the pushrod assemblies to lubricate the rocker
arms and valve stems.
Oil returning to the oil pan assembly from the cylinder head assemblies and the front camshaft bearing lubricates the timing chain assembly and crankshaft and
camshaft sprockets.
5.7 LITER va ENGINE UNIT REPAIR RPO LT1 - VIN P 6A3B-7
NC1042-6A1B-Y-RP
Figure 5 - Engine Assembly Lubrication - Left Side View
J~
SECTION A-A
NC1043-6A1BYRP
Figure 6 - Engine Assembly Lubrication - Front View
5.7 LITER VB ENGINE UNIT REPAIR RPO LT1 -VIN P 6A3B9
SECTION 8-8
SECTION C-C
c
NC10446A1BY-RP
Figure 7 - Engine Assembly Lubrication - Rear Views
6A3810 5.7 LITER V8 ENGINE UNIT REPAIR RPO LT1 -VIN P
DISASSEMBLY
133
When beginning the engine assembly unit repair, the

belt tensioner, power steering pump and bracket, generator, A/C compressor, and generator and A/C compressor
braces should already be removed. For removal procedures, refer to the specific section in the service manual
for each component.
FLYWHEEL ASSEMBLY
Figure 8

1. Flywheel bolts/screws (136 or 138).
2. Flywheel assembly (135 or 137).
DRAINING THE ENGINE ASSEMBLY

1. Oil pan plug and drain engine oil.
2. Oil filter assembly.
3. Both knock sensor assemblies and allow coolant to
drain.

B
A
B
C
98
133
134
135
136
137
138

LOCATOR HOLE
CRANKSHAFT ASSEMBLY
PIN, FLYWHEEL LOCATOR
WEIGHT, FLYWHEEL
FLYWHEEL ASSEMBLY
FLYWHEEL ASSEMBLY
PCOOOB6A3BFRP

2. Fuel injectors and fuel rail assembly (2) from intake
3. Exhaust gas recirculation (EGR) vacuum harness

assembly and crankcase vent hoses.
4. EGR solenoid assembly and bracket.
5. Canister purge valve assembly and bracket.
6. Move wiring harness assemblies out of area.
Figures 11 and 12
7. Disconnect distributor wiring harness assembly, if

necessary.
8. EGR valve assembly.
9. Right exhaust manifold air injection pipe nuts (14),
pipe (12), gasket (22) and check valve (11) as
an assembly from intake and exhaust manifold
assemblies and cylinder head assembly.
10. Accelerator cable bracket.
11. Throttle body bolts/screws (4 ), throttle body assembly (3) and gasket (5).
13. Intake manifold assembly (6) and gaskets (10).

1. Right cylinder bank spark plug wire harness assembly from spark plugs and supports.
2. Oil level indicator tube nut.
3. Oil level indicator and tube.
4. Right exhaust manifold studs (20) and bolts/screws
(21).
5. Right heat shields, exhaust manifold assembly (19)
and gasket (18).
5.7 LITER VS ENGINE UNIT REPAIR RPO LT1 -VIN P 6A3B11
1
2
3
4
5
6
7
BOLT/SCREW, FUEL INJECTION FUEL RAIL

BODY ASSEMBLY, THROTTLE
BOLT/SCREW, THROTTLE BODY
TUBE ASSEMBLY, FUEL PRESSURE REGULATOR
VACUUM
6
5
PC0009-6A38-F-RP
Figure 9 - Fuel Rail and Throttle Body Assemblies

1. Left exhaust manifold secondary air injection pipe
assembly (15), check valve (11) and hose assembly
from exhaust manifold assembly (16).
2. Left cylinder bank spark plug wire harness assembly
from spark plugs and supports.
J Left exhaust manifold bolts/screws (21 ).

4. Left heat shields, exhaust manifold assembly (16)
and gasket (17).

ASSEMBLIES
Figure 14

1. Rocker arm nuts (31) and balls (30).
2. Rocker arms (29) and pushrod assemblies (27).
Place rocker arms (29), rocker arm balls (30)
and pushrod assemblies (27) in a rack so that
they can be reinstalled in same locations from
3. Rocker arm ball stud (28).
Figure 13
Figure 15
Right Valve Rocker Arm Cover Assembly
l+..f Remove or Disconnect

2. Right valve rocker arm cover bolts/screws (24).
3. Right valve rocker arm cover assembly (23) and gasket (25).
1. Valve lifter guide retainer bolts/screws (32) and

retainer (33).
2. Valve lifter guides (35) and valve lifter assemblies
(36).
Some valve lifter assemblies (36) may be stuck
in their bores because of gum or varnish deposits. These lifter assemblies (36) can be
removed using J 3049 or J 9290-01.
Left Valve Rocker Arm Cover Assembly
WATER PUMP ASSEMBLY
l+"'I Remove or Disconnect
Figure 16
1. Left valve rocker arm cover bolts/screws (24 ).

2. Left valve rocker arm cover assembly (23) and gas~
ket (25).

1. Water pump bolts/screws (40 and 41).
232
229
230
14
11
12
13
14
15
22
229
A
6
8
9
10

STUD, SECONDARY AIR INJECTION PIPE
NUT, SECONDARY AIR INJECTION PIPE
GASKET, SECONDARY AIR INJECTION PIPE
VALVE
230 CLAMP, SECONDARY AIR INJECTION CHECK VALVE
HOSE
232 CONNECTOR, SECONDARY AIR INJECTION CHECK
VALVE HOSE
SEALER
MANIFOLDASSEMBLY, INTAKE
PC0010-6A3B-F-RP
Figure 10 - Intake Manifold Assembly
PC00116A3B-F-AP
Figure 11 - Secondary Air Injection Components
5.7 LITERV8 ENGINE UNIT REPAIR RPO LT1 -VIN P 6A3B-13
16
17
18
19
20
21

STUD, EXHAUST MANIFOLD
19
21
PC00126A3B-F-RP
Figure 12 - Exhaust Manifold Assemblies
27
28
29
30
31

ARM, VALVE ROCKER
31
30
PC0014-6A3B-F-RP
Figure 14 - Valve Rocker Arm and Pushrod Assemblies

24 BOLT/SCREW, VALVE ROCKER ARM COVER
PC00136A3Bf-RP
rn
Important
A. Keep ignition wires connected to distributor

assembly until water pump is removed.
B. Make sure coolant is drained.
2. Water pump assembly (37), coupling (39) and gaskets (38).

HUB
Figure 17
Tool Required:
I Remove or Disconnect
f ..
1. Crankshaft balancer bolts/screws (46) and balancer

assembly (42).

Figure 19

1. Front cover bolts/screws (52).
2. Front cover assembly (50) and gasket (51).

Figures 20 and 21
Tools Required:
J 39243 Driven Gear Assembly Remover
J 5825-A Crankshaft Gear Remover

27
32
33
34
35
36

BOLT/SCREW, VALVE LIFTER GUIDE RETAINER
GUIDE, VALVE LIFTER
PC0015-6A3B-F-RP
Figure 15 - Valve Lifter Assemblies
2. Crankshaft balancer hub bolt/screw and washer.

3. Crankshaft balancer hub (45) using J 39046.
Figure 18

1. Spark plug and ignition harness assemblies from
coil assembly and spark plugs.
Do not remove wires from distributor assembly unless necessary.
2. Distributor bolts/screws (4 7) and distributor assembly (49).
3. Distributor driveshaft (48).
OIL PAN ASSEMBLY

1. Oil level sensor assembly.
Oil level sensor assembly must be removed to
prevent it from being damaged as oil pan
assembly is removed.
2. Oil pan bolts/screws, nuts and studs.
3. Oil pan assembly, reinforcements and gasket.

NOTICE: To prevent damage to piston or valve
assemblies, do not turn the crankshaft assembly after
the timing chain assembly has been removed.
(61).
3. Water pump driveshaft bolts/screws (64) and driveshaft assembly (63) using J 39243.
4. Crankshaft sprocket (62) using J 5825-A.
5. Key, if necessary.
CAMSHAFT ASSEMBLY

I. Bolt/screw (66) and oil pump driveshaft assembly
(65).
2. Camshaft retainer bolts/screws (58) and retainer
(59).
assembly to avoid damage to the bearings.
camshaft bolt holes.
(60) out of bearings.
CYLINDER HEAD ASSEMBLY

Figures 24 and 25

I. Engine coolant air bleed pipe bolts/screws and pipe.
Use a backup wrench on pipe fitting when
removing bolts/screws.
2. Generator bracket bolts/screws (122 and 123) spark
plug wire support (173) and bracket assembly (121)
from right cylinder head assembly (34~.
5.7 LITER VS ENGINE UNIT REPAIR RPO LT1 -VIN P 6A3815
!VIEWA!
63
37
A
B
37
38
39
40
41
63
156
40
41
SHAFT, WATER PUMP

TAB ON GASKET
GASKET, WATER PUMP
COUPLING, WATER PUMP DRIVESHAFT
SEAL, WATER PUMP DRIVESHAFT
PC0016-6A3B-F-RP
Figure 16 - Water Pump Assembly
42
45
46
77
BALANCER ASSEMBLV, CRANKSHAFT

PC001.7-6A3BF-RP
Figure 17 - Crankshaft Balancer Assembly and Hub
47 BOLT/SCREW, DISTRIBUTOR
48 DRIVESHAFT, DISTRIBUTOR
49 DISTRIBUTOR ASSEMBLY
PC0018-6A3B-F-RP
Figure 18 - Distributor Assembly

NOTICE: After removal, place the cylinder head
assembly on two wood blocks to prevent damage.
S. Coil and bracket assembly from left cylinder head
assembly (34).
OIL PUMP ASSEMBLY

Figure26

1. Oil pan baffle nuts.
6A38-16 5.7 LITER V8 ENGINE UNIT REPAIR RPO LT1 -VIN P
50
50
51
52
74

PC00196A3BF-RP
2. Bolt/screw (120) attaching oil pump assembly (118)

3. Oil pan baffle (119), oil pump assembly (118),
driveshaft (89) and retainer (95).

ASSEMBLY
Figure27
Tool Required:

1. Ring ridge.
assembly (103) is at top of its stroke.
[I] Important
assemblies (104).
Keep bearings (101) with their original connecting rod assembly (104) and connecting
rod cap (99) for reassembly if they are being
reused.
Wipe oil from bearings ( 101) and crankpins.

( 103) out of top of engine block using J 5239.

AND CRANKSHAFT ASSEMBLY
Figures 28 and 29

screws (116).
2. Crankshaft rear oil seal housing assembly (114) with
assembled seal, and gasket (113 ).
3. Crankshaft rear oil seal from crankshaft rear oil seal
housing assembly ( 114).
4. Crankshaft bearing cap bolts/screws (108) and
studs.
5. Crankshaft bearing caps (107) and rear crankshaft
bearing cap (109).
6. Crankshaft assembly (98).
7. Crankshaft bearings ( 110 and 111) from engme
block (67).
8. Crankshaft bearings ( 110 and 111 ) from crankshaft
bearing caps ( 107) and
rear
CAMSHAFT BEARINGS
Figures 30 and 31
Tool Required:
J 6098-01 Camshaft Bearing Remover/Installer

1. Camshaft rear bearing hole plug.
2. Inner camshaft bearings using J 6098-01.
5.7 LITER VS ENGINE UNIT REPAIR RPO LT1 -VIN P 6A3B17
A
B
56
57
58
59
60
61
62
63
64
TIMING MARKS
KEYWAY
SPROCKET, CAMSHAFT
RETAINER, CAMSHAFT
CAMSHAFT ASSEMBLY
RETAINER
PC0020-6A3BFRP
Figure 20 - Camshaft Assembly, Sprockets and Water Pump Driveshaft Assembly
A. With nut and thrust washer installed to end of

puller screw threads, index pilot in camshaft
front bearing and install puller screw through
pilot and bearing
to be removed.
I
B. Install bearing tool with shoulder toward bearing. Make. sure that enough threads are
engaged.
C. Using two wrenches, hold puller screw while

turning nut to draw bearing out of bore.
When bearing has been pulled from bore,
remove bearing tool and bearing from
puller screw.
D. Repeat above steps for remaining inner camshaft bearings.
Index pilot in rear camshaft bearing to
remove rear inner bearing.
3. Front and rear camshaft bearings using J 6098-01.
A. Assemble bearing tool to driver handle.
B. Drive front and rear bearings out, toward center of engine block (67).
CLEANING, INSPECTION AND

REPAIR
ENGINE BLOCK
Figure 32

1.
2.
3.
4.
5.
6.
Engine oil cooler assembly (141).

Oil filter adapter bolts/screws (143).
Oil filter adapter assembly (142).
Front and rear oil gallery plugs.
Fuel pump and oil pressure sensor assembly.
Starter motor assembly. Refer to SECTION 6D2.
Clean
Engine block in solvent.

Gasket surfaces.
Coolant passages.
6A3818 5.7 LITER VS ENGINE UNIT REPAIR RPO LT1 -VIN P
65 DRIVESHAFT ASSEMBLY, OIL PUMP

66 BOLT/SCREW, OIL PUMP DRIVES HAFT
PC0022-6A38-F-RP
Figure 22 - Oil Pump Driveshaft Assembly
62 SPROCKET, CRANKSHAFT
PC00216A3B-F-RP
Figure 21 - Crankshaft Sprocket Replacement
Oil passages.
IL'l'I Inspect
For cracks in cylinder walls, coolant jacket, valve
lifter bores and crankshaft bearing webs.
l@i I Measure
Cylinder bores for taper, out-of-round, or excessive
ring ridge at top of ring travel. Use a dial indicator.
Compare measurements to "Specifications" in this
section.
- Cylinders with less than 0.025 mm (0.0010
inch) of wear or taper may be reconditioned
with a hone.
- Cylinders with more than 0.025 mm (0.0010
inch) of wear or taper must be bored and honed
to smallest oversize piston assembly that will
permit complete resurfacing of all cylinders.
A 5/16-18x4"BOLTS
PC0023-6A3B-FR~
Figure 23 - Removing Camshaft Assembly
5.7 LITER VB ENGINE UNIT REPAIR RPO LT1 -VIN P 6A3B19
16 12
A
B
34
67
81
82
GASKET TAB (YELLOW SIDE UP)

BOLT TIGHTENING SEQUENCE
BLOCK, ENGINE
GASKET, CYLINDER HEAD .
PC0024-6A3B-F-RP
121

PUMP
122 BOLT/SCREW GENERATOR BRACKET
123 BOLT/SCREW GENERATOR BRACKET
173 SUPPORT, SPARK PLUG WIRE
PC0025-6A3Bf-RP
Figure 25 - Generator and Air Conditioning Compressor and Power Steering Pump Bracket Assembly
Boring
1. Draw a flat file across top of engine block several
times to remove any burrs or gasket material. If
engine block surface is not completely smooth and
flat, boring bar may be tilted which would result in
cylinder having an incorrect angle to crankshaft

assembly.
2. Measure piston assembly to be installed 11.5 mm
(0.45 inch) from bottom of piston skirt and at right
angles to piston pin.
6A3820 5.7 LITER VS ENGINE UNIT REPAIR RPO LT1 -VIN P
89
95
118
119
120

PUMP ASSEMBLY, OIL
BAFFLE, OIL PAN
98
PC0026-6A3B-F-RP
3. Bore cylinder to same diameter as piston assembly.

4. Hone cylinder as outlined below to provide specified clearance.
Follow instructions provided by manufacturer
of boring equipment being used.
NOTICE: Handle piston assemblies with care. Do
not attempt to force them into the cylinder. The piston assembl;es may be easily distorted.
Honing
1. Follow instructions provided by manufacturer of
honing equipment being used.
2. Occasionally during honing operation:
A. Clean cylinder bore.
B. Measure cylinder bore for proper piston fit.
3. Finish operation with a 45 to 65 degree crosshatch
pattern on cylinder walls.
Finish marks should be clean but not sharp,
free from imbedded particles and torn or faded
metal.
~FAT
jv1Ewe
A FLANGES OF CONNECTING RODS MUST FACE TO THE

FRONT IN THE LEFT BANK AND TO THE REAR IN THE
RIGHT BANK
B ARROW TO BE ORIENTED TO FRONT OF ENGINE
99 CAP, CONNECTING ROD
100 NUT, CONNECTING ROD
101 BEARING, CONNECTING ROD
102 BOLT/SCREW, CONNECTING ROD
103 PISTON ASSEMBLY
PC0027-&A3B-F-RP
Figure 27 - Piston and Connecting Rod Assembly
115
67
98
107
108
109
110
111
112
113
114
115
116
139
BLOCK, ENGINE
CRANKSHAFT ASSEMBLY
BEARING, CRANKSHAFT
BEARING, CRANKSHAFT
139
PC0028-6A3B-F-RP
4. Place a permanent mark on each piston assembly to

match it to its proper cylinder.
IOl
Clean
Cylinder bores and block with hot water and detergent using a stiff bristle brush. Rinse thoroughly and
dry with a clean cloth.
- Any abrasive material left in cylinder bores
will cause rapid wear of piston rings, bearings,
and other engine assembly parts.
- Do not use kerosene or gasoline for cleaning.
- After cleaning, swab cylinder bores with light
engine oil and a clean cloth. Then wipe them
out with a clean dry cloth.
CRANKSHAFT BEARING FITIING

Figure 28
If replacing rear crankshaft bearing, check for correct part number. Some rear crankshaft bearings are
0.20 mm (0.008-inch) wider than standard. Crankshaft
assembly will be identified by "0.008" stamped on rear

counterweight.
It is necessary to measure clearance of each crankshaft bearing to determine proper sizes. Factory installed
crankshaft bearings may not be same size for each journal.
ll'l'l tnspect
Lower half of crankshaft bearing ( 110 or 111 ).
- If lower half is worn or damaged, both upper
and lower half should be replaced.
- If lower half is suitable for use, upper half will
also be suitable for use.
l@I Measure
NOTICE: See "Notice" on page 6A3B-1 of this
section.
Crankshaft bearing clearance using gaging plastic.
A. Place a piece of gaging plastic full width of
crankshaft bearing ( 110 or 111) onto journal.
6A3822 5.7 LITER VB ENGINE UNIT REPAIR RPO LT1 - VIN P
114
NC0022-6A1-Y-RP
A SEAL REMOVAL NOTCHES

114 HOUSING ASSEMBLY, CRANKSHAFT REAR OIL SEAL
Figure 31 - Replacing Camshaft Front Bearing
PC00296A3BfRP
Figure 29 - Removing Crankshaft Rear Oil Seal
67
A
B
C
D
E
67
BEARING TOOL
PILOT
PULLER SCREW
WASHER
NUT
BLOCK, ENGINE
67
PC00306A3BfRP
Figure 30 - Removing Camshaft Inner Bearing
B. Measure all five bearing clearances at same

time.
rn
Important
Do not rotate the crankshaft assembly

(98) while the gaging plastic is between
the journal and the crankshaft bearing
(110 or 111 ).
C. Install crankshaft bearing caps (107) and
rear crankshaft bearing cap ( I 09) with arrows
pointing toward front of engine block assembly.
67
141
142
143
144
BLOCK, ENGINE
PC00326A3BfRP
Figure 32 - Oil Cooler and Filter Adapter Assemblies

D. Install bearing cap bolts/screws ( 108) and
studs.
l~.J
Tighten
Crankshaft bearing cap bolts/screws

(108) and studs to 106 Nm (78 lb. ft.).
E. Remove crankshaft bearing cap bolts/screws
(108), studs, crankshaft bearing caps (107) and
rear crankshaft bearing cap (109).
F. Measure gaging plastic at its widest using scale
provided with gaging plastic. Refer measurements to "Specifications" in this section.
If gaging plastic shows an irregularity
in journal exceeding 0.025 mm (0.0010
inch), measure journal with a micrometer.
select an undersize bearing and remeasure clearance. Always replace both
upper and lower crankshaft bearings
(110 and 111) as a unit.
If clearance cannot be brought to specifications using a standard undersize bearing, regrind crankshaft assembly (98) for
use with next undersize bearing.
A PRESS
103 PISTON ASSEMBLY
PC0033-6A3B-F-RP
CRANKSHAFT ASSEMBLY
Figure 33 - Removing Piston Pin
Figu,e 28
li,I
Clean
Crankshaft assembly (98) in solvent and dry it with

compressed air.
l~I
Measure
Crankpins for out-of-round, taper, or undersize with

a micrometer. Refer to "Specifications" in this section.
Crankshaft run-out at front and rear intermediate
journals with a dial indicator. Support crankshaft
front and rear journals on V-blocks. Refer to "Specifications" in this section.
Replace or recondition crankshaft assembly (98) if
measurements are outside of specifications.
A FEELER GAGE
106 RING, PISTON
PC0034-6A3B-F-RP

ASSEMBLY
Tool Required:
J 24086-B Piston Pin Remover and Installer
Set
!+I
Disassemble
1. Piston rings (106) from piston assembly (103).

2. Piston pin (105) from piston assembly (103), using
J 24086-B (Figure 33).
106
Figure 34 - Measuring Piston Ring End Gap
!t:.'I
Clean
1. Connecting rod assembly (104) in cleaning solvent.

2. Dry connecting rod assembly (104) with compressed air. Do not wire brush any part of piston
assembly.
3. Varnish from piston skirts and pins with cleaning
solvent.
4. Piston ring grooves with a groove cleaner.
6A38-24 5.7 LITER VS ENGINE UNIT REPAIR RPO LT1 -VIN P
J 24086-8
A FEELER GAGE
103 PISTON ASSEMBLY
106 RING, PISTON
PC0035-8A3B-F-RP
Figure 35 - Measuring Piston Ring Side Clearance
5. Piston oil ring holes and slots.
IL'l"I Inspect
Connecting rod assembly (104) for twisting, nicks
and cracks. Replace any damaged connecting rod
assemblies (104).
Piston assemblies (103) for:
- Cracked ring lands, skirts, or pin bosses.
- Grooves for nicks or burrs that may cause
binding.
- Warped or worn ring lands.
- Scuffed or damaged skirts.
- Eroded areas at top of piston assembly ( 103).
- Worn piston bores and piston pins ( 105).
- Replace piston assemblies (103) that are damaged or show signs of excessive wear.
f@I Measure
1. Piston pin bore-to-piston pin clearance.
A. Piston pin bores and piston pins ( 105) must be
free of varnish or scuffing when being measured.
B. Use a micrometer to measure piston pin (105)
and an inside micrometer to measure piston pin
bore.
C. If clearance is in excess of 0.025 mm (0.0010
inch), piston assembly (103) and piston pin
(105) should be replaced. Piston assembly
(103) and piston pin (105) are matched and are
not serviced separately.
2. Piston compression ring end gap.
rn
Important
Fit each compression ring to cylinder in which

it will be used.
A
103
104
105
PRESS
PISTON ASSEMBLY
PIN, PISTON
Figure 36 - Installing Piston Pin
A. Place compression ring into cylinder

bore.
B. Push compression ring into cylinder bore
to approximately 6.5 mm ( 1/4 inch)
above ring travel. Ring must be square to
cylinder wall.
C. Measure end gap with a feeler gage.
Refer to "Specifications" in this section
for acceptable end gaps.
D. If end gap exceeds specifications, select
another size ring set.
3. Piston ring side clearance.
A. Roll piston ring (106) entirely around its ring
groove on piston assembly (103).
B. If any binding is caused by ring groove, dress
groove with a fine cut file.
C. If any binding is caused by a distorted piston
ring ( 106), replace piston ring (106).
D. Measure side clearance of piston ring (106)
and groove with a feeler gage. For acceptable
side clearances, refer to "Specifications" in
this section.
E. If side clearance is too small, try another piston
ring (106).
4. Piston-to-cylinder bore clearance to determine suitability of a used piston assembly (103). Measure piston-to-cylinder bore clearance as follows:
5.7 LITER VS ENGINE UNIT REPAIR RPO LT1
Q
ENGlt,IELEFT
ENGINE FRONT
ENGINE RIGHT
e--c-
-AD
e--A
OIL RING SPACER GAP

(TANG IN HOLE OR SLOT WITHIN ARC)
OIL RING RAIL GAPS
2ND COMPRESSION RING GAP
TOP COMPRESSION RING GAP
Figure 37 - Piston Ring Gap Locations
A. Measure cylinder bore diameter at a point
B.
C.
D.
E.
F.
G.
l+!+I
64 mm (2 1/2 inches) from top of cylinder

bore using a bore gage.
Measure piston assembly ( 103) 11.5 mm (0.45
inch) from bottom of skirt at right angles to
piston pin (105) using a caliper or micrometer.
Subtract piston diameter from cylinder bore
diameter. This will indicate piston-to-bore
clearance.
Compare measurements to "Specifications" in
this section.
If clearance exceeds specifications, subtract
size of new piston assembly from cylinder bore
diameter previously measured.
If clearance with new piston assembly is
within specifications, mark that piston assembly to cylinder to which it is to be installed.
If clearance is within specifications, used piston assembly (103) may be reinstalled.
Assemble
Tool Required:
J 24086-B Piston Pin Remover and Installer
Set
rn
Important
When assembling piston assembly (103) and

connecting rod assembly (104), stamped arrow
on piston assembly (103) must point to front of
engine block assembly while flange on connecting rod assembly must face toward front of
piston assembly on left hand assembly and
face toward rear of piston assembly on right
hand assembly. Refer to Figure 27.
P 6A3B25
NOTICE: After J 24086-B installer bottoms on support assembly, do not exceed 34 475 kPa (5000 psi)
or the tool may be damaged.
1. Piston assembly (103) and connecting rod assembly
(104).
A. Lubricate piston pin holes in both piston
assembly (103) and connecting rod assembly
(104).
B. Press piston pin (105) into piston assembly
(103) and connecting rod assembly (104) using
J 24086-B (Figure 36).
ll'l'I
LC0011-6A4-B-RP
-1- VIN
Inspect
For freedom of movement of piston

assembly (103) on piston pin (105).
2. Piston rings (106) onto piston assembly (103).
Marked side of piston rings (106) must face
toward top of piston assembly (103). Locate
piston ring gaps as shown in Figure 37.
A. Install oil ring spacer in groove.
B. Hold spacer ends together and install
lower oil ring rail with gap properly
located.
C. Install upper oil ring rail with gap properly located.
D. Flex oil ring assembly to make sure rings
are free.
E. Install lower compression ring with gap
properly located.
F. Install upper compression ring with gap
properly located.

Figure 27
and do not use shims for adjustment. Do not file connecting rod assemblies or rod caps. If clearances are found to
be excessive, a new bearing will be required. Service
bearings are available in standard size and 0.001 and
0.002-inch undersize for use with new and used standard
size crankshaft assemblies, and in 0.010 and 0.020-inch
undersize for use with reconditioned crankshaft assemblies.
When removing a connecting rod cap, you may
find a 0.010-inch undersize bearing. These are used in
manufacturing for selective fitting.
ll'l'I
Inspect
l~I
Measure
NOTICE: See "Notice" on page 6A3B-l of this

section.
section.
If not within specifications, replace or recondition crankshaft assembly.
6A3B-26 5.7 LITER VB ENGINE UNIT REPAIR RPO LT1 -VIN P

If installing new bearings (101), determine
new bearing size from maximum crankpin
diameter.
2. Bearing clearances using gaging plastic.
A. Place a piece of gaging plastic full width
of bearing (101), (parallel to crankshaft
assembly) onto crankpin.
Plastic gage should be positioned in
C. Install connecting rod nuts ( 100).
l~I
87
Tighten

64 Nm (47 lb. ft.).
Important
D.
E.
F.
G.
Do not turn crankshaft assembly with

gaging plastic installed or accuracy of
Remove connecting rod nuts (100) and cap.
Measure gaging plastic at its widest using scale
provided with gaging plastic. Refer measurements to "Specifications" in this section.
If clearance is greater than specified, select
an undersize bearing (101) and re-measure
clearance.
If clearance cannot be brought to specifications, regrind crankpin. If crankpin is already
at maximum undersize, replace crankshaft
assembly (98).
88
86
87
88
89
90
91
92
93
94
95
96
97
GEAR, OIL PUMP DRIVEN

HOUSING ASSEMBLY, OIL PUMP
SCREEN ASSEMBLY, OIL PUMP
PIN, OIL PRESSURE RELIEF VALVE SPRING SEAT
SPRING, OIL PRESSURE RELIEF VALVE
VALVE, OIL PRESSURE RELIEF
PLUG, OIL PRESSURE RELIEF VALVE BORE
GEAR, OIL PUMP DRIVE
COVER, OIL PUMP
BOLT/SCREW, OIL PUMP COVER
PC0038-6A3B-F-~P
Figure 38 - Oil Pump Components
OIL PUMP ASSEMBLY

Figure 38
l+!+I
Disassemble
1. Oil pump cover bolts/screws (97) and pump cover

(96).
Matchmark gear teeth for reassembly.
2. Driven gear (86), drive gear (94), driveshaft (89) and
retainer (95) from housing assembly (87).
3. Oil pressure relief valve pin (90), relief valve (92),
spring (91) and plug (93).
4. Screen assembly (88) from housing assembly (87),
if replacement is necessary.
Mount housing assembly (87) in a soft-jaw
vise and extract screen assembly (88).
Screen assembly (88) is serviced as a unit. Do
not disturb pipe on screen.
lr,I
Clean
1. All parts in cleaning solvent.
2. Dry parts with compressed air.
ll'l'I
Inspect
Housing assembly (87) and cover (96) for cracks,

scoring, casting imperfections, and damaged
threads.
Drive gear shaft. If loose in housing assembly (87),
replace oil pump.
Pressure relief valve (92) for scoring and sticking.
- Burrs may be removed with a fine oil stone.
Relief valve spring (91) for loss of tension.
Screen assembly (88) for broken wire mesh or
screen, or looseness.
- If pipe is loose or has been removed from
screen, screen assembly (88) must be replaced.
Gears for chipping, galling, and wear.
5.7 LITER VB ENGINE UNIT REPAIR RPO LT1 - VIN P 6A3827

Drive gear (94) and driveshaft (89) for looseness and
wear.
[ ] Important
If wear is noted, replace entire pump assembly.
l!+I Assemble
Tool Required:
J 21882 Oil Suction Pipe Installer
section.
rn
1.
2.
3.
4.
5.
6.
34
Important
Be careful not to twist, shear, or collapse

screen assembly while installing it to oil pump
assembly.
A new screen assembly (88), if previously disassembled, to housing assembly (87).
A. ~ount housing assembly (87) in a soft-jaw
vise.
B. Apply sealer to end of pipe.
C. Tap pipe into place using J 21882 and a plasticfaced hammer.
Relief valve (92), spring (91), plug (93) and pin (90).
Drive gear (94), driveshaft (89) and retainer (95) to
Driven gear (86) to housing assembly (87) with
smooth side of gear toward pump cover (96).
Pump cover (96).
Oil pump cover bolts/screws (97).
l~I Tighten
34
PC0039-6A3BfRP

6. Valve seal (73).
7. Valve.
Place valves in a rack in proper sequence so
they can be assembled in their original order.
8. Shim (76).
1-:.WI
Clean
1. Carbon from combustion chambers and valve parts
using J 8358.
2. Valve guides using J 8101 (Figure 41).
Oil pump cover bolts/screws (97) to 9 Nm

(80 lb. in.).
ILl 1nspect
For smoothness of operation by turning pump driveshaft (89) by hand.

Tools Required:
J 9666 Valve Spring Tester
J 8062 Valve Spring Compressor
J 8358 Carbon Removing Brush
J 8101 Valve Guide Cleaner
l!I Disassemble
1.
2.
3.
4.
Spark plugs from cylinder head assembly.

Compress valve springs (69) using J 8062.
Valve stem keys (72).
Cap (70) from valve.

PC0040-6A3B-F-RP
Figure 40 - Cleaning Combustion Chamber
6A3B-28 5.7LITER VS ENGINE UNIT REPAIR RPO LT1 -VIN P

J 8101
69

PC0041-6A3B-F-RP
Figure 41 - Cleaning Valve Guide
3. Carbon and sludge from pushrod assemblies and

rocker arms.
4. Valve stems and heads on a buffing wheel.
5. Cylinder head assembly and engine block gasket
surfaces.
6. Bolt/screw hole threads in cylinder head assembly
(34) and engine block (67).
lll
1nspect
1. Cylinder head assembly (34) for cracks in exhaust

ports, combustion chambers, or external cracks to
water chamber.
2. Valves for burned heads, cracked faces, or damaged
stems.
3. Valve springs (69) for squareness.
A TORQUE WRENCH
69 SPRING, VALVE
PC0042-6A3B-F-RP
Figure 42 - Checking Valve Spring Tension
necessary to ream valve guides for oversize

valves. Refer to "Specifications" in this section.
F. Service valves are available in standard, 0.003,
0.015, 0.030 inch oversize.
Recondition
1. Valves with oversize stems are available as outlined
above. Ream valve guide bores for oversize valves
as necessary.
2. Reconditioning valve seats is very important. Valve
seat reconditioning must be done after reaming
valve guide bores or installing new valve guides.
l'!!i I Measure
1. Valve spring tension using J 9666 (Figure 42).
If spring tension is less than 360 N (81 lb.) at
45.2 mm (1.78 inch), replace spring.
2. Valve stem-to-bore clearance.
A. Excessive valve stem-to-bore clearance will
cause excessive oil consumption and may
cause a valve to break. Insufficient clearance
will result in noisy and sticky functioning of
valve and disturb engine assembly smoothness.
B. Clamp J 8001 on exhaust port side of cylinder
head assembly.
C. Locate indicator so movement of valve stem
from side to side (crosswise to cylinder head
assembly) will cause a direct movement of
indicator stem. Indicator stem must contact
side of valve stem just above valve guide.
D. Drop valve head about 1.6 mm (1/16 inch) off
valve seat.
E. Move stem of valve from side to side using
light pressure to obtain a clearance reading.
If clearance exceeds specifications, it will be
A STEM, VALVE
B GUIDE, VAL VE
NC0032-6A1Y-RP
Figure 43 - Measuring Valve Stem Clearance
5.7 LITER VB ENGINE UNIT REPAIR RPO LT1 -VIN P 6A38-29

71
ln
A SCALE
69 SPRING, VALVE
69
PC00456A3B-F-RP
Figure 45 - Measuring Valve Spring Installation Height
l+!+I Assemble
69
70
71
72
73
76
SPRING, VALVE
CAP, VALVE SPRING
VALVE, INTAKE
KEY, VALVE STEM
SHIM, VALVE SPRING
PC0044-6A3B-F-RP
Figure 44 - Valve Assembly (Intake Shown, Exhaust Similar)
Seating of valves must be perfect for engine

assembly to deliver optimum power and performance.
Another important factor is cooling of valve
heads. Good contact between each valve and
its seat in cylinder head assembly is necessary
to insure that heat in valve head will be properly carried away.
Several different types of equipment are available for reconditioning valve seats. Recommendations of manufacturer of equipment
being used should be carefully followed to
attain proper results.
Regardless of what type of equipment is used,
it is essential that valve guide bores be free
from carbon or dirt to ensure proper centering
of pilot in guide. Valve seats should be concentric to within 0.05 mm (0.002 inch) total indicator reading.
3. Valves that are pitted can be refaced to proper angle,
insuring correct relation between head and stem, on
a valve refacing mechanism. Valve stems which
show excessive wear, or valves that are warped
excessively should be replaced. If edge of valve
head is less than 0.79 mm (1/32 inch) thick after
grinding, replace valve.
Several different types of equipment are available for refacing valves. Recommendation of
manufacturer of equipment being used should
be carefully followed to attain proper results.
1. Shim (76) to cylinder head assembly.

2. Valve into proper port.
3. Valve seal (73) and seat valve seal (73) against shim
(76).
5. Cap (70) on valve stem.
6. Compress valve spring (69) using J 8062 (Figure
39).
A. Use grease to hold keys (72) in place while disconnecting J 8062.
B. Make sure keys (72) seat properly in upper
groove of valve stem.
C. Tap end of stem with a plastic-faced hammer to
seat keys (72), if necessary.
8. Remaining valves.
1@1 Measure
Valve spring installed height from valve spring seat
to top of cap (Figure 45).
- If installed height exceeds 45.2 mm ( 1. 78 inch),
install a valve spring seat shim approximately
1.6 mm (1/16 inch) thick.
- Do not shim a valve spring to obtain a less than
specified installed height.
CAMSHAFT ASSEMBLY
Figures 46 and 47
Tool Required:
J 7872 Magnetic Base Indicator Set
I@!
Measure
1. Camshaft journals with a micrometer.

If journals are more than 0.025 mm (0.0010
inch) out-of-round, replace with a new camshaft assembly.
6A38-30 5.7 LITER va ENGINE UNIT REPAIR RPO LT1 -VIN P

A
CAMSHAFT JOURNALS
Figure 19
Tools Required:
J 35468 Front Cover Aligner and Oil Seal
Installer
J 39090 Distributor Driveshaft Front Cover
Seal Installer
Installer
li,I
Clean
Front cover assembly and engine block gasket surfaces.

NC10146A1BY-RP
Figure 46 - Measuring Camshaft Journals
lll
1nspect
Front cover assembly (50) for damage to seals or

gasket surface.
ENGINE FRONT COVER OIL SEALS
l++I
Front cover oil seals for crankshaft assembly, distributor shaft and water pump driveshaft assembly.
l++I
Install or Connect
1. Crankshaft seal using J 35468.

2. Distributor driveshaft seal using J 39090.
3. Water pump driveshaft seal using J 39088.
KC0024-6A3f.RP
Figure 47 - Measuring Camshaft Runout
OIL PAN ASSEMBLY
li,I
2. Camshaft runout using J 7872.
Mount camshaft assembly in V-blocks or
between centers. Using J 7872, check intermediate camshaft journal. If runout exceeds
0.038 mm (0.0015 inch) camshaft assembly is
excessively bent and should be replaced.

Figures 20 and 21
ll'l"I
Inspect
Camshaft and crankshaft sprockets (57 and 62) and

water pump driveshaft assembly (63) for wear.
One edge of teeth worn or teeth no longer concentric.
Valley between teeth worn.
Key and crankshaft keyway for wear.
Timing chain assembly for binding.
Clean
Oil pan assembly in solvent. Remove all sludge and

varnish.
Gasket surfaces.
!ll
1nspect
Gasket flanges for bending or damage.
Oil pan assembly for rock damage or cracks.

Oil pan baffle for lack of fit.
Drain plug threads for stripping.
WATER PUMP ASSEMBLY

Figure 16
Tool Required:
Installer
1i,1
Clean
Water pump assembly (37) and engine block gasket

surfaces.
lll
ASSEMBLY
1nspect
0-ring seals on water pump driveshaft assembly

(63) and water pump shaft. Replace seals, if necessary, using J 39089.

Figure 15
lll
ENGINE BLOCK
Figure 32

section.
1. Front and rear oil gallery plugs.
1nspect
Lifter body for wear and scuffing. Also inspect bore

in engine block for scuffing.
Lifter roller for:
- Binding or roughness.
- Excessive looseness in roller bearings.
- Flat spots.
- Pitting.
Lifter pushrod seat and pushrod end for wear or
scoring.

ASSEMBLIES
l..I
Rear engine block oil gallery plugs to 24 Nm

(18 lb. ft.).
lll
l..I
Inspect
Rocker arms (29) and balls (30) at their mating surfaces. These surfaces should be smooth and free of
scoring or other damage.
Rocker arm pushrod sockets and valve stem mating
surfaces. These surfaces should be smooth with no
scoring or exceptional wear.
Pushrod assemblies (27) for scored ends or bends.

Figure 13
li,I
Clean
Valve rocker arm cover and cylinder head gasket

surfaces.
lll
1nspect
Gasket flanges for damage.

Rubber grommets for deterioration.

Figure 10
li,I
Clean
Intake manifold bolts/screws (8) and studs (9).

Cylinder head assembly, engine block and intake
manifold sealing surfaces.
1nspect
Oil filter adapter bypass valve and spring for

operation.
For cracked or broken bypass valve.
- Oil filter adapter and bypass valve assembly must be replaced as a unit.
2. Oil filter adapter assembly (142).
3. Oil filter adapter bolts/screws (143).
Figures 14 and 15
ll'l'I
Tighten
4.
5.
6.
7.
8.
Tighten
Oil filter adapter bolts/screws (143) to 23 Nm

(17 lb. ft.).
Engine oil cooler assembly (141 ).
Oil filter assembly (144).
Fuel pump and oil pressure sensor assembly.
Knock sensor assemblies.
Starter motor assembly and bolts/screws.
l..I
Tighten
Knock sensor assemblies to 19 N m ( 14 lb. ft.).

Starter motor bolts/screws to 46 Nm (34 lb.
ft.).
Fuel pump switch and oil pressure gage sensor
assembly to 12 Nm (108 lb. in.).
CAMSHAFT BEARINGS
Tool Required:
J 6098-01 Camshaft Bearing Remover/Installer
Outer front and rear camshaft bearings must be
installed first. These bearings serve as guides for tool
pilot, and help center inner bearings during installation
process.
Important
Align camshaft bearing oil holes properly during installation.

D. Using two wrenches, hold puller screw while
turning nut to draw bearing into bore.
When bearing has been pulled into bore,
remove bearing tool and puller screw and
check alignment of bearing oil hole to
bore oil hole.
E. Repeat above steps for remaining inner camshaft bearings.
Index pilot in rear camshaft bearing to
install rear inner bearing.
68
8.733 mm'
........_ (11/32")
3. New camshaft rear bearing hole plug (68).

A. Coat plug outside diameter with GM P/N
1052080 sealant, or equivalent.
B. Install camshaft rear bearing hole plug (68) as
shown in Figure 48.
CRANKSHAFT ASSEMBLY
Figure28

67 BLOCK, ENGINE
SECTION AA
68 PLUG, CAMSHAFT REAR BEARING HOLE

PC00486A3BFRP
1.
Figure 48 - Camshaft Rear Bearing Hole Plug
- Number one (front) camshaft bearing oil

holes must be positioned so that they are
at 1 o'clock and 5 o'clock positions.
- Number two through number four inner
camshaft bearing oil holes must be positioned at 5 o'clock toward left side of
engine block and even with bottom of
cylinder bore.
- Number five (rear) camshaft bearing oil
hole must be positioned at 12 o'clock.
1. Front and rear camshaft bearings using J 6098-01.
A. Assemble bearing tool to driver handle.
B. Align oil holes as outlined above.
C. Drive front and rear bearings in, toward center
of engine block.
2. Inner camshaft bearings using J 6098-01.
A. With nut and thrust washer assembled to end of
puller screw threads, index pilot in camshaft
front bearing and install puller screw through
pilot.
B. Index camshaft bearing in bore, aligning oil
hole as outlined above.
C. Install puller screw through bearing bore and
bearing to be installed and assemble bearing

tool to puller screw with shoulder toward bearing. Make sure that enough threads are
engaged.
2.
3.
4.

section.
Crankshaft bearings ( 110 and 111) into engine block
(67) and crankshaft bearing caps (107) and rear
Coat crankshaft bearings ( 110 and 111 J with
oil.
Crankshaft assembly (98).
Crankshaft bearing caps (107) and rear crankshaft
bearing cap (109) with assembled crankshaft bearings ( 110 and 111) with arrows pointing toward front
of engine block.
studs.
bearings ( 110 and 111) and crankshaft bearing
caps ( 107) and rear crankshaft bearing cap
(109) installed and bolts/screws (108) and
studs started, thrust crankshaft assembly (98)
rearward to set and align bearing caps (107 and
109). Then thrust crankshaft assembly forward
to align rear faces of rear crankshaft bearings
(Ill).
l~I Tighten
studs to 106 Nm (78 lb. ft.).
l@I Measure
Crankshaft end play using a dial indicator or
feeler gage. Refer to "Specifications" in this
section.
- If using a feeler gage, measure between
front of rear crankshaft bearing cap ( 109)
and crankshaft thrust surface.
5.7 LITERV8 ENGINE UNIT REPAIR RPO LT1 -VIN P 6A38-33

Figure28
1.,1 Clean
Gasket surfaces.

2. Piston assembly (103) with stamped arrow facing
forward into its matched bore using J 8037 and
lightly tapping top of piston assembly (103) with
wooden hammer handle.
Hold J 8037 firmly against engine block until

section.
[I] Important
Figure27
Always use new crankshaft rear oil seal and

new housing gasket ( 113) during installation of
crankshaft rear oil seal housing assembly
(114).
1. New gasket (113) and crankshaft rear oil seal housing assembly (114) on studs (112).
It is not necessary to use any type of sealant to
hold gasket (113) in place.
screws (116).
!~I Tighten
Crankshaft rear oil seal housing nuts ( 115) and
CRANKSHAFT REAR OIL SEAL

Figures 28 and 49
Tool Required:
J 35621 Rear Main Seal Installer

1. Coat new seal entirely with engine oil.
2. Seal onto J 35621.
3. J 35621 onto rear of crankshaft assembly (98).
Tighten screws snugly to ensure seal will be
tnstalled squarely over crankshaft assembly (98).
4. Crankshaft rear oil seal to crankshaft assembly (98)
and crankshaft rear oil seal housing ( 114).
Tighten wing nut on J 35621 until it bottoms.
5. Remove J 35621 from crankshaft rear oil seal houstng (114).

section.
1. Coat inside surface of bearings ( 101) with engine
oil.
[I] Important
When assembled, flanges on connecting rod
assembly and cap should face to front in left
bank and to rear in right bank.
l~I Tighten
(47 lb. ft.)
!~I Measure
1. When all connecting rod bearings (101) have been
installed, tap each connecting rod assembly lightly
parallel to crankpin to make sure they have clearance.
2. Side clearance between connecting rod caps (99)
using a feeler gage or dial indicator.

ASSEMBLY
Figures 27 and 50

Tool Required:
NOTICE: Place short length of fuel hose over connecting rod bolts/screws to protect bearing surface
and threads.
LC0012-6A4-B-RP
Figure 49 - Installing Crankshaft Rear Oil Seal
6A38-34 5.7 LITER VB ENGINE UNIT REPAIR RPO LT1 -VIN P
13
10
16
Figure 50 - Installing Piston Assembly
l~I
1.
2.
3.
4.
1.
2.
3.
4.
Install or Connect

section.
New cylinder head gasket (82).
Gasket (82) over locating pins, with yellow side of
tab on outboard side facing up.
Cylinder head assembly (34) over locating pins and
gasket (82).
Coat threads of cylinder head bolts/screws (81)
with sealing compound (GM P/N 1052080 or
equivalent).
NC1022-6A1B-Y-RP
Use a backup wrench on pipe fittings when

installing bolts/screws.
Figures 24 and 51
15
6. Engine coolant air bleed pipe and bolts/screws.
l~I
11
5. Spark plugs.
CAMSHAFT ASSEMBLY
Tighten
Tighten

section.
Oil pump assembly ( 118), and driveshaft (89).
Align slot on end of driveshaft (89) with drive
tang on oil pump shaft.
Oil pan baffle ( 119).
Bolt/screw (120) attaching oil pump assembly (118)
Oil pan baffle nuts.
Oil pump bolt/screw (120) to 88 Nm (65 lb.

ft.).
Oil pan baffle nuts to 34 Nm (25 lb. ft.).
1++1

OIL PUMP ASSEMBLY
Install or Connect
Figure 51 - Cylinder Head Tightening Sequence
Rod side clearance should be 0.16 to 0.35 mm

(0.006 to 0.014 inch).
l++I
~FRT
NC1028-6A1BYRP
Figure26
12
l~I
Tighten
Engine coolant air bleed pipe bolts/screws to

41 Nm (30 lb. ft.).
When installing new camshaft assembly, coat camshaft lobes and journals with engine oil.
When installing a new camshaft assembly, inspect
all valve lifter assemblies and replace as necessary to
ensure durability of camshaft lobes and lifter rollers.
l++I
Install or Connect

section.
2. Camshaft retainer (59) and camshaft retainer bolts/
screws (58).
l~I
Tighten
Camshaft retainer bolts/screws (58) to 12 Nm

(108 lb. in.).
3. Oil pump driveshaft assembly (65) and bolt/screw
(66).
Bolt/screw hole "ear" must be seated on boss
before tightening bolt/screw (66).
l~I

Tighten

J 5590 Crankshaft Gear Installer

Installer
J 39092 Driven Gear Assembly Installer

section.
Key, if previously removed.
Water pump driveshaft assembly (63) using J 39092.
Water pump driveshaft bearing retainer bolts/screws
(64).
l~I
Tighten
Camshaft sprocket bolts/screws (56) to 28 Nm

(21 lb. ft.).

Figure 19
Tool Required:

2.
3.
4.
l~I
7. New 0-ring seal to water pump driveshaft assembly

(63) using J 39089.
Figures 20 and 21
Tools Required:
1.
Make sure that camshaft and crankshaft timing

marks align as shown in Figure 20.
Tighten
Water pump driveshaft bearing retainer bolts/

screws (64) to 12 Nm (108 lb. in.).
(61).
Gears must mesh, or damage to camshaft
retainer could occur.

Protector

section.
NOTICE: Be careful not to damage seal when
installing front cover assembly over water pump
driveshaft assembly.
1. Gasket (51) and front cover assembly (50) using
J 39087 on water pump driveshaft assembly.
2. Front cover bolts/screws (52).
l~I Tighten
Front cover bolts/screws (52) to 11 Nm
(100 lb. in.).
~ I
55
55
A SEALER
53 REINFORCEMENT, OIL PAN
54 PAN ASSEMBLY, OIL
55 GASKET, OIL PAN
PC00526A3BFRP
Figure 52 - Oil Pan Seal
6A38-36 5.7 LITER VS ENGINE UNIT REPAIR RPO LT1 - VIN P
4. Oil level sensor assembly (178).
l~I
Figure 18
rn
l++I
Oil level sensor assembly (178) to 22 Nm

(16 lb. ft.).
Important
Distributor driveshaft (48) has a keyway (missing

spline) on both ends that positively locates distributor assembly (49) to camshaft sprocket.
Install distributor driveshaft (48) to camshaft
sprocket. Rotate crankshaft assembly until keyway
on driveshaft distributor end is near 12 o'clock position. Remove distributor dri veshaft (48 ), install in
distributor assembly (49) and turn until keyway on
camshaft sprocket end is in same position
(12 o'clock) when crankshaft assembly was turned.
This will help make installation of distributor
assembly (49) easier.

HUB
Figure 17
Tool Required:
l++I
1.
Install or Connect

section.
1. Distributor assembly (49) and distributor driveshaft
(48).
Before torquing bolts/screws, make sure distributor assembly is properly seated. If it is difficult to seat, check shaft alignment.
2. Distributor bolts/screws (47).
l~I
2.
3.
4.
If crankshaft balancer assembly is replaced,

new balancer weights of same size must be
installed on new balancer assembly in same
location as old balancer assembly.
l~I
Install or Connect
Tighten
Corner bolts/screws (84) or stud (83), and nuts

(85) to 20 Nm (15 lb. ft.).
Remainder of bolts/screws (84) and studs (83)
to 11 Nm (100 lb. in.).
Tighten
Crankshaft balancer hub bolt/screw to 102 Nm

(75 lb. ft.).
Crankshaft balancer bolts/screws (46) to 81
Nm (60 lb. ft.).
Figures 52 and 53
l~I

section.
Crankshaft balancer hub (45) must be installed by
following procedure:
A. Set number 1 piston assembly to top dead center.
B. Install crankshaft balancer hub with cast arrow
on hub in 12 o'clock position.
Crankshaft balancer hub (45) using J 39046.
Crankshaft balancer hub washer and bolt/screw.
Crankshaft balancer assembly (42) and bolts/screws
(46).
Important
OIL PAN ASSEMBLY

section.
1. Apply a small amount of sealer, GM PIN 1052914 or
equivalent, to front cover assembly and engine block
junction and to rear seal housing and engine block
junction. Apply sealer 25 mm (1 inch) in either
direction of radius cavity of junctions. See Figure
52.
2. Oil pan gasket (55), oil pan assembly (54) and reinforcements (53).
3. Oil pan nuts (85), bolts/screws (84) and studs (83).
Install or Connect
Tighten
Distributor bolts/screws (47) to 11 Nm

(100 lb. in.).
3. Spark plug and ignition harness assemblies to distributor assembly (49) if removed.
l++I
Tighten
WATER PUMP ASSEMBLY

Figure 16
l++I
Install or Connect

section.
1. Coupling (39) to water pump shaft with groove on
coupling toward engine block.
Apply a light coat of grease to 0-ring seals and
grease to coupling.
2. Position water pump assembly (37) and gaskets
(38), with tabs straight up, to engine block and rotate
coupling (39), if necessary, to align it to water pump
driveshaft splines and then seat water pump assembly (37).
3. Water pump bolts/screws (40 and 41).
5.7 LITERV8 ENGINE UNIT REPAIR RPO LT1 -VIN P 6A38-37
l~I
Tighten
Water pump bolts/screws (40 and 41) to

41 Nm (30 lb. ft.).

Figure 15

section.
1. Coat valve lifter rollers with prelube, GM P/N
2. Valve lifter assemblies (36) in same location from
3. Valve lifter guides (35), retainer (33) and valve lifter
guide retainer bolts/screws (32).
l~I
Tighten
Valve lifter guide retainer bolts/screws (32) to

20 Nm (15 lb. ft.).
VALVE ROCKER ARM BALL STUDS

Figure 14

53

section.
1. Apply sealer, GM P/N 1052080 or equivalent, to
threads of new rocker arm ball stud.
2. Rocker arm ball stud (28).
l~I Tighten
Valve rocker arm ball stud (28) to 68 Nm
(50 lb. ft.).

ASSEMBLIES
Figures 14 and 54
Tool Required:
J 8520 Cam Lobe Lift Indicator
53 REINFORCEMENT, OIL PAN
54 PAN ASSEMBLY, OIL
55 GASKET, OIL PAN
83 STUD, OIL PAN
84 BOLT/SCREW, OIL PAN
85 NUT, OIL PAN
178 SENSOR ASSEMBLY, ENGINE OIL LEVEL SWITCH
190 BRACKET, ENGINE WIRING HARNESS
PC0053-6A3B-F-RP
l++l lnstall or Connect

1. Coat rocker arm and rocker arm ball bearing surfaces with prelube, GM PIN 1052365 or equivalent,
when installing. Install these components and pushrod assemblies (27) in locations from which they
were removed.
l@I
Measure
Camshaft lobe lift.

A. Position J 8520 with ball socket adapter
on pushrod assembly. Make sure pushrod
assembly is in lifter socket.
B. Rotate crankshaft assembly slowly in
direction of rotation until lifter roller is
on heel of cam lobe. At this point, pushrod assembly will be in its lowest position.
C. Set J 8520 on zero.
D. Rotate crankshaft assembly slowly until

pushrod assembly is in fully raised position.
nn
E. Compare total lift shown on J 8520 with

specifications. Refer to "Specifications"
in this section.
F.
Remove J 8520.
Figure 54 - Measuring Camshaft Lobe Lift
3. Rocker arms (29).

4. Rocker arm balls (30) and nuts (31 ).
[el Adjust

Figure 13
Rocker arm nuts until all lash is eliminated.

A. Turn crankshaft assembly until cast arrow on
crankshaft balancer hub is in 12 o'clock position and number 1 cylinder is in firing position
(top dead center).
Watch number 1 cylinder valves as

crankshaft
balancer
hub
arrow
approaches 12 o'clock position. If a valve
moves as arrow moves to position,
engine assembly is in number 6 cylinder
firing position. Crankshaft assembly
must then be turned one more time to
reach number 1 cylinder firing position.
B. With engine assembly in number 1 cylinder firing position, following valves can be adjusted:
Right Valve Rocker Arm Cover Assembly

section.
1. Gasket (25) and valve rocker arm cover assembly
(23).
2. Valve rocker arm cover bolts/screws (24).
l~I Tighten
Valve rocker arm cover bolts/screws (24) to
11 Nm (100 lb. in.).
Exhaust 1, 3, 4, 8
Left Valve Rocker Arm Cover Assembly
Intake 1, 2, 5, 7
C. Back off rocker arm nut (31) until lash is felt in

pushrod assembly (27). Then tighten rocker
arm nut (31) until all lash is removed. Zero lash
can be felt by rotating pushrod assembly (27)
between thumb and forefinger until there is no
more movement.
D. When all free play has been removed, tighten

rocker arm nut (31) one additional turn (360
degrees).
E. Turn crankshaft assembly one revolution until
hub arrow is again at 12 o'clock position. This
is number 6 cylinder firing position. Following
valves can now be adjusted:
Exhaust 2, 5, 6, 7
Intake 3, 4, 6, 8
1. Gasket (25) and valve rocker arm cover assembly

(23).
2. Valve rocker arm cover bolts/screws (24).
l~I Tighten
Valve rocker arm cover bolts/screws (24) to
11 Nm (100 lb. in.).


section.
5.7 LITER VB ENGINE UNIT REPAIR RPO LT1 -VIN P 6A3B-39

1. Apply a 5 mm (3/16-inch) bead of RTV sealer, GM
PIN 1052366 or equivalent, to front and rear of
engine block. Extend bead 13 mm (1/2 i~ch) up each
cylinder head assembly to seal and retam gaskets.
2. Intake manifold assembly (6) with new gaskets (10).
!~I Tighten
Intake manifold bolts/screws (8) and studs (9)
in a first pass to 8 Nm (71 lb. in.) in sequen~e
as shown in Figure 55. Tighten in sequence m
a second pass to final specifications of 48 N m
(35 lb. ft.).
4. Throttle body assembly (3), gasket (5) and bolts/
screws (4).
l~I
Tighten
Throttle body bolts/screws (4) to 26 Nm

(19 lb. ft.).
5. Accelerator cable bracket.
l~I
Tighten
Accelerator control cable bracket bolts/screws

to 10 Nm (90 lb. in.).
7. EGR solenoid assembly and nut.
l~I
Tighten
EGR valve bolts/screws to 22 Nm (16 lb. ft.).

EGR control valve relay nut to 22 Nm
(16 lb. ft.).
8. Canister purge valve assembly bracket and bolt/
screw.
l~I
Tighten
Evaporative emission canister purge solenoid

valve bracket bolt/screw to 6 Nm (53 lb. in.).
9. EGR vacuum harness assembly and crankcase vent
hoses.
10. Generator bracket assembly, spark plug wire support
and bolts/screws.
l~I
Tighten
Generator bracket bolts/screws to 34 N m

(25 lb. ft.).
11. Fuel injectors with fuel rail assembly (2) to intake
13. Fuel rail bolts/screws (1).
l~I
Tighten
Fuel injection fuel rail bolts/screws ( 1) to

20 Nm (15 lb. ft.).
14. Wiring harness assemblies if moved or disconnected.
6 MANIFOLD ASSEMBLY, INTAKE
PC0055-&A3BFRP
Figure 55 - Intake Manifold Tightening Sequence

Figures 11 and 12

section.
1. Exhaust manifold gasket (18), manifold assembly
( 19) and heat shields.
2. Exhaust manifold studs (20) and bolts/screws (21 ).
l~I
Tighten
Exhaust manifold studs (20) and bolts/screws

(21) to 35 Nm (26 lb. ft.).
3. Air injection pipe (12), gasket (22) and check valve
(11) as an assembly with nuts (14).
l~I
Tighten
Secondary air injection pipe fitting-to-exhaust

manifold assembly to 34 Nm (25 lb. ft.).
Secondary air injection pipe nuts (14) to 26
Nm (19 lb. ft.).
4. Apply sealer, GM PIN 1052080 or equiv~lent,
around oil level indicator tube 13 mm (1/2 mch)
below bead.
5. Oil level indicator, tube and bolt/screw to engine
block.
l~I
Tighten
Oil level indicator bolt/screw to 11 Nm

(100 lb. in.).
6. Spark plug wire harness assembly.

section.

1. Exhaust manifold gasket (17), manifold assembly
( 16) and heat shields.
Figure 8
2. Exhaust manifold bolts/screws (21 ).
l~I
l++I
Tighten
Exhaust manifold bolts/screws (21) to 35 Nm

(26 lb. ft.).
4. Secondary air injection pipe assembly (15), check
valve (11) and hose assembly.
l~I
FLYWHEEL ASSEMBLY
Install or Connect

section.
1. Flywheel assembly (135 or 137) to crankshaft
assembly (98).
Align locator hole to pin (133).
2. Flywheel bolts/screws (136 or 138).
l~I
Tighten
Secondary air injection pipe fitting-to-exhaust

manifold assembly to 34 Nm (25 lb. ft.).
Tighten
Flywheel bolts/screws (136 or 138) to 100 Nm

(74 lb. ft.).
SPECIFICATIONS
Camshaft Retainer Bolt/Screw ........................................ 12 Nm (108 lb. in.)
Camshaft Sprocket Bolt/Screw ......................................... 28 Nm (21 lb. ft.)
Coolant Air Bleed Pipe Bolt/Screw ..................................... 41 Nm (30 lb. ft.)
Crankshaft Balancer Bolt/Screw ........................................ 81 Nm (60 lb. ft.)
Crankshaft Balancer Hub Bolt/Screw ................................... 102 Nm (75 lb. ft.)
Crankshaft Bearing Cap Bolt/Screw and Stud ............................ 106 Nm (78 lb. ft.)
Crankshaft Rear Oil Seal Housing Nut and Bolt/Screw . . . . . . . . . . . . . . . . . . . . . . 15 N m (11 lb. ft.)
Cylinder Head Bolt/Screw ............................................ 88 Nm (65 lb. ft.)
Distributor Bolt/Screw .............................................. 11 Nm (100 lb. in.)
EGR Control Valve Relay Nut ......................................... 22 Nm (16 lb. ft.)
EGR Valve Bolt/Screw ............................................... 22 Nm (16 lb. ft.)
Engine Block Oil Gallery Plug ......................................... 24 Nm (18 lb. ft.)
Engine Front Cover Bolt/Screw ....................................... 11 Nm (100 lb. in.)
Evaporative Emission Canister Purge Solenoid Valve Bracket Bolt/Screw ........ 6 Nm (53 lb. in.)
Exhaust Manifold Stud and Bolt/Screw .................................. 35 Nm (26 lb. ft.)
Flywheel Bolt/Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 Nm (74 lb. ft.)
Fuel Injection Fuel Rail Bolt/Screw ..................................... 20 Nm (15 lb. ft.)
Fuel Pump Switch and Oil Pressure Gage Sensor Assembly ................. 12 Nm (108 lb. in.)
Ignition Coil ....................................................... 34 Nm (25 lb. ft.)
Intake Manifold Bolt/Screw and Stud
First Pass ......................................................... 8 Nm (71 lb. in.)
Final Pass ....................................................... 48 Nm (35 lb. ft.)
Knock Sensor Assembly .............................................. 19 Nm (14 lb. ft.)
Oil Filter Adapter Bolt/Screw .......................................... 23 Nm (17 lb. ft.)
Oil Level Indicator Tube Bolt/Screw ................................... 11 Nm (100 lb. in.)
Oil Level Sensor .................................................... 22 Nm (16 lb. ft.)
Oil Pan Assembly
Corner Bolt/Screw and Nut .......................................... 20 Nm (15 lb. ft.)
Side Rail Bolt/Screw .............................................. 11 N m ( 100 lb. in.)
Oil Pan Baffle Nut ................................................... 34 Nm (25 lb. ft.)
Oil Pump Bolt/Screw-to-Rear Crankshaft Bearing Cap ...................... 88 Nm (65 lb. ft.)
Oil Pump Cover Bolt/Screw ............................................ 9 Nm (80 lb. in.)
Oil Pump Driveshaft Bolt/Screw ....................................... 18 Nm (13 lb. ft.)
Secondary Air Injection Pipe Nut ....................................... 26 Nm (19 lb. ft.)
5.7 LITER va ENGINE UNIT REPAIR RPO LT1 -VIN P 6A38-41

Secondary Air Injection Pipe Fitting-to-Exhaust Manifold Assembly ........... 34 Nm (25 lb. ft.)
Throttle Body Bolt/Screw ............................................. 26 Nm (19 lb. ft.)
Valve Lifter Guide Retainer Bolt/Screw .................................. 20 Nm (15 lb. ft.)
Valve Rocker Arm Cover Bolt/Screw ................................... 11 Nm (100 lb. in.)
Valve Rocker Arm Ball Stud ........................................... 68 Nm (50 lb. ft.)
Water Pump Bolt/Screw .............................................. 41 Nm (30 lb. ft.)
Water Pump Driveshaft Retainer Bolt/Screw ............................. 12 Nm (108 lb. in.)
ENGINE ASSEMBLY SPECIFICATIONS 5.7L (LT1)

GENERAL
Type .......................................................... , ............... V8
Displacement..... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.7L (350 CID)
Bore ............................................................ 101.60 mm (4.000")
Stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88.39 mm (3.480")
Compression Ratio ............................................................ 10.5:1
Firing Order ......................................................... 1-8-4-3-6-5-7-2
Spark Plugs
Type .................................................................. AC41-906
Gap ............................................................ 1.27 mm (0.050")
Torque .......................................................... 15 Nm (11 lb. ft.)
Oil Pressure (Minimum) ............................. 41.4 kPa (6.0 psig) at 1,000 engine rpm
Oil Filter Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Nm (14 lb. ft.)
CYLINDER BORE
Out-of-Round
Production .................................................. 0.02 mm (0.001 ") MAX.
Service Limit ................................................ 0.05 mm (0.002") MAX.
Taper
Production
Thrust Side ............................................. 0.012 mm (0.0005") MAX.
Relief Side .............................................. 0.025 mm (0.0010") MAX.
PISTON ASSEMBLY
Piston Bore Clearance
Production ........................................ 0.025 - 0.068 mm (0.0010 - 0.0027")
PISTON RINGS
Groove Clearance
Production Top .................................. 0.030 - 0.081 mm (0.0012 - 0.0032")
Production 2nd .................................. 0.030 - 0.081 mm (0.0012 - 0.0032")
Service Limit ............................................ 0.107 mm (0.0042") MAX.
Gap
Production Upper .................................... 0.25 - 0.50 mm (0.010 - 0.020")
Production Lower .............................. 0.46 - 0.66 mm (0.018 - 0.026") MAX.
Piston Oil Ring
Groove Clearance
Production ......................................... 0.051 - 0.17 mm (0.002 - 0.007")
Service Limit .............................................. 0.20 mm (0.008 ") MAX.
Gap
Production .......................................... 0.25 - 0.76 mm (0.010 - 0.030")
Service Limit ...................................... : ....... 1.65 mm (0.065") MAX.

PISTON PIN
11
Diameter ......................................... 23.546 - 23.548 mm (0.9270 - 0.9271 )

Clearance in Piston Assembly
11
Production ...................................... 0.0127 - 0.0203 mm (0.0005 - 0.0008 )
11
Service Limit .............................................. 0.025 mm (0.0010 ) MAX.
11
Fit In Connecting Rod Assembly .............. 0.021 - 0.040 mm (0.0008 - 0.0016 ) Interference
CRANKSHAFT ASSEMBLY
Main Journal
Diameter # 1 ..................................... 62.189 - 62.212 mm (2.4484 - 2.4493 11 )
Diameter #2, #3, #4 ............................... 62.182 - 62.205 mm (2.4481 - 2.4490 11 )
Diameter #5 ..................................... 62.177 - 62.120 mm (2.4481 - 2.4488 11 )
Taper
11
Production .............................................. 0.005 mm (0.0002 ) MAX.
Service Limit ............................................ 0.025 mm (0.0010 11 ) MAX.
Out-of-Round
11
Service Limit ............................................ 0.025 mm (0.0010 11 ) MAX.
Crankshaft Bearing Clearance
11
Production #1 ..................................... 0.020 - 0.051 mm (0.0008 - 0.0020 )
Production #2, #3, #4 ............................... 0.028 - 0.051 mm (0.0011 - 0.0020 11 )
11
Production #5 ..................................... 0.043 - 0.081 mm (0.0017 - 0.0032 )
11
Service Limit #1 ................................... 0.025 - 0.038 mm (0.0010 - 0.0015 )
11
Service Limit #2, #3, #4 ............................. 0.025 - 0.064 mm (0.0010 - 0.0025 )
11
Service Limit #5 ................................... 0.064 - 0.089 mm (0.0025 - 0.0035 )
11
Crankshaft Assembly End Play ............................. 0.03 - 0.17 mm (0.001 - 0.007 )
CONNECTING ROD ASSEMBLY
11
Diameter ....................................... 53.068 - 53.334 mm (2.0893 - 2.0998 )
Taper
11
11
Service Limit ............................................ 0.025 mm (0.0010 ) MAX.
Out-of-Round
11
11
Service Limit ............................................ 0.025 mm (0.0010 ) MAX.
Rod Bearing Clearance
11
Production ........................................ 0.033 - 0.088 mm (0.0013 - 0.0035 )
11
Service Limit .............................................. 0.076 mm (0.0030 ) MAX.
11
Rod Side Clearance ....................................... 0.16 - 0.35 mm (0.006 - 0.014 )
CAMSHAFT ASSEMBLY
11
Journal Diameter ................................... 47.452 - 47.477 mm (1.8682 - 1.8692 )

11
End Play ............................................... 0.11 - 0.30 mm (0.004 - 0.012 )
11
Lobe Lift ....................................................... 0.050 mm (0.002 )
11
Intake ........................................................... 7.62 mm (0.300 )
11
Exhaust ......................................................... 7.62 mm (0.300 )
VALVE SYSTEM
Rocker Arm Ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.50: 1
Face Angle .................................................................... 45
Seat Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
11
Seat Runout ................................................... 0.05 mm (0.002 ) MAX.
Seat Width
11
Intake ................................................ 0.76 - 1.27 mm (0.030 - 0.050 )
11
Exhaust .............................................. 1.52 - 2.03 mm (0.060 - 0.080 )
5.7 LITER VB ENGINE UNIT REPAIR RPO LT1 - VIN P 6A3B-43

Stem Clearance
Production
11
Intake .......................................... 0.027 - 0.069 mm (0.0011 - 0.0027 )
11
Exhaust ........................................ 0.027 - 0.069 mm (0.0011 - 0.0027 )
Service
11
Intake ................................................... 0.093 mm (0.003 ) MAX.
11
Exhaust ................................................. 0.119 mm (0.004 ) MAX.
Valve Spring
11
Free Length ....................................................... 51.1 mm (2.01 )
Pressure
Closed ................................... 360 - 395 Nat 45.2 mm (81 - 89 lb. at 1.78 11 )
11
Open ............................... 1121 - 1208 Nat 33.1 mm (252 - 272 lb. at 1.305 )
Installed Height
Intake .......................................................... 45.2 mm (1.78 11 )
11
Exhaust ........................................................ 45.2 mm (1.78 )
Valve Lift
11
Intake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.43 mm (0.450 )
11
Exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.68 mm (0.460 )
6A38-44 5.7 LITER VB ENGINE UNIT REPAIR RPO LT1 -VIN P
SPECIAL TOOLS
1.
J 5590
6.
2.
J 39087
7.
J 5825-A
8.
3.
4.
~
~
J 3049
9.
J 6098-01
J 39088
J 8037
10.
5.
J 8062
J 39089
11.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
J 9666 or
J 8056
CRANKSHAFT GEAR INSTALLER

DRIVEN GEAR SHAFT FRONT COVER SEAL PROTECTOR
CRANKSHAFT GEAR REMOVER
HYDRAULIC VALVE LIFTER REMOVER (PLIER TYPE)
DRIVEN GEAR/WATER PUMP SHAFT SEAL INSTALLER
CAMSHAFT BEARING REMOVER AND INSTALLER
DRIVEN GEAR SHAFT FRONT COVER SEAL INSTALLER
VALVE SPRING TESTER
VALVE SPRING COMPRESSOR (HEAD-OFF)
HYDRAULIC VALVE LIFTER REMOVER (SLIDE HAMMER
TYPE)
13. DRIVEN GEAR ASSEMBLY REMOVER
12.
a
~
J 5239
J9290-01
13.
J 39243
PC0056-6A3B-F-RP
5.7 LITER VS ENGINE UNIT REPAIR RPO LT1 - VIN P 6A3B-45
, .
J8358
~~
J 8520
15.
iiiiil
r1
c:::::::,
16.
17.
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CARBON REMOVING BRUSH

CRANKSHAFT HUB REMOVER AND INSTALLER
SPARK PLUG PORT ADAPTOR (14 mm TAPERED SEAT)
MAGNETIC BASE INDICATOR SET
PISTON PIN REMOVER AND INSTALLER SET
FRONT COVER ALIGNER AND OIL SEAL INSTALLER
REAR MAIN SEAL INSTALLER
VALVE GUIDE CLEANER
DRIVEN GEAR ASSEMBLY INSTALLER
DISTRIBUTOR DRIVESHAFT FRONT COVER SEAL
INSTALLER
PC0057-6A3B-F-RP
COOLING AND RADIATOR 681
SECTION 68
COOLING AND RADIATOR

result.
CONTENTS
General Description . . . . . . . . . . . . . . . . . . . . . . . . 6B- l
Radiator Assembly . . . . . . . . . . . . . . . . . . . . . . . 6B-2
Cross-Flow Radiator Core and
Outlet and Inlet Tanks ................ 6B-2
Transmission Oil Cooler Assembly . . . . . . . . 6B-2
Engine Oil Cooler Assembly . . . . . . . . . . . . . 6B-2
Radiator Drain Cock Assembly . . . . . . . . . . . 6B-2
Heater Core . . . . . . . . . . . . . . . . Refer to Section 1A
Radiator Filler Cap Assembly .............. 6B-2
Electric Engine Coolant Fan Assembly ....... 6B-2
Engine Coolant Temperature Gage Sensor .... 6B-3
Engine Coolant Temperature (ECT) Sensor ... 6B-3
Engine Coolant Thermostat Assembly . . . . . . . 6B-3
Coolant Recovery System . . . . . . . . . . . . . . . . . 6B-3
Radiator Air Baffle Assemblies and
Deflectors ............................ 6B-3
Serpentine Drive Belt ..................... 6B-3
Engine Block Coolant Drain Hole Plug . . . . . . . 6B-3
Maintenance Recommendations .............. 6B-3
Checking Engine Coolant . . . . . . . . . . . . . . . . . 6B-3
Engine Coolant Concentration . . . . . . . . . . . . . . 6B-3
Hose Assemblies and Clamps Inspection ..... 6B-3
Pressure Testing . . . . . . . . . . . . . . . . . . . . . . . . . 6B-4
_Ex.teri.or Radiator Assembly Cleaning ........ 6B-4
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-4
Cooling System Overheating . . . . . . . . . . . . . . . 6B-4
Engine Coolant Thermostat Assembly Test . . . . 6B-4
Radiator Filler Cap Assembly .............. 6B-4
Pressure Test . . . . . . . . . . . . . . . . . . . . . . . . . 6B-5
Cooling System Diagnosis Chart . . . . . . . . . . . . 6B-5
Serpentine Drive Belt ..................... 6B-6
Draining and Refilling Cooling System . . . . . . . 6B-6
Aluminum Radiator Service . . . . . . . . . . . . . . . 6B-8
Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-8
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-9
Repairable Leaks . . . . . . . . . . . . . . . . . . . . . 6B- l O
Repair Methods . . . . . . . . . . . . . . . . . . . . . . 6B-10
Cooling Fin Removal . . . . . . . . . . . . . . . . . . 6B- ll
Tube Blocking . . . . . . . . . . . . . . . . . . . . . . . 6B- l 1
Header Repair . . . . . . . . . . . . . . . . . . . . . . . 6B-11
General Core Repair . . . . . . . . . . . . . . . . . . 6B- l 1
Radiator Side Tank Gasket Leak Repair . . . 6B-13
Transmission Oil Cooler Gasket . . . . . . . . . 6B-13
Transmission Oil Cooler . . . . . . . . . . . . . . . 6B-14
Recore ............................. 6B-14
Radiator Drain Cock Assembly . . . . . . . . . . 6B-14
Engine Coolant Thermostat Assembly ...... 6B-14
Electric Engine Coolant Fan Assembly ...... 6B-15
Water Pump Assembly ................... 6B-16
Battery Tray and Coolant Recovery
Reservoir Assembly ................... 6B-19
Engine Oil Cooler Inlet and Outlet
Hose Assemblies . . . . . . . . . . . . . . . . . . . . . 6B- l 9
Coolant Level Sensor . . . . . . . . . . . . . . . . . . . . 6B-19
Radiator Assembly ...................... 6B-19
Radiator Air Baffle Assemblies
and Deflectors ....................... 6B-20
Radiator Air Lower Baffle Assembly
and Deflector . . . . . . . . . . . . . . . . . . . . . . 6B-20
Radiator Air Upper Baffle Assembly ..... 6B-21
Engine Coolant Hose Assemblies .......... 6B-21
Coolant Air Bleed Pipe Assembly . . . . . . . . . . 6B-22
Engine Coolant Testing .................. 6B-22
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-23
General Specifications . . . . . . . . . . . . . . . . . . . 6B-23
Fastener Tightening Specifications . . . . . . . . . 6B-23
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6B-23
GENERAL DESCRIPTION
On the 5.7L LTl engine, coolant is drawn from the

radiator assembly by the water pump assembly and circulated through coolant jackets in the cylinder heads, then
through coolant jackets in the engine block. It is then
directed back to the radiator assembly.
The cooling system, which consists of a radiator

assembly and coolant recovery subsystem, electric engine
coolant fan assembly, engine coolant thermostat assembly
and water pump assembly and serpentine drive belt,
works to maintain engine temperature at an efficient level
during all engine operating conditions.
On the 3.4L L32 engine, coolant is drawn from the
radiator assembly by the water pump assembly and circulated through coolant jackets in the engine block assembly,
intake manifold assembly, and cylinder head assemblies.
It is then directed back to the radiator assembly.
The system directs some engine coolant through

hose assemblies to the heater core to provide defrost and
passenger compartment heat. A coolant recovery reservoir assembly is connected to the radiator assembly to
recover engine coolant displaced by expansion. As the
engine assembly cools, the engine coolant is drawn back
into the radiator assembly by vacuum.
68-2 COOLING AND RADIATOR
RADIATOR ASSEMBLY
Cross-Flow Radiator Core and Outlet and
Inlet Tanks
A cross-flow radiator core is used on all models.
Outlet and inlet tanks are located to the right and left of
the cross-flow radiator core. All radiator assemblies used
with automatic transmissions have transmission oil coolers and inlet and outlet fittings for transmission fluid
circulation. Vehicles with manual transmission assemblies use radiator assemblies without transmission oil
coolers. Vehicles equipped with air conditioning use a
radiator assembly with extra cooling capability.
An aluminum-plastic radiator assembly can be identified by a note on the outlet tank 127 mm (5 inches)
below the filler neck which reads, "Important - for repair
see Harrison Service Manual." Service procedures for the
aluminum-plastic radiator assembly are described in that
manual and in this section.
Transmission Oil Cooler Assembly

If equipped, the transmission oil cooler assembly is
located in the outlet tank on the right side of the radiator
assembly. For information on servicing the transmission
oil cooler and pipe assemblies, refer to SECTION 7A.
Engine Oil Cooler Assembly

On 5.7L LTl engines, an optional engine oil cooler
assembly is located in the inlet tank on the left end of the
radiator assembly. Engine oil cooler pipe assemblies connect the radiator assembly to the engine block assembly
through an adapter assembly, located between the oil filter
assembly and engine block.
Radiator Drain Cock Assembly

The radiator drain cock assembly includes the radiator drain cock and the radiator drain cock sealer; it is
located on the inner right side of the radiator assembly,
near the bottom.
RADIATOR FILLER CAP ASSEMBLY

Figure 1
A pressure-type radiator filler cap assembly is used
with the cross-flow radiator assembly to allow a buildup
of 124 kPa (18 psi) in the cooling system. This pressure
raises the boiling point of engine coolant to approximately
125C (257F) at sea level.
CAUTION: Do not remove radiator filler
cap assembly to check engine coolant level; check engine coolant at the
coolant recovery reservoir assembly.
Engine coolant should be added only
to the coolant recovery reservoir
assembly, when the system cools.
CAUTION: As long as there is pressure
in the cooling system, the temperature
can be considerably higher than the
boiling temperature of the solution.
Removal of the radiator filler cap
assembly while engine assembly is hot
and pressure is high will cause the
0
0
VACUUM RELIEF
PRESSURE RELIEF
KC0056-6B-B-RP
Figure 1 - Pressure-Type Radiator Filler Cap Assembly

(Typical)
. solution to boil instantaneously and

pc,ssibly with explosive force, spewing
the solution over engine assembly,
fenders and person removing cap. If
the solution contains flammable anti
freeze, such as alcohol (not recommended for use at any time), there is
also the possibility of causing a serious
fire.
The pressure-type radiator filler cap assembly
contains a blow-off (pressure) valve and a vacuum
(atmospheric) valve. The pressure valve is held against its
seat by a heavy spring. This spring protects the radiator
assembly by relieving pressure exceeding 124 kPa
(18 psi).
To prevent radiator assembly collapse caused by
vacuum as the engine assembly cools, the vacuum valve
prevents excessive pressure differences from occurring
between the cooling system and the atmosphere.
The radiator filler cap assembly has been designed
without finger grips to discourage inadvertent removal.
To safely remove the radiator filler cap assembly, rotate
the cap assembly slowly counter-clockwise (do not press
down) to detent. Allow any pressure to be relieved. Next,
press down on the cap assembly and continue to rotate cap
assembly counterclockwise and lift off the cap assembly.
Embossed on the cap assembly is a caution against opening it and arrows indicating the proper closed position.
ELECTRIC ENGINE COOLANT FAN

ASSEMBLY
An electric engine coolant fan assembly aids air
flow through the radiator assembly. There are five plastic
blades on each fan blade assembly. The fan blade assembly is driven by a motor attached to the radiator support.
The 5.7L LTI engine assembly equipped with air conditioning has two engine coolant fan assemblies attached to
the radiator support.
The fan motor is activated by an ECM controlled fan
relay. If the vehicle is equipped with air conditioning, the
fan motor also operates when the compressor assembly is
operating.
COOLING AND RADIATOR 683

CAUTION: If a fan blade assembly is
bent or damaged in any way, no attempt
should be made to repair or reuse the
damaged part. A bent or damaged fan
blade assembly should always be
replaced. It is essential that fan blade
assemblies remain in proper balance
and proper balance cannot be assured
once a fan blade assembly has been
bent or damaged. A fan blade assembly
that is not in proper balance could
fail and fly apart during subsequent
use, creating an extremely dangerous
condition.
The fan blade assembly is designed to aid air flow
through the radiator and air conditioning condenser.
ENGINE COOLANT TEMPERATURE GAGE

SENSOR
This sensor controls a temperature gage in the
instrument cluster assembly. The temperature gage indicates the operating temperature of the engine assembly.
Refer to SECTION 8A for engine coolant temperature
. gage sensor diagnosis and location.
ENGINE COOLANT TEMPERATURE (ECT)

SENSOR
This sensor sends a signal to the electronic control
module (ECM) which completes the ground for the
electric engine coolant fan relay, which operates the fan
assembly when the engine coolant temperature exceeds
l 10C (230F). Refer to SECTION 8A for engine coolant
temperature (ECT) sensor diagnosis and location.
ENGINE COOLANT THERMOSTAT

ASSEMBLY
A pellet-type engine coolant thermostat assembly is
used in the engine coolant outlet passage to control the
flow of engine coolant to provide fast engine warm-up
and to regulate engine temperatures. A wax pellet element
in the thermostat assembly expands when heated and
contracts when cooled. The pellet element is connected
through a piston to a valve. The valve remains closed
while the engine coolant is cold, preventing circulation
of engine coolant through the radiator assembly and
allowing the circulation of engine coolant only through
the engine assembly.
As the engine assembly warms, the pellet element
expands and the thermostat valve opens, permitting
engine coolant to flow through the radiator assembly.
COOLANT RECOVERY SYSTEM

A plastic reservoir is connected to the radiator
assembly by a hose. As the vehicle is driven, the engine
coolant is heated and expands. The portion of the engine
coolant displaced by this expansion flows from the radiator assembly into the reservoir assembly. When the engine
assembly is stopped and the engine coolant cools and contracts, the displaced engine coolant is drawn back into the
radiator assembly by vacuum. Thus, the radiator assembly
is kept filled with engine coolant to the desired level at all
times, resulting in increased cooling efficiency.
RADIATOR AIR BAFFLE ASSEMBLIES AND

DEFLECTORS
Radiator air baffle assemblies and deflectors are
located at the top and bottom of the radiator assembly to
increase air flow through the radiator assembly.
SERPENTINE DRIVE BELT

The serpentine drive belt drives the water pump
assembly and engine accessories. To check the condition
of the serpentine drive belt and tensioner assembly, refer
to SECTION 6A2A or SECTION 6A3A.
ENGINE BLOCK COOLANT DRAIN HOLE

PLUG
The engine block coolant drain hole plug is on the
left side of the engine block assembly. It must be removed
during a complete drain and refill of the coolant system.
The knock sensor on the right side of the engine block
assembly must also be removed.
MAINTENANCE RECOMMENDATIONS
Regular maintenance of the cooling system will help
keep it operating properly. Use the following procedures
to check the cooling system at least once a year or 25 000
km (15,000 miles).
CHECKING ENGINE COOLANT

Check the engine coolant level in the reservoir
assembly by removing the reservoir cap and checking the
dipstick while the engine is cold. The level should be at or
above the "FULL COLD" mark on the dipstick when the
engine assembly is cold. At normal operating temperatures the engine coolant level should be at or above the
"FULL HOT" mark on the dipstick.
Engine coolant should be added only to the reservoir
assembly to raise the level to the appropriate mark. Use a
50/50 mixture of high quality ethylene glycol and water
for engine coolant additions. Do not use recycled coolant.
Every two years or 50 000 kilometers (30,000 miles),
whichever come first, the cooling system should be drained
and refilled. Refer to "Draining and Refilling the Cooling
ENGINE COOLANT CONCENTRATION

The percentage of ethylene glycol in the engine
coolant should be checked periodically and when the
engine coolant level is adjusted or the system drained and
refilled.
This test is done by using a refractometer engine
coolant tester. Refer to "Engine Coolant Testing" in this
section for the test procedures.
HOSE ASSEMBLIES AND CLAMPS

INSPECTION
Inspect the condition of all hose assemblies and
clamps. Hose assemblies should be flexible and show no
signs of bulging, cracks, cuts, kinks or area of possible
leaks. Inspect the brackets, supports, ties and clamps.
Adjust and tighten as necessary.
684 COOLING AND RADIATOR
PRESSURE TESTING
Idle in "NEUTRAL" as much as possible and

raise engine rpm using accelerator pedal
assembly.
Turn air conditioning "OFF" during extended
idling.
2. If above does not apply, refer to diagnosis chart.
Test the radiator filler cap assembly for the proper

pressure holding capacity. Refer to "Pressure Test" in this
section.
EXTERIOR RADIATOR ASSEMBLY

CLEANING
Clearing away bugs, leaves and other debris from
the small air passageways of the radiator assembly will
improve the operation of the cooling system.
Use compressed air to blow through the radiator
assembly from the rear towards the front of the vehicle. If
compressed air is not available, water can be used by
directing the water hose from the rear of the radiator
assembly.
NOTICE: The radiator fins are necessary for good

heat transfer and should not be brushed. Brushing
may damage the fins, reducing heat transfer.

ASSEMBLY TEST
Figure2
Tools Required:
J 24731-188 Tempi! Stick
J 24731-206 Tempil Stick
ll'l'I Inspect
Thermostat assembly opening temperature (Figure 2).
RADIATOR FILLER CAP ASSEMBLY
ll'l'I Inspect
DIAGNOSIS
COOLING SYSTEM OVERHEATING
Figure2
1. If overheating occurs due to prolonged idling in
gear, instruct operator on driving techniques which
would reduce possibility of engine assembly overheating:
Cap assembly for weak spring washer or damage

to gasket. If spring washer is weak, replace cap
assembly.
Relief valve gasket in cap assembly and inner sealing surface of neck assembly for damage or debris.
Hose fitting on neck assembly for cracks. If fitting is
loose or cracked, replace radiator end tank.
ENGINE OVERHEAT - BOILING - POOR ENGINE COOLING

1.
2.
3.
RELIEVE PRESSURE AND CAREFULLY REMOVE RADIATOR

FILLER CAP ASSEMBLY.
RUB 206F TEMPERATURE STICK* ONTO ENGINE COOLANT
THERMOSTAT WATER OUTLET ASSEMBLY.
WARM UP ENGINE AT FAST IDLE.
WATCH FOR ENGINE COOLANT FLOW BEFORE MARK BEGINS

TO MELT.
i------
-----1
INSTALL NEW ENGINE

COOLANT THERMOSTAT
ASSEMBLY (WITH GASKET)
----..oi
INSTALL NEW ENGINE

COOLANT THERMOSTAT
ASSEMBLY (WITH GASKET)
NO ENGINE COOLANT FLOW
ENGINE COOLANT FLOW

I
PROBLEM IS CAUSED BY OTHER
THAN BAD ENGINE COOLANT
THERMOSTAT ASSEMBLY (WITH
GASKET)
COLD ENGINE- SLOW WARM UP- NOT ENOUGH HEAT

1.
2.
3.
RELIEVE PRESSURE AND CAREFULLY REMOVE RADIATOR

FILLER CAP ASSEMBLY.
RUB 188F TEMPERATURE STICK* ONTO ENGINE COOLANT
THERMOSTAT WATER OUTLET ASSEMBLY.
WARM UP ENGINE AT FAST IDLE.
WATCH FOR ENGINE COOLANT FLOW BEFORE MARK BEGINS

TO MELT.
- - - - - - ENGINE COOLANT FLOW
NO ENGINE COOLANT FLOW

PROBLEM IS CAUSED BY OTHER
THAN BAD ENGINE COOLANT
THERMOSTAT ASSEMBLY (WITH
GASKET)
*NOTE: THE TEMPERATURE STICK IS A PENCIL LIKE DEVICE WHICH HAS A WAX MATERIAL CONTAINING CERTAIN CHEMICALS WHICH MELT AT A GIVEN
TEMPERATURE. TEMPERATURE STICKS CAN BE USED TO DETERMINE THERMOSTAT OPERATING TEMPERATURE BY RUBBING 108F AND 206"F STICKS
ON THE ENGINE COOLANT THERMOSTAT WATER OUTLET ASSEMBLY. THE MARKS MADE BY THE STICKS SHOULD MELT WHEN ENGINE COOLANT
TEMPERATURES OF 188F AND 206F ARE REACHED, RESPECTIVELY. THESE TEMPERATURES ARE THE NORMAL OPERATING RANGE OF THE ENGINE
COOLANT THERMOSTAT ASSEMBLY (WITH GASKET), THEREFORE IF THE ENGINE COOLANT FLOWS AS INDICATED ON THE DIAGNOSIS CHART, THE
ENGINE COOLANT THERMOSTAT ASSEMBLY (WITH GASKET) MAY BE DEFECTIVE.
PC0001-6B-F-RP
Figure 2 - Thermostat Assembly Diagnosis
COOLING AND RADIATOR 68-5
Pressure Test
Tool Required:
J 24460-01 Cooling System Tester
1. Clean cap assembly.
2. Install cap assembly on J 24460-01.
3. Pump pressure tester slowly to obtain minimum

holding pressure.
A. If cap assembly fails to hold 83 kPa (12 psi),
replace cap assembly.
B. If installing new cap assembly, coat both
gaskets with engine coolant.
COOLING SYSTEM DIAGNOSIS CHART

CONDITION
POSSIBLE CAUSE
CORRECTION
Engine overheats.
a.
Loss of engine coolant.
a.
Refer to next condition - "Loss of

engine coolant."
b.
Loss of system pressure.
b.
Perform radiator filler cap

assembly pressure test.
c.
Weak engine coolant solution.
c.
Test engine coolant for proper

50-50 mixture.
d.
Loose serpentine drive belt.
d.
Check serpentine drive belt

tension. Refer to SECTION 6A2A
or SECTION 6A3A.
e.
Advanced/Retarded ignition timing.
e.
Refer to SECTION 6E.
f.
Obstructed radiator fins.
f.
Remove or relocate added-on parts

that block air to radiator assembly.
Clean away bugs, leaves, and other
debris.
g.
Cooling system passages blocked

by rust or scale.
g.
Flush cooling system or flow

check radiator assembly. Remove
cylinder head assembly and
inspect, if required.
h.
Kinked reservoir hose assembly.
h.
Re-route reservoir hose assembly.
l.
Inoperative engine coolant ternperature fan assembly.
l.
J.
Loose, damaged, and/or missing

radiator upper and lower shrouds,
air deflectors or baffle assemblies.
J.
Repair or replace as required.
k.
Thermostat assembly.
k.
Replace thermostat assembly stuck

in closed position.
1.
Faulty water pump assembly.
1.
Replace water pump assembly.
m.
Incorrect radiator assembly.
m.
Determine proper radiator assembly

for vehicle and replace radiator
assembly if necessary.
n.
Incorrect or damaged fan blade

assembly.
n.
Check for correct part number.

Replace fan blade assembly if
required.
0.
Faulty emission system components. o.

- PCVvalve.
- Catalytic converter plugged.
Refer to SECTION 6E or 6F.
p.
Engine oil overfill.
Check engine oil level.
p.

CONDITION
POSSIBLE CAUSE
Loss of engine coolant.
a.
Leaking radiator assembly.
a.
Inspect radiator assembly. Repair

as necessary.
b.
Radiator filler cap assembly faulty.
b.
Perform cap assembly pressure test.
c.
Distorted neck assembly.
c.
If radiator neck assembly upper

sealing area is distorted, use wood
block and mallet to reform neck
assembly to fit cap assembly.
d.
Leaking reservoir or hose

assemblies.
d.
Replace reservoir or hose

assembly.
e.
Loose or damaged radiator or heater e.

hose assemblies or connections.
Reseat hose assemblies. Replace

hose assemblies or clamps.
f.
Water pump assembly seal leaking.
f.
Replace water pump assembly.
g.
Water pump gasket leaking.
g.
Replace water pump gasket.
h.
Improper cylinder head assembly

torque.
h.
Re-tighten cylinder head bolts/

screws to specifications. Replace
cylinder head gasket if required.
l.
Leaking
- intake manifold assembly
(3.4L L32 engine).
- cylinder head assembly gasket.
- engine block coolant drain
hole plug or knock sensor.
- heater core.
- heater water valve, if equipped.
l.
Make repairs or replace components as necessary to correct leak.
a.
Thermostat assembly stuck open or

wrong type of thermostat assembly.
a.
Install new thermostat assembly of

correct type and heat range.
b.
Engine coolant is below the "FULL

COLD" mark.
b.
Add engine coolant.
Engine fails to reach normal

operating temperature. Cool
air from the heater.
SERPENTINE DRIVE BELT

Routine inspection of the serpentine drive belt may
reveal cracks in the belt ribs. These cracks will not impair
belt performance and are not a basis for belt replacement.
For belt tensioning and replacement procedures, refer to
SECTION 6A2A or SECTION 6A3A.
CORRECTION
[I] Important
Dispose of used coolant in a proper fashion, i.e., in a
used coolant holding tank. Never pour used coolant
down the drain. Ethylene glycol antifreeze is a very
toxic chemical; disposing of it into the sewer system
or ground water is both illegal and ecologically
unsound.
ON-VEHICLE SERVICE
DRAINING AND REFILLING COOLING
SYSTEM
CAUTION: To avoid the danger of being
burned, do not remove the radiator
filler cap assembly while the engine
and radiator assembly are still hot.
Scalding fluid and steam may be blown
out under pressure.
section.
Engine Coolant Recycling

As the need arises to conduct cooling system
maintenance or repairs, all of the used coolant must be
removed and replaced with qualified new coolant. If only
the radiator is drained, up to 40 percent of the used, contaminated coolant can remain in the cooling system. Used
coolant removal (from the vehicle) can be accomplished
by two methods:
Use a waterless, coolant evacuation system available
in the GM Dealer Equipment program (or equivalent) which removes the used coolant and replaces it
with approved new coolant.

Recover coolant and store in a used coolant holding
tank and submit the used coolant for recycling on a
regular basis.
The following ethylene glycol/water fill ratios have
been established to ensure a minimum of 50 percent ethylene glycol in the coolant mixture following our recommended coolant flush and drain procedure. The following
quantities assure 100 percent water remains in the coolant
system following the flush and drain procedure, and that
all block drains and air bleeds were utilized.
The following procedure will ensure a minimum
concentration of 50 percent ethylene glycol in the coolant
system and simplify the customer fill task.
3.4L L32 Engine

1. Park vehicle on a level surface.
2. Remove, clean and reinstall reservoir assembly.
Refer to "Battery Tray and Coolant Recovery
Reservoir Assembly" in this section.
3. Remove pressure cap assembly.
A. Turn pressure cap assembly slowly counterclockwise until it reaches the "stop." Do
not press down while turning pressure cap
assembly.
B. Wait until any remaining pressure (indicated

by hissing sound) is relieved.
C. After all hissing ceases, press down on
pressure cap assembly and continue to rotate
pressure cap assembly counterclockwise.
4. Open drain cock assembly.
5. Remove drain hole plug and knock sensor, located
on either side of engine block.
6. Allow system to drain completely.
7. Close drain cock assembly.
8. Install drain hole plug and knock sensor.
l~I
Tighten
Drain hole plug to 21 Nm (15 lb. ft.).

Knock sensor to 19 Nm (14 lb. ft.).
Drain cock assembly to 12 Nm (106 lb. in.).
9. Add enough water to fill cooling system.
10. Run engine assembly until thermostat assembly
opens.
11. Stop engine assembly. Repeat steps 2 through 10,
until drained fluid is nearly colorless.
12. Remove, empty and reinstall reservoir assembly.
NOTICE: Use new ethylene glycol antifreeze,

meeting GM specification 1825M, to provide the
required freezing and corrosion protection - at least
50 percent solution, at temperature of - 37C
( - 34 F). Do not use recycled coolant.
13, Add enough water and new ethylene glycol antifreeze (meeting GM specification 1825M) to provide a solution that is at least 50 percent antifreeze,
but no more than 70 percent antifreeze.
A. Fill radiator assembly to below neck assembly.
B. Fill reservoir assembly to "FULL COLD"
mark.
C. Add two cooling system sealer pellets.
D. Install reservoir assembly cap.
14. Run engine assembly, with radiator cap assembly
removed, until normal operating temperature is
reached (radiator inlet hose assembly becomes hot).
CAUTION: Under some conditions,
ethylene glycol in engine coolant is
flammable. To avoid being burned
when adding engine coolant, do not
spill it on the exhaust system or on hot
engine parts.
15. With engine assembly idling, add engine coolant to
radiator assembly until level reaches bottom of neck
assembly.
16. Install cap assembly.
Arrows on cap assembly must line up with
reservoir hose assembly.
5.7L LT1 Engine

1. Park vehicle on a level surface.
2. Remove, clean and reinstall reservoir assembly.
3. Remove pressure cap assembly.
A. Turn pressure cap assembly slowly counterclockwise until it reaches the "stop." Do
not press down while turning pressure cap
assembly.
B. Wait until any remaining pressure (indicated
by hissing sound) is relieved.
C. After all hissing ceases, press down on
pressure cap assembly and continue to rotate
pressure cap assembly counterclockwise.
4. Open drain cock assembly.
5. Open air bleed vents on engine coolant thermostat
assembly and heater outlet hose pipe. Air bleed
vents should be opened two to three turns.
6. Remove drain hole plug and knock sensor, located
on either side of engine block.
7. Allow system to drain completely.
ll"'l
lnspect
Drained engine coolant.

If engine coolant is discolored, flush
cooling system using steps 8 and 9.
- If engine coolant appearance is normal,
continue refill procedure with step 10.

8. Close radiator cock valve. Reinstall all engine block
drains (use sealer on plug). Fill cooling system
through radiator neck with clean water until level of
water is at base of radiator neck. Close air bleed
vents opened in step 5 and install radiator pressure
cap assembly.
ll'l'l lnspect
[I] Important
Block drive wheels, place transm1ss1on in
"Park" or "Neutral" and set parking brake.
9.
Run engine until thermostat opens (coolant temperature approximately 93C (200F).) Stop engine
drain and refill system as described in steps 1
through 8. Repeat this process until liquid drained is
nearly colorless.
10. Close radiator drain valve tightly. Reinstall all block

drains removed in step 6.
rn
Freeze protection of engine coolant after

engine heats up and cools down three times
using a refractometer or a thermohydrometer
to ensure proper freeze protection (-37C or
-34 F). Obtain engine coolant mixture for
inspection from base of radiator neck, not from
coolant recovery reservoir assembly.
Important
After cooling system has been filled, low coolant

warning light will remain on until ignition system is
cycled.
rn
Important
It is owner's responsibility to:
11. Remove coolant recovery reservoir assembly and

empty. Refer to "Battery Tray and Coolant Recovery Reservoir Assembly" in this section.
- Keep freeze protection at level appropriate to

temperatures which may occur in area where
vehicle may be operating.
NOTICE: Use new ethylene glycol coolant meeting

GM specification 1825M to provide the required
freezing and corrosion protection - at least 50 percent solution, at temperature of-37C (-34F). Do
not use recycled coolant.
- Maintain cooling system freeze protection at

- 37C ( - 34 F) to ensure protection against
corrosion.
12. Slowly open air vents in engine coolant thermostat

assembly and heater outlet hose, then fill cooling
system through radiator assembly neck using
following procedures.
If cooling system has been flushed, add 100
percent ethylene glycol. Then slowly add clean
water to system until level has reached base of
radiator assembly neck. Wait for two minutes
and recheck level of coolant mixture, add clean
water if necessary to restore coolant mixture
level to base of radiator assembly neck.
If cooling system is being refilled only (no
flush), a 50 percent ethylene glycol and 50
percent clean water mix should be used to fill
system until level of 50/50 mixture has reached
base of radiator assembly neck. Wait two
minutes and recheck level of coolant mixture,
add a 50/50 ethylene glycol/water coolant mixture if necessary to restore coolant mixture
level to base of radiator assembly neck.
13. Add two cooling system sealer pellets.

14. Install radiator cap assembly making certain arrows
line up with overflow tube.
15. Close all air bleed valves opened in step 5. Do not
over-torque air bleed valves. Air bleed valve is made
out of brass.
16. Install reservoir assembly. Refer to "Battery Tray
and Coolant Recovery Reservoir Assembly" in this
section.
17. Fill coolant reservoir assembly with a 50 percent
ethylene glycol and a 50 percent clean water coolant
mixture.
NOTICE: Alcohol or methanol base coolants, or

plain water, are not recommended at any time.
ILl
1nspect
For leaks, after running engine assembly until

normal operating temperature is reached.
NOTICE: A solution stronger than 70 percent antifreeze should never be used. The solution's freezing
point rises after this point. Pure antifreeze will
freeze at -20C (-4F).
ALUMINUM RADIATOR SERVICE

Figures 3 and 4
This radiator uses an aluminum core with plastic
side tanks. The core and side tanks can be replaced
separately. Core repair is easily made with the hot melt
adhesive method. A transmission oil cooler may be
located in one of the side tanks. The drain cock is located
on the lower part of one of the tanks.
The following components are serviceable:
- Radiator core.
- Tanks and gaskets. Cfanks cannot be repaired if
broken or cracked).
- Oil cooler and gaskets.
- Drain cock and gaskets.
PRECAUTIONS
CAUTION: Failure to follow any one of
these procedures could result in personal injury or components damage.

3
~fur
6
'1
I
1
2
3
4
5
6
7
8
CORE, CROSS-FLOW RADIATOR

TANK, RADIATOR OUTLET
TANK, RADIATOR INLET
GASKET, RADIATOR SIDE TANK
COOLER ASSEMBLY, TRANSMISSION OIL
GASKET, TRANSMISSION OIL COOLER
NUT, TRANSMISSION OIL COOLER RETAINING
COCK ASSEMBLY, RADIATOR DRAIN
;:
(/ :--~,-- c... _
'
------
I -~
PC00026BFRP
Figure 3 -Aluminum Radiator Assembly
Do not remove radiator cap while engine is at

normal operating temperature. Cooling system will
release scalding fluid and steam under pressure if
cap is removed while engine and radiator are still
hot.
Do not use boil-out tanks or any tank that has been
used for copper or brass radiators.
Do not open hood if steam or coolant can be seen
escaping from engine compartment.
Do not remove cap on coolant recovery reservoir if
an engine over temperature is suspected.
DIAGNOSIS
Leak Testing
Some core leaks can be detected by adding water to
the radiator. Clean the core so the damaged area is easier
to find.
On-Vehicle Pressure Testing
Figure 5
8 COCK ASSEMBLY, RADIATOR DRAIN
9 SEALER, RADIATOR DRAIN COCK THREAD
10 ELBOW, RADIATOR DRAIN COCK
PC0003-6BFRP
Figure 4 - Aluminum Radiator Drain Cock Assembly
Tool Required:
1. Ensure that radiator hose clamps and heater hose
clamps are properly positioned and secured.
2. Inspect connections for leaks. Repair as required.

CAUTION: To avoid being burned, do
not remove radiator cap assembly
while engine assembly is at normal
operating temperature. The cooling
system will release scalding fluid and
steam under pressure if radiator f.iller
cap assembly is removed while engine
assembly and radiator assembly are
still hot.
3. Remove radiator filler cap assembly.
4. Fill cooling system to base of radiator assembly
neck.
5. Attach J 24460-01 to radiator assembly neck.
Follow instructions supplied with J 24460-01.
6. Build up pressure to no more than 138 kPa (20 psi).
7. System should hold pressure for about two minutes.
A. If a measurable amount of pressure drops in
less than two minutes, check for leak.
B. Mark leaking area and remove radiator assembly for repair. Refer to "Radiator Assembly"
in this section.
~-
Figure 5 - Pressure Testing the Radiator Assembly
Off-Vehicle Leak Testing

NOTICE: Do not use boil-out tanks or any tank that
has been used for copper or brass radiator assemblies. The remaining solutions or chemicals in these
tanks could cause radiator assembly failure.
Figures 6 and 7
Tool Required:
1. Plug radiator inlet and outlet tubes. Make sure drain
cock is closed.
2. Attach J 24460-01 to radiator assembly.
3. Build up pressure to 138 kPa (20 psi).
4. Observe gage for any pressure loss.
5. Run water over repair area and look for any bubbles.
If a large tank is available, radiator assembly
can be submerged to check for air bubbles.
A PLUGS
PC0004-6BfR~
Figure 6 - Aluminum Radiator Assembly and Oil Cooler

Plugs
Repairable Leaks
Core leaks and gasket leaks are the two types of
leaks that can be repaired on the radiator assembly. Core
leaks can occur in a tube or in the joints between the tubes
and headers. Gasket leaks can occur between the oil
cooler fittings and the tank.Some leaks can be repaired
while the radiator assembly is on the vehicle; however, it
is more practical to remove the radiator assembly from the
vehicle.
Repair Methods
The hot melt adhesive is the most effective method
of repairing the radiator core. The hot melt adhesive kit
contains adhesive sticks, cotton swabs, wire brush and
primer. The adhesive kit is reusable, has an indefinite
shelf life and is waste free. The sticks must be stored in a
sealed container to keep them dry.
D
A
B
C
D
E
F
GASKET, RADIATOR INLET TANK

TUBE ASSEMBLIES, RADIATOR CORE
GASKET, RADIATOR OUTLET TANK
GASKET, RADIATOR DRAIN COCK
GASKETS, OIL COOLER
JOINT BETWEEN TUBE AND HEADER
PC0005-6BfRP
Figure 7 - Possible Leak Areas
APPLY A
WET
CLOTH
~~,
H20005-6B
Figure 8 - Hot Melt Adhesive Repair Kit
nra
UI/ 1/UUIIUUI/\II/Ull l/l/111/ vuwuuuuuvuu VYM v11uw 11vuv 111/!1 uuv VVY II \111'1 I/ 11v 1111 !I mi WI
N1M@WIDl!UWUu11)Jui111m@WIWMMnnn111n ,1 nnn nn nM nn ~nn nn

wtwwwMw1mwuuuw@mm111m,2 ~~~l~~~~~EE~0 N g
1(1WIMMTh'UU/RMPJ1Jolfil@/lll1llfM}l@lli/:Ull//UWMlifi,i,1,uw miJ:rK
H20008-6B
Figure 11 - Using a Wet Cloth on the Side Tank
.liJl~lliUlll',115~11~11111
SUBMERGE
TANKKEEP
HEADER
ABOVE
WATER LINE
WIJIJWIIWl!UINUlll01/Jl11iliYIW1W1111@lllUIUlll/n@llRllll&JliOW,
:mmtmll ltm~W~tlHMmOOl@flMl @JJl/0MW,J:1,1Mmi: ),
:~\
rm1@@1l1111@mmw@UOOt!WWil~1mwwu,'1@1'1 W/llh 1. '!/hi! i.!H/'1/iq

1
rnnn m1n11nn 111nr111Mt nnn111111nm1r11111r111nr1nnnnnnnri0,

1
H2ooos-ss
Figure 9 - Fins Removed from Damaged Area
H20009-6B
Figure 12 - Submerging the Side Tank
Header Repair
Figure 1O - Tube Blocking
Cooling Fin Removal

For damaged areas that are between the cooling fins,
it may be necessary to remove some of the fins. Do not
remove more fins than necessary. Usually removal of fins
6 mm ( 1/4 inch) beyond the leak or damage area is enough
to make an accurate repair.
Tube Blocking
If a tube is severely damaged, it can be blocked off.
NOTICE: Do not block off more than two tubes in
radiator assembly. Blocking off more then two tubes
will reduce the cooling capability of the system.
The tube should be cut off 6 mm ( 1/4 inch) from the
header and pinched shut before it is cleaned and sealed.
NOTICE: To prevent damage to the tank or gasket,

the following procedures must be used when repairs
are made on or near the header.
If the header or the tube near the header requires a
repair, the side tank does not have to be removed. A damp
cloth can be placed against the side tank where the repair
has to be made. The side tank can also be submerged in a
tank of water up to the header.
General Core Repair

If the leak area surface is not clean, the repair
material will not stick to the surface.
1. Position core so repair area is accessible.
2. Apply wet cloth between core pipes and headers if
working near plastic tanks or joints or submerge
tank in water.
Figure 16 - Applying Hot Melt Adhesive
Figure 13 - Cleaning the Area with a Steel Brush
5.
H20011-6B
Figure 14 - Scrubbing the Area with Primer
6.
7.
8.
9.
H20012-6B
Figure 15 - Heating the Repair Area
3. Heat repair area slightly with small torch or heat gun

to be sure it is dry.
Do not use blow torch.
4. Brush area to be repaired with small steel brush that
is supplied in kit and remove dust away from repair
area.
10.
11.
CAUTION: To help avoid personal

injury when using the primer (which
contains trichloroethane) the following precautions and steps should be
followed:
If primer is swallowed, seek medi
cal attention.
If primer contacts the eyes, do not
rub eyes. Splash the affected area
with large quantities of cold water
and seek medical attention.
If primer contacts the body, wash
thoroughly with soap and water.
Do not mix the primer with water.
Open tube of primer using spurred cap or pin and
apply primer to repair area only. Use of primer
produces stronger repair.
Scrub repair area with cotton swab until fresh swab
stays clean.
Clear, yellow-brown coating does not have to
be removed.
Heat repair area with heat gun or by moving small
torch in circular pattern using soft, blue flame.
Withdraw small torch or heat gun and rub adhesive
stick on repair area. Adhesive will flow at temperature of approximately 260C (500F).
If stick doesn't start to melt, remove it and
reapply heat. Do not heat stick directly with
flame. High heat will burn and char adhesive.
Continue heating until adhesive flows and wets
entire repair area and fills joint. If a hole is in center
of tube, heat tube and let hot surface melt and pull in
adhesive. Force of flame or heat gun will also tend to
guide adhesive toward hole. For leaks between tube
and header, flow adhesive completely around tube
and header joint with tank installed.
Heat repair area until adhesive is bubble free,
smooth and has light yellow color. Curing is not
required.
Test radiator assembly for leaks when cool. Refer to
"Off-Vehicle Testing" in this section. If repair area
still leaks, heat it gently to dry it. Heat and flow
adhesive or apply more as necessary to repair leak.
Radiator Side Tank Gasket Leak Repair

Tool Required:
J 33419-A Radiator Core Remover/Installer

Radiator side tank gasket leaks can easily be mistaken for tank or header leaks. If a plastic tank leaks from the
header joint gasket, tighten the clinch tabs with
J 33419-A or locking-type pliers. If the tank still leaks,
remove and repair it.
1. Pry open clinch tabs except those under inlet, outlet
and radiator assembly neck, using J 33419-A or
screwdriver.
Lift tabs only enough to allow removal.
NOTICE: Do not overbend tabs. Overbending tabs
could result in breaking tab. If more than three tabs
are broken on one side of header or more than two
adjacent tabs are broken, the core must be replaced.
2. Lift tank and slide it out from under remaining
clinched tab.
Tapping tank with your hand may be required
to dislodge gasket.
3. Lift remaining tab(s) with pliers.
4. Remove and discard gasket.
!.,I
Figure 17 - Tightening the Clinch Tabs
SLIP J 33419-A
UNDER TAB
AND PUSH BACK
Clean
Header gasket groove of dirt and old rubber.

Sealing edge of plastic tank.
!l'l'I
Inspect
Header gasket surface and tank flange for

evidence of leaks.
Surfaces and remove dirt, burrs and bumps.
5. Remove transmission oil cooler, if equipped, and
install it into new tank.
6. Dip or coat new gasket in engine coolant and
position it on header surface.
7. Position tank and gasket to header. Clamp it in place
and secure it by bending four clinch tabs.
LC0006-6B-F-RP
Figure 18 - Opening the Clinch Tabs
BEND FOUR
CLINCH TABS
8. Clamp remaining clinch tabs around header using

J 33419-A or pliers.
Start at center and work towards end.
9. Replace core if there are more than three tabs broken
on one side or if two adjacent tabs are broken.
10. Install radiator drain cock assembly, if removed.
11. Test radiator assembly for leaks. Refer to "OffVehicle Leak Testing" in this section.
TRANSMISSION OIL COOLER GASKET
H20016-6B
Figure 19 - Seating the Tank to the Core
Figure 21
1. Remove radiator assembly. Refer to "Radiator

The outlet tank must be removed to replace the

transmission oil cooler but the transmission oil cooler
gasket can be replaced without removing the outlet tank.
Lay radiator assembly on flat surface.

2. Remove bottom transmission oil cooler pipe and
loosen top pipe connection.
TRANSMISSION OIL COOLER

Figure 3
H20017-6B
Figure 20 - Clinching Sequence
1. Radiator assembly. Refer to "Radiator Assembly"

in this section.
2. Outlet tank.
3. Transmisison oil cooler retaining nuts.
4. Transmission oil cooler gaskets.
5. Transmission oil cooler.
l~I Clean
Sealing surfaces.

1.
2.
3.
4.
5.

section.
New transmission oil cooler gaskets without lubrication.
Transmission oil cooler into outlet tank.
Transmission oil cooler retaining nuts.
Outlet tank.
Be careful not to loosen or misalign gaskets.
Radiator assembly. Refer to "Radiator Assembly"
in this section.
RECORE
Figure 21 - Removing the Transmission Oil Cooler Gasket
3. Press transmission oil cooler into hole and remove

gasket using small hook.
4. Blow dry all surfaces on outlet tank and transmission oil cooler.
5. Install new transmission oil cooler gasket without
lubrication.
Be sure gasket is properly seated inside lip of
fitting.
6. Reach into inlet or outlet opening and push transmission oil cooler into position against outlet tank.
section.
7. Install transmission oil cooler pipe loosely.
To replace other gasket, follow previous steps
in order.
l~I Tighten
Transmission oil cooler pipe connections to
20 Nm (15 lb. ft.).
- Do not overtighten.
8. Leak test radiator assembly. Refer to "Off-Vehicle
Leak Testing" in this section.
9. Install radiator assembly. Refer to "Radiator Assembly" in this section.
If the radiator core is damaged beyond repair and the

other parts are serviceable, install the original inlet and
outlet tanks, transmission oil cooler, radiator filler cap
assembly and radiator drain cock assembly onto a new
core and install new gaskets.
RADIATOR DRAIN COCK ASSEMBLY

Figure 4
If the drain cock assembly does not seal when
tightened snugly, remove the radiator drain cock, assembly clean the drain and replace the radiator drain cock
assembly. If the body of the radiator drain cock assembly
is broken, remove the body from the tank by squeezing the
sides together with needle nose pliers.

ASSEMBLY
Figures 22 and 23

section.
1. Open radiator drain cock assembly and drain engine
coolant from .radiator assembly to below level of
engine coolant thermostat assembly.
2. Close radiator drain cock assembly.
!~I
3.
4.
5.
6.
7.
8.
11
Tighten
Radiator drain cock assembly to 12 Nm

(106 lb. in.).
Air cleaner assembly.
Inlet hose assembly and clamp from engine coolant
thermostat assembly.
Water outlet bolt/screw (12 or 15).
Water outlet assembly (11 or 14).
Water outlet gasket (16), if equipped.
Engine coolant thermostat assembly ( 13 or 17).
li,I Clean
Gasket surfaces of water outlet assembly and intake
manifold assembly or water pump assembly.
11 OUTLET ASSEMBLY, WATER

12 BOLT/SCREW, WATER OUTLET
13 THERMOSTAT ASSEMBLY, ENGINE COOLANT

1.
2.
3.
4.
section.
Engine coolant thermostat assembly into intake
manifold assembly or water pump assembly.
New water outlet gasket ( 16), if equipped.
Water outlet assembly (11 or 14).
Water outlet bolt/screw ( 12 or 15).
l~I
Figure 22 - Engine Coolant Thermostat Assembly

(3.4L L32 Engine)
14
Tighten
Water outlet bolt/screw (12 or 15) to 28 N m

(21 lb. ft.).
5. Inlet hose assembly and clamp. Refer to SECTION
lA.
6. Air cleaner assembly.
7. Add engine coolant. Refer to "Draining and
Refilling the Cooling System" in this section.
lll
PC000&-68-F-RP
1nspect
For leaks, after running engine assembly to normal

ELECTRIC ENGINE COOLANT FAN

ASSEMBLY
Figures 24 and 25
CAUTION: Keep hands, tools, and
clothing away from electric engine
coolant fan(s) to help prevent personal
injury. This/These fan is/are electric
and can come on whether or not the
engine is running. The fan(s) can start
automatically in response to a heat
sensor with the ignition in the "ON"
position.

2. Electrical connector and clips.
14
15
16
17
OUTLET ASSEMBLY, WATER

BOLT/SCREW, WATER OUTLET
GASKET, WATER OUTLET
THERMOSTAT ASSEMBLY, ENGINE COOLANT
PC0007-6B-F-RP
Figure 23 - Engine Coolant Thermostat Assembly

(5.7L LT1 Engine)
3. Electric engine coolant fan assembly (19 or 20).

Electric engine coolant fan assembly ( 19 or 20)
will slide out.
4. Fan blade nut (23 or 24 ).
5. Fan blade assembly (24 or 25).
ll'l'I
Inspect
For bent or cracked fan blades.

Mating surfaces for smoothness. Remove burrs
or other imperfections as necessary.
CAUTION: If a fan blade assembly is

bent or damaged in any way, no attempt
should be made to repair and/or reuse
the damaged part. A bent or damaged
fan blade assembly should always be
replaced with a new fan blade assembly.

section.
19
1. Fan blade assembly (25 or 26).

2. Fan blade nut (23 or 24)
3. Electric engine coolant fan assembly (19 or 20).
Electric engine coolant fan assembly ( 19 or 20)
will slide into place.
4. Electrical connector and clips.
5 Air cleaner assembly.
A
B
18
19
20
21
ENGINE ASSEMBLV, LT1 5.7L

ENGINE ASSEMBLV, L32 3.4L
RADIATORASSEMBLY
FAN ASSEMBLY, ENGINE COOLANT
RETAINER, RADIATOR AIR SIDE DEPRESSION
(PUSH-IN)
22 DEFLECTOR, RADIATOR AIR SIDE
PCOOOB-68-F-RP
Figure 24 - Engine Coolant Fan Assembly
CAUTION: It is essential that the fan

blade assembly remain in proper balance. Balance cannot be assured once
a fan blade assembly has been bent or
damaged. A fan blade assembly that is
not in proper balance could fail and fly
apart during subsequent use, creating
an extremely dangerous condition.
WATER PUMP ASSEMBLY


3.4L L32 Engine
1. Drain radiator assembly. Refer to "Draining and Refilling Cooling System" in this section.
2. Air duct and electrical connector.
3. Top coil of coil pack.
4. Loosen tensioner pulley bolt/screw.
5. Heater hose from pump. Refer to SECTION IA.
A
B
19
20
23
24
25
26
5.7L LT1 ENGINE

3.4L L32 ENGINE
NUT, FAN BLADE
NUT, FAN BLADE
BLADE ASSEMBLV, FAN
BLADE ASSEMBLV, FAN
PC0009-6B-F-RP
Figure 25 - Fan Blade Assembly

6. Loosen water pump pulley bolts/screws (27).
7. Power steering bracket bolts/screws. Refer to

SECTION 3B.
8. Serpentine belt. Refer to SECTION 6A2A and
SECTION 6A3A.
9. Water pump pulley (28).
10. Power steering pump bracket and pump. Refer to
SECTION 3B.
11. Water pump bolts/screws (29).

13. Water pump cover bolts/screws (31).
14. Water pump assembly (32) and water pump gasket
(33).
l~I
l~I
Tighten
Engine front cover bolts/screws (30) to 21 Nm

(16 lb. ft.).
5. Water pump bolt/screw (29).
l~I
Tighten
Water pump bolts/screws (29) to 10 Nm

(89 lb. in.).
6. Power steering pump and bracket. Refer to SECTION 3B.
7. Water pump pulley (28).
8. Serpentine belt. Refer to SECTION 6A2A or
SECTION 6A3A.
Clean
All gasket surfaces.

Water pump bolts/screws.
l++I
Install or Connect

section.
1. New water pump gasket (33).
2. Water pump assembly (32).

3. Water pump cover bolts/screws (31 ).
!~I Tighten
21 Nm (16 LB. FT.)

10 Nm (89 LB. IN.)
Water pump cover bolts/screws (31) to 45 N m

(33 lb. ft.).
PC0018-6B-F-RP
Figure 26 - Water Pump Bolt/Screw Torques

(3.4L L32 Engine)
33
32
28
"\~~
_f /
29
27
28
29
30
31
32
33
BOLT/SCREW, WATER PUMP PULLEY, 25 Nm (18 LB. FT.)

PULLEY, WATER PUMP
BOLT/SCREW, WATER PUMP, 10 Nm (89 LB. IN.)
BOLT/SCREW, ENGINE FRONT COVER, 21 Nm (16 LB. FT.)
BOLT/SCREW, WATER PUMP COVER, 45 Nm (33 LB. FT.)
GASKET, WATER PUMP
PC0010-6B-F-RP
Figure 27 -Water Pump Assembly (3.4L L32 Engine)

9. Power steering pump bracket bolts/screws. Refer to
SECTION 3B.
l~I
10.
11.
12.
13.
14.
lll
Tighten
Power steering bracket bolts/screws to 31 Nm

(23 lb. ft.).
Heater hose to pump. Refer to SECTION lA.
Top coil of coil pack.
Electrical connector to alternator.
Air duct and electrical connector.
Add engine coolant. Refer to "Draining and
1.,1 Clean
Water pump gasket surfaces.
Water pump bolts/screws ( 17).
1nspect
For leaks, after running engine to normal operating

temperature.
l++I
9. Heater hose assemblies from water pump assembly

and throttle body. Refer to SECTION lA.
10. Electrical connector from coolant sensor.
11. Reposition coil and bracket.
13. Water pump cover bolt/screw (37).
14. Water pump assembly (34).
15. Water pump gaskets (35).
16. Shaft coupling (36).
5.7L LT1 Engine

1. Electrical connector from electric engine coolant fan
assembly.
2. Right electric engine coolant fan assembly. Refer to
"Electric Engine Coolant Fan Assembly" in this
section.
3. Block drain plug and knock sensor.
4. Drain engine coolant. Refer to "Draining and
5. Install drain plug and knock sensor.
6. Air intake duct.
8. Upper and lower radiator hose assembly from water
pump assembly.
34
35
36
37
38
l++I
1.
2.
3.
4.
Install or Connect
Shaft coupling (36).

Water pump gaskets (35).
Water pump assembly (34).
Water pump cover bolt/screw (37).
l~I
Tighten
Water pump cover bolt/screw (37) to 45 Nm

(33 lb. ft.).
l~I
Tighten
Water pump bolts/screws (38) to 42 Nm

(31 lb. ft.).
6. Reposition coil and bracket.
7. Electrical connector to coolant sensor.

GASKET, WATER PUMP
COUPLING, SHAFT
BOLT/SCREW, WATER PUMP COVER, 45 Nm (33 LB. FT.)
BOLT/SCREW, WATER PUMP, 42 Nm (31 LB. FT.)
PC0011-6E-F-RP
Figure 28 -Water Pump Assembly (5.7L LT1 Engine)

8. Heater hose assemblies to water pump assembly and
throttle body. Refer to SECTION IA.
9. Upper and lower radiator hose assembly to water
pump assembly.
12. Refill cooling system. Refer to "Draining and
13. Electrical connector to electric engine coolant fan
assembly.
ll'l"I Inspect
For leaks, after running engine assembly to normal
BATTERY TRAY AND COOLANT RECOVERY

RESERVOIR ASSEMBLY
Figure29

1.
2.
3.
4.
5.
Battery. Refer to SECTION 6D 1.

Coolant recovery hose assembly.
Bolt/screw (40).
Retainer (41 ).
Battery tray and reservoir assembly (39).
1.,1
Clean
Battery tray and reservoir assembly (39) with soap

and water. Rinse thoroughly.

section.
1. Battery tray and reservoir assembly (39).
2. Retainer (41 ).
3. Bolt/screw (40).
l~I Tighten
4. Coolant recovery hose assembly.
5. Battery. Refer to SECTION 601.
6. Add engine coolant to "FULL COLD" mark on
reservoir assembly.
ENGINE OIL COOLER INLET AND OUTLET

HOSE ASSEMBLIES
Refer to SECTION 6A2A for service information on
inlet and outlet hose assemblies.
COOLANT LEVEL SENSOR

(5.7L LT1 Engine Only)

3. Lower vehicle.
4. Battery. Refer to SECTION 601.
5. Electrical connector at sensor.
6. Sensor.
40

1.
2.
3
4.
Sensor.
Electrical connector to sensor.
Battery. Refer to SECTION 601
Add engine coolant. Refer to "Draining and
RADIATOR ASSEMBLY
Figures 30 and 31
39 RESERVOIR ASSEMBLY, BATIERY TRAY AND
COOLANT RECOVERY
40 BOLT/SCREW, COOLANT RECOVERY RESERVOIR,
12 Nm (106 LB. IN.)
41 RETAINER, COOLANT RECOVERY RESERVOIR
PC0012-6BF-RP
Figure 29 - Battery Tray and Coolant Recovery Reservoir

Assembly

1. Airintake duct.
43
45
18 RADIATOR ASSEMBLY
42 INSULATOR, RADIATOR LOWER (LEFT HAND)
43 INSULATOR, RADIATOR LOWER (RIGHT HAND)
44 SEAL ASSEMBLY, RADIATOR AIR LOWER
PC0013-6B-F-RP
Figure 30 - Radiator Insulators and Seal Assembly
5. Electrical connector(s) at electric engine coolant fan

assembly.
6. Electric engine coolant fan assembly. Refer to
section.
7. Transmission oil cooler lines. Refer to SECTION
7A.
8. Coolant level sensor, if equipped. Refer to "Coolant
Level Sensor" in this section.
9. Lower vehicle.
10. Loosen receiver dehydrator bracket.
11. Lower radiator hose assembly at water pump
assembly.
12. Upper radiator hose assembly.
13. Overflow tube.
14. Radiator from condenser.
15. Radiator assembly (18).

1.
2.
3.
4.
5.
6.
7.

section.
Radiator assembly (8).
Make sure radiator assembly is seated on
radiator insulators (24 and 25).
Radiator assembly to condenser.
Overflow tube.
Upper radiator hose.
Lower radiator hose assembly to water pump
assembly.
Tighten receiver dehydrator bracket.
PANEL ASSEMBLY, UPPER

RADIATOR ASSEMBLY
INSULATOR, RADIATOR UPPER
INSULATOR, RADIATOR UPPER MOUNTING PANEL
FAN ASSEMBLY, ENGINE COOLING
BAR ASSEMBLY, FRONT BUMPER IMPACT
BAR ASSEMBLY, FRONT END UPPER TIE
BOLT/SCREW, RADIATOR UPPER MOUNTING PANEL,
12 Nm (106 LB. IN.)
.
48 PANEL, RADIATOR UPPER MOUNTING
A
B
C
D
E
45
46
47
PC0014-6B-FRP
Figure 31 - Radiator Upper Mounting Panel Assembly
8. Coolant level sensor, if equipped. Refer to "Coolant

Level Sensor" in this section.
9. Transmission oil cooler lines. Refer to SECTION
7A.
10. Electric engine coolant fan assembly. Refer to
section.
11. Electrical connector( s) to electric engine coolant fan
assembly.
13. Lower vehicle.
.15. Air intake duct.
ll'l'I Inspect
For leaks, after running engine assembly until
normal operating temperature is reached.
RADIATOR AIR BAFFLE ASSEMBLIES AND

DEFLECTORS
Radiator Air Lower Baffle Assembly and
Deflector
Figure 32

1. Radiator air lower deflector retainers (52).
2. Radiator air lower deflector (51).
50
49
50
51
52
BAFFLE ASSEMBLY, RADIATOR AIR LOWER

RETAINER, RADIATOR AIR LOWER BAFFLE
DEFLECTOR, RADIATOR AIR LOWER
RETAINER, RADIATOR AIR LOWER DEFLECTOR
52
PC0015-6B-F-RP
Figure 32 - Radiator Air Lower Baffle Assembly
3. Radiator air lower baffle retainers (50)

4. Radiator air lower baffle assembly (49).

section.
1. Radiator air lower baffle assembly (49).
2. Radiator air lower baffle retainers (50)
46
3. Radiator air lower deflector ( 51 ).

4. Radiator air lower deflector retainers (52).
Radiator Air Upper Baffle Assembly

45-----
Figure 33

1. Radiator air upper baffle retainers (54).
2. Radiator air upper baffle assembly (53).
45
46
53
54
BAR ASSEMBLY, FRONT BUMPER IMPACT

BAR ASSEMBLY, FRONT END UPPER TIE
BAFFLE ASSEMBLY, RADIATOR AIR UPPER
RETAINER, RADIATOR AIR UPPER BAFFLE
PC0016-6B-F-RP
Figure 33 - Radiator Air Upper Baffle Assembly

section.
1. Radiator air upper baffle assembly (53) to radiator
assembly (18).
2. Radiator air upper baffle retainers (54).
ENGINE COOLANT HOSE ASSEMBLIES

1. Drain radiator assembly so level of engine coolant is
below hose assembly being removed.
6822 COOLING AND RADIATOR

3. Inlet hose assembly from radiator assembly and
engine coolant thermostat assembly.
4. Outlet hose assembly from radiator assembly and
water pump assembly.
l++I
Install or Connect

section.
1. Outlet hose assembly and clamps to radiator
assembly and water pump assembly.
2. Inlet hose assembly to radiator assembly and engine
coolant thermostat assembly.
Refilling Cooling System" in this section.
COOLANT AIR BLEED PIPE ASSEMBLY
l++I
1. Drain coolant. Refer to "Draining and Refilling

Cooling System" in this section.
2. Transmission. Refer to SECTION 7A or SECTION
7B.
3. Left and right bleed pipe mounting (banjo) bolts.
Use a backup wrench.
4. Lower vehicle.
5. Upper alternator bracket. Refer to SECTION 603.
6. Electrical connectors and vacuum hoses, as necessary, to gain access to bleed pipe.
7. Air bleed pipe mounting nut at intake manifold.
8. Coolant hose at air bleed pipe.
9. Coolant air bleed pipe assembly.
l++I
Install or Connect

section.
1. Coolant air bleed pipe assembly.
2. Coolant hose at air bleed pipe.
3. Air bleed pipe mounting nut at intake manifold.
l~I
Tighten
Mounting nut to 21 Nm (15 lb. ft.).

4. Electrical connectors and vacuum hoses, as necessary.
5. Upper alternator bracket. Refer to SECTION 603.
6. Raise and suitably support vehicle. Refer to SECTION GA.
7. Left and right bleed pipe mounting (banjo) bolts.

Use a backup wrench.
l~I
Tighten
Mounting bolts to 42 Nm (31 lb. ft.).

8. Transmission. Refer to SECTION 7A or SECTION
7B.
9. Refill cooling system. Refer to "Draining and
Refilling Cooling System" in this section.
ENGINE COOLANT TESTING

Tool Required:
J 26568 or J 23688 Coolant Tester
Coolant testers J 26568 (Celsius Scale) or J 23688
(Fahrenheit Scale) can be used to check the antifreeze
protection of the engine coolant. Make sure the refractometer markings are correct. Unless J 26568 or J 23688
has a provision for temperature correction, test the temperature at which J 26568 or J 23688 is calibrated. If the
engine coolant is warmer or cooler the reading may be
incorrect. Follow the manufacturers directions on using
J 26568 or J 23688.
lr,I
Clean
1. Before each use, swing plastic cover at slanted end

of J 26568 or J 23688, exposing measuring window
and bottom of plastic cover.
2. Wipe dry with tissue or clean soft cloth.
3. Close plastic cover.
l~I
Measure
Engine coolant strength.

A. Do not remove clear plastic pump from
J 26568 or J 23688.
B. Release tip of pump from J 26568 or J 23688
housing.
C. Insert tip of pump into neck assembly.
Make sure tip of pump is below level of
engine coolant.
D. Press and release bulb to get sample.
E. Insert tip of pump into cover plate opening.
F. Press bulb and allow a few drops to fall onto
measuring surface.
Do not open plastic cover when taking
readings because water evaporation can
change readings.
G. Point J 26568 or J 23688 toward any light and
look into eyepiece.
Engine coolant protection reading is at
point where dividing line between light
and dark crosses scale (antifreeze
protection is scale on right).
Temperature scale is reversed from
standard thermometer scale.
- Below zero readings are on upper
half of scale.
COOLING AND RADIATOR, 68-23

Readings on lower half of scale indicate
solutions without enough antifreeze
concentration to provide adequate rust
protection.
ff readings are not clear, measuring

surfaces were not cleaned and dried
properly. Wipe dry and make new test.
Do not allow dirt or water to enter transmission oil

cooler.
Remove dirt and insects from fins with water hose
(without nozzle) or with compressed air. Excessive
water pressure could damage fins.
Scrub core with soft bristle brush using clean hot
water with mild detergent solution.
SPECIFICATIONS
Cooling System Approximate Fluid Capacities
3.4L L32 Engine
With Manual Transmission .......................................
With Automatic Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5. 7L LTl Engine
With Manual Transmission .......................................
With Automatic Transmission ....................................
11.8 liters (12.5 qt.)

11.6 liters (12.3 qt.)
14.5 liters (15.3 qt.)
14.3 liters (15.1 qt.)

Air Bleed Pipe Mounting Bolts/Screws .................................. 42 Nm (31 lb. ft.)
Air Bleed Pipe Mounting Nut .......................................... 21 Nm (15 lb. ft.)
Battery Tray and Coolant Recovery Reservoir Bolt/Screw .................. 12 Nm (106 lb. in.)
Engine Block Coolant Drain Hole Plug .................................. 21 Nm (15 lb. ft.)
Engine Front Cover Bolt/Screw ........................................ 21 Nm (16 lb. ft.)
Knock Sensor ...................................................... 19 Nm (14 lb. ft.)
Oil Cooler Pipe Connections .......................................... 20 Nm (15 lb. ft.)
Power Steering Bracket Bolt/Screw ..................................... 31 Nm (23 lb. ft.)
Radiator Drain Cock Assembly ....................................... 12 Nm (106 lb. in.)
Water Outlet Bolt/Screw .............................................. 28 Nm (21 lb. ft.)
Water Pump Bolt/Screw (3.4L L32 Engine) ............................... 10 Nm (89 lb. in.)
Water Pump Bolt/Screw (5.7L LTl Engine) .............................. 42 Nm (31 lb. ft.)
Water Pump Cover Bolt/Screw ......................................... 45 Nm (33 lb. ft.)
SPECIAL TOOLS
1.
~.;;;;;;;ww;;:z::::=;;i1::J
J 24131-188
qg;.;1;.isell.tC~-:;;;;;;;;;;;;;;i1;;;:i1
J 24131-206
2.
3.
J33419-A
J 24460-01
1.
2.
3.
4.
COOLING SYSTEM TESTER

TEMPIL STICKS
RADIATOR CORE REMOVER/INSTALLER
COOLANT TESTER
4.
J 23688 OR J 26568
PC00176B-F-RP
ENGINE FUEL 6C-1
SECTION 6C
ENGINE FUEL
CAUTION: This vehicle is equipped with Supplemental Inflatable Restraint (SIR}. Refer
to CAUTIONS in Section 9J under "ON-VEHICLE,SERVICE" and the SIR Component and
Wiring Location view in Section 9J before performing service on or around SIR
components or wiring. Failure to follow CAUTIONS could result in possible air bag
used. Fasteners that are not reused, and those requiring thread-locking compound will be called out. The
correct torque value must be used when installing fasteners that require it. If the above conditions are not
followed, parts or system damage could result.
CONTENTS
General Description
Fuel Tank
Fuel Tank Vent Valve
(Remote mounted)
Fuel Tank Filler Neck

Fuel Filler Cap
Fuel Sender Assembly
Fuel Sender
Fuel Pump and Reservoir Assembly
Fuel Pump Strainer
In-Line Fuel Filter
Fuel Feed and Return Pipes/Hoses
Nylon Fuel Pipes
Quick-Connect Fittings
Fuel Line 0-ri ngs
Fuel Vapor Pipes and Hoses
Accelerator Controls
Diagnosis
Alcohol-In-Fuel
Testing Procedure
Fuel Tank Leak Check
Fuel Tank Vent Valve Check
Fuel System Pressure Test
See Section 6E3, Chart A-7
Fuel Sender Diagnosis
See Section 8A
Fuel Pump Electrical Diagnosis
See Section 6E3 and Section 8A
On-Vehicle Service
Fuel System Pressure Relief
Servicing Quick-Connect Fittings

In-Line Fuel Filter Replacement
6C-2
6C-2
6C-2
6C-2
6C-2
6C-3
6C-3
6C-3
6C-5
6C-5
6C-5
6C-5
6C-6
6C-6
6C-6
6C-6
6C-6
6C-6
6C-6
6C-6
6C-7
6C-7
6C-7
6C-7
6C-9
Draining Fuel Tank

Fuel Tank Replacement
Fuel Sender Assembly Replacement

Fuel Sender Assembly Service
Fuel System Cleaning
Fuel Tank
Fuel Feed and Return Pipes/Hoses
Replacement
Rear Fuel Feed Pipe/Hose Assembly
(Fuel Tank)
Chassis Fuel Feed and Return Pipes
Engine Compartment Connecting
Fuel Pipes (Chassis to Engine)
Engine Fuel Pipes See Section 6E3-C2
Fuel Vapor Pipes and Hoses Repair/
Replacement
Accelerator Control Cable Replacement
(3.4L VIN S)
(5.7L VIN P)
Accelerator Pedal Replacement
Specifications
Torque Specifications
Fuel Specifications
Octane Requirements
Gasoline With Alcohol

Methyl Tertiary-Butyl Ether (MTBE)
Ethanol
Methanol
Special Tools
6C-9
6C-10
6C-11
6C-11
6C-12
6C-13
6C-13
6C-14
6C-14
6C-14
6C-15
6C-17
6C-18
6C-18
6C-19
6C-20
6C-20
6(-20
6C-20
6C-20
6C-20
6C-20
6C-20
6C-20
6(-2 ENGINE FUEL
GENERAL DESCRIPTION
The fuel supply is stored in the fuel tank. An
electric fuel pump, attached to the fuel sender
assembly (inside the fuel tank) pumps fuel through an
in-line filter to the fuel rail assembly. The pump is
designed to provide fuel at a pressure above the
regulated pressure needed by the injectors. A pressure
regulator keeps fuel available to the injectors at a
regulated pressure. Unused fuel is returned to the fuel
tank by a separate pipe. For further information on
the fuel injection system, refer to "Fuel Metering
System" located in SECTION 6E3-C2.
Unleaded fuel must be used with all gasoline
engines for proper emission control system operation.
Using unleaded fuel will also decrease spark plug
fouling and extend engine oil life. Leaded fuel can
damage the emission control system, and its use can
result in loss of emission warranty coverage.
All vehicles with gasoline engines are equipped
with an evaporative emission system that minimizes
the escape of fuel vapors to the atmosphere.
Information on this system is located in SECTION
6E3-C3.
FUEL TANK
The fuel tank is used to store fuel for the vehicle.
The tank is located in the rear of the vehicle and is
held in place by two metal straps that are attached to
the frame. The fuel tank is made of steel and is coated
internally with a special corrosion inhibiter.
Fuel Tank Vent Valve (Remote Mounted)

Figure 1
The fuel tank vent valve, located in the left rear of
the vehicle by the fuel tank, is a pressure/vacuum
relief valve. When fuel tank pressure exceeds a
specified pressure the valve will open allowing tank
pressure to bleed off. When the fuel tank is in a
vacuum condition, the vent valve will open when the
vacuum is within a specified range allowing fresh air
to be pulled in.
MOUNTING CLIP
2
FUEL TANK
FUEL TANK VENT VALVE
NS 15941
Figure 1 Fuel Tank Vent Valve
Fuel Filler Cap

Figure 2
Failure to use the correct cap can result in a
serious malfunction of the system. The fue 1 tank filler
neck is equipped with a non-vented threaded-type cap.
The threaded part of the cap requires several turns
counterclockwise to remove. A built-in torquelimiting device prevents over tightening. To install,
turn the cap clockwise two full turns until a clicking
noise is heard. This signals that the correct torque has
been reached and the cap is fully seated.
Fuel Tank Filler Neck

Figure 2
To prevent refueling with leaded fuel, the fuel
filler neck has a built-in restrictor and deflector.
OJ
FUEL FILLER CAP
[ } ] FUEL TANK FILLER NECK
IT]
FUEL FILLER DOOR
Figure 2 Fuel Filler Cap
MS 9071-6C
ENGINE FUEL 6C-3

NOTICE: If a fuel filler cap requires replacement,
use only a cap with the same features.
FUEL SENDER ASSEMBLY

The fuel sender assembly is attached to the top of
the tank, and extends from the top of the tank to the
sump located in the bottom of the tank.
The fuel sender assembly consists of the following
major components: a fuel sender, fuel pump and
reservoir assembly, fuel pump strainer and a roll-over
valve.
Fuel Sender
Figure 3
The fuel sender consists of the fuel tank cover
plate, fuel feed, return, vent pipes, a float, wire float
arm, sensor and roll-over valve. The fuel level is
sensed by the position of the float arm, and a signal is
sent to the display in the vehicle instrument cluster.
The roll-over valve is pressed into the vapor tube of

the fuel sender and is not serviced separately. The
roll-over valve prevents fuel spilling from the fuel
sender vapor pipe if the vehicle rolls over.
Fuel Pump and Reservoir Assembly
Figure 4
An electric high pressure roller vane fuel pump is
mounted inside the fuel reservoir, which is located in
the fuel tank. The fuel is pumped to the engine at a
specified flow and pressure through the fuel feed pipe.
Excess fuel is returned to the fuel tank by the return
line. The fuel pump delivers a constant flow of fuel to
the engine even during low fuel conditions and
aggressive vehicle maneuvers. As part of the fuel
pump and reservoir assembly, three hoses are
permanently attached. The fuel pump feed hose has
the quick-connect fitting, the fuel return hose has a
square end and the fuel vapor hose is cut on an angle.
10
QUICK-CONNECT FITTING
(FUEL FEED HOSE)
LOCKING TABS
ROLL-OVER VALVE
FUEL PUMP STRAINER
VENT HOSE RETAINER
10
VENT HOSE
11
FLOAT
SENSOR
12
FLOAT ARM
FUEL SENDER
13
FUEL PUMP &

RESERVOIR ASSEMBLY
BUMPER
14
FUEL RETURN HOSE

NA 5094-AS
Figure 3 - Fuel Sender Assembly
6C-4 ENGINE FUEL
AS INSTALLED IN FUEL TANK
r..::
'
---.11)1,, FUEL FEED
"" .. >
c:==>
FUEL RETURN
VAPOR VENT
11-2-92
NA 5054-SY
Figure 4 - Fuel Pump and Reservoir Fuel Flow
ENGINE FUEL 6C-5

The fuel pump feed hose also acts to dampen fuel
pulses and noise generated by the fuel pump.
The electric fuel pump operation is controlled by
the Engine Control Module (ECM) through a fuel
pump relay. Refer to to "Fuel Metering System"
located in SECTION 6E3-C2 and SECTION 8A of this
manual for further description and a wiring diagram
of fuel pump relay.
Fuel Pump Strainer
Figure 4
A woven plastic fuel pump strainer is attached to
the lower end of the fuel pump and reservoir assembly
in the fuel tank. The functions of the fuel pump
strainer is to filter contaminants and to wick fuel.
The life of the fuel pump strainer is generally
considered to be that of the fuel pump. The fuel pump
strainer is self-cleaning and normally requires no
maintenance. Fuel stoppage at this point indicates
that the fuel tank contains an abnormal amount of
sediment or water. In which case, the tank should be
thoroughly cleaned. (See "Fuel System Cleaning.") If
the fuel pump strainer is plugged, replace it with a
new one.
IN-LINE FUEL FILTER
Figure 5
A fuel filter is used in the fuel feed pipe ahead of
the fuel injection system and mounted directly in front
of the rear axle. The filter housing is constructed of
steel with a quick-connect inlet and threaded outlet
fittings. The threaded fitting is sealed with an 0-ring.
The filter element is made of paper, and is designed to
trap particles in the fuel that may damage the
injection system. There is no service interval for fuel
filter replacement. Only replace fuel filter if it is
restricted.
FUEL FEED AND RETURN PIPES/HOSES

The fuel feed and return pipes and hoses carry fuel
from the fuel sender assembly to the fuel rail
assembly. The fuel feed and return pipes and hoses
consist of four sections:
The rear fuel pipe assemblies are located from the
top of the fuel tank to the chassis fuel pipes. The
rear fuel pipes are constructed of ny Ion.
The chassis fuel pipes are located under the vehicle
and connect the rear fuel pipes to the engine
compartment connecting fuel pipes. These pipes
are constructed of steel.
SHELL
2
PAPER ELEMENT
INNER END PLATE
MA SOSO-SY
Figure 5 - In-Line Fuel Filter (Typical)
The engine compartment connecting fuel pipes

connect the chassis pipes to the engine fuel pipes.
These fuel pipes are routed from the chassis fuel
pipes under the vehicle and behind the front driver
side wheel house liner to the engine compartment.
These fuel pipes are constructed of nylon.
Nylon Fuel Pipes

Nylon fuel pipes are designed to perform the same
job as the steel or flexible fuel lines they replace.
Nylon pipes are constructed to withstand maximum
fuel system pressure, exposure to fuel additives, and
changes in temperature. There are two sizes used: 3/8"
ID for the fuel feed, and 5/16" ID for the fuel return.
The fuel feed and return pipes are assembled as a
harness. Retaining clips hold the pipes together and
provide a means for attaching the pipes to the vehi:le.
Sections of the pipes that are exposed to chafing, high
temperature or vibration are protected with heat
resistant rubber hose and/or corrugated plastic
conduit.
Nylon fuel pipes are somewhat flexible and can be
formed around gradual turns under the vehicle.
However, if forced into sharp bends, nylon pipes will
kink and restrict fuel flow. Also, once exposed to fuel,
nylon pipes may become stiffer and are more likely to
kink if bent too far. Special care should be taken when
working on a vehicle with nylon fuel pipes:
CAUTION: To Reduce the Risk of Fire and

Personal Injury:
Always cover nylon fuel lines with a
wet towel before using a torch near
them. Also, never expose the ~ehicle to
temperatures higher then 115 C (239 0 F)
for more than one hour, or more than
90((194F) for any extended period.
6C-6 ENGINE FUEL

Take care not to nick or scratch the
nylon fuel lines. If damaged, they must
be replaced.
Quick-Connect Fittings
Quick-connect type fittings provide a simplified
means of installing and connecting fuel system
components. Depending on the vehicle model, there
are two types of quick-connect fittings, each used at
different locations in the fuel system. Each type
consists of a unique female connector and a compatible
male pipe end. 0-rings, located inside the female
connector, provide the fuel seal. Integral locking tabs
or fingers hold the fittings together.
Fuel Pipe 0-rings

The feed and return pipe threaded connections are
sealed with 0-ring seals. Fuel system 0-ring seals are
made of special material, and should only be serviced
with the correct service part.
FUEL VAPOR PIPES AND HOSES

The fuel vapor pipe extends from the fuel sender
assembly to the charcoal canister.
ACCELERATOR CONTROLS
The accelerator control system is cable type. There
are no linkage adjustments. Therefore, the specific
cable must be used.
DIAGNOSIS
ALCOHOL-IN-FUEL
Alcohol-in-fuel can be detrimental to fuel system
components and may cause driveability problems such
as hesitation, lack of power, stall, no start, etc.
The problems may be due to fuel system corrosion
and subsequent fuel filter or strainer plugging,
deterioration of rubber components and/or air-fuel
mixture leaning.
Various types and concentrations of alcohol are
used in commercial fuel. Some alcohols are more
detrimental to fuel system components than others. If
an excessive amount of alcohol in the fuel is suspected
as the cause of a driveability condition, the following
procedure may be used to detect the presence of alcohol
in the fuel. In this procedure, water is used to extract
the alcohol from the fuel.
Testing Procedure
The fuel sample should be drawn from the bottom
of the tank so that any water present in the tank will
be detected. The sample should be bright and clear. If
the sample appears cloudy, or contaminated with
water (as indicated by a water layer at the bottom of
the sample), this procedure should not be used, and the
fuel system should be cleaned (see "Fuel System
Cleaning").
1. Using a 100 ml cylinder with 1 ml graduation
marks, fill with fuel to the 90 ml mark.
2. Add 10 ml of water to bring the total fluid volume
to 100 ml and install a stopper.
3. Shake vigorously for 10 to 15 seconds.
4. Carefully loosen the stopper to release pressure.
5. Close the stopper and shake vigorously again for
10 to 15 seconds.
6. Put the graduated cylinder on a level surface for
approximately 5 minutes to allow adequate liquid
separation.
If alcohol is present in the fuel, the volume of the
lower layer (which would now contain both alcohol and
water) will be greater than 10 ml. For example, if the
volume of the lower layer is increased to 15 ml, it will
indicate at least 5 percent alcohol in fuel. The actual
amount of alcohol may be somewhat greater because
this procedure does not extract all of the alcohol from
the fuel.
FUEL TANK LEAK CHECK
rn
1.
Important
Before attempting "Fuel Tank Leak Check" place

a dry chemical (Class B) fire extinguisher near
work area.
Before removing the fuel tank for a suspected leak,
make sure fuel pipes are not leaking onto the tank.
Once removed, make sure fuel is not leaking
around fuel sender assembly 0-ring.
This check requires a fuel sender assembly, fuel
filler cap, and a 0-ring to be installed in the fuel
tank.
Relieve fuel system pressure (see applicable "Fuel

System Pressure Relief'' procedure).
2. Drain fuel tank (see "Draining Fuel Tank").
3. Remove fuel tank (see "Fuel Tank Replacement").
4. Cap fuel feed tube, fuel return tube, and vapor
tube on fuel sender assembly.
5. Connect a piece of hose to the vent tube.
6. Submerge tank in water or apply soap solution to
outside of tank.
7. Apply 7 to 10 kPa (1 to 1t psi) air pressure to the
piece of hose on the fuel tank vent tube.
Air bubbles appearing from fuel tank indicate
a leak. Replace fuel tank if it is leaking (see
"Fuel Tank Replacement").
ENGINE FUEL 6C-7

FUEL TANK VENT VALVE CHECK
The fuel tank vent valve, located in the left rear of
the vehicle by the fuel tank, is a pressure/vacuum
relief valve. If the valve is not functioning properly it
could cause excessive pressure or vacuum to build up
in the tank. The result may be possible fuel discharge
when removing cap or possible damage to the tank or
fuel sender.
Checking procedure:
1. Loosen fuel filler cap to relieve tank pressure.
2. Remove tank vent valve from vehicle.
3. Wrap vent valve in shop towel and shake out
any remaining fuel.
4. Using the appropriate adapters, connect vent
valve to a radiator pressure check device.
5. Slowly apply pressure to vent valve. The valve
should open at approximately 1 psi. If not,
replace vent valve.
6. Disconnect vent valve from pressure tester.
7. Using the appropriate adapters, connect vent
valve to a hand operated vacuum pump.
8. Slowly apply vacuum to the vent valve. The
valve should open at approximately 1-2" Hg. If
not, replace vent valve.
Connect J 34730-1 to fuel pressure connection.

gage to avoid spillage.
5. Install bleed hose into an approved container and
open valve to bleed system pressure. Fuel
connections are now safe for servicing.
6. Drain any fuel remaining in gage into an approved
container.
4.
SERVICING QUICK-CONNECT FITTINGS
Figure 6
Tools required:
J 37088-A tool set, fuel line quick-connect
separator.
Important
1.
ON-VEHICLE SERVICE
Important
Before attempting any "On-Vehicle Service" place

a dry chemical (Class B) fire extinguisher near
work area.

Tool Required:
CAUTION: To reduce the risk of fire and

personal injury, it is necessary to relieve
the fuel system pressure before servicing
fuel system components.
small amount of fuel may be released
when servicing fuel pipes or connections.
In order to reduce the chance of personal
injury, cover fuel pipe fittings with a shop
towel before disconnecting, to catch any
fuel that may leak out. Place the towel in
an approved container when disconnect
is completed.
Ignition "OFF."
Disconnect negative battery cable to avoid possible
fuel discharge if an accidental attempt is made to
start the engine.
3. Loosen fuel filler cap to relieve tank pressure. (Do
not tighten until service has been completed.)
1.
2.
Relieve fuel system pressure before servicing any

fuel system connection (see "Fuel System Pressure
Relief'').
Slide dust covers from quick-connect fittings, if
equipped.
Grasp both sides of fitting. Twist female
connector t turn in each direction to loosen any
dirt within fitting.
CAUTION: Safety glasses must be worn

when using compressed air, as flying dirt
particles may cause eye injury.
2.
Using compressed air, blow dirt out of fitting.
- For plastic (Hand Releasable) Fitting3. Squeeze plastic retainer release tabs.
4. Pull connection apart.
-OR-
- For Metal Fitting 3. Choose correct tool from J 37088-A tool set for
size of fitting. Insert tool into female
connector, then push inward to release locking
tabs.
121 ILI Cleaning and Inspection

NOTICE: If it is necessary to remove rust or burrs
from fuel pipe: use emery cloth in a radial motion
with the pipe end to prevent damage to 0-ring
sealing surface.
6C-8 ENGINE FUEL
A:: >O])~--'
Metal Collar Quick-connect Fitting
Plastic Collar Quick-connect Fitting
Removal
Step 1
Step2
OR
Insta Ilation
6
6
Step 1
c:::=nJ])obo
Step2
c:::i~
~~
Step3
c::: ill)
....... _
->->--4(Figure 6 - Quick-Connect Fittings
4-30-92
NA 5089-AS
ENGINE FUEL 6C-9

t
Using a clean shop towel, wipe off male pipe

end.
Inspect both ends of fitting for dirt and burrs.
Clean or replace components/assemblies as
required.
I+! Install or Connect

CAUTION: To Reduce the Risk of Fire and
Personal Injury:
Before connecting fitting, always
apply a few drops of clean en9.ine oil to
the male pipe end. This will ensure
proper reconnection and prevent a
possible fuel leak. (During normal
operation, the 0-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.
2. Push both sides of fitting together to cause the
retaining tabs/fingers to snap into place.
3. Once installed, pull on both sides of fitting to make
sure connection is secure.
Reposition dust cover over quick-connect fitting, if
equipped.
IN-LINE FUEL FILTER REPLACEMENT

Figure 7
rn
Important
There is no service interval for fuel filter

replacement. Only replace fuel filter if it is restricted.

1. Relieve fuel system pressure (see "Fuel System
Pressure Relief' procedure).
2. Raise vehicle on hoist.
~ Clean
5.
6.
Fuel pipe 0-ring for cuts, nicks, swelling or

distortion. Replace if necessary.
IN-LINE FUEL Fil TER BRACKET
Figure 7 - In-Line Fuel Filter Replacement

!~I Tighten
1. Position new filter to chassis fuel pipe.
2.
3.
4.
5.
6.
7.
In-line fuel filter fitting to 27 Nm (20 lb. ft.).

Fuel filter bracket.
Quick-connect fitting to fuel filter inlet (see
"Servicing Quick-Connect Fittings").
Lower vehicle.
Tighten fuel filler cap.
Ignition "OFF."
ILI Inspect
Turn ignition switch to "ON," position for two

seconds, then turn to "OFF" for ten seconds.
Again, turn to "ON" position and check for fuel
leaks.
DRAINING FUEL TANK

CAUTION: Never drain or store fuel in an
open container due to the possibility of
fire or explosion.
ll'l'I Inspect
IN-LINE FUEL FILTER
NS 15923
3.
4.
Clean both fuel feed pipe connections and

surrounding areas at in-line fuel filter before
disconnecting to avoid possible contami.nation
of the fuel system.
Fuel filter bracket.
Quick-connect fitting at fuel filter inlet (see
Threaded outlet fitting from chassis fuel pipe.
Fuel filter.
THREADED FITTING
Use a hand operated pump device to drain fuel

through the fuel filler neck. Remove fuel and
install fuel filler cap.
6C-10 ENGINE FUEL

FUEL TANK REPLACEMENT
Figure 8

CAUTION: To help avoid personal injury
when a vehicle is on a hoist, provide
additional support for the vehicle on the
opposite end from which components are
being removed. This will reduce the
po~sibility of the vehicle falling off the
hoist.

1.
2.
3.
4.
5.
6.
7.

System Pressure Relief" procedure).
Drain fuel tank (see "Draining Fuel Tank").
Raise vehicle on hoist.
Fuel filler neck shield.
Rear axle assembly, refer to SECTION 4B.
Exhaust system (pipe & muffler), refer to
SECTION6F.
Muffler heat shield.
!t:'! Clean
Clean all fuel pipe and hose connections and

surrounding areas before disconnecting to
avoid possible contamination of the fuel
system.
8.
9.
Rear fuel feed pipe assembly from fuel sender

assembly, fuel return, vapor, and vent hoses at fuel
sender assembly (see "Servicing Quick-Connect
Fittings").
Electrical connector.
NOTICE: Do Not bend fuel tank straps, as this

may damage straps.
10. With aid of an assistant, support fuel tank, and
remove fuel tank strap front attaching bolts (2).,
fuel tank straps (2) and remove fuel tank.
Fuel tank from vehicle and plaGe in a suitable
work area.
J+!+! Disassemble
I.
2.
Fuel tank insulator pads (2) and tank strap

insulator pads (2). If damaged, otherwise leave on.
Fuel sender assembly (see "Fuel Sender Assembly
Replacement").
!+;+-!
Assemble
Install fuel sender assembly (see "Fuel Sender

Assembly Replacement").
2. Install tank strap insulator pads (2) and fuel tank
insulator pads (2) (if needed).
Peel off release paper on insulators and apply
to tank and straps.
1.
UNDERBODY
INSULATOR
QUARTER PANEL
INSULATOR
INSTALL THIS END OF STRAP FIRST
BOLT TORQUE
26-40 Nm (19-29 lb. ft.)
FUEL TANK ASSEMBLY 9S53516E
Figure 8 - Fuel Tank Insulators & Fuel Tank Mounting
ENGINE FUEL 6C-11
!+! Install or Connect

Hook rear end of fuel tank straps (2) into
underbody bracket.
2. With the aid of assistant, position and support fuel
tank. Position fuel tank straps (2), loosely install
front fuel tank strap attaching bolts.
1.
!~I Tighten
Front fuel tank strap attaching bolts (2) to 34

N m (25 lb. ft.).
3. Electrical connector.
4. Fuel return, vapor, and vent hoses and clamps at
5.
6.
7.
8.
9.
10.
11.
12.
fuel sender assembly, rear fuel feed and return

pipe assemblies to fuel sender assembly (see
Muffler heat shield and attaching screws (6).
Exhaust system (pipe & muffler), refer to
SECTION 6F.
Rear axle assembly, refer to SECTION 4B.
Fuel filler neck shield.
Lower vehicle.
Add fuel and install fuel filler cap.
Ignition "OFF."
IL! Inspect

Again, turn to "ON" position and check for fuel
leaks.
rn
Important
Always replace fuel sender assembly 0-rings,
when reinstalling fuel sender assembly.

System Pressure Relief' procedure).
2. Drain fuel tank (see "Draining Fuel Tank").
3. Fuel tank (see "Fuel Tank Replacement").
1.
Clean
surrounding areas before disconnecting to a void
possible contamination of the fuel system.
!+!+I Disassemble
1.
2.
Fuel sender retaining nuts and retaining ring.

Discard fuel sender 0-ring.
CAUTION: To reduce risk of fire and

personal injury, drain fuel from fuel
sender assembly into an approved
container.
Fuel sender assembly 0-ring sealing surfaces.
I*+! Assemble
1.
Position new fuel sender assembly 0-ring on fuel

tank.
rn
FUEL TANK VENT VALVE

The fuel tank vent valve is located above the
passenger side rear tire and exhaust heat shield.

1.
!LI Cleaning and Inspection
Important
Fuel pump strainer must be in a horizontal
position. When installing the fuel sender
assembly, assure that the fuel pump strainer
does not block full travel of float arm.
Ignition "OFF."

3. Fuel filler cap.
4. Raise vehicle.
5. Hose.
6. Squeeze tabs & remove from bracket.
Gently fold fuel strainer over itself.

Slowly position fuel sender assembly in fuel
tank so that fuel strainer is not damaged or
trapped by sump walls.
3. Install fuel sender assembly into fuel tank.
!~I Tighten
2.
1. Reverse removal procedure.
FUEL SENDER ASSEMBLY REPLACEMENT
Figure 9
NOTICE: Do Not handle the fuel sender by the
fuel sender pipes. Due to the length of the tubes,
the amount of leverage generated could damage
the solder joints.
Fuel sender assembly retaining nuts to 7

Nm (63 lb. in.).
l+l lnstall or Connect

1.
Fuel tank and check for leaks (see "Fuel Tank

Replacement").
6C-12 ENGINE FUEL

FUEL SENDER ASSEMBLY SERVICE
Figure 10
l++I
1.
2.
3.
4.

Drain fuel tank (see "Draining Fuel Tank").
Fuel tank (see "Fuel Tank Replacement").
Replacement").
l+!+I
1.
2.
3.
Disassemble
IL! Inspect
6.
1-+;+I Assemble
1.
2.
Support fuel sender assembly with one hand and

grasp strainer with other hand.
Rotate strainer in one direction and pull fuel
strainer off of pump. Discard strainer after
inspection.
4.
5.
Fuel pump strainer.

If strainer is
contaminated, the fuel tank should be cleaned.
Fuel pump inlet for dirt and debris. If found,
fuel pump and reservoir should be replaced.
- If fuel pump and reservoir is being replaced, proceed

to step 2. -
Vent hose and fuel return hose from under cover.

Quick-connect fitting on fuel feed hose (see
Electrical connector from fuel pump.
Pry locking tabs on bottom of fuel reservoir, lift
reservoir to clear locking tabs and pull reservoir
downward to clear guides on fuel sender.
Bumper on fuel sender.
3.
4.
5.
6.
Newbumperonfuelsender.
Align tabs on reservoir with guide on fuel sender,
push upward to stop on top of reservoir and snap
locking tabs over ramps on bottom ofreservoir.
Fuel vent and return hose.
Quick-connect fitting on fuel feed hose (see
Electrical connector on fuel pump.
Push new fuel pump strainer onto fuel pump inlet.
Push on outer edge of strainer ferrule until fully
seated.
I-++! Install or Connect

1.
2.

Replacement").
Fuel tank and check for leaks (see "Fuel Tank
Replacement").
1 / !l
/
.......-.i.-J;
.,,,
-::--..
RETAINING NUT TORQUE
TO 7 Nm (63 lb. in.)
FUEL SENDER RETAINING

RING
FUEL SENDER SEAL
FUEL TANK
NS 15922
Figure 9 - Fuel Sender Assembly Replacement
ENGINE FUEL GC-13

FUEL SYSTEM CLEANING
6.
(I] Important
!L'l'!
Only use oil free compressed air to blow out fuel

pipes.
If the in-line fuel filter is plugged, the fuel tank
should be inspected internally and cleaned if
necessary.
7.
1. Ignition ''OFF."
3. Relieve fuel system pressure, see "Fuel System
Pressure Relier' in this section.
4. Drain fuel tank, see "Draining Fuel Tank" in this
section.
5. Fuel tank, see "Fuel Tank Replacement" in this
section.
Inspect
Fuel Tank
Fuel sender assembly, see "Fuel Sender Assembly

8.
Whenever the fuel tank is cleaned, the fuel

pump strainer must be inspected. If strainer is
contaminated, it must be replaced and the fuel
pump must be inspected.
Fuel pump inlet for dirt and debris. If found,
fuel pump should be replaced.
Flush fuel tank with running hot water for at least
five minutes.
Pour water out of fuel sender assembly opening.
(Rock tank to be sure that removal of water from
tank is complete.)
!.. +! Install or Connect

1.
2.
Fuel sender assembly, see "Fuel Sender Assembly

Fuel tank, see "Fuel Tank Replacement" in this
section.
SENDER ASSEMBLY - FUEL LEVEL
FUEL PUMP AND RESERVIOR

ASSEMBLY (ROLLERVANE FUEL)
A
VAPOR VENT HOSE
FUEL FEED HOSE AND

FUEL RETURN HOSE
STRAINER(EXTERNAL)-FUEL
SENDER
NA 5017-XV
Figure 10 Fuel Sender Assembly Disassembly
6C-14 ENGINE FUEL

3.
4.
5.
Add fuel and install fuel filler cap.

Ignition "OFF."
meet the GM specifications for those parts. The

replacement pipes must have the same type of
fittings as the original pipes to ensure the
integrity of the connection.
Do not use copper or aluminum tubing to
replace steel tubing. Only tubing meeting the 124M specification or its equivalent is capable of
meeting all pressure, corrosion and vibration
characteristics necessary to ensure the durability
standard required.
When replacing fuel hoses or repairing fuel
pipes with hoses, always replace them with
original equipment or parts meeting GM
specifications, use only reinforced fuel-resistant
hose which is identified with the word
"Fluoroelastomer" or "GM 6163-M" on the hose.
Inside hose diameter must match outside pipe
diameter.
Do not use rubber hose within 100 mm (4") of
any part of the exhaust system or within 254 mm
(10") of the catalytic converter.
A minimum of 13 mm (-f') clearance must be
maintained around sharp edges such as flanges,
pinch welds, etc., to prevent contact and chaffing.
A minimum of 19 mm (f') clearance must be
maintained around all moving parts.
If more than a 6 inch length of pipe is removed,
use a combination of steel pipe and hose so that the
total hose lengths, including the lOOmm (4")
additional length will not be more than 254 mm
(10") long. Follow the same routing as the original
pipe.
Cut ends of pipe remaining on car square with
a tube cutter. Using the first step of a double
flaring tool, form a bead on the end of both pipe
sections. If pipe is too corroded to withstand the
beading operation without damage, the pipe
should be replaced. If a new section of pipe is used,
form a bead on both ends of it also.
Use screw type hose clamp No. 2494772. Slide
clamps onto pipe and push 51 mm (2") onto each
portion of fuel pipe. Tighten clamps on each side of
repair.
!L'l'I Inspect
Turn ignition switch to "ON" position for two

Again turn to "ON" position and check for fuel
leaks.
FUEL FEED AND RETURN PIPES/HOSES

REPLACEMENT
Rear Fuel Feed Pipe/Hose Assembly
{Fuel Tank)
Figure 11
NOTICE: Do Not attempt to repair rear fuel feed
pipe/hose assembly. If damaged, replace.
!+-+I Remove or Disconnect

1.

Clean
2.
3.
4.

surrounding areas before disconnecting to
avoid possible contamination of the fuel
system.
Rear fuel feed pipe assembly from Chassis fuel
pipes (see "Servicing Quick-Connect Fittings").
Fuel tank (Refer to "Fuel Tank Replacement")
Rear fuel pipes from fuel sender assembly (see
!-++I Install or Connect

1.
2.
3.
4.
5.
6.
Rear fuel feed pipe assembly to fuel sender

assembly (see "Servicing Quick-Connect
Fittings").
Fuel tank (Refer to "Fuel Tank Replacement").
Rear fuel pipes to chassis fuel pipes (see "Servicing
Quick-Connect Fittings").
Ignition "OFF."

1.
!L'l'I Inspect

Again turn to "ON" position, and check for fuel
leaks.
Chassis Fuel Feed and Return Pipes

Figure 12
NOTICE:
When replacing fuel pipes, always

replace them with original equipment or parts that

2.
3.
Clean
Clean all fuel feed and return pipe/hose

connections and surrounding areas before
disconnecting to avoid possible contamination
of the fuel system.
Raise vehicle.
Engine compartment connecting fuel feed and
return pipe/hose assemblies from chassis fuel feed
and return pipes (under vehicle).
ENGINE FUEL 6(-15

4.
5.
6.
Fuel feed pipe from outlet side of in-line fuel filter.

Discard 0-ring.
Fuel return pipe from rear fuel pipe (see "Servicing
Desired fuel pipe and attaching hardware from
under body.
Note position of fuel pipe to be removed for
installation.
!L'l'I Inspect
Pipes for bends, kinks and cracks. Repair or

replace pipe or pipes as required.
In the repairable areas, cut a piece of fuel hose
100 mm (4") longer than portion of the pipe
removed. If more than a 152 mm (6") length of
pipe is removed, use a combination of steel pipe
and hose so that the total hose lengths,
including the 100 mm (4") additional length
will not be more than 254 mm (10") long.
I.. +! Install or Connect

1.
2.
Position new or repaired fuel pipe or pipes in body

clips as noted during removal and install with
attaching hardware.
Position new 0-ring on fuel feed pipe and connect
to outlet side of in-line fuel filter.
!~I Tighten
3.
4.
5.
6.
7.
8.
Fuel feed pipe fitting to 27 N m (20 lb. ft.).

Fuel return pipe to rear fuel pipes (see "Servicing
Chassis fuel pipes to engine compartment
connecting fuel pipes (see "Servicing QuickConnect Fittings").
Lower vehicle.
Ignition "OFF."
!L'l'I Inspect

Again turn to "ON" position, and check for fuel
leaks.
Engine Compartment Connecting Fuel Pipes

(Chassis to Engine)
Figure 13
NOTICE: Do Not attempt to repair sections of
engine compartment connecting fuel pipes. If
damaged, replace.

2
FUEL TANK
FUEL FILLER NECK
EVAPORATIVE EMISSION CANISTER
FUEL RETURN PIPE QUICK-CONNECT FITTING
IN-LINE FUEL Fil TER

NS15919
Figure 11 - Fuel and Vapor Pipe Replacement (Rear Fuel Pipes)
6(-16 ENGINE FUEL
RETAINING CLAMP
2
IN-LINE FUEL FILTER
EVAPORATIVE EMISSION PIPE
QUICK-CONNECT FITTINGS
NS 15920
Figure 12 - Fuel and Vapor Pipe Replacement (Chassis Fuel Pipes)
ENGINE COMPARTMENT CONNECTING PIPES
RETAINING CLAMP
EVAPORATIVE EMISSION PIPE
GROMMET {WHEELHOUSE OPENING)
RETAINING CLIP
TO CHASSIS FUEL PIPES
Figure 13 - Fuel and Vapor Pipe Replacement (Engine Compartment Connecting Fuel Pipes)
NS 15921
ENGINE FUEL 6C-17

When replacing vapor hoses or repairing
sections of vapor pipe with vapor hoses, always
replace them with original equipment or parts
meeting GM specifications, use only reinforced
fuel-resistant hose which is identified with the
word "Fluoroelastomer" or "GM 6163-M" on the
hose. Inside hose diameter must match outside
pipe diameter.
Do not use rubber hose within 100 mm (4") of
any part of the exhaust system or within 254 mm
(10") of the catalytic converter.
A minimum of 13 mm (!") clearance must be
maintained around sharp edges such as flanges,
pinch welds, etc., to prevent contact and chaffing.
A minimum of 19 mm (t") clearance must be
maintained around all moving parts.
Use screw-type hose clamps. Slide clamps onto
pipe and push 51 mm (2") onto each portion of
vapor pipe.

1.

Clean
Clean all engine compartment connecting fuel

pipe connections and surrounding areas before
disconnecting to avoid possible contamination
of the fuel system.
2. Quick-connect fittings at engine fuel pipes (see
3. Fuel pipes from routing clip and conduit. (note
position for installation.
4. Fuel pipes through grommet in wheel house.
5. Raise vehicle.
6. Quick-connect fittings at chassis fuel pipes (see
7. Fuel pipes from clips and routing bracket (note
positions for installation.)

1.
2.
3.
4.
5.
6.
7.
Quick-connect fittings at chassis fuel pipes (see

Route pipes through clips, brackets, and conduits
as noted during disassembly.
Lower vehicle
Engine compartment connecting fuel pipes to
engine fuel pipes (see "Servicing Quick-Connect
Fittings").
Ignition "OFF."
l~I Tighten

1.
2.
Hardware retaining section of pipe to be replaced.

Note location of attaching hard ware for
installation.
Section of pipe and hoses.
ll'l'I Inspect
IL'l'I Inspect

Again turn to "ON" position and check for fuel
leaks.
FUEL VAPOR PIPES AND HOSES REPAIR/

REPLACEMENT
Hoses for cuts, swelling, cracks and distortion.

Replace as required.
Pipes for kinks and cracks. Repair or replace
sections as required.
In the repairable areas, cut a piece of fuel
hose 100 mm (4") longer than portion of
the line removed. If more than a 152 mm
(6") length of pipe is removed, use a
combination of steel pipe and hose so that
the total hose lengths, including the 100
mm (4") additional length will not be more
than 254 mm (10") long.
NOTICE: When replacing vapor pipes, always

replace them with original equipment or parts that
meet the GM specifications for those parts.
Do not use copper or aluminum tubing to
replace steel tubing. Only tubing meeting the
124-M specification or its equivalent is capable of
meeting all pressure, corrosion and vibration
characteristics necessary to ensure the durability
standard required.
Clamps on each side of repair.
[I] Important
1.
Follow the same routing as the original hoses

and pipes.
Hoses and pipes must be properly secured to
prevent chafing.
Reverse removal procedure.
6C-18 ENGINE FUEL

ACCELERATOR CONTROL CABLE
REPLACEMENT (3.4L VIN S)
Figures 14 and 15

1.
2.
3.
4.
5.
Sound insulator.
Accelerator cable from accelerator pedal.
Squeeze accelerator cable cover tangs and push
cable through dash panel (bulkhead).
Accelerator cable retainer and accelerator cable
from throttle body lever.
cable through accelerator cable bracket.
----
NOTICE: To prevent possible interference,

flexible components (hoses, wires, conduits, etc.)
must not be routed within 50 mm (2") of moving
parts, unless routing is positively controlled.
1.
2.
Apply Accelerator Linkage Lubricant, 1052541 or

equivalent to throttle body lever.
ILI Inspect
3.
Check for complete throttle opening and

closing positions by operating accelerator
pedal. Also check for poor carpet fit under the
accelerator pedal.
Throttle should operate freely without binding
between full closed and wide open throttle.
Apply heavy bodied sealer around accelerator
cable at engine compartment side of dash panel
(bulkhead).
SOUND IN SULA TOR

2
ACCELERATOR CABLE
ACCELERATOR CABLE RETAINER
ACCELERATOR PEDAL ASSEMBLY
NS 15917
Figure 14-Accelerator Controls - Pass Compartment
ACCELERATOR CONTROL CABLE

REPLACEMENT (5.7L VIN P)
Figures 14 and 16

1.
2.
3.
4.
5.
Sound insulator.
Accelerator cable from accelerator pedal.
cable through dash panel (bulkhead).
Accelerator cable retainer and accelerator cable
from throttle body lever.
Release locking tabs and slide accelerator cable
from bracket.

NOTICE:
To prevent possible interference,

flexible components (hoses.wires, conduits, etc.)
must not be routed within 50 mm (2") of moving
parts, unless routing is positively controlled.
THROTTLE BODY
ACCELERATOR CABLE BRACKET
ACCELERATOR CABLE
CRUISE CONTROL CABLE

NS15918
Figure 15 - Accelerator Controls - Engine

Compartment (3.4L VIN S)
ENGINE FUEL 6C-19
THROTTLE BODY
2
CRUISE CONTROL CABLE
ACCELERATOR CABLE
NS 15916
Figure 16 - Accelerator Controls Engine Compartment (5. 7L VIN P)
1.
2.
Apply A~celerator Linkage Lubricant, 1052541 or

equivalent to throttle body lever.
!L'l'!
!-++! Install or Connect
[I] Important
tnspect
3.

pedal. Also check for poor carpet fit under the
accelerator pedal. Throttle should operate
freely without bind between full closed and
wide open throttle.
Apply heavy bodied sealer around accelerator
cable at engine compartment side of dash panel
(bulkhead).
1.
2.
Accelerator pedal and accelerator pedal retainer

clip.
Accelerator cable on accelerator pedal.
!L'l'!
ACCELERATOR PEDAL REPLACEMENT

Figure 14

1. Sound insulator.
2. Accelerator cable from accelerator pedal rod.
3. Accelerator pedal retainer clip from stud and
accelerator pedal.
The mounting surface between support and

dash panel must be free of insulation. The
carpet and padding in pedal and tunnel area
must be positioned to lay flat and be free of
wrinkles and bunches.
3.
tnspect

pedal. Also, check for poor carpet fit under the
accelerator pedal.
Throttle should operate freely without bind
between full closed and Wide Open Throttle
(WOT).
Lower instrument panel trim, lower instrument
panel trim attaching screws (4) and nut.
6C-20 ENGINE FUEL

Methyl Tertiary-Butyl Ether (MTBE)
SPECIFICATIONS
TORQUE SPECIFICATIONS
In-line Fuel Filter Fitting
27 Nm (20 lb. ft.)
Fuel Tank Strap Attaching
Bolts (2) 34 N m (25 lb. ft.)
Fuel Sender Assembly Retaining
Nuts 7 N m (63 lb. in.)
FUEL SPECIFICATIONS
The fuel must meet ASTM Standard:
(U.S.), CGSB 3.5-M87 (Canada)
D4814
Octane Requirements
Fuel containing Methyl Tertiary-Butyl Ether

(MTBE) may be used, providing there is no more than
15% MTBE by volume.
Ethanol
Fuel containing ethanol (ethyl) or grain alcohol
may be used, providing that there is no more than 10%
ethanol alcohol by volume.
Methanol
Fuel containing methanol (methyl) or wood alcohol
may be used, providing that there is no more than 5%
methanol by volume.
3.4L (VIN S) and 5. 7L (VIN P)

Min. Octane Recommended: 87[(R + M)/2] (pump)
octane Where R = research octane number, and M =
motor octane number.
NOTICE: Do Not use fuel that contains more

than 5% methanol. Use of a fuel (gasohol) that
contains more than 5% of methanol can corrode
metal fuel system components and damage plastic
and rubber parts.
Gasoline With Alcohol
SPECIAL TOOLS
NOTICE: Do Not spill fuel containing alcohol on
the vehicle. Alcohol can cause damage to the paint
finish and trim.
Fuel Pressure Gage J 34 730-1

Fuel Line Quick-Connect
Separator Set J 37088-A
ENGINE ELECTRICAL 60-1
SECTION 60
ENGINE ELECTRICAL
CONTENTS
General Description . . . . . . . . . . . . . . . . . . . . . . . . 60-1
GENERAL DESCRIPTION
The engine electrical system includes the storage
battery assembly, ignition (primary and secondary),
starter motor assembly (and related wiring) and the
generator assembly (and related wiring). To diagnose and

troubleshoot system faults, refer to SECTION 8A for
wiring diagrams, component locations and system checks.
When a fault is traced to a particular component,
refer to that component's section of the service manual.
BATTERY 601-1
SECTION 601
BATIE RY
could easily come in contact with "live" exposed electrical terminals, disconnect the battery
negative cable assembly to help prevent personal injury and/or damage to the vehicle or
components. Unless instructed otherwise, the ignition switch must be in the "OFF" or
"LOCK" position.
result.
CONTENTS
Battery Assembly .......................
Battery Assembly Ratings ................
Reserve Capacity .....................
Cold Cranking Amps ..................
Common Causes of Failure ...............
Electrolyte Freezing ............. ; .......
Battery Tray Assembly and Hold-Down
Retainer ............................
Battery Assembly Protection During
Vehicle Storage ......................
.Built-~n Hydrometer ....................
D1agnos1s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Battery Assembly Testing ................
Battery Assembly Electrical Drain .........
Parasitic Load Test . . . . . . . . . . . . . . . . . . . .
On-Vehicle Service . . . . . . . . . . . . . . . . . . . . . . .
Battery Assembly Charging ...............
6D 1-1
601-1
6D 1-2
601-2
601-2
6D 1-2
6D 1-2
6D 1-2
6D 1-3
601-3
6D 1-3
6D 1-3
6D 1-4
6D 1-4
6D 1-6
601-6
CAUTION: All battery assemblies generate hydrogen gas which is extremely

flammable. If ignited by a spark or
flame, the gas may explode violently,
causing spraying of acid, fragmentation of the battery assembly and
possible severe personal injuries. Wear
approved eye protection. Battery
assembly fluid is corrosive acid. Flush
any contacted area with water immediately and thoroughly.
Charging Procedure . . . . . . . . .. . . . . . . . . . . 6D 1-7

Charging Time Required . . . . . . . . . . . . . . . 6D 1-7
Charging a Very Low or Completely
Discharged Battery Assembly ........... 601-7
Jump Starting in Case of Emergency with
Auxiliary (Booster) Battery Assembly . . . . 6D 1-8
Battery Tray Assembly Replacement . . . . . . . 6D 1-8
Battery Assembly Replacement ............ 601-8
Battery Cable Assembly Replacement
and Routing . . . . . . . . . . . . . . . . . . . . . . . . . 6D 1-9
Negative Cable Assembly . . . . . . . . . . . . . . 6D 1-9
Positive Cable Assembly .............. 601-10
Ground Straps ........................ 601-10
Charging Equipment . . . . . . . . . . . . . . . . . . . 6D 1-10
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . 6D 1-13
Battery Assembly Usage ................ 601-13
Fastener Tightening Specifications . . . . . . . . 6D 1-13
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . 6D 1-14
GENERAL DESCRIPTION
BATTERY ASSEMBLY
Figures 1 and 2
The maintenance-free battery assembly is standard
on all vehicles. See "Specifications" in this section for
battery assembly usage applications. There are no vent
plugs in the cover. The battery assembly is completely
sealed except for two small vent holes in the sides. These
vent holes allow the small amount of gas produced in the
battery assembly to escape.
601 -2 BATTERY
Cold Cranking Amps

The cold cranking amperage (CCA) test is expressed
at a battery temperature of -l8C (0F). The current
rating is the minimum amperage which must be maintained by the battery assembly for 30 seconds, at the
specified temperature, while meeting a minimum voltage
requirement of 7.2 volts. This rating is a measure of cold
cranking capacity.
COMMON CAUSES OF FAILURE
The battery assembly has three major functions in

the electrical system: first, it provides a source of energy
for cranking the engine; second, it acts as a voltage stabilizer for the electrical system; and third, it provides energy
for a limited time when the electrical load exceeds the
output of the generator assembly.
The battery assembly specifications label contains
important information for servicing the battery assembly.
This information includes test rating and both original
equipment and recommended replacement part numbers.
Refer to "Specifications" at the end of this section.
The battery assembly is not designed to last indefinitely; however, with proper care, it will provide many
years of service.
If the battery assembly tests "good," but fails to
perform satisfactorily in service for no apparent reason,
the following are some of the more important factors that
may point to the cause of trouble:
1. Vehicle accessories are left on overnight.
2. Slow average driving speeds for short periods.
3. The vehicle's electrical load being more than the
generator assembly output, particularly with the
addition of aftermarket equipment.
4. Conditions in the charging system such as electrical
shorts, slipping serpentine belt, faulty generator
assembly, or generator voltage regulator.
5. Battery assembly abuse, including failure to keep
the battery assembly terminals clean and tight, or
loose battery assembly hold-down. See "Battery
Assembly Replacement" in this section for torque
specifications.
6. Mechanical conditions in the electrical system, such
as shorted or pinched wires.
7. Extended storage of vehicles.
8. Extended cranking periods due to plug fouling.
9. Incorrect interpretation of the hydrometer.
l 0. Insufficient ampere-hour charge rate for a discharged battery assembly.
11. Continuous current draw on the battery assembly
through excessive parasitic drain.
BATTERY ASSEMBLY RATINGS
ELECTROLYTE FREEZING
A battery assembly has two ratings: (1) a reserve

capacity rating and (2) a cold cranking amperage rating at
-l8C (0F). When replacing the battery assembly, use
these two ratings as a guide in selecting a replacement.
For the catalog number of a replacement battery assembly
with ratings similar to the original battery assembly, refer
to "Specifications" at the end of this section.
The freezing point of electrolyte depends on its

specific gravity. Since freezing may ruin a battery
assembly, it should be protected against freezing by
keeping it in a charged condition.
As long as the green dot is visible in the hydrometer,
the freezing point of the battery will be somewhere below
-32C (-25F).
The higher the state of charge, the lower the freezing
point. A fully charged battery will not freeze until the
temperature gets below-65C (-85F).
PC6001 -601 -0-RP
Figure 1 - Maintenance-Free Battery Assembly
llelco Remy CAT. NO.
514
CCA
LOAD
TEST
REPLACEMENT
MODEL
525
260
75-60
1-2
For warranty transaction, remove and attach to warranty claim.
PC0001-6D1-F-RP
Figure 2 - Battery Assembly Label
Reserve Capacity
The "Reserve Capacity" is an estimate of the
maximum length of time it is possible to travel at night
with minimum electrical load and no generator assembly
output.
Expressed in minutes, it is the approximate time the
fully-charged battery assembly can support a 25-amp load
without the battery assembly terminal voltage dropping
below 10.5 volts at 27C (80F).
BATIERY TRAY ASSEMBLY AND

HOLD-DOWN RETAINER
The battery tray assembly and hold-down retainer
should be clean and free from corrosion before installing
the battery assembly.
BATIERY 601-3
The battery tray assembly should be in a sound
condition so that it will hold the battery assembly securely
and keep it level. Make certain there are no parts in the
battery tray assembly before installing battery assembly.
To prevent the battery assembly from shaking in its
battery tray assembly, the hold-down retainers should be
tight, but not overtight.
BATTERY ASSEMBLY PROTECTION

DURING VEHICLE STORAGE
Today's vehicles have many high technology electronic devices which result in very small but continuous
current drains on the battery assemblies, commonly
referred to as "parasitic loads." Vehicles that are not used
for an extended period of time may develop an extremely
discharged and/or permanently damaged battery assembly
resulting from parasitic loads.
Any battery assembly discharged by parasitic loading and then allowed to stand in this condition for a period
of time may not accept recharge. However, if properly
recharged, most battery assemblies will return to a good
usable condition.
An extremely discharged battery assembly can
freeze at temperatures as high as -7C (20F) causing
permanent damage. Permanent damage to a discharged
battery assembly can also be accelerated by high temperatures.
To prevent this condition, the battery negative cable
assembly should be disconnected on vehicles which are
not going to be in service within a 30-day period, beginning from the time the vehicle is shipped. If this is not
possible, battery assemblies should be recharged periodically (every 20-45 days) until the green dot of the built-in
hydrometer is visible.
BUILT-IN HYDROMETER
Figure 3
The maintenance-free battery assembly has a
built-in temperature compensated hydrometer in the top
of the battery assembly. This hydrometer is used with the
following diagnostic procedure.
STORAG.E
BATTERY
ASSEMBLY TOP
STORAGE
BATTERY
ASSEMBLY TOP
STORAGE
BATTERY
ASSEMBLY TOP
Ci]~[@]
DARKENED
INDICATOR
(WITH GREEN
DOT)
DARKENED
INDICATOR
(NO GREEN
DOT)
LIGHT
YELLOW OR
BRIGHT
INDICATOR
PC6009-6D 1-D-RP
Figure 3 - Built-In Hydrometer
When observing the hydrometer, make sure that the

battery assembly has a clean top. A light may be required
in some poorly-lit areas. Tap the hydrometer lightly on
top to dislodge any air bubbles that might cause a false
indication.
Under normal operation, two indications can be
observed.
1. GREEN DOT VISIBLE
Any green appearance is interpreted as a "green.
dot" and the battery assembly is ready for testing.
2. DARK; GREEN DOT NOT VISIBLE
If there is cranking complaint, the battery assembly
should be tested as described in the "Diagnosis" in
this section. The charging and electrical systems
should also be checked at this time.
Occasionally, a third condition may appear:
3. CLEAR OR LIGHT YELLOW
This means the fluid level is below the bottom of
the hydrometer. This may have been caused by
excessive or prolonged charging, a broken case, or
excessive tipping. When finding a battery assembly
in this condition it may indicate high charging
voltages caused by a faulty charging system, therefore, the charging and electrical systems may need to
be checked. If a cranking complaint exists and is
caused by the battery assembly, the battery assembly
should be replaced.
DIAGNOSIS
BATTERY ASSEMBLY TESTING
Figures 3, 4 and 5
The following procedure should be used for testing
battery assemblies:
1. VISUAL INSPECTION
Check for obvious damage, such as a cracked or
broken case or cover that could permit loss of
electrolyte. If obvious damage is noted, replace the
battery assembly. Determine the cause of damage
and correct as needed. If not, proceed to step 2.
2. HYDROMETER CHECK (Figure 3).
GREEN DOT VISIBLE - Go to step 3.
DARK; GREEN DOT NOT VISIBLE.
Charge the battery assembly as outlined under
"Charging Procedure" in this section and
proceed to step 3.
3. LOADTEST
Load testing requires using battery assembly side
terminal adapters to ensure good connection (Figure
4). Do not load test a frozen battery assembly
A. Connect a voltmeter and a battery assembly
load tester across the battery assembly terminals.
B. Apply a 300-amp load for 15 seconds to
remove surface charge from the battery
assembly.
601-4 BATIERV
Parasitic Load Test

Figures 6 and 7
Tool Required:
J 38758 Parasitic Draw Test Switch
If the battery assembly discharges while the vehicle
sits for a few hours or days, the vehicle should be diagnosed for parasitic loads. Simple connection of an
ammeter in series with the battery assembly may not find
the cause as the condition may not show up when power is
restored unless that particular component is repeatedly
cycled. Parasitic loads can be diagnosed using either of
the procedures below, but use of the special tool as
described in the first procedure is recommended.
PC6013-601-D-RP
Figure 4 - Battery Assembly Side Terminal Adapters
ESTIMATED
TEMPERATURE
MINIMUM
VOLTAGE
21C(70F)
10C (50F)
0C (32F)
-10C (14F)
-18C (0F)
BELOW: - 18C (0F)
9.6
9.4
9.1
8.8
8.5
8.0
NOTICE: Parasitic draw test switch should never be

turned to "OFF" position with engine running or
damage could occur to attached ammeter or vehicle
electrical system.
NC1004-6D1-F-RP
Figure 5 - Battery Assembly Voltage Drop Temperature
C. Wait 15 seconds to let the battery assembly
recover. Apply load specified on the battery

assembly label or in "Specifications" at the
end of this section. Read voltage after 15
seconds, then remove load.
D. If voltage does not drop below the minimum

listed in Figure 5, the battery assembly is good
and should be returned to service. The battery
assembly temperature must be estimated by
feel and by the temperature the battery assembly has been exposed to for the past few hours.
-+
E. If voltage drops below the minimum listed,

replace the battery assembly.
BATTERY ASSEMBLY ELECTRICAL DRAIN

Battery assembly electrical drain is a small amount
of current required by specific control modules that is
needed to retain system memory and system monitoring.
Too much electrical drain, however, can cause an
extremely discharged and/or permanently damaged battery assembly. To test the battery assembly electrical
drain, refer to "Parasitic Load Test" in this section.
A AMMETER, HIGH CAPACITY (10A)

2 CABLE ASSEMBLY, BATTERY NEGATIVE
3 BATTERY ASSEMBLY, STORAGE
PC0002-6D1fRP
Figure 6 - Use of Parasitic Draw Test Switch
BATIE RY 601 5
1993 COMPONENT PARASITIC LOADS (mA)
Component
Approximate
Parasitic Draw
PASS-Key 11
Voltage Regulator in Generator Assembly

HVAC Control Head
Before 2.5 hour timeout
After 2.5 hour timeout*
15
5
5-10
5
ECM
Radio Control Head
*After specified timeout period elapses, component switches from "AWAKE" to "ASLEEP" mode.
PC0009-&D1F-RP
Figure 7 - Component Parasitic Loads
1. Turn test switch knob to "OFF" position.

Cable Assembly" in Section OA.
2. Remove battery negative cable assembly.
3. Install parasitic draw test switch male (cable) end to
negative battery terminal.
4. Install battery negative cable assembly to female
end of test switch tool.
5. Turn test switch tool knob to "ON" position.
6. Road test vehicle while activating all accessories
(radio, A/C, etc.).
7. Turn ignition switch to "LOCK" position and
remove ignition key.
8. Set ammeter to 10-amp scale and connect to terminals on test switch tool with alligator clips. Use of
10-amp scale may prevent damage to meter.
9. Turn test switch tool knob to "OFF" position to
allow current to flow through ammeter.
10. Check current reading. Allow time for reading to
stabilize. Verify that retained accessory power
(RAP) is off. If current reading is at or below two
amps, turn test tool knob to "ON" position (to maintain continuity in electrical system) and switch to a
lower scale for a more accurate reading, or install a
more accurate meter, if necessary. Turn test tool
knob to "OFF." If current reading is above 25 milliamps, refer to components parasitic load chart
(Figure 7) for specific current loads and microprocessor "time-outs" for modules in "awake" and
"asleep" states. Total reading below 20 milliamps is
normal, and a reading below 25 milliamps is acceptable. A zero reading indicates a problem with meter,
scale being used, or connection.
11. If current draw is above specifications listed in
component parasitic load chart, remove system
maxifuses and circuit breakers one at a time until
current draw returns to a value less than or equal to

specifications listed. This should be done while
monitoring ammeter so that a disruption of drain
will be evident. Perform steps 9 and 10 each time a
fuse is removed. Refer to SECTION 8A for specific
circuit schematics. Total readings in the hundreds of
milliamps may suggest grounded wires, sticking
relays, or small lamps remaining lit.
rn
Important
Always turn test switch tool knob to "ON"

position before removing each fuse to maintain
continuity in electrical system and to avoid
damaging ammeter due to accidental overloading (i.e., opening door). Do not turn switch to
"OFF" while engine is running.
12. When cause of excessive current draw has been
located and repaired, repeat steps 9 and 10 to verify
the repair. Then turn test tool to "OFF," remove
tool, and reconnect battery negative cable assembly
to battery assembly negative terminal.
l~I
Tighten
Negative cable assembly to 15 Nm (11 lb. ft.).

Alternate Parasitic Load Test
Figures 4, 7 and 8
The following alternate procedure may be used
when testing for parasitic load if J 38758 is not available.
1. Disconnect battery negative cable assembly.

2. Install a battery side terminal adapter, AC Delco
P/N ST-1201 or GM P/N 12303040 or equivalent,
in negative terminal of battery (See Figure 4 ).
601-6 BATTERY
c
ST-1201 or
GM P/N 12303040
ST-1201or
GM P/N 12303040
ST-1201 or
GM P/N 12303040
A AMMETER, HIGH CAPACITY (10A)

B NUT, 3/8-INCH
C MULTIMETER
1 CABLE ASSEMBLY, BATTERY POSITIVE

PC0003-6D1-F-RP
Figure 8 - Alternate Parasitic Load Diagnosis Procedure
3. Install other battery side terminal adapter or a

3/8-inch nut with standard threads (16 UNC) on
battery negative cable assembly to assure a good
electrical contact with metal face on cable for testing
(add a washer behind nut if nut does not contact
firmly). Yellow or black finish nuts are generally
non-conductive and should not be used.
4. With all lights, accessories, retained accessory
power (RAP), and ignition switch off, connect a
high capacity ammeter (at least 10 amps) from
battery negative cable assembly to side terminal
adapter. This high capacity ammeter is connected to
verify whether or not a high current draw is occurring at a constant rate. It is this type of high current
draw which will blow the fuse in lower capacity
ammeters.
NOTICE: If a high capacity ammeter is not available, install a section of heavy wire (preferably
battery cable section) between existing battery
negative cable assembly and side terminal adapter.
Allow time for initial draw to occur or check for
reduced current with an inductive ammeter (current
clamp) and proceed to step 5.
5. With high capacity ammeter or battery cable section
still connected, connect digital multimeter, set on
2000 mA de range, in parallel with high reading
ammeter.
6. Disconnect high capacity ammeter and take reading
with digital multimeter.
If current draw is above specifications listed in

component parasitic load chart, remove system
fuses and mini-breakers one at a time until current
draw returns to a value less than or equal to specifications listed. This should be done while monitoring
ammeter so that a disruption of drain will be evident.
Refer to Figure 7 for approximate parasitic loads
for various vehicle components. Set ammeter on
maximum scale when pulling fuses to avoid
damage. Refer to SECTION 8A for specific circuit
schematics.
7. When cause of excessive draw has been located and
repaired, repeat step 6 to verify the repair. Reconnect
battery negative cable assembly to battery assembly
negative terminal.
l~.J
Tighten
Negative cable assembly to 15 Nm (11 lb. ft.).
ON-VEHICLE SERVICE
BATIERY ASSEMBLY CHARGING
NOTICE: Always disconnect the negative cable
assembly when charging a battery assembly or electronic components may be damaged.
When it is necessary to charge the battery assembly,
follow these basic rules:
1. Do not charge battery assembly if hydrometer is
clear or light yellow. Replace battery assembly.
BATIERY 601-7
2. If the battery assembly feels hot (52C (125F) or
higher), or if electrolyte violently gasses or spews
through the vent holes, discontinue charging or
reduce charging rate.
3. Do not charge a battery assembly if it seems to be
frozen.
Charging Procedure
Tool Required:
A/C Delco PIN ST-1201 or GM PIN 12303040
Battery Side Terminal Adapters (Pair)
1. Battery assemblies with green hydrometer dot
showing do not require charging unless they have
just been discharged (such as in cranking vehicle).
2. When charging battery assembly with side terminals, install adapter kit (AC Delco PIN ST-1201 or
GM PIN 12303040 or equivalent). Refer to Figure 4.
The adapter should be snugged up against the
battery assembly terminals to keep resistance
between the adapter and the battery assembly terminal to a minimum. Recommended battery assembly
side terminal adapter torque is 15 Nm (11 lb. ft.).
3. Make sure all battery charger connections are clean
and tight.
4. For best results, battery assemblies should be
charged while electrolyte and plates are at room
temperature. A battery assembly that is extremely
cold may not accept current for several hours after
starting battery charger.
5. Charge battery assembly until green dot of built-in
hydrometer appears. Refer to "Charging Time
Required" in this section. Battery assembly should
be checked every half-hour while charging. Tap the
hydrometer lightly on top to dislodge any air
bubbles that might cause a false indication.
6. After charging, battery assembly should be tested.
Refer to "Diagnosis" in this section.
Charging Time Required

The time required to charge a battery assembly will
vary depending on the following factors:
Size of Battery Assembly - A completely discharged large heavy-duty battery assembly requires
more than twice the recharging as a completely discharged small passenger vehicle battery assembly.
Temperature - A longer time will be needed to
charge any battery assembly at -18 C (0F) than at
27C (80F). When a fast battery charger is connected to a cold battery assembly the current
accepted by the battery assembly will be very low at
first, then in time, the battery assembly will accept a
higher rate as the battery assembly warms.
Battery Charger Capacity - A battery charger
which can supply only five amps will require a much
longer period of charging than a battery charger that
can supply 30 amps or more.
State-of-Charge - A completely discharged battery

assembly requires more than twice as much charge
as a half-charged battery assembly. Because the
electrolyte is nearly pure water and a poor conductor
in a completely discharged battery assembly, the
current accepted by the battery assembly is very low
at first. Later, as the charging current causes the electrolyte acid content to increase, the charging current
will also increase.
CHARGING A VERY LOW OR COMPLETELY

DISCHARGED BATTERY ASSEMBLY
The following procedure should be used to recharge
a very low or completely discharged battery assembly.
Unless the procedure is properly followed, a perfectly good battery assembly ll}ay be needlessly replaced.
1. Measure voltage at battery assembly terminals with
an accurate voltmeter. If below 11 volts, the charge
current will be very low and it could take some time
before it accepts a current in excess of a few
milliamps. Such low current may be detectable on
ammeter available in the field.
2. Set battery charger on high setting.
3. Some chargers feature polarity protection circuitry
which prevents charging unless the battery charger
leads are connected to the battery terminals correctly. A completely discharged battery assembly
may not have enough voltage to activate this
circuitry even though battery charger leads are
connected properly, making it appear that the battery
assembly will not accept charging current. Therefore, follow the specific charger manufacturer's
instructions telling how to bypass or override the
circuitry so that the charger will turn on and charge a
low-voltage battery assembly.
4. Battery chargers vary in the amount of voltage and
current they provide. The time required for the
battery assembly to accept measurable charger
current at various voltages may be as follows:
CHARGING VOLTAGE
HOURS
Up to 4 Hours
16.0 or more
14.0- 15.9
Up to 8 Hours
13.9 or less
Up to 16 Hours
If the charge current is still not measurable at the end
of the above charging times, the battery assembly
should be replaced.
If the charge current is measurable during the
charging time, the battery assembly is considered
good and charging should be completed in the
normal manner.
5. It is important to remember that a completely
discharged battery assembly must be recharged for a
sufficient number of ampere hours (AH) to restore it
to a usable state. As a general rule of thumb, using
the reserve capacity (RC) rating of the battery
assembly as the number of ampere hours of charge
will usually bring the green dot into view. For
reserve capacity refer to "Specifications" in this
section. If battery assembly is rated at 75 RC
minutes, it would usually be completely recharged
as follows:
601 -8 BATIE RY
10 ampere charge x 7 1/2 hours
= 75 AH
Do not permit vehicles to touch each other as this

could cause a ground connection and counteract the
benefits of this procedure.
or
25 ampere charge x 3 hours
= 75 AH, etc.
CAUTION: To prevent sparking and

possibly explosion of battery gases, do
not connect jumper cable directly to the
battery negative terminal of the dead
battery assembly.
6. It is recommended that any battery assembly

recharged by this procedure be LOAD TESTED to
establish serviceability. Refer to "Battery Assembly
Testing" in this section.
JUMP STARTING IN CASE OF EMERGENCY

WITH AUXILIARY (BOOSTER) BATTERY
ASSEMBLY
NOTICE: Do not push or tow the vehicle to start.
Damage to the emission system and/or to other parts
of the vehicle may result.
Both auxiliary battery assembly and discharged
battery assembly should be treated carefully when using
jumper cables.
CAUTION: Departure from these conditions or the procedure below could

result in: (1) serious personal injury
(particularly to eyes) or property
damage from such causes as battery
assembly explosion, battery assembly
acid, or electrical burns; and/or (2)
damage to electronic components of
either vehicle.
Never expose battery assembly to
open flame or electric spark - battery
assemblies generate a gas which is
flammable and explosive. Remove
rings, watches, and other jewelry. Wear
approved eye protection.
Do not allow battery assembly fluid to
contact eyes, skin, fabrics, or painted
surfaces - battery assembly fluid is a
corrosive acid. Flush any contacted
area with water immediately and thoroughly. Be careful that metal tools or
jumper cables do not contact the
battery assembly positive terminal (or
metal in contact with it) and any other
metal on the vehicle, because a short
circuit could occur.
1. Set parking brake lever assembly and place automatic transmission assembly in "PARK." Turn off
the ignition, lamps and all other electrical loads.
2. Check the built-in hydrometer. If it is clear or light
yellow, replace the battery assembly.
NOTICE: Do not jump start a vehicle with charging

equipment unless the equipment is specifically
designed for jump starting. Using improper equipment can cause serious damage to the electrical
system or electronic parts.
3. Attach the end of one jumper cable to the auxiliary
battery assembly positive terminal and the other end
of the same cable to the positive terminal of the
junction block assembly.
4. Attach one end of the remaining negative cable to

the auxiliary battery assembly negative terminal,
and the other end to a solid engine ground (such as
the compressor assembly bracket or power steering
pump bracket assembly) at least 46 cm (18 inches)
from the battery assembly of the vehicle being
started.
5. Start the engine of the vehicle that is providing the
jump start and turn off electrical accessories. Then
start the engine of the vehicle with the discharged
battery assembly.
6. Reverse these directions exactly when removing the
jumper cables. The negative cable must first be
disconnected from the engine that was jump started.
BATIERY TRAY ASSEMBLY REPLACEMENT

The battery tray is part of the coolant recovery
reservoir assembly. Refer to Section 6B for replacement.
BATIERY ASSEMBLY REPLACEMENT

Figure 9
l++I

l. Negative cable assembly (2) from battery assembly
negative terminal.
2. Positive cable assembly (1) from battery assembly
positive terminal.
3. Battery hold-down retainer bolt/screw (5) and
battery hold-down retainer (9).
4. Battery assembly (3).
l++I
Install or Connect

section.
1. Battery assembly (3).
2. Battery hold-down retainer (9) and battery holddown retainer bolt/screw (5).
l~I
Tighten
Battery hold-down retainer bolt/screw (5) to

18 Nm (13 lb. ft.).
3. Positive cable assembly (1) to battery assembly
positive terminal.
l~I
Tighten
Positive cable assembly (1) to 15 Nm

(11 lb. ft.).
BATIERY 601-9
2
-
1 CABLE ASSEMBLY, BATTERY POSITIVE

5 BOLT/SCREW, BATTERY HOLD-DOWN RETAINER,
18 Nm (13 LB. FT.)
9 RETAINER, BATTERY HOLD-DOWN
23 TRAY ASSEMBLY, BATTERY
!vtEWA
PC0004-6D1-F-RP
Figure 9 - Battery Assembly
4. Negative cable assembly (2) to battery assembly

negative terminal.
!~I Tighten
Negative cable assembly (2) to 15 Nm
(11 lb. ft.).
BATTERY CABLE ASSEMBLY

REPLACEMENT AND ROUTING
Whenever battery cable assemblies are replaced,
always be certain to use a replacement battery c~~le
assembly that is the same type and length. Some positive
cable assemblies have additional feed wires attached to
them and some negative cable assemblies have additional
ground straps attached.
Always be certain when replacing a battery cable
assembly to route it the same as the one being replaced.
Negative Cable Assembly

Figures 10 and 11

1. Battery assembly. Refer to "Battery Assembly
2. Nut (8) and negative cable assembly (2) from stud
(7) on wheelhouse assembly.

4. Using a standard screwdriver, pop open cable
assembly clip (16) and remove negative cable
assembly (2).
5. Negative cable assembly (2) from engine block.
On 3.4L L32 engines, negative cable assembly
(2) is connected to engine block by a stud
threaded into engine block just behind crankshaft pulley assembly. Remove nut (10) and
then remove negative cable assembly (2).
On 5. 7L LTl engines, negative cable assembly
(2) is connected to the engine block by either
a stud (13) or nut (10) just behind the air
conditioning compressor assembly. Remove
stud ( 13) or nut ( I 0) and negative cable assembly (2).

NOTICE: See "Notice" on page 6Dl-1 of this
section
1. Negative cable assembly (2) to engine block.
On 3.4L L32 engines, connect negative cable
assembly (2) and nut (10) to engine block stud
just behind crankshaft pulley.
On 5.7L LTl engines, connect negative cable
assembly (2) and either stud (13) or nut (10) to
engine block just behind air conditioning
compressor assembly.
60110 BATTERY
l~I
Nut (10) to 22 Nm (16 lb. ft.).

or
Stud (13) to 33 Nm (24 lb. ft.).
2. Place negative cable assembly (2) back into cable
assembly clip ( 16) and snap clip closed.
3. Lower vehicle.
4. Negative cable assembly (2) and nut (8) to stud (7)
on wheelhouse assembly.
l~I
Tighten
Nut (8) to 5.5 Nm (49 lb. in.).

Positive Cable Assembly

Figures 10 and 11
l++I
may be damaged during installation of positive

cable assembly and cause starter to fail later.
Tighten

2. Positive cable assembly (1) from junction block.
A. Open junction block cover (4 ).
B. Remove nut (6) from stud (14).
C. Remove positive cable assembly ( l) from stud
(14).
3. Positive cable assembly (1) from generator assembly (21).
A. Move boot covering connection and slide out
of way.
B. Remove positive cable assembly (1).
On 3.4L L32 engines, positive cable
assembly ( 1) is connected to generator
assembly (21) with nut (18). Remove nut
(18) and positive cable assembly (1 ).
On 5.7L LTl engines, positive cable
assembly (1) is connected to generator
assembly (21) with bolt/screw (20).
Remove bolt/screw (20) and positive
cable assembly (1).
5. Using a standard screwdriver, pop open cable
assembly clip (16) and remove positive cable
assembly (1).
6. Bolt/screw (11) securing positive cable assembly (1)
and clip ( 17) to engine mount bracket.
7. Nut ( 12) and positive cable assembly ( 1) from starter
solenoid switch ( 19).
NOTICE: Before installing positive cable assembly
to starter solenoid switch, be sure solenoid terminal
is secure in cap by tightening terminal nut next to
cap. If terminal is not tight in solenoid cap, the cap
l++I
Install or Connect

section.
1. Positive cable assembly (1) and nut (12) to starter
solenoid switch (19).
l~I
Tighten
Nut (12) to 9.5 Nm (84 lb. in.).

2. Bolt/screw ( 11) and clip ( 17) securing positive cable
assembly to engine mount bracket.
l~I
Tighten

3. Place positive cable assembly (1) back into cable
assembly clip (16) and snap clip (16) closed.
4. Lower vehicle.
5. Positive cable assembly (1) to generator assembly
(21).
On 3.4L L32 engines, positive cable assembly
(1) is connected to the generator assembly (21)
with nut (18).
l~I
Tighten
Nut (18) to 10 Nm (89 lb. in.).

On 5.7L LTl engines, positive cable assembly
( 1) is connected to generator assembly (21)
with bolt/screw (20).
l~I
Tighten

6. Carefully slide boot over positive cable assembly ( 1)
and generator assembly (21) connection.
7. Positive cable assembly ( 1) to junction block.
A. Place positive cable assembly (1) and nut (6)
on stud (14).
l~I
Tighten
Nut (6) to 2.0 Nm (18 lb. in.).

B. Close junction block cover (4).
Route positive cable assembly between heater
hoses as shown in Figure 11.
GROUND STRAPS
Additional ground straps are used to connect the
body and frame to the engine and transmission. Always
connect all ground straps to ensure a good ground path to
the battery assembly from all electrical components
CHARGING EQUIPMENT
A battery charger that is considered sufficient is
usually capable of a 16-volt output. When choosing
BATIERV 601-11
!VIEWB
A
B
C
1
2
3
4
6
7
8
10
11
12
13
14
15
16
17
19
3.4L L32 ENGINE

A
5.7L LT1 ENGINE
BLOCK, ENGINE
CABLE ASSEMBLY, BATIERY POSITIVE
CABLE ASSEMBLY, BATIERY NEGATIVE
BATIERY ASSEMBLY, STORAGE
COVER, JUNCTION BLOCK
NUT, BATIERY POSITIVE CABLE-TO-JUNCTION
BLOCK, 2.0 Nm (18 LB. IN.)
STUD, GROUND
NUT, BATIERY NEGATIVE CABLE GROUND,
5.5 Nm (49 LB. IN.)
NUT, BATIERY NEGATIVE CABLE-TO-ENGINE BLOCK
GROUND, 22 Nm (16 LB. FT.)
BOLT/SCREW, BATIERY POSITIVE AND NEGATIVE
CABLE ASSEMBLY CLIP, 10 Nm (89 LB. IN.}
NUT, BATIERY POSITIVE CABLE, 9.5 Nm (84 LB. IN.)
STUD, BATIERY NEGATIVE CABLE-TO-ENGINE BLOCK
GROUND, 33 Nm (24 LB. FT.)
STUD, JUNCTION BLOCK POSITIVE TERMINAL
CLIP, CABLE ASSEMBLY
SWITCH, STARTER SOLENOID
c
B
PC0005-6D1 -F-RP
Figure 1O- Battery Cable Assemblies Routing (1 of 2)
601-12 BATIERY
15
A
A
B
1
3
11
12
15
16
17
18
20
21
22
3.4L L32 ENGINE

5.7L LT1 ENGINE
CABLE ASSEMBLY, BATTERY POSITIVE
BATTERY ASSEMBLY, STORAGE
BOLT/SCREW, BATTERY POSITIVE AND NEGATIVE
CABLE ASSEMBLY CLIP, 10.Nm (89 LB. IN.)
NUT, BATTERY POSITIVE CABLE, 9.5 Nm (84 LB. IN.)
NUT, ENGINE WIRING HARNESS GENERATOR LEAD,
10 Nm (89 LB. IN.)
BOLT/SCREW, ENGINE WIRING HARNESS GENERATOR
LEAD, 15 Nm (11 LB. FT.)
GENERATOR ASSEMBLY
HOSE ASSEMBLY, HEATER INLET/OUTLET
PC0006-6D1-F-RP
Figure 11 - Battery Cable Assemblies Routing (2 of 2)
BATIE RY 601 -13

a charger, the following items should be considered
essential:
l. A 16-volt minimum output.
2. To prevent overcharging, the unit should have a

timer ( l to 2 hours) or a voltage regulator that would
regulate a maximum of 18 volts, or have an automatic shut-off feature at full charge.
3. Ammeter or charging rate meter.
4. An automatic polarity protector.

Some equipment that is available includes the AC
Delco MP2101-07, Associated No. 6001, the Sun 720, or
equivalent. Very few chargers have sensitive low-voltage
meters, therefore, separate voltmeters may be necessary.
A suitable load tester such as the Sun VAT-40 (or
equivalent) is available and is a very useful tool to
properly diagnose battery assembly problems.
SPECIFICATIONS
BATTERY ASSEMBLY USAGE
STORAGE BATTERV ASSEMBLV USAGE CHART
CATALOG NUMBER
TEST
LOAD
AMPS
COLD
CRANKING
AMPS*
RESERVE
CAPACITY
MINUTES**
REPLACEMENT
NUMBER
514 (Std. LT1, L32)
260
525
90
75-60
*Cold Cranking= Amperage available for 30 seconds of engine cranking at-18'C (O'F).
**Reserve Capacity= The approximate time in minutes a storage battery assembly can support a 25 amp load
without the terminal voltage dropping below 10.5 volts at 27'C (BO'F) in the event of a charging system failure.
PC0007-6D1-F-RP

Battery Hold-Down Retainer Bolt/Screw ................................. 18 Nm (13 lb. ft.)
Battery Negative Cable Assembly-to-Battery Assembly ..................... 15 Nm (11 lb. ft.)
Battery Negative Cable Ground Body-to-Nut ............................ 5.5 Nm (49 lb. in.)
Battery Negative Cable-to-Engine Block Nut ............................. 22 Nm (16 lb. ft.)
Battery Negative Cable-to-Engine Block Stud ............................. 33 Nm (24 lb. ft.)
Battery Positive and Negative Cable Retainer Bolt/Screw .................... 10 Nm (89 lb. in.)
Battery Positive Cable Assembly-to-Battery Assembly ...................... 15 Nm (11 lb. ft.)
Battery Positive Cable-to-Generator Bolt/Screw ........................... 15 Nm (11 lb. ft.)
Battery Positive Cable-to-Generator Nut ................................. 10 Nm (89 lb. in.)
Battery Positive Cable-to-Junction Block Nut ............................ 2.0 Nm (18 lb. in.)
Battery Positive Cable-to-Starter Solenoid Switch Nut ..................... 9.5 Nm (84 lb. in.)
601-14 BATIERY
SPECIAL TOOLS
1.
J 38758
2.
ST-1201
1. PARASITIC DRAW TEST SWITCH

2. BATTERY SIDE TERMINAL ADAPTERS (PAIR)
PC0010-6D1 -F-RP
CRANKING SYSTEM 602-1
SECTION 602
CRANKING SYSTEM
negative cable assembly to help prevent personal injury and/or damage to the vehicle or
components. Unless instructed otherwise, the ignition switch must be in the "OFF" or
"LOCK" position.
result.
CONTENTS
General Description . . . . . . . . . . . . . . . . . . . . . . . 602-1
Cranking Circuit . . . . . . . . . . . . . . . . . . . . . . . 602-1
.Starte~ Motor Assembly . . . . . . . . . . . . . . . . . . 602-1
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 602-1
Lubrication ............................ 602-2
Starter Motor Assembly Replacement ....... 602-2
Unit Repair .............................. 602-5
Starter Solenoid Switch Replacement ....... 602-5
No-Load Test . . . . . . . . . . . . . . . . . . . . . . . . . . 602-7
PG-250 Starter Motor Assembly
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . 602-9
SD210 Starter Motor Assembly
Disassembly ........................ 602-10
Cleaning, Inspection and Testing (PG-250 and

SD210 Starter Motor Assemblies) . . . . . . . 602-10
Checking Pinion Clearance (PG-250 and
SD210 Starter Motor Assemblies) ....... 602-12
PG-250 Starter Motor Assembly .......... 602-13
SD210 Starter Motor Assembly ........... 602-14
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . 602-15
Starter Motor Assembly Usage Chart ...... 602-15
Fastener Tightening Specifications . . . . . . . . 602-16
General Specifications . . . . . . . . . . . . . . . . . . 602-16
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . 602-16
GENERAL DESCRIPTION
relay will send battery voltage to the starter solenoid

switch. The starter solenoid switch will move the starter
shift lever, causing the starter drive pinion to engage the
flywheel ring gear. After engagement, the starter solenoid
switch will close the main contacts, which results in
cranking of the engine. When the engine starts, pinion
overrun protects the armature from excessive speed until
the switch is opened, at which time the solenoid switch
plunger spring causes the pinion to disengage. To prevent
excessive overrun, the ignition switch should be opened
immediately when the engine starts.
CRANKING CIRCUIT
The cranking circuit consists of the battery assembly, starter motor assembly, ignition switch, control circuits, starter enable relay and related electrical wiring;
these components are connected electrically. Refer to
SECTION 8A for a complete electromechanical
schematic.
STARTER MOTOR ASSEMBLY

Figure 1
When the ignition switch is moved to the start position, battery voltage is applied to the PASS-Key II
decoder module and resistance is read at this time. If
proper resistance is recognized and vehicle is in "PARK"
or "NEUTRAL," then the PASS-Key II decoder module
will energize the starter enable relay. The starter enable
DIAGNOSIS
Before removing any unit in a cranking circuit for
repair, perform the diagnostic procedures recommended
in Figures 2, 3 and 4, and in SECTION 8A. Then check
the following items:
6022 CRANKING SYSTEM
1
2
3
4
5
6
7
8
9
10
11
12
CONTACT, STARTER SOLENOID SWITCH

PLUNGER, STARTER SOLENOID SWITCH
SPRING, STARTER SOLENOID SWITCH PLUNGER
LEVER, STARTER SHIFT
BUSHING, STARTER DRIVE
COLLAR, STARTER DRIVE STOP
DRIVE, STARTER
COIL, ST ARTER FIELD
ARMATURE, STARTER
BRUSH.STARTER
TERMINAL, STARTER SOLENOID
Figure 1 - Starter Motor Assembly (Typical)
NOTICE: Never operate the starter motor assembly

more .than 30 seconds at a time without pausing to
allow it to cool for at least two minutes. Overheating, caused by excessive cranking, will seriously
damage the starter motor assembly.
Battery Assembly: Determine condition of battery assembly. Follow testing procedure outlined in SECTION 6Dl.
Wiring: Inspect wiring for damage. Inspect all connections to starter motor assembly, solenoid switch, ignition switch, and battery assembly, including all ground
connections. Clean and tighten all connections as
required.
Ignition Switch and Control Circuits: Inspect
all switches and relays to determine condition.
Cranking or Slow Cranking: If engine assembly
does not crank, or cranks slowly, follow diagnostic procedure in Figures 2, 3 and 4, and in SECTION 8A. If faulty
starter motor assembly is diagnosed, remove starter motor
assembly and follow test procedures.
Starter Motor Assembly Noise: Correct starter
motor assembly noise using the following procedure:
1. Refer to Figure 4 to determine problem.
2. Shims are not installed during vehicle assembly.
However if complaint is similar to problem 1 or 2 in
Figure 4, correct "shimming" as follows:
ON-VEHICLE SERVICE
LUBRICATION
Starter motor assemblies do not require lubrication
except during overhaul. When the starter motor assembly
is taken apart for any reason, lubricate only as described
under "PG-250 Starter Motor Assembly" or "SD210
Starter Motor Assembly" in this section.
STARTER MOTOR ASSEMBLY

REPLACEMENT
Figures 5 and 6

[I] Important
For starter motor assembly noise during cranking, add one 0.38 mm (0.015 inch) single shim
(13 or 18) to outer bolt/screw only. Refer to
Figure 5.
For high-pitched whine after engine assembly
fires, add 0.38 mm (0.015 inch) double shims
(14 or 19) until noise disappears. Number of
shims should not exceed 1.14 mm (0.045 inch).
Starter Motor Assembly: General diagnosis is

part of starter motor assembly testing procedure. If battery
assembly, wiring and switches are in satisfactory condition, engine assembly is functioning properly, and problem has been traced to starter motor assembly, remove
starter motor assembly (refer to "Starter Motor Assembly
Replacement" in this section) and proceed to "Unit
1.
2.
3.
4.
This vehicle was designed for starter mounting

without shims. However if single shims (13 or
18) or double shims (14 or 19) have been
added to correct a noise or engagement condition, they should be reinstalled in their original
location to ensure proper pinion-to-flywheel
assembly engagement. Refer to Figure 6.
602-1 of this section.
Exhaust crossover pipe at the manifolds. Refer to
SECTION 6F.
Two starter mounting bolts/screws (16 and 17 or 21)
and lower starter motor assembly (15 or 20).
NO CRANKING, NO SOUND FROM SOLENOID
TURN HEADLAMPS AND DOME LAMP ON.

TURN KEY TO "START."
I
I
LAMPS DIM OR GO OUT.
CHECK BATTERY ST ATE-OF-CHARGE.
EYE DARK
I
I
GREEN EYE SHOWING
LAMPS STAY BRIGHT.
TURN ON RADIO AND HEATER.
OPERATE OK
DON'T OPERATE
CHARGE BATTERY
ASSEMBLY.
CHECK FOR DRAIN
AND CHECK
GENERATOR ASSEMBLY.
CHECK CRANKING
VOLTAGE AT
BATTERY POSTS.
I
9.6 VOLTS OR MORE
LESS THAN 9.6 VOLTS

TEST BATTERY
ASSEMBLY.
IF OK, REPAIR STARTER
MOTOR ASSEMBLY.
CHECK BULKHEAD CONNECTOR, FUSIBLE LINK

AND IGNITION SWITCH
CONNECTIONS.
CHECK CONNECTIONS
ANDVOLTAGEAT
SOLENOID "S" TERM.
CHECK VOLT AGE FROM

ENGINE BLOCK ASSEMBLY
TO BATTERY NEGATIVE POST. KEY IN
"START" POSITION. (POSITIVE LEAD
ON ENGINE BLOCK ASSEMBLY).
0. 5 VOLT OR MORE
LESS THAN 0.5 VOLT
LESS THAN 7 VOLTS
7 VOLTS
OR MORE
I
REPAIR STARTER
MOTOR ASSEMBLY.
WITH KEY IN "START", CHECK VOLTAGE AT

IGNITION SWITCH SOLENOID TERMINAL.
CLEAN AND TIGHTEN

GROUND CABLE
CONNECTION AND/OR
REPLACE CABLE ASSEMBLY.
CHECK CRANKING
VOLT AGE AT ST ARTER
"B" TERMINAL.
LESS THAN 9 VOLTS
9 VOLTS OR MORE
CLEAN AND TIGHTEN

BATTERY POSITIVE
CABLE TERMINALS
AND/OR REPLACE
CABLE ASS EMBLY.
CHECK FUSIBLE LINK

AND BULKHEAD
CONNECTOR.
I 7 VOLTS OR MORE I
REPAIR WIRE FROM

IGNITION SWITCH.
LESS THAN 7 VOL TS
11
REPLACE IGNITION
SWITCH.
PC0002-6D2-BRP
Figure 2 - Electrical System General Diagnosis (1 of 2)
602-4 CRANKING SYSTEM
SLOW CRANKING. SOLENOID CLICKS OR CHATTERS

CHECK: BATTERY ASSEMBLY FOR GREEN INDICATOR.
VISUAL CONDITION OF BATTERY CABLE ASSEMBLIES AND
CONNECTIONS.
IF BATTERY ASSEMBLY NEEDS CHARGING, MAKE GENERA TOR AND
BATTERY DRAIN CHECK, CHARGE BATTERY ASSEMBLY AND CHECK
CRANKING. IF PROBLEM HAS NOT BEEN FOUND, DO THE FOLLOWING:
I
REMOVE BATTERY LEAD FROM DISTRIBUTOR OR IGNITION MODULE.
MAKE ALL VOLTMETER READINGS WITH KEY IN "START" POSITION.
I
MEASURE CRANKING VOLTAGE AT BATTERY TERMINAL POSTS.
9.6 VOLTS OR MORE.
LESS THAN 9.6 VOL TS.
MEASURE VOLTAGE FROM BATTERY

NEGATIVE TERMINAL TO ENGINE
BLOCK ASSEMBLY. (POSITIVE LEAD
ON ENGINE BLOCK ASSEMBLY.)
CHARGE AND LOAD TEST

BATTERY ASSEMBLY.
I
I
0. 5 VOLT OR MORE.
LESS THAN 0.5 VOLT.
OK
REPAIR GROUND
CABLE AND
CONNECTIONS.
MEASURE VOLTAGE
AT SOLENOID "B"
TERMINAL, CLEAN
AND TIGHTEN
CONNECTIONS
AT STARTER
MOTOR ASSEMBLY.
REPAIR
STARTER
MOTOR
ASSEMBLY.
9 VOL TS OR MORE.
LESS THAN 9 VOLTS.
FAULTY
REPLACE
BATTERY
ASSEMBLY.
REPAIR ST ARTER
MOTOR ASSEMBLY.
CLEAN AND TIGHTEN POSITIVE CABLE CONNECTIONS

IF OK, REPLACE CABLE.
THIS PROCEDURE IS DESIGNED FOR USE ON

ENGINE AND BATTERY ASSEMBLIES
AT ROOM OR NORMAL OPERATING TEMPERATURES.
IT ALSO ASSUMES THERE ARE NO ENGINE ASSEMBLY
DEFECTS WHICH WOULD CAUSE CRANKING PROBLEMS.
TO USE IT UNDER OTHER CONDITIONS MIGHT RESULT
IN AN IMPROPER DIAGNOSIS.
PC0003-6D2-BRP
Figure 3 - Electrical System General Diagnosis (2 of 2)
CRANKING SYSTEM 6025
PROBLEM
CAUSE
1.
HIGH PITCHED WHINE DURING CRANKING

(BEFORE ENGINE FIRES} BUT ENGINE CRANKS
AND FIRES OK.
DISTANCE TOO GREAT BETWEEN ST ARTER DRIVE

PINION AND FLYWHEEL ASSEMBLY.
2.
HIGH PITCHED "WHINE" AFTER ENGINE

FIRES, AS IGNITION KEY IS BEING
RELEASED. ENGINE CRANKS AND FIRES OK.
THIS INTERMITTENT COMPLAINT IS OFTEN
DIAGNOSED AS "STARTER HANG-IN" OR
"SOLENOID WEAK."
DISTANCE TOO SMALL BETWEEN ST ARTER DRIVE

PINION AND FLYWHEEL ASSEMBLY. FLYWHEEL
ASSEMBLY RUNOUT CONTRIBUTES TO THE
INTERMITTENT NATURE.
3.
A LOUD "WHOOP" AFTER THE ENGINE

FIRES BUT WHILE THE STARTER DRIVE
PINION IS STILL HELD ENGAGED. SOUNDS
LIKE A SIREN IF THE ENGINE IS REVVED
WHILE STARTER DRIVE PINION IS
ENGAGED.
A NEW STARTER DRIVE ASSEMBLY WILL OFTEN

CORRECT THIS PROBLEM.
4.
A "RUMBLE," "GROWL" OR (IN SEVERE

CASES} A "KNOCK" AS THE STARTER
MOTOR ASSEMBLY IS COASTING DOWN TO
A STOP AFTER STARTING THE ENGINE.
MOST PROBABLE CAUSE IS A BENT OR

UNBALANCED STARTER ARMATURE. A NEW
ST ARTER ARMATURE WILL OFTEN CORRECT THIS
PROBLEM.
PC6004-6D2-D-RP
Figure 4 - Starter Motor Assembly Noise Diagnosis
5. Electrical leads from starter motor assembly

(15 or 20).
Note position of wires before disconnecting.
6. Starter motor assembly ( 15 or 20).

section.
NOTICE: Before attaching electrical leads, tighten
inner nuts on the solenoid terminals. If the nuts are
not tight, solenoid cap may be damaged during
installation of leads. Tighten inner nut of "BAT"
terminal to 9 Nm (80 lb. in.) on both PG-250 and
SD210 starter motor assemblies.
1. Electrical leads to starter motor assembly ( 15 or 20).
l~I
Tighten
Starter solenoid switch "BAT" terminal outer

nut to 9 Nm (80 lb. in.).
Starter solenoid switch "S" terminal nut to
2.5 Nm (22 lb. in.).
2. Starter motor assembly (15 or 20) to engine
assembly.
3. Bolts/screws (16 and 17 or 21 ).
l~I
Tighten
Bolts/screws (16 and 17 or 21) to 47 Nm

(35 lb. ft.).
l@I Measure
Pinion-to-flywheel clearance (see Figure 6).
Add shims (13 and 14 or 18 and 19) if
necessary.
4. Exhaust crossover pipe to the manifolds. Refer to

SECTION 6F.
5. Lower vehicle.
l~I
Tighten
Battery negative cable assembly to 15 Nm

(11 lb. ft.).
UNIT REPAIR
STARTER SOLENOID SWITCH
REPLACEMENT
5.7L LT1 Engine
Figure 7
When a "no crank and no sound" starter motor
assembly condition exists, check solenoid switch (23)
before disassembling starter motor assembly. Solenoid
switch (23) can be checked without removal. Refer to
"Cleaning, Inspection and Testing" in this section. Solenoid switch (23) must be replaced with drive housing
(36). For removal and installation procedures, refer to
"PG-250 Starter Motor Assembly Disassembly" and
"PG-250 Starter Motor Assembly" in this section.
3.4L L32 Engine
Figure 8

1. Starter solenoid switch nut (61).
2 Field lead from solenoid switch "M" terminal.
3. Nuts (62) and solenoid switch heat shield (71).
4. Starter solenoid switch clamp bolts/screws (63) and
clamp (66).
5. Starter solenoid switch (56).
13
17
1,
18
A
B
13
14
15
16
17
18
19
20
21
5.7L LT1 ENGINE

3.4L L32 ENGINE
SHIM, STARTER MOTOR SINGLE
SHIM, STARTER MOTOR DOUBLE
BOLT/SCREW, STARTER MOTOR, 47 Nm (35 LB. FT.)
SHIM, STARTER MOTOR SINGLE
SHIM, STARTER MOTOR DOUBLE
21
PC0005-6D2F-RP
Figure 5 - Mounting Starter Motor Assembly
l++I
Install or Connect

section.
1. Starter solenoid switch (56).
2. Clamp (66) and starter solenoid switch clamp
bolts/screws (63).
84
l~I
85
Tighten
Starter solenoid switch clamp bolts/screws

(63) to 11 Nm (97 lb. in.).
3. Solenoid switch heat shield (71) and nuts (62).
A INSERT 0.5 mm (0.20") WIRE

GAGE HERE TO CHECK
85 PINION, STARTER DRIVE
l~I
PC000&-602-B-RP
Figure 6 - Flywheel Assembly-to-Pinion Clearance
Tighten
Nuts (62) to 8 Nm (71 lb. in.).

23
28
'+c
40
26
37
41
42
.,.....-@'
llll~~V!O
...._ _ __,,)).....,l)J-- -
--
38
A
B
C
23
24
25
26
27
28
29
30
31
32
SHAFT
CLUTCH, STARTER DRIVE
DRIVE AND SHAFT ASSEMBLY, STARTER
DRIVE ASSEMBLY, STARTER
BEARING, STARTER DRIVE SHAFT DRIVE END
ARMATURE, STARTER
BEARING, COMMUTATOR END BALL
SHIELD, PLANETARY GEARS
SHAFT AND GEAR ASSEMBLY
BUSHING
GEAR, INTERNAL TOOTH
NUT, STARTER SOLENOID SWITCH OUTER, 8 Nm
(71 LB. IN.)
.

RETAINER, STARTER DRIVE STOP COLLAR
COLLAR, STARTER DRIVE THRUST
HOUSING, STARTER DRIVE
FRAME AND FIELD
HOLDER ASSEMBLY, BRUSH
SPRING, BRUSH
FRAME, STARTER COMMUTATOR END
BOLT/SCREW, BRUSH HOLDER ATIACHMENT, 6.5 Nm
(58 LB. IN.)
42 THROUGH-BOLT/SCREW, STARTER, 8.5 Nm (75 LB. IN.)
43 PIN, SHIFT COLLAR
44 TUBE, DRAIN
33
34
35
36
37
38
39
40
41
PC0007-6D2F-RP
Figure 7 - PG-250 Starter Motor Assembly Disassembled View
NOTICE: Before attaching field lead, tighten inner

nut on the solenoid switch "M" terminal. If inner
nut is not tight, solenoid cap may be damaged during
installation of outer nut. Tighten inner nut on the
solenoid switch "M" terminal to 9 Nm (80 lb. in.).
4. Field lead to solenoid switch "M" terminal.
5. Starter solenoid switch outer nut (61).
l~I
Tighten
Starter solenoid switch outer nut (61) to

10 Nm (89 lb. in.).
NO-LOAD TEST
Figure 9
With carbon pile "OFF," make connections as
shown in Figure 9. Close the switch, adjust carbon pile to
obtain 10 volts, and compare the RPM, current and voltage readings with "Specifications" listed at the end of
this section.
Make disconnections only with the switch open.

Use the test results as follows:
1. Rated current draw and no-load speed indicates normal starter motor assembly condition.
2. Low free speed and high current draw indicates:
Too much friction. This can be caused by tight,
dirty or worn bearings, or bent armature shaft
allowing armature to drag.
Shorted armature. This can be further checked
on growler after disassembly.
Grounded armature or fields. Check further
after disassembly.
3. Failure to operate with high current draw indicates:
Direct ground in terminal or fields.
"Frozen" bearings (this should have been
determined by hand turning armature).
4. Failure to operate with no current draw indicates:
Open field circuit. After disassembly inspect
internal connections and tracing circuit with
test lamp.
54
51
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70
71
72
73
FRAME, STARTER COMMUTATOR END

BEARING, STARTER ARMATURE COMMUTATOR END
FRAME KIT, STARTER WITH FIELD
ARMATURE, STARTER
HOUSING, STARTER DRIVE
BEARING, STARTER DRIVE SHAFT DRIVE END
LEVER, STARTER SHIFT
RETAINER. STARTER DRIVE STOP COLLAR
COLLAR, STARTER DRIVE THRUST
NUT, STARTER SOLENOID SWITCH OUTER,
10 Nm (89 LB. IN.)
NUT, STARTER MOTOR ASSEMBLY HEAT SHEILD,
8 Nm (71 LB. IN.)
BOLT/SCREW, STARTER SOLENOID SWITCH CLAMP,
11 Nm (97 LB. IN.)
WASHER, STARTER ARMATURE BRAKE COMMUTATOR
END
BOLT/SCREW, COMMUTATOR END FRAME,
8.5 Nm (75 LB. IN.)
CLAMP, STARTER SOLENOID SWITCH
PLUG, STARTER SHIFT LEVER RETAINER
PLUNGER, STARTER SOLENOID SWITCH
RETAINER, STARTER SHIFT LEVER
SHIELD, STARTER DRIVE HOUSING
SHIELD, STARTER MOTOR ASSEMBLY HEAT
SPRING, STARTER SOLENOID SWITCH PLUNGER
TUBE, STARTER DRAIN
PC00086D2-F-RP
Figure 8 - SD21 O Starter Motor Assembly Disassembled View

22
A---.;.......j
23
OR
56
E
A
B
C
D
E
15
20
22
23
56
15
OR
CARBON PILE
AMMETER
VOLTMETER
SWITCH
RPM INDICATOR
MOTOR ASSEMBLY, STARTER (PG-250)
MOTOR ASSEMBLY, STARTER (50210)
SWITCH, STARTER SOLENOID (PG250)
SWITCH, STARTER SOLENOID (50210)
20
PC0009-6D2-F-RP
Figure 9 - No-Load Test
Open armature coils. Inspect commutator for

badly burned bars after disassembly.
Broken brush springs, worn brushes, high
insulation between commutator bars or other
causes which would prevent good contact
between brushes and commutator.
5. Low no-load speed and low current draw indicates:
High internal resistance due to poor connections, defective leads, dirty commutator and
causes listed above under number 4.
6. High free speed and high current draw usually indicate shorted fields. If shorted fields are suspected,
replace field coil assembly. Also check for shorted
armature, using growler.
PG-250 STARTER MOTOR ASSEMBLY

DISASSEMBLY
Figures 7 and 10
Tool Required:
J 28509-A Counter Gear Bearing Remover
!+!+! Disassemble
1. Field lead from solenoid switch terminal by removing nut (32).
2. Through-bolts/screws (42).
3. Bolts/screws (41) and end frame (40) from starter
motor assembly. Brush holder assembly (38) and
bearing (27) remain on armature (26).
CAUTION: Magnets in frame and field

have strong attraction to armature.
Keep fingers clear of pinch points to
avoid personal injury.
4. Armature (26) from frame and field (37).
5. Frame and field (37) and shield (28) from housing
(36).
6. Bearing (27) from armature (26), using J 28509.
A. Bearing (27) is press-fit over shaft.

NOTICE: Before removing brush holder assembly,
lift each brush spring and rest against side of brush;
this prevents brush damage or contamination when
brush holder assembly is pulled off of commutator.
7. Brush holder assembly (38) from armature (26).
8. Slightly separate shaft and gear assembly (29) and
drive assembly (24) from housing (36) and use a
screwdriver to pry plastic shift lever off of pins ( 43).
9. Shaft and gear assembly (29) and drive assembly
(24) from housing (36).
10. Collar (35) from shaft.
11. Slide deep socket over shaft and tap socket to drive
collar (33) off of retainer (34 ).
12. Retainer (34), collar (33) and drive assembly (24)
from shaft.
13. Gear (31) and bushing (30) from shaft and gear
assembly (29). Bushing (30) is press-fit into gear
(31), and should only be removed if damaged.
CLEANING, INSPECTION AND TESTING

(PG-250 AND SD210 STARTER MOTOR
ASSEMBLIES)
NOTICE: Do not use grease dissolving solvents for

cleaning the overrunning clutch or armature. Solvents dissolve the grease packed in the clutch and
damage armature and field coil insulation.
1. Clean all starter motor assembly parts. Wipe parts
with a clean shop cloth.
2. Test drive assembly (24 or 53) action. Pinion should
turn freely in overrunning direction. Check pinion
teeth for chipping, cracking or excessive wear.
Replace drive assembly (24 or 53) if necessary.
Badly chipped pinion teeth may indicate chipped
teeth on ring gear; replace if necessary.
26 ARMATURE, STARTER
27 BEARING, COMMUTATOR END BALL
38 HOLDER ASSEMBLY, BRUSH
PC0010-6D2-F-RP
Figure 10 - Removing Commutator End Ball Bearing
SD210 STARTER MOTOR ASSEMBLY

DISASSEMBLY
Figures
!+!+I Disassemble
1. Nuts (62) and heat shield (71), if equipped, from
clamp bolts/screws (63).
2. Nut (61) and field lead from solenoid switch (56).
3. Clamp bolts/screws (63) and solenoid switch (56)
with clamp (66) from drive housing (54).
4. Bolts/screws (65) from starter motor assembly.
5. Commutator end frame (49), brake washer (64), and
frame kit (51) from armature (52) and drive housing
(54).
6. Plug (67) from drive housing (54).
7. Armature (52) with drive assembly (53), shift lever
(57), plunger (68), and return spring (72) from drive
housing (54).
8. Return spring (72) from plunger (68).
9. Plunger (68) from shift lever (57).
10. Shift lever (57) from drive housing (54) by spreading lever arms slightly to disengage.
11. Thrust collar (60) from armature shaft.
12. Retainer (59) by pushing pinion stop collar (58) off
of retainer (59) and sliding it off of armature shaft.
Discard retainer (59).
13. Pinion stop collar (58) and drive assembly (53) from
armature shaft.
3. On SD210 starter motor assembly, check drive

assembly (53) for slipping by leaving drive assembly (53) attached to armature (52). Wrap armature
(52) with shop towel and clamp in vice. Using
12-point deep socket and torque wrench, put socket
on pinion and turn counterclockwise. Drive should
not slip up to 68 Nm (50 lb. ft.) of torque. If it does,
replace drive assembly (53).
4. Starter drive assembly (24 or 53) requires no
lubrication; however, drive assembly (24 or 53)
should be wiped clean.
5. Inspect armature commutator. If commutator is
dirty, clean with 400 grit polishing cloth. If commutator is rough, replace armature (26 or 52). Do not
undercut or turn commutators. Inspect points where
armature conductors join commutator bars to make
sure they have good connection. Burned commutator bar is usually evidence of poor connection
6. Inspect brushes and brush holder assemblies. When
brushes appear excessively worn when compared to
new brushes they should be replaced. Make sure
brush holder assemblies are clean and brushes are
not binding in brush holder assemblies. Full brush
surface should ride on commutator to give proper
performance.
Check to ensure that brush springs are giving
firm contact between brushes and commutor.
When brush springs are distorted or discolored, they should be replaced.
- On PG-250 starter motor assembly, brush
holder (38) and springs (39) are available
as separate items.
- On SD210 starter motor assembly, all
brush and brush holder parts are part of
the frame kit (51).
7. If test equipment is available:
A. Check armature (26 or 52) for short circuits by
placing on growler and holding hacksaw blade
over armature core while armature is rotated. If
saw blade vibrates, armature (26 or 52) is
shorted. Replace armature (26 or 52).
A SERIES COIL CONNECTION

B SELF POWERED TEST LIGHT
C INSULATED BRUSH
PC1010-6D2-B-RP
Figure 12 - Testing Series Coil for Open

A
B
24
26
29
31
43
LUBRICATED GEAR TEETH

GEAR, STARTER ARMATURE
ARMATURE, STARTER
SHAFT AND GEAR ASSEMBLY
GEAR, INTERNAL TOOTH
PIN, SHIFT COLLAR
THIS TERMINAL MUST

NOT TOUCH
GROUND
DURING TEST
PC00116D2-F-RP
Figure 11 - Starter Armature and Starter Drive Assembly
B. On SD210 starter motor assembly, check field

windings by using self-powered test lamp.
Place one lead on field lead terminal and other
lead on one insulated brush. If lamp fails to
light, series coil is open and will require repair
or replacement. Perform this test for each insulated brush to check brush and lead continuity
(Figure 12).
C. On SD210 starter motor assembly, using selfpowered test lamp, place one lead on grounded
brush holder assembly and other lead on either
insulated brush. If lamp lights, grounded series
coil is indicated and frame kit (51) must be
replaced (Figure 13).
D. Check armature (26 or 52) for grounds using a
self-powered test lamp. Place one lead on commutator and other lead on armature core or
shaft. If lamp lights, armature (26 or 52) is
grounded and must be replaced.
A SELF-POWERED TEST LAMP

B HOLDER, STARTER INSULATOR BRUSH
C HOLDER, STARTER GROUND BRUSH
PC0017-6D2FRP
Figure 13 - Testing Series Coil for Ground

E. Check current draw of solenoid windings as
follows:
a. If solenoid switch (23 or 56) is not
removed from starter motor assembly,
field lead must be removed from "M"
terminal on solenoid switch (23 or 56)
before making these tests. Complete tests
in minimum of time to prevent overheating of solenoid switch (23 or 56).
b. To check hold-in winding, connect
ammeter in series with 12-volt battery
and "S" terminal on solenoid switch (23
or 56). Connect voltmeter to "S" terminal and to ground. Connect carbon pile
across battery. Adjust voltage to 10 volts
and note ammeter reading. Reading
should be 10 to 20 amperes.
c. To check both windings, connect as for

previous test. Ground solenoid "M" terminal. Adjust voltage to 10 volts and note
ammeter reading. Reading should be 60
to 85 amperes.
II] Important
Current will decrease as windings heat up.
Current draw readings that are over specifications indicate shorted turns or a
ground in the windings of the solenoid
switch (23 or 56) and the solenoid switch
(23 or 56) should be replaced. No or low
current draw readings that are under
specifications indicate excessive resistance. A zero reading indicates an open
circuit. Check connections, then replace
solenoid switch (23 or 56) if necessary.
8. On SD210 starter, solenoid switch (56) is serviced as
an assembly. On PG-250 starter, solenoid switch (23)
and drive housing (36) are serviced as an assembly.
Checking Pinion Clearance (PG-250 and

SD210 Starter Motor Assemblies)
Figure 15
NOTICE: When the starter motor assembly has

been disassembled or the solenoid switch has been
replaced, it is necessary to check the pinion clearance. Starter motor assembly may not engage properly if pinion clearance is incorrect.
l@I
Measure
Pinion clearance as follows:
CAUTION: Keep fingers, tools, and

other objects away from opening in
drive housing while making electrical
connections during this procedure.
The strong shifting action of the solenoid switch could cause personal
injury or damage as the drive pinion
moves into cranking position.
A
B
C
D
F
22
CARBON PILE
AMMETER
VOLTMETER
SWITCH
GROUND
PC00126D2-a-RP
Figure 14 - Testing Solenoid Windings
A. Secure starter motor assembly in vise or equivalent fixture so that opening in drive housing is
accessible for measurement.
B. Disconnect field lead from solenoid switch
"M" terminal and insulate it carefully.
C. Connect one 12-volt battery lead to solenoid
switch ''S" terminal and the other to starter
frame.
D. Flash jumper lead momentarily from solenoid
switch "M" terminal to starter frame. This will
shift pinion into cranking position and it will
remain so until battery is disconnected.
E. Push pinion back as far as possible to take up
any movement, and check clearance with
feeler gage. Clearance should be 0.25 mm to
4.06 mm (0.010 inch to 0.160 inch).
F. Means for adjusting pinion clearance is not
provided on starter motor assembly. If clearance does not fall within limits, check for
improper installation and replace all worn
parts.
G. Disconnect 12-volt battery leads from solenoid
switch "S" terminal and starter frame.
H. Reconnect field lead. Refer to "Starter Motor
Assembly PG-250" or " Starter Motor Assembly SD210" in this section.
22
24
OR
85
5~
33
OR
58
..._0.25 mm TO 4.06 mm
(0.010" TO 0.160")
PINION
CLEARANCE
c
A
B
C
22
24
LEAD, FIELD (DISCONNECTED)

MOMENTARY GROUND
GAGE, FEELER
DRIVE ASSEMBLY, STARTER (PG-250)
33
53
58
85
COLLAR, STARTER DRIVE STOP (PG-250)

DRIVE ASSEMBLY, STARTER (50210)
COLLAR, STARTER DRIVE STOP (50210)
PINION, STARTER DRIVE
PC0013-602-F-RP
Figure 15 - Electrical Connections and Checking Pinion Clearance
PG-250 STARTER MOTOR ASSEMBLY
5. New retainer (34) into groove on shaft. Do not reuse

old retainer (34).
6. Collar (35) to end of shaft with flange toward

retainer (34). Use pliers as shown in Figure 16 to
snap collar (33) over retainer (34).
lll 1nspect
Bushing (30), bearing (25), shaft and gear assembly
(29) and bearing (27). When dry, bushing (30), and
shaft and gear assembly (29) may be lightly lubricated with GM lubricant 10497186 or equivalent.
Bearings (25 and 27) are permanently lubricated do not add lubricant. If dry, replace the bearings
(25 and 27). Replace bushing or bearings when
damaged.
l+!+I Assemble
1.
2.
3.
4.
section.
Bearing (25) to drive housing (36). Press bearing
(25) to 0.35 mm (0.014 inch) below face of casing.
Refer to Figure 17.
Lubricate gear (31), planetary gear of the shaft and
gear assembly (29), and armature shaft gear teeth
lightly with GM lubricant 10497186 or equivalent.
Refer to Figure 11.
Gear (31) and drive assembly (24) over shaft and
gear assembly (29) with pinion away from armature
(26).
Collar (33) onto shaft.
7. Drive assembly (24) and shaft and gear assembly

(29) into housing (36).
Use screwdriver to gently guide shift lever
over pins (43) on drive assembly (24).
8. Shield (28) and frame and field (37) into housing
(36).
ll"l'I Inspect
Brushes. Replace if damaged or excessively
worn.
9. Brush holder assembly (38) onto armature (26).
Release brushes onto commutator by sliding
springs to ends of brushes.
10. Bearing (27) onto armature (26) by pressing on inner
race until bearing (27) rests against shoulder on
armature shaft.
CAUTION: Magnets in frame and field

have strong attraction to armature.
Keep fingers clear of pinch points to
avoid personal injury.
11. Armature (26) to frame and field (37).

12. End frame (40) to brush holder assembly (38) using
bolts/screws (41).
l~.J
Tighten
Bolts/screws (41) to 6.5 Nm (58 lb. in.)

l~I
Tighten
Through-bolts/screws
(75 lb. in.).
(42)
to
8.5
Nm
l@i I Measure
33
34
35
58
59
60
COLLAR, STARTER DRIVE STOP (PG-250)

RETAINER, STARTER DRIVE STOP COLLAR (PG-250)
COLLAR, STARTER DRIVE THRUST (PG-250)
COLLAR, STARTER DRIVE STOP (SD210)
RETAINER, STARTER DRIVE STOP COLLAR (SD210)
COLLAR, STARTER DRIVE THRUST (SD210)
PC0014-6D2-F-RP
Pinion clearance. Refer to "Checking Pinion

Clearance" in this section.
NOTICE: When installing electrical connections to
starter motor assembly, the inner nut on the solenoid
switch "M" terminal must be tightened before field
lead is installed. If inner nut is not tight, cap may be
damaged during installation of electrical connector.
l~I
Tighten
Starter solenoid switch "M" terminal inside

nut to 9 Nm (80 lb. in.).
14. Field lead to solenoid switch "M" terminal.
15. Nut (32).
l~I
Figure 16 - Installing Pinion Stop Collar
Tighten
Nut (32) to 8 Nm (71 lb. in.).
SD210 STARTER MOTOR ASSEMBLY

Figures 8 and 16
!+!+I Assemble
1.
2.
RECESS STARTER
DRIVE BEARING
0.35 mm (0.014")
INTO CASTING
3.
4.

section.
Drive assembly (53) onto armature shaft.
Pinion stop collar (58) onto armature shaft with flat
side toward drive assembly (53).
New retainer (59) onto armature shaft and slide it
down shaft until seated in shaft groove.
Thrust collar (60) onto armature shaft with flange
toward retainer (59).
Use two sets of pliers and squeeze pinion stop
collar (58) and thrust collar (60) to snap pinion
stop collar (58) onto retainer (59).
IL'l'I Inspect
25 BEARING, STARTER DRIVE SHAFT DRIVE END
36 HOUSING, STARTER DRIVE
PC0015-6D2-F-RP
Figure 17 - Starter Drive Shaft Drive End Bearing
End bearing (55). If bearing (55) has no

lubrication visible or appears damaged, replace
bearing (55).
Press bearing (55) from drive housing
(54) and then press in new bearing (55)
until recessed 1.6 mm (1/16 inch ) into
drive housing casting. Bearing (55) is
pre-lubricated and no additional lubrication is needed.

5. Shift lever (57) to drive assembly (53) by spreading
arms slightly.
6. Plunger (68) to other end of shift lever (57) by
snapping into place.
7. Armature shaft into end bearing (55) while sliding
lever retainer (69) into slot in drive housing (54).
8. Plug (67) into slot in drive housing (54).
9. Return spring (72) over plunger (68).
10. Solenoid switch (56) with clamp (66) to drive
housing (54).
Align motor terminal and solenoid switch (56)
with field lead.
11. Clamp bolts/screws (63).
l~I
Tighten
Clamp bolts/screws (63) to 11 Nm (97 lb. in.).
l~I
Clean
Contact surface of frame kit brushes and

armature commutator with soft cloth.
12. Frame kit (51) onto armature (52) and drive housing
(54) by pushing in and holding brushes and aligning
notch in frame kit (51) with locator on drive housing
(54). When in place, release brushes and make sure
they move freely and contact commutator.
ll'l'I
Inspect
Bearing (50) in commutator end frame (49). If

bearing (50) has no visible lubrication or
13.
14.
15.
16.
appears damaged, press in a new bearing (50)

until recessed 2 mm (0.08 inch) into commutator end frame (49). Bearing (50) is pre-lubricated and no additional lubrication is needed.
Washer (64) onto armature shaft.
Commutator end frame (49) onto armature shaft and
seat into frame kit (51).
Identification tag over bolt/screw hole in commutator end frame (49) with fluted end around bearing
well.
Bolts/screws (65) to starter motor assembly.
l~I
Tighten

NOTICE: Before attaching electrical leads, tighten
inner nuts on solenoid switch terminals. If nuts are
not tight, solenoid cap may be damaged during
installation of leads. Tighten inner nuts on "S" terminal to 2.5 Nm (22 lb. in.). Tighten inner nut at
"BAT" terminal to 10 Nm (89 lb. in.).
17. Nut (61) to solenoid switch (56).
l~I
Tighten
Nut (61) to 10 Nm (89 lb. in.).

18. Heat shield (71) and nuts (62) onto protruding ends
of clamp bolts/screws (63).
l~I
Tighten
Nuts (62) to 8 Nm (71 lb. in.).
SPECIFICATIONS
STARTER MOTOR ASSEMBLY USAGE CHART
3.4L L32 Engine
Starter Type ................................................................. SD210
No-Load Test at 10 Volts
Amps-Minimum ............................................................. 45
Amps-Maximum ............................................................. 75
RPM at Drive Pinion
Minimum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6,000
Maximum .............................................................. 11,000
Starter Solenoid Switch
Hold-in Windings at 10 Volts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-20 Amps
Both Windings at 10 Volts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-85 Amps
5. 7L LTl Engine
Starter Type ................................................................. PG-250
No-Load Test at 10 volts
Current . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65-95 Amps
Starter Drive Pinion Speed ........................................... 2750-3250 RPM
Starter Solenoid Switch
Hold-in Windings at 10 Volts ............................................. 10-20 Amps
Both Windings at 10 Volts ............................................... 60-85 Amps

Battery Negative Cable Assembly ...................................... 15 Nm (11 lb. ft.)
Starter Motor Assembly Heat Shield Nut .................................. 8 Nm (71 lb. in.)
Starter Motor Brush Holder Bolt/Screw (PG-250) ......................... 6.5 Nm (58 lb. in.)
Starter Motor Commutator End Frame Bolt/Screw ........................ 8.5 Nm (75 lb. in.)
Starter Solenoid Switch "BAT" Terminal Inner Nut ......................... 9 Nm (80 lb. in.)
Starter Solenoid Switch "BAT" Terminal Outer Nut ......................... 9 Nm (80 lb. in.)
Starter Solenoid Switch Clamp Bolt/Screw ............................... 11 Nm (97 lb. in.)
Starter Solenoid Switch Inner Nut ....................................... 9 Nm (80 lb. in.)
Starter Solenoid Switch Outer Nut (PG-250) ............................... 8 Nm (71 lb. in.)
Starter Solenoid Switch Outer Nut (SD210) ............................... 10 Nm (89 lb. in.)
Starter Solenoid Switch "S" Terminal Nut .............................. 2.5 Nm (22 lb. in.)
Starter Through-Bolt/Screw (PG-250) .................................. 8.5 Nm (75 lb. in.)
Pinion Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.25 mm to 4.06 mm (0.010" to 0.160")
SPECIAL TOOLS
1.
J 28509-A
1. COUNTER GEAR BEARING REMOVER

PC6016-6D2-D-RP
CHARGING SYSTEM 603-1
SECTION 603
CHARGING SYSTEM
CAUTION: This vehicle is equiped with Supplemental Inflatable Restraint (SIR). Refer to
Location view in SECTION 9J before performing service on or around SIR components or
negative cable to help prevent personal injury and/or damage to the vehicle or components.
Unless instructed otherwise, the ignition switch must be in the "OFF" or "LOCK" position.
result.
CONTENTS
General Description . . . . . . . . . . . . . . . . . . . . . . . 603-1
Charging Circuit . . . . . . . . . . . . . Refer to Section 8A
CS-130 and CS-144 Generator Assemblies ... 603-1
Diagnosis ............................... 603-2
CS Generator Assembly
On-Vehicle Check .................... 603-2
CS Generator Assembly Bench Check ...... 603-2
Generator Assembly Replacement .......... 603-3
CS-130 105-Amp Generator Assembly
(3.4L L32 Engine) .................. 603-3

(5.7L LTl Engine) .................. 603-6
Unit Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 603-6
(3.4L L32 Engine) . . . . . . . . . . . . . . . . . . . . 603-6
CS-144 124-Amp Generator Disassembly,
Test and Reassembly (5.7L LTl Engine) .. 603-6
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . 603-11
Generator Assembly Usage Chart ......... 603-11
Fastener Tightening Specifications . . . . . . . . 603-12
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . 603-12
GENERAL DESCRIPTION
tor assemblies instead of, or in addition to, the "L" terminal which must be stepped down. The "S" terminal may
be connected to an external voltage source, such as voltage near the battery assembly, for voltage control. If the
"S" terminal is not used, internal generator voltage is
used for control.
CHARGING CIRCUIT
Refer to SECTION 8A for operation and additional
charging circuit diagnosis.
CS-130 AND CS-144 GENERATOR

ASSEMBLIES
The charging system generator assemblies use a
built-in voltage regulator with fault detection, a stator,
rectifier bridge, and rotor with slip rings and brushes. A
conventional pulley and fan is used to cool the slip ring
end frame, rectifier bridge and voltage regulator.
These generator assemblies use only two connections - battery positive and "L" terminal, in addition to
the ground path through the generator bracket. Use of
"P," "I" and "S" terminals is optional. The "P" terminal
is connected to the stator and may be connected externally
to a tachometer or other device. The "I" terminal can be
connected directly to battery voltage to power the genera-
The voltmeter reads battery voltage when the engine

is not running and reads charging system voltage when the
engine is running. The normal indication is between 11
volts and 16 volts.
The regulator voltage setting varies with temperature and limits system voltage by controlling rotor field
current. While the field current is "on," this regulator
actually switches rotor field current on and off at a fixed
frequency of about 400 cycles per second to help control
radio noise. By varying the overall on-off time, correct
average field current for proper system voltage control
can be obtained. At high speeds, the on-time may be 10
percent and the off-time 90 percent. At low speeds, with
high electrical loads, on-off time may be 90 percent and
10 percent respectively.
603-2 CHARGING SYSTEM
DIAGNOSIS
CS GENERATOR ASSEMBLY ON-VEHICLE
CHECK
Tool Required:
J 34029-A Digital Multimeter
When the CS charging system is operating normally,
the voltmeter will read between 11 volts and 16 volts
when the engine is running. If the voltmeter operates
abnormally, or if an undercharged or overcharged battery
assembly condition occurs, the following procedure may
be used to diagnose the charging system. Remember that
an undercharged battery assembly is often caused by
accessories being left on overnight, or by a hood or instrument panel compartment lamp that stays on.
Noise from a generator assembly may be caused by a
loose drive pulley, loose mounting bolts/screws, worn or
dirty bearings, faulty diode or faulty stator.
To avoid damage to the electrical equipment, always
observe the following precautions:
Do not reverse connections to generator assembly.
Do not short across or ground any of the terminals in
charging circuit, except as directed by instructions.
NEVER disconnect generator "BAT" terminal with
generator assembly operating.
When connecting charger or booster battery assembly to battery assembly, refer to SECTION 601.
In some vehicles, voltmeter may be used instead of
indicator lamp. In this case, steps 1 through 4 pertaining to faulty indicator lamp operation, should be
omitted from troubleshooting procedure.
Do not attempt to disassemble CS-130 generator
assembly. Damage to generator assembly could
result.
Trouble in the charging system will show up as one
or more of the following conditions:
Faulty voltmeter operation.
Undercharged battery assembly, as evidenced by
slow cranking or dark hydrometer.
Overcharged battery assembly, as evidenced by
spewing of electrolyte from vents or a yellow
hydrometer.
To diagnose the CS-130 or CS-144 charging system,
use the following procedure:
rn
Important
Only the CS-144 generator assembly may be

repaired.
1. Visually check serpentine drive belt and wiring.
2. Battery assembly unden:harged or overcharged
(voltage lower than 11 volts or higher than 16 volts).
A. Detach wiring harness connector from generator assembly.
B. With ignition switch "ON" and engine assembly not running, connect J 34029-A as voltmeter from ground to "L" terminal in wiring
harness connector. Connect to "F" or "I" ter-
minal for gage equipped vehicles. At least one

terminal should have battery voltage.
C. Zero volts indicates open circuit between terminal and battery assembly. Correct as
required.
D. Reconnect harness connector to generator
assembly.
CAUTION: Disconnect battery negative

cable assembly before installing or
removing a series-type ammeter at generator battery terminal.
CAUTION: See "Caution"
on
page
E. Install ammeter at generator output terminal.

With load off, install carbon pile load test
across battery terminals. Start engine assembly
and run at moderate speed.
F. Measure voltage across battery assembly,

using J 34029-A. If voltage is above 16 volts,
replace or repair generator assembly.
G. Turn on accessories and load battery assembly
with carbon pile to obtain maximum generator
assembly output. Maintain voltage at 13 volts
or above. Use ammeter to check amperage.
Compare output to ampere rating in "Specifications" at the end of this section.
If within 15 amps ofrated output, generator assembly is OK.
If not within 15 amps of rated output,
repair or replace generator assembly.
CS GENERATOR ASSEMBLY BENCH

CHECK
Figure 1
Tool Required:
J 34029-A Digital Multimeter

The following bench check may be used to simulate
operation on a vehicle. Use the bench check to verify
operation of a CS-144 generator assembly that has been
repaired.
l. Mount generator assembly in suitable test stand
according to test stand manufacturer's instructions.
Test stand must be capable of driving generator
assembly at 6,500 rpm.
2. Make connections as shown in Figure 1. Be sure carbon pile is turned off. Ground polarity of generator
assembly and battery assembly must be same. Battery assembly must be fully charged. Use a 30-500
ohm resistor between battery assembly and ''L'' terminal of generator assembly.
3. Slowly increase generator assembly speed and
observe voltage using J 34029-A.
GENERATOR ASSEMBLY REPLACEMENT

B
CS-130 105-AMP Generator Assembly

(3.4L L32 Engine)
Figure2

1. Battery negative cable assembly from battery terminal.

2. Serpentine drive belt. Refer to SECTION 6A2A or
6A3A.
3. Battery positive cable assembly from generator
"BAT" terminal.
4. Electrical connector from generator assembly (5).

D
A
B
C
D
E
5
6
CARBON PILE
VOLTMETER
RESISTOR (30-5000)
AMMETER
CONNECTOR RESISTOR TO "L" TERMINAL
GENERATOR ASSEMBLY
PC6001-603-0-RP
Figure 1 - Generator Assembly Bench Check
5. Nuts (2 and 25) and bolt/screw (21).

6. Generator rear inner brace ( 1).
8. Generator assembly (5) from accessory mounting
bracket (7).

Important
The battery assembly must be fully charged

when making this test.
4. If voltage is uncontrolled and increases above 16
volts, repair or replace generator assembly.
5. If voltage is below 16 volts, increase speed and connect and adjust carbon pile to obtain maximum
amperage output. Maintain voltage above 13 volts.
6. Use ammeter to check amperage. If output is within
15 amp ofrated output, generator assembly is good.
7. If output is not within 15 amps of rated output, repair
or replace generator assembly.
Important
Only the CS-144 generator assembly may be

repaired.
ON-VEHICLE SERVICE
The CS generator assembly does not require periodic lubrication. The rotor shaft is mounted on permanently lubricated bearings. At periodic intervals, check
mounting bolts/screws for tightness and check serpentine
drive belt tension. Refer to SECTION 6A2A or 6A3A.
I. Generator assembly (5) to accessory mounting

bracket (7).
l~I
Tighten

3. Generator rear inner brace (1).
4. Nuts (2 and 25) and bolt/screw (21).
l~I
Tighten
Nut (2) to 25 Nm (18 lb. ft.).

Nut ((25) to 50 Nm (37 lb. ft.).
5. Electrical connector to generator assembly (5).
6. Battery positive cable assembly to generator "BAT"
terminal.
l~I
Tighten
Cable nut to 20 Nm (15 lb. ft.).

6A3A.
8. Battery negative cable assembly to battery terminal.
6034 CHARGING SYSTEM
1 BRACE, GENERATOR REAR INNER

2 NUT, GENERATOR BRACE, 25 Nm (18 LB. FT.)
5 GENERATOR ASSEMBLY
7 BRACKET, ACCESSORY MOUNTING
9 BOLT/SCREW, GENERATOR REAR BRACE,
25 Nm (18 LB. FT.)
17 BOLT/SCREW, GENERATOR, 50 Nm (37 LB. FT.)
25 NUT, GENERATOR, 50 Nm (37 LB. FT.)
PC0001-6D3-FRP
Figure 2 - CS-130 105-Amp Generator Assembly Mounting (3.4L L32 Engine)
CHARGING SYSTEM 6035
10
5 GENERATOR ASSEMBLY
7 BRACKET, ACCESSORY MOUNTING
9 BOLT/SCREW, GENERATOR REAR BRACE,
50 Nm (37 LB. FT.)
10 BRACE ASSEMBLY, GENERATOR REAR OUTER
12 NUT, GENERATOR REAR BRACE, 33 Nm (24 LB. FT.)
PC00026D3FRP
Figure 3 - CS-144 124-Amp Generator Assembly Mounting (5.7L LT1 Engine)
l~I
!++I
Tighten
Battery negative cable bolt/screw to 15 Nm

(11 lb. ft.).

(5.7L LT1 Engine)
Figure 3
l++I
Install or Connect

1. Generator assembly (5) to accessory mounting
bracket (7).
2. Generator rear outer brace ( 10).
3. Nut (12) at generator rear outer brace (10).
l~I

1. Battery negative cable assembly from battery terminal.
6A3A.
3. Lower vehicle.
4. Battery positive cable assembly from generator
"BAT" terminal.
5. Electrical connector from generator assembly (5).
6. Bolts/screws (9, 17 and 21) at generator assembly
(5).
7. Nut (12) at generator rear outer brace (10).
8. Generator rear outer brace (10).
9. Generator assembly (5) from accessory mounting
bracket (7).
Tighten
Nut (12) to 33 Nm (24 lb. ft.).

4. Bolts/screws (9, 17 and 21) at generator assembly
(5).
l~I
Tighten

5. Electrical connector to generator assembly (5).
6. Battery positive cable assembly to generator "BAT"
terminal.
l~I
Tighten
Cable nut to 20 Nm (15 lb. ft.).

6A3A.
9. Battery negative cable assembly to battery terminal.
l~I
Tighten
Battery negative cable bolt/screw to 15 Nm

(11 lb. ft.).
UNIT REPAIR
CS-130105-AMP GENERATOR ASSEMBLY
(3.4L L32 Engine)
NOTICE: Do not attempt to disassemble a CS-130
generator assembly. Damage to the generator assembly could result. The CS-130 generator assembly is
replaced as a complete assembly.
CS-144124-AMP GENERATOR
DISASSEMBLY, TEST AND REASSEMBLY
(5.7L LT1 Engine)
l+!+I
A "P" "L" "I" "S" TERMINALS
26 THROUGH-BOLT/SCREW, GENERATOR
27 TERMINAL, GENERATOR BATTERY
PC6003-6D3-D-RP
Figure 4 - Generator Through-BolVScrew Location
Disassemble
l. Make scribe marks on slip ring end frame (43) and
drive end frame (59) to ease reassembly.
2. Through-bolts/screws (26) and separate slip ring end
frame (43) and drive end frame (59).
3. End frame bearing (28) from rotor shaft.
A OHMMETER CHECK FOR GROUNDS

B OHMMETER CHECK FOR SHORTS AND OPENS
C RING, SLIP
D RING, SLIP
31 ROTOR.GENERATOR
32
33
34
35
36
57
BOLT/SCREW, REGULATOR ATTACHING

REGULATOR, GENERATOR VOLTAGE
HOLDER, GENERATOR BRUSH
NUT, STATOR LEAD ATTACHIN~
STATOR.GENERATOR
BOLT/SCREW, GENERATOR BRUSH HOLDER
PC6005-6D3-D-RP
PC6004-6D3-D-RP
Figure 6 - Generator Slip Ring End Frame View
Figure 5 - Testing Generator Rotor
l@I Measure
Rotor (31) for grounds, opens and shorts (Figure 5).
rn
Important
Test should be performed at approximately

21 C (70F). A different temperature may
result in inaccurate ohmmeter readings.
A Connect ohmmeter to slip ring and clean

metal grounding surface on frame of
rotor (31) to check for grounds.
Ohmmeter should read infinity
(open). If not, replace rotor (31).
B. Connect ohmmeter to both slip rings to

check for shorts and opens.
Ohmmeter should read 1. 7 to 2.1
ohms. If not, replace rotor (31 ).
4. Nuts (35).
5. Stator (36) from slip ring end frame (43).
l@I Measure
Stator (36) for grounds (Figure 7).
A Connect ohmmeter to stator terminal and
to clean metal ground on laminations.
A
B
C
36
OHMMETERCHECKFORGROUNDS
TERMINAL, GENERATOR STATOR
LAMINATIONS
STATOR.GENERATOR
PC6006-6D3-D-RP
Figure 7 - Testing Generator Stator
6038 CHARGING SYSTEM
38
A
B
C
32
33
34
38
CONNECTION, SOLDERED
CONNECTION, SOLDERED
STRAP, REGULATOR ATTACHING
HOLDER,GENERATORBRUSH
STRAP, REGULATOR CONNECTOR
A
B
C
D
39
53
OHMMETER
SINK, GROUNDED HEAT
SINK, INSULATED HEAT
STRAP, GENERATOR CAPACITOR
CAPACITOR, GENERATOR
BRIDGE, GENERATOR RECTIFIER
PC6007-603-D-RP
PC6008-6D3-D-RP
Figure 8 - Removing Generator Voltage Regulator and

Generator Brush Holder
6.
7.
8.
9.
B. If ohmmeter reading is low, replace stator

(36). Stator (36) cannot be checked for
opens and shorts with ohmmeter.
Unsolder connections at connector strap (38) and
brush holder (34) to voltage regulator (33).
Bolt/screw (32) and bolt/screw (57).
Voltage regulator (33) and brush holder (34) with
dust shield (60) from slip ring end frame (43).
Tap plastic retaining pin from dust shield
retaining clip. Be sure to keep pin for reassembly.
Brushes (41) and dust shield (60) from brush holder
(34).
IW:,I
Clean
Brushes (41) with soft, dry cloth.
1@1 Measure
Rectifier bridge (53) for continuity (Figure 9).
A. Connect ohmmeter to grounded heat sink
and flat metal clip at rectifier bridge (53).
B. Reverse leads. One reading should be
high (open) and one low (continuity). If
both readings are the same, replace rectifier bridge (53).
Figure 9 - Testing Generator Rectifier Bridge
10.
11.
12.
13.
14.
15.
16.
17.
18.
C. Repeat test between grounded heat sink

and clips at two other bridge terminals.
D. Repeat test between insulated heat sink
and at bridge terminals.
Capacitor (39) and rectifier bridge (53).
Washers (55) and bolts/screws (56 and 58).
Bearing (28) from slip ring end frame (43) by pushing through to inside.
Nut (49), using hex wrench to hold rotor shaft
Washer (47), pulley (48), fan collar (46), fan (45)
and outside collar (50).
Rotor (31) from drive end frame (59).
Inside collar (52) from rotor (31).
Bolts/screws (51) and retainer (42).
Bearing (44).
l+!+I Assemble
NOTICE: See "Notice" on page 6D3-1 of this section.
1. Be~ring (44) in drive end frame (59) by pushing
agamst outer race.
Bearing (44) is double sealed; no additional
lubricant is required.
2. Retainer (42) and bolts/screws (51).
3. Inside collar (52) onto rotor (31 ).
42 RETAINER, GENERATOR ROTOR DRIVE END BEARING

44 BEARING, GENERATOR ROTOR DRIVE END
45 FAN.GENERATOR
46 COLLAR, GENERATOR ROTOR DRIVE END FAN
47 WASHER, GENERATOR ROTOR SHAFT DRIVE END
48 PULLEY, GENERATOR
49 NUT, GENERATOR ROTOR SHAFT DRIVE END, 100 Nm
(75 LB. FT.)
50 COLLAR, GENERATOR ROTOR DRIVE END BEARING

OUTSIDE
51 BOLT/SCREW, GENERATOR ROTOR DRIVE END

BEARING RETAINER
52 COLLAR, GENERATOR ROTOR DRIVE END BEARING

INSIDE
59 FRAME, GENERATOR DRIVE END

PC6010-6D3-D-RP
Figure 1O- Generator Rotor Drive End Bearing
4. Rotor (31) to drive end frame (59).

5_ Outside collar (50), fan (45), fan collar (46), pulley
(48) and washer (47) onto rotor shaft.
6. Nut (49).
l~I
Tighten
Nut (49) to 100 Nm (75 lb. ft.).

7. Bearing (28) into slip ring end frame (43) from outside, until flush with outside shoulder of slip ring
end frame (43).
8. Slip ring end frame electrical components.
rn
Important
Installation of the slip ring end frame electrical

components must be done in the following
order to insure proper operation of the unit.
Assembly in any other manner will result in
either no output from generator assembly (5)
or a direct internal ground in the generator
assembly (5).
A Rectifier bridge (53)_
B. Capacitor (39).
C. Washers (55).
D. Bolts/screws (56 and 58)_
rn
Important
The capacitor (39) has an insulator material on one side which must rest against
the drive end frame (59) (ground)_
The capacitor/rectifier bridge insulated
attaching bolt/screw (58) must be
installed in the proper hole, attaching the
capacitor strap and rectifier bridge (53) to
the slip ring end frame (43).
E. Brushes (41) into brush holder (34) with
retaining pin (40).
F. Dust shield (60) onto brush holder (34).

G. Voltage regulator (33), and brush holder (34)
with dust shield (60), brushes (41) and retaining pin (40) installed into slip ring end frame
(43).
rn
Important
The metal side of the capacitor strap must

be against the regulator connection_
H. Tap plastic retaining pin on dust shield (60)

into retaining clip.
43
28
-0-
A
B
C
D
E
F
28
32
33
34
35
38
39
40
41
43
53
54
55
56
57
58
CLIPS, SOLDER
STRAP, GENERA TOR CAPACITOR
METALSIDE
INSULATED SIDE
PIN, PLASTIC RETAINING
CLIP, DUST SHIELD RETAINING
BEARING, GENERATOR ROTOR SLIP RING END FRAME
HOLDER, GENERATOR BRUSH
NUT, STATOR LEAD ATTACHING
STRAP, REGULATOR CONNECTOR
CAPACITOR, GENERATOR
PIN, BRUSH RETAINING
BRUSH.GENERATOR
FRAME, GENERATOR SLIP RING END
BRIDGE, GENERATOR RECTIFIER
NUT, GENERATOR BATTERY TERMINAL
WASHER, GENERATOR RECTIFIER BRIDGE
BOLT/SCREW, GENERATOR RECTIFIER BRIDGE
BOLT/SCREW, GENERATOR BRUSH HOLDER
BOLT/SCREW, GENERATOR CAPACITOR/RECTIFIER
BRIDGE
INSULATED ATTACHING
60 SHIELD, DUST
PC1010-6038-RP
Figure 11 - Generator Slip Ring End Frame Components
34
34
40
41
60
HOLDER,GENERATORBRUSH
PIN, BRUSH RETAINING
BRUSH.GENERATOR
SHIELD, DUST
PC6009-6D3-D-RP
Figure 12 - Generator Brushes Retained in Generator Brush Holder
Be sure brush retaining pin (40) goes

through access hole to outside of slip ring
end frame (43) for removal after generator is assembled.
I.
Bolt/screw (32) and bolt/screw (57).
J.
Connector strap (38) to voltage regulator solder clip, and brush holder connection to other
voltage regulator solder clip.
Crimp and solder voltage regulator solder
clip connections.
NOTICE: Avoid excessive heat when soldering
connections, as this can cause voltage regulator

damage.
K. Stator (36), placing stator terminals over rectifier bridge terminals.
L. Nuts (35).
M. Slip ring end frame (43) and drive end frame
(59), noting scribe marks.
N. Slip ring end bearing outer race into bearing
well in slip ring end frame casting.
P. Remove retaining pin (40) to release brushes
(41) against slip rings.
SPECIFICATIONS
GENERATOR ASSEMBLY USAGE CHART
ENGINE
EQUIPMENT
MODEL
RATED AMPERES
3.4L L32
ALL
CS-130
105
5.7L LTl
ALL
CS-144
124

CS 130 I05-Amp Generator Assembly (3.4L L32 Engine)
Battery Negative Cable Assembly-to-Battery Terminal .................... 15 Nm (11 lb.
Battery Positive Cable Assembly-to-Generator Nut ....................... 20 Nm ( 15 lb.
Generator-to-Accessory Mounting Bracket Bolt/Screw (Lower) ............. 50 Nm (37 lb.
Generator-to-Accessory Mounting Bracket Bolt/Screw (Upper) ............. 50 Nm (37 lb.
Generator-to-Generator Brace Bolt/Screw .............................. 25 Nm (18 lb.
Generator-to-Generator Brace Nut (Lower) ............................. 50 Nm (37 lb.
Generator-to-Generator Brace Nut (Upper) ............................. 25 Nm (18 lb.
CSl44 124-Amp Generator Assembly (5.7L LT! Engine)
Battery Negative Cable Assembly-to-Battery Terminal .................... 15 Nm (11 lb.
Battery Positive Cable Assembly-to-Generator Nut ....................... 20 Nm (15 lb.
Generator Outer Brace Mounting Nut ................................. 33 Nm (24 lb.
Generator Rotor Shaft Drive End Nut ................................ 100 Nm (75 lb.
Generator-to-Accessory Mounting Bracket Bolt/Screw (Lower) ............. 50 Nm (37 lb.
Generator-to-Accessory Mounting Bracket Bolt/Screw (Upper) ............. 50 Nm (37 lb.
Generator-to-Generator Lower Brace Bolt/Screw ........................ 25 Nm (18 lb.
Generator-to-Generator Upper Brace Bolt/Screw ......................... 50 Nm (37 lb.
ft.)
ft.)
ft.)
ft.)
ft.)
ft.)
ft.)
ft.)
ft.)
ft.)
ft.)
ft.)
ft.)
ft.)
ft.)
SPECIAL TOOLS
1 DIGITAL MULTIMETER
NC4003-6D3B-RP
IGNITION SYSTEM 6041
SECTION 604
IGNITION SYSTEM
CAUTION: Before removing or installing any electrical unit or when a tool or equipment
could easily come in contact with "live" exposed electrical terminals, disconnect the negative battery cable to help prevent personal injury and/or damage to the vehicle or components. Unless instructed otherwise, the ignition switch must be in the "OFF" or "LOCK"
position.
result.
CONTENTS
General Description .......................
Ignition System (5.7L LTl Engine) .........
Ignition System (3.4L L32 Engine) .........
Camshaft Position Sensor Assembly
(3.4L L32 Engine) ..................
24X Signal Crankshaft Position Sensor
Assembly (3.4L L32 Engine) ..........
3X Signal Crankshaft'Position Sensor
Assembly (3.4L L32 Engine) ..........
Spark Plug Wire Harness Assembly ........
Spark Plugs ...........................
Ignition Switch .........................
Knock Sensor System ...................
Ignition Timing ........................
Diagnosis ...............................
Ignition System ........................
Spark Plugs ...........................
Spark Plug Wire Harness Assembly ........
6D4- l
6D4-l
6D4-2
6D4-2
6D4-2
6D4-2
6D4-2
6D4-3
6D4-3
6D4-3
6D4-3
6D4-3
6D4-3
6D4-3
6D4-4
6D4-4
GENERAL DESCRIPTION
The ignition system controls fuel combustion by
providing a spark to ignite the compressed air/fuel mixture at the correct time. To provide improved engine performance, fuel economy, and control of exhaust
emissions, the engine control module (ECM) controls distributor spark advance (timing) with an ignition control
system.
IGNITION SYSTEM (5.7L LT1 ENGINE)

The 5.7L LTl engine ignition system consists of a
distributor assembly, control circuits for ignition timing in
the engine control module (ECM), a separate ignition
coil/ignition control module assembly, primary and secondary wiring, and the spark plugs. All ignition timing is
controlled by the ECM; there is no "bypass" mode built
into the ignition control module as in other ignition systems.
Service Precautions . . . . . . . . . . . . . . . . . . . . . 6D4-4

Spark Plug Wire Harness
Assembly Replacement ................ 6D4-5
Spark Plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . 6D4-5
Distributor (5.7L LTl Engine) ............. 6D4-6
Ignition Coil Assembly (5.7L LTl Engine) ... 6D4-7
Ignition Coil Assembly (3.4L L32 Engine) ... 6D4-8
Assembly (3.4L L32 Engine) ............ 6D4-8
Assembly (3.4L L32 Engine) ............ 6D4-8
(3.4L L32 Engine) .................... 6D4-9
Unit Repair .............................. 6D4-9
Ignition Coil and Ignition Coil Module
(5.7L LTl Engine) .................... 6D4-9
Ignition Coil Assembly (3.4L L32 Engine) .. 6D4-10
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . 6D4- l 1
Fastener Tightening Specifications . . . . . . . . 6D4-11
The distributor assembly is mounted directly to the

camshaft assembly next to the water pump assembly. It
directs the spark from the ignition coil assembly to the
proper spark plug secondary wire through a rotor. The
secondary output connectors in the distributor cap are
each connected to an individual spark plug. The connectors in the cap are arranged for convenience in routing
spark plug wire harness assemblies. The corresponding
cylinder number is molded into the distributor cap next to
each output connector.
The distributor assembly also contains a signal disk
and two optical camshaft position (CMP) sensor assemblies that provide signals to the ECM for timing control.
One CMP sensor assembly senses 360 equally-spaced
slots in the signal disk to provide 720 signals per camshaft
revolution for high-resolution timing control. The other
CMP sensor assembly senses eight disk slots of variable
length, providing a low-resolution signal that tells the
ECM which spark plug is being fired. Power for the optical CMP sensor assemblies, a system ground, and the two
604-2 IGNITION SYSTEM

CMP sensor assembly signals are transferred between the
ECM and the distributor assembly through a shielded harness connected to the four-terminal connector on the distributor.
The ignition system supplies two timing inputs to
the ECM, a high resolution signal (360 pulses per one
camshaft revolution) and a low resolution signal (eight
pulses per one camshaft revolution). The ECM can determine if one of the timing inputs is not being received by
comparing the two inputs. If the ECM detects one timing
pulse without detecting the other timing pulse, diagnostic
trouble code 16 will set.
The reference signals toggle between O and 5 volts
as the camshaft assembly turns. Therefore, an open, a
short to voltage, a short to ground, or a defective sensor
inside the distributor assembly can prevent the voltage
from pulsing at the ECM.
The ignition coil/ignition control module assembly
provides spark to the distributor assembly, timed by signals from the ECM. Power (B+) for the ignition coil primary circuit and the ignition control module is supplied
by the ignition switch. The ECM combines the camshaft
position information supplied by the distributor with other
system parameters and calculates the required spark
advance and coil dwell. The ECM signals the ignition
control module, which turns on the primary current to the
ignition coil by grounding the primary circuit, and then
turns it off by removing the ground. When the primary
current flow stops, high voltage induced in the ignition
coil secondary winding becomes the spark voltage for the
spark plug. The spark voltage is delivered to the distributor assembly through the coil output (secondary) wire,
and then directed to the proper spark plug connector by
the distributor rotor.
which are equally spaced (60 degrees apart). The seventh

slot is spaced 10 degrees from one of the other slots. As
the reluctor rotates with the crankshaft, the slots change
the magnetic field of the crankshaft position sensor
assembly, causing an induced voltage pulse.
By counting the time between pulses, the ignition
control module can recognize the pulse of the seventh slot
(sync pulse). Based on this sync pulse, the ignition control
module sends the reference signal to the ECM to calculate
crankshaft position (used to fire coils in correct sequence)
and engine speed.
To properly control timing, the ECM relies on the
following information:
Engine load (manifold pressure or vacuum).
Atmospheric (barometric) pressure.
Engine temperature.
Intake air temperature.
Crankshaft position.
Engine speed (rpm).
For further information refer to SECTION 6E3.
IGNITION SYSTEM (3.4L L32 ENGINE)
The 24X signal crankshaft position sensor assembly

is mounted to the engine front cover assembly and is partially behind the crankshaft balancer assembly. This sensor reads 24 notches in the crankshaft balancer assembly
for crankshaft position and is used for ignition control
during engine cranking and improved idle control. The
ECM uses the 24X signal crankshaft position sensor
assembly to improve spark accuracy at speeds below 1200
rpm, and influence fuel delivery at speeds below 2000
rpm. This is a hall-effect sensor. For additional information, refer to SECTION 6E3.
The 3.4L L32 engine ignition system uses a "waste

spark" method of spark distribution. Each cylinder is
paired with its opposing cylinder in the firing order, so
that one cylinder on compression fires simultaneously
with its opposing cylinder on exhaust. Since the cylinder
on the exhaust requires very little of the available voltage
to fire its plug, most of the voltage is used to fire the cylinder on compression. The process reverses when the cylinders reverse roles. There are three coils for this electronic
ignition (El) system.
Components of the EI system include an ignition
coil, ignition coil module, 3X signal crankshaft position
sensor assembly, camshaft position sensor assembly, 24X
signal crankshaft position sensor assembly, crankshaft
reluctor ring, crankshaft balancer assembly with interrupter rings, and the ECM. The coil pack consists of three
separate, interchangeable, ignition coils. The ignition coil
module is located above the power steering pump assembly and is connected to the ECM. The ignition coil module
controls the primary circuit to the coils, turning them on
and off.
This system also uses a magnetic crankshaft position
sensor assembly which protrudes into the engine block,
within approximately 1.27 mm (0.050 inch) of the crankshaft reluctor. The reluctor is a special wheel cast on the
crankshaft assembly that has seven machined slots, six of
Camshaft Position Sensor Assembly (3.4L

L32 Engine)
The camshaft position sensor assembly is located on
the engine block behind the water pump assembly near the
lower intake manifold assembly.
The camshaft position sensor assembly is used for
timing the injectors for sequential injection. This sensor is
a hall-effect type switch. Refer to SECTION 6E3 formore
information.

Assembly (3.4L L32 Engine)

The 3X signal crankshaft position sensor assembly
inserts through the right side of the engine block at midengine, near the crankshaft reluctor ring. Notches in the
crankshaft reluctor ring trigger the magnetic pickup sensor to provide timing information to the ECM. This is also
a hall-effect sensor. For additional information, refer to
SECTION 6E3.
SPARK PLUG WIRE HARNESS ASSEMBLY

The spark plug wire harness assemblies used with
both ignition systems use carbon impregnated cord conductors, encased in 8 mm (5/16-inch) diameter silicone
jackets. The silicone jackets withstand very high temperatures and also provide excellent insulation for the high
IGNITION SYSTEM 604-3

voltage of the system. Silicone spark plug boots form a
tight seal to the spark plugs.
SPARK PLUGS
For a complete explanation of the key and lock cylinder, and the actuator rod assembly, refer to SECTION
3F or SECTION 3F5B. For electrical switching information, refer to SECTION 8A.
Figure 1
KNOCK SENSOR SYSTEM
Resistor type, tapered seat spark plugs are used on

all engine assemblies. No gasket is used on these taperedseat spark plugs. Refer to SECTION OB for spark plug
type and gap size. When replacing spark plugs, use only
the type specified.
Normal service is assumed to be a mixture of idling,
slow speed, and high speed driving. Occasional or intermittent high-speed driving is needed for good spark plug
performance. It gives increased combustion heat, burning
away carbon or oxides that have built up from frequent
idling, or continual stop-and-go driving.
Spark plugs are protected by insulating nipples
made of special heat-resistant materials, which cover the
spark plug terminals and extend downward over a portion
of the plug insulators. These nipples prevent flash-over,
which causes engine misfiring. Do not mistake corona
discharge for flash-over, or a shorted insulator. Corona is a
steady blue light appearing around the insulator, just
above the shell crimp. It is the visible evidence of a hightension field and has no effect on ignition performance.
Usually it can be detected only in darkness. This discharge
may repel dust particles, leaving a clear ring on the insulator just above the shell. This ring is sometimes mistakenly
regarded as evidence that combustion gases have blown
out between shell and insulator.
The knock sensor system retards the spark advance

when detonation occurs. Further information is found in
SECTION 6E3.
IGNITION SWITCH
The mechanical key and lock cylinder ignition
switch is located in the steering column assembly on the
right-hand side, just below the steering wheel. The electrical switching portion of the assembly is separate from the
key and lock cylinder. However, both are synchronized
and work in conjunction through the action of the actuator
rod assembly.
A. TYPICAL IDENTIFICATION NUMBER
PC6012604-D-RP
Figure 1 - Spark Plug Identification
IGNITION TIMING
The base timing is preset when the engine is
manufactured, no adjustment is possible. Timing advance
and retard are accomplished through the ECM with ignition control and knock sensor systems.
DIAGNOSIS
IGNITION SYSTEM
Diagnosis for the ignition system is in SECTION
6E3.
SPARK PLUGS
Worn or dirty spark plugs may give satisfactory
operation at idling speed, but frequently fail at higher
rpm. Faulty spark plugs may cause poor fuel economy,
power loss, loss of speed, hard starting and generally poor
engine performance. Follow the scheduled maintenance
services recommendations given in SECTION OB, to
assure satisfactory spark plug performance.
Normal spark plug operation will result in brown to
grayish-tan deposits appearing on the portion of the spark
plug that projects into the cylinder area. A small amount
of red-brown, yellow, and white powdery material may
also be present on the insulator tip around the center electrode. These deposits are normal combustion by-products
of fuels and lubricating oils with additives. Some electrode wear will also occur.
Engine assemblies which are not running properly
are often referred to as "misfiring." This means the ignition spark is not igniting the fuel/air mixture at the proper
time. While other ignition and fuel system causes must
also be considered, possible causes include spark plug
conditions which allow the spark voltage to reach ground
in some other manner than by jumping across the air gap
at the tip of the spark plug, leaving the fuel/air mixture
unburned. Refer to SECTION 6E3. Misfiring may also
occur when the tip of the spark plug becomes overheated
and ignites the mixture before the spark jumps. This is
referred to as "pre-ignition."
Spark plug misfiring may be indicated in a number
of ways: poor fuel economy, power loss, loss of speed,
hard starting, and/or generally poor engine performance.
Worn or dirty plugs may give satisfactory operation at
idling speed, but will misfire under other operating conditions. Spark plugs may also misfire due to fouling, excessive gap, or a cracked or broken insulator. Should
misfiring occur before the recommended replacement
interval, locate and correct the cause.
Carbon fouling of the spark plug is indicated by dry,
black carbon (soot) deposits on the portion of the spark
plug in the cylinder. Excessive idling and slow speeds

under light engine loads can keep the spark plug temperatures so low that these deposits are not burned off. Overrich fuel mixtures or poor ignition system output may also
be the cause. Refer to SECTION 6E for diagnosis.
Oil fouling of the spark plug is indicated by wet oily
deposits on the portion of the spark plug in the cylinder,
usually with little electrode wear. This may be caused by
oil getting past worn piston rings. This condition also may
occur during break-in of new or newly overhauled engine
assemblies.
Deposit fouling of the spark plug occurs when the
normal red-brown, yellow or white deposits of combustion by-products become sufficient to cause misfiring. In
some cases, these deposits may melt and form a shiny
glaze on the insulator around the center electrode. If the
fouling is found in only one or two cylinders, valve stem
clearances or intake valve seals may be allowing excess
lubricating oil to enter the cylinder, particularly if the
deposits are heavier on the side of the spark plug that was
facing the intake valve.
Excessive gap means that the air space between the
center and side electrodes at the bottom of the spark plug
is too wide for consistent firing. This may be due to
improper gap adjustment or to excessive wear of the electrodes during use. A check of the gap size and comparison
to the gap specified for the vehicle in SECTION OB, will
tell if the gap is too wide. Excessive gap wear can be an
indication of continuous operation at high speeds or with
high engine loads, causing the spark plug to run too hot.
Another possible cause is an excessively lean fuel mixture.
Low or high spark plug installation torque or
improper seating can result in the spark plug running too
hot and cause excessive gap wear. The plug and cylinder
head seats must be in good contact for proper heat transfer
and spark plug cooling. Dirty or damaged threads in the
head or on the spark plug can keep it from seating even
though the proper torque is applied. Once spark plugs are
properly seated, tighten to torque shown under "Specifications" in this section. Low torque may result in poor
contact of seats due to a loose spark plug. Over-tightening
may cause spark plug shell to be stretched and also result
in poor contact between seats. In extreme cases, exhaust
blow-by and damage beyond simple gap wear may occur.
Cracked or broken insulators may be the result of
improper installation, damage during spark plug regapping, or heat shock to the insulator material. Upper insulators can be broken when a poorly fitting tool is used
during installation or removal, or when the spark plug is
hit from the outside. Cracks in the upper insulator may be
inside the shell and not visible. Also, the breakage may
not cause problems until oil or moisture penetrates the
crack later.
A broken or cracked lower insulator tip (around the
center electrode) may result from damage during regapping or from "heat shock" (spark plug suddenly operating too hot).
Damage during regapping can happen if the gapping
tool is pushed against the center electrode or the insulator
around it, causing the insulator to crack. When regapping
a spark plug, make the adjustment by only bending the

side electrode, keeping the tool clear of other parts.
"Heat shock" breakage in the lower insulator tip
generally occurs during severe engine operating conditions (high speeds or heavy loading) and may be caused
by over-advanced timing or low grade fuels. Heat shock
refers to a rapid increase in the tip temperature that causes
the insulator material to crack.
Spark plugs with less than the recommended amount
of service can sometimes be cleaned and regapped, then
returned to service. However, if there is any doubt about
the serviceability of a spark plug, replace it. Spark plugs
with cracked or broken insulators should always be
replaced.

Spark plug wire harness assemblies can be checked
by connecting an ohmmeter to the ends of each wire in
q~estion. If the meter reads over 30,000 ohms, replace the
wue.
ON-VEHICLE SERVICE
SERVICE PRECAUTIONS
Allow engine assembly to cool before removing
spark plugs. Attempting to remove spark plugs from
a hot engine assembly may cause spark plugs to
seize, causing damage to cylinder head threads.
Clean spark plug recess area before removing spark
plug. Failure to do so can result in engine damage
due to dirt or foreign material entering cylinder head
assembly, or in contamination of cylinder head
threads. Contaminated threads may prevent proper
seating of new spark plug.
Do not install spark plugs that are either "hotter" or
"colder" than the heat range specified for the
vehicle. Refer to SECTION OB, for spark plug usage
information. Today's technology requires a specific
spark plug heat range for each engine type. Installing spark plugs of any other heat range can severely
damage the engine assembly.
When disconnecting connectors, do not use a screwdriver or other tool to release the locking tab, as it
may break.
Care should be exercised when connecting a timing
light or other pick-up equipment. Do not force anything between the boots and wiring, or through the
silicone jackets. Connections should be made in parallel using an adapter. The tachometer terminal must
never be allowed to touch ground, as damage to the
ECM and/or ignition coil assembly can result.
The material used to construct spark plug wires is
very soft. This wire will withstand more heat and
carry a higher voltage, but chaffing and cutting
become easier. The spark plug wires must be routed
correctly to prevent chaffing or cutting. See "Spark
Plug Wire Harness Assembly Replacement" in the
following procedure, for routing. When removing a
spark plug wire from a spark plug, twist the boot on
the spark plug one-half turn while pulling on the
boot.

REPLACEMENT
Figures 2 and 3
NOTICE: The boots should be twisted one-half turn
while removing. Do not pull on the wires to remove
them from the spark plugs. Pull on the boots, or use a
tool designed for this purpose.
When replacing spark plug wire harness assemblies
(secondary wiring), route the wires correctly and through
the proper retainers. Failure to route the wires properly
can lead to radio ignition noise and crossfiring of the
spark plugs, or shorting of the leads to ground.
For location and routing of the spark plug wire harness assemblies refer to Figures 2 and 3. Note the positions and locations of wires, retainers, studs, etc. for ease
of installation.
SPARK PLUGS
Figures 2 and 3
CAUTION: If you smoke while handling
coated spark plugs, wear gloves to prevent transfer of the coating to cigarettes and subsequent burning of the
coating. Wash hands after installing
spark plugs.

1. Be sure ignition switch is in "OFF" or "LOCK"
position.
NOTICE: The boots should be twisted one-half turn
while removing. Do not pull on the wires to remove
them from the spark plugs. Pull on the boots, or use a
tool designed for this purpose.
Note positions of wires before removing.
FRTt
A
B
C
D
E
F
G
H
1
E
F
CYLINDER 2
CYLINDER 4
CYLINDER 6
CYLINDER 8
CYLINDER 1
CYLINDER 3
CYLINDER 5
CYLINDER 7
DISTRIBUTOR ASSEMBLY, IGNITION
PC0002-6D4-F-RP
Figure 2 - Spark Plug Wire Harness Assembly Routing (5.7L LT1 Engine)
6046 IGNITION SYSTEM
..
l-
a:
u.
..
l-
a:
u.
A
B
C
D
E
F
2
CYLINDER 2
CYLINDER 4
CYLINDER 6
CYLINDER 1
CYLINDER 3
CYLINDER 5
IGNITION COIL ASSEMBLY
PC0003-604-F-RP
Figure 3 - Spark Plug Wire Harness Assembly Routing (3.4L L32 Engine)
rn
Important
Clean dirt and debris from spark plug recess

areas.
3. Spark plugs from cylinder head assemblies.

NOTICE: Be sure spark plugs thread smoothly into
cylinder head assemblies and are fully seated. Crossthreading or failing to fully seat spark plugs can
cause overheating of spark plugs, exhaust blow-by,
or thread damage. Follow recommended torque
specifications carefully. Over or under-tightening
can also cause severe damage to cylinder head
assemblies or spark plugs.
1. Spark plugs to cylinder head assemblies.
l~I Tighten
Spark plugs to 15 N m (11 lb. ft.).
2. Spark plug wire harness assemblies, routed properly

as note during removal.
DISTRIBUTOR (5.7L LT1 ENGINE)
Figure 4

position.
2. Water pump assembly. Refer to SECTION 6B.
3. Crankshaft balancer assembly. Refer to SECTION
6A3A.
4. Spark plug wire harness assemblies from distributor
assembly ( 1).
5. Four-terminal ECM connector from distributor
assembly (1).
7. Distributor assembly (1).
IGNITION COIL ASSEMBLY (5.7L LT1

ENGINE)
Figure 5
1 DISTRIBUTOR ASSEMBLY
3 BOLT/SCREW, DISTRIBUTOR
4 DRIVESHAFT, DISTRIBUTOR
PC0018-6A3B-F-RP
Figure 4- Distributor Assembly (5.7L LT1 Engine)
A. Pull distributor assembly forward until driveshaft (4) disengages from end of camshaft
assembly.

position.
2. Four-terminal ECM connector at ignition coil module.
3. Ignition coil wiring connectors.
4. Ignition coil harness.
5. Bolt/screw (6).
6. Stud (5).
7. Ignition coil assembly (8).
Do not wipe silicone grease from bottom of
ignition coil assembly (8) if it is to be reinstalled.

NOTICE: See" Notice" on page 604-1 of this section.
NOTICE: If a new ignition coil assembly is to be
installed, a package of silicone grease will be
included in the box. This grease is necessary for
ignition coil assembly cooling.
B. Mark top surface of driveshaft (4), for alignment during installation.

1. Distributor driveshaft (4) into distributor assembly
(1 ), if removed.
Turn driveshaft (4) until alignment mark made

during removal is on top.
2. Distributor assembly (1) into position with driveshaft (4) in end of camshaft assembly.
l~I Tighten
Bolts/screws (3) to 11 N m (97 lb. in.).

4. Four-terminal ECM connector to distributor assembly (1).
5. Spark plug wire harness assemblies to distributor
assembly ( 1).
6A3A.
7. Water pump assembly. Refer to SECTION 6B.
5
6
7
8
STUD, IGNITION COIL

BOLT/SCREW, IGNITION COIL
RETAINER, FUEL CANISTER PURGE TUBE
PC00056D4-F-RP
Figure 5- Ignition Coil Assembly (5.7L LT1 Engine)

1. Spread silicone grease on metal mounting face of
ignition coil bracket ( 14) if necessary, and position
ignition coil assembly (8) to cylinder head assembly.
2. Stud (5).
l~I
Tighten
Stud (5) to 25 Nm (18 lb. ft.).

3. Bolt/screw (6).
l~I
Tighten

4. Ignition coil harness.
5. Ignition coil wiring connectors.
6. Four-terminal ECM connector to ignition coil module.
IGNITION COIL ASSEMBLY (3.4L L32

ENGINE)
16
Figure 6
2 IGNITION COIL ASSEMBLY

16 NUT, IGNITION COIL ASSEMBLY
17 BRACKET, IGNITION COIL AND POWER STEERING
PUMP

position.
PC00076D4-FRP
2. Spark plug wire harness assembly from ignition coil

assembly (2).
4. Nuts (16).

2. Nuts (16).
l~I
Tighten
Nuts (16) to 10 Nm (89 lb. in.).

3X SIGNAL CRANKSHAFT POSITION

SENSOR ASSEMBLY (3.4L L32 ENGINE)
Figure 7

position.
2. Sensor electrical connector.
3. Bolt/screw (26).
4. Sensor assembly (25) from engine block.
Figure 6 - Ignition Coil Assembly (3.4L L32 Engine)
ll'l'I
Inspect
Sensor 0-ring for wear, cracks or leakage. Replace if

necessary.

1. Lubricate sensor 0-ring with engine oil.
2. Sensor assembly (25) to the engine block.
3. Bolt/Screw (26).
l~I Tighten
24X SIGNAL CRANKSHAFT POSITION

SENSOR ASSEMBLY (3.4L L32 ENGINE)
Figure 7

position.
6A2A.
4. Sensor (23).
r-~
26
25
23 SENSOR ASSEMBLY, CRANKSHAFT POSITION

(24X SIGNAL)
24 BOLT/SCREW, CRANKSHAFT POSITION SENSOR
25 SENSOR ASSEMBLY, CRANKSHAFT POSITION
(3XSIGNAL)
26 BOLT/SCREW CRANKSHAFT POSITION SENSOR
27 SENSOR ASSEMBLY, CAMSHAFT POSITION
28 BOLT/SCREW, CAMSHAFT POSITION SENSOR
23
PC0009-6D4-F-RP
Figure 7 - Crankshaft and Camshaft Position Sensor Assemblies (3.4L L32 Engine)

1. Sensor (23).
l~I Tighten
6A2A.
CAMSHAFT POSITION SENSOR ASSEMBLY

(3.4L L32 ENGINE)
Figure 7

position.
2. Electrical connector from sensor assembly (27).
3. Bolt/screw (28).
NOTICE: Be careful not to damage sensor assembly when prying at its base during removal.
4. Sensor assembly (27) using a small-bladed screwdriver to gently pry between sensor assembly (27)
and engine block.
Pry from alternate sides to loosen sensor
assembly (27) in its mounting boss.
ll'l'I
Inspect
Sensor 0-rings for wear, cracks or leakage. Replace

if necessary.

1. Lubricate sensor 0-rings with engine oil.
2. Sensor (27) in engine block.
3. Bolt/screw (28).
l~I
Tighten

UNIT REPAIR
IGNITION COIL AND IGNITION COIL
MODULE (5.7L LT1 ENGINE)
Figure 8
l+!+I Disassemble
1. Coil (10) from brackets (13 and 14) by drilling out
rivets (9).
3. Ignition coil module (11).
l+!+I Assemble
NOTICE: See" Notice" on page 604-1 of this section.
NOTICE: A package of silicone grease is included
with a new ignition coil module. This grease is necessary for ignition coil module cooling.
1. Spread silicone grease on metal face of ignition coil
module (11) and on bracket (13) where it seats, and
position ignition coil module (11) to bracket (13 ).
13
l~I Tighten
3. Coil (10) to brackets (13 and 14) using bolts/screws
provided with replacement coil ( 10).
l~I Tighten
Bolts/screws to 2.8 Nm (25 lb. in.).
9
10
11
12
13
14
IGNITION COIL ASSEMBLY (3.4L L32

ENGINE)
Figure 9
l+!+I Disassemble
1.
2.
3.
4.
RIVET, BRACKET ATTACHMENT

COIL, IGNITION
MODULE, IGNITION COIL
BOLT/SCREW, IGNITION COIL MODULE
BRACKET, IGNITION COIL
BRACKET, IGNITION COIL
PC0006-6D4-F-RP
Bolts/screws (22).
Ignition coils (18).
Seals (19).
Module (20) from bracket (21 ).
Figure 8 - Ignition Coil and Ignition Coil Module

(5.?L LT1 Engine)
2. Seals ( 19).
3. Ignition coils (18).
l+!+I Assemble
1. Module (20) to bracket (21 ).
l~I Tighten
18
21
20
18
19
20
21
22
COIL, IGNITION
SEAL, IGNITION COIL
MODULE, IGNITION COIL
BRACKET, ELECTRONIC IGNITION COIL MODULE
BOLT/SCREW, IGNITION COIL
18
PCOOOS-604-F-RP
Figure 9 - Ignition Coils and Ignition Coil Module (3.4L L32 Engine)
SPECIFICATIONS
Camshaft Position Sensor Assembly Bolt/Screw (3.4L L32 Engine) .......... 1.9 Nm (17 lb. in.)
Distributor Bolt/Screw (5.7L LTl Engine) ................................ 11 Nm (97 lb. in.)
Ignition Coil Assembly Bolt/Screw (3.4L L32 Engine) ...................... 4.5 Nm 40 lb. in.)
Ignition Coil Assembly Bolt/Screw (5.7L LTl Engine) ...................... 25 Nm (18 lb. ft.)
Ignition Coil Assembly Nut (3.4L L32 Engine) ............................ 10 Nm (89 lb. in.)
Ignition Coil Assembly Stud (5.7L LTl Engine) ........................... 25 Nm (18 lb. ft.)
Ignition Coil Bolt/Screw (5.7L LTl Engine) ............................. 2.8 Nm (25 lb. in.)
Ignition Coil Module Bolt/Screw (5.7L LTl Engine) ...................... 1.7 Nm (15 lb. in.)
Spark Plugs ........................................................ 15 Nm (11 lb. ft.)
3X Signal Crankshaft Position Sensor Assembly
Bolt/Screw (3.4L L32 Engine) ....................................... 10 Nm (89 lb. in.)
24X Signal Crankshaft Position Sensor Assembly
Bolt/Screw (3.4L L32 Engine) ...................................... 1.9 Nm (17 lb. in.)
ENGINE WIRING 6051
SECTION 605
ENGINE WIRING
CONTENTS
Right-Hand Side Engine Wiring Harness
Assembly (3.4L L32) . . . . . . . . . . . . . . . . . . . . 605-2
Left-Hand Side Engine Wiring Harness
Assembly (3.4L L32) .................... 605-3
Rear View Engine Wiring Harness
Assembly (3.4L L32) . . . . . . . . . . . . . . . . . . . . 605-4
Right-Hand Side Engine Wiring Harness

Assembly (5.7L LTl) .................... 605-5
Left-Hand Side Engine Wiring Harness
Assembly (5.7L LTl) .................... 605-6
Transmission Engine Wiring Harness
Assembly (All) ......................... 605-7
The following figures illustrate engine wiring harness routing and the various electrical/electronic components that have
terminal connectors attached to them. In the illustration legends, the connectors are identified with the component name
that completes their connection. Refer to SECTION 8A for detailed diagnostics.
605-2 ENGINE WIRING
A CONNECTOR, OXYGEN SENSOR ELECTRICAL

B CONNECTOR, EXHAUST GAS RECIRCULATION
SOLENOID ELECTRICAL
C TUBE, VACUUM
D CONNECTOR, INJECTOR ELECTRICAL
E CONNECTOR, GENERATOR ELECTRICAL
F CONNECTOR, IDLE AIR CONTROL STEPPER MOTOR
ELECTRICAL
G CONNECTOR, IDLE AIR TEMPERATURE SENSOR
ELECTRICAL
H CONNECTOR, THROTILE POSITION SENSOR
ELECTRICAL
J TERMINAL, ENGINE GROUND
K CONNECTOR, A/C COMPRESSOR CLUTCH ELECTRICAL
L CONNECTOR, MANIFOLD ABSOLUTE PRESSURE
SENSOR ELECTRICAL
M CONNECTOR, CRANKSHAFT SENSOR ELECTRICAL
N CONNECTOR, KNOCK SENSOR ELECTRICAL
1 HARNESS ASSEMBLY, ENGINE WIRING
2 NUT, ENGINE WIRING HARNESS GROUND
3 NUT, ENGINE WIRING HARNESS START LEAD
4 WASHER, ENGINE WIRING HARNESS START LEAD
6 LEAD, ENGINE WIRING HARNESS START
15 SENSOR ASSEMBLY, MANIFOLD ABSOLUTE
PRESSURE
PC0001-6D5-F-RP
Figure 1 - Right-Hand Side Engine Wiring Harness Assembly (3.4L L32)
ENGINE WIRING 605-3
K
A CONNECTOR, DISTRIBUTOR SENSOR INPUT/OUTPUT
ELECTRICAL
B CONNECTOR, DISTRIBUTOR POWER INPUT
ELECTRICAL
C CONNECTOR, ENGINE COOLANT TEMPERATURE GAGE
SENSOR ELECTRICAL
D CONNECTOR, CANISTER PURGE SOLENOID VALVE
ELECTRICAL
E CONNECTOR, CAMSHAFT POSITION SENSOR
ELECTRICAL
F CONNECTOR, OXYGEN SENSOR ELECTRICAL
G CONNECTOR, OIL PRESSURE SENSOR ELECTRICAL
H CONNECTOR, OIL LEVEL SENSOR ELECTRICAL
J STRAP, RIGHT FRONT GROUND
K CONNECTOR, POWER STEERING PRESSURE SWITCH
ELECTRICAL
L CONNECTOR, CRANKSHAFT POSITION SENSOR
ELECTRICAL
M CONNECTOR, CRANK SENSOR INPUT ELECTRICAL
5 NUT, ENGINE WIRING HARNESS CLAMP
PC0002-6D5-F-RP
Figure 2 - Left-Hand Side Engine Wiring Harness Assembly (3.4L L32)
6054 ENGINE WIRING

7 BOLT/SCREW, ENGINE WIRING HARNESS CLAMP
8 BOLT/SCREW, FLYWHEEL HOUSING
PC0003-605-F-RP
Figure 3 - Rear View Engine Wiring Harness Assembly (3.4L L32)
ENGINE WIRING 605-5
11
13
jv1Ewe
A CONNECTOR, IGNITION DISTRIBUTOR ELECTRICAL
B CONNECTOR, CANISTER PURGE SOLENOID VALVE
ELECTRICAL
C CONNECTOR, INJECTOR ELECTRICAL
D CONNECTOR, MANIFOLD ABSOLUTE PRESSURE
SENSOR ELECTRICAL
E CONNECTOR, GENERATOR ELECTRICAL
F CONNECTOR, NC COMPRESSOR CLUTCH ELECTRICAL
G TUBE, VACUUM
H CONNECTOR, KNOCK SENSOR ELECTRICAL
J TERMINAL, ENGINE GROUND
K CONNECTOR, IDLE AIR CONTROL STEPPER MOTOR
ELECTRICAL
14
12
L CONNECTOR, THROTILE POSITION SENSOR

ELECTRICAL
M CONNECTOR, OXYGEN SENSOR ELECTRICAL
9 BOLT/SCREW, ENGINE WIRING HARNESS CLAMP
12 NUT, ENGINE WIRING HARNESS START LEAD
13 WASHER, ENGINE WIRING HARNESS START LEAD
14 LEAD, ENGINE WIRING HARNESS START
15 SENSOR ASSEMBLY, MANIFOLD ABSOLUTE
PRESSURE
PC0004-6D5-F-RP
Figure 4- Right-Hand Side Engine Wiring Harness Assembly (5.7L LT1)
605-6 ENGINE WIRING
A CONNECTOR, IGNITION COIL DRIVER ELECTRICAL

B CONNECTOR, INJECTOR ELECTRICAL
C CONNECTOR, EXHAUST GAS RECIRCULATION
SOLENOID VALVE ELECTRICAL
D CONNECTOR, OXYGEN SENSOR ELECTRICAL
E CONNECTOR, OIL PRESSURE SENSOR ELECTRICAL
F CONNECTOR, OIL LEVEL SENSOR ELECTRICAL
G CONNECTOR, ENGINE COOLANT TEMPERATURE GAGE
SENSOR ELECTRICAL
H STRAP, RIGHT FRONT GROUND
J CONNECTOR, IGNITION COIL ELECTRICAL
K CONNECTOR, ENGINE COOLANT TEMPERATURE
SENSOR ELECTRICAL
L TERMINAL, GROUND
16 NUT, ENGINE WIRING HARNESS CLAMP
17
PC0005-6D5F-RP
Figure 5 - Left-Hand Side Engine Wiring Harness Assembly (5.7L LT1)
ENGINE WIRING 6057
G
B
A TRANSMISSION ASSEMBLY, AUTOMATIC (MOS)

B TRANSMISSION ASSEMBLY, MANUAL (5-SPEED M49)
C TRANSMISSION ASSEMBLY, MANUAL (6-SPEED M28
AND M29)
D CONNECTOR, TORQUE CONVERTOR CLUTCH
ELECTRICAL
E CONNECTOR, VEHICLE SPEED SENSOR ELECTRICAL
F CONNECTOR, BACKUP SWITCH ELECTRICAL
G CONNECTOR, VEHICLE SPEED SENSOR ELECTRICAL
H CONNECTOR, BACKUP SWITCH ELECTRICAL
J CONNECTOR, VEHICLE SPEED SENSOR ELECTRICAL
K CONNECTOR, REVERSE LOCKOUT SOLENOID
ELECTRICAL
PC0006-6D5-F-RP
Figure 6 - Transmission Engine Wiring Harness Assembly (All)
DRIVEABILITY AND EMISSIONS - FUEL INJECTION 6E-1
SECTION 6E
DRIVEABILITY AND EMISSIONS

GENERAL INFORMATION
CAUTION: On vehicles equipped with Supplemental Inflatable Restraint (SIR), refer to
CAUTIONS in Section 9J under "ON-VEHICLE SERVICE" and the SIR Component and
Wiring Location view in Section 9J before performing service on or around SIR
CONTENTS
Emissions Control Information Label
Maintenance Schedule
Section Content
Visual/Physical Underhood
Inspection
Basic Knowledge and Tools
Required

Electrostatic Discharge Damage
Diagnostic Information
Malfunction Indicator Lamp (MIL)
Intermittent Malfunction Indicator
Lamp
GE-1
GE-1
GE-1
GE-3
GE-3
GE-3
GE-3
GE-3
Reading Diagnostic Trouble Codes

Clearing Diagnostic Trouble
Codes
Diagnostic Mode
Field Service Mode
Learning Ability
On-Board Diagnostic System Check
DLC Scan Tools
Tech 1 Tool Use With lntermittents

Wiring Harness Service
Tools Needed to Service the System
Special Tools (1 of 6)
6E-3
GE-4
GE-4
GE-4
GE-4
GE-5
GE-5
GE-5
GE-5
GE-5
GE-5
GE-6
EMISSIONS CONTROL INFORMATION LABEL
SECTION CONTENT
The underhood "Vehicle Emissions Control

Information" label (Figure 1) contains important
emission specifications and setting procedures. In the
upper left corner is exhaust emission information
which identifies the year, the manufacturing division
of the engine, the displacement of the engine in liters,
the class of vehicle, and type offuel metering. There is
also an illustrated emission components and vacuum
hose schematic.
This label is located in the engine compartment of
every General Motors vehicle. If the label has been
removed, it can be ordered from GM Service Parts
Operations (GMSPO).
The driveability and emissions section describes

the function and operation of the engine control
module system that controls the driveability and
emissions of the vehicle. Emphasis is placed on the
diagnosis and repair of problems related to the system.
It is divided into three major sub-sections dealing
with diagnosis and repair. They can be summarized as
follows:
SECTION A: ENGINE COMPONENTS/WIRING
DIAGRAMS/DIAGNOSTIC CHARTS
MAINTENANCE SCHEDULE
Refer to the General Motors Maintenance

Schedule in SECTION OB for the maintenance service
that should be performed to retain emission control
performance.
Component Locations.
Wiring Diagrams.
ECM/PCM/VCM Terminal End View and
Terminal Definitions.
On-Board Diagnostic System Check. This must be
the first step of any diagnostic procedure.
Diagnostic Trouble Code Charts with facing pages
containing circuit diagrams, circuit operation
information, and helpful diagnostic information.
6E-2 DRIVEABILITY AND EMISSIONS - FUEL INJECTION
--------
ENGINE ADJUSTMENT
SPECIFICATIONS
ADJUSTMENT
PROCEDURE
LABEL CODE
ENGINE SIZE
-- -
__.,
\
\
\
\
\
-- --
\
\
\
- - - _.J
EMISSION COMPONENT
AND VACUUM HOSE SCHEMATIC
LABEL PART NUMBER
"ALWAYS REFER TO THE VEHICLE EMISSION CONTROL INFORMATION LABEL

FOR THE CORRECT AND MOST CURRENT SPECIFICATIONS" .
....___ _ EVAPORATIVE EMISSION SYSTEM
- - - - - - - - - E X H A U S T EMISSION SYSTEM
P 1G 3.8 V 8 JAW 7
CERT YEAR
P = 1993
1G
2G
3G
4G
= GMPT CAR
= (RESERVED)
= GMPT TRUCK
= SATURN
CHECK SUM
DIGIT
VEHICLE CLASS AND STANDARDS

V = Gasoline Vehicle
W = Calif. Std Gasoline Vehicle
T = Gasoline Truck
X = Calif Std. Gasoline Truck
K = Diesel Truck
M = Methanol/Gas Vehicle
N = Cal Meth'I/Gas Vehicle
CATALYST DESIGNATOR
FUEL METERING
B = CMFI
5 = TBI
6 = SFI-SC
7 = IFI (DIESEL)
8 = MFI or SFI or
MFI/SFI
4-8-92
MS11461-6E
Figure 1 - Vehicle Emission Control Information Label

SECTION B: SYMPTOMS
This sub-section assists in diagnosis of
intermittent problems or problems which don't
result in the storing of diagnostic trouble codes. It
is arranged by symptoms of poor driveability and
emissions and lists possible causes of the problems.
SECTION C: COMPONENT SYSTEMS
Component and Circuit Descriptions
On-Vehicle Service for each Sub-System
Functional Checks/Diagnostic Charts
VISUAUPHYSICAL UNDERHOOD INSPECTION

A careful visual and physical underhood
inspection must be performed as part of any
diagnostic procedure or in finding the cause of an
emissions test failure. This can often lead to fixing a
problem without further steps. Inspect all vacuum

hoses for correct routing, pinches, cuts, or disconnects.
Be sure to inspect hoses that are difficult to see
beneath the air cleaner, compressor, generator, etc.
Inspect all the wires in the engine compartment for
proper connections, burned or chafed spots, pinched
wires, or contact with sharp edges or hot exhaust
manifolds. This visual/physical inspection is very
important. It must be done carefully and thoroughly.
BASIC KNOWLEDGE AND TOOLS REQUIRED

To use the driveability and emissions section most
effectively, a general understanding of basic electrical
circuits and circuit testing tools is required. You
should be familiar with wiring diagrams, the meaning
of voltage, ohms, amps, the basic theories of electricity,
and understand what happens in an open or shorted
wire.
To perform system diagnosis, the use of a Tech 1
Diagnostic Computer or equivalent scan tool is
required. A tachometer, test light, ohmmeter, digital
voltmeter with 10 megohms impedance, vacuum
gauge, and jumper wires are also required. Become
acquainted with the special tools and their use before
attempting to diagnose a vehicle. Special tools which
are required for system service are illustrated at the
end of this section.
Electrostatic Discharge Damage

Refer to SECTION OA for handling electronic
discharge service parts.
DIAGNOSTIC INFORMATION
The diagnostic charts in SECTION A and
functional checks in SECTION C are designed to
locate a faulty circuit or component through logic
based on the process of elimination.
The charts are prepared with the requirement that the

vehicle functioned correctly at the time of assembly
and that there are no multiple failures.
There is a continual self-diagnosis on certain
control functions. This diagnostic capability is
complemented by the diagnostic procedures contained
in this manual. The language for communicating the
source of a malfunction is a system of diagnostic
trouble codes. The diagnostic trouble codes are two
digit numbers that can range from 12 to 55. When a
malfunction is detected by the ECM/PCM/VCM, a
diagnostic trouble code is set and the Malfunction
Indicator Lamp (MIL) "Service Engine Soon" is
illuminated.

The MIL (Service Engine Soon) lamp is on the
instrument panel and has the following functions.
It informs the driver that a problem has occurred
and that the vehicle should be taken for service as
soon as reasonably possible.
It displays diagnostic trouble codes stored by the
ECM/PCM/VCM which help the technician
diagnose system problems.
It indicates "Open Loop" or "Closed Loop"
operation.
As a bulb and system check, the MIL (Service
Engine Soon) will come "ON" with the key "ON" and
the engine not running. When the engine is started,
the lamp will turn "OFF." If the lamp remains "ON,"
the self-diagnostic system has detected a problem. If
the problem goes away, the lamp will go out in most
cases after 10 seconds, but a diagnostic trouble code
will remain stored.
When the light remains "ON" while the engine is
running, or when a malfunction is suspected due to a
driveability or emissions problem, a On-Board
Diagnostic System Check must be performed. The
procedures for these checks are given in SECTION A.
These checks will expose malfunctions which may not
be detected if other diagnostics are performed
prematurely.
Intermittent Malfunction Indicator Lamp

In the case of an "intermittent" problem, the MIL
(Service Engine Soon) will light for ten (10) seconds
and then will go out. However, the corresponding
diagnostic trouble code will be stored in the memory or
until the battery voltage has been removed. When
unexpected diagnostic trouble codes appear during the
diagnostic trouble code reading process, one can
assume that these diagnostic trouble codes were set by
an intermittent malfunction and could be helpful m
diagnosing the system.

An intermittent diagnostic trouble code may or
may not re-set. If it is an intermittent failure, a
Diagnostic Trouble Code Chart is not used. Consult
the "Diagnostic Aids" on the page facing the diagnostic
trouble code chart corresponding to the intermittent
diagnostic trouble code. SECTION B also covers the
"Intermittents." A physical inspection of the
applicable sub-system most often will resolve the
problem.
TERMINAL IDENTIFICATION
GROUND
TCC (IF USED)
DIAGNOSTICTERMINAL
SERIALDATA
SERIAL DATA {If USED)
Reading Diagnostic Trouble Codes

10-1-91
*6S2615-6E
The provision for communicating is the Data Link

Connector (DLC) connector (refer to Figure 2). It is
usually located under the instrument panel and is
sometimes covered by a plastic cover labeled
"DIAGNOSTIC CONNECTOR." It is used in the
assembly plant to receive information in checking that
the engine is operating properly before it leaves the
plant. The diagnostic trouble code(s) stored in
memory can be read either through Tech 1 Diagnostic
Computer, a hand-held diagnostic scanner plugged
into the DLC connector or by counting the number of
flashes of the "Service Engine Soon" lamp when the
diagnostic terminal of the DLC connector is grounded.
The DLC connector terminal "B" (diagnostic terminal)
is the second terminal from the right of the DLC
connector's top row. The terminal is grounded by
connecting it to terminal "A" (internal
ECM/PCM/VCM ground), the terminal to the right of
terminal "B" on the top row of the DLC connector.
Once terminals "A" and "B" have been connected,
the ignition switch must be moved to the "ON"
position, with the engine not running. At this point,
the MIL (Service Engine Soon) should flash Diagnostic
Trouble Code (DTC) 12 three times consecutively.
This would be the following flash sequence: "flash,
pause, flash-flash, long pause, flash, pause, flash-flash,
long pause, flash, pause, flash-flash." OTC 12
indicates that the diagnostic system is operating. If
DTC 12 is not indicated, a problem is present within
the diagnostic system itself, and should be referred to
the appropriate diagnostic chart in SECTION A.
Following the output of DTC 12, the MIL (Service
Engine Soon) will indicate a diagnostic trouble code
three times if a diagnostic trouble code is present, or it
will continue to output OTC 12. If more than one
diagnostic trouble code has been stored in memory, the
diagnostic trouble codes will be output from the lowest
to the highest, with each diagnostic trouble code being
displayed three times.
When the diagnostic terminal is grounded with the

ignition "ON" and the engine "OFF," the system will
enter what is called the Diagnostic Mode. In this mode
the ECM/PCM/VCM will:
1. Display a DTC 12 by flashing the MIL (Service
Engine Soon) (indicating the system is operating
correctly).
2. Display any stored OTC by flashing the MIL
(Service Engine Soon). Each DTC will be flashed
three times, then DTC 12 will be flashed again.
3. Energize all system controlled relays and solenoids
except fuel pump relay. This allows checking
circuits which may be difficult to energize without
driving the vehicle and being under particular
operating conditions.
4. The IAC valve moves to its fully extended position
on most models, blocking the idle air passage. This
is useful in checking the minimum idle speed.
Clearing Diagnostic Trouble Codes
Field Service Mode
To clear any Diagnostic Trouble Code (DTC) from

the memory, either to determine if the malfunction
will occur again or because repair has been completed,
power feed must be disconnected for at least thirty (30)
If the diagnostic terminal is grounded with the

engine running, the system will enter the Field
Service mode.
Figure 2 - DLC Connector
seconds. Depending on how the vehicle is equipped,

the system power feed can be disconnected at the
positive battery terminal "pigtail," or the inline
fuseholder that originates at the positive connection at
the battery. (The negative battery terminal may be
disconnected, but other on-board memory data, such as
preset radio tuning, will also be lost.)
NOTICE: To prevent system damage, the key

must be "OFF" when disconnecting or
reconnecting power.
When using a hand-held Tech 1 Diagnostic
Computer, or scan tool to read the diagnostic trouble
codes, clearing the diagnostic trouble codes is done in
the same manner as in the above procedure.
Diagnostic Mode

In "Open Loop" the MIL (Service Engine Soon)
flashes two and one-halftimes per second.
In "Closed Loop," the light flashes once per second.
Also, in "Closed Loop," the light will stay "OFF" most
of the time if the system is running lean. It will stay
"ON" most of the time if the system is running rich.
While the system is in Field Service Mode, new
codes cannot be stored and the "Closed Loop" timer is
bypassed.
Learning Ability
The system has a "learning" ability which allows it
to make corrections for minor variations in the fuel
system to improve driveability. If the battery is
disconnected, to clear diagnostic trouble codes or for
other repair, the "learning" process resets and begins
again. A change may be noted in the vehicle's
performance. To "teach" the vehicle, ensure that the
engine is at operating temperature. The vehicle
should be driven at part throttle, with moderate
acceleration and idle conditions until normal
performance returns.
ON-BOARD DIAGNOSTIC SYSTEM CHECK

Refer to "On-Board Diagnostic System Check" in
SECTION A.
DLC SCAN TOOLS

The system can communicate a variety of
information through DLC connector terminals "E" or
"M" (depending on the engine). This data is
transmitted at a high frequency which requires a Tech
1 Diagnostic Computer (scan) tool for interpretation.
There are several scan tools available for reading this
information.
With an understanding of the data which the tool
displays, and knowledge of the circuits involved, the
tool can be very useful in obtaining information which
would be more difficult or impossible to obtain with
other equipment.
Tech 1 and scan tools do not make the use of
diagnostic trouble code charts unnecessary, nor can
they indicate exactly where a problem is in a
particular circuit. Tree charts incorporate diagnosis
procedures using a Tech 1 tool where possible and most
charts require the use of a Tech 1 when it is applicable.
A TECH 1 TOOL THAT DISPLAYS FAULTY DATA
SHOULD NOT BE USED AND THE PROBLEM
SHOULD BE REPORTED TO THE MANUFACTURER.
THE USE Of A FAULTY SCAN TOOL CAN RESULT IN
MISDIAGNOSIS AND UNNECESSARY PARTS
REPLACEMENT.
TECH 1 TOOL USE WITH INTERMITTENTS

In some scan tool applications, the data update
rate makes the tool less effective than a voltmeter,
such as when trying to detect an intermittent problem
which lasts for a very short time. However, the Tech 1
allows manipulation of wiring harnesses or
components under the hood with the engine not
running, while observing the Tech 1 readout.
The Tech 1 tool can be plugged in and observed
while driving the vehicle under the condition when the
MIL (Service Engine Soon) turns "ON" momentarily
or when the engine driveability is momentarily poor.
If the problem seems to be related to certain
parameters that can be checked on the Tech 1, they
should be checked while driving the vehicle. If there
does not seem to be any correlation between the
problem and any specific circuit, the Tech 1 can be
checked on each position, watching for a period of time
to see if there is any change in the readings that
indicates intermittent operation.
The Tech 1 is also an easy way to compare the
operating parameters of a poorly operating engine
with those of a known good one. For example, a sensor
may shift in value but not set a diagnostic trouble
code. Comparing the sensor's readings with those of a
known good vehicle may uncover the problem.
The Tech 1 has the ability to save time in diagnosis
and prevent the replacement of good parts. The key to
using the Tech 1 successfully for diagnosis lies in the
technician's ability to understand the system he is
trying to diagnose as well as an understanding of the
Tech 1 operation and limitations. The technician
should read the tool manufacturer's operating manual
to become familiar with the tool's operation.
WIRING HARNESS SERVICE

Refer to SECTION SA for wiring harness service.
Special tools needed to service:
J 38125-A
Terminal Repair Kit
J 34636
Circuit Tester
J 35689-A
Metri-Pack Terminal Remover
J 28742-A
Weather-Pack Terminal Remover
J 33095
Micro-Pack Terminal Remover
TOOLS NEEDED TO SERVICE THE SYSTEM

Refer to "Special Tools" at the end of this section
for driveability and emissions tools needed to service
system.

REFER TO USERS MANUAL FOR COMPLETE
INSTRUCTIONS.
VOLTMETER -Voltage position measures magnitude
of voltage when connected in parallel to an existing
circuit. A digital voltmeter with a 10 megohm input
impedance is used because this type of meter will
not load down the circuit and result in faulty
readings. Some circuits require accurate low voltage
readings because they have a very high resistance.
AMMETER - When used as an ammeter, this meter
accurately measures extremely low current flow.

Refer to meter instructions for more information.
Selector must be set properly for both function
and range. DC is used for most automotive
measurements.
OHMMETER - Measures resistance of circuit directly
in
ohms.
OL display in all ranges indicates open circuit.
Zero display in all ranges indicates a short circuit.
An intermittent connection in a circuit may be
indicated by a digital reading that will not
stabilize on the circuit.
HIGH IMPEDANCE MULTIMETER
Range Switch - Automatic and Manual.
(DIGITAL VOLTMETER-DVM)
400Q - Reads ohms directly
4K,40K,400Kn - Reads ohms in thousands
4M,40Mn,400Mn - Reads ohms in millions
J 39200
VACUUM PUMP WITH GAGE (20 IN. HG. MINIMUM)
Use the gage to monitor manifold engine

vacuum and use the hand pump to check vacuum
sensors, solenoids and valves.
J 23738-A
UNPOWERED TEST LIGHT
Used for checking wiring for complete circuit,

short to ground, or voltage.
J 34142-B
CONNECTOR TEST ADAPTER KIT
Used for making electrical test connections in

current Weather Pack, Metri-Pack and MicroPack style terminals.
3-24-92
7S 3382-GE
J 35616-A/BT-8637
DRIVEABILITY AND EMISSIONS- FUEL INJECTION 6E-7
TECH 1 DIAGNOSTIC SCAN TOOL
A hand-held scan tool used to analyze and

diagnose control module systems. To be used
with interchangeable program cartridge kits, or
mass storage cartridge.
MASS STORAGE CARTRIDGE
Use with GM 81-93 Powertrain Software
SIGNAL GENERATOR & INSTRUMENT

PANEL TESTER
Used to generate VSS signal.
J 33431-8
INLET & RETURN FUEL LINE SHUT-OFF ADAPTERS
Used with J 34730-1 for checking and monitoring

fuel line pressure.
J37287-1 Inlet Adapter
J37287-2 Return Adapter
J 37287
FUEL PRESSURE GAGE
Used for checking and monitoring fuel line

pressure of TBI fuel system.
J 29658-150 Fuel Pressure Gage Relief Valve
J 29658-80 Fuel Pressure Quick Connect
Adapters
J 29658-D
FUEL LINE QUICK CONNECT SEPARATOR
Used to release fuel line quick-connect fittings.
J 37088-A/BT-9171
FUEUINJECTION LINE WRENCH
i)
Used to service fuel or injection line.

6-25-92
MS 11457-6E
J 29698-A/BT-82 51
PORT FUEL INJECTION DIAGNOSTIC KIT
J 34730-C
Used to diagnose port fuel injection systems.

The kit includes:
Fuel Pressure Gage - used for checking fuel pump
pressure and compare injector pressure drop for
equal fuel distribution. (J 34730-1)
Injector Test Light - (J 34730-2()
Injector Tester - used for energizing each fuel
injector for a precise amount of time to perform
injector balance test. (J 34730-3A)
Test Light - Geo Metro only. (J 34730-28)
Plastic case and instructions.
FUEL PRESSURE GAGE AND HOSE
Used for checking and monitoring fuel line pressure of

port fuel system.
Part of Test Kit J 34730-C.
J 34730-1
INJECTOR TEST LIGHT
Used for checking the electrical circuit to a port fuel

injector.
Part of Diagnostic Kit J 34730-C, OR J 34730-D.
J 34730-2(/BT-8329
INJECTOR TESTER
Separately energizes each injector to compare - for

equal fuel impulses over a constant time interval
which pinpoints a faulty injector.
Part of Test Kit J 34730-C, OR J 34730-D.
~34730-3A
INJECTOR HARNESS TESTER
Used for checking the electrical circuit to a TBI fuel

injector.
J 34730-350/BT-8320
INJECTOR HARNESS TESTER
Used for checking the electrical circuit to a port fuel

injector or 700 TBI unit.
J 34730-2A/BT-8329A
IAC MOTOR ANALYZER
Used to test IAC motors for correct functioning and

proper response to commands.
J 37027-3 IAC System Check Lights
ALSO
222-L IAC Driver and Node Light Kit
5-12-92
MS 1118B-6E
J 37027-A

EXHAUST BACK PRESSURE TESTER
Used to diagnose a restricted exhaust at 025.

AIR PUMP ADAPTER
Used to diagnose a restricted exhaust when 025 is

inaccessible.
J 35314-A/BT-8515/BT-8515A
SPARK TESTER
Used for checking available secondary ignition

voltage. Also called an ST 125.
, : :792/BT-7220-1
TRANSAXLE TEST BOX
(3800 Engine)
J 38791
CRANKSHAFT SENSOR ALIGNMENT TOOL (C31
SYSTEMS)
Used for properly aligning crank or combination

sensor to harmonic balancer interrupter.
J 37089-A/BT-9124
BALANCER REMOVER
(3300/3800 Engine)
Used to remove crankshaft pulley.
J 38197/BT-9189
~~=t!(;'
J 38491
SPARK PLUG BOOT REMOVAL TOOL
(3300/3800 Engine)
Used to prevent damage to wire by breaking
plug/boot bond.
COOLANT SENSOR SOCKETS
(3300/3800 Engine)
J 38724
IDLE AIR CONTROL REMOVER

35632/BT-8514A
Used to remove idle air control assembly on port fuel

injection engine.
4.30.92
MS 11459-6E
J 34730-D
PORT FUEL INJECTION DIAGNOSTIC KIT

Used to diagnose port fuel injection systems.
The kit includes:
Fuel Pressure Gage - used for checking fuel pump
pressure and compare injector pressure drop for
equal fuel distribution. (J 34730-1A)
Injector Test Light- (J 34730-2()
Injector Tester - used for energizing each fuel
injector for a precise amount of time to perform
injector balance test. (J 34730-3A)
Adapter Harness - 4.3L (J 34730-225)
Poppet Valve Test Device - 4.3L (J 34730-230)
Plastic case and instructions.
FUEL PRESSURE GAGE AND HOSE

Used for checking and monitoring fuel line pressure
of port fuel system.
Part of Test Kit J 34730-D.
J 34730-225
INJECTOR HARNESS CONNECTOR

Used as a harness for manually adapting the manual
injector test to the injector harness.
Part of Test Kit J 34730-D. Also can be used with
J 34730-C.
INJECTOR POPPET TESTERS

Six testers used on the CPI to test for fuel flow.
Part of Test Kit J 34730-D. Also can be used with
J 34730-C.
J 34730-230
FUEL PRESSURE GAGE AND ADAPTOR
Used for high fuel pressure testing (0-100 psi).
Modifies J 34730-1 (0-60 psi) fuel pressure gage to
J 34730-1A(0-100 psi) gage.
5-8-92
MS 9270-6E
J 34730-250
OXYGEN SENSOR WRENCH
J 29533-A/BT-8127
Used for removing or installing the oxygen

sensor.
HEATED OXYGEN SENSOR WRENCH
Used to remove or install the heated oxygen

sensor.
J 39194
OIL PRESSURE SENDING UNIT SOCKET
Used to remove and install oil pressure

sending unit.
J 35748
IDLE AIR CONTROL WRENCH
Used for removing or installing IAC valve on

throttle body.
J 33031/BT-8130
FUEL INJECTOR TEST HARNESS ADAPTER
Used with J 34730-3A to check electrical

circuit on 2.2L engine.
J 34730-200
FUEL LINE DISCONNECT TOOL SET (W CAR)
Used to disconnect fuel line disconnect

locking tabs under ABS modulator.
J 39504
OIL PRESSURE SENSOR WRENCH
(U-Van 3300/3800 Engine)
Used to remove or install oil pressure sensor.
J 39228
SPARK PLUG BOOT PULLER
(U-Van w/3800 Engine)
J 39294
Used to remove spark plug wire on rear

bank of engine.
6-25-92
MS 11466-6E
DRIVEABILITY AND EMISSIONS 3.4L (L32) (VIN S) (SFI) & 5.7L (LT1) (VIN P) (MFI) 6E3-1
SECTION 6E3
DRIVEABILITY AND EMISSIONS

FUEL INJECTION
THIS SECTION APPLIES TO:
11
3.4L (L32) (VIN S) F" CARLINE (SFI)

5. 7L (LT1) (VIN P) ''F" CARLINE (MFI)
CAUTION: The procedures in this section must be followed in the order listed to
temporarily disable the Supplemental Inflatable Restraint (SIR) System and prevent false
Diagnostic Trouble Codes from setting. Failure to follow procedures could result in
possible air bag deployment, personal injury, or otherwise unneeded SIR system repairs.
removed. If a fastener needs to be replaced, use the correct part number fastener for that application. If the
correct part number fastener is not available, a fastener of equal size and strength (or stronger) may be used.
Fasteners that are not reused, and those requiring thread-locking compound will be called out. The correct
torque value must be used when installing fasteners that require it. If the above conditions are not followed,
parts or system damage could result.
CONTENTS
3.4L (L32) (VIN S) "F" CARLINE
General Description
Diagnosis Procedure
3.4L (VIN S)
6E3-3
3.4L (VIN S)
6E3-3
Section A
Engine Components/Wiring Diagrams/Diagnostic Charts
3.4L (VIN S)
6E3-A-1
Section B
Symptoms
3.4L (VIN S)
6E3-B-1
Section C
Component Systems
3.4L (VIN S)
6E3-C-1
3.4L (VIN S)
6E3-C1-1
3.4L (VIN S)
6E3-C2-1
. . . . . . . . . . . . . . . . . . . ..
3.4L (VIN S)
6E3-C3-1
3.4L (VIN S)
6E3-C4-1
3.4L (VIN S)
6E3-CS-1
3.4L (VIN S)
6E3-C6-1
3.4L (VIN S)
6E3-C7-1
3.4L (VIN S)
6E3-C8-1
C10 A/C Compressor Clutch Control
3.4L (VIN S)
6E3-C10-1
C12 CoolingFanControl
3.4L (VIN S)
6E3-C12-1
3.4L (VIN S)
6E3-C13-1
3.4L (VIN S)
6E3-C14-1
Cl
Engine Control Module (ECM) and Sensors
C2
Fuel Metering System
C3
Evaporative Emission (EVAP) Control System
C4
Electronic Ignition (El) System
cs
Knock Sensor (KS) System
CG
Secondary Air Injection (AIR) System
C7
Exhaust Gas Recirculation (EGR) System
C8
Torque Converter Clutch (TC() System
Index
Cl 3 Crankcase Ventilation System

C14 Air Intake System
. . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . .
End of Section
6E3-2 3.4L (L32) (VIN S) (SFI) & 5.7L (LT1) (VIN P) (MFI) DRIVEABILITY AND EMISSIONS
5.7L (VIN P) "F" CARLINE
General Description
.........................................
5.7L (VIN P) 6E3-3
Diagnosis Procedure
5.7L (VIN P) 6E3-3
Section A
Engine Components/Wiring Diagrams/Diagnostic Charts
Section B
Symptoms
Section C
Component Systems
.....................................
.
Cl
Engine Control Module (ECM) and Sensors
C2
C3
C4
Distributor Ignition (DI) System
CS
CG
C7
C8
Torque Converter Clutch (TCC) System (A/T)
..............................
5.7L (VIN P) 6E3-A-1

5.7L (VIN P) 6E3-B1
5.7L (VIN P) 6E3-C1
5.7L (VIN P) 6E3-C1-1
5.7L (VIN P) 6E3-C2-1
5.7L (VIN P) 6E3-C3-1
5.7L (VIN P) 6E3-C4--1
5.7L (VIN P) 6E3-C5-1
5.7L (VIN P) 6E3-C6-1

5.7L (VIN P) 6E3-C7-1
5.7L (VIN P) 6E3-C8-1
Automatic Transmission Gear Switch System,

Reverse Lockout System (MIT)
..........................
5.7L (VIN P) 6E3-C10-1
5.7l (VIN P) 6E3-C12-1
Cl O A/C Clutch Circuit Diagnosis

C12 Electric Cooling Fan(s)
C13 Crankcase Ventilation System

C14 Air Intake System
Index
5.7L (VIN P) 6E3-C13-1
5.7L (VIN P) 6E3-C14-1
............................................
End of Section
DRIVEABILITY AND EMISSIONS 3.4L {L32) {VIN S) {SFI) & 5.7L {LT1) {VIN P) {MFI) 6E3-3
ALL NEW GENERAL MOTORS VEHICLES ARE CERTIFIED BY THE UNITED STATES
ENVIRONMENTAL PROTECTION AGENCY AS CONFORMING TO THE REQUIREMENTS OF THE
REGULATIONS FOR THE CONTROL OF AIR POLLUTION FROM NEW MOTOR VEHICLES. THIS
CERTIFICATION IS CONTINGENT ON CERTAIN ADJUSTMENTS BEING SET TO FACTORY
STANDARDS. IN MOST CASES, THESE ADJUSTMENT POINTS EITHER HAVE BEEN
PERMANENTLY SEALED AND/OR MADE INACCESSIBLE, TO PREVENT INDISCRIMINATE OR
ROUTINE ADJUSTMENT IN THE FIELD. FOR THIS REASON, THE FACTORY PROCEDURE FOR
TEMPORARILY REMOVING PLUGS, CAPS, ETC., FOR PURPOSES OF SERVICING THE PRODUCT,
MUST BE STRICTLY FOLLOWED AND, WHEREVER PRACTICABLE, RETURNED TO THE
ORIGINAL INTENT OF THE DESIGN.
INTRODUCTION
GENERAL DESCRIPTION
DIAGNOSIS PROCEDURE
This section applies to the 3.4L (VIN S) and 5. 7L

(VIN P) engines. These engines have a fuel injector in
the intake manifold near the intake valve for each
cylinder.
These engines have controls that reduce exhaust
emissions, and maintain good driveability and fuel
economy.
An Engine Control Module (ECM) is the hear.t of
this control system and has sensors used to provide
information about engine operation and the various
systems it controls. Details of basic operation,
diagnosis, functional checks, and on-vehicle service
are covered in "Component Systems," Section "6E3-C".
The ECM has the ability to do some diagnosis of
itself, and of other parts of the system. When it finds a
problem, it will light the Malfunction Indicator Lamp
(MIL) "Service Engine Soon" on the instrument panel
and a Diagnostic Trouble Code (DTC) will be stored in
the ECM memory. This does not mean the engine
should be stopped right away, but that the cause of the
light coming "ON" should be checked as soon as
reasonably possible.
The following sections are written for specific

engine applications and are clearly identified. Be sure
to use only the section which applies to the engine
family being diagnosed.
Before using this section of the manual, you should
be familiar with the information and the proper
diagnostic procedures as described in SECTION 6E. If
the proper diagnosis procedures are not followed, as
described in SECTION 6E, it may result in
unnecessary replacement of good parts.
Diagnostic charts incorporate diagnostic
procedures using a Data Link Connector (DLC) scan
(Tech 1 Diagnostic Computer) tool, where possible.
The scan tool has the ability to save time in
diagnosis and prevent the replacement of good parts.
The key to using a scan tool successfully for
diagnosis lies in the technician's ability to understand
the system being diagnosed, as well as an
understanding of the scan tool's limitations. Refer to
SECTION 6E for more information.
6E3-4 3.4L (L32) (VIN S) (SFI) & 5. 7L (LT1) (VIN P) (MFI) DRIVEABILITY AND EMISSIONS
BLANK
DRIVEABILITY AND EMISSIONS 3.4L (L32) (VIN S) (SFI) 6E3-A-1
SECTION A
ENGINE COMPONENTS/WIRING DIAGRAMS

DIAGNOSTIC CHARTS
BASIC PROCEDURE
On-Board Diagnostic (OBD) System Check
If you have not reviewed the basic information on

how to use the diagnostic procedures, go the
Introduction of this section. The facing page of each
chart in this s~ction will provide a general circuit
description and in some instances, alternate diagnostic
steps or other diagnostic aids specific to that chart or
circuit.
The OBD system check verifies the system is

functioning correctly and is the starting point for
diagnosing. Some special considerations to keep in
mind when diagnosing are:
Blocking Drive Wheels

The vehicle drive wheels should always be blocked
and the emergency brake set while checking the
system.
CONTENTS
Engine Component Locations
Uncterhood Electrical Center
ECMWiringDiagram(1 ofS)
ECM Connector Terminal End View (1 of 3)

Typical Tech 1 Data Values
Typical Tech 1 Data Definitions
ECrv1 Diagnostic Trouble Codes
No Malfunction Indicator Lamp (MIL) "Service Engine Soon" - Chart A-1
Engine Cranks But Will Not Run - Chart A-3

Fuel System Diagnosis- ChartA-7 (1 of 3)
DTC 13 - Left {Bank 2) Oxygen Sensor (025) Circuit (Open Circuit)
DTC 14- Engine Coolant Temperature (ECT) Sensor Circuit (High Temperature Indicated)
DTC 15 - Engine Coolant Temperature (ECT) Sensor Circuit (Low Temperature Indicated)
DTC 16 - System Low Voltage
DTC 17 - Camshaft Position Sensor Circuit Error

DTC 21 - Throttle Position (TP) Sensor Circuit (Signal Voltage High)
DTC 22 - Throttle Position (TP) Sensor Circuit (Signal Voltage Low)

DTC 23 - Intake Air Temperature (IAT) Sensor Circuit (Low Temperature Indicated)
DTC 24-Vehicle Speed Sensor (VSS) Circuit
DTC 25 - Intake Air Temperature (IAT) Sensor Circuit (High Temperature Indicated)
DTC 33 - Manifold Absolute Pressure (MAP) Sensor Circuit (Signal Voltage High-Low Vacuum)
DTC 34- Manifold Absolute Pressure (MAP) Sensor Circuit (Signal Voltage Low-High Vacuum)
DTC 35 - Idle Air Control (IAC) Error
DTC 36 - 24X Signal Circuit Error
DTC 39 - Clutch Switch Error
DTC 42 - Ignition Control (IC) Error

DTC 43 - Knock Sensor (KS) Circuit
DTC 44- Left (Bank 2) Oxygen Sensor (025) Circuit (Lean Exhaust Indicated)
DTC 45 - Left (Bank 2) Oxygen Sensor (025) Circuit (Rich Exhaust Indicated)
DTC 46 - Personal Automotive Security System (PASS -KeyII) Circuit
DTC 53 - System Voltage Overcharge (High Battery Voltage)
DTC 54 - Fuel Pump Circuit (Low Voltage)
DTC 61 - A/C System Performance
DTC 63 - Right (Bank 1) Oxygen Sensor (025) Circuit (Open Circuit)
DTC 64- Right (Bank 1) Oxygen Sensor (025) Circuit (Lean exhaust indicated)
Page A-3
PageA-4
Page A-5
Page A-10
Page A-14
Page A-16
Page A-18
Page A-21
Page A-24
PageA-26
Page A-28
Page A-34
Page A-36
Page A-38
Page A-40
Page A-42
Page A-44
Page A-46
Page A-48
PageA-50
Page A-52
Page A-54
Page A-56
Page A-58
Page A-60
Page A-62
Page A-64
Page A-66
Page A-68
Page A-70
Page A-72
Page A-74
Page A-76
PageA-78
PageA-80
Page A-82
6E3-A-2 3.4L (L32) (VIN S) (SFI) DRIVEABILITY AND EMISSIONS

DTC 65 - Right (Bank 1) Oxygen Sensor (025) (Rich exhaust indicated)
DTC 66 -AJC Refrigerant Pressure Sensor Circuit (Low Pressure)
DTC 67 -AJC Refrigerant Pressure Sensor (Circuit Error)

DTC 68-A/C Compressor Relay (Shorted Circuit)
DTC 69 -AJC Compressor Relay (Open Circuit)

DTC 70-A/C Refrigerant Pressure Sensor Circuit (High Pressure)
DTC 71 -A/C Evaporator Temperature Sensor Circuit (Low Temperature Indicated)
DTC 73 -A/C Evaporator Temperature Sensor Circuit (High Temperature Indicated)
DTC 75- Digital EGR #1 Solenoid Error- Exhaust Gas Recirculation (EGR) Circuit
(Electrical Diagnosis)
DTC 76 - Digital EGR #2 Solenoid Error - Exhaust Gas Recirculation (EGR) Circuit
DTC 77 - Digital EGR # 3 Solenoid Error - Exhaust Gas Recirculation (EGR) Circuit
DTC 81 - Brake Switch Error
DTC 82 - Ignition Control 3X Signal Error
DTC 51 - PROM Error
DTC 85 - PROM Error

OTC 87 - EEPROM ERROR
DTC 86 -A/D Error
Page A-84
Page A-86
PageA-88
Page A-90
Page A-92
Page A-94
Page A-96
Page A-98
Page A-100
Page A-102
PageA-104
PageA-106
PageA-108
Page A-111
Page A-111
Page A-111
Page A-112
II
F"
RPO: L32
CARLINE
COMPUTER HARNESS
C1
C2
C3
C4
cs
C6
ca
Engine Control Module (ECM)

Data Link Connector (DLC)
"SERVICE ENGINE SOON"
Battery Junction Block
ECM harness grounds
1/P Fuse panel
Underhood Electrical Center*
NOT ECM CONNECTED

N1 Crankcase Ventilation Valve
N7 Oil pressure sensor
N17 Evaporative Emission Canister (not
shown), located in left rear fender,
near filler tube
* See Figure A-2 for full Illustration of

fuses and relays.
D CONTROLLED DEVICES
Fuel injector
2
s
8
9
10
15
18
Idle Air Control (IAC) valve

Torque Converter Clutch (TCC)
connector
Fuel pump relay
Air Injection Pump
Ignition Coil Assembly
Evaporative Emission Canister Purge
solenoid valve
Engine Cooling Fan
Digital Exhaust Gas Recirculation

(EGR)valve
SIR System Components. Refer to

Section 9J of the Service Manual, for
"Cautions" and information on SIR
System Components.
3.4L
V6 SFI
INFORMATION SENSORS
A
B
Manifold Absolute Pressure (MAP)

Oxygen Sensor (025)
Throttle Position (TP) Sensor
Engine Coolant Temperature (ECT)
Sensor (Beneath Intake Plenum)
Vehicle Speed Sensor (VSS)
(Transmission mounted, not shown)
Intake Air Temperature (IA T) Sensor
Knock Sensor (KS)
A/C Refrigerant Pressure Sensor
A/C Evaporator Temperature Sensor
A/C Compressor Low Pressure Cutoff
Switch
Camshaft Position Sensor
Low Resolution 3x Crankshaft Position
Sensor
High Resolution 24x Crankshaft
Position Sensor
c
D
F
G
K
L
M
N
p
R
Figure A-1 Engine Component Locations 3.4L (VIN S) "F" Carline
11-13-92
NS 15594

A/C COMPRESSOR
RELAY
ABS
RELAY
COOLANT FAN
RELAY PRIMARY
AIR PUMP
RELAY
FANS/ACTR
FOG LTS
AIR PUMP
R HDLP DR
~
~
~
~#8~
0.0
OY
ABS IGN
~~
~ 0.0
NOT USED
INJECTOR
ABS BAT
INJECTOR
IGNITION
A/C-CRUISE
L HDLP DR
LOW COOLANT
RELAY
FOG LIGHTS
RELAY
HIGH BLOWER
RELAY
TOP VIEW
#48
~#8~
#78
502
502
B,
004
B,
~}
0,
[!]
#18
84
sE] cfu EJ sB cfu 00 s[~~J cfu
#38
#2
#5~
641
E]4
#128
B sEJ cfu B
2
0,
sE] ~B sEJ !z;J El s[~J !z;J BsB !z;J fil;]

E
El
B,
#118
.....
#108
#98
BACK VIEW
11-5-92
NS 15595
Figure A-2- Underhood Electrical Center 3.4L (VIN S) "F" Carline
DRIVEABILITY AND EMISSIONS 3.4L (L32) (VIN S) {SFI} 6E3-A-5
ENGINE
COOLANT
TEMPERATURE
(ECT) SENSOR
10-WAY INJ/ECM CONN. (BLACK)
ECM
~ B 410YEL---T11~--~1 , , - - - - - - - - - - 4 1 0 Y E L
~
470 BLK _ _ _..._.
ECT SENSOR SIGNAL
...- - - ,
THROTTLE
POSITION
(TP)
SENSOR
470 BLK - - - - - - - - - < - - - - - - - 4 7 0 BLK
SENSOR GROUND
417DKBLU
417DKBLU
TP SENSOR SIGNAL
416 GRY
5 VOLT REFERENCE
MANIFOLD
ABSOLUTE
PRESSURE
(MAP)
SENSOR
416GRY---~
416 GRY
MAP SENSOR SIGNAL
432 LT GRN
808BLK--------+-----~
INTAKE AIR
TEMPERATURE
(IAT) SENSOR
~ B 472 TAN
~
808 BLK
IAT SENSOR SIGNAL
--------+---------------1
--------+---380 RED/BLK - - - - - - + - - - - - - + - - - - - -
SENSOR GROUND
808 BLK
A/C
REFRIGERANT
PRESSURE
SENSOR
416 GRY - - - - - - - -
A/C
~808BLK
EVAPORATOR
TEMPERATURE
B
732 DK BLU - - - - - - - - + - - - - - - - - - - - - 0
SENSOR
A
416GRY - - - - - - - '
A/C
1/P FUSE #3
SELECT SWITCH
TO ~ 2 4 1 BRN - - - - - - - - ~ - - - - - - - 7 6 2 LT GRN/BLK
A/C REFRIGERANT
PRESSURE SENSOR
SIGNAL
AIC EVAPORATOR
TEMPERATURE SENSOR
SIGNAL
A/C REQUEST
FUSE #12 *
IGNITION
25 AMP
SWITCH~~ _ _ _ _ _... __
- . . . . - - - - - - - - - - ~ 139 PNK--~
20AMP
10-WAY FWD LAMP HARNESS

CONNECTOR (BLACK)
A/C
COMPRESSOR
RELAY*
,---,
I
A/C
COMPRESSOR
CLUTCH
459 DK GRN/WHT
A/C COMPRESSOR
CLUTCH RELAY CONTROL
A/C STATUS
A/C
COMPRESSOR
LOW PRESSURE
CUTOFF SWITCH
603 DK GRN
* LOCATED IN UNDERHOOD ELECTRICAL CENTER
Figure A-3 - ECM Wiring Diagram 3.4L (VIN S) "F" Carline (1 of 5)
10-20-92
NS 15519
6E3-A-6 3.4L {L32) {VIN S) {SFI) DRIVEABILITY AND EMISSIONS
ECM
1744 BLK
INJ DRIVER CYL #1
1746 PNK/BLK
INJ DRIVER CYL #3
845 BLK1WHT
INJ DRIVER CYL #5
844 LT BLU/BLK
INJ DRIVER CYL #4
846 YEUBLK
INJ DRIVER CYL #6
INJ DRIVER CYL #2
KNOCK SENSOR
SIGNAL
1----
E~2~~E
GROUND
CAMSHAFT
POSITION
SENSOR
CAMSHAFT POSITION
SENSOR SIGNAL
633 BRN/WHT
1-----
------
632 PNK/BLK
CAMSHAFT & 24X

CRANKSHAFT POSITION
SENSORS REF LOW
HIGH
RES.
1800 LT BLU/WHT - - - - - - - - - - 1
24X REFERENCE
SIGNAL
24X CRANKSHAFT
POSITION SENSOR
10-WA Y FWD LAMP

FUSE #11 *
HARNESS CONNECTOR
10 AMP
(BLACK)
I G N I T I O N ~ 239PNK - - - - 1 G t - - - - - - 4 1
B+
450 BLK
LOW RESOLUTION
3X CRANKSHAFT
POSITION SENSOR
GND
;:~ =ffi I
SIGNAL
TWISTED 9 TIMES/FOOT
MINIMUM
1----------
----1
IGNITION CONTROL
BYPASS
423 WHT - - - - '
IGNITION CONTROL
424 TAN/BLK
0-----------
121 WHT ----TACH SIGNAL

ELECTRONIC
IGNITION
D
CONTROL
MODULE
E 0 - - - - - - - - - 647 LT BLU/BLK - - - - "
(ICM)
~ - - - - - < F - - - - - - - - - 453 RED/BLK - - - - I
3X REF HIGH
3X REF LOW
PRIMARY
WINDING
Figure A-4 - ECM Wiring Diagram 3.4L (VIN S) ''F'' Carline (2 of 5)
10-27-92
NS 15520
DRIVEABILITY AND EMISSIONS 3.4L {L32) {VIN S) {SFI) 6E3-A-7
TO PASS-Key II
DECODER MODULE
ECM
10-WAY INLINE 1/P
CONNECTOR #2
(BLUE)
1/P FUSE #5
TO IGN - - - - - - - a----111-------1 G
SWITCH
15AMP
1------ 439 PNK
465 DK GRN/WHT
451 BLK/WHT
150
BLK
1/P FUSE
#4
VEHICLE
SPEED SENSOR (VSS)
(TRANSMISSION
MOUNTED)
FUEL PUMP PRIME

CONNECTOR
r -
+ FOR BRANCH CIRCUITS
EJ
10AMP
ogQ;J
340 ORN
BATTERY INPUT
340 ORN
BATTERY INPUT
400 YEL
VSS INPUT HIGH
401 PPL
VSS INPUT LOW
~-l---01---817DKGRN/WHT
INSTRUMENT
CLUSTER
FUEL PUMP SIGNAL
REFER TO SECTION SA
4-WAY INLINE 1/P

CONNECTOR #3 (BLACK)
B + ,,c
INLINE 1/P
CONNECTOR #1
FUEL PUMP REQUEST
-=:l_
i------------120GRY
FUEL TANK/ABS
PASS THRU
CONNECTOR
IGNITION FEED
BUFFERED SPEED OUTPUT

(4000 PULSES PER MILE)
10-WAY INLINE
1/P CONNECTOR #1
(NATURAL)
10 WAY INLINE 1/P

MALFUNCTION INDICATOR CONNECTOR #2 (BLUE)
LAMP(MIL)
/
r--,
(n'\
1/P FUSE #9
;
j ,-,/
TOIGN - - - - - - . ,,.__..,__39PNK/BLK ~ 4 1 9 B R N / W H T
SWITCH
10 AMP
L - - J
"SERVICE ENGINE SOON",--------------,
I
BRAKE SWITCH
I
TO BRAKE
:
ASSEMBLY
:
TRANSMISSION SHIFT
INTERRUPT (BTSI)
39 PNK/BLK
TC(
:I
I
BRAKE
SOLENOID
583 LT BLU/BLK
SWITCH :
L--------------J
4th GEAR
SWITCH
- . . - - - - - - - - - 5 s 3 LT BLU/BLK
MIL CONTROL
=I
~----
.......
--~~~~~
t-------------446LTBLU
AUTOMATIC
TRANS TCC
SOLENOID
......o - - - - - - - - - - - - - - 4 2 2 TAN/BLK
.....
~~~~~~~_._
DATA LINK
CONNECTOR
(DLC)
TCC/ BRAKE SWITCH INPUT
4th GEAR SWITCH
TCCCONTROL
F ---~
CLUTCH
ANTICIPATE/CRUISE
RELEASE SWITCH
t---------48GRY
451 BLK/WHT
CLUTCH ANTICIPATE
INPUT (MIT ONLY)
10-27-92
NS15521

ECM
B+
FUSE LINK
~402RED
10-WAY INLINE FWD
LAMP HARNESS
CONNECTOR (BLACK)
335DKGRN
COOLING
FAN
CONTROL
RELAY*
COOLING FAN CONTROL
541 BRN
~409LTBLU
~150BLK--i
ENGINE
COOLING FAN
EVAPORATIVE
EMISSION (EVAP)
CANISTER PURGE
SOLENOID VALVE
II
FUSE #6*
TO
IGNITION
SWITCH
10AMP
428 DK
GRN/WHT
DIGITAL
EXHAUST GAS
RECIRCULATION
(EGR) VALVE
EVAP CANISTER PURGE

SOLENOID CONTROL
EGR #3 CONTROL
EGR #2 CONTROL
EGR #1 CONTROL
TO
FUSE #7*
I G N I T I O N ~ 4 4 1 BRN
SWITCH
20 AMP
SECONDARY
AIR INJECTION
PUMP
RELAY*
SECONDARY
AIR
INJECTION
PUMP
ASSEMBLY
436 BRN
SECONDARY AIR INJECTION

PUMP RELAY CONTROL
A - - - - 7 8 RED--~
10-WAY FORWARD
LAMP HARNESS
CONNECTOR (BLACK)
c
150
BLK
_j_
*LOCATED IN UNDERHOOD ELECTRICAL CENTER
10-1392
NS 15522

ECM
IACCOIL "A" HIGH

IACCOIL "A" LOW
IA( COIL "B" HIGH
IAC COIL "B" LOW
TO PASS-KeyII - - - - - - - - - - - - 2 2 9 D K B L U
DECODER MODULE
PASS-Key"'ll SIGNAL
(FUEL ENABLE INPUT)
TO HATCH
RELEASE
PARK/NEUTRAL " POSITION (PNP) I

SWITCH
!.
~ --
- I B - - - - - 1 - - - - - - - 4 3 4 ORNiBLK
B
-
PARK/NEUTRAL
POSITION SWITCH
SIGNAL
451 BLK/WHT----i~
(PART OF THE
TRANSMISSION
POSITION SWITCH)
LEFT 025 GROUND
ENGINE
GROUND
-*-=-
ENGINE
351 BLK/WHT
RIGHT 025 GROUND
l I~
551 TAN/WHT
ECMGROUND
ECMGROUND
551 TAN/WHT
-f
GROUND -
~ 1666 PPL
RIGHT(BANK 1)
025 SIGNAL
LEFT (BANK 2) OXYGEN SENSOR ( 0 2 5 ) ; = :

RIGHT (BANK 1) OXYGEN SENSOR (025)
'-f---------------<~1665PPL/WHT
LEFT (BANK 2)
025 SIGNAL
TO
TCC . - - - < 1 1 1 - - - - - - - - - - - - - - - - - - - - - - 4 2 2 TAN/BLK
SOLENOID
10-WAY 1/P CONN.
(BLUE)
422 TAN/BLK
448 WHT/BLK - - - - - @ - - 4 4 8 WHT/BLK
DIAGNOSTIC
TEST
TERMINAL
IN-LINE 1/P CONN #3 (BLACK)
DIAGNOSTIC
ENABLE
TO OIL LEVEL SENSOR

ECMGROUND
I
I
I
ECMGROUND
~ ___ _.REFER TO SECTION BA
FOR BRANCH CIRCUITS
DATA LINK
CONNECTOR (DLC)
JUNCTION
BLOCK
~----soOTAN
TO DIAGNOSTIC _ __.
ENERGY RESERVE
MODULE (DERM)
800 TAN
10-WAY FWD
LAMP HARNESS
CONNECTOR
(BLACK)
TO ELECTRONIC BRAKE
CONTROL MODULE (EBCM)
Figure A-7 - ECM Wiring Diagram 3.4l (VIN S) "F" Carline (5 of 5)
10-20-92
NS15571
ECM CONNECTOR A" (CLEAR}

II
ECM PIN/FUNCTION
CKT#
WIRE COLOR
A1
SENSOR GROUND FOR MAP, IA T, A/C REFRIGERANT

PRESSURE AND A/C EVAPORATOR TEMPERATURE SENSORS
808
BLK
A2
A/C REQUEST
762
DKGRN/WHT
A3
A/C EVAPORATOR TEMPERATURE SENSOR SIGNAL
732
DK BLU
AS
A/C REFRIGERANT PRESSURE SENSOR SIGNAL
380
RED/BLK
A6
FUEL PUMP SIGNAL
120
GRY
FUEL PUMP REQUEST
465
DK GRN/WHT
422
TAN/BLK
A 17 SENSOR GROUND FOR TP SENSOR AND ECT SENSOR
470
BLK
A18 TCC/BRAKE SWITCH INPUT
583
LTBLU/BLK
A4
A7
AB
32
A9
A10
A11
A12
A13
A14
A 15 TCC CONTROL
A16
A19
A20
A21
O O
00
00
00
00
00
00
00
00
00
00
00
00
00
00
17 0 0
16
FRONT VIEW
32 PIN
ECM CONNECTOR A"
(CLEAR}
II
-------------------A22 4th GEAR SWITCH - (A/T)
CLUTCH ANTICIPATE SWITCH - (MIT)
""'"--- -----446
LTBLU
48
GRY
A23
A24
A25
A26
A27
A28
A29 MAP SENSOR SIGNAL
432
LTGRN
A30 TP SENSOR SIGNAL
417
DKBLU
A31 ECT SENSOR SIGNAL
410
YEL
A32
11-10-92
NS 15590
Figure A-8 - ECM Connector Terminal End View (1 of 3)
ECM CONNECTOR "B" (BLACK)

ECM PIN/FUNCTION
CKT# WIRE COLOR
81
82
COOLANT FAN RELAY CONTROL
335
DKGRN
83
SECONDARY AIR INJECTION PUMP RELAY CONTROL
436
BRN
84
EVAP CANISTER PURGE CONTROL
428
DK GRN/WHT
86
A/C COMPRESSOR CLUTCH RELAY CONTROL
459
DK GRN/WHT
87
MALFUNCTION INDICATOR LAMP (MIL)

419
BRN/WHT
85
32
88
89
810
811 EGR #1 CONTROL
697
LT BLU
812 EGR #2 CONTROL
698
BRN
813 EGR #3 CONTROL
699
RED
814 BATTERY+ (KEEP ALIVE MEMORY)
340
ORN
815 BATTERY+ (KEEP ALIVE MEMORY)
340
ORN
816 ECM GROUND
451
BLK/WHT
817
17
818
819 SERIAL DATA
800
TAN
820 LEFT (BANK 2) 025 GROUND
351
BLK/WHT
821 LEFT (BANK 2) 025 SIGNAL
1665
PPUWHT
822 RIGHT (BANK 1) 025 SIGNAL
1666
PPL
823 RIGHT (BANK 1) 025 GROUND
351
BLK/WHT
824 IAC COIL "B" HIGH
1749
LTGRN/WHT
825 IAC COIL "B" LOW
444
LT GRN/BLK
826 IAC COIL" A" LOW
1748
LT BLU/BLK
827 IAC COIL" A" HIGH
1747
LT BLU/WHT
828 BUFFERED SPEED OUTPUT (4000 PULSES/MILE)
817
DK GRN/WHT
829 VSS INPUT LOW
401
PPL
830 VSS INPUT HIGH
400
YEL
831 5 VOLT REFERENCE - MAP, TP AND A/C REFRIGERANT

PRESSURE SENSORS
416
GRY
832 ECM GROUND
451
BLK/WHT
0 O
00
00
00
00
00
00
00
00
00
00
00
00
00
00
0 0
16
FRONT VIEW
32 PIN
ECM CONNECTOR "B"
(BLACK)
10-29-92
NS 15591
ECM CONNECTOR "C" (BLUE)

ECM PIN/FUNCTION
CKT#
WIRE COLOR
C1
ECMGROUND
551
TAN/WHT
C2
A/C STATUS
59
DKGRN
C3
IGNITION FEED
439
PNK
C4
cs
C6
C7
cs
448
WHT/BLK
C11 PARK/NEUTRAL POSITION SWITCH INPUT
434
ORN/BLK
C12 INJECTOR DRIVER CVL #3
1746
PNK/BLK
1745
LT GRN/BLK
1744
BLK
846
YEL/BLK
845
BLK/WHT
C17 ECM GROUND
551
TAN/WHT
C18 REFERENCE LOW CAMSHAFT & CRANKSHAFT SENSORS
632
PNK/BLK
C20 KNOCK SENSOR SIGNAL
496
DK BLU
C21 24X REFERENCE SIGNAL
1800
LT BLU!WHT
229
DKBLU
633
BRN/WHT
C27 IGNITION CONTROL
423
WHT
C28 IGNITION CONTROL BYPASS
424
TAN/BLK
C29 IAT SENSOR SIGNAL
472
TAN
C30 3X REFERENCE HIGH
647
LT BLU/BLK
C31 3X REFERENCE LOW
453
RED/BLK
C32 INJECTOR DRIVER CYL #4
844
LT BLU/BLK
C9
0 017
00
00
00
00
00
00
00
00
00
00
00
00
00
00
16 0 0 32
1
DIAGNOSTIC ENABLE
C10
C19
C22
C23 PASS-KeyII SIGNAL (FUEL ENABLE)
FRONT VIEW
32 PIN
ECM CONNECTOR "C"
(BLUE)
C24
C25 CAMSHAFT POSITION SENSOR SIGNAL
C26
10-29-92
NS 15592
DRIVEABILITY AND EMISSIONS 3.4L (L32) (VIN S) {SFI) 6E3-A-13
BLANK
ECM
TO TCC - - - - - - - - - - - - - - - - - - - - - - - - 422 TAN/BLK
SOLENOID
10-WAY INLINE 1/P
CONNECTOR #2
INLINE 1/P
(BLUE)
K CONNECTOR #2
448 WHT/BLK
DIAGNOSTI
TEST
TERMINAL
0t------
448 WHT/BLK
DIAGNOSTIC ENABLE
TO OIL LEVEL
SENSOR
ECMGROUND
I
REFER TO SECTION SA
TO ELECTRON!
FOR BRANCH CIRCUITSi----l~BRAKE CONTROL
JUNCTION
MODULE (EBCM)
BLOCK
...___ _ 800 TAN
800 TAN
TO DIAGNOSTIC ENERGY-----~
10-WAY FWD
RESERVE MODULE (DERM)
LAMP
L- - -
DATA LINK
CONNECTOR
(DLC)
TCCCONTROL
HARNESS
CONNECTOR
(BLACK)
r---,
ECMGROUND
SERIAL DATA
KEEP ALIVE
MEMORY B+
r - ,
1/PFUSE #9
TO IGN ~ 9 PNK/BLK - - r ~ - : : : , , - ~ - - - - - - t - 1 B
419 BRN,WHT
I
I
SWITCH
10 AMP
.._ _ _. T O ~ I / P F U S E # S
"SERVICE
439 PNK
TO BRAKE
ENGINE IGN
G
SWITCH
SOON"
15AMP L - ...J
(MIL)
10-WAY INLINE 1/P
CONNECTOR #2(BLUE)
MIL CONTROL
IGNITION FEED
11-11-92
NS 15596
ON-BOARD DIAGNOSTIC (OBD) SYSTEM CHECK

3.4L (VIN S) "F" CARLINE (SFI)
The on-board diagnostic system check is an organized approach to identifying a problem created by an
electronic engine control system malfunction. It must be the starting point for any driveability complaint
diagnosis, because it directs the service technician to the next logical step in diagnosing the complaint.
Understanding the chart and using it correctly will reduce diagnostic time and prevent the unnecessary
replacement of good parts.

1. This step is to determine if the Tech 1 can establish
communication with the ECM. If it cannot, "No
D LC Data" will be displayed on the Tech 1.
2. This test is to determine if the ECM can control the
MIL using the MIL system check.
rn
Important
This vehicle is equipped with an Engine

Control Module (ECM) utilizing an
Electrically Erasable Programmable Read
Only Memory (EE PROM).
When diagnostics call for replacement of the
ECM, the new ECM must be programmed.
Refer to "ECM Replacement and Programming
Procedures" in Section "6E3-Cl".
ON-BOARD DIAGNOSTIC (OBD)

SYSTEM CHECK
G)
IGNITION "OFF," ENGINE "OFF."

INSTALL TECH 1 SCAN TOOL.
IGNITION "ON" ENGINE "OFF."
SELECT APPLICABLE CARLINE DATA LIST.
IS DLC COMMUNICATION PRESENT?
(TECH 1 WILL DIAPLAY "WAITING FOR DATA" WHILE WAITING FOR COMMUNICATION.)
CHECK SERIAL DATA CKT 461 FOR OPEN, SHORT TO GROUND

OR
SHORT TO VOLTAGE SEE ELECTRICAL DIAGNOSIS SECTION
"SA". IF "OK" THEN FAULTY CALIBRATION OR FAULTY ECM.
REFER TO ECM AND SENSORS SECTION "(1 "FOR
REPROGRAMMING AND/OR REPLACEMENT OF ECM.
USING A TECH 1 PERFORM THE MIL

SYSTEM CHECK.
DOES MIL FUNCTION PROPERLY?
----------,
USE CHART A-1.
--------,
USE CHART A-3. I
L----------.J
L----------.J
REFER TO ECM DIAGNOSTIC TROUBLE CODES

TABLE IN THIS SECTION FOR VALID DTCs.
ARE ALL DTCs DISPLAYED VALID?
INCORRECT
OR
FAULTY CALIBRATION
OR
FAULTY ECM. REFER TO "ECM
AND SENSORS'' SECTION "(1"
FOR REPROGRAMMING AND/OR
REPLACEMENT OF ECM.
COMPARE TECH 1 SCAN DATA WITH TYPICAL VALUES

SHOWN IN THIS SECTION. ARE VALUES NORMAL OR
WITHIN TYPICAL RANGES?
REFER TO "INDICATED
COMPONENT(S) SYSTEM
CHECKS" IN SECTION"(".
11-30-92
NS 15099
6E3-A-16 3.4l {L32) {VIN S) {SFI) DRIVEABILITY AND EMISSIONS

If after completing the "On-Board Diagnostic (OBD) System Check" and finding the Tech 1 diagnostics
functioning properly and no diagnostic trouble codes displayed, the "Typical Tech 1 Data Values" may be used for
comparison with values obtained on the vehicle being diagnosed. The "Typical Tech 1 Data Values," are an
average of display values recorded from normally operating vehicles and are intended to represent what a
normally functioning system would display.
A SCAN TOOL THAT DISPLAYS FAULTY DATA SHOULD NOT BE USED, AND THE PROBLEM SHOULD BE
REPORTED TO THE MANUFACTURER. THE USE OF A FAULTY SCAN TOOL CAN RESULT IN MISDIAGNOSIS
AND UNNECESSARY PARTS REPLACEMENT.
Only the parameters listed are used in this manual for diagnosis. If a scan tool reads other parameters, the
values are not recommended by General Motors for use in diagnosis. For more description on the values and use
of the Tech 1 to diagnosis ECM inputs, refer to the applicable diagnosis section in "Component Systems," Section
'6E3-C". If all values are within the range illustrated, refer to "Symptoms," Section ''6E3-B".
TYPICAL TECH 1 DATA VALUES

11
11
3.4L (VIN S) F CARLINE
Idle I Upper Radiator Hose Hot I Closed Throttle I Park or Neutral I "Closed Loop" I Acc. "OFF"
Scan Position
Units Displayed
Typical Data Value
6E3 Reference Sec.
Engine Speed
RPM
Desired Idle
RPM
Engine Coolant Temp

Intake Air Temp
C/Fo
ca;Fo
100 RPM from desired RPM

( 50 RPM in drive)
BARO
kPa/Volts
Throt Position
Throttle Angle
025 Right (Bank 1)
025 Left (Bank 2)
S. T. Fuel Trim
(Bank 1)
L. T. Fuel Trim
(Bank 1)
S. T. Fuel Trim
(Bank 2)
L. T. Fuel Trim
(Bank 2)
Loop Status
Fuel Trim Cell
Volts
0 - 100%
Millivolts
Millivolts
Counts
ECM idle command

(varies with temperature)
85C-109C ( 185F-223F)
10C-80C (50F-176F) depends
on underhood temperature.
29 - 48 kPa ( 1 - 2 vol ts) depends
on Vac. & Baro pressure.
58 - 114 kPa (2. 5 - 5.5) depends
on altitude & Baro pressure.
.29 - .98
0%
100-1000 and varying
100-1000 and varying
Varies
Counts
110 - 156
Counts
Varies
Counts
110 - 156
Open Lp/Closed Lp
Cell Numbers
Closed Loop
0 - 16 (Depends on air flow and RPM)
Fuel Trim Enable
No/Yes
No
Spark Advance
# of Degrees
Varies
Spark Retard
# of Degrees
O*
MAP
kPa/Volts
* NOTICE: If maximum retard is indicated, go to CHART C-5.
C2, CHART C-28

C2, CHART C-28
C1
C1
C1,CHARTC-1D
Cl, CHART C-1 D
C1, C2
Cl, C2
C1, C2
C1, C2
C2, Typical Tech 1
Data Definitions
C2, Typical Tech 1
Data Definitions
C2, Typical Tech 1
Data Definitions
C2, Typical Tech 1
Data Definitions
C1, C2, Typical Tech 1
C2, Typical Tech 1 Data
Definitions
C2, Typical Tech
Data
Definitions
C5, Typical Tech 1
Data Definitions
CS, Typical Tech 1
Data Definitions

Knock Signal
No/Yes
EGR 1/EGR 2
EGR3
Idle Air Control
ParkJNeutral Pos
MPH Km/h
Torque Converter
Clutch
System Voltage
Off/On
Off/On
Counts (steps)
P-N and R-DL
vehicle speed
No (Yes, indicates knock is being

detected)
Off (On when commanded by ECM)
5-50
Park/Neutral (P-N), Reverse/Drive (R-DL)
0
Off/On
Volts
Off/(On with TCC commanded)

13.5- 14.5 Volts
Fuel Pump Volts

lgn Cntrl 3X SIG
Volts
RPM
13.5 - 14.5 Volts

Varies
lgn Cntrl 24X SIG
RPM
Varies
lgn Cntrl CAM SIG
0/1
Varies
A/C Request
A/C Clutch
A/C Status
A/C Refrigerant
Pressure
A/C EVAP Temp
Engine Cool Fan
No/Yes
On/Off
On/Off
No (Yes with A/C requested)

Off (On with A/C commanded On)
Off (On with A/C clutch engaged)
psi/Volt
OC/OF
lnj. Pulse Width

Fuel EVAP Purge
TCC
4th gear switch
TCC Brake Switch
Clutch Pedal Switch
Air Pump Relay
PASS-Key/Vats
DTC lgn Counter
Milliseconds
0-100%
Off/On
Off/On
Released/Applied
Off/On
Off/On
Fault/OK
# of Key Cycles
Varies (Depends on temperature)

Varies (Depends on temperature)
"Off" (On@ 109C, then
"Off" @ 98()
1-4 and varying
0%
Off (On with TCC commanded)
Off (On when.4th gear switch closes)
Released (Applied with brake depressed)
Off (On with clutch pedal depressed)
OK (Fault if DTC 46 is set)
0 (Counts Key Cycles)
DTC5tored
# of DTCs stored
0 (Counts# of DTCs Stored)
Time From Start
Hrs/Min
Varies
Off/On
CS, Typical Tech 1

Data Definitions
C7
C7
C2, CHART C-28
C1,CHARTC-1A
C1, C8, 8A
CB
Typical Tech 1 Data
Definitions
C2
C1, C4 Typical Tech
Data Definitions
C1, C4 Typical Tech
Data Definitions
C1, C4 Typical Tech! Data
, Definitions
C10
C10
C10
C10,C12
C10,C12
C10,C12
C2, CHART C-2A
C3
C1, CB, BA
C8,8A
C1, CB, BA
C1, CB, BA
CG
DTC46, BA
Typical Tech
Data
Definitions
Typical Tech
Data
Definitions
Typical Tech 1 Data
Definitions
11-11-92
NS 15597
6E3-A-18 3.4L (L32) (VIN S} (SFI) DRIVEABILITY AND EMISSIONS
TYPICAL TECH 1 DATA DEFINITIONS

ECM DATA DESCRIPTION
A list of explanations for each data message displayed
on the Tech 1 scan tool begins below.
This information will assist in tracking down emission
or driveability problems, since the displays can be
viewed while the vehicle is being driven. Refer to the
"On-Board Diagnostic System Check" for additional
information.
THROT POSITION - Used by the ECM to determine the

amount of throttle demanded by the driver. Should
read .29 - 98 volt at idle to above 4 volts at Wide Open
Throttle (WOT).
THROTILE ANGLE - Computed by the ECM from TP
sensor voltage (Throt position); should read 0% at idle,
100% at Wide Open Throttle (WOT).
025 RIGHT (BANK 1) - Represents the right exhaust
ENGINE SPEED - Engine speed is computed by the ECM
from the fuel control reference input (low resolution

crankshaft position sensor). It should remain close to
desired idle under various engine loads with engine
idling.
Oxygen Sensor (02S) output voltage. Should fluctuate

constantly within a range between 100 mV (lean
exhaust) and 1000 m V (rich exhaust) when operating
in "Closed Loop."
025 LEFT (BANK 2) - Represents the left exhaust
DESIRED IDLE - The calculated idle speed that is
commanded by the ECM. The ECM will compensate

for various engine loads to keep the engine at the
desired idle speed.
ENGINE COOLANT TEMP - The Engine Coolant
Temperature (ECT) sensor is mounted in the intake
manifold and sends engine temperature information to
the ECM. The ECM supplies 5 volts to the ECT sensor
circuit. The sensor is a thermistor which changes
internal resistance as temperature changes. When the
sensor is cold (internal resistance high), the ECM
monitors a high signal voltage which it interprets as a
cold engine. As the sensor warms (internal resistance
decreases), the voltage signal will decrease and the
ECM will interpret the lower voltage as a warm
engine.
INT AIR TEMP SENSOR - The Intake Air Temperature
(IAT) sensor is used by the ECM to adjust fuel delivery
and spark timing according to incoming air density.
The ECM supplies 5 volts to the IAT thermistor. As
intake air temperature varies, the resistance changes
causing a change in voltage drop across the sensor.
The ECM measures the voltage drop and calculates
the air temperature at the air intake.
MAP - The Manifold Absolute Pressure (MAP) sensor
measures the changes in the intake manifold pressure

which results from engine load and RPM changes and
converts these into a voltage output.
BARO - MAP sensor is also used to measure barometric
pressure during ignition key "ON" cycle and during

Wide Open Throttle (WOT), allowing the ECM to
make adjustments for altitudes. The ECM uses the
MAP sensor to control fuel delivery and ignition
timing.
Oxygen Sensor (02S) output voltage. Should fluctuate

constantly within a range between 100 m V (lean
exhaust) and 1000 m V (rich exhaust) when operating
in "Closed Loop."
SHORT TERM FUEL TRIM - (Bank 1 or Bank 2) - This
represents a short-term correction to fuel delivery by

the ECM in response to the amount of time the oxygen
sensor voltage spends above or be low the 450 m V
threshold. If the oxygen sensor voltage has mainly
been below 450 mV, indicating a lean air/fuel mixture,
short term fuel trim will increase to tell the ECM to
add fuel. If the oxygen sensor voltage stays mainly
above the threshold, the ECM will reduce fuel delivery
to compensate for the indicated rich condition. Under
certain conditions such as extended idle and high
ambient temperatures, EVAP canister purge may
cause short term fuel trim to read less than 100
counts.
LONG TERM FUEL TRIM - (Bank 1 or Bank 2) - Long
term fuel trim is derived from the short term fuel trim
value and is used for long-term correction of fuel
delivery. A value of 128 counts indicates that fuel
delivery requires no compensation to maintain a
14.7:1 air/fuel ratio. A value below 128 counts means
that the fuel system is too rich and fuel delivery is
being reduced (decreased injector pulse width). A
value above 128 counts indicates that a lean 02S
signal condition exists and the ECM is compensating
by adding fuel (increased injector pulse width). Long
term fuel trim tends to follow short term fuel trim;
normal values of 110-150 counts at idle should not be
considered unusual.
DRIVEABILITY AND EMISSIONS 3.4l {L32) {VIN S) {SFI) 6E3-A-19

FUEL TRIM CELL - The 60 V6 engine uses sixteen fuel
trim cells. Cell sixteen is the idle mode cell. Throttle
position and MAP determine which cell the engine will
bein
LOO? STATUS - "Closed Loop" displayed indicates that
the ECM is controlling fuel delivery according to
oxygen sensor voltage. In "Open Loop," the ECM
ignores the oxygen sensor voltage and bases the
amount of fuel to be delivered on TP sensor, engine
coolant, and MAP sensor inputs only. "Closed Loop"
operation should begin when both oxygen sensors
become active and engine coolant temperature exceeds
65C (149F) for more than 30 seconds.
FUEL TRIM ENABLE - (Tech 1 Will Display "YES") - If
the fuel trim enable system is learning, the L. T. fuel
trim is responding to the S. T. fuel trim. If fuel trim
enable reads "NO" then L. T. fuel trim will not respond
to changes in S. T. fuel trim.
SPARK ADVANCE - This is a display of the spark
advance calculation determined by the Ignition
Control (IC) logic which the ECM is delivering to the
electronic ignition control module. It computes the
desired spark advance using data such as engine
coolant temperature, RPM, load, vehicle speed, and
operating mode.
SPARK RETARD - Indicates the amount of spark
advance the ECM is removing from the Ignition
Control (IC) timing in response to the Knock Sensor
(KS) signal. Tech 1 should display 0 at idle.
KNOCK SIGNAL - Indicates whether or not a knock
signal is being detected by the ECM. Tech 1 should

display "NO" at idle.
EGR 1/EGR 2/EGR 3 - Any combination of the EGR
solenoids may be opened during engine operation. The

Tech 1 can indicate which solenoids are open or when
all three are closed, such as at idle. The Tech 1 can
cycle each solenoid to evaluate its operation.
MPH KM/H - The Vehicle Speed Sensor (VSS) signal is

converted into km/h and mph for display.
TORQUE CONVERTER CLUTCH (TCC) - Tech 1 displays
TCC "OFF" or "ON" as commanded by the ECM.
SYSTEM VOLTAGE - System voltage with ignition
"ON" and engine "OFF" will reflect battery voltage.
Ignition "ON" engine "ON" will indicate charging
system voltage applied to the ECM ignition input.
FUEL PUMP VOLTS - When the ignition switch is
turned to the "ON" position, the ECM turns the fuel

pump relay "ON" for two seconds. If the ECM does not
receive ignition reference pulses within two seconds,
the ECM will shut "OFF" the fuel pump.
IGNITION CONTROL 3X SIGNAL - Indicates the ECM is
receiving 3X reference signal from the ignition control

module.
IGNITION CONTROL 24X SIGNAL - Indicates the ECM
is receiving 24X reference signals from the 24X, high

resolution crankshaft position sensor.
IGNITION CONTROL CAM SIGNAL - The ignition
control CAM signal provides the ECM with the

information to determine when the intake valve on
number one cylinder will open. "O" CLOSED, "1"
OPENED - The ECM sequences the injectors in
cylinder firing order based on the input from the
camshaft position sensor.
A/C REQUEST - Represents the state of the A/C request
input from the control head.
A/C CLUTCH - Represents the commanded state of the
A/C clutch control relay. Clutch should be engaged
when "ON" is displayed.
A/C STATUS - The Tech 1 will display "ON" if voltage
has been applied to the A/C compressor clutch.
A/C REFRIGERANT PRESSURE - Tech 1 displays
IDLE AIR CONTROL - Displays the commanded position
of the Idle Air Control (IAC) pintle in counts. The

higher the number of counts, the greater the
commanded idle speed. Idle Air Control (IAC) should
respond fairly quickly to changes in engine load to
maintain desired idle RPM.
PARK/NEUTRAL POSITION - P-N displayed indicates
the gear select lever is in "Park" or "Neutral." R-DL

displayed indicates the gear select lever is in
"Reverse", "Drive" or "Low Range."
refrigerant pressure represented by psi and voltage.

A/C EVAP TEMPERATURE -The Tech 1 will display the
AJC system temperature used by the ECM for cooling

fan operation, A/C compressor clutch control and A/C
diagnostic trouble codes.
ENGINE COOL FAN - When the ECM is commanding
the engine cooling fan "ON," the Tech 1 display will
switch from "OFF" to "ON." The coolant fan can also
be selected as an output test by the Tech 1.

INJECTOR PULSE WIDTH - Indicates the on time of the
CLUTCH PEDAL SWITCH - Tech 1 displays "ON" with
injectors in milliseconds. When engine load is

increased, injector pulse width will increase.
the clutch pedal depressed and "OFF" with the clutch

pedal at rest.
FUEL EVAP PURGE - A signal used to control canister

purge function. 0% indicates the evaporative emission
canister purge solenoid valve is commanded fully
closed while 100% indicates that the valve is
commanded fully open.
AIR PUMP RELAY - The Tech 1 displays "ON" when
(TCC) - A/T - The Tech 1 only indicates when the ECM
has enabled the Torque Converter Clutch (TCC)

driver, but this does not confirm that the TCC has
engaged. To determine if TCC is operating properly,
engine RPM should decrease when TCC is enabled.
Refer to Chart C-8.
secondary air is commanded by the ECM and "OFF"

when conditions do not require secondary air injection.
PASS-KeyII -An input from the PASS-KeyII decoder
module that tells the ECM to enable the injectors if the

proper signal is received. The Tech 1 will normally
display "OK." If the PASS-KeyII test has failed, the
display will switch to "FAULT" and the fuel system
may be disabled.
OTC IGNITION COUNTER - Tech 1 displays the number
of key cycles after a DTC was stored in ECM memory.
The count increases by 1 with each key cycle.
4th GEAR SWITCH - The 4th gear switch is used to send

a signal to the ECM when the transmission is in 4th
gear. The ECM uses this information to vary the
conditions under which the clutch applies or releases
in 4th gear only. However, the transmission does not
have to be in fourth gear in order for the ECM to turn
the Torque Converter Clutch (TCC) "ON."
TIME FROM START - Range 0:00:00 - 18:12:15

HR/MIN/SEC - A measure of how long the engine has
TCC BRAKE SWITCH - Tech 1 displays "Released" when
been running. When the engine stops, it is reset to

zero.
OTC STORED - Tech 1 displays the number of history

diagnostic trouble codes stored in ECM memory.
the brake pedal is at rest and "Applied" when the

brake pedal is applied. The switch sends a signal to
the ECM to disengage the TCC.
11-11-92
NS 15604
ECM DIAGNOSTIC TROUBLE CODES

DESCRIPTION
DTC
ILLUMINATE
MIL
OTC 13
Left (Bank 2) Oxygen Sensor (025) - Circuit Error
YES
OTC 14
Engine Coolant Temperature (ECT) Sensor Circuit (high temperature indicated)
YES
OTC 15
Engine Coolant Temperature (ECT) Sensor Circuit (low temperature indicated)
YES
OTC 16
System Voltage Discharge (low battery voltage)
YES
OTC 17
Camshaft Position Sensor Circuit Error
NO
DTC21
Throttle Position (TP) Sensor Circuit (signal voltage high)
YES
DTC22
Throttle Position (TP) Sensor Circuit (signal voltage low)
YES
DTC23
Intake Air Temperature (IAT) Sensor Circuit (low temperature indicated)
YES
DTC24
Vehicle Speed Sensor (VSS) Circuit- (No Signal)
YES
DTC25
Intake Air Temperature (IAT) Sensor Circuit (high temperature indicated)
YES
DTC33
Manifold Absolute Pressure (MAP) Sensor Circuit (signal voltage high-low

vacuum)
YES
DTC34
Manifold Absolute Pressure (MAP) Sensor Circuit (signal voltage low-high

vacuum)
YES
DTC35
Idle Air Control (IAC) Circuit Error
YES
DTC36
24X Signal Circuit Error
NO
DTC39
Clutch Switch Error
YES
DTC42
Ignition Control (IC) Error
YES
DTC43
Knock Sensor (KS) Circuit Error
YES
DTC44
Left (Bank 2) Oxygen Sensor (025) Circuit Error - lean exhaust inc!icated
YES
DTC45
Left (Bank 2) Oxygen Sensor (025) Circuit Error- rich exhaust indicated
YES
DTC46
PASS-KeyII Circuit (out of frequency range)
NO
DTC51
Prom Error (Faulty or Incorrect Calibration)
YES
OTC 53
System Voltage Overcharge (high battery voltage)
YES
DTC54
Fuel Pump Circuit (low voltage)
YES
DTC61
A/C System Performance
NO
DTC63
Right (Bank 1) Oxygen Sensor (025) - Circuit Error
YES
DTC64
Right (Bank 1) Oxygen Sensor (025) - Lean Exhaust Indicated
YES
DTC65
Right (Bank 1) Oxygen Sensor (025) - Rich Exhaust Indicated
YES
DTC66
A/C Refrigerant Pressure Sensor Circuit (low pressure)
NO
DTC67
A/C Refrigerant Pressure Sensor - Circuit Error
NO
DTC68
A/C Relay Circuit (Shorted Circuit)
NO
DTC69
A/C Relay Circuit (Open Circuit)
NO
ECM DIAGNOSTIC TROUBLE CODES (CONT.)

DTC
DESCRIPTION
ILLUMINATE
MIL
DTC70
A/C Refrigerant Pressure Sensor Circuit (high pressure)
NO
DTC71
A/C Evaporator Temperature Sensor Circuit (low temperature indicated)
NO
DTC73
A/C Evaporator Temperature Sensor Circuit (high temperature indicated)
NO
DTC75
Digital EGR - Exhaust Gas Recirculation (EGR) Circuit (electrical diagnosis, EGR
#1 solenoid error)
YES
DTC76
Digital EGR- Exhaust Gas Recirculation (EGR) Circuit (electrical diagnosis, EGR
#2 solenoid error)
YES
DTC77
Digital EGR - Exhaust Gas Recirculation (EGR) Circuit (electrical diagnosis, EGR
#3 solenoid error)
YES
DTC81
TCC Brake Switch Input Circuit Error
NO
DTC82
Ignition Control 3X Signal Circuit Error
NO
DTC85
Prom Error (faulty or incorrect calibration)
YES
DTC86
Analogue/Digital ECM Error
YES
DTC87
Electrically Erasable Programmable Read Only Memory (EEPROM) Error
NO
1208-92
NS 15605
BLANK
ECM
r e c - ~ , - - - - - - - - - - - - - - - - - - - - - - 422 TAN/BLK
TO
SOLENOID
TCCCONTROL
10-WAY INLINE 1/P

CONNECTOR #2
(BLUE)
INLINE 1/P
CONNECTOR #2
---01------
448 WHT/BLK
448 WHT/BLK
DIAGNOSTIC ENABLI
TO OIL LEVEL
SENSOR
ECMGROUND
I
DATA LINK
CONNECTOR
(DLC)
L- - -
REFER TO SECTION SA
TO ELECTRON I
FOR BRANCH CIRCUITS
.-------,,._BRAKE CONTROL
JUNCTION
MODULE {EBCM)
BLOCK
~--BOOTAN
TO DIAGNOSTIC ENERGY-.-----'
10-WAYFWD
RESERVE MODULE {DERM)
LAMP
HARNESS
CONNECTOR
{BLACK)
.... - ....
800 TAN
ECMGROUND
SERIAL DATA
KEEP ALIVE
MEMORY B+
r - ,
1/PFUSE #9
TO IGN ~ 9 PNK/BLK -,-~":::.,1--r--------H B
419 BRN/WHT
SWITCH
10 AMP
I
I
.._ _ _. T O ~ I / P F U S E # S
"SERVICE
G
439 PNK
TO BRAKE
ENGINE IGN
SWITCH
SOON"
15AMP L - ...I
10-WAY INLINE 1/P
{MIL)
CONNECTOR #2{BLUE)
MIL CONTROL
IGNITION FE ED
11-20-92
NS 15596
CHART A-1
11
NO MALFUNCTION INDICATOR LAMP (MIL) SERVICE ENGINE SOON

3.4L (VIN S) ''F'' CARLINE (SFI)
11
There should always be a steady Malfunction Indicator Lamp (MIL) "Service Engine Soon" when the ignition
switch is "ON" and engine stopped. Battery voltage is supplied directly to the light bulb. The Engine Control
Module (ECM) will control the light and turn it "ON" by providing a ground path through CKT 419 to the ECM.

1. A fused jumper must be used. Do Not use a test
light.
2. Using a test light connected to 12 volts, probe each
of the system ground circuits to be sure a good
ground is present. See ECM connector terminal
end view in front of this section for ECM pin
locations of ground circuits.
3. If the fusible link is open, determine short to
ground in CKT 1002.
4. Make sure to check CKT 439 if the I/P fuse #5 is
open and both 340 circuits if the I/P fuse #4 was
open.
Refer to ECM wiring diagrams for information.
Diagnostic Aids:
If engine runs OK, check:
Faulty light bulb.
CKT 419 open.
Open I/P fuse #9.
If engine cranks but will not run, check:
Continuous battery - fusible link open.
1/P fuse #4 ECM/BAT open.
1/P fuse #5 ECM/IGN open.
Battery CKT 340 to ECM open.
Ignition CKT 439 to ECM open.
Poor connection to ECM.
Faulty ECM ground circuit(s).
PASS-KeyII circuit problem.
CHART A-1
NO MALFUNCTION INDICATOR LAMP {MIL)
3.4L {VIN S) "F" CARLINE {SFI)
DOES THE ENGINE START?
G)
IGNITION "OFF."
DISCONNECT ECM CONNECTORS.
IGNITION "ON."
PROBE CKT 419, WITH 10 AMP FUSED
JUMPER TO GROUND.
IS THE MIL "ON"?
G)
IS FUSIBLE LINK "F" (GRAY) FROM

THE BATTERY JUNCTION.BLOCK
AND 1/P FUSE #4 (10 AMP) OK?
FAULTY ECM
CONNECTION
ORECM.
CHECK:
1/P FUSE #9
FAUL TY CONNECTION AT 10 WAY
1/P CONNECTOR #2 (BLUE)
FAULTY BULB
OPENCKT419
CKT 419 SHORTED TO VOLTAGE
OPEN IGNITION FEED TO BULB
IGNITION "OFF."
DISCONNECT ECM
CONNECTORS.
IGNITION "ON."
PROBE CKT 340 & 439
WITH TEST LIGHT TO
GROUND.
IS THE LIGHT "ON" FOR
BOTH CIRCUITS?
FAUL TY ECM GROUNDS

ORECM.
LOCATE AND CORRECT

SHORT TO GROUND IN
CIRCUIT THAT HAD A
BLOWN FUSE.
REPAIR OPEN IN CIRCUIT

THAT DID NOT LIGHT THE
TEST LIGHT.
"AFTER REPAIRS,"' CONFIRM "CLOSED LOOP" OPERATION AND NO MIL (SERVICE ENGINE SOON).
10-16-92
NS-15599-6E
6E3-A-26 3.4L (L32) (VIN S) (SFI) DRIVEABIUTY AND EMISSIONS

ECM
INJ DRIVER CYL #1
INJ DRIVER CYL #3
INJ DRIVER CYL #5
INJ DRIVER CYL #2
INJ DRIVER CYL #4
INJ DRIVER CYL #6
FUSIBLE
TOB+
LINK
JUNCTION---c:::::}--1002 RED
BLOCK
KEEP ALIVE
MEMORY B+
CONNECTOR (BLACK)
---- G
340 ORN
TO CAMSHAFT POSITION SENSOR
AND
HIGH RESOLUTION 24X CRANKSHAFT
POSITION SENSOR
: ~ =ill I I
LOW RESOLUTION 3X
CRANKSHAFT POSITION SENSOR
1--------- 424 TAN/BLK - - - - - 1

1---------- 423 WHT - - - -.......
ELECTRONIC
IGNITION
CONTROL
MODULE
(ICM)
121 WHT
IGNITION CONTROL
BYPASS
IGNITION CONTROL
TACH SIGNAL
D
E
647L T BLU/BLK
3XREF HIGH
453 RED/BLK
3XREF LOW
LOCATED IN UNDERHOOD ELECTRICAL CENTER
11-10-92
NS 15600
CHART A-3
. . D
. .
C1rcu1t escr1pt1on:
ENGINE CRANKS BUT WILL NOT RUN

This chart assumes that battery condition and engine cranking speed are OK, and there is adequate fuel in
the tank.
this test indicates the ignition control module is
not triggering the coils.
1. A MIL (Service Engine Soon) "ON" is a basic test
4. This test will determine if there is B + at the
to determine if there is a 12 volts supply and
injectors. The injectors are powered by 2 fuses
ignition 12 volts to the ECM. No data may oe due
located in the underhood electrical center.
to an ECM problem. The engine will not start
5. This test will determine if the ignition control
without reference _pulses and therefore the Tech 1
module is not triggering the problem coil or if the
scan tool should display RPM (reference) during
tested
coil is at fault. This test could also be
crank. If RPM is erratic it is possible that the
performed by using another known good coil.
reluctor wheel on the crankshaft is damaged. See
6. This test will determine if the ignition control
SECTION 6A for base engine information.
2. For the first two seconds with ignition "ON " or
module is not generating the reference pulse or if
whenever reference pulses are bemg received', the
the wiring or ECM are at fault. By touching and
scan tool should indicate fuel pump circuit voltage
removing a test light to 12 volts on CKT 647, a
(8 to 12 volts).
reference pulse should be generated. If RPM is
3. Because the electronic ignition system uses two
indicated,
the ECM and wiring are OK.
plugs and wires to complete the circuit of each coil,
Diagnostic Aids:
the companion spark plug lead should be
con,:iected to a good ground. If RPM was indicated
A damaged reluctor wheel may cause a crank but
during crank, the electronic ignition control
will not run. See SECTION 6A for base engine
module is receiving a crank signal, but no spark at
diagnosis.
CHART A-3
r----------------------------------------------------1
r.'\1
~:
1
:
I
IGN "ON" IF NO DATA.REFER TO "ON-BOARD DIAGNOSTIC SYSTEM CHECK."

CHECK THE FOLLOWING:
CHECK FOR DIAGNOSTIC TROUBLE CODES AND REFER TO THOSE CHARTS FIRST.
TP SENSOR - IF OVER 2.S VOLTS AT CLOSED THROTTLE, SEE DTC21.
MONITOR "IGNITION CONTROL 3X SIGNAL" WITH TECH 1.
IS RPM INDICATED DURING CRANKING?
__________________________________________________
J
{RPM SHOULD NOT BE ERRATIC).
ISFUELPUMPVOLTAGE
INDICATED DURING CRANK?
IGNITION "OFF."
INSTALL FUEL PRESSURE GAUGE.
IGNITION "ON."
IS PRESSURE BETWEEN 41-47 PSI
(284-325 KPA)?
USING AN ST-125 (SPARK CHECKER) J 26792 OR

EQUIVALENT CHECK FOR SPARK ON EACH COIL (14, 2-5 AND 3-6).
CHECK ONE WIRE AT A TIME. GROUND THE
COMPANION CYLINDER PLUG LEAD. LEAVE THE
OTHER FOUR WIRES CONNECTED TO SPARK PLUGS
WHILE CRANKING.
IS THERE A CRISP, BLUE SPARK ON ALL WIRES?
r- -----,
NO SPARK. I
: SEE OTC
:
I CHART 82. 1
L-------.J
DISCONNECT #1 AND #2 INJECTOR

HARNESS CONNECTORS.
WITH TEST LIGHT CONNECTED TO
GROUND, PROBE CKTs 639 AND 839 ON
INJECTOR HARNESS CONNECTORS.
LIGHT SHOULD BE "ON." IS IT?
SEE FUEL
SYSTEM
DIAGNOSIS
CHART A-7.
CONNECT INJECTOR TESTER J 34730-3C.

TO #1 INJECTOR AND CRANK ENGINE.
REPEAT TEST ON REMAINING 5
INJECTORS. J 34730-3C TESTER
SHOULD FLASH AT EACH INJECTOR
WHILE ENGINE IS CRANKING .
DOESIT?
OPEN IN
CIRCUIT
THAT DID
NOT LIGHT
THE TEST
LIGHT.
NO TROUBLE FOUND.
SEE DIAGNOSTIC AIDS ON FACING
PAGE.
IGNITION "OFF."
DISCONNECT IGNITION
CONTROL MODULE
6-WA Y CONNECTOR.
IGNITION "ON."
MOMENTARILY TOUCH CKT
647 WITH A TEST LIGHT TO
12 VOLTS WHILE OBSERVING
CRANK RPM.
IS RPM INDICATED?
SPARK ON ONE
CHECK PAIR OF WIRES

THAT DID NOT SPARK.
EACH WIRE SHOULD
MEASURE LESS THAN
30,000 OHMS. IF OK,
SWAP IGNITION COILS.
DOES PROBLEM
FOLLOW SUSPECT COIL?
FAULTY 6-WAY
CONNECTION
OR
ELECTRONIC
IGNITION
CONTROL
MODULE.
CKT647
OPEN
OR
SHORTED TO
GROUND
OR
FAULTY
ECM.
OPEN IN
INJECTOR
CIRCUIT THAT
DID NOT
FLASH TESTER
OR
FAULTY ECM
CONNECTION
ORECM.
"AFTER REPAIRS," CONFIRM "CLOSED LOOP" OPERATION AND NO MIL {SERVICE ENGINE SOON).
11-12-92
NS 16197

CAUTION:
ENGINE FUEL PIPES
TO REDUCE THE RISK OF FIRE AND PERSONAL INJURY,

WRAP A SHOP TOWEL AROUND THE FUEL PRESSURE
CONNECTION TO ABSORB ANY FUEL LEAKAGE THAT
MAY OCCUR WHEN INSTALLING THE PRESSURE GAGE.
PLACE TOWEL IN APPROVED CONTAINER.
DO NOT PINCH OR RESTRICT NYLON FUEL LINES TO

AVOID DAMAGE THAT COULD CAUSE A FUEL LEAK,
RESULTING IN POSSIBLE FIRE OR PERSONAL INJURY.
J 37287
FUEL LINE
SHUT-OFF
ADAPTERS
RETURN LINE
J 34730-1
FUEL PRESSURE
GAGE ASSEMBLY
FUEL PUMP AND
RESERVOIR ASSEMBLY
NS 16047
CHART A-7
(Page 1 of 3)
FUEL SYSTEM DIAGNOSIS

When the ignition switch is turned "ON," the Engine Control Module (ECM) will turn "ON" the in-tank fuel
pump. It will remain "ON" as long as the engine is cranking or running, and the ECM is receiving reference
pulses. If there are no reference pulses, the ECM will shut "OFF" the fuel pump within 2 seconds after ignition
"ON" or engine stops.
Inside the fuel tank an electric fuel pump (within an integral reservoir) supplies fuel through an in-line filter
to the fuel rail assembly. The pump is designed to provide fuel at a pressure above the regulated pressure needed
by the injector. A pressure regulator attached to the fuel rail, keeps fuel available to the injectors at a regulated
pressure. Unused fuel is returned to the fuel tank by a separate line.

1. Connect fuel pressure gage as shown in
illustration. Wrap a shop towel around the fuel
connection to absorb any small amount of fuel
leakage that may occur when installing the gage.
With ignition "ON," and fuel pump running,
pressure should be 284-325 kPa (41-47 psi). This
pressure is controlled by spring pressure within
the regulator assembly.
2. When the engine is idling, manifold pressure is
low (high vacuum) and is applied to the r; ressure
regulator diaphragm. Vacuum will offset spring
pressure and result in a lower fuel pressure. Fuel
pressure at idle will vary somewhat depending on
3.
4.
barometric pressure but, should be less than

pressure noted in Step (1).
A system that does not hold pressure is caused by
one of the following:
Leaking fuel pump check valve.
Leaking fuel pump feed hose.
Leaking valve/seat within pressure regulator.
Leaking injector(s).
A leaking injector can best be determined by
checking for a fouled or saturated spark plug(s).
CHART A-7
{Page 1 of 3)
G)
INSTALL FUEL PRESSURE GAGE AS SHOWN ON FACING PAGE.

IGNITION "OFF" FOR 10 SECONDS. A/C "OFF."
IGNITION "ON." FUEL PUMP WILL RUN FOR ABOUT 2 SECONDS.
IT MAY BE NECESSARY TO CYCLE THE IGNITION "ON" MORE
THAN ONCE TO OBTAIN MAXIMUM PRESSURE.
NOTE FUEL PRESSURE WITH PUMP RUNNING, PRESSURE
SHOULD BE 284-325 kPa (41-47 psi). WHEN PUMP STOPS,
PRESSURE MAY VARY SLIGHTLY THEN SHOULD HOLD STEADY.
IS PRESSURE CORRECT ANO DOES IT HOLD?

3.4L {VIN S) "F'' CARLINE {SFI)
r-------- .---,
I
FROM CHART A-3
L----~
-------------------------,
FUEL PRESSURE
WITHIN SPEC., BUT
DOES NOT HOLD.
: IF FUEL PRESSURE IS WITHIN NORMAL

:
I RANGE BUT IS SUSPECTED OF DROPPING
I
: OFF DURING ACCELERATION, CRUISE OR
:
I HARD CORNERING, SEE CHART A-7 (2 OF 3). 1
L
-------------------------~
------J
FUEL
PRESSURE
OUT OF SPEC.
NO FUEL PRESSURE
r- - - - - - - - - - - - - - ,
I USE OTC 54 CHART TO
I
,- --------, : DIAGNOSEFUELPUMP :
: SEE CHART A-7 : I ELECTRICAL CIRCUIT.
I
~ 2_~F_3_)_____ )
J
,...L- ~ - - - _ , - -
STARTENGINE,ALLOWITTOIDLEAT
NORMAL OPERATING TEMPERATURE.
FUEL PRESSURE NOTED IN STEP (1) SHOULD
DROP APPROXIMATELY 21-69 kPa (3-10 psi).
DOESIT?
NO TROUBLE
FOUND,
REVIEW
"SYMPTOMS,"
SECTION "B".
DISCONNECT VACUUM HOSE

FROM PRESSURE REGULATOR
ASSEMBLY.
WITH ENGINE IDLING, APPLY
12-14 INCHES OF VACUUM TO
PRESSURE REGULATOR. FUEL
PRESSURE NOTED IN STEP (1)
SHOULD DROP
APPROXIMATELY 21-69 kPa
(3-10 psi).
DOESIT?
LOCATE AND
REPAIR LOSS
OF VACUUM
TO PRESSURE
REGULATOR.
PRESSURE
REGULATOR
IS FAULTY.
INSTALLJ 37287 FUEL LINE

SHUT-OFF ADAPTORS, REFER TO
PAGES 3 OF 3 AND FACING PAGE
ILLUSTRATION.
MAKE SURE VALVES ARE OPEN.
IGNITION "OFF."
USING A 10 AMP FUSED JUMPER
WIRE, CONNECT FUEL PUMP
"TEST" CONNECTOR TO B +
AND WAIT FOR PRESSURE TO
BUILD.
DISCONNECT JUMPER AND
CLOSE VALVE IN FUEL PRESSURE
LINE. PRESSURE SHOULD HOLD.
DOESIT?
OPEN VALVE IN FUEL

PRESSURE LINE.
RECONNECT PUMP "TEST"
JUMPER AND WAIT FOR
PRESSURE TO BUILD.
CLOSE VALVE IN FUEL
RETURN LINE. PRESSURE
SHOULD HOLD.
DOES IT?
-- -- _
CHECK FOR:
PLUGGED IN-LINE
FILTER.
RESTRICTED FUEL
PRESSURE LINE.
PLUGGED FUEL
PUMP STRAINER.
LEAKING FUEL
PUMP FEED HOSE.
CHECK FOR:
LEAKING FUEL
PUMP FEED HOSE.
FUEL PUMP IS
FAULTY. (LEAKING
CHECK BALL INSIDE
PUMP.)
LOCATE AND CORRECT LEAKING

INJECTOR(S).
"AFTER REPAIRS," CONFIRM "CLOSED LOOP" OPERATION AND NO MIL (SERVICE ENGINE SOON).
11-30-92
NS 16048-6E

CAUTION:
ENGINE FUEL PIPES


RE SUL TING IN POSSIBLE FIRE OR PERSONAL INJURY.
J 37287
FUEL LINE
SHUT-OFF
ADAPTERS
RETURN LINE
J 34730-1
FUEL PRESSURE
GAGE ASSEMBLY
FUEL PUMP AND
RESERVOIR ASSEMBLY
NS 160'7
CHART A-7
(Page 2 of 3)
FU EL SYSTEM DIAGNOSIS
5. Fuel pressure that drops off during acceleration,
cruise or hard cornering may cause a lean
condition and result in a loss of power, surging or
misfire. This condition can be diagnosed using a
Tech 1 scan tool. If the fuel system is very lean,
one or both oxygen sensors will stop toggling and
output voltage will drop below 500 m V. Also,
injector pulse width will increase.
rn
6.
Important
Make sure system is not operating at "FuelCut-Off' which may cause false readings on
the scan tool.
Fuel pressure below 284 kPa (41 psi) may cause a

lean condition and may set a OTC 44/64.
Driveability conditions can include hard starting
cold, hesitation, poor driveability, lack of power,
surging or misfire.
7.
Restricting the fuel return line causes fuel

pressure to build above regulated pressure. With
battery voltage applied to the pump "test"
connector, pressure should rise above 325 kPa (47
psi) as the valve in the return line is partially
closed.
NOTICE: Do not allow pressure to exceed 414

kPa (60 psi) as damage to the regulator may result.
8. Fuel pressure above 325 kPa (47 psi) may cause a
rich condition and may set a OTC 45/65.
(followed by black smoke) and a strong sulphur
smell in the exhaust.
9. This test determines if the high fuel pressure is
due to a restricted fuel return line or a faulty fuel
pressure regulator.
CHART A-7
(Page 2 of 3)

r--------,
:
FROM
:
CHARTA7 1
:L- (1______
OF 3) J:
I
FUEL PRESSURE DROPS OFF

DURING ACCELERATION, CRUISE
OR HARD CORNERING.
CHECK FOR RESTRICTED IN-LINE
FUEL FILTER OR FUEL PRESSURE
LINE. IS THERE A RESTRICTION?
SERVICE AS
REQUIRED
AND RECHECK
CHECK FOR:
RESTRICTED FUEL PUMP STRAINER.
LEAKING FUEL PUMP FEED HOSE.
WRONG FUEL PUMP.
INSTALLJ 37287-2 FUEL

RETURN LINE SHUT-OFF
ADAPTER, REFER TO PAGES
3 OF 3 AND FACING PAGE
ILLUSTRATION.
MAKE SURE VALVE IS OPEN.
IGNITION "OFF."
USING A 10AMPFUSED
JUMPER WIRE, CONNECT FUEL
PUMP "TEST" CONNECTOR
TOB+.
SLOWLY CLOSE SHUT-OFF
VALVE. PRESSURE SHOULD
RISE ABOVE 325 kPa (47 psi).
DO NOT EXCEED 414 kPa (60
psi).
DOES PRESSURE RISE ABOVE
325 kPa (47 psi)?
FUEL PRESSURE ABOVE

325 kPa (47 psi).
G)
DISCONNECT QUICK-CONNECT
FITTING AT ENGINE FUEL RETURN
PIPE, REFER TO PAGES 3 OF 3 AND
FACING PAGE ILLUSTRATION.
ATTACH ALENGTH OF FLEXIBLE
FUEL HOSE TO ENGINE FUEL
RETURN PIPE. PLACE OPEN END OF
HOSE INTO AN APPROVED
GASOLINE CONTAINER.
IGNITION "OFF" FOR 10 SECONDS.
IGNITION "ON." NOTE FUEL
PRESSURE WITH PUMP RUNNING.
PRESSURE SHOULD BE 284-325 kPa
(41-47 psi).
ISIT?
CHECK FOR RESTRICTED

ENGINE FUEL RETURN
PIPE OR FUEL RAIL
OUTLET PASSAGE.
IS THERE A RESTRICTION?
FUEL PUMP IS
FAULTY.
LOCATE AND
CORRECT
RESTRICTION IN
FUEL RETURN
LINE TO FUEL
TANK.
SERVICE AS
REQUIRED
AND
RECHECK.
11-30-92
NS 16049-6E
CHART A-7
(Page 3 of 3)

FUEL SYSTEM PRESSURE RELIEF PROCEDURE

Engines With Fuel Pressure Connection
(Must Be Performed Before Disconnecting Fuel Line Fittings)
CAUTION:
To reduce the risk of fire and personal injury, it is necessary to relieve fuel system
pressure before disconnecting fuel line fittings.
After relieving system pressure, a small amount of fuel may be released when
disconnecting fuel line fittings. In order to reduce the chance of personal injury,
cover fuel line fittings with a shop towel before disconnecting, to catch any fuel
that may leak out. Place the towel in an approved container when disconnect is
completed.
Tool Required: ,J 347,30-1 Fuel Pressure Gage
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
Ignition "OFF."
Disconnect negative battery cable to avoid possible fuel discharge if an accidental attempt is made to
start the engine.
Connect gage J 34730-1 to fuel pressure connection. Wrap a shop towel around fitting while connecting
Install bleed hose into an approved container and open valve to bleed system pressure. Fuel line fittings
are now safe for servicing.
Drain any fuel remaining in gage into an approved gasoline container.
Perform service required.
Ignition "OFF."
Connect negative battery cable.
Cycle ignition ''ON" and "OFF" twice, waiting ten seconds between cycles, then check for fuel leaks.
11-11-92
NS 14624
CHART A-7
{Page 3 of 3)

rn
SERVICING QUICK-CONNECT FITTINGS

Important
[n order to install fuel system diagnostic equipment on vehicles equipped with plastic quick-connect
fittings, fuel line separator tools must be used to disconnect the fittings. C sing the separator tools to
release the fittings will cause the plastic retainer to remain inside the female connector allowing
diagnostic equipment to be connected.
Tools required:
,J 37088-A tool set, fuel line quick-connect separator;
J 39504 tool set, fuel line quick-connect separator (restricted access).

1. Relieve fuel system pressure (see "Fuel System Pressure Relief').
2. If equipped, slide dust cover back to access quick-connect fitting.
3. Grasp both sides of fitting. Twist female connector 1/4 turn in each direction to loosen any dirt within
fitting.
CAUTION: Safety glasses must be worn when using compressed air, as flying dirt
4. Using compressed air, blow dirt out of fitting.
5. Choose correct tool from ,J 37088-A or J 39504 tool set for size of fitting.
connector, then push/pull inward to release locking tabs.
lnsert tool into female
IL1tl Clean and Inspect
NOTICE: If it is necessary to remove rust or burrs from fuel pipe, use emery cloth in a radial motion
with the pipe end to prevent damage to 0-ring sealing surface.
Using a clean shop towe 1, wipe off male pipe end.

[nspect both ends of fitting for dirt and burrs. Clean or replace components/assemblies as required.
CAUTION: To Reduce the Risk of Fire and Personal Injury:
Before connecting fitting, always apply a few drops of clean engine oil to the
male pipe end of engine fuel pipe, pressure gage adapter or fuel line shut-off
adapter. This will ensure proper reconnection and prevent a possible fuel leak.
{During normal operation, the 0-rings located in the female connector will swell
and may prevent proper reconnection if not lubricated.)
Apply a few drops of clean engine oil to the male pipe end of engine fuel pipe, pressure gage adapter or
fuel line shut-off adapter.
2. Push both sides of fitting together to cause the retaining tabs/fingers to snap into place.
3. Once installed, pull on both sides of fitting to make sure connection is secure.
11-14-92
4. [f equipped, reposition dust cover over quick-connect fitting.
NS 14628
1.
ECM
LEFT (BANK 2) OXYGEN
l~'---+l------------(<-1665PPL/WHT
LEFT 02S GROUND
1 351
BLK/WHT
RIGHT 02S GROUND
ENGINE _ L
GROUND-=-
10-7-92
NS 15602
OTC 13
LEFT (BANK 2) OXYGEN SENSOR (02S) CIRCUIT
(OPEN CIRCUIT)
The ECM supplies a voltage of about .45 volt between terminals "B20" and "B21". (If measured with a 10
megohm digital voltmeter, this may read as low as .35 volt.) The Oxygen Sensor (028) varies the voltage within
a range of about 1 volt. If the left (Bank 2) exhaust is rich, the 028 will display close to 1000 millivolts and when
the exhaust is lean the 028 will display close to 100 millivolts.
The sensor is like an open circuit and produces no voltage when it is below 316C (600F). An open 028
circuit or cold 028 causes "Open Loop" operation.

1. DTC 13 will set under the following conditions:
Engine running at least 2 minutes after start.
Engine coolant. temperature greater than 85C
(185F).
028 signal voltage steady between 350
millivolts and 550 millivolts.
Throttle position greater than 3%.
All conditions must be met and held for at least
30 seconds.
If the conditions for a DTC 13 exist, the system will
not go "Closed Loop."
2. This will determine if the sensor is at fault or the

wiring or ECM is the cause of the DTC 13.
3. In doing this test use only a high impedance digital
volt ohmmeter. This test checks the continuity of
CKT 1665 and CKT 351 because if CKT 351 is
open the ECM voltage on CKT 1665 will be greater
than .6 volt (600 mV).
Diagnostic Aids:
Normal Tech 1 scan voltage varies between 100
mV to 999 mV (.1 and 1.0 volt) while in "Closed Loop."
DTC 13 sets if voltage remains between 350 millivolts
and 550 millivolts, but the system will go "Open Loop"
in about 15 seconds. Refer to "lntermittents" in
"Symptoms," Section "6E3-B".
DTC 13
(OPEN CIRCUIT)
G)
ENGINE AT NORMAL OPERATING TEMPERATURE (ABOVE 80C/176"F).

RUN ENGINE ABOVE 1200 RPM FOR TWO MINUTES.
DOES SCAN TOOL INDICATE "CLOSED LOOP"?
G)
DISCONNECT 02S CONNECTOR.

JUMPER HARNESS CKT 1665 (ECM SIDE) TO GROUND.
SCAN TOOL SHOULD DISPLAY OXYGEN SENSOR VOLTAGE
BELOW .2 VOLT (200 mV) WITH ENGINE RUNNING.
DOESIT?
DTC 13 IS INTERMITTENT. IF NO ADDITIONAL

DTC(s) WERE STORED, REFER TO "DIAGNOSTIC
REMOVE JUMPER.
CHECK VOLTAGE OF CKT 1665 (ECM SIDE)AT
02S HARNESS CONNECTOR USING A DVM .
FAULTY 02S CONNECTION

OR
SENSOR.
.3- .6 VOLT
(300 - 600 mV)
FAULTY ECM.
GREATER THAN
.6 VOLT (600 mV)
OPEN CKT351
OR
FAULTY CONNECTION
OR
FAULTY ECM.
LESS THAN .3
VOLT(300 mV)
OPEN CKT 1665
OR
FAULTY ECM CONNECTION
OR
FAULTY ECM.
"AFTER REPAIRS," REFER TO OTC CRITERIA ON FACING PAGE AND CONFIRM DTC DOES NOT RESET.
9-4-92
NS 15603

- - - - ENGINE COOLANT TEMPERATURE (ECT)
SENSOR
ECM
10-WAV INJ/ECM CONN. (BLACK)
ENGINE COOLANT
TEMPERATURE SENSOR
SIGNAL
I"----,
---.~
470 BLK
~...-~~~~~--1
sv
----'-t
SENSOR GROUND
TOTPSENSOR
FRONT VIEW ENGINE COOLANT
TEMPERATURE (ECT) SENSOR
HARNESS CONNECTOR
9-8-~2
NS 15607
OTC 14
ENGINE COOLANT TEMPERATURE (ECT) SENSOR CIRCUIT
{HIGH TEMPERATURE INDICATED)

The Engine Coolant Temperature (ECT) sensor is a thermistor which varies the signal voltage at the ECM.
The EC:M applies 5 volts to sensor on CKT 410. The sensor's resistance is inversely proportional to the
temperature it is sensing.
As the engine warms, the sensor resistance becomes less, and the voltage drops. At normal engine operating
temperature, the voltage will measure about 1.5 to 2.0 volts at the ECM terminal "A31".
Engine coolant temperature is one of the inputs used to control:
Fuel delivery.
EVAP canister purge.
Ignition Control (IC).
Exhaust Gas Recirculation (EGR).
Idle Air Control (IAC).
Cooling fan operation.
Torque Converter Clutch (TCC).

1. OTC 14 will set if:
Signal voltage indicates engine coolant
temperature is greater than 135C (270F).
Engine running longer than 20 seconds.
2. This test will determine if CKT 410 is shorted to
ground which will cause the conditions for OTC 14.
Diagnostic Aids:
Check harness routing for a potential short to
ground in CKT 410. Circuit is routed from the ECM to
the 10-way INJ/ECM connector, and then to the
Engine Coolant Temperature (ECT) sensor.
Tech 1 scan tool displays engine coolant

temperature in degrees centigrade. After the engine is
st.arted the temperature should rise steadily to about
90C (194F) then stabilize when the thermostat opens.
Refer to "Intermittcnts" in "Symptoms," Section "6E3B".
Verify that engine is not overheating and has not
been subjected to conditions which could create an
overheating condition (i.e. overload, trailer towing,
hilly terrain, heavy stop and go traffic, etc.). The
"Temperature VS. Resistance Value" scale at the right
may be used to test the engine coolant sensor at
various temperature levels to evaluate the possibility
of a "shifted" (mis-scaled) sensor. A "shifted" sensor
could result in poor driveability complaints.
DRIVEABILITY AND EMISSIONS 3.4l (L32) (VIN S) (SFI) 6E3-A-37
OTC 14
(HIGH TEMPERATURE INDICATED)
DOES SCAN TOOL DISPLAY ENGINE COOLANT

TEMPERATURE OF 130C {266F) OR HIGHER?
DISCONNECT ENGINE COOLANT

TEMPERATURE SENSOR.
SCAN TOOL SHOULD DISPLAY ENGINE
COOLANT TEMPERATURE BELOW -30C
{22F).
DOESIT?
REPLACE ENGINE COOLANT

TEMPERATURE SENSOR.
OTC 14 IS INTERMITTENT. IF NO
ADDITIONAL DTC(s) WERE STORED, REFER
TO "DIAGNOSTIC AIDS" ON FACING PAGE.
CKT 410 SHORTED TO GROUND

OR
CKT 410 SHORTED TO SENSOR GROUND CIRCUIT
OR
FAULTY ECM.
DIAGNOSTIC AID
ENGINE COOLANT TEMPERATURE SENSOR
TEMPERATURE VS. RESISTANCE VALUES
{APPROXIMATE)
OF
100
90
80
70
60
50
45
40
35
30
25
20
15
10
5
0
5
-10
15
-20
-30
-40
212
194
176
158
140
122
113
104
95
86
77
68
59
so
41
32
23
14
5
.4
-22
-40
OHMS
177
241
332
467
667
973
1188
1459
1802
2238
2796
3520
4450
5670
7280
9420
12300
16180
21450
28680
52700
100700
"AFTER REPAIRS," REFER TO OTC CRITERIA ON FACING PAGE AND CONFIRM OTC DOES NOT RESET.
6-292
7S 3055-6E

- - - - ENGINE COOLANT TEMPERATURE (ECT)
SENSOR
ECM
10-WA Y INJ/ECM CONN. (BLACK)
ENGINE COOLANT
TEMPERATURE SENSOR
SIGNAL
r----,
- - . - I1
I
.__
_ _ _ _ _ _....
SV
470BLK----'-I
SENSOR GROUND
TOTPSENSOR
FRONT VIEW ENGINE COOLANT
TEMPERATURE (ECT) SENSOR
HARNESS CONNECTOR
9-8-92
NS 15607
DTC 15
(LOW TEMPERATURE INDICATED)

The Engine Coolant Temperature (ECT) sensor is a thermistor which varies the signal voltage at the ECM.
The ECM applies 5 volts to the sensor on CKT 410. The sensor's resistance is inversely proportional to the
temperature it is sensing.
As the engine warms, the sensor resistance becomes less, and the voltage drops. At normal engine operating
temperature the voltage will measure about 1.5 to 2.0 volts at the ECM terminal "A31".
Coolant temperature is one of the inputs used to control:
Fuel delivery.
EVAP canister purge.
Ignition Control (IC).
Cooling fan operation.

1. DTC 15 will set if:
Signal voltage indicates engine coolant
temperature is less than -38.5C (-37 .30F).
2. This test simulates a OTC 14. If the ECM
recognizes the low signal voltage (high
temperature), and the Tech 1 scan tool reads 130C
(266F), the ECM and wiring are OK.
3. This test will determine ifCKT 410 is open. There
should be 5 volts present at sensor connector if
measured with a DVM.
Diagnostic Aids:
Check harness routing for a potential open in CKT
410. This circuit is routed from the ECM through the
10 way INJ/ECM connector and then to the engine
coolant temperature sensor.
A Tech l scan tool reads engine temperature in
degrees centigrade. After engine is started the
temperature should rise steadily to about 95C (203Fl
then stabilize when thermostat opens.
CKT 410 is routed from the ECM to a mini harness,

and then to the Engine Coolant Temperature (ECT)
sensor.
A faulty connection, or an open in CKT 410 or 470
will result in a OTC 15.
DTCs 15 and 21 stored at the same time could be
the result of an open CKT 470 which would also turn
the temperature warning indicator "ON." The
"Temperature VS. Resistance Value" scale at the right
may be used to test the engine coolant temperature
sensor at various temperature levels to evaluate the
possibility of a "shifted" (mis-scaled) sensor. A
"shifted" sensor could result in poor driveability
complaints.
Refer to "Intermittents" in "Symptoms," Section
"6E3-B".
DTC 15
0
0
CD
DOES TECH 1 SCAN TOOL DISPLAY ENGINE COOLANT TEMPERATURE OF -38.sC (-37.30F) OR LESS?
DISCONNECT ENGINE COOLANT TEMPERATURE SENSOR.

JUMPER HARNESS TERMINALS TOGETHER.
TECH 1 SCAN TOOL SHOULD DISPLAY 130C (266F) OR MORE.
DOESIT?
DTC 1 SIS INTERMITTENT. IF NO

ADDITIONAL DTC(S) WERE STORED, REFER
JUMPERCKT410TOGROUND.
TECH 1 SCAN TOOL SHOULD DISPLAY OVER 130C (266F).
DOESIT?
FAULTY CONNECTION OR ENGINE

COOLANT TEMPERATURE SENSOR.
OPEN ENGINE COOLANT TEMPERATURE SENSOR GROUND

CIRCUIT, FAULTY CONNECTION OR FAULTY ECM.
OPEN CKT 410, FAULTY

CONNECTION AT ECM, OR
FAULTY ECM.
DIAGNOSTIC AID
(APPROXIMATE)
oc
OF
OHMS
100
90
80
70
60
212
194
176
158
140
122
113
104
95
86
177
241
332
467
667
973
1188
1459
1802
2238
2796
3520
4450
5670
7280
9420
12300
16180
21450
28680
52700
100700
so
45
40
35
30
25
20
15
10
5
0
-5
-10
-15
-20
-30
-40
77
68
59
so
41
32
23
14
5
-4
-22
-40
"AFTER REPAIRS, "REFER TO DTC CRITERIA ON FACING PAGE AND CONFIRM DTC DOES NOT RESET.
5-12-92
NS 15052
ECM
10-WAY INLINE 1/P
CONNECTOR #2
(BLUE)
~----r-------1~11-------
1/P FUSE #5
E-------"""'
TO IGN .,....
SWITCH
15AMP
439 PNK
'c3
SEE SECTION SA
(ELECTRICAL DIAGNOSIS)
FOR COMPLETE CIRCUIT
DETAILS
IGNITION FEED
11-0692
NS 15601
DTC 16
SYSTEM LOW VOLTAGE
OTC 16 will set when ignition is "ON" and the engine speed is greater than 1000 RPM and the ECM is
sensing an ignition voltage input of less than 8 volts for more than two seconds.

1. Test generator output as outlined in SECTION
603 to determine proper operation of the voltage
regulator. Run engine above 1000 RPM and
measure voltage across the batterv. If less than 8
volts, repair generator as outlin~d in SECTION
603.
Diagnostic Aids:
An intermittent may be caused by poor
connections, chafed insulation, a broken wire inside
the insulation or poor ECM grounds.
Intermittent Test - Monitor system VOLTS display
with a Tech 1 while moving related connectors. If
the failure is induced, the display will abruptly
change. This may help to isolate the location of the
malfunction.
OTC 16
SYSTEM LOW VOLTAGE
3.4L (VIN S)
11
F" CARLINE (SFI)
INSTALL TECH 1.
START ENGINE, WITH ENGINE RUNNING ABOVE 1000 RPM.
SCAN SYSTEM VOLTAGE.
I
I
LESS THAN 8 VOL TS
BETWEEN 9 AND 14 VOLTS
INSTALL DVM ACROSS BATTERY.

RUN ENGINE ABOVE 1000 RPM.
DOES DVM SHOW BATTERY
VOLTAGE ABOVE 12 VOL TS OR
LESS THAN 8 VOLTS?
LOAD ELECTRICAL SYSTEM WITH

HEADLAMPS AND HIGH A/C BLOWER.
RAISE ENGINE RPM TO 2000.
NOTE SYSTEM VOLTAGE ON TECH 1.
I
LESS THAN 8 VOL TS
BETWEEN 8 AND 14 VOLTS
SEE SECTION 6D
FOR REPAIR.
ABOVE 12 VOLTS
BELOW 8 VOL TS
I
HEADLAMPS AND HIGH A/C BLOWER.
NOTE BATTERY VOLTAGE AT BATTERY.
FAULT IS NOT PRESENT.

SEE SECTION 6D FOR REPAIR.
I
ABOVE 12 VOL TS
LESS THAN 8 VOLTS
COMPARE TECH 1 READING OF SYSTEM

VOLTAGE WITH DVM READING.
TECH 1 DATA DOES NOT

REFLECT DVM VALUES.
I
SEE SECTION 6D FOR REPAIR.
FAULTY ECMCONNECTOR
OR FAULTY ECM.
BOTH ABOVE 12 VOLTS
I
FAULT IS NOT PRESENT. REFER TO
10-13-92
NS 15043
ECM
.,.___ _ 633 BRN/WHT - - - - - 1
CAMSHAFT
POSITION
SENSOR
11
FUSE #
*
10 AMP
CAM REFERENCE SIGNAL
- - - 5 3 2 PNK/BLK - - - - - ,
t-------~
10-WAY FWD LAMP

HARNESS CONNECTOR (BLACK)
IGNITION ~ 2 3 9 PNK/BLK
TO ELECTRONIC
IGNITION CONTROL
MODULE (ICM)
A
HIGH
RES.
- - - 632 PNK/BLK
-----1
1800 LT BLU/WHT
REFERENCE LOW CAMSHAFT

AND 24X SIGNALS
24X REFERENCE SIGNAL
24X CRANKSHAFT
POSITION SENSOR
9-9-92
NS 15508
OTC 17
CAMSHAFT POSITION SENSOR CIRCUIT ERROR
The camshaft position sensor is a "Hall-effect" switch, located on the front of the engine. The camshaft
position sensor sends a signal to the ECM when the #1 cylinder is on the intake stroke. This signal is used by the
ECM to synchronize Sequential Fuel Injection (SFI) mode ofoperation with each intake valve opening. If the cam
reference signal is not received by the ECM, the ECM will still pulse the fuel injectors sequentially, but the fuel
injectors may not be in synch with each intake valve opening. That is, fuel injector timing may not be as accurate
because the ECM does not know the exact time each intake valve is opening. A loss of this signal or extra (false)
cam reference signals, above 500 RPM, will set a DTC 17.

1. The ECM performs a test for DTC 17 when the
engine is running or during cranking.
DTC 17 will set when:
Cam pulse is missing on the first pass through
the internal ECM self test of the camshaft
position sensor.
OR
Cam pulse is missing for 3 seconds.
2. By repeatedly "tapping" the starter the camshaft
timing mark and the camshaft position sensor will
align with each other. At this point, the voltage
from the sensor applied to the ECM should drop to
near zero temporarily. This indicates that the
camshaft position sensor is capable of sending a
signal to the ECM.
3. Before replacing the camshaft position sensor,
inspect the sensor for proper installation.
Diagnostic Aids:
An intermittent cam reference signal can be
caused by poor connections, cracked sensor or internal
engine problem.
DRIVEABILITY AND EMISSIONS 3.4L {L32) {VIN S) {SFI). 6E3-A-43
DTC17
CAMSHAFT POSITION SENSOR CIRCUIT ERROR
11
3.4L {VIN S) F" CARLINE {SFI)
G)
IF ENGINE CRANKS BUT WON'T RUN, USE CHART A-3.

IGNITION "ON" ENGINE IDLING. TECH 1 SCAN TOOL SHOULD
DISPLAY CAM SIGNAL PULSES CONSTANTLY CHANGING "O" TO "1".
DOES IT.
IGNITION "OFF."
DISCONNECT ECM HARNESS CONNECTOR "C".
PROBE ECM HARNESS PIN "C25" WITH A DVM TO GROUND SET
TO DC VOLTAGE.
IGNITION "ON."
DOES DVM DISPLAY APPROXIMATE SYSTEM VOLTAGE?
OTC 17 INTERMITTENT. REFER TO

WITH KEY IN THE "ON" POSITION, CYCLE IGNITION TO

CRANK POSITION MOMENTARILY SEVERAL TIMES
WHILE OBSERVING DVM.
VOLTAGE SHOULD TEMPORARILY DROP TO NEAR ZERO
EACH TIME THE CAMSHAFT TIMING MARK ALIGNS
WITH THE CAMSHAFT POSITION SENSOR.
DOESIT?
DISCONNECT CAM SENSOR 3-WAY

HARNESS.
PROBE HARNESS TERMINAL "C" WITH
A TEST LIGHT TO BATTERY VOLTAGE.
IS TEST LIGHT "ON"?
FAULTY HARNESS CONNECTION

OR
OPEN CAMSHAFT POSITION
SENSOR GROUND WIRE
OR
FAULTY CAMSHAFT POSITION
SENSOR.
FAULTY ECM
CONNECTION
OR
FAULTY ECM.
OPEN HARNESS
GROUND
CIRCUIT.
DISCONNECT CAMSHAFT POSITION SENSOR

HARNESS.
CONNECT DVM BETWEEN HARNESS TERMINAL "A"
AND GROUND.
DOES DVM DISPLAY APPROXIMATE BATTERY
VOLTAGE?
WITH A FUSED JUMPER, JUMP

CAM SENSOR PIGTAIL TERMINAL
"A" TO BATTERY VOLTAGE.
PROBE TERMINAL "B" WITH
DVM TO GROUND.
DOES DVM DISPLAY
APPROXIMATE BATTERY
VOLTAGE?
OPEN OR SHORTED CAMSHAFT

POSITION SENSOR IGNITION FEED
WIRE TO SENSOR
OR
OPEN OR SHORTED CAMSHAFT
POSITION SENSOR SIGNAL WIRE
FROM SENSOR
OR
FAULTY CAMSHAFT POSITION
SENSOR.
FAULTY HARNESS
IGNITION FEED
CIRCUIT.
FAULTY
CAMSHAFT
PIGTAIL
CONNECTION
OR
FAULTY ECM
CONNECTION
OR
OPEN
CAMSHAFT
POSITION
SENSOR SIGNAL
WIRE TO ECM.
11-12-92
NS 15255
TP SENSOR
HARNESS
CONNECTOR
ECM
TO ECT SENSOR
THROTTLE
POSITION (TP)
SENSOR
HARNESS
CONNECTOR
FRONT VIEW _ _ _ ___.
416 GRY
SV REFERENCE
417 DK BLU
TP SENSOR SIGNAL
470 BLK
SENSOR GROUND
TO A/C REFRIGERANT
PRESSURE SENSOR & A/C EVAPORATOR
TEMPERATURE SENSOR
TO MAP SENSOR
9-8-92
NS 15609
OTC 21
THROTTLE POSITION (TP) SENSOR CIRCUIT
{SIGNAL VOLTAGE HIGH)

The Throttle Position (TP) sensor provides a voltage signal that changes relative to the throttle blade. Signal
voltage will vary from about .5 at idle to about 4.8 volts at Wide Open Throttle (WOT).
The TP sensor signal is one of the most important inputs used by the ECM for fuel control and for many of the
ECM control outputs.
Test Description: ~umber(sl below refer to circled
Diagnostic Aids:

No OTC 33 or DTC 34.
Engine is running and RPM greater than 600.

TP sensor signal voltage is greater than 3.82
volts.
All conditions met for 10 seconds.
OR
With throttle closed, the TP sensor should read
less than .98 volt. If it doesn't, make sure cruise
control and throttle cables are not being held open.
2. With the TP sensor disconnected, the TP sensor
voltage should go low, if the ECM and wiring are
OK.
3. Probing CKT 470 with a test light checks the 5 volt
return circuit. Faulty sensor ground circuit will
cause a OTC 21. OTC 33, 66 or 71 may also be set.
A Tech 1 scan tool reads throttle position in volts.

Voltage should increase at a steady rate as throttle is
moved toward WOT.
Also some scan tools will read: throttle angle 0%
= closed throttle, 100% = WOT.
An open in CKT 470 will re:,;ult in a OTC 21.
the result of an open CKT 470 which would also turn
the temperature warning indicator "ON." Scan the TP
sensor while depressing accelerator pedal with engine
stopped and ignition "ON." Display should vary from
about .5 volt when throttle was closed, to about 4.8
volts when throttle is held at Wide Open Throttle
(WOT) position.
"6E3-B".
DTC21
(SIGNAL VOLTAGE HIGH)
THROTTLE CLOSED.
DOES TECH 1 SCAN TOOL DISPLAY
THROTTLE POSITION OVER 2.5 VOLTS?
DISCONNECT THROTTLE POSITION SENSOR.

TECH 1 SCAN TOOL SHOULD DISPLAY
THROTTLE POSITION BELOW .2 VOLT (200 mV).
DOES IT?
OTC 21 IS INTERMITTENT. IF NO ADDITIONAL DTC(s) WERE

STORED, REFER TO "DIAGNOSTIC AIDS" ON FACING PAGE.
PROBE SENSOR GROUND CIRCUIT

WITH A TEST LIGHT CONNECTED TO
BATTERY VOLTAGE.
TP SENSOR SIGNAL CIRCUIT SHORTED TO VOLTAGE

OR
FAULTY ECM.
FAULTY CONNECTION
OR
THROTTLE POSITION SENSOR.
OPEN SENSOR GROUND CIRCUIT

OR
FAULTY ECM.
3-26-92
75 3057-GE
TPSENSOR
HARNESS
CONNECTOR
ECM
GRYMINI
HARNESS CONNECTOR
1-----THROTTLE
POSITION (TP)
SENSOR
HARNESS
CONNECTOR
IDLE
FRONT VIEW _ _ _ ___.
416 GRY
-1111,,,-SV
REFERENCE
t - - - - - 417 DK BLU
1------
808 BLK
3-26-92
MS 8254-6E
DTC22
(SIGNAL VOLTAGE LOW)

The Throttle Position (TP) sensor provides a voltage signal that changes relative to the throttle blade. Signal
voltage will vary from about .5 at idle to about 4.8 volts at Wide Open Throttle (WOT).
The TP sensor signal is one of the most important inputs used by the ECM for fuel control and for many of the
ECM control outputs.

Engine running and RPM greater than 400.
TP sensor signal voltage is less than about .20
volt for 3 seconds.
2. Simulates DTC 21: (high voltage) If the ECM
recognizes the high signal voltage, the ECM and
wiring are OK.
3. Check for good sensor connection. If connection is
good, replace TP sensor.
4. This simulates a high signal voltage to check for
an open in CKT 417.
5. CKT 416 is a 5 volts buffered reference signal. If
CKT 416 is shorted to ground, DTC 22 will set. To
determine if the MAP sensor is causing the DTC
22 problem, disconnect it to see if OTC 22 resets.
Be sure TP sensor is connected and clear DTC(s)
before testing.
Diagnostic Aids:
A Tech 1 scan to.ol reads throttle position in volts.
Voltage should increase at a steady rate as throttle is
moved toward WOT.
Also so~e scan tools will read: throttle angle 0%
= closed throttle 100% = WOT.
An open or short to ground in CKTs 416 or 417 will
result in a OTC 22.
Scan TP sensor while depressing accelerator pedal
with engine stopped and ignition "ON." Display
should vary from about .5 volt when throttle was
closed, to about 4.8 volts when throttle is held at Wide
Open Throttle (WOT) position.
Also some scan tools will read throttle angle.
0% = closed throttle.
100% = open throttle.
If DTC 22 is set, check CKT 416 for faulty wiring
or connections.
Refer to "lntermittents" in "Symptoms," Section
"6E3-B".
DTC22
THROTTLE CLOSED
DOES TECH 1 SCAN TOOL DISPLAY TP SENSOR .2V (200 mV) OR LESS?

DTCs WERE STORED, REFER TO "DIAGNOSTIC
DISCONNECT TP SENSOR.
JUMPER HARNESS CKTs416 AND417 TOGETHER.
TECH 1 SCAN TOOL SHOULD DISPLAY TP SENSOR GREATER THAN 4.0V
(4000 mV).
DOES IT?
PROBE CKT 417 WITH A TEST LIGHTCONNECTEDTO 12 VOLTS.

TECH 1 SCAN TOOL SHOULD DISPLAY TP SENSOR GREATER THAN 4.0V
(4000 mV).
DOES IT?
REFER TO FACING PAGE FOR

SPECIFIC INSTRUCTIONS.
(i)
CKT 416 OPEN, SHORTED TO GROUND.

IF OK, IT IS A FAULTY CONNECTION
OR
FAULTY ECM.
CKT 417 OPEN, SHORTED TO GROUND,

FAULTY CONNECTION
OR
FAULTY ECM.
11-12-92
NS 15387
6E3-A-48 3.4L (L32} (VIN S} (SFI} DRIVEABILITY AND EMISSIONS
INTAKE AIR TEMP. SENSOR
ECM
IAT SENSOR SIGNAL

SENSOR GROUND
TO MAP
SENSOR
TO A/C REFRIGERANT
PRESSURE SENSOR
TO A/C EVAPORATOR
TEMPERATURE SENSOR
9-4-92
NS 15610
DTC23
INTAKE AIR TEMPERATURE (IAT) SENSOR CIRCUIT
(LOW TEMPERATURE INDICATED}

The Intake Air Temperature (IAT) sensor uses a thermistor to control the signal voltage to the ECM. The
ECM applies a voltage (about 5 volts) on CKT 472 to the sensor. When the air is cold the sensor (thermistor)
resistance is high, therefore. the ECM will see a high signal voltage. If the air is warm the sensor resistance is
low, therefore, the EC~I will see a low voltage.
The IAT sensor is located in the air cleaner.
A signal voltage indicates an Intake Air
Temperature (IAT) less than -35C (-31F).
A signal voltage indicates that engine coolant
temperature is greater than -35.5C (-31.9F).
Time since engine start is 4 minutes or longer.
Vehicle speed less than 1 mph.
All conditions met for 25seconds.
2. A DTC 23 will set due to an open sensor, wire, or
connection. This test will determine if the wiring
and ECM are OK.
3. This will determine if the signal CKT 472 or the
5 volts return CKT 808 is open.
Diagnostic Aids:
A Tech 1 scan tool reads the temperature of the air
entering the engine and should read close to ambient
air temperature when the engine is cold and rises as
underhood temperature increases.
A faulty connection or an open in CKT 472 or CKT
802 will result in a DTC 23.
the result of an open CKT 808, which would also turn
the temperature warning indicator "ON." A faulty
connection could result in intermittent failures. The
"Temperature VS. Resistance Values" scale at the
right may be used to test the IAT sensor at various
temperature levels to evaluate the possibility of a
shifted (mis-scaled) sensor. A shifted sensor could
result in poor driveability complaints.
"6E3-B".
DTC23
8 .
0
DOES TECH 1 SCAN TOOL DISPLAY IAT -30C (-22F) OR COLDER?
DISCONNECT SENSOR.
JUMPER HARNESS TERMINALS
TOGETHER.
DTC 23 IS INTERMITTENT. IF NO
TECH 1 SCAN TOOL SHOULD

DISPLAY TEMPERATURE OVER
ADDITIONAL DTC(S) WERE

STORED, REFER TO "DIAGNOSTIC
130c (266'F).
DOES IT?
JUMPER CKT 472 TO GROUND.

130c (266F).
DOESIT?
DIAGNOSTIC AID
INTAKE AIR TEMPERATURE SENSOR
(APPROXIMATE)
OF
OHMS
OPEN SENSOR
OPEN CKT 472,
GROUND CIRCUIT,
FAUL TY CONNECTION
FAULTY CONNECTION
OR FAUL TY ECM.
OR FAUL TY ECM.
100
90
80
70
60
50
45
40
35
30
25
20
15
10
5
0
-5
-10
-15
-20
-30
-40
212
194
176
158
140
122
113
104
95
86
77
68
59
50
41
32
23
14
5
-4
-22
-40
177
241
332
467
667
973
1188
1459
1802
2238
2796
3520
4450
5670
7280
9420
12300
16180
21450
28680
52700
100700
"AFTER REPAIRS," REFER TO DTC CRITERIA ON FACING PAGE AND CONFIRM OTC DOES NOT RESET.
3-17-92
75 3285-6E
6E3-A-50 3.4L (L32) (VIN S} (SFI} DRIVEABILITY AND EMISSIONS
ECM
VEHICLE SPEED SENSOR (VSS)

(P.M. GENERATOR)
I<0
~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~-4::oP::L
~t---
;-r:;~
LOCATED ON TRANSMISSION
TO
SPEEDOMETER
l~ l
817DK GRNtWHT
'"' - - '-'
10-WAY INLINE
1/P CONNECTOR
#1
(NATURAL)
r----~
_j_
-=-
434 ORN/BLK
VSS SIGNAL (LOW)

VSS SIGNAL(HIGH)
VSSOUTPUT
(4000 PPM)
12V
' ""
PARK NEUTRAL POSITION
(PNP) SWITCH (CLOSED IN
PARK OR NEUTRAL)
9-4-92
NS 15611
DTC24
VEHICLE SPEED SENSOR (VSS) CIRCUIT
Vehicle speed information is provided to the Engine Control Module (ECM) by the Vehicle Speed Sensor
(VSS), which is a Permanent Magnet (PM) generator mounted in the transaxle. The PM generator produces a
pulsing voltage whenever vehicle speed is over about 3 mph. The AC voltage level and the number of pulses
increases with vehicle speed. The EC:VI then converts the pulsing voltage to mph, which is used for calculations.
The vehicle speed can be displayed with a Tech 1 scan tool.
The ECM supplies a signal, on CKT 817, to operate the speedometer and the odometer. The VSS signal is also
sent to the cruise control module.

1. OTC 24 will set if vehicle speed equals O mph
when:
Engine speed is between about 2200 and 4400
RPM.
TP sensor voltage less than 2%.
Low load condition (low MAP voltage), high

manifold vacuum).
Transaxle not in park or neutral.
VSS less than or equal to 3 mph.
All above conditions are met for 4 seconds.
These conditions are met during a road load
deceleration.
Disregard a OTC 24 that sets when the drive
wheels are not turning. This can be caused by a
faulty PNP switch circuit.
The PM generator only produces a signal if the
drive wheels are turning greater than 3 mph.
2. At this point, the ECM is not sending vehicle speed
data to the Tech 1 scan tool. If the scan tool is
connected and functioning properly, the ECM is at
fault. ff the ECM is faulty and must be replaced,
the new ECM must be programmed. Refer to
"ECM Replacement and Programming
Procedures" in Section "6E3-C 1."
Diagnostic Aids:
Scan tool should indicate a vehicle speed whenever
the drive wheels are turning greater than 3 mph.
A problem in CKT 817 will not affect the VSS
input or the readings on a scan tool.
Check CKTs 400 and 401 for proper connections to
be sure they are clean and tight and the harness is
routed correctly. Refer to ''Intermittents" in
A faulty or misadjusted Park/Neutral Position
(PNP) switch can result in a false OTC 24. Use a
scan tool and check for the proper signal while in a
drive range. Refer to CHART C-lA for the PNP
switch check.
DTC24
3.4L (VIN S) F" CARLINE (SFI)
11
DISREGARD OTC 24 IF SET WHILE DRIVE WHEELS ARE NOT TURNING.
RAISE DRIVE WHEELS.

WITH ENGINE IDLING IN GEAR, SCAN TOOL SHOULD DISPLAY VEHICLE SPEED ABOVE O MPH.
DOESIT?
OTC 24 IS INTERMITTENT. IF NO ADDITIONAL

IGNITION "OFF."
DISCONNECT VSS HARNESS CONNECTOR AT TRANSAXLE.
CONNECT SIGNAL GENERATOR TESTER J 33431-B OR EQUIVALENT
TO VSS HARNESS CONNECTOR.
IGNITION "ON," TOOL "ON" AND SET TO GENERATE A VSS SIGNAL.
SCAN TOOL SHOULD DISPLAY VEHICLE SPEED ABOVE OMPH.
DOES IT?
CKT400
OR
401 OPEN, SHORTED TO GROUND, SHORTED
TOGETHER, FAULTY CONNECTIONS
OR
FAULTY ECM.
9-4-92
NS15612
INTAKE AIR TEMP. SENSOR
ECM
IAT SENSOR SIGNAL

SENSOR GROUND
TO MAP
SENSOR
TO A/C REFRIGERANT
PRESSURE SENSOR
TO A/C EVAPORATOR
TEMPERATURE SENSOR
9-4-92
NS 15610
DTC25
The Intake Air Temperature ([AT) sensor uses a thermistor to control the signal voltage to the ECM. The
ECM applies a voltage (about 5 volts) on CKT 472 to the sensor. When the air is cold. the sensor (thermistor)
resistance is high, therefore the ECM will see a high signal voltage. If the air is warm the sensor resistance is
low, therefore the ECM will see a low voltage.
The IAT sensor is located in the rear air intake duct.

A signal voltage indicates an Intake Air
Temperature (IAT) greater than 145C (293F)
for 2 second.
A vehicle speed greater than 1 mph is present.
Due to the conditions necessary to set a OTC 25 the
MIL (Service Engine Soon) will re1~ain "ON" while the
signal is low and vehicle speed is present.
Diagnostic Aids:
A Tech 1 scan tool reads temperature of the air
air temperature when engine is cold and rises as
A short to ground in CKT 472 will result in a DTC
25.
The "Temperature VS. Resistance Values" scale at
the right may be used to test the IAT sensor at various
temperature levels to evaluate the possibility of a
shifted (mis-scaled) sensor. A shifted sensor could
result in poor dri veability complaints.
"6E3-B".
DTC25
G)
DOES TECH 1 SCAN TOOL DISPLAV

IAT OF 145( (293F) OR HOTTER?
DISCONNECT SENSOR.
TEMPERATURE BELOW-30C (-22F).
DOES IT?

DTC(S) WERE STORED, REFER TO

OR
TO SENSOR GROUND
OR
ECM IS FAUL TV.
DIAGNOSTIC AID
(APPROXIMATE)
OF
OHMS
100
90
80
70
60
50
45
40
35
30
25
20
15
10
5
0
-5
-10
-15
-20
-30
-40
212
194
176
158
140
122
113
104
95
86
77
68
59
50
41
32
23
14
5
-4
-22
-40
177
241
332
467
667
973
1188
1459
1802
2238
2796
3520
4450
5670
7280
9420
12300
16180
21450
28680
52700
100700
"AFTER REPAIRS," REFER TO OTC CRITERIA ON FACING PAGE ANO CONFIRM OTC DOES NOT RESET.
2-25-92
7S3190-6E
ECM
MANIFOLD ABSOLUTE
PRESSURE (MAP) SENSOR
MANIFOLD
UR ~
_ __
APBRSEOSSLUTEE
SENSOR GROUND
(VACUUM)
SVOLT
REFERENCE
TO A/C EVAPORATOR
TEMPERATURE SENSOR
9-8-92
NS 15&13
DTC33
MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR CIRCUIT
(SIGNAL VOLTAGE HIGH - LOW VACUUM)

The Manifold Absolute Pressure (MAP) sensor responds to changes in manifold pressure (vacuum). The ECM
receives this information as a signal voltage that will vary from about 1 - 2 volts at idle (high vacuum) to 4 - 4.8
volts at Wide Open Throttle (WOT) (low vacuum). If the MAP sensor fails, the ECM will substitute a MAP value
based on RPM and Throttle Position (TP) sensor to control fuel delivery.

1. DTC 33 will set when:
No DTC 21 or DTC 22.
Engine running.
Manifold pressure greater than 74 kPa (A/C
"OFF") greater than 84.3 kPa (A/C "ON").
Throttle angle between 3 and 30%.
Conditions met for 4 seconds.
Engine misfire or a low unstable idle may set
DTC33.
2. With the MAP sensor disconnected, the ECM
should see a low voltage if the ECM and wiring are
OK.
Diagnostic Aids:
If idle is rough or unstable, refer to "Symptoms,"
Section "6E3-B" for items which can cause an unstable
idle.
An open in CKT 808 or the connection will result
inaDTC 33.
With the ignition "ON" and the engine stopped,

the manifold pressure is equal to atmospheric pressure
and the signal voltage will be high. This information
is used by the ECM as an indication of vehicle altitude.
Comparison of this reading with a known good vehicle
with the same sensor is a good way to check accuracy
of a "suspect" sensor. Readings should be the same
.4 volt.
Check all connections.
rn
Important
Make sure electrical connector remains

securely fastened.
Disconnect sensor from bracket and twist sensor

(by hand only) to check for intermittent
connections. Output changes greater than .1 volt
indicates a faulty connector or connections. If OK,
replace sensor.
Refer to CHART C-lD, MAP sensor voltage output
check for further diagnosis.
"6E3-B".
DTC33
MANIFOLD ABSOLUTE PRESSURE {MAP) SENSOR CIRCUIT
IF ENGINE IDLE IS ROUGH, UNSTABLE OR INCORRECT, CORRECT BEFORE USING CHART.

REFER TO "SYMPTOMS," SECTION "B".
ENGINE IDLING.
DOES TECH 1 SCAN TOOL DISPLAY A MAP OF 3.75 VOLTS OR GREATER?
IGNITION "OFF."
DISCONNECT MAP SENSOR ELECTRICAL CONNECTOR.
IGNITION "ON."
TECH 1 SCAN TOOL SHOULD DISPLAY A VOLTAGE OF 1 VOLT OR LESS.
DOESIT?

PROBE MAP SENSOR GROUND CIRCUIT WITH A TEST LIGHT TO 12 VOL TS.
TEST LIGHT SHOULD LIGHT.
DOESIT?
MAP SENSOR SIGNAL CIRCUIT

SHORTED TO VOLTAGE, SHORTED
TO 5 VOLT REFERENCE CIRCUIT
OR
FAULTY ECM.
PLUGGED OR LEAKING
SENSOR VACUUM HOSE
OR
FAUL TY MAP SENSOR.
9-9-92
NS 15614
ECM
MANIFOLD ABSOLUTE
MANIFOLD
ABSOLUTE~
PRESSURE - - ~
(VACUUM)
SENSOR GROUND
SVOLT
REFERENCE
TO A/C EVAPORATOR
TEMPERATURE SENSOR
9-8-92
NS 15613
DTC34
(SIGNAL VOLTAGE LOW- HIGH VACUUM)

receives this information as a signal voltage that will vary from about 1 - 2 volts at idle (high vacuum) to 4 - 4.8
volts at Wide Open Throttle (WOT) (low vacuum). If the MAP sensor fails, the ECM will substitute a MAP value
based on RPM and Throttle Position (TP) sensor to control fuel delivery.

DTC 34 will set if:
Engine RPM less than 1200.
Manifold pressure reading less than 13 kPa.
Throttle angle greater than 2%.
Conditions met for 2.5 seconds.
1. This test is to see if the sensor is at fault for the low
voltage or if there is an ECM or wiring problem.
an open in CKT 432. If the test light is bright
during this test, CKT 432 is probably shorted to
ground. If Tech 1 scan tool reads over 4 volts at
this test, CKT 474 can be checked by measuring
the voltage at terminal "C" (should be 5 volts).
Diagnostic Aids:
An intermittent open in CKT 432 or CKT 416 will
result in a DTC 34.
With the ignition "ON" and the engine stopped,
the manifold pressure is equal to atmospheric pressure
is used by the ECM as an indication of vehicle altitude.
Comparison of this reading with a known good vehicle
with the same sensor is a good way to check accuracy
of a "suspect" sensor. Readings should be the same
.4 volt.
Check all connections.
rn
Important

securely fastened.

connections. Output changes greater than .1 volt
indicates a faulty connector or connections. If OK,
replace sensor.
Refer to CHART C-lD, MAP sensor voltage output
check for further diagnosis.
"6E3-B".
DTC34
(SIGNAL VOLTAGE LOW - HIGH VACUUM)

START ENGINE AND IMMEDIATELY NOTE MAP
VALUE ON TECH 1 SCAN TOOL.
DOES SCAN DISPLAY MAP BELOW .25 VOLT?
IGNITION "OFF."
JUMPER HARNESS TERMINALS "B" TO"(".
IGNITION "ON."
DOES MAP VOLTAGE READ OVER 4 VOLTS?
DTC-34 IS INTERMITTENT. IF NO ADDITIONAL

IGNITION "OFF."
REMOVE JUMPER WIRE.
PROBE TERMINAL "B" (MAP SENSOR SIGNAL CIRCUIT) WITH
A TEST LIGHT TO 12 VOL TS.
IGNITION "ON."
DOES TECH 1 SCAN TOOL DISPLAY OVE~ 4 VOL TS?
FAUL TY CONNECTION
OR
SENSOR.
5 VOLT REFERENCE CIRCUIT OPEN

OR
SHORTED TO GROUND
OR
FAULTY ECM.
MAP SENSOR SIGNAL CIRCUIT OPEN

OR
SHORTED TO GROUND
OR
FAULTY ECM.
10-7-92
NS 15615
ECM
i - - - - - - - - - - - 441
LT BLU/WHT
IACCOIL "A" HIGH
1 - - - - - - - - - - 442 LT BLU/BLK
IAC COIL "A" LOW
~~::t:::J-~
443 LT GRN/WHT
IAC COIL "B" HIGH
- - - - - - - - - 444 LT GRN/BLK
IAC COIL "B" LOW

9-17-92
NS 15616
DTC35
IDLE AIR CONTROL (IAC) ERROR
DTC 35 will set when the closed throttle engine speed is 300 RPM above or below the desired (commanded)
idle speed for 50 seconds. Review the "General Description" of the IAC operation in "Fuel 11etering System,"
Section "6E3-C2".
Test Description: Number(sl below refer to circled

1. The Tech 1 scan tool RP.\1 control mode is used to
extend and retract the IAC valve. The valve
should move smoothly within the specified range.
If the idle speed is commanded (IAC extended) too
low (below 700 RPM), the engine may stall. This
may be normal and would not indicate a problem.
Retracting the IAC beyond its controlled range
(above 1500 RPM) will cause a delay before the
RPMs start dropping. This too is normal.
2. This test uses the Tech 1 scan tool to command the
IAC controlled idle speed. The ECM issues
commands to obtain commanded idle speed. The
node lights each should flash red and green to
indicate a good circuit as the ECM issues
commands. While the sequence of color is not
important if either light is "OFF" or does not flash
red and green, check the circuits for faults,
beginning with poor terminal contacts.
Diagnostic Aids:
A slow, unstable, or fast idle may be caused by a
non-IAC system problem that cannot be overcome by
the IAC valve. Out of control range IAC Tech 1 scan
tool counts will be above 60 if idle is too low and zero
counts if idle is too high. If idle speed is above 600-700
RPM in drive with an A/T, locate and correct vacuum
leak. If RPM is below spec., check for foreign material
around throttle plates. Refer to "Fuel '.\1etering
System," Section "6E3-C2". The following checks
should be made to repair a non-IAC system problem.
Vacuum leak (high idle). - If idle is too high, stop
the engine. Fully extend (low) IAC with tester.
Start engine. If idle speed is above 800 RPM,
locate and correct vacuum leak including
crankcase ventilation system. Also check for
binding of throttle blade or linkage
System too lean (high air/fuel ratio). - The idle

speed may be too high or too low. Engine speed
may vary up and down and disconnecting the [AC
valve does not help. DTC 44 may set. Tech 1 scan
tool 02S voltage will be less than 300 m V (.3 volt).
Check for low regulated fuel pressure, water in the
fuel or a restricted injector.
System too rich (low air/fuel ratio). - The idle speed
will be too low. Tech l scan tool IAC counts wilt
usually be above 80. System is obviously rich and
may exhibit black smoke in exhaust. DTC 45 may
set.
Tech l scan tool 025 voltage will be fixed above
800 mV (.8 volt).
Check for high fuel pressure, leaking or sticking
injector. Silicone contaminated Oxygen Sensor(s)
will cause sluggish voltage variations on Tech 1
scan tool.
Throttle body. - Remove IAC valve and inspect
bore for foreign material.
IAC valve electrical connections. - lAC valve
connections should be carefully checked for proper
contact.
Crankcase ventilation valve. - An incorrect or
faulty valve may result in an incorrect idle speed.
Refer to "Rough, Unstable, Incorrect Idle, or
Stalling" in "Symptoms," Section "6E3-B".
If intermittent poor driveability or idle symptoms
are resolved by disconnecting the IAC, carefully
recheck connections, valve terminal resistance, or
replace IAC.
AIC compressor or relay failure. - Refer to CHART
C-10 if the A/C control relay drive circuit is
shorted to ground or if the relay is faulty, an idle
problem may exist.
If above are all OK, refer to ''Rough, Unstable,
Incorrect Idle, or Stalling" in "Symptoms," Section
"6E3-B".
DTC35
'2\
V
IDLE AIR CONTROL (IAC) ERROR

INSTALL TECH 1 SCAN TOOL,
ENGINE AT NORMAL OPERA TING TEMPERATURE
IN PARK/NEUTRAL WITH PARKING BRAKE SET.
A/C "OFF."
SELECT RPM CONTROL. (MISC. TESTS)
CYCLE IAC THROUGH ITS RANGE FROM 700 RPM
UP TO 1500 RPM.
RPM SHOULD CHANGE SMOOTHLY.
DOESIT?
INSTALL IAC NODE LIGHT* IN IAC HARNESS.

ENGINE RUNNING. CYCLE IAC WITH TECH 1 SCAN TOOL.
EACH NODE LIGHT SHOULD CYCLE RED AND GREEN BUT
NEVER "OFF."
DO THEY?
IF CIRCUIT(S) DID NOT TEST RED AND

GREEN, CHECK FOR:
FAULTY CONNECTOR TERMINAL
CONTACTS.
OPEN CIRCUITS INCLUDING
CONNECTORS.
CIRCUITS SHORTED TO GROUND OR
VOLTAGE.
FAULTY ECM CONNECTIONS OR
REPLACE ECM.
REPAIR AS NECESSARY AND RETEST.
CHECK IAC
CONNECTIONS.
CHECK IAC
PASSAGES.
IF OK, REPLACE IAC.
USING THE IAC DRIVER* OR OTHER

CONVENIENT CONNECTOR, CHECK
RESISTANCE ACROSS IAC COILS.
SHOULD BE 40 TO 80 OHMS BETWEEN
IAC TERMINALS" A" TO "B" AND "C"
TO"D".
CHECK RESISTANCE BETWEEN IAC

TERMINALS "B" AND "C" AND
"A" AND "D".
SHOULD BE INFINITE.
IDLE AIR CONTROL CIRCUIT OK.

REFER TO '"DIAGNOSTIC AIDS"
ON FACING PAGE.
REPLACE IAC
VALVE AND
RETEST.
REPLACE IAC
VALVE AND
RETEST.
IAC DRIVER AND NODE LIGHT REQUIRED KIT

222-L FROM: CONCEPT TECHNOLOGY, INC.
J 37027 FROM: KENT-MOORE, INC.
CLEAR DIAGNOSTIC TROUBLE CODES, CONFIRM "CLOSED LOOP"

OPERATION, NO MIL (SERVICE ENGINE SOON). PERFORM IAC RESET
PROCEDURE PER APPLICABLE SERVICE MANUAL AND VERIFY
CONTROLLED IDLE SPEED IS CORRECT.
4-1-92
"AFTER REPAIRS," REFER TO DTC CRITERIA ON FACING PAGE AND CONFIRM DTC DOES NOT RESET.
95 6034-6E
6E3-A-60 3.4l (L32) (VIN S) (SFI) DRIVEABILITY AND EMISSIONS
ECM
CAMSHAFT
POSITION
SENSOR
t - - - - 633 BRN/WHT
t - - - - 632 PNK/BLK - - - - - - - - - ,
...,.ll(!--~V"'9--- 239 PNK

HIGH
RES.
CAM REFERENCE
SIGNAL
TO ELECTRONIC
IGNITION CONTROL
MODULE (ICM)
10-WAV FWD LAMP

HARNESS CONNECTOR
(BLACK)
FUSE #11*
1 O AMP
IGNITION
----------1
G -------~
t - - - - 632 PNK/BLK
----------t
t - - - - 1800 LT BLU/WHT
---------1
24X CRANKSHAFT
POSITION SENSOR
REFERENCE LOW
CAMSHAFT
AND 24X SIGNALS
24X REFERENCE
SIGNAL
9-29-92
NS15617
DTC36
24X SIGNAL CIRCUIT ERROR
The 24X crankshaft position sensor is used to improve spark during cranking and engine speeds up to
approximately 2000 RPM.
DTC 36 will set if:
Engine running.
The ECM detects that six or more 24X crankshaft position sensor reference pulses have not occurred.
DTC 36 diagnostic is executed once per ignition cycle.

1. The 24X signal RPM should be the same as engine
speed up to approximately 2000 RPM at which
time it stops. This test determines if the ECM is
putting out a 24X signal.
2. If CKT 1800 is shorted to voltage, this could also
lead to a faulty sensor.
3. If CKT 632 is shorted to voltage, this will set both
DTC 17 and DTC 36.
Diagnostic Aids:
An intermittent 24X signal. DTC 36 can be caused
by poor connections. Visually and physically check all
connections.
DTC36
24X SIGNAL CIRCUIT ERROR
3.4L (VIN S) ''F" CARLINE (SFI)
G)

INSTALL TECH 1 SCAN TOOL
IGNITION "ON," ENGINE IDLING.
MONITOR "IGNITION CONTROL 24X SIGNAL" WITH TECH 1.
IS RPM INDICATED?

DISCONNECT 24X CRANKSHAFT POSITION SENSOR HARNESS CONNECTOR.
WITH DVM TO GROUND PROBE TERMINAL "B" (24X REFERENCE SIGNAL
CIRCUIT) OF HARNESS CONNECTOR.
DVM SHOULD DISPLAY SYSTEM VOLTAGE.
DOES IT?
WITH DVM TO B + PROBE TERMINAL"(" OF HARNESS CONNECTOR.

DVM SHOULD DISPLAY SYSTEM VOLTAGE.
DOES IT?
FAULTY 24X CRANKSHAFT POSITION SENSOR

OR
SENSOR CONNECTOR.
OPEN OR SHORTED 24X REFERENCE SIGNAL

CIRCUIT, FAUL TY ECM CONNECTOR
OR
ECM.
OPEN OR SHORTED REFERENCE LOW

CAMSHAFT AND 24X SIGNALS, FAUL TY
ECM CONNECTOR
OR
ECM.
10-13-92
NS15256
ECM
CLUTCH SW. CLOSED

WHEN CLUTCH PEDAL
IS AT REST
CLUTCH ANTICIPATE
SIGNAL
10WAY 1/P
CONNECTOR
48GRY
> cRL?sE
CONTROL
451 BLK/WHT
I
I
I
B+
~
i..L:::-J_J j_
ENGINE
GROUND
10-9-92
NS 15890
DTC39
CLUTCH SWITCH ERROR
The clutch switch is normally closed when the clutch pedal is at rest. When the clutch pedal is depressed
(clutch disengaged), the switch will change from "OFF" to "ON." The ECM runs a diagnostic check that looks for
a change of st3:te in the switch logic. If there is a failure in the clutch switch circuit, a DTC 39 will be stored in
memory and the :MIL (Service Engine Soon) will be illuminated.
DTC 39 will set when:
Engine at normal operating temperature [above 90C (194F)].
Vehicle speed greater than or equal to 40 mph, the ECM must see VSS to from Oto 40 mph and back to O
mph for the clutch diagnostic to run.
The clutch switch must fail four consecutive times per ignition cycle.

1. When the clutch pedal is depressed, the switch
should go from closed to open and the status on the
Tech 1 scan tool should change from "OFF" to
"ON."
2. This test will check for a poor ground to the clutch
switch.
3. This test will determine if the clutch switch is
being supplied with "B +" or if CKT 48 is shorted
to ground.
Diagnostic Aids:
If DTC 39 was stored in memory and no
problem was found, make sure clutch switch
fastener is secure and is not sticking or binding.
The clutch and the cruise control share the same
switch.
DTC39
CLUTCH SWITCH ERROR

IGN "ON" ENG "OFF."
MONITOR "CLUTCH SWITCH" STATE USING TECH 1.
CLUTCH SWITCH SHOULD READ "OFF."
DOES IT?
DEPRESS CLUTCH PEDAL.

CLUTCH SWITCH SHOULD CHANGE
STATUS FROM "OFF" TO "ON."
DOESIT?
NO TROUBLE FOUND.
DISCONNECT CLUTCH.
SWITCH HARNESS CONNECTOR.
WITH TEST LIGHT CONNECTED TO "B + ",
PROBE CAVITY "D" OF HARNESS.
LIGHT SHOULD BE "ON."
IS IT?
DISCONNECT CLUTCH SWITCH

HARNESS CONNECTOR.
WITH FUSED JUMPER WIRE, JUMPER
CAVITIES "D" AND "C" TOGETHER.
TECH 1 SHOULD READ "OFF."
DOESIT?
CLUTCH SWITCH OUT OF

ADJUSTMENT
OR
FAUL TY SWITCH.
WITH TEST LIGHT CONNECTOR TO

GROUND, PROBE CAVITY "C".
ISIT?
CLUTCH SWITCH OUT OF ADJUSTMENT.

FAULTY CONNECTION
OR
FAUL TV SWITCH.
OPEN OR SHORT TO GROUND IN CKT 48.

FAUL TY ECM CONNECTION
OR
FAULTY ECM.
11-12-92
MS 12599
ECM
10-WA Y FWD LAMP

HARNESS CONNECTOR
(BLACK)
FUSE #11 *
10 AMP
IGNITION-----~--- 239 PNK
G - - - - - - T O HIGH RESOLUTION 24X

CRANKSHAFT POSITION
SENSOR AND CAMSHAFT
POSITION SENSOR.
B+
450BLK-i
GND
LOW RESOLUTION
3X CRANKSHAFT
POSITION SENSOR
: ~ =ill I
SIGNAL
MINIMUM
1 - - - - - - - - - 424 TAN/BLK
1 - - - - - - - - - - 423WHT
-----1
----~
IGNITION CONTROL
BYPASS
IGNITION CONTROL
121 WHT ----'~TACH SIGNAL
ELECTRONIC
IGNITION
CONTROL
MODULE
(ICM)
D
E
1 - - - - - - - - 647 LTBLU/BLK - - - - ~
3XREF HIGH
~-----t1
453 RED/BLK - - - - - 1 1
3XREFLOW
PRIMARY
WINDING
11-12-92
NS 15618
DTC42
IGNITION CONTROL (IC) ERROR
Ignition control timing is provided by the ECM on CKT 423. Using inputs from both the 3X and 24X
crankshaft position sensors, spark timing is calculated and delivered to the electronic ignition control module to
sequence and energize the coil packs. If this ignition control circuit is grounded, the electronic ICM will control
spark timing from a preset base timing schedule and a OTC 42 will be set.
The ignition control bypass circuit should always have 5 volts applied to it. This input controls the solid state
switch internal to the ICM, which provides a complete circuit for timing signals delivered from the ECM to the
electronic ICM. If the bypass circuit is open or grounded, timing signals from the ECM on the ignition control
circuit are grounded inside the electronic ICM. The ICM will use it's own base timing schedule and a OTC 42 will
be set.
4.

1. OTC 42 means the ECM has seen an open or short
to ground in the IC or bypass circuits. This test
confirms OTC 42 and that the fault causing the
OTC is present.
2. Checks for a normal IC ground path through the
ignition control module. An IC CKT 423 shorted to
ground will also read less than 500 ohms; however,
this will he checked later.
3. As the test light voltage touches CKT 424, the
module should switch causing the ohmmeter to
"overrange" if the meter is in the 1000-2000 ohms
position. Selecting the 10-20,000 ohms position
will indicate above 5000 ohms. The important
thing is that the module "switched."
Diagnostic Aids:
The module did not switch and this step checks for:
IC CKT 423 shorted to ground.
Bypass CKT 424 open.
Faulty electronic ignition control module
connection or module.
5. Confirms that OTC 42 is a faulty ECM and not an
intermittent in CKTs 423 or 424.

"6E3-B".
DTC42
(0
G)
IGNITION CONTROL (IC) ERROR

CLEAR DTC{s).
IDLE ENGINE FOR 1 MINUTE
OR UNTIL OTC 42 SETS.
DOES OTC 42 SET?
IGNITION "OFF."
DISCONNECT BLUE ECM CONNECTOR.
IGNITION "ON."
SET OHMMETER SELECTOR SWITCH IN THE 1000 TO
2000 OHMS RANGE.
GROUND THE BLACK(-) OHMMETER LEAD.
PROBE ECM HARNESS IGNITION CONTROL CKT 423
USING THE RED (+)OHMMETER LEAD. THE
OHMMETER SHOULD READ LESS THAN 500 OHMS.
DOES IT?
DTC42 INTERMITTENT. REFER TO

PROBE ECM HARNESS CONNECTOR CKT 424 WITH A TEST

LIGHT TO BATTERY VOLTAGE AND OBSERVE LIGHT.
OPEN CKT 423, FAUL TY CONNECTION, OR

FAUL TY ELECTRONIC IGNITION CONTROL
MODULE {ICM).
LIGHT "ON"
G)
WITH OHMMETER STILL CONNECTED TO ECM HARNESS

CKT 423 AND GROUND AS DESCRIBED IN STEP #2, AGAIN
PROBE ECM HARNESS CKT 424 WITH THE TEST LIGHT
CONNECTED TO BATTERY VOLTAGE. AS TEST LIGHT
CONTACTS CKT 424, RESISTANCE SHOULD SWITCH FROM
HUNDREDS TO THOUSANDS OHMS.
DOESIT?
DISCONNECT IGNITION CONTROL MODULE 6-PIN

CONNECTOR. NOTE OHMMETER THAT IS STILL
CONNECTED TO
CKT 423 AND GROUND. RESISTANCE SHOULD HAVE
BECOME VERY HIGH {OPEN CIRCUIT).
DOESIT?
CKT 424 OPEN, FAULTY CONNECTIONS,

OR
FAULTY ELECTRONIC IGNITION
CONTROL MODULE.
TO GROUND.
DISCONNECT IGNITION CONTROL MODULE 6-PIN

CONNECTOR.
REPLACE IGNITION
CONTROL MODULE.
G).
RECONNECT ECM AND IDLE

ENGINE FOR ONE MINUTE
OR
UNTIL OTC 42 SETS.
DOES OTC 42 SET?
DTC42 INTERMITTENT.
11-12-92
NS 15395
ECM
KNOCK
SIGNAL
5V
5-9-92
NS 15039
DTC43
KNOCK SENSOR (KS) CIRCUIT
The knock sensor is used to detect engine detonation and the EC:VI will retard the Ignition Control (IC) based
on the signal being received. The circuitry within the knock sensor causes the EC:vt 5 volts to be pulled down so
that under a no knock condition, CKT 496 would measure about 2.5 volts. The knock sensor produces an AC
signal which rides on the 2.5 volts DC voltage. The amplitude and signal frequency is dependent upon the knock
level.
IfCKT 496 becomes open or shorted to ground, the voltage will either go above 4.6 volts or below .89 volt. If
either of these conditions are met for about 10 seconds a DTC 43 will be stored.
The test is performed continuously when the following conditions are met.
Engine coolant temperature is over 90C (194F).
IAT temperature is over 0C (32F).

High engine load based on air flow and RPM between 3400 and 4400.

1. If the conditions for DTC 43, as described above,
are being met the Tech 1 scan tool will always
indicate "Yes" when the knock signal position is
selected. If an audible knock is heard from the
engine, repair the internal engine problem, as
normally no knock should be detected at idle.
2. If tapping on the engine lift hook does not produce
a knock signal, try tapping engine closer to sensor.
3. The ECM has a 5 volts pull-up resistor which
should be present at the knock sensor terminal.
Diagnostic Aids:
Check CKT 496 for a potential open or short to
ground.
Refer to "Intcrmittents" in "Symptoms," Section
"6E3-B".
If the customer's complaint is the MIL (Service
Engine Soon) comes oN" when in acceleration. There
is a possibility that the electronic ignition system was
in bypass mode when the OTC 43 test was run. An
intermittent open in the IC circuit will put the ignition
control module in bypass which will not allow the
spark to be advanced so the OTC 43 test would fail. If
the ECM also had a DTC 42 stored, then the IC circuit
is likely the cause of the OTC 43.
DTC43
G)
INSTALL TECH 1.
ENGINE IDLING, ENGINE COOLANT TEMP ABOVE 67C.
DOES TECH 1 INDICATE A FIXED VALUE OF KNOCK
RETARD BETWEEN 4 AND 20 DEGREES?
G)
DISCONNECT KNOCK SENSOR.

IGNITION "ON."
USING A DVM, MEASURE VOLTAGE BETWEEN
HARNESS CKT 496 AND GROUND.
VOLTAGE SHOULD BE 4-6 VOLTS.
ISIT?
OTC 4315 INTERMITTENT. SEE "DIAGNOSTIC AIDS"

ON FACING PAGE.
MEASURE RESISTANCE OF KNOCK SENSOR BY

CONNECTING OHMMETER BETWEEN SENSOR
TERMINAL AND ENGINE BLOCK.
SHOULD BE BETWEEN 3.3KQ & 4.SKQ.
ISIT?
CHECK HARNESS AND SENSOR CONNECTOR.

IFOK:
REMOVE ECM AND BE SURE KS MODULE IS
PROPERLY SEA TED INTO ECM.
IFOK:
REPLACE MODULE.
OVER6VOLTS
CHECK FOR CKT 496 BEING ROUTED TOO

CLOSE TO SECONDARY IGNITION WIRES
OR
OR
FAULTY ECM.
LESS THAN 4 VOL TS

I
CKT 496 OPEN,

SHORTED TO GROUND
OR
FAULTY ECM.
REMOVE KNOCK SENSOR AND ENSURE THAT THREADS ON

SENSOR AND BLOCK ARE CLEAN AND FREE OF CORROSION,
TEFLON TAPE, ANTI-SEIZE COMPOUNDS, OR SEALANTS. IF
OK, REPLACE FAUL TY KNOCK SENSOR.
9-4-92
NS 15640

ECM
SENSOR (025)
l~........,..l------------c((-1665PPUWHT
LEFT 025 GROUND
1 351
BLK/WHT
RIGHT 025 GROUND
ENGINE _ L
GROUND-=-
10-7-92
NS 15602
DTC44
{LEAN EXHAUST INDICATED)

The Engine Control Module (ECM) supplies a voltage of about .45 volt between terminals "B21" and "B20".
(If measured with a 10 megohm digital voltmeter, this may read as low as .32 volt.)
When the 028 reaches operating temperature, it varies this voltage from about 100 millivolts (exhaust is
lean) to about 900 millivolts (exhaust is rich).
The sensor is like an open circuit and produces no voltage when it is below 316C (600F). An open sensor
circuit, or cold sensor, causes "Open Loop" operation.

1. DTC 44 is set when the 028 signal voltage on CKT
1665 remains below .25 volt (280 m V) for 60
seconds or more.
Diagnostic Aids:
Using the Tech 1 scan tool, observe the long term
fuel trim at different RPM and air flow conditions.
The Tech 1 scan tool also displays the fuel trim cells, so
the long term fuel trim values can be checked in each
of the cells to determine when the DTC 44 may have
been set. If the conditions for DTC 44 exist, the long
term fuel trim values will be around 150.
Check the following possible causes:
Oxygen Sensor Wire - Sensor pigtail may be
mispositioned and contacting the exhaust
manifold. Check for ground in wire between
connector and sensor.
Lean lnjector(s). Perform injector balance test

CHARTC-2A.
Fuel Contamination - Water, even in small
amounts, near the in-tank fuel pump inlet can
be delivered to the iajectors. The water causes
a lean exhaust and can set a DTC 44.
Fuel Pressure - System will be lean if fuel
pressure is too low. It may be necessary to
monitor fuel pressure while driving the vehicle
at various road speeds and/or loads to confirm.
Refer to "Fuel System Diagnosis," CHART
A-7.
Exhaust Leaks - If there is an exhaust leak,
the engine can cause outside air to be pulled
into the exhaust and past the sensor. Vacuum
or crankcase leaks can cause a lean condition.
If DTC 44 is intermittent, refer to "Symptoms,"
Section "6E3-B".
A cracked or otherwise damaged 028 may set
an intermittent DTC 44.
DTC44
(LEAN EXHAUST INDICATED)
G)
RUN WARM ENGINE (75C/167F TO 95C/203F) AT 1200 RPM.

DOES TECH 1 INDICATE LEFT 025 (BANK 2) VOLTAGE FIXED BELOW .28 VOLT (280 mV)?
DISCONNECT LEFT 025 (BANK 2) ELECTRICAL CONNECTOR.

WITH ENGINE IDLING, TECH 1 SHOULD DISPLAY LEFT 025
(BANK 2) VOLTAGE BETWEEN .28 VOLT AND .7 VOLT
(280 mV AND 700 MV).
DOES IT?

OTC(s) WERE STORED, REFER TO "DIAGNOSTIC
CKT1665SHORTEDTO
GROUND
OR
11-20-92
NS 15620
6E3-A-70 3.4L (L32) {VIN S) {SFI) DRIVEABILITY AND EMISSIONS

ECM
SENSOR {025)
l~----l----------(~1665PPL/WHT
LEFT 025 GROUND
1 351 BLKJWHT
RIGHT 025 GROUND
ENGINE _t_
GROUND-=-
10-7-92
NS 15602
DTC45
(RICH EXHAUST INDICATED)

The Engine Control :\lodule (ECM) supplies a voltage of about .45 volt between terminals "B21" and "B20".
with a 10 megohm digital voltmeter, this may read as low as .32 volt.)
When the 02S reaches operating temperature, it varies this voltage from about 100 millivolts (exhaust is
The sensor is like an open circuit and produces no voltage when it is below 316C (600V:Fl. An open sensor
(If measured

1. DTC 45 is set when the 02S signal voltage on CKT
412 remains above .75 volt (750 mV) under the
following conditions:
Engine run time after start is 2 minutes or

more.
System is operating in ""Closed Loop."

Throttle angle is greater than 6% but less than
20%.
Above conditions exist for 60 seconds or more.
Diagnostic Aids:
C sing the Tech scan tool, observe the long term
fuel trim value at different RPM and air flow
conditions. The Tech 1 scan tool also displays the fuel
trim cells, so the long term fuel trim values can be
checked in each of the cells to determine when the
DTC 45 may have been set. If the conditions for DTC
45 exists, the long term fuel trim values will be around
115 or lower.
Fuel Pressure - System will go rich, if pressure

is too high. The ECM can compensate for some
increase. However, if it gets too high, a OTC
45 will be set. Refer to "Fuel System
Diagnosis" CHART A-7.
Leaking Fuel Injector(s) - Refer to CHART

A-7.
An open ground CKT 351 - May result in

induced electrical "noise." The ECM
interprets this "noise" as reference pulses. The
additional pulses result in a higher than
actual engine speed signal. The ECM then
delivers too much fuel causing the system to go
rich. The engine tachometer will also show
higher than actual engine speed, which can
help in diagnosing this problem.
Canister Purge - Check for fuel saturation. If

fuel vapor canister is full of fuel, check EV AP
canister control valve and hoses. Refer to
"Canister Purge," in "Evaporative Emission
(EV AP) Control System," Section "6E3-C3".
MAP Sensor - An output that causes the ECM
to sense a higher than normal manifold
pressure (low vacuum) can cause the system to
go rich. Disconnecting the Manifold Absolute
Pressure (:VIAP) sensor will allow the ECM to
set a fixed value for the MAP sensor.
Substitute a different :VIAP sensor if the rich
condition is gone, while the sensor is
disconnected.
TP Sensor - An intermittent Throttle Position
(TP) sensor output will cause the system to
operate richly due to a false indication of the
engine accelerating.
02S Contamination - Inspect Oxygen Sensor
(025) for silicone contamination from fuel, or
use of improper RTV sealanl. The sensor may
have a white, powdery coating and result in a
high but false signal voltage (rich exhaust
indication). The EC:VI will then reduce the
amount of fuel delivered to the engine causing
a severe surge driveability problem.
EGR Valve - Exhaust Gas Recirculation (EGR)
sticking open at idle is usually accompanied by
a rough idle and/or stall condition.
If DTC 45 is intermittent, refer to "Symptoms,"
Section "6E3-B".
Engine Oil Contamination - Fuel fouled
engine oil could cause the 025 to sense a rich
air/fuel mixture and set a DTC 45.
DTC45
{RICH EXHAUST INDICATED)

DOES TECH ONE DISPLAY LEFT 025 (BANK 2) VOLTAGE FIXED ABOVE .7 VOLT (700 mV)?
DISCONNECT LEFT 025 (BANK 2) AND

JUMPER HARNESS CKT 1665 TO GROUND.
TECH ONE SHOULD DISPLAY LEFT 025
(BANK 2) LESS THAN .28 VOLT (280 mV).
DOESIT?
OTC 45 IS INTERMITTENT.
IF NO ADDITIONAL DTCs WERE STORED,
FACING PAGE.
9-10-92
NS15621
ECM
B+
1/PFUSE #4
BATTERY
JUNCTION
BLOCK
10AMP
4-WAY IN-LINE
1/P CONNECTOR #3
(BLACK)
r-----
I
I
I
A1 1 - - - - - - - - e - - - - - 1 C
PASS-KEY II
DECODER
MODULE
L -
A3
340 ORN - 9 ' - - - 1
1-----------1 E
_.._____.
229 DK BLU
10-WAY 1/P
CONNECTOR
(BLUE)
----t
KEEP ALIVE
MEMORYB+
VEHICLE ANTI-THEFT
SYSTEM INPUT
(FUEL ENABLE SIGNAL)
9-21-92
NS 15647
DTC46
PERSONAL AUTOMOTIVE SECURITY SYSTEM (PASS-Keyn) CIRCUIT
The PASS-Key I I system is designed to disable vehicle operation if the incorrect key or starting procedure is
used. The PASS-KeyII decoder module sends a signal to the ECM if the correct key is being used. If the proper
signal does not reach the ECM on CKT 229, the ECM will not pulse the injectors "ON" and thus not allow the
vehicle to be started.
DTC 46 will set, if the proper signal is not being received on CKT 229 by the ECM when the ignition is turned
"ON." A PASS-KeyII fault will store a OTC 46 in the ECM memory.

1. If the engine cranks, but doesn't start. It indicates
that the portion of the module which generates the
signal to the ECM is not operating or CKT 229 is
open or shorted to ground. If the decoder module is
found to be OK, as determined from SECTION 8A,
the ECM may be at fault, but this is not a likely
condition.
2.
If OTC 46 is stored, and the engine will not crank,
it indicates that there is a PASS-KeyII problem

or an incorrect key or starting procedure is being
used.
DTC46
PERSONAL AUTOMOTIVE SECURITY SYSTEM (PASS-Key@11) CIRCUIT
IGNITION "ON."
DOES SCAN TOOL INDICATE PASS-KeyII STATUS AS "OK"?
PROBLEM IS INTERMITTENT. IF NO
OTHER DTC(S) IS STORED, REFER TO
"INTERMITTENTS" IN SECTION "8".
G)
CHECK FOR OPEN OR SHORT TO GROUND IN CKT 229

OR
FAULTY CCM
OR
FAULTY ECM.
"AFTER REPAIRS," REFER
PASS-KeyII SYSTEM PROBLEM. REFER TO

PASS-KeyII DIAGNOSIS" IN SECTION "SA"
AND "90".
TO DTC CRITERIA ON FACING PAGE AND CONFIRM DTC DOES NOT RESET.
4-7-92
LS 8512-6E
ECM
10-WAY INLINE 1/P
CONNECTOR #2
(BLUE)
1/P FUSE #5
TO IGN
SWITCH
<01,C::-----~----1r~-----t01----15 AMP
439 PNK
SEE SECTION SA
FOR COMPLETE CIRCUIT
DETAILS
IGNITION FEED
11-06-92
NS 15601
DTC53
SYSTEM VOLTAGE OVERCHARGE
(HIGH BATTERY VOLTAGE)

DTC 53 will set when the ignition is "ON" and the ECM is sensing an ignition feed voltage of more than 16.5
volts for 10 seconds.
Any time a OTC 53 failure is current, all ECM outputs will become disengaged.

I. Normal battery output is between 10 - 16.5 volts.
2. Checks to see if the high voltage reading is due to
the generator or EC:.VI. With engine running,
check voltage at the battery. If the voltage is
above 12.1 volts, the EC~1 is OK.
3. Checks to see if generator is faulty under load
condition. If the voltage is above 16.5 volts, refer
to SECTION 60.
DTC53
SYSTEM VOLTAGE OVERCHARGE
{HIGH BATTERY VOLTAGE)
8 .
ENGINE RUNNING ABOVE 800 RPM.

NOTE SYSTEM VOLTAGE ON TECH 1 SCAN TOOL.
I
I
ABOVE 16.5 VOLTS
I
I
BELOW 16.S VOL TS
CHECKSYSTEMVOLTAGEATBATTERY.
ABOVE 16.5 VOL TS
BELOW 16.5 VOL TS
I
REMOVE GENERATOR
FOR REPAIR.
REFER TO SECTION 60 .
FAULTY ECM
CONNECTOR OR
FAULTY ECM.

LOAD ELECTRICAL SYSTEM WITH HEADLAMPS
AND HIGH BLOWER "ON."
NOTE DATA VALUE.
I
I
ABOVE 16.5 VOL TS
BELOW 16.5VOLTS
I
REMOVE GENERATOR
FOR REPAIR.
FAULT IS NOT PRESENT.

REFER TO "NOTE ON
INTERMITTENT$ .. "
10-13-92
NS 15042
ECM
TO PASS-Key" II
DECODER MODULE
1/P FUSE #5
10-WAY INLINE 1/P

CONNECTOR #2
{BLUE)
.,..E-------<~-------------------11f"c;"l
TO IGN
SWITCH
439 PNK
15AMP
IGNITION FEED
439 PNK
465 DK GRN/WHT
FUEL
PUMP
RELAY
FUEL PUMP
MOTOR IN
FUEL TANK
K
451 WHT/BLK
FUEL PUMP REQUEST
-i
12 0GRY
120GRY
-0
EJ1------r-------
FUEL TANK/ABS PASS

INLINE I/;
THRU CONNECTOR
CONNECTOR #1
120GRY
FUEL PUMP SIGNAL
FUEL PUMP PRIME

CONNECTOR
11-12-92
NS 15619
DTC54
FUEL PUMP CIRCUIT
(LOW VOLTAGE)

The status of the fuel pump CKT 120 is monitored by the ECM at terminal "A6" and is used to compensate
fuel delivery based on system voltage. This signal is also used to store a diagnostic trouble code if the fuel pump
relay is defective or fuel pump voltage is lost while the engine is running. There should be about 12 volts on CKT
120 for 2 seconds after the ignition is turned ''ON," or any time reference pulses are being received by the ECM.
DTC 54 will set if the voltage at terminal "A6" is less than 7 volts for .3 second since the last reference pulse
was received. This DTC is designed to detect a faulty relay causing extended crank time and the DTC will help
the diagnosis of an engine that "CRAN KS BUT WI LL NOT RUN."
If a fault is detected during start-up the Malfunction Indicator Lamp (MIL) "Service Engine Soon" will stay
"ON" until the ignition is cycled "OFF." However, if the voltage is detected below 7 volts with the engine
running, the light will only remain "ON" while the condition exists.
DTC 54
FUEL PUMP CIRCUIT
{LOW VOLTAGE)
CLEAR DTC(S).
IGNITION "ON."
IGNITION "ON."
LISTEN FOR IN-TANK FUEL PUMP.
PUMP SHOULD RUN FOR 2 SECONDS AFTER IGNITION "ON."
DOES IT?
IGNITION "OFF."
USING A 10 AMP FUSED JUMPER WIRE, CONNECT
FUEL PUMP PRIME CONNECTOR TO 12 VOL TS.
DOES PUMP RUN?
IGNITION "OFF."
DISCONNECT FUEL
PUMP RELAY.
PROBE CKT 439 WITH A
TEST LIGHT TO GROUND.
CONNECT TEST .
LIGHT BETWEEN
CKTs 439 & 451.
REPAIR
OPEN IN
CKT 439.
DISCONNECT FUEL
PUMP RELAY.
USING THE FUSED JUMPER
WIRE, CONNECT CKT 120 TO
12 VOLTS.
DOES PUMP RUN?
FAULTY
CONNECTION
OR
FAULTY RELAY.
CLEAR DTC(S).
START AND RUN ENGINE FOR 30
SECONDS OR UNTIL DTC 54 SETS.
DOES DTC SET?
DISCONNECT ECM
CONNECTOR "A".
WITH A DVM CHECK FOR
CONTINUITY FROM CKT 120
OF FUEL PUMP RELAY TO
ECMPIN"A6".
DO YOU HAVE CONTINUITY?
DTC541S
INTERMITTENT.
REFER TO
"INTERMITTENTS"
IN SECTION "B".
OPEN CKT 120,

FAULTY IN-TANK
PUMP OR FAUL TY
PUMP GROUND.
CONNECT TEST LIGHT BETWEEN HARNESS CKT 465 AND GROUND.

NOTE TEST LIGHT WITHIN 2 SECONDS AFTER IGNITION "ON."
REPLACE FAULTY FUEL PUMP RELAY.
REPAIR OPEN CKT 451.
CKT 465 OPEN, SHORTED TO GROUND

OR
FAULTY ECM.
9-29-92
NS 15623

TOIATAND
MAP SENSOR
A/C
REFRIGERANT
PRESSURE
SENSOR
808BLK---------------------1
SENSOR GROUNDS
----------+-------1
A/C REFRIGERANT
PRESSURE SENSOR
SIGNAL
380 RED/BLK
416GRY - - - - - ~
A/C
EVAPORATOR
TEMPERATURE
SENSOR
ECM
808BLK-------+----
732DKBLU------+-----------t
A/C
SELECT SWITCH
1/P FUSE #3
~~-TO TP AND
MAP SENSOR
TO ~ 2 4 1 BRN - - - - - - ~ - - - - - - - 7 6 2 LT GRN/BLK
A/C EVAPORATOR
TEMPERATURE SIGNAL
5V REFERENCE
A/C REQUEST
IGNITION
25AMP
FUSE #12 *
SWITC~~
-...----------- ~ 139 PNK - - - - ,
20AMP
~----1811---------'
A/C
COMPRESSOR
CLUTCH
CONTROL
RELAY*

CONN ECTOR (BLACK)
r--,
59 DK GRN
A/C
~ 6 0 3 DK GRN
COMPRESSOR
CLUTCH
B
450 BLK
459 DK GRN/WHT
-----+-1
A/C COMPRESSOR
CLUTCH RELAY
A/CSTATUS
a
~ A/C COMPRESSOR LOW
PRESSURE CUTOFF SWITCH
11-12-92
NS 15598
DTC61
A/C SYSTEM PERFORMANCE
AIC refrigerant charge is calculated by the inputs from the NC refrigerant pressure and NC evaporator
temperature sensors. The ECM will calculate system charge when the NC is selected "ON" by using three
variables. NC evaporator temperature, A/C refrigerant pressure and vehicle speed are factored together to yield
a minimum charge allowable for the NC system to operate. If system charge falls below a given value for the
temperature and vehicle speed variables, a OTC 61 will set. As ambient temperature falls, so does static (NC
"OFF") refrigerant pressure. This produces a sliding scale which requires temperature, pressure and vehicle
speed inputs to calculate a reliable system charge value that indicates when NC refrigerant charge is too low to
safely allow the compressor to operate.

1. This test determines if OTC is intermittent and
will also check the NC system for other failures.
Repair all other OTC(s) first before proceeding.
2. This test is to evaluate the A/C refrigerant
pressure sensor for accuracy. A reliable gage set
should be used and no more than 20 psi difference
in pressure between gages and Tech 1 is allowable.
3. The system is operating though OTC 61 is
intermittent. Hardware failures including worn
compressor etc are diagnosed in SECTION 18.
Diagnostic Aids:
After a subsequent key cycle, the A/C will be
enabled and OTC 61 will be erased from the current
OTC memory and added as a history OTC. If A/C
pressure, evaporator temperature and vehicle speed
again indicate a low charge, the ECM will store a
current OTC 61 and disable the NC compressor clutch.
Only after a relatively high number of failures occur
will the NC be disabled and become inoperative until
the code is cleared, from both current and history OTC
memory.
The A/C status circuit allows the ECM to
determine if the clutch is receiving a complete circuit
via the NC relay. If the status line is intermittently
open or grounded a DTC 61 may set.
DTC61
~------------------------------------~
: THIS CHART ASSUMES THAT THE A/C SENSORS, CLUTCH
A/C SYST.EM PERFORMANCE

3.4L {VIN S) "F" CARLINES {SFI)
CONTROL AND RELAYS ARE FUNCTIONING PROPERLY.

: IF ANY OF THE ABOVE IS NOT "OK," REFER TO THE
I APPROPRIATE CHARTS FOR PROPER DIAGNOSIS.
I
~------------------------------------~
G)
IGNITION "OFF," ENGINE "OFF," A/C "OFF."

INST ALL TECH 1 SCAN TOOL.
IGNITION "ON," ENGINE IDLING.
TURN A/C "ON."
ROAD TEST VEHICLE.
DOES DTC 61 OR ANY OTHER A/C DTCs SET?
DTC 61 IS INTERMITTENT, REFER

TO SECTION 181 FOR FURTHER
SYSTEM DIAGNOSIS.
ENGINE "OFF."
INSTALL A/C MANIFOLD GAGE SET. (SEE SECTION
1B FOR PROPER INSTALLATION INSTRUCTIONS
AND A/C PRESSURE SPECIFICATIONS.)
IGNITION "ON," ENGINE IDLING, A/C "OFF."
IS A/C REFRIGERANT PRESSURE WITHIN
SPECIFICATION LISTED IN 1B?
G)
SCAN A/C PRESSURE USING TECH 1.

ARE TECH 1 SCAN TOOL PRESSURES WITHIN
20 LBS OF HIGH SIDE GAGE PRESSURE?
SCAN A/C EVAPORATOR TEMPERATURE

USING TECH 1.
A/C CLUTCH SHOULD ENGAGE WHEN
EVAPORATOR TEMPERATURE IS GREATER
THAN 39 F AND DISENGAGE WHEN
TEMPERATURE IS LESS THAN 36 F.
DOES IT?
REFER TO A/C SECTION 181 AND

PERFORM A/C PERFORMANCE TEST.
CHECK SENSOR CONNECTIONS.

IF OK, REPLACE A/C REFRIGERANT
PRESSURE SENSOR.
LOW A/C REFRIGERANT CHARGE

OR
FAULTY A/C EVAPORATOR TEMPERATURE
SENSOR CONNECTION
OR
FAULTY A/C EVAPORATOR TEMPERATURE
SENSOR
OR
A/C EVAP TEMPERATURE SENSOR IN IMPROPER
LOCATION.
12-8-92
NS16211
ECM
RIGHT (BANK 1) OXYGEN
SENSOR (02S)
1~~1------c(~1666PPL
LEFT 02S GROUND
1 351
-L
BLK,WHT
RIGHT 02S GROUND
ENGINE
GROUND-=-
10-8-92
NS 15889
DTC63
RIGHT (BANK 1) OXYGEN SENSOR (02S) CIRCUIT
(OPEN CIRCUIT)

The EC:Vt supplies a voltage of about .55 volt between terminals ''822" and "823". (If measured with a 10
megohm digital voltmeter, this may read as low as .35 volt.) The Oxygen Sensor (02S) varies the voltage within
a range of about l mil. If the right ( Bank l J exhaust is rich, the 028 will display close to 1000 millivolts and
when the exhaust is lean the 028 will display close to 100 millivolts.
The sensor is like an open circuit and produces no voltage when it is below 316C (600F). An open 02S
circuit or cold 028 causes "Open Loop" operation.

1. DTC 63 will set under the following conditions:
Engine running at least 2 minutes after start.
Engine coolant temperature greater than 85C

(185F).
028 signal voltage steady between 350
millivolts and 550 millivolts.
Throttle position greater than 3%.
All conditions must be met and held for at least

30 seconds.
Cf the conditions for a OTC 63 exist, the system will
not go "Closed Loop."
2.
3.
This will determine if the sensor is at fault or the

wiring or ECM is the cause of the OTC 63.
In doing this test use only a high impedance digital
volt ohmmeter. This test checks the continuity of
CKT 1666 and CKT 351 because if CKT 351 is
open the ECM voltage on CKT 1666 will be greater
than .6 volt (600 m V).
Diagnostic Aids:
Normal Tech l scan voltage varies between 100
mV to 999 mV (.1 and 1.0 volt) while in "Closed Loop."
OTC 63 sets if voltage remains between 350 millivolts
and 550 millivolts, but the system will go "Open Loop"
in about 15 seconds. Refer to "Intermittent:,;'' in
DTC63
RIGHT (BANK 1) OXYGEN SENSOR (02S) CIRCUIT
(OPEN CIRCUIT)
G)
ENGINE AT NORMAL OPERATING TEMPERATURE (ABOVE 80C!176F).

DOES SCAN TOOL INDICATE "CLOSED LOOP"?
G)
DISCONNECT 025 CONNECTOR.

SCAN TOOL SHOULD DISPLAY OXYGEN SENSOR VOLTAGE
BELOW .2 VOLT (200 mV) WITH ENGINE RUNNING.
DOES IT?

REMOVE JUMPER.
CHECK VOLTAGE OF CKT 1666 (ECM SIDE) AT
025 HARNESS CONNECTOR USING A DVM .
FAULTY 025 CONNECTION

OR
SENSOR.
.3- .6 VOLT
(300 - 600 mV)
FAULTY ECM.
GREATER THAN
.6 VOLT (600 mV)
OPEN CKT 351
OR
FAUL TY CONNECTION
OR
FAULTY ECM.
LESS THAN .3
VOLT (300 mV)
OPEN CKT 1666
OR
OR
FAULTY ECM.
10-7-92
NS 15928
ECM
RIGHT (BANK 1) OXYGEN
SENSOR (025)
l~-l------c((--1666PPL
LEFT 025 GROUND
1 351
BLKJWHT
RIGHT 025 GROUND
ENGINE _t_
GROUND
-=-
10-8-92
NS 15889
DTC64
RIGHT (BANK 1} OXYGEN SENSOR (02S} CIRCUIT
3.4L (VIN S} "F" CARLINE (SFI}

The Engine Control Module (EC11) supplies a voltage of about .45 volt between terminals g22" and "823".
When the 028 reaches operating temperature, it varies this voltage from about 100 millivolts (exhaust is
The sensor is like an open circuit and produces no voltage when it is below 3 l6C (600''F). An open sensor

1. OTC 64 is set when the 028 signal voltage on CKT
1666 remains below .25 volt (280 m V) for 60
seconds or more.
Diagnostic Aids:
Using the Tech l scan tool, observe the long term
fuel trim at different RPM and air flow conditions.
The Tech l scan tool also displays the fuel trim cells, so
the long term fuel trim values can be checked in each
of the cells to determine when the OTC 64 may have
been set. [f the conditions for OTC 64 exist, the long
term fuel trim values will be around 150.
Oxygen Sensor Wire - Sensor pigtail may be
manifold. Check for ground in wire between
Lean lnjector(s). Preform injector balance test

CHARTC-2A.
Fuel Contamination - Water, even in small
amounts, near the in-tank fuel pump inlet can
be delivered to the injectors. The water causes
a lean exhaust and can set a DTC 64.
Fuel Pressure - System will be lean if fuel
pressure is too low. It may be necessary to
monitor fuel pressure while driving the vehicle
at various road speeds and/or loads to confirm.
Refer to "Fuel System Diagnosis," CHART
A-7.
Exhaust Leaks - If there is an exhaust leak,

the engine can cause outside air to be pulled
into the exhaust and past the sensor. Vacuum
or crankcase leaks can cause a lean condition.
If OTC 64 is intermittent, refer to symptoms,"
Section "6E3-8".
A cracked or otherwise damaged 028 may set
an intermittent OTC 64.
DRIVEABILITY AND EMISSIONS 3.4L {L32} {VIN S} {SFI) 6E3-A-83
DTC64
RIGHT (BANK 1) OXYGEN SENSOR (025) CIRCUIT
3.4L (VIN S)
G)
11
F" CARLINE (SFI)

DOES TECH 1 INDICATE RIGHT 025 (BANK 1) VOLTAGE FIXED BELOW .28 VOLT (280 mV)?
DISCONNECT RIGHT 025 (BANK 1) ELECTRICAL CONNECTOR.

WITH ENGINE IDLING, TECH 1 SHOULD DISPLAY RIGHT 025
(BANK 1) VOLTAGE BETWEEN .28 VOLT AND .7VOLT
(280 mV AND 700 MV).
DOESIT?
DTC 6415 INTERMITTENT. IF NO ADDITIONAL


OR
FAULTY ECM.
10-7-92
NS 15930

ECM
RIGHT {BANK 1) OXYGEN
SENSOR {02S)
l~--t-l-------<(f--1666PPL
LEFT 02S GROUND
1 351
BLKJWHT
RIGHT 02S GROUND
ENGINE _L
GROUND
-=-
10-8-92
NS 15889
DTC65
RIGHT {BANK 1) OXYGEN SENSOR (025)

The Engine Control Module (ECM) supplies a voltage of about .45 volt between terminals "822" and "B23".
When the 02S reaches operating temperature, it varies this voltage from about 100 millivolts (exhaust is
~

1. OTC 65 is set when the 02S signal voltage on CKT
1666 remains above .75 volt (750 mV) under the
Engine run time after start is 2 minutes or
more.
System is operating in "Closed Loop."
Throttle angle is greater than 6% but less than
20%.
Above conditions exist for 60 seconds or more.
Diagnostic Aids:
Using the Tech scan tool, observe the long term
fuel trim value at different RPM and air flow
conditions. The Tech 1 scan tool also displays the fuel
trim cells, so the long term fuel trim values can be
checked in each of the cells to determine when the
OTC 65 may have been set. If the conditions for OTC
65 exists, the long term fuel trim values will be around
115 or lower.
Fuel Pressure - System will go rich, if pressure
is too high. The ECM can compensate for some
increase. However, if it gets too high, a DTC
65 will be set. Refer to "Fuel System
Diagnosis" CHART A-7.
Leaking Fuel Injector(s) - Refer to CHART
A-7.
An open ground CKT 351 - May result in
induced electrical "noise." The ECM
interprets this "noise" as reference pulses. The
additional pulses result in a higher than
actual engine speed signal. The ECM then
delivers too much fuel causing the system to go
rich. The engine tachometer will also show
higher than actual engine speed, which can

help in diagnosing this problem.
Canister Purge - Check for fuel saturation. If
fuel vapor canister is full of fuel, check EVAP
canister control valve and hoses. Refer to
"Canister Purge," in "Evaporative Emission
(EVAP) Control System," Section "6E3-C3".
MAP Sensor - An output that causes the ECM
to sense a higher than normal manifold
pressure (low vacuum) can cause the system to
go rich. Disconnecting the Manifold Absolute
Pressure (MAP) sensor will allow the ECM to
set a fixed value for the MAP sensor.
Substitute a different MAP sensor if the rich
condition is gone, while the sensor is
disconnected.
TP Sensor - An intermittent Throttle Position
(TP) sensor output will cause the system to
operate richly due to a false indication of the
engine accelerating.
02S Contamination - Inspect Oxygen Sensor
(02S) for silicone contamination from fuel or
use of improper RTV sealant. The sensor ~ay
have a white, powdery coating and result in a
high but false signal voltage (rich exhaust
indication). The ECM will then reduce the
amount offuel delivered to the engine causing
a severe surge driveability problem.
EGR Valve - Exhaust Gas Recirculation (EGR)
sticking open at idle is usually accompanied by
a rough idle and/or stall condition.
If DTC 65 is intermittent, refer to "Symptoms "
Section "6E3-B".
'
Engine Oil Contamination - Fuel fouled
engine oil could cause the 02S to sense a rich
air/fuel mixture and set a OTC 65.
DRIVEABILITY AND EMISSIONS 3.4l {L32) {VIN S) {SFI) 6E3-A-85
DTC65
RIGHT (BANK 1) OXYGEN SENSOR (02S)
RUN WARM ENGINE (75C/167F TO 95C/203F)AT 1200 RPM.

OOES TECH ONE DISPLAY RIGHT02S (BANK 1) VOLTAGE FIXED ABOVE .7 VOLT (700 mV)?
DISCONNECT RIGHT 025 (BANK 1) AND

JUMPER HARNESS CKT 1666 TO GROUND.
TECH ONE SHOULD DISPLAY RIGHT 025
(BANK 1) LESS THAN .28 VOLT (280 mV).
DOES IT?
DTC 65 IS INTERMITTENT.
IF NO ADDITIONAL DTCs WERE STORED,
FACING PAGE.
"AFTER REPAIRS,"' REFER TO DTC CRITERIA ON FACING PAGE AND CONFIRM DTC DOES NOT RESET.
10-7-92
NS 15932

TOIATAND
MAP SENSOR
SENSOR GROUNDS
808 BLK
A/C
REFRIGERANT
PRESSURE
SENSOR
A/C REFRIGERANT
PRESSURE SENSOR
SIGNAL
380 RED/BLK
416GRY
A/C
EVAPORATOR
TEMPERATURE
SENSOR
ECM
808 BLK
A/C EVAPORATOR
TEMPERATURE SIGNAL
732 DKBLU
416GRY
A/C
SELECT SWITCH
1/P FUSE #3
......_____,~ TO TP AND
MAP SENSOR
TO ~ 2 4 1 BRN - - - - - - ~ - - - - - - - - 7 6 2 LT GRN/BLK
5V REFERENCE
A/C REQUEST
IGNITION
25 AMP
FUSE #12 *
SWITC~~
~ .....,,,--139PNK--~
20AMP
~----1
A/C
COMPRESSOR
CLUTCH
CONTROL
RELAY*
81 - - - - - - ~
CONNECTOR (BLACK)
r---,
t-------~---rl
I
459 DK GRN/WHT
A/C COMPRESSOR
CLUTCH RELAY
A/CSTATUS
L..--..J
COM:~~SSOR ~ 6 0 3 D K G R N
CLUTCH
~450BLKl
~A/C COMPRESSOR LOW

11-12-92
NS 15598
DTC66
A/C REFRIGERANT PRESSURE SENSOR CIRCUIT
(LOW PRESSURE)

The NC refrigerant pressure sensor responds to changes in NC refrigerant system high side pressure. This
input indicates how much load the NC compressor is putting on the engine and is one of the factors used by the
ECM to determine IAC valve position for idle speed control, and engine cooling fan operation. The circuit consists
of a 5 volts reference and a ground, both provided by the ECM, and a signal line to the ECM. The signal is a
voltage which is proportional to the pressure. The sensor's range of operation is O to 450 psi. At O psi, the signal
will be about .1 volt, varying up to about 4.9 volts at 450 psi or above. DTC 66 sets if the voltage is less than .1
volt (approximately less than O psi) for 5 seconds or more. The NC compressor is disabled by the ECM if OTC 66
is present or if pressure is above or below calibrated values described in "Air Conditioning Compressor Clutch
Control" Sectioq "6E3-C10".
Diagnostic Aids:
DTC 66 sets when signal voltage falls outside the
1. This step checks the voltage signal being received
by the ECM from the A/C refrigerant pressure
normal possible range of the sensor and is not due to a
sensor.
refrigerant system problem. If problem is
2. Checks to see if low voltage signal is from the
intermittent, check for opens or shorts in harness or
sensor or the circuit. Jumpering the sensor signal
poor connections.
CKT 732 to 5 volts checks the circuit, connections,
andECM.
3. This step checks to see if the low voltage signal
was due to an open in the sensor signal circuit or
the 5 volts reference circuit since the proper step
eliminated the pressure sensor.
DTC66
A/C PRESSURE SENSOR (LOW) CIRCUIT
11
G)
IGNITION "OFF" ENGINE "OFF"

INSTALL TECH 1 SCAN TOOL
IGNITION "ON" ENGINE NOT RUNNING.
SCAN A/C REFRIGERANT PRESSURE SENSOR VOLTAGE
IS VOLTAGE LESS THAN.1V?
DISCONNECT A/C REFRIGERANT PRESSURE SENSOR CONNECTOR.

JUMPER TERMINALS "B" AND "C".
DOES TECH 1 DISPLAY GREATER THAN 4.6 VOLTS?
OTC 66 INTERMITTENT REFER TO

REMOVE JUMPER.
CONNECT VOLTMETER FROM TERMINAL "A" TO "B".
IS VOLTAGE ABOUT 5 VOLTS?
FAUL TY A/C REFRIGERANT PRESSURE SENSOR

CONNECTION
OR
FAUL TY A/C REFRIGERANT PRESSURE SENSOR.
WITH TEST LIGHT TO B +, PROBE PRESSURE

SENSOR CONNECTOR TERMINAL" A".
IS LIGHT "ON"?
FAUL TY CKT 380 ECM CONNECTION

OR
OPEN CKT380
OR
FAULTY ECM.
OPEN A/C REFRIGERANT PRESSURE

SENSOR GROUND CKT 808.
12-8-92
NS 15624

TO IAT AND
MAP SENSOR
A/C
REFRIGERANT
PRESSURE
SENSOR
808BLK-------------il,::-------~
SENSOR GROUNDS
----------+------t
A/C REFRIGERANT
PRESSURE SENSOR
SIGNAL
380 RED/BLK
416GRY - - - - - ~
A/C
EVAPORATOR
TEMPERATURE
SENSOR
ECM
808 BLK
---------l------'
732DKBLU------+----------~
A/C
SELECT SWITCH
1/P FUSE #3
'-----l~TO TP AND
MAP SENSOR
TO ~ 2 4 1 BRN - - - - - - - ~ - - - - - - - 7 6 2 LTGRN/BLK
A/C EVAPORATOR
TEMPERATURE SIGNAL
5V REFERENCE
A/C REQUEST
IGNITION
25 AMP
FUSE #12 *
SWITCH~ _ _ ______ _ - ~ ___________,. ....,-- 139 PNK - - ~
20AMP
A/C
COMPRESSOR
CLUTCH
CONTROL
RELAY*
10-WA Y FWD LAMP HARNESS

CONNECTOR (BLACK)
r--,
I
1------------rl
459 DK GRN/WHT
A;C COMPRESSOR
CLUTCH RELAY
AC STATUS
A/C
~603DKGRN
B
COMPRESSOR
CLUTCH
~450BLKl
11-12-92
NS 15598
DTC67
A/C REFRIGERANT PRESSURE SENSOR
{CIRCUIT ERROR)

The ECM can determine if the A/C compressor clutch is engaged or not engaged through the NC clutch status
line. If the ECM has grounded the coil of the A/C clutch control relay, current can tlow lhrough the relay contacts
to the AJC compressor clutch and the ECM on the A/C status circuit.
When voltage is present at the ECM A/C clutch status terminal, A/C status "ON" will be displayed on the
Tech 1. As the ECM detects that the A/C compressor clutch has cycled "OFF" (through the A/C control switch
etc.), the ECM will record AJC system pressure from the A/C refrigerant pressure sensor. If the A/C refrigerant
pressure does not increase more than 9 psi when the A/C clutch is turned hack "ON," a DTC 67 will set. This
condition can occur if the A/C refrigerant pressure sensor is fixed at one value, or if the A/C refrigerant pressure
sensor ground is open.

l. OTC 67 will set if: the ECM does not detect an A/C
refrigerant pressure change of more than 9 psi
when the A/C clutch has been cycled.
2. If the relay power feed CKT 139 is intermittent,
the A/C clutch status terminal may not detect
voltage when A/C is commanded "ON."
3. [f the A/C clutch status line becomes
intermittently open or shorted while the
compressor is "ON," the EC:'.1 will be wrongly
detecting the A/C clutch going ''ON" and "OFF."
When the ECM falsely detects the clutch cycling
from oN" to '"OFF" and the clulch is remaining
"ON," a DTC 67 will set since no pressure change
was detected.
4.
5.
If the A/C compressor clutch is disconnected or if

CKT 59 is open between the splice and the clutch,
the A/C compressor clutch will not engage, but the
ECM will detect voltage on the A/C status line
which will indicate the clutch is "ON." If the A/C
controls are cycled from oFF" to "ON" at this
point, a OTC 67 will set since the clutch did not
engage and therefore no pressure change was
detected.
The remaining tests check the A/C refrigerant
pressure sensor circuit for proper operation.
Diagnostic Aids:
A OTC 67 will store in ECM memory but will not
turn ''ON" the Malfunction [ndicator Lamp (YIIL l
"Service Engine Soon."
DTC67
{CIRCUIT ERROR)
IF OTC 66 OR 70 IS PRESENT USE THAT CHART FIRST.

CLEAR DTC(s).
START ENGINE.
TURN A/C "ON."
DID AiC COMPRESSOR CLUTCH ENGAGE?
USING TECH 1, OBSERVE AiC REFRIGERANT PRESSURE WHILE

CYCLING THE A/C COMPRESSOR CLUTCH FROM "OFF'' TO "ON."
DID A/C REFRIGERANT PRESSURE INCREASE MORE THAN 10 psi
WHEN A/CCONTROLS WERE TURNED "ON"?
IGNITION "OFF."
DISCONNECT A/C
COMPRESSOR CLUTCH
CONNECTOR.
CONNECT A TEST LIGHT
BETWEEN TERMINALS
"A" AND"B".
IGNITION "ON," A/C
"ON."
IS TEST LIGHT "ON"?
OPEN CKT 139

OR 59
OR
FAULTY RELAY
CONNECTION.
PROBE A/C COMPRESSOR

CLUTCH TERMINAL "A"
WITH TEST LIGHT TO
GROUND.
IS TEST LIGHT "ON"?
FAULTY A/C
COMPRESSOR
CLUTCH
CONNECTION
OR
OPEN A/C
COMPRESSOR
CLUTCH COIL.
OPEN A/C
COMPRESSOR
CLUTCH GROUND
CIRCUIT.
FAULTY ECM
CONNECTION
OR
OPEN OR
GROUNDEDS
VOLT
REFERENCE
CIRCUIT
OR
FAULTY ECM.
OPEN OR SHORTED A/C

COMPRESSOR CLUTCH
CIRCUIT FROM CLUTCH
TO SPLICE.
IGNITION "Off."
DISCONNECT A/C REFRIGERANT
PRESSURE SENSOR ELECTRICAL
CONNECTOR.
JUMPER HARNESS CONNECTOR
TERMINALS "B" AND "C.
IGNITION "ON."
DOES TECH 1 INDICATE REFRIGERANT
PRESSURE SENSOR VOLTAGE
GREATER THAN 4.8 VOL TS?
USING DVM MEASURE

VOLTAGE FROM
PRESSURE SENSOR
CONNECTOR TERMINAL
"B" TO GROUND.
DOES DVM DISPLAY
ABOUT 5 VOL TS?
FAULTY ECM
CONNECTION
OR
OPEN OR
GROUNDED
A/C
REFRIGERANT
PRESSURE
SENSOR
SIGNAL WIRE
OR
FAULTY ECM.
DTC67 IS
INTERMITTENT.
REFER TO
"DIAGNOSTIC AIDS"
ON FACING PAGE.
WITH TEST LIGHT TO 12

VOL TS, PROBE A/C
SENSOR CONNECTOR
TERMINAL" A".
IS TEST LIGHT "ON"?
OPEN A/C
REFRIGERANT
PRESSURE
SENSOR
GROUND
CIRCUIT.
FAULTY
SENSOR
CONNECTION
OR
FAULTY
SENSOR.
11-11-92
NS 15625

TOIATAND
MAP SENSOR
A/C
REFRIGERANT
PRESSURE
SENSOR
808BLK-----------*------I
SENSOR GROUNDS
----------1-------t
A/C REFRIGERANT
PRESSURE SENSOR
SIGNAL
380 RED/BLK
416GRY - - - - - ~
A/C
EVAPORATOR
TEMPERATURE
SENSOR
ECM
808BLK--------+----~
732DKBLU------+-----------t
1/P FUSE #3
416GRv---------~---------t
A/C
'------'~ TO TP AND
SELECT SWITCH
MAP SENSOR
TO ~ 2 4 1 BRN - - - - - - ~ e - - - - - - - 7 6 2 LTGRN/BLK
A/C EVAPORATOR
TEMPERATURE SIGNAL
5V REFERENCE
A/C REQUEST
FUSE #12 *
IGNITION
25 AMP
SWITC~~--.------------ ~ 139 PNK - - - ,
20AMP
A/C
COMPRESSOR
CLUTCH
CONTROL
RELAY*

CONNECTOR (BLACK)
r--,
1------------...t
I
~ 6 0 3 DK GRN
A/C
COMPRESSOR
CLUTCH
B
450 BLK
459 DK GRN/WHT
A/C COMPRESSOR
CLUTCH RELAY
A/C STATUS
"""--._ A/C COMPRESSOR LOW

11-12-92
NS 15598
DTC68
A/C COMPRESSOR RELAY
(SHORTED CIRCUIT)

When the ECM detects that A/Chas been requested, the ECM will activate the A/C clutch relay. When the
relay is activated, voltage should be present at both the NC compressor clutch and the A/C status terminal at the
ECM.
If the ECM detects voltage on the NC status terminal when the NC relay has not been commanded "ON" by
the ECM, a DTC 68 will set.
A short to voltage at any point in CKT 59 or CKT 603, a grounded relay control circuit or stuck NC relay
contacts can set a DTC 68.
A DTC 68 fault will be stored in ECM memory but will not turn "ON" the Malfunction Indicator Lamp (MIL)

Voltage is detected on the A/C status line for
more than 10 seconds after the ECM has
disengaged the NC relay.
2. This will isolate the ignition feed portion of the
circuit from the clutch circuit.
3. If DTC 68 reappears at this step the ECM is
internally shorted to voltage.
Diagnostic Aids:
Check for intermittent shorts to NC clutch circuit
or sticking NC relay.
DTC68
(SHORTED CIRCUIT)
G)
IGNITION "OFF."
A/C "OFF."
DISCONNECT A/C COMPRESSOR CLUTCH.
IGNITION "ON."
PROBE CKT 603 WITH TEST LIGHT TO GROUND.
IS TEST LIGHT "ON"?
DISCONNECT A/C COMPRESSOR CLUTCH

CONTROL RELAY.
IS TEST LIGHT "ON"?
SHORTED TO VOLTAGE.
FAULTY A/C COMPRESSOR

CLUTCH CONTROL RELAY
OR
CKT 459 SHORTED TO
GROUND.
IGNITION "OFF."
DISCONNECT A/C COMPRESSOR CLUTCH CONTROL RELAY.
IGNITION "ON."
CLEAR DTC(s).
START ENGINE AND RUN FOR 30 SECONDS.
DOES OTC 68 REAPPEAR?
OTC 6815 INTERMITTENT.

11-11-92
NS 15626

TOIATAND
MAP SENSOR
SENSOR GROUNDS
808 BLK
A/C
REFRIGERANT
PRESSURE
SENSOR
A/C REFRIGERANT
PRESSURE SENSOR
SIGNAL
380 REO/BLK
416 GRY
A/C
EVAPORATOR
TEMPERATURE
SENSOR
808 BLK
732 DK BLU
416 GRY
A/C
SELECT SWITCH
1/P FUSE #3
TO
ECM
~ 241
...._----;.,... TO TP AND
MAP SENSOR
BRN - - - - - - ~ - - - - - - - 7 6 2 LTGRN/BLK
A/C EVAPORATOR
TEMPERATURE SIGNAL
5V REFERENCE
A/C REQUEST
IGNITION
25 AMP
FUSE #12 *
SWITC~~
--------------- ~ 139 PNK - - - ,
20AMP
,------tB11--e------'
A/C
COMPRESSOR
CLUTCH
CONTROL
RELAY*

CONNECTOR (BLACK)
r- - - .,
I
I
1------------.-1
459 DK GRN/WHT
A/C COMPRESSOR
CLUTCH RELAY
A/CSTATUS
L--~
A/C
~ 6 0 3 DK GRN
COMPRESSOR
CLUTCH
B
450 BLK
a
11-12-92
NS 15598
DTC69
(OPEN CIRCUIT)

When the ECM detects that NC has been requested, the ECM will activate the A/C clutch relay. When the
relay has been activated, voltage should be present at both the NC compressor clutch and the A/C clutch status
line terminal of the ECM.
If the ECM activates the A/C clutch relay but does not detect voltage present at the NC status terminal for
more than 10 seconds, a DTC 69 will set.
An open or short to ground at any point in CKT 59 will cause DTC 69 to set.
A DTC 69 fault will be stored in the ECM memory but will not turn "ON" the Malfunction Indicator Lamp
(MIL) "Service Engine Soon."

ECM has commanded NC "ON."
No voltage detected on NC status line after 20

seconds.
2. If the NC compressor clutch operates properly and
the Tech 1 shows A/C status "OFF," then an open
exists between the ECM and the splice to the
compressor.
DTC69
(OPEN CIRCUIT)
3.4L {VIN S}
11
F" CARLINE {SFI}
CLEAR DTC(s).
START ENGINE .
CYCLE A/C SELECT CONTROLS TO "ON" AND "OFF" WITHIN 20 SECONDS .
DOES A/C COMPRESSOR CLUTCH OPERA TE PROPERLY?
IGNITION "OFF."
DISCONNECT A/C COMPRESSOR CLUTCH CONTROL
RELAY.
IGNITION "ON."
PROBE UNDERHOOO ELECTRICAL CENTER* TERMINALS
"81 AND "82" WITH A TEST LIGHT TO GROUND.
LIGHT "ON" BOTH
$J
DOES TECH 1 INDICATE A/C STATUS "ON"?

OR
OPEN CKT 59 FROM SPLICE TO ECM
OR
FAULTY ECM.
I
LIGHT "OFF" ONE OR BOTH
DTC691S
INTERMITTENT
GROUND DIAGNOSTIC "TEST" TERMINAL.

PROBE UNDERHOOD ELECTRICAL CENTER* TERMINAL "85"
WITH TEST LIGHT TO 8 +.
OPEN IN CKT 139 THAT DID NOT LIGHT.
LIGHT "ON"
LIGHT "OFF"
I
JUMPER UNDERHOOD ELECTRICAL CENTER*
TERMINALS "81" TO "84."
DOES A/C COMPRESSOR CLUTCH ENGAGE?
~
FAUL TY A/C COMPRESSOR CLUTCH CONTROL RELAY
CONNECTION
OR
FAUL TY A/C COMPRESSOR CLUTCH CONTROL RELAY.
OPEN A/C COMPRESSOR CLUTCH CONTROL RELAY CIRCUIT

OR
FAULTY ECMCONNECTION
OR
FAULTY ECM.
$
OPEN IN CKT 59 FROM RELAY TO SPLICE.
* REFER TO FIGURE "A2" "UNDERHOOD ELECTRICAL CENTER" FOR RELAY AND TERMINAL LOCATIONS.
11-11-92
NS 15627
6E3-A-94 3.4l (L32) (VIN S} (SFI} DRIVEABILITY AND EMISSIONS

TOIATAND
MAP SENSOR
A/C
REFRIGERANT
PRESSURE
SENSOR
SOSBLK-------------------1
SENSOR GROUNDS
----------------1
A/C REFRIGERANT
PRESSURE SENSOR
SIGNAL
380 RED/BLK
416GRY-------,
A/C
EVAPORATOR
TEMPERATURE
SENSOR
808BLK-------+----~
732DKBLU------+-------------t
A/C
SELECT SWITCH
1/P FUSE #3
TO
ECM
~ - ~ T o TP AND
MAP SENSOR
~ 241 BRN - - - - - - ~ - - - - - - - 7 6 2 LTGRN/BLK
A/C EVAPORATOR
TEMPERATURE SIGNAL
5V REFERENCE
A/C REQUEST
FUSE #12 *
IGNITION
25 AMP
SWITCH~~
......--------- ~139PNK--~
20AMP
~----181 ---------~
A/C
COMPRESSOR
CLUTCH
CONTROL
RELAY*

CONNECTOR (BLACK)
r--,
459 DK GRN/WHT
A/C COMPRESSOR
CLUTCH RELAY
A/CSTATUS
A/C
~ 6 0 3 DK GRN
COMPRESSOR
450 BLK
CLUTCH
B

11-12-92
NS 15598
DTC70
(HIGH PRESSURE}

The A/C refrigerant pressure sensor responds to changes in A/C refrigerant system high side pressure. This
input indicates how much load the A/C compressor is putting on the engine and is one of the factors used by the
ECM to determine IAC valve position for idle speed control. The circuit consists of a 5 volts reference and a
ground, both provided by the ECM, and a signal line to the ECM. The signal is a voltage which is proportional to
the pressure. The sensor's range of operation is Oto 450 psi. At Opsi, the signal will he about .1 volt, varying up
to about 4.9 volts at 450 psi or above. OTC 70 sets if the voltage is greater than 4.9 volts for 5 seconds or mDre.
The A/C compressor clutch is disabled by the ECM if OTC 70 is present or if pressure is above calibrated values
described in "A/C Compressor Clutch Control," Section "6E3-Cl0".

1. This step checks the voltage signal being received
by the ECM from the A/C refrigerant pressure
sensor.
2. Checks to see of the high voltage signal is from a
shorted sensor or a short to voltage in the circuit.
Normally, disconnecting the sensor would make a
normal circuit go to near zero volt.
Diagnostic Aids:
OTC 70 sets when signal voltage falls outside the
normal possible range of the sensor and is not due to a
intermittent, check for opens or shorts in harness or
poor connections.
DTC70
(HIGH PRESSURE)

IGNITION "ON" ENGINE NOT RUNNING.
IS A/C REFRIGERANT PRESSURE SENSOR VOLTAGE GREATER THAN 1.8 V?
DISCONNECT A/C REFRIGERANT PRESSURE

SENSOR HARNESS CONNECTOR.
DOES TECH 1 DISPLAY LESS THAN 1 VOLT?

SIGNAL CIRCUIT SHORTED TO VOLTAGE
OR
FAULTY ECM.
OTC 70 IS INTERMITTENT. REFER TO

"DIAGNOSTIC Alos ON FACING PAGE.
FAULTY A/C REFRIGERANT PRESSURE SENSOR CONNECTION

OR
OPEN CKT808
OR
FAUL TY SENSOR.
11-12-92
NS 15628

TOIATAND
MAP SENSOR
A/C
REFRIGERANT
PRESSURE
SENSOR
808 BLK
SENSOR GROUNDS
380 RED/BLK
A/C REFRIGERANT
PRESSURE SENSOR
SIGNAL
416GRY
A/C
EVAPORATOR
TEMPERATURE
SENSOR
ECM
808 BLK
A/C EVAPORATOR
TEMPERATURE SIGNAL
732 DK BLU
416 GRY
A/C
SELECT SWITCH
1/P FUSE #3
~ - - T O TP AND
MAP SENSOR
TO ~ 2 4 1 BRN - - - - - - ~ - - - - - - - - 7 6 2 LT GRN/BLK
5V REFERENCE
A/C REQUEST
25 AMP
FUSE #12 *
IGNITION
SWITC~~--------------- ~ 139 PNK - - ~
20AMP
~-------81 - - - - - - - - ~
A/C
COMPRESSOR
CLUTCH
CONTROL
RELAY*

CONNECTOR (BLACK)
r--,
A/C
~603DKGRN
COMPRESSOR
CLUTCH
B
450 BLK
459 DK GRN/WHT
A/C COMPRESSOR
CLUTCH RELAY
A/CSTATUS
a
~A/C COMPRESSOR LOW
11-12-92
NS 15598
DTC71
A/C EVAPORATOR TEMPERATURE SENSOR CIRCUIT

Integral to the A/C system is the A/C evaporator temperature sensor. This sensor is mounted to the
evaporator which is located within the I/P. The ECM receives a voltage signal inversely proportional to the
temperature at the evaporator coils. As the evaporator temperature increases or decreases, the resistance of the
sensor changes and varies the voltage signal to the ECM. This voltage is converted to a temperature valve by the
ECM and can then be displayed in degrees by the Tech 1. A DTC 71 fault will be stored in the ECM when
evaporator temperature is less than -7C but will not illuminate the Malfunction Indicator Lamp (MIL) "Service
Engine Light Soon."

AJC evaporator temperature sensor indicates
less than -7C (19F).
Time since start is 5 seconds.
Diagnostic Aids:
DTC 71 set when signal voltage falls outside the
normal range of the sensor and is not due to a
intermittent, check for opens or shorts in the harness,
or poor connections. A sensor which has backed out of
the evaporator coil bracket will also set a false DTC.
DTC71
DOES TECH 1 DISPLAY Ai( EVAPORATOR

TEMPERATURE -7( (19F) OR LESS?
DISCONNECT A/C EVAPORATOR TEMPERATURE

SENSOR CONNECTOR.
JUMPER TERMINALS "B" TO"(".
DOES TEMPERATURE ON TECH 1 INDICATE 32(.
ADDITIONAL DTCs WERE STORED,
FACING PAGE.
TEST LIGHT CONNECTED

TO B + PROBE HARNESS
CONNECTOR CAVITY C.
LIGHT "ON"
CKT732 OPEN
OR
SHORTED TO VOLTAGE
OR
FAULTY ECM CONNECTOR
OR
FAULTY ECM
11-20-92
NS 16234
6E3-A-98 3.4L {L32) (VIN S) (SFI) DRIVEABILITY AND EMISSIONS

TOIATAND
MAP SENSOR
A/C
REFRIGERANT
PRESSURE
SENSOR
BOBBLK-------------------1
SENSOR GROUNDS
----------1-------1
A/C REFRIGERANT
PRESSURE SENSOR
SIGNAL
380 RED/BLK
416GRY-----~
A/C
EVAPORATOR
TEMPERATURE
SENSOR
ECM
8088LK-------+------'
1/P FUSE #3
732DKBLU------+-----------1
A/C EVAPORATOR
TEMPERATURE SIGNAL
416GRv---------------------1
A/C
,.___---;~ TO TP AND
SELECT SWITCH
MAP SENSOR
5V REFERENCE
A/C REQUEST
TO ~ 2 4 1 BRN - - - - - - ~ - - - - - - - 7 6 2 LTGRN/BLK
FUSE #12 *
IGNITION
25 AMP
SWITC~..._____
~----------------- ~ 139 PNK - - - ,
20AMP
A/C
COMPRESSOR
CLUTCH
CONTROL
RELAY*

CONNECTOR (BLACK)
.---,
1-------------rl
I
459 DK GRN/WHT
A/C COMPRESSOR
CLUTCH RELAY
A/C STATUS
L--.J
~ 6 0 3 DK GRN
A/C
COMPRESSOR
450 BLK
CLUTCH
B
............. A/C COMPRESSOR LOW

11-12-92
NS 155~8
DTC73

Integral to the NC system is the NC evaporator temperature sensor. This sensor is mounted to the
evaporator which is located within the I/P. The ECM receives a voltage signal inversely proportional to the
temperature at the evaporator coils. As the evaporator temperature increases or decreases, the resistance of the
sensor changes and varies the voltage signal to the ECM. This voltage is converted to a temperature value by the
ECM and can then be displayed in degrees by the Tech 1. A OTC 73 fault will be stored in the ECM when
temperature sensor circuit is greater than 31C but will not illuminate the Malfunction Indcator Lamp (MIL)
NC evaporator temperature sensor indicates,
refrigerant temperature above 31 C.
Time since engine start is 5 seconds.
Diagnostic Aids:
DTC 73 set when signal voltage falls outside the
or poor connections.
DTC73
DOES TECH 1 DISPLAY A/C EVAPORATOR

TEMPERATURE OF 32C (90F) OR GREATER?
DISCONNECT A/C EVAPORATOR

TEMPERATURE SENSOR. TECH 1 SHOULD
DISPLAY TEMPERATURE BELOW 7( (19F).
DOES IT?
REPLACE SENSOR.

OR
TO SENSOR GROUND
OR
ECM IS FAULTY.
11-23-92
NS 16237
6E3-A-100 3.4L (L32) {VIN S) (SFI) DRIVEABILITY AND EMISSIONS
TO COOLING
FAN CONTROL
TO EVAP CANISTER
PURGE
SOLENOID]
VALVE -
RELAY
r:,
UNDERHOOD
ELECTRICAL CENTER
FUSE #6
10AMP
ECM
L!..Jo----~tAJ-~--- IGNITION
- - - - - - - 541 BRN
10 WAY INLINE FWD. LAMP HARN. CONN. (BLK)
- ~ - - 698 BRN
- - - - - - - - - - - - - - 6 9 9 RED
~---.....---+--
697 LT BLU - - - - - - - - - - - - 697 LT BLU
TOP VIEW OF EGR VALVE AND

EGR VALVE CONNECTOR
10-20-92
NS 15638
DTC75
DIGITAL EGR #1 SOLENOID ERROR
EXHAUST GAS RECIRCULATION (EGR) CIRCUIT

The ECM performs an EGR diagnostic check to monitor flow through each individual valve of the three
solenoid EGR valves.
When the vehicle is under deceleration the EGR valves are normally closed. The ECM then opens each valve
in succession (while keeping previous valves open) and manifold pressure is monitored for a calculated MAP
increase associated with each valve's application. Should the response in manifold pressure not be seen by the
ECM, a DTC 75 will set.

1. This test determines if there is power to the EGR
valve.
2. This test will determine if there is an open circuit
in the EGR wiring or if the EGR valve is at fault.
3. This test will determine if there is a short to
ground in CKT 697 going to the EGR valve or if
the ECM is at fault.
Diagnostic Aids:
An intermittent may be caused by a poor
connection, chafed wire insulation, or a wire broken
inside the insulation.
Intake plenum should be checked for possible
plugged passages.
DTC75

INSTALL TECH 1.
IS DTC 75 STORED?
DISCONNECT EGR VALVE ELECTRICAL CONNECTOR.

KEY "ON" ENGINE"OFF."
WITH TEST LIGHT CONNECTED TO GROUND,
PROBE TERMINAL "D" OF EGR HARNESS CONNECTOR.
DTC 75 INTERMITTENT.
SEE "DIAGNOSTIC AIDS" ON FACING PAGE.
WITH TEST LIGHT CONNECTED TO B +,

PROBE TERMINAL "A" OF EGR
HARNESS CONNECTOR.
REPAIR OPEN IN
CKT 541.
GROUND DLC TEST TERMINAL.

WITH TEST LIGHT STILL CONNECTED TO B +,
PROBE TERMINAL" A", OF EGR CONNECTOR.
DISCONNECT (BLACK) ECM CONNECTOR "B".

WITH TEST LIGHT STILL CONNECTED TO B +,
PROBE TERMINAL" A" OF EGR HARNESS CONNECTOR.
REPAIR SHORT TO
GROUND IN CKT 697.
LIGHT "ON"
FAUL TY EGR CONNECTION

OR
DIGITAL EGR VALVE.
OPEN IN CIRCUIT 697

OR
ECM CONNECTOR
OR
FAULTY ECM.
* THESE STEPS MUST BE DONE VERY QUICKLY AS THE ECM WILL COMPENSATE FUEL DELIVERY.
11-11-92
NS 15641
TO COOLING
FAN CONTROL
TO EVAP CANISTER
PURGE
RELAY
SOLENOID]
VALVE -
r:,
698 BRN
FUSE #6
10 AMP
ECM
L!..Jt---e--~----'Jo~ IGNITION
t - - - + - - - 541 BRN
t----,---
UNDERHOOD
ELECTRICAL CENTER
10 WAY INLINE FWD LAMP HARN. CONN. (BLK)
----+-+- 699 RED

.......- - - - - , ~ - 697LT BLU - - - - - - - - - - - - 6 9 7 L T B L U

EGR VALVE CONNECTOR
10-2092
NS 15638
DTC76

The ECM performs an EGR diagnostic check to monitor flow through each individual valve in the three
When the vehicle is under deceleration the EGR valves are normally closed. The ECM then opens each valve
in succession (while keeping previous valves open) and manifold pressure is monitored for a calculated increase
associated with each valve's application. Should the calibrated response in manifold pressure not be seen by the

valve.
2. This test will determine of there is an open circuit
Diagnostic Aids:
plugged passages.
DTC76

INSTALL TECH 1.
IS DTC 76 STORED?

KEY "ON" ENGINE"OFF."
SEE "DIAGNOSTIC AIDS" ON FACING PAGE.
WITH TEST LIGHT CONNECTED TO 8 +,

PROBE TERMINAL "8" OF EGR
HARNESS CONNECTOR.
REPAIR OPEN IN
CKT 541.

WITH TEST LIGHT STILL CONNECTED TO 8 +,
PROBE TERMINAL "8", OF EGR CONNECTOR.
DISCONNECT ECM CONNECTOR "8" (BLACK).

WITH TEST LIGHT STILL CONNECTED T.O 8 +,
PROBE TERMINAL "8" OF EGR HARNESS CONNECTOR.
REPAIR SHORT TO
GROUND IN CKT 698.
LIGHT "ON"
FAULTY EGR CONNECTION

OR
DIGITAL EGR VALVE.
OPEN IN CIRCUIT 698

OR
ECM CONNECTOR
OR
FAULTY ECM.
* THESE STEPS MUST BE DONE VERY QUICKLY AS THE ECM WILL COMPENSATE FUEL DELIVERY.
11-11-92
NS 15642
TO COOLING
FAN CONTROL
RELAY
TO EVAP CANISTER
PURGE
SOLENOID]
VALVE 1t---\-----
r:,
L!...J
541 BRN
UNDERHOOD
?ELECTRICAL CENTER
FUSE #6
10AMP
ECM
e"\J,-----:,.. IGNITION
- - - - - - - - - - - - - - 6 9 9 RED
~---....,,....+--
697LT BLU - - - - - - - - - - - - 6 9 7 L T B L U

EGR VALVE CONNECTOR
10-20-92
NS 15638
OTC 77
EXHAUST GAS RECIRCULATIOI\L(EGR) CIRCUIT ~

The ECM performs an EGR diagnostic check to monitor flow through each individual valve in the three
When the vehicle is under deceleration the EGR valves are normally closed. The EC'.\1 then opens each valve
in succession (while keeping previous valves open) and manifold pressure is monitored for a calculated increase
associated with each valve's application. Should the calibrated response in manifold pressure not be seen by the

valve.
2. This test will determine if there is an open circuit
Diagnostic Aids:
plugged passages.
DTC77
{ELECTRICAL DIAGNOSIS)
3.4L {VIN S) "F" CARLINE (SFI)
0
V

INSTALL TECH 1.
IS OTC 77 STORED?

KEY "ON" ENGINE "OFF."
OTC 77 INTERMITTENT.
SEE "'DIAGNOSTIC AIDS" ON FACING PAGE.
WITH TEST LIGHT CONNECTED TO 8 +,

PROBE TERMINAL "C" OF EGR
HARNESS CONNECTOR.
REPAIR OPEN IN
CKT541.

PROBE TERMINAL "C" OF EGR CONNECTOR.
DISCONNECT ECM CONNECTOR "8" (BLACK).

PROBE TERMINAL "C" OF EGR HARNESS CONNECTOR.
REPAIR SHORT TO
GROUND IN CKT 699.
LIGHT "ON"
FAUL TY EGR CONNECTION

OR
DIGITAL EGR VALVE.
OPEN IN CKT 699

OR
ECM CONNECTOR
OR
FAULTY ECM.
11-12-92
NS 15643
6E3-A-106 3.4l {L32) {VIN S) {SFI) DRIVEABILITY AND EMISSIONS
ECM
10-WAY INLINE 1/P
CONNECTOR #2 (BLUE)
~1
I/PFUSE#9
r
/
SWITCH ________
TOIGN
.r11o----39PNK/BLK - 4 1 9 B R N / W H T
L -
TO BRAKE
TRANSMISSION SHIFT
INTERRUPT (BTSI)
SOLENOID
39 PNK/BLK
--~~~~---1,-...-.--.
BRAKE
--ili_J SWITCH
- - - - - - - - - - - - 583 LT BLU/BLK
1------------446LTBLU
---~~~~~~-----
t - - - - - - - - - - - - - - 4 2 2 TAN/BLK
DATA LINK
CONNECTOR
(DLC)
MIL CONTROL
583 LT BLU/BLK
4th GEAR
SWITCH
AUTOMATIC
TRANS TCC
SOLENOID
MIL
(SERVICE ENGINE SOON)
4th GEAR SWITCH
TCC ENABLE
F t------'
9-18-92
NS 15629
DTC81
BRAKE SWITCH ERROR
The ECM monitors the status of the brake switch circuit through ECM terminal "Al8".
OTC 81 will set if:
Vehicle speed has been greater than or equal to 35 mph for 10 seconds and back to O mph for four times or
more.
Status of CKT 583 has not changed from "Released" to "Applied" or" Applied" to "Released" as displayed
on the Tech 1.
Diagnostic Aids:
A DTC 81 can be caused by a rnisadjusted brake
switch or a poor connection.
NOTICE: If the brake switch has failed in an open

state, TCC will not engage.
DTC81
BRAKE SWITCH ERROR

OBSERVE TCC BRAKE SWITCH STATUS ON TECH 1.
MPLIED
RELEASED
DISCONNECT BRAKE SWITCH.

JUMPER TERMINALS" A" AND "B"
TOGETHER.
OBSERVE TCC BRAKE SWITCH STATUS.
I
I
A?PLIED
RELEASED
RELEASED

TO GROUND.
PROBE TERMINAL" A"
OF BRAKE SWITCH
HARNESS .
LuGHT "ON"
1
LIGHT "OFF"
t(T 583 OPEN, ECM

CONNECTION
OR
FAULTY ECM.
CHECK BRAKE SWITCH

ADJUSTMENT. IF OK,
REPLACE SWITCH.
DEPRESS BRAKE PEDAL.

OBSERVE TCC BRAKE SWITCH STATUS.
CHECK 10 AMP FUSE AND

REPAIR SHORT TO GROUND IN
CKT 39 IF BLOWN, REFER TO
"FUSE BLOCK DETAILS" IN
ELECTRICAL DIAGNOSIS
(SECTION SA). IF FUSE IS "OK"
REPAIR OPEN CKT 39 TO BRAKE
SWITCH.
APPLIED
DISCONNECT BRAKE SWITCH

CONNECTOR.
OBSERVE TCC BRAKE SWITCH
STATUS.
APPLIED
FAUL TY BRAKE
SWITCH HARNESS
CONNECTION OR
FAUL TY BRAKE
SWITCH.
NO TROUBLE FOUND,
RELEASED
CKT 583 SHORTED

TO VOLTAGE
OR
FAULTY ECM.
11-13-92
NS16238
ECM
10-WA Y FWD LAMP

HARNESS CONNECTOR
(BLACK)
FUSE #11 *
1O AMP
IGNITION ......- - - ~ - - - 239 PNK
G - - - - - - - T O HIGH RESOLUTION 24X

CRANKSHAFT POSITION
SENSOR AND CAMSHAFT
POSITION SENSOR.
B+
450BLK
GND
--=:i_
LOW RESOLUTION
3X CRANKSHAFT
POSITION SENSOR
: ~ =tH. :_.I__
SIGNAL
>----------
424 TAN/BLK - - - - .___ _ _ _ _ _ _ _ _ 423 WHT - - - - - - 1

ELECTRONIC
IGNITION
CONTROL
MODULE
(ICM)
IGNITION CONTROL
BYPASS
IGNITION CONTROL
t------,-----
647 LT BLU/BLK - - - - - - 1
~ - - - - - o f - - - - - - - - 453 RED/BLK
3X REF HIGH
3X REF LOW
PRIMARY
WINDING
11-12-92
NS 15618
DTC82
IGNITION CONTROL 3X SIGNAL ERROR
If the Tech 1 scan tool did not indicate a cranking RPM and there is no spark present at the plugs, the problem
lies in the electronic ignition system or the power and ground supplies to the module.
The magnetic crank sensor is used to determine engine crankshaft position much the same way as the pickup coil did in distributor type systems. The sensor is mounted in the block near a seven slot wheel on the crank
shaft. The rotation of the wheel creates a magnetic field in the sensor which induces a voltage signal. The
electronic ignition module then processes this signal and creates the reference pulses needed by the ECM and the
signal triggers the correct coil at the correct time.

1. This test will determine if the 12 volts supply and
a good ground is available at the electronic
ignition module.
2. Checks for resistance of the crank sensor and
connections.
3. Voltage will vary in this test depending on
cranking speed of engine.
DTC82
IGNITION CONTROL 3X SIGNAL ERROR
r------------------1
: NO IGN CONTROL 3XSIG RPM :
I AND NO SPARK.
1
L-
G)
----------------~
DISCONNECT IGNITION CONTROL MODULE 2 PIN

CONNECTOR.
IGNITION "ON."
CONNECT TEST LIGHT BETWEEN HARNESS TERMINALS.
CONNECT TEST LIGHT FROM

HARNESS TERMINAL "B" TO
GROUND.
DISCONNECT 3X CRANKSHAFT POSITION SENSOR 3-WAY CONNECTOR

FROM IGNITION CONTROL MODULE.
WITH OHMMETER IN 2K OHMS POSITION, PROBE HARNESS TERMINALS
"A" & "(" {SHOULD READ BETWEEN 900-1200 OHMS).
LIGHT "ON"
REPAIR OPEN
GROUND (KT 450.
REPAIR OPEN
IGNITION FEED
CKT 239.
SET VOLTMETER ON 2 VOLT

AC POSITION.
CRANK ENGINE AND
OBSERVE VOLTAGE
READING. READING SHOULD
BE GREATER THAN .1 VOLT
(100 mV).
IS IH
REPLACE IGNITION
CONTROL MODULE.
GREATER THAN
12000HMS
CRANKSHAFT
POSITION
SENSOR LEADS
SHORTED
TOGETHER OR
FAULTY 3X
CRANKSHAFT
POSITION
SENSOR.
OPEN
CRANKSHAFT
POSITION
SENSOR CIRCUIT,
FAULTY
CONNECTION OR
FAULTY 3X
CRANKSHAFT
POSITION
SENSOR.
FAUL TY CONNECTION
OR
FAUL TY 3X CRANKSHAFT
POSITION SENSOR.
11-11-92
NS 15630
BLANK
DTC 51, 85, 87

51 PROM ERROR
85 PROM ERROR
87 ELECTRICALLY ERASABLE PROGRAMMABLE READ
ONLY MEMORY(EEPROM) ERROR
FOR DTCs 51, 85, 87 CHECK THAT ALL ECM CONNECTORS ARE FULLY INSERTED IN THE SOCKET. IF OK, REPROGRAM THE
ECM. REFER TO SECTION 6E3-C1 (ECM AND SENSORS). IF ECM WILL NOT REPROGRAM, REPLACE ECM.
NOTICE: TO PREVENT POSSIBLE ELECTROSTATIC DISCHARGE DAMAGE TO THE ECM, DO NOT TOUCH THE
COMPONENT LEADS.
9-1-92
NS 15100
SFI-U ECM
TO A/C REFRIGERANT
PRESSURE SENSOR
HARNESS CONNECTOR "C''
380 RED/BLK
TO FUEL PUMP PRIME

CONNECTOR, FUEL
PUMP RELAY AND INTANK FUEL PUMP - - - 120GRY
A/C REFRIGE RANT

PRESSURE SE NSOR
SIGNAL
10
FUELPUM p
FEEDBAC K
SIGNAL
11
AID
MUX
TO KNOCK
SENSOR -
KNOCK
SENSOR
SIGNAL
496 DK BLU
TO ENGINE COOLANT
TEMPERATURE
SENSOR HARNESS
CONNECTOR "B" . - - - - 410 YEL
ENGINE COOLAN T
TEMPERATURE
SENSOR SIGNAL
15
16
INTERNAL VIEW OF SFI-U ECM
9-17-92
NS 15631
DTC86
A/D ERROR
The AID multiplexer chip is an internal part of the ECM. Some ECM sensor inputs lead to the AID
multiplexer. If any one of those circuits should short to B + for a time of greater than or equal to 15 seconds, the
AID error diagnostic will set.
Diagnostic Aids:
If DTC 86 is not present, all circuits leading to the
ECM that are connected to the AID multiplexer should
be checked for an intermittent short to 8 +. Move the
harnesses of each component and watch the scan data
on the Tech 1. The circuit that is shorted to B + will
show erratic changes in data on the Tech 1.
DTC86
A/D ERROR
FOR OTC 86, CHECK FOR ANY DTCs THAT ARE STORED AND REFER TO THOSE CHARTS. IF NO OTHER DTCs ARE STORED,
CHECK ALL ECM CONNECTORS AND TERMINALS FOR PROPER LOCATION. OTC 86 Will SET ONLY WHEN THE CIRCUITS
LEADING TO THE A/0 MULTIPLEXER, INTERNAL TO THE ECM GETS SHORTED TO B +. IF OTC 86 IS INTERMITTENT, REFER TO
9-1-92
NS 15377
BLANK
DRIVEABILITY AND EMISSIONS 3.4L (L32) (VIN S) (SFI) 6E3-B-1
SECTION B
SYMPTOMS
CONTENTS
Important Preliminary Checks

Before Using This Section
Symptom
Visual/Physical Check
lntermittents ( 1 of 2)
Hard Start
Surges and/or Chuggles
Lack of Power, Sluggish, or Spongy
Detonation/Spark Knock
Hesitation, Sag, Stumble
Cuts Out, Misses (1 of 2)
Rough, Unstable, or Incorrect Idle, Stalling (1 of 2)
Poor Fuel Economy
Excessive Exhaust Emissions or Odors
Dieseling, Run-On
Backfire
ECM Connector "A" Symptom Chart (1 of 2)
ECM Connector "B" Symptom Chart (1 of 2)
ECM Connector "C" Symptom Chart (1 of 2)
Restricted Exhaust System Check (Chart 8-1)
.. . . . . . . ..
Page B-2
Page B-2
Page B-2
Page B-2
Page B-3
Page B-5
Page B-6
Page B-7
Page B-8
Page B-9
Page B-10
Page B-12
Page B-14
Page B-15
Page B-16
Page B-17
Page B-18
Page B-20
Page B-22
Page B-24
6E3-B-2 3.4L (L32) (VIN S) (SFI) DRIVEABILITY AND EMISSIONS
IMPORTANT PRELIMINARY CHECKS
BEFORE USING THIS SECTION

Before using this section you should have performed the "On-Board Diagnostic (OBD) System
Check" and determined that:
1. The ECM and MIL (Service Engine Soon) are operating correctly.
2. There are no diagnostic trouble codes stored, or there is a diagnostic trouble code but no MIL
(Service Engine Soon).
SYMPTOM
Verify the customer complaint and locate the correct symptom in the table of contents. Check
the items indicated under that symptom.
VISUAL/PHYSICAL CHECK
Several of the symptom procedures call for a careful visual/physical check. The importance of
this step cannot be stressed too strongly - it can lead to correcting a problem without further checks
and can save valuable time. This check should include:
ECM grounds and sensors for being clean, tight and in their proper location.
Vacuum hoses for splits, kinks, and proper connections, as shown on "Vehicle Emission
Control Information" label. Check thoroughly for any type ofleak or restriction.
Air leaks at throttle body mounting area and intake manifold sealing surfaces.
Ignition wires for cracking, hardness, proper routing and carbon tracking.
Wiring for proper connections, pinches and cuts.
INTERMITTENTS
(Page 1 of 2)
Definition:
Problem may or may not turn "ON" the MIL

(Service Engine Soon) or store a DTC.
DO NOT use the diagnostic trouble code charts in "Engine Components/Wiring

Diagrams/Diagnostic Charts," Section "6E3-A" for intermittent problems. The fault must be present
to locate the problem. If a fault is intermittent, use of diagnostic trouble code charts may result in
replacement of good parts.
Ylost intermittent problems are caused by faulty electrical connections or wiring. Perform
careful visual/physical check as described at start of "Symptoms," Section "6E3-B". Check for:
Poor mating of the connector halves or terminal not fully seated in the connector body
(backed out).
Improperly formed or damaged terminal. All connector terminals in the problem circuit
should be carefully reformed or replaced to insure proper contact tension.
Poor terminal to wire connection. This requires removing the terminal from the connector
body to check. Refer to "Introduction" in SECTION 6E, "Wiring Harness Service."
If a visual/physical check does not find the cause of the problem, the vehicle can be driven with a
voltmeter connected to a suspected circuit. A Tech l scan tool can also be used to help detect
intermittent conditions. An abnormal voltage or Tech 1 scan tool reading, when the problem
occurs, indicates the problem may be in that circuit.
Loss of diagnostic trouble code memory. To check, disconnect TP sensor and idle engine until
MIL (Service Engine Soon) comes "ON." DTC 22 should be stored and kept in memory when
ignition is turned "OFF." If not, the ECM connections or the ECM is faulty.
An intermittent MIL (Service Engine Soon) with no stored diagnostic trouble code may be caused
by:
Ignition coil shorted to ground and arcing at spark plug wires or plugs.
MIL (Service Engine Soon) wire to ECM shorted to ground (CKT 419).
Diagnostic enable terminal wire to ECM shorted to ground (CKT 451).
ECM grounds, refer to ECM wiring diagrams.
Excessive current draw from faulty systems such as damaged cooling fan motor etc.
6E3-B-4 3.4L (L32) (VIN S) (SFI} DRIVEABILITY AND EMISSIONS
INTERMITIENTS
(Page 2 of 2)
Definition:
Problem may or may not turn "ON" the MIL

(Service Engine Soon) or store a DTC.
Check for an electrical system interference caused by a defective relay, ECM driven solenoid, or
switch. They can cause a sharp electrical surge. Normally, the problem will occur when the
faulty component is operated.
Check for improper installation of electrical options such as lights, 2-way radios, etc.
Ignition control wires should be routed away from spark plug wires, Electronic Ignition (EI)
system wires, Electronic [gnition (EI) system assembly and generator. Wires from EGM to
Electronic fgnition (E[) system should have a good connection.
Check for open diode across NC compressor clutch, and for other open diodes (refer to wiring
diagrams).
If problem has not been found, refer to "ECM Connector Symptom" charts at the end of
"Symptoms," Section ''6E3-B".
HARD START
Definition:
Engine cranks OK, but does not start for a

long time. Does eventually run, or may start
but immediately dies.
PRELIMINARY CHECKS
Perform the careful visual/physical checks as described at start of"Symptoms," Section "6E3-B".
Make sure the driver is using the correct starting procedure.
ADDITIONAL CHECKS
CHECK: IAC operation - use CHART C-28.
CHECK: Basic engine problem. Refer to SECTION 6A.
CHECK: Service Bulletins for updates.
SENSORS
CHECK: Engine Coolant Temperature (ECT) sensor using a Tech 1 scan tool, compare engine
coolant temperature with ambient temperature on cold engine.

If engine coolant temperature readings are 5 degrees greater than or less than
ambient air temperature on a cold engine, check resistance in engine coolant
temperature sensor circuit or sensor itself. Compare ECT sensor resistance value to
the "Diagnostic Aid" chart on DTC 15 chart.
CHECK: MAP sensor. Check for flooding.
CHECK: TP sensor for binding or a high TP sensor voltage with the throttle closed (should read
between .29 volt and .98 volt.)
IGNITION SYSTEM
CHECK: For proper ignition voltage output with spark tester ,J 26792 (ST-125).
CHECK: Spark plugs. Remove spark plugs, check for wet plugs, cracks, wear, improper gap,
burned electrodes, or heavy deposits. Repair or replace as necessary.

CHECK: Bare or shorted wires.
CHECK: Crankshaft position sensor, resistance and connections.
FUEL SYSTEM
CHECK: Fuel pump relay operation - pump should turn "ON" for 2 seconds when ignition is
turned "ON." Use OTC 54.

CHECK: Fuel pressure, use CHART A-7.
CHECK: Contaminated fuel.
CHECK: Both injector fuses (visual inspect).
NOTICE: A faulty in-tank fuel pump check valve will allow the fuel in the lines to drain back to
the tank after engine is stopped. To check for this condition, perform fuel system diagnosis
CHART A-7.
6E3-B-6 3.4L {L32) {VIN S) {SFI) DRIVEABILITY AND EMISSIONS
SURGES AND/OR CHUGGLES

Definition:
Engine power variation under steady

throttle or cruise feels like the vehicle
speeds up and slows down with no change in
the accelerator pedal.
PRELIMINARY CHECKS
Perform the careful visual checks as described at start of"Symptoms," Section "6E3-B".
Be sure driver understands transmission torque converter clutch and AJC compressor operation as
explained in the owner's manual.
ADDITIONAL CHECKS
CHECK:
CHECK:
CHECK:
CHECK:
CHECK:
EC11 grounds for being clean, tight and in their proper location.
Vacuum lines for kinks or leaks.
Generator output voltage. Repair ifless than 9 volts or more than 16 volts.
Speedometer reading with the speed on a Tech 1 scan tool are equal.
Service Bulletins for updates.
SENSORS
CHECK: Oxygen Sensor(s) 02S. The Oxygen Sensor(s) 02S should respond quickly to different
throttle position. [f they do not, check the Oxygen Sensor(s) 02S for silicon or other
contaminations from fuel or improper use of RTV sealant. The sensor(s) may have a
white, powdery coating and result in a high but false signal voltage (rich exhaust
indication). The ECM will then reduce the amount of fuel delivered to the engine,
causing a severe driveability problem. Also, watch for green (glycol) contamination or
cracking.
IGNITION SYSTEM
CHECK: For proper ignition voltage output using spark tester (ST-125) J 26792 or equivalent.
burned electrodes, or heavy deposits. Repair or replace as necessary. Also, check spark
plug wires.
FUEL SYSTEM
NOTICE: To determine if the condition is caused by a rich or lean system, the vehicle should be
driven at the speed of the complaint. Monitoring long term and short term fuel trim will help
identify a problem.
Lean - Long term fuel trim above 150. Refer to "Diagnostic Aids" on facing page of DTC 44/64.
Rich - Long term fuel trim below 110. Refer to ''Diagnostic Aids" on facing page of DTC 45/65.
CHECK: Fuel pressure while condition exists. Use CHART A-7.
CHECK: In-line fuel filter. Replace if dirty or plugged.
LACK OF POWER, SLUGGISH OR SPONGY

Definition:
Engine delivers less than expected power.

Little or no increase in speed when accelerator
pedal is pushed down part way.
PRELIMINARY CHECKS
Perform the careful visual/physical checks as described at start of "Symptoms," Section "6E3-B".
Compare customer's vehicle to similar unit. Make sure the customer has an actual problem.
Remove air filter and check for dirt, or other contamination. Replace as necessary.
ADDITIONAL CHECKS
CHECK: EC:\l grounds for being clean, tight and in their proper locations. Refer to EC:\l wiring
CHECK: EGR operation for being open or partly open all the time. Refer to CHART C-7.
CHECK: Generator output voltage. Repair ifless than 9 volts or more than 16 volts.
CHECK: Exhaust system for possible restriction.
diagrams.
Inspect exhaust system for damaged or collapsed pipes.

Inspect muffler for heat distress or possible internal failure.
CHECK: Torque Converter Clutch (TCC) for proper operation. Refer to SECTIO~ 7 A.
ENGINE MECHANICAL
CHECK: Engine valve timing and compression.

CHECK: Engine for correct or worn camshaft. Refer to SECTION 6A.
IGNITION SYSTEM
CHECK: Knock Sensor (KS) system for excessive spark retard activity. Refer to CHART C-5. Use
CHECK: Secondary voltage using a shop oscilloscope or a spark tester J 26792 (ST-125).
Tech 1 scan tool.
FUEL SYSTEM
CHECK: Restricted fuel filter.

6E3-B-8 3.4L {L32) {VIN S) {SFI) DRIVEABILITY AND EMISSIONS
DETONATION/SPARK KNOCK
Definition:
A mild to severe ping, usually worse under

acceleration. The engine makes sharp metallic
knocks that change with throttle opening.
PRELIMINARY CHECKS
Perform the careful visual/physical checks as described at start of''Symptoms," Section "6E3-B".
Park/Neutral Position (PNP) switch. Be sure Tech 1 scan indicates drive with gear selector in
drive or overdrive. Use CHART C- lA.
NOTICE: If Tech 1 scan tool readings are normal (refer to facing page of "On-Board Diagnostic
System Check") and there are no engine mechanical faults, fill fuel tank with a premium gasoline
that has a minimum octane reading of92 and revaluate vehicle performance.
CHECK: EGR system for not opening. C"se CHART C-7.
CHECK: TCC operation, TCC applying too soon. Use CHART C-8.
ADDITIONAL CHECKS
IGNITION SYSTEM
CHECK: Spark plugs for proper heat cause. Refer to "Owner's .\1anual."
CHECK: Knock Sensor (KS) system for no retard, use CHART C-5.
ENGINE MECHANICAL
CHECK: For excessive oil in the combustion chamber.
Valve oil seals for leaking.

CHECK: Combustion chambers for excessive carbon build up.
Remove carbon with top engine

cleaner and follow instructions on can.
CHECK: Combustion chamber pressure by performing a compression test. Refer to SECTION 6A.
CHECK: For incorrect basic engine parts such as cam, heads, pistons, etc.
COOLING SYSTEM
Check for obvious overheating problems:
Low engine coolant.
Loose water pump belt.
Restricted air flow to radiator, or restricted water flow through radiator.
Inoperative electric cooling fan circuit, use CHART C-12.
Correct coolant solution should be a 50/50 mix of GM #1052753 anti-freeze coolant (or
equivalent) and water.
FUEL SYSTEM
driven at the speed of the complaint. Monitoring long term fuel trim will help identify problem.
Lean - Long term fuel trim above 150. Refer to "Diagnostic Aids" on facing page of OTC 44/64.
Rich - Long term fuel trim below 110. Refer to "Diagnostic Aids" on facing page of OTC 45/65.
HESITATION, SAG, STUMBLE

Definition:
Momentary lack of response as the accelerator is

pushed down. Can occur at all vehicle speeds.
Usually most severe when first trying to make the
vehicle move, as from a stop sign. May cause
engine to stall if severe enough.
PRELIMINARY CHECKS
SENSORS
CHECK: TP sensor - Check TP sensor for binding or sticking. Voltage should increase at a steady
rate as throttle is moved toward Wide Open Throttle (WOT).

CHECK: :\IAP sensor - use CHART C-10.
IGNITION SYSTEM
CHECK: Spark plugs for being fouled or for faulty spark plug wire routing.
CHECK: Electronic ignition system ground, CKT 453.
FUEL SYSTEM
CHECK:
CHECK:
CHECK:
CHECK:
Fuel pressure, use CHART A-7.

Contaminated fuel.
EVAP canister purge system for proper operation. Use CHART C-3.
Fuel injectors. Perform injector balance test, use CHART C-2A.
ADDITIONAL CHECKS
CHECK:
CHECK:
CHECK:
CHECK:

EGRoperation, useCHARTC-7.
Engine thermostat functioning correctly and proper heat range.
Generator output voltage. Repair if less than 9 volts or more than 16 volts.
CUTS OUT, MISSES

(Page 1 of 2)
Definition:
Steady pulsation or jerking that follows engine

speed, usually more pronounced as engine load
increases, not normally felt above 1500 RPM or 48
km/h (30 mph). The exhaust has a steady spitting
sound at idle or low speed.
PRELIMINARY CHECKS
ADDITIONAL CHECKS
CHECK: For Electromagnetic Interference (E"MI). A mistake can be caused by Electromagnetic
Interference (E:\11) on the 3X reference low circuit. E11I can usually be detected by
monitoring engine RP:\1 with a Tech 1 scan tool. A sudden increase in RP:\1 with little
change in actual engine RP"M change indicates E:\11 is present. [f the problem exists,
check routing of spark plug wires and ignition control ground circuit.
CHECK: Intake and exhaust manifold passage for casting flash.
IGNITION SYSTEM
Check for cylinder miss:
1. Start engine allowing engine to stabilize then disconnect IAC motor. Remove one spark plug
wire at a time using insulated pliers.
CAUTION: Do Not perform this test for more than 2 minutes, as this test may
cause damage to the catalytic converter.
If there is an RPM drop on all cylinders (equal to within 50 RPM), go to "Rough, Unstable, or
Incorrect Idle, Stalling" symptom. Reconnect IAC valve.
3. If there is no RPM drop on one or more cylinders or excessive variation in RPM drop, check for
spark on the suspected cylinder(s) using a shop oscilloscope or with ,J 26792 (ST-125) spark
tester or equivalent. If no spark, refer to SECTION 6D for intermittent operation or miss. If
there is a spark, remove spark plug(s) in these cylinders and check for:
Insulator Cracks.
Wear.
Improper Gap.
Burned Electrodes.
Heavy Deposits.
CHECK: Spark plug wires by connecting ohmmeter to ends of each wire in question. If meter
reads over 30,000 ohms, replace wire(s).
2.
DRIVEABILITY AND EMISSIONS 3.4L {L32) {VIN S) {SFI) 6E3-B-11
CUTS OUT, MISSES

{Page 2 of 2)
Definition: Steady pulsation or jerking that follows engine

ENGINE MECHANICAL
CHECK: Compression. Perform compression check on questionable cylinder(s) found above. If
compression is low, repair as necessary. Refer to SECTION 6A.

CHECK: Base engine. Remove rocker covers. Check for bent pushrods, worn rocker arms, broken
valve springs, worn camshaft lobes and valve timing. Repair as necessary. Refer to
SECTION6A.
FUEL SYSTEM
CHECK: Fuel system - Plugged fuel filter, low pressure. Use CHART A-7.
CHECK: Injector drivers. Disconnect all injector harness connectors. Connect J 34730-2C injector
test light between the harness terminal of each injector connector and note light while
cranking. Iftester light fails to blink at any connector, it is a faulty injector drive circuit
harness, connector or terminal.
CHECK: Perform the injector balance test. Refer to CHART C-2A.
ROUGH, UNSTABLE, OR INCORRECT IDLE,

STALLING
(Page 1 of 2)
Definition:
Engine runs unevenly at idle. If severe, the engine or

vehicle may shake. Engine idle speed may vary in RPM.
Either condition may be severe enough to stall engine.
PRELIMINARY CHECKS
CHECK: For vacuum leaks.
CHECK: ECM grounds for being clean, tight and proper routing. Refer to ECM wiring diagrams.
ADDITIONAL CHECKS
CHECK: .MAP sensor. Refer to CHART C-10.
CHECK: Throttle linkage for sticking or binding.
CHECK: P:t\P switch circuit. Refer to CHART C-lA, or use Tech 1 scan tool and be sure tool
indicates vehicle is in drive with gear selector in drive or overdrive.

CHECK: IAC operation, use CHART C-2C.
CH ECK: EGR valve. there should be no EGR at idle. Refer to CHART C-7.
CHECK: NC signal to ECM, Tech 1 scan tool should indicate NC is being requested whenever
CHECK:
CHECK:
CHECK:
CHECK:
NC is selected. If problem exists with NC "ON," check A/C system operation CHART
C-10 or applicable DTC.
Crankcase ventilation valve for proper operation by placing finger over inlet hole in
valve end several times. Valve should snap back. If not, replace valve. Refer to
"Crankcase Ventilation," Section "6E3-Cl3".
For broken motor mounts.
Generator output voltage. Repair ifless than 9 volts or more than 16 volts.
IGNITION SYSTEM
CHECK: Ignition system; wires, plugs, etc.
ENGINE MECHANICAL
CHECK: Perform a cylinder compression check. Refer to SECTION 6.
CHECK: For correct camshaft or weak valve springs.

STALLING
(Page 2 of 2)
Definition:
Engine runs unevenly at idle. If severe, the engine or

vehicle may shake. Engine idle speed may vary in RPM.
Either condition may be severe enough to stall engine.
FUEL SYSTEM
NOTICE: 11onitoring long term fuel trim will help identify the cause of the problem. If the
system is running lean (long term fuel trim greater than 150), refer to "Diagnostic Aids" on facing
page of OTC 44/64. If the system is running rich (long term fuel trim less than 110), refer to
"Diagnostic Aids" on facing page of DTC 45/65.
CHECK:
CHECK:
CHECK:
CHECK:
Injector balance. Refer to CHART C-2A.

For fuel in pressure regulator hose. If fuel is present, replace regulator assembly.
Evaporative Emission Evap Control System, use CHART C-3.
The Oxygen Sensor(s) (02S) should respond quickly to different throttle positions. If they
do not, check the Oxygen Sensor(s) (02S) for silicon contamination from fuel or improper
use of RTV sealant. The sensor will have a white, powdery coating and will result in a
high but false signal voltage (rich exhaust indication). The EC:VI will then reduce the
amount of fuel de Ii vered to the engine, causing a severe dri veability problem.
POOR FUEL ECONOMY

Definition:
Fuel economy, as measured by an actual road

test, is noticeably lower than expected. Also,
economy is noticeably lower than it was on
this vehicle at one time, as previously shown
by an actual road test.
PRELIMINARY CHECKS
Perform the careful visual checks as described at start of"Symptoms," Section "6E3-B".
Visually (physically) check: Vacuum hoses for splits, kinks, and proper connections as shown on
"Vehicle Emission Control Information" label.
Check owner's driving habits.
Is NC "ON" full time (Defroster mode "ON")?
Are tires at correct pressure?
Are excessively heavy loads being carried?
Is acceleration too much, too often?
Check air cleaner filter for dirty or being plugged.
Fuel leaks.
ADDITIONAL CHECKS
CHECK: TCC operation. Use CHART C-8. A Tech 1 scan tool should indicate an RPM drop, when
the TCC is commanded "ON."

CHECK: For exhaust system restriction.
CHECK: For proper calibration of speedometer.
CHECK: Air intake system and crankcase for air leaks.
IGNITION SYSTEM
CHECK: Spark plugs.
Remove spark plugs, check for wet plugs, cracks, wear, improper gap,
COOLING SYSTEM
CHECK: Engine coolant level.
CHECK: Engine thermostat for faulty part (always open) or for wrong heat range.
SECTION 68.
ENGINE MECHANICAL
CHECK: Compression. Refer to SECTION 6A.
Refer to
EXCESSIVE EXHAUST EMISSIONS OR ODORS

Definition:
Vehicle fails an emission test. Vehicle has

excessive "rotten egg" smell. Excessive odors do
not necessarily indicate excessive emissions.
PRELIMINARY CHECKS
Perform "On-Board Diagnostic (OBD) System Check."
NOTICE: IF EMISSION TEST shows excessive CO and HC check items which cause vehicle to
run RICH (long term fuel trim less than 110), refer to "Diagnostic Aids" on facing page of DTC
45/65.
NOTICE: If EMISSION TEST shows excessive NOx, check items which cause vehicle to run lean
or too hot such as inoperative cooling fan, or inoperative EGR valve.
ADDITIONAL CHECKS
CHECK: EGR valve for not opening. Use CHART C-7.
CHECK: For lead contamination for catalytic converter (look for the removal of fuel filler neck
restrictor).
CHECK: Carbon build-up. Remove carbon with top engine cleaner. Follow instructions on can.
CHECK: Crankcase ventilation valve for being plugged or stuck or fuel in the crankcase.
IGNITION SYSTEM
CHECK: Spark plugs, plug wires, and ignition components. Refer to SECTION 6D.
COOLING SYSTEM
NOTICE: If the Tech 1 scan tool indicates a very high engine coolant temperature and the
system is running lean:
CHECK: Engine thermostat for faulty part (always open) or for wrong heat range.
Refer to
SECTION6B.
CHECK: Cooling fan operation, use CHART C-12.
FUEL SYSTEM
NOTICE: If the system is running RICH (long term fuel trim near 110), refer to "Diagnostic
Aids" on facing page ofDTC 45/65.
If the system is running LEAN (longterm fuel trim near 150) refer to "Diagnostic Aids" on facing
page of DTC 44/64.
CHECK:
CHECK:
CHECK:
CHECK:
For properly installed fuel cap.

Fuelpressure. UseCHARTA-7.
Injector balance test. Use CHART C-2A.
Evaporative emission canister for fuel loading. Use CHART C-3.
DIESELING, RUN-ON
Definition:
Engine continues to run after key is turned

"OFF," but runs very roughly. If engine runs
smoothly, check ignition switch and
adjustment.
PRELIMINARY CHECKS
FUEL SYSTEM
CHECK: Injectors for leaking. Refer to "Fuel System Diagnosis" CHART A-7.
DRIVEABILl'fY AND EMISSIONS 3.4L (L32) (VIN S) (SFI) 6E3-B-17
BACKFIRE
Definition:
Fuel ignites inside intake manifold or in

exhaust system, making loud popping
noise.
PRELIMINARY CHECKS
Perform the careful visual/physical checks as described at start of"Symptoms," Section ''6E3-B".
ADDITIONAL CHECKS
CHECK: EGR gasket for faulty or loose fit.
CHECK: EGR operation for being open all the time. Refer to "Exhaust Gas Recirculation (EGR)"
CHARTC-7.
CHECK: Intake and exhaust manifold for casting flash.
IGNITION SYSTEM
CHECK: Proper ignition coil output voltage with spark tester J 26792 or equivalent (ST-125).

CHECK: Spark plug wires for crossfire, also inspect Electronic Ignition (EI) system assembly,
spark plug wires, and proper routing of plug wires.
NOTICE:
If an intermittent condition exists in the ignition system, refer to "Electronic

Ignition (EI) System" Section "6E3-C4" or SECTION 6D.
ENGINE MECHANICAL
CHECK: Compression - Look for sticking or leaking valves.
CHECK: Valve timing, refer to SECTION 6A.
CHECK: Intake and exhaust manifold passages for casting flash.
FUEL SYSTEM
CHECK: Perform fuel system diagnosis check, see CHART A-7.
CHECK: Fuel injectors. Perform injector balance test, refer to CHART C-2A.

II
ECM CONNECTOR A" SYMPTOMS CHART

CLEAR 32 PIN CONNECTOR
PIN FUNCTION
CKT
WIRE COLOR
COMPONENT
CONNECTOR
CAVITY
DTC(s)
AFFECTED
POSSIBLE SYMPTOMS FROM

FAULTY CIRCUIT
A1
SENSOR GROUND FOR IA T, MAP,

A/C REFRIGERANT PRESSURE
AND A/C EV APO RA TOR
TEMPERATURE SENSORS
808
BLK
IAT, MAP, A/C REF.

PRESS SENSORS
HARN CONN" A"
ANDA/C
EVAPORATOR
T(MP. SENSOR "C'"
23 (1)
31 (1)
71 (1)
ENGINE STARTS AND STALLS NO POWER,

ENGINE WILL NOT RUN
A2
A/C REQUEST
762
LT GRN/BLK
HEATER AND A/C

CONTROL
ASSEMBLY
NONE
A/C INOPERATIVE. REFER TO SECTION C10
A3
A/C EVAPORATOR
TEMPERATURE SENSOR SIGNAL
732
DKBLU
A/C EVAPORATOR
TEMP. SENSOR "B"
73 (3)
7114)
A/C INOPERATIVE REFER TO TO SECTION

(10
AS

SENSOR SIGNAL
380
RED/BLK
A/C REF. PRESS

SENSOR HARN
CONN "C"
66(2)
70 (4)
NO A/C, REFER TO SECTION C10

A/CCLUTCH TOGGLES "OFF","'ON,"
HIGH AND UNSTABLE IDLE
A6
FUEL PUMP SIGNAL
120
GRY
FUEL PUMP RELAY

"A2" AND FUEL
PUMP PRIME
CONNECTOR
54(2)
HARD TO START, LONG CRANK TIME.

REFER TO CHART A7
FUEL PUMP ENABLE
465
DKGRN/WHT FUEL PUMP RELAY

"C2"
54(2)
HARD TO START, LONG CRANK TIME.
A4
A7
AS
REFER TO CHART A7
A9
A10
A11
A12
A13
A14
A 15 TCC CONTROL
422
TAN/BLK
TCC HARN CONN

"D ..
NONE
NO TCC, POOR FUEL ECONOMY, CHUGGLE

OR TRANS BUMP. REFER TO SECTION C8
470
BLK
ECTSENSOR"A"
TP SENSOR "B"
15 (1)
21 (1)
ENGINE STARTS AND STALLS, NO POWER,

ENGINE WILL NOT RUN.
583
LT BLU/BLK
TCC SOLENOID" A"

TCCBRAKE
SWITCH "B"
81 (3)
REFER TO SECTION CS*
A16
A 17 SENSOR GROUND FOR TP AND
ECT SENSORS
A18 TCC/BRAKE SWITCH INPUT
A19
*
REFER TO ELECTRICAL DIAGNOSIS (SECTION SA).
(1) OPEN CIRCUIT
(2) GROUNDED CIRCUIT
(3) OPEN OR GROUNDED CIRCUIT
(4) SHORTED TO VOLTAGE
11-12-92
NS 15632
ECM CONNECTOR" A" SYMPTOMS CHART

CLEAR 32 PIN CONNECTOR
PIN FUNCTION
CKT
WIRE COLOR
COMPONENT
CONNECTOR
CAVITY
DTC(s)
AFFECTED

FAUL TY CIRCUIT
LTBLU
TCC SOLENOID-"B"
NONE
NO 4TH GEAR. POOR FUEL ECONOMY,

CHUGGLE OR SHUTTER CONDITION. REFER
TO SECTION CS
A20
A21
A22 4th GEAR SWITCH-(A/T)
-----------------------
A22 CLUTCH ANTICIPATE SWITCH(MIT)
446
--- -------48
GRY
------- -------------------------------------CLUTCH
NONE
IDLE FLARE WITH CLUTCH PEDAL
ANTICIPATE
CRUISE RELEASE
SWITCH-"B"
DEPRESSED
A23
A24
A25
A26
A27
A28
A29 !/!AP SENSOR SIGNAL
432
LTGRN
MAP SENSOR
HARN CONN "B"
33(4)
34(3)
44(2)
UNSTABLE IDLE, ROUGH, HESITATION,

HIGH IDLE, HUNTING IDLE, LEAN EXHAUST,
POOR PERFORMANCE, STALLS, MISS,
SURGE.
A30 TP SENSOR SIGNAL
417
DKBLU
TP SENSOR HARN
CONN "C"
21 (4)
22 (3)
HIGH IDLE, SURGE, LACK OF

PERFORMANCE
A31 ENGINE COOLANT TEMP.

5ENSOR SIGNAL
410
YEL
ECT SENSOR HARN

CONN "B"
14 (2)
15(1.4)
HARD TO START, LACK OF PERFORMANCE,

POOR FUEL ECONOMY.
A32
* REFER TO ELECTRICAL DIAGNOSIS (SECTION SA)

(1) OPEN CIRCUIT
(3) OPEN/GROUNDED CIRCUIT
11-12-92
NS 15633
ECM CONNECTOR "B" SYMPTOMS CHART

BLACK 32 PIN CONNECTOR
PIN FUNCTION
CKT
#
WIRE COLOR
COMPONENT
CONNECTOR
CAVITY
DTC(s)
AFFECTED

FAULTY CIRCUIT
81
82
COOLING FAN RELAY CONTROL
335
DKGRN
ENGINE COOLING
FAN CONTROL
RELAY- "02"
NONE
INOPERATIVE FAN. FAN RUNS ALL THE

TIME. REFER TO SECTION C12.
83
SECONDARY AIR INJECTION

PUMP RELAY CONTROL
436
BRN
SECONDARY AIR
INJECTION PUMP
RELAY CONN "E2"
NONE
INOPERATIVE AIR BYPASS SOLENOID. HC

AND CO EMISSION LEVELS WILL BE TOO
HIGH. REFER TO SECTION C6.
84
EVAP CANISTER PURGE
428
DKGRN/WHT
EVAP CANISTER
PURGE SOLENOID
CONN "A"
NONE
FUEL LOSS OR FUEL VAPOR ODOR. POOR

IDLE, STALLING, POOR DRIVE ABILITY.
REFER TO SECTION C3.
A/C COMPRESSOR CLUTCH
459
DKGRN/WHT
A/C RELAY HARN

CONN "85"
68 (2)
NO A/C CLUTCH ENGAGEMENT (1) A/CON

ALL THE TIME (2). REFER TO SECTION C10.
419
BRN/WHT
10-WAY IN-LINE
1/PCONN. "B"
NONE
NO MIL (1) MIL ON ALL THE TIME (2).

REFER TO "ON-BOARD DIAGNOSTIC
SYSTEM CHECK." *
811 EGR #1 CONTROL
697
LTBLU
DIGITAL EGR HARN

CONN "A"
75 (3)
ROUGH IDLE, SPARK KNOCK, STALLS

AFTER COLD START, SURGE DURING
CRUISE. REFER TO SECTION C6.
812 EGR #2 CONTROL
698
BRN
DIGITAL EGR HARN

CONN"B"
76(3)

813 EGR #3 CONTROL
699
RED
DIGITAL EGR HARN

CONN"C"
77(3)

814 BATTERY+ (KEEP ALIVE
480
ORN
1/PFUSE #4
NONE
CRANKS BUT WILL NOT START IF BOTH

BATTERY FEEDS ARE OPEN. REFER TO
"ON-BOARD DIAGNOSTIC SYSTEM
CHECK."*
480
ORN
1/P FUSE #4
NONE
451
WHT/BLK
ENGINE GROUND
LOCATED AT LFT
FRT OF ENGINE
NONE
CRAN KS BUT WILL NOT START IF BOTH

BATTERY FEEDS ARE OPEN. REFER TO
"ON-BOARD DIAGNOSTIC SYSTEM
CHECK."*
NO SYMPTOMS, IF BOTH POWER
GROUNDS ARE OPEN, ON START. REFER
TO "ON-BOARD DIAGNOSTIC SYSTEM
CHECK."*
800
TAN
DATA LINK
CONNECTOR "M"
NONE
BS
86
RELAY CONTROL
87
MALFUNCTION INDICATOR
LAMP (MIL) "SERVICE ENGINE
SOON"
88
89
810
MEMORY)
815 BATTERY+ (KEEP ALIVE

MEMORY)
816 ECM GROUND
817
818
819 SERIAL DATA
(1)
(2)
(3)
*
NO DLC DATA. REFER TO "ON-BOARD

DIAGNOSTIC SYSTEM CHECK."*
OPEN CIRCUIT
GROUNDED CIRCUIT
OPEN OR GROUNDED CIRCUIT
REFER TO SECTION SA
12-2-92
NS 15634
ECM CONNECTOR "B" SYMPTOMS CHART

BLACK 32 PIN CONNECTOR
PIN FUNCTION
CKT
WIRE COLOR
COMPONENT
CONNECTOR
CAVITY
DTC(s)
AFFECTED

FAULTY CIRCUIT
820 LEFT (BANK 2) 025 GROUND
351
BLK/WHT
LEFT02S
13,44,45
ROUGH OR INCORRECT IDLE, LEAN

EXHAUST. POOR PERFORMANCE.
821 LEFT (BANK 2) 025 SIGNAL
1665
PPLJWHT
LEFT02S
13,44,45
ROUGH OR INCORRECT IDLE, LEAN

EXHAUST POOR PERFORMANCE.
822 RIGHT(BANK 1)025 SIGNAL
1666
PPL
RIGHT02S
63 (1)
64(3)
65(4)
ROUGH OR INCORRECT IDLE, LEAN OR

RICH EXHAUST, HESITATION, SURGE,
POOR PERFORMANCE, POOR FUEL
ECONOMY
823 RIGHT (BANK 1) 025 GROUND
351
BLK/WHT
RIGHT02S
63 (1)
64 (3)
65 (4)
ROUGH OR INCORRECT IDLE, LEAN OR

RICH EXHAUST, HESITATION, SURGE,
POOR PERFORMANCE, POOR FUEL
ECONOMY
824 IAC COIL "B" HIGH
1749
LTGRN/WHT
IAC HARN CONN

"B"
35 (3)
HIGH OR LOW IDLE, STALLS. REFER TO

CHARTC-28
825 IAC COIL "B" LOW
444
LTGRN/BLK
IAC HARN CONN
35 (3)

CHARTC-28
35 (3)

CHARTC-28
35 (3)

CHARTC-28
"A"
826 IAC COIL "A" LOW
1748
LTBLU/BLK
IAC HARN CONN
"C"
827 IACCOIL "A" HIGH
1747
LTBLU/WHT
IAC HARN CONN
"D"
828 BUFFERED SPEED OUTPUT
(4000 PULSES/MILE}
817
DKGRN/WHT
INST. CLUSTER
80(1)
INOPERATIVE SPEEDOMETER,
INOPERATIVE CRUISE CONTROL *
829 VSS INPUT HIGH
400
YEL
VSS HARN CONN
79 (4)
80 (1)
INOPERATIVE CRUISE CONTROL, TRANS
SHIFT FROM DRIVE TO NEUTRAL. *
INOPERATIVE CRUISE CONTROL, TRANS
SHIFT FROM DRIVE TO NEUTRAL.*
"B ..
830 VSS INPUT LOW
401
PPL
VSS HARN CONN
79 (4)
80 (1)
831 5 VOLT REF MAP, TP, A/C

REFRIGERANT PRESSURE AND
SENSORS
416
GRY
TPS HARN CONN

"A",MAPHARN
CONN "C" A/C
PRESS SENSOR
HARN CONN "B"
A/C EVAPORATOR
TEMPERATURE
SENSOR CONN "A"
22 (3)
34(3)
66
67
70
ENGINE GROUND
LOCATED A TL EFT
FRONT OF ENGINE
NONE
832 ECM GROUND
451
BLK/WHT
.,A
ENGINE STARTS AND STALLS, NO POWER,

ENGINE WILL NOT RUN.
A/CINOP
71
73
POWER GROUNDS ARE OPEN. CHECK
GROUNDS AT ENGINE BLOCK, ELECTRONIC
IGNITION SYSTEM, PARK/NEUTRAL
POSITION SWITCH. REFER TO "ON-BOARD
DIAGNOSTIC SYSTEM CHECK." *
(1) OPEN CIRCUIT

*
REFER TO SECTION BA
11-12-92
NS 15635
ECM CONNECTOR "C" SYMPTOMS CHART

BLUE 32 PIN CONNECTOR
PIN FUNCTION
CKT
#
WIRE COLOR
COMPONENT
CONNECTOR
CAVITY
DTC{s)
AFFECTED

FAUL TV CIRCUIT
C1
ECMGROUND
551
TAN/VVHT
ENGINE GROUND
LOCATED AT
FRONT OF ENGINE
NONE

ECM GROUNDS OPEN, CHECK GROUNDS
AT ENGINE BLOCK, ELECTRONIC IGNITION
SYSTEM, PARK/NEUTRAL POSITION
SWITCH. REFER TO "ON-BOARD
DIAGNOSTIC SYSTEM CHECK."
C2
A/CSTATUS
59
DKGRN
A/C CLUTCH RELAY

"84" A/CLOW
PRESS SWITCH "A"
68(4)
POOR A/C PERFORMANCE
FUEL PUMP RELAY

"C1"
87 (1)
NO START. REFER TO "OBD SYSTEM

CHECK."
69 (1)
IGNITION FEED
439
PNK
DIAGNOSTIC ENABLE
448
WHT/BLK
DATA LINK
CONNECTOR "B"
NONE
NO SYMPTOMS. REFER TO "OBD SYSTEM

CHECK."
C11 PARK/NEUTRAL POSITION (PNP)

SWITCH INPUT
434
ORN/BLK
TRANSMISSION
POSITION SWITCH
"B"
NONE
POOR FUEL ECONOMY, STALLS INCORRECT

IDLE.
1746
PNK/BLK
10-WAV INJ/
ENGINE HARNESS
CONN. "C" &
INJECTOR #3
NONE
MISFIRE, RUNS ROUGH, POOR

PERFORMANCE, POOR FUEL ECONOMY.
REFER TO CHART C2A *
1745
LTGRN/BLK
10-WAV INJ/
ENGINE HARNESS
CONN. "B" &
INJECTOR #2
NONE

1744
BLK
10-WAY INJ/
ENGINE HARNESS
CONN. "A" &
INJECTOR #1
NONE

846
YEUBLK
NONE

845
BLK/WHT
10-WAV INJ/
ENGINE HARNESS
CONN. 'T' &
INJECTOR #6
10-WAY INJ/
ENGINE HARNESS
CONN. 'T' &
INJECTOR #5
NONE

C17 ECM GROUND
551
TAN/VVHT
ENGINE GROUND
LOCATED AT
FRONT OF ENGINE
NONE
C18 REFERENCE LOW CAMSHAFT

POSITION SENSOR &
632
PNK/BLK
CAMSHAFT
POSITION SENSOR
HARNESS CONN
"C" CRANKSHAFT
POSITION SENSOR
HARN CONN"("
36 (3)
NO SYMPTOMS. IF BOTH ECM GROUNDS

ARE OPEN, NO START, REFER TO "OBD
SYSTEM CH ECK."
SLIGHT ENGINE MISS, POOR
PERFORMANCE, POOR FUEL ECONOM'I
C3
C4
cs
CG
C7
CB
C9
C10
17 (3)
C19
*
(1)
(2)
(3)
(4)
REFER TO ELECTRICAL DIAGNOSIS (SECTION SA)

OPEN CIRCUIT
GROUNDED CIRCUIT
OPEN/GROUNDED CIRCUIT
SHORTED TO VOLTAGE
ECM Connector"(" Symptom Chart (1 of 2)
11-12-92
NS 15644
DRIVEABILITY AND EMISSIONS 3.4l {L32) {VIN S) {SFI) 6E3-B-23
ECM CONNECTOR "C" SYMPTOMS CHART

BLUE 32 PIN CONNECTOR
PIN FUNCTION
CKT
C20 KNOCK SENSOR SIGNAL
496
C21 24X REFERENCE SIGNAL
1800
WIRE COLOR
DK/BLU
COMPONENT
CONNECTOR
CAVITY
KNOCK SENSOR
LTBLU/WHT HIGH RESOLUTION

24X CRANKSHAFT
POSITION SENSOR
"B'.
DTC(s)
AFFECTED

FAULTY CIRCUIT
43 (3)
LACK OF PERFORMANCE, SPARK KNOCK.

REFER TO SECTION CS.
36 (3)
LONG CRANK TIME, INCORRECT IDLE, LACK

OF POWER, HESITATION OR SAG.
C22
C23 PASS-KEY II SIGNAL
1FUEL ENABLE)
229
DK BLU
PASS-KEYII
DECODER MODULE
CONNECTOR" A3"
46
633
BRN/WHT
CAMSHAFT
POSITION SENSOR
"B"
17 (3)
SLIGHT ENGINE MISS, POOR

PERFORMANCE POOR FUEL ECONOMY.
C27 IGNITION CONTROL (IC)
423
WHT
ELECTRONIC
IGNITION
CONTROL MODULE
HARN CONN "B"
42 (2)
SURGE, HESITATION, RUNS ROUGH,

STALLS, LACK OF PERFORMANCE.
C28 IGNITION CONTROL BYPASS
424
TAN/BLK
ELECTRONIC
IGNITION
CONTROL MODULE
HARNCONN"A"
42 (2)
SURGE, HESITATION, RUNS ROUGH,

STALLS, LACK OF PERFORMANCE.
C29 IAT SENSOR SIGNAL
472
TAN
IAT HARNESS
CONN "B"
23 (1)
HARD TO START, POOR PERFORMANCE.
CRANKS, BUT WON'T START.
C24
C25 CAMSHAFT POSITION SENSOR
SIGNAL
C26
25 (2)
C30 3X REFERENCE HIGH
647
LT BLU/BLK
ELECTRONIC
IGNITION
CONTROL MODULE
HARN CONN "E"
82 (3)
CRANKS BUT WILL NOT START. REFER TO

"ON-BOARD DIAGNOSTICS SYSTEM
CHECK."
C31 3X REFERENCE LOW
453
RED/BLK
ELECTRONIC
IGNITION
CONTROL MODULE
HARN CONN "F"
NONE
NO SYMPTOMS, REFER TO SECTION C4.
844
LT BLU/BLK
10-WAY INJ/
ENGINE HARNESS
CONN. "D"
INJECTOR #4
NONE

REFER TO CHART C-2A.
* REFER TO ELECTRICAL DIAGNOSIS (SECTION BA)

(1) OPEN CIRCUIT
11-12-92
NS 15645
ECM Connector "C" Symptom Chart (2 of 2)
CHART B-1
RESTRICTED EXHAUST SYSTEM CH ECK
Proper diagnosis for a restricted exhaust system is essential before any components are replaced. Either of
the following procedures may be used for diagnosis, depending upon engine or to.ol used:
CHECK AT AIR PIPE:

1.
2.
3.
OR CHECK AT OXYGEN SENSOR (025):
Remove the rubber hose at the exhaust

manifold AIR pipe check valve. Remove
check valve.
Connect exhaust backpressure kit (with air
adapter) J 35314-A.
Insert the adapter into the exhaust manifold
AIR pipe.
1.
2.
Carefully remove oxygen sensor.

Install exhaust backpressure gage J 35314-A
in place of oxygen sensor (refer to
illustration).
After completing test described below, coat
threads of oxygen sensor with anti-seize
compound PIN 5613695 or equivalent prior to
re-installation.
3.
'
2
~'.
~--,
_ - - -,)
\__ a
,~
EXHAUST BACK PRESSURE KIT WITH AIR ADAPTER

2
AIR PIPE (EXHAUST PORT)
CHECK VALVE
BACK PRESSURE GAGE
75 3363-6E
OXYGEN SENSOR (025)
EXHAUST MANIFOLD
75 3338-6E
DIAGNOSIS:
1.
2.
3.
4.
5.
With the engine idling at normal operating temperature, observe the exhaust system backpressure
reading on the gage. Reading should not exceed 8.6 kPa (1.25 psi).
Increase engine speed to 2000 RPM and observe gage. Reading should not exceed 20.7 kPa (3 psi).
If the backpressure at either speed exceeds specification, a restricted exhaust system is indicated.
Inspect the entire exhaust system for a collapsed pipe, heat distress, or possible internal muffier failure.
If there are no obvious reasons for the excessive backpressure, the catalytic converter is suspected to be
restricted and should be replaced using current recommended procedures.
4-30-92
75 3340-6E
BLANK
6E3-C-1 3.4L (L32) (VIN S) (SFI) DRIVEABILITY AND EMISSIONS
SECTION C
COMPONENT SYSTEMS
removed. If a fastener needs to be replaced, use the correct part number fastener for that application If
used. Fasteners that are not reused, and those requiring thread-locking compound will be called out. The
correct torque value must be used when installing fasteners that require it. If the above coliditions are not
followed, parts or system damage could result.
Section "C" provides information on the following:
General description of components and systems.
On-vehicle service.
Part names.
Diagnostic charts. These include a functional check of the system as well as diagnosis of any problem
found in the functional check.
For locations of components, wiring diagrams, and ECM connector end view, refer to the front on the "A"
Section of the engine being diagnosed.
Following are the sub-section identification and the system covered:
Cl
Engine Control Module (ECM) and Sensors Page Cl-1
C2
Fuel Metering System Page C2-1
Page C3-1
C3
Electronic Ignition (El) System Page C4-1
C4
cs Knock Sensor (KS) System
Page CS-1
Secondary Air Injection (AIR) System Page C6-1
CG
C7
Exhaust Gas Recirculation (EGR) System Page C7-1
Torque Converter Clutch (TCC) System
Page (8-1
CB
C10 A/C Compressor Clutch Control PageCl0-1
C12 Cooling Fan Control Page C12-1
(13 Crankcase Ventilation System Page C13-1
(14 Air Intake System
Page C141
.. . . . . . . . . . . . . . . . . . . .. . .
. . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . .
DIAGNOSTIC CHARTS
The diagnostic charts for each system are found after the on-vehicle service and parts information at the back of
each section. Following are the charts found in this section.
ChartC-1A
Park/Neutral Position (PNP) Switch Diagnosis Page Cl-14
Chart C-1 D
Manifold Absolute Pressure (MAP) Output Check
Page C1-16
ChartC-2A
Injector Balance Test
Page C2-16
Idle Air Control (IAC) Circuit Page C2-18
Chart C-28
Evaporative Emission (EVAP) Canister Purge Solenoid Valve Check Page C3-6
Chart C-3
Chart C-4F
Misfire Page C4-8
Chart C-5
Knock Sensor (KS) System Check Page CS-4
Chart C-6
Secondary Air Injection (AIR) System Check
Page C6-6
Chart C-7
Exhaust Gas Recirculation (EGR) Flow Check Page C7-4
Chart C-8
Torque Converter Clutch (TCC) System ( 1 of 2) Page (8-4
Chart C-10
A/C Compressor Clutch Control Circuit Diagnosis (1 of 2)
Page C104
Cooling Fan Control Circuit Diagnosis (1 of 2)
Page C12-2
ChartC-12
. . . .. ... . .. .. .. . . . . . . . .. . . . .. . . . . .
. . . .. . . ... . . . . . ... .
DRIVEABILITY AND EMISSIONS 3.4L (L32) (VIN S) (SFI) 6E3-C1-1
SECTION C1
ENGINE CONTROL MODULE (ECM) AND SENSORS

CONTENTS
General Description C1-1
Engine Control Module (ECM) C1-1
ECM Function C1-1
Memory C1-2
EEPROM C1-2
RAM C1-2
Short Term Fuel Trim C1-2
Long Term Fuel Trim C1-2
Speed Density System C1-3
Speed C1-3
Density
C1-3
Information Sensors C1-3
Sensor C1-3
C1-4
Intake Air Temperature (IAT) Sensor
Manifold Absolute. Pressure (MAP)
Sensor C1-4
Oxygen Sensor (025) C1-4
Throttle Position (TP) Sensor C1-5
Vehicle Speed Sensor (VSS) C1-5
Knock Sensor {KS) C1-5
A/C "Request" Signal C1-6
Park/Neutral Position (PNP) Switch C1-6
3X. Crankshaft Position Sensor C1-6
Camshaft Position Sensor C1-7
24X Crankshaft Position Sensor C1-7
Diagnosis C1-7
ECM Inputs C1-8
Sens-or
Intake Air Temperature (IAT)

Sensor
Manifold Absolute Pressure (MAP}
Sensor
Oxygen Sensor (025)
vss ..................... .
PNP Switch
Crankshaft Position Sensor

24X Crankshaft Position Sensor
On-Vehicle Service
Engine Control Module (ECM}
ECM and Components Replacement
ECM
If ECM is Being Replaced
EEPROM Programming
Functional Check
Engine Coolant Temperature (ECT}
Sensor
Oxygen Sensor (025)
Sensor
Throttle Position (TP} Sensor
vss . . . . . . . . . . . . . . . . . . . . . . .
Park/Neutral Position (PNP) Switch
GEN',,ERAL DESCRIPTION
ENGINE CONTROL MODULE (ECM)
NOTICE: To prevent possible Electrostatic
Discharge damage to the ECM, Do Not touch the
connector pins or soldered components on the
circuit board.
The Engine Control Module (ECM) (Figure Cl-1),
is located underhood between the right shock tower
and the bulkhead. It is the control center of the fuel
injection system and constantly monitors the
information from various sensors and controls the
systems that affect vehicle performance. The ECM
also performs the diagnostic function of the system. It
can recognize operational problems, alert the driver
through the Malfunction Indicator Lamp (MIL)
"Sel'vice Engine Soon," and store a Diagnostic Trouble
Code (DTC) which identifies the problem areas to aid
the technician in making repairs. Refer to
C1-8
C1-8
C1-8
C1-8
C1-8
C1-9
C1-9
C1-9
C1-9
C1-9
C1-9
C1-9
C1-10
C1-10
C1-10
C1-10
C1-10
C1-1 O
C1-11
C1-11
C1-12
C1-12
C1-12
C1-12
"Introduction," SECTION 6E for more information on

using the diagnostic function of the ECM.
The ECM used on the 3.4L engine is referred to as
SFI-66. For service, this ECM consists of only two
parts: a dual processor controller and Knock Sensor
(KS) module.
ECM FUNCTION
The ECM contains a power supply which regulates
the 12 volt vehicle supply input to 5 and 12 volts, and
these voltages are used for various internal and
external functions.
The ECM supplies a buffered 5 or 12 volts to power
various sensors or switches. This is done through
resistances in the ECM which are so high in value that
a test light will not light when connected to the circuit.
In some cases, even an analog shop voltmeter will not
give an accurate reading because its resistance is too
low.. Therefore, the use of a 10 megohm input
im~edance digital voltmeter or a Tech 1 scan tool is
necessary to assure accurate voltage readings.
6E3-C1-2 3.4L (L32) (VIN S) (SFI) DRIVEABILITY AND EMISSIONS
ECM
ECM HARNESS CONNECTOR (B)
ECM HARNESS CONNECTOR (C)
ECM HARNESS CONNECTOR(A)
ECM ENGINE HARNESS CONNECTORS
SECONDARY PUSH LOCK RETAINERS

ECM HARNESS CONNECTORS
NS 15050
Figure C1-1 - Engine Control Module (ECM)
The Input/Output (I/0) devices in the ECM include

analog to digital converters, signal buffers, counters
and special drivers. The ECM controls output circuits
such as the injectors, IAC, cooling fan relay, etc. by
controlling the ground circuit through transistors or a
device called a "quad-driver" in the ECM.
Memory
There are two types of memory storage within the
ECM: EEPROM and RAM.
EEPROM
Electrically Erasable Programmable Read Only
Memory (EEPROM) is a permanent memory that is
physically soldered to the circuit boards within the
ECM. The EEPROM contains the overall control
algorithms. The EEPROM can be reprogrammed by
using the Tech 1 scan tool or other Techline
terminal/equipment.
RAM
Random Access Memory (RAM) is the
microprocessor "scratch pad." The processor can write
into or read from this memory as needed. This
memory is volatile and needs a constant supply of
voltage to be retained. If the voltage is lost, the
memory is lost and the ECM logs a OTC indicating
this loss.
Short Term Fuel Trim

Short term fuel trim is an ECM volatile memory
register that will contain a number between O and 255.
The neutral value for the short term fuel trim is 128;
any deviation from this value indicates the short term
fuel trim is changing the injector pulse width. The
amount of pulse width change depends on how far the
short term fuel trim value is from 128. The short term
fuel trim changes the pulse width by varying the
"Closed Loop" factor of the base pulse width equation.
As the ECM monitors the Oxygen Sensor (028) inputs,
it is constantly varying the short term fuel trim value.
The value is updated very quickly, therefore, the short
term fuel trim only corrects for short term fuel trim
trends. The correction of long term fuel trim trends is
the function of the long term fuel trim.
Long Term Fuel Trim

The long term fuel trim is a matrix of cells
arranged by RPM and MAP. Each cell of the long term
fuel trim is a register like the short term fuel trim. As
the engine operating conditions change, the ECM will
switch from cell to cell to determine what "long term
fuel trim" factor to use in the base pulse width
equation.

While in any given cell, the ECM also monitors the
short term fuel trim. If the short term fuel trim is far
enough from 128, the ECM will change the long term
fuel trim value. Once the long term fuel trim value is
changed it should force the short term fuel trim back
toward 128.
If the mixture is still not correct (as judged by the
02S), the short term fuel trim will continue to have a
large deviation from the ideal 128. In this case, the
long term fuel trim value will continue to change until
the short term fuel trim becomes balanced.
Both the short term fuel trim and long term fuel
trim are limited by calibrated values. If the mixture is
off enough so that long term fue 1trim reaches the limit
of its control and still cannot correct the condition, the
short term fuel trim would also go to its limit of control
in the same direction. If the mixture is still not
corrected by both short term fuel trim and long term
fuel trim at their extreme values, a OTC 44, 45, 64 or
65 will likely result. Under the conditions of power
enrichment, the ECM sets the short term fuel trim to
128 and freezes it there until power enrichment is no
longer in effect. This is done so the "Closed Loop"
factor and the long term fuel trim will not try to
correct for the commanded richness of power
enrichment.
SPEED DENSITY SYSTEM

The Sequential Fuel Injection (SFI) system is a
speed and air density system. The system is based on
"speed density" fuel management which calculates air
volume through the intake.
Three specific data sensors provide the ECM with
the basic information for the fuel management portion
of its operation. That is, three specific signals to the
ECM establish the engine speed and air density to
determine the optimum fuel delivered by the injectors.
Speed
The engine speed signal from the 3X crankshaft
position sensor is conditioned by the electronic
Ignition Control Module (ICM) system module. This
signal is input to the ECM on the crank reference high,
CKT 647. The ECM uses this information to
determine the "speed" or RPM factor for fuel and
ignition management.
Density
Three sensors contribute to the density factor, the
Intake Air Temperature (IAT), the Manifold Absolute
Pressure (MAP) and the Engine Coolant Temperature
(ECT) sensors.
The IAT sensor is a 2-wire sensor that measures

the temperature of the air entering the intake
manifold. The IAT sensor is a thermistor that changes
its resistance as an inverse function of temperature.
When the temperature is low, the resistance is high,
and when the temperature is high, the resistance is
low.
The engine coolant temperature sensor is also a 2wire sensor that measures temperature. It is mounted
in the engine coolant stream and operates the same
way as the IAT sensor.
The IAT and ECT sensors work together to assure
that proper temperature information gets to the ECM.
The Manifold Absolute Pressure (MAP) sensor is a
3-wire sensor that monitors the changes in intake
manifold pressure which results from changes in
engine loading. These pressure changes are supplied
to the ECM in the form of analog electrical signals.
As intake manifold pressure increases, the air
density in the intake manifold also increases and
additional fuel is required. The MAP sensor sends this
pressure information to the ECM and the ECM
increases the amount of fuel injected by increasing the
injector pulse width. Conversely, as manifold pressure
decreases, the amount of fuel is decreased.
These four inputs MAP, IAT, ECT sensors, and
RPM are the major determinants of the air/fuel
mixture delivered by the fuel injection system.
The remaining sensors and switches provide
electrical inputs to the ECM which are used for
modification of the air/fuel mixture, as well as for
other ECM control functions, such as Idle Air Control
(IAC).
INFORMATION SENSORS
Engine Coolant Temperature (ECT) Sensor
Figure C1-2
The engine coolant temperature sensor is a
thermistor (a resistor which changes value based on
temperature) mounted in the engine coolant stream.
Low coolant temperature produces a high resistance
(100,000 ohms at -40C/-40F) while high temperature
causes low resistance (70 ohms at 130C/266F).
The ECM supplies a 5 volt signal to the engine
coolant temperature sensor through a resistor in the
ECM and measures the voltage. The voltage will be
high when the engine is cold, and low when the engine
is hot. By measuring the voltage, the ECM calculates
the engine coolant temperature. Engine coolant
temperature affects most systems the ECM controls.
A failure in the coolant sensor circuit should set
either a OTC 14 or OTC 15. Remember, these OTC(s)
indicate a failure in the coolant temperature circuit so
proper use of the chart will lead to either repairing a
wiring problem or replacing the sensor to properly
repair a problem.
HARNESS CONNECTOR
LOCKING TAB
SENSOR
SS 1640-6E
Figure C1-2 Engine Coolant Temperature Sensor
MAP SENSOR
45 0552-6E
Figure C1-3 MAP Sensor

The Intake Air Temperature OAT) sensor is a
the temperature of air entering the engine and is
mounted in the air cleaner). Low temperature
produces a high resistance (approximately 100,000
ohms at -40C/-40F) while high temperature causes
low resistance (approximately 70 ohms at
130C/266F). The ECM supplies a 5 volt signal to the
sensor through a resistor in the ECM and measures
the voltage. The voltage will be high when the intake
air is cold and low when the air is hot. By measuring
the voltage the ECM calculates the intake air
temperature.
The IAT sensor is used to control spark timing and
delays EGR when the intake air is cold.
A failure in the IAT sensor circuit should set either
a OTC 23 or OTC 25. Once a diagnostic trouble code is
set, the ECM will use an artificial default value for
IAT and some vehicle performance will return.
Manifold Absolute Pressure (MAP) Sensor

Figure C1-3
The Manifold Absolute Pressure (MAP) sensor
measures the changes in the intake manifold pressure
which result from engine load and speed changes, and
converts this to a voltage output.
A closed throttle on engine coastdown would
produce a relatively low MAP output, while a wideopen throttle would produce a high output. Manifold
Absolute Pressure (MAP) is the OPPOSITE of what
you would measure on a vacuum gage. When manifold
pressure is high, vacuum is low. The MAP sensor is
also used to measure barometric pressure under
certain conditions, which allows the ECM to
automatically adjust for different altitudes.
The ECM sends a 5 volt reference signal to the
MAP sensor. As the manifold pressure changes, the
electrical resistance of the sensor also changes. By
monitoring the sensor output voltage, the ECM
calculates the manifold pressure. A higher pressure
EXHAUST OXYGEN SENSOR (025)
4-292
* 45 0078-6E
Figure C1-4 Exhaust Oxygen Sensor (025)
(high voltage) requires more fuel, while a lower

pressure (low voltage) requires less fuel.
A failure in the MAP sensor circuit should set a
DTC 33 or OTC 34. CHART C-10 can also be used to
check this MAP sensor.
Oxygen Sensor (025)

The Oxygen Sensors (028) are essentially small
variable batteries; they have the ability to produce a
low voltage signal that feeds information on engine
exhaust oxygen content from each bank of cylinders.
Two oxygen sensors are used in the 3.4L VIN S. One
sensor is placed in each exhaust manifold to measure
the state of the gases produced by each bank of
cylinders. This allows for more precise fuel control
which lowers emissions and increases efficiency to the
ECM (Figure Cl-5).
The 028 is constructed from a zirconia/platinum
electrolytic element. Zirconia is an electrolyte that
conducts electricity under certain chemical conditions.
The insulator is made of a ceramic material. The
element is an insulator when cold.
OXYGEN SENSOR ELEMENT

21%
OXYGEN
..'....
....
....
......
..
,'
EXHAUST
GAS WITH
0%
OXYGEN
....
..
......
..
......
....
0.6V
....
MORE CONDUCTION
EXHAUST
GAS WITH
2%
OXYGEN
..
0.3V
The Oxygen Sensor (028) provides the feedback

information for the "Closed Loop" operating mode of
the fuel delivery system. The oxygen sensor indicates
to the ECM what is happening in the exhaust. It does
not cause things to happen. It is a type of gage: Lean
mixture = high oxygen content in the exhaust = low
voltage output; rich mixture = low oxygen content in
the exhaust = high voltage output.
An open Oxygen Sensor (028) circuit should set a
DTC 13 or 63. A constant low voltage in the Oxygen
Sensor (028) circuit should set a DTC 44 or 64 .

Figure C1-7
LESS CONDUCTION
95 6325-6E
Figure C1-5- Oxygen Sensor (02S} Element
At exhaust temperatures around 316C (600F), the

element becomes a semiconductor. A platinum coating
on the outer surface of the element stimulates further
combustion of the exhaust gases right at the surface
and this helps keep the element up to the desired
temperature. The oxygen sensor has an internal
cavity which is filled with atmospheric (reference) air.
The atmosphere has approximately 21 % oxygen in it.
In the electrical circuit this internal cavity is the
positive ( +) terminal. The outer surface of the
element is exposed to the exhaust gas stream. It is the
negative(-) or ground terminal. Due to the electrolytic
properties of the element, the oxygen concentration
differences between the reference air and exhaust
gases produce small voltages.
A rich exhaust (excessive fuel) has almost no
oxygen. When there is a large difference in the
amount of oxygen touching the inside and outside
surfaces, there is more conduction, and the sensor puts
out a voltage signal greater than 0.6 volt.
When lean (excessive oxygen) there is about two
percent oxygen in the exhaust. This is a smaller
difference in oxygen from the outside surfaces which
results in less conduction and a voltage signal less
than 0.3 volt. The voltages are monitored and used by
the ECM to "fine tune" the air fuel ratio to achieve the
ideal mixture desired.
The ECM puts out a reference signal of 0.45 volt
(refer to Figure Cl-6). The reference signal serves two
purposes. The first is to run the engine when it is in
"Open Loop" mode of operation. When the air/fuel
ratio is correct the ECM "senses" 0.45 volt. When the
engine is operating with a rich air/fuel ratio there is a
reduction of free oxygen in the exhaust stream and the
028 voltage rises above the reference voltage. When
the engine is run lean, the voltage drops below the
reference voltage due to excess oxygen in the exhaust
stream.
The Throttle Position (TP) sensor is a

potentiometer connected to the throttle shaft on the
throttle body. The TP sensor electrical circuit consists
of a 5 volt supply line and a ground line, both provided
by the ECM. By monitoring the voltage on this signal
line the ECM calculates throttle position. As the
throttle valve angle is changed (accelerator pedal
moved), the output of the TP sensor also changes. At a
closed throttle position, the output of the TP sensor is
low (approximately .29 to .98 volt). As the throttle
valve opens, the output increases so that, at wide-open
throttle, the output voltage should be approximately 5
volts.
The ECM can determine fuel delivery based on
throttle valve angle (driver demand). A broken or
loose TP sensor can cause intermittent bursts of fuel
from the injector, and an unstable idle, because the
ECM senses the throttle is moving. A problem in any
of the TP sensor circuits should set either a DTC 21 or
22. Once a diagnostic trouble code is set, the ECM will
use an artificial default value for the TP sensor, and
some vehicle performance will return. A high idle will
result when either DTC 21 or DTC 22 is set.
Refer to "On-Vehicle Service" for replacement of
the TP sensor.

The Vehicle Speed Sensor (VSS) sends a pulsing
voltage signal to the ECM which the ECM converts to
miles per hour. This sensor mainly controls the
operation of the TCC system. There are several
different types of vehicle speed sensors. Refer to
"Torque Converter Clutch (TCC) System," Section
"6E3-C8", OTC 24 or SECTION SA for more
information.
Knock Sensor (KS)

Refer to "Knock Sensor (KS) System," Section
"6E3-C5" for description of KS system.

A/C "Request" Signal
This signal tells the ECM that the AJC selector
switch is turned "ON." The ECM uses this to adjust
the idle speed before turning "ON" the AJC compressor
clutch.
If this signal is not available to the ECM, the AJC
compressor will be inoperative. Refer to "A/C
Compressor Clutch Control," Section "6E3-Cl0" for
repair procedures.
Park/Neutral Position (PNP) Switch (Part of

Transmission Position Switch)
Figure C1-8
The Park/Neutral Position (PNP) switch indicates
to the ECM when the transmission is in park or
neutral or drive. This information is used for the TCC,
EGR, and the IAC valve operation.
rn
Important
Vehicle should not be driven with transmission

position switch disconnected, as idle quality will be
affected and a possible false DTC 24 (VSS).
Refer to "On-Vehicle Service," in SECTION 7A for

more information on the PNP switch, which is part of
the transmission position switch assembly, mounted
on the transmission shift lever.
SENSOR - THROTTLE POSITION (TP)

2
9P 1074-6E
Figure C17 - Throttle Position (TP) Sensor
Refer to CHART C-lA for PNP switch check.
3X CRANKSHAFT POSITION SENSOR

The crankshaft position sensor provides a signal
through the electronic ignition control module which
the ECM uses as reference to calculate RPM and
crankshaft position. Refer to "Electronic Ignition (EI)
System," Section "6E3-C4" for further information.
RICH
0.60v
RICH
0.60v
ECM02S
REFERENCE
SIGNAL
0.45v
ECM02S
REFERENCE
SIGNAL
0.45v
LEAN
0.30v
LEAN
0.30v
NORMAL OPERATION
RICH
0.60v
SCREW ASSEMBLY -TP SENSOR ATTACHING
RICH TOO LONG - OTC 45 OR 65

RICH
0.60v
ECM02S
REFERENCE
SIGNAL
0.45 v .,__ _ _ _ _ _ _ _ _ __
LEAN
0.30v
ECM02S
REFERENCE
SIGNAL
0.45v
LEAN
0.30v
LEAN TOO LONG - OTC 44 OR 64
BETWEEN 0.3-0.6v TOO LONG - OTC 13 OR 63

3-19-92
95 6344-6E
Figure C16 Normal 02S Voltage and Abnormal Trends
TRANSMISSION POSITION SWITCH

HARNESS CONNECTOR
2
MS 11588
Figure C18 Transmission Position Switch
CAMSHAFT POSITION SENSOR

The camshaft position sensor is a "Hall-effect"
switch, located on the front top of the engine. It is
supplied ignition voltage and has its own ground. The
camshaft position sensor sends a signal to the ECM
when the #1 cylinder is on the intake stroke. This
signal is used by the ECM to synchronize Sequential
Fuel Injection (SFI) mode of operation with the intake
valve opening. If the camshaft position sensor signal
is not received by the ECM, the ECM will still operate
in SFI mode based on the reference signal, however,
SFI mode timing may not be as accurate because the
ECM does not know the exact time the intake valve is
opening. A slightly rough idle would result. A loss of
this signal or extra cam signals, above 500 RPM, to the
ECM will set a OTC 17.
KNOCK SENSOR
2
BOLT/SCREW
NS 15845
Figure C1-9 Low Resolution 3X Crankshaft Position

Sensor

The 24X crankshaft sensor is used to improve idle
spark control at engine speeds up to approximately
2000 RPM. Refer to "Electronic Ignition (EI) System,"
Section "6E3-C4" for further information.
DIAGNOSIS
To read Diagnostic Trouble Code(s) [DTC(s)], use a
Tech 1 scan tool. To clear the DTC(s) from memory:
t
Ignition "OFF."
Disconnect 1/P Fuse #4 for 30 seconds or use
the Tech 1 scan tool to clear DTC(s) function.
Since the ECM can have a failure which may affect
only one circuit, following the diagnostic procedures in
this section will determine which circuit has a problem
and where it is.
BOLT (1) TORQUE 10 Nm (8 lb. ft.)
NS 15091
Figure C110 Camshaft Position Sensor
If a diagnostic chart indicates that the ECM

connections or ECM is the cause of a problem and the
ECM is replaced, the Knock Sensor (KS) module must
be transferred to the new ECM and the new ECM must
then be programmed. If this does not correct the
problem, one of the following may be the reason:
There is a problem with the ECM terminal
connections. - The diagnostic chart will say
ECM connections or ECM. The terminals may
have to be removed from the connector in order
to check them properly.
The problem is intermittent. - This means that

the problem is not present at the time the
system is being checked. In this case, refer to
the "Symptoms," Section "6E3-B" portion of
the manual and make a careful physical
inspection of all portions of the system
involved.
Shorted solenoid. relay coil, or harness. Solenoids and relays are turned "ON" and
"OFF" by the ECM using internal electronic
switches called "drivers." Each driver is part
of a group of four called "quad-drivers."
Failure of one driver can damage any other
driver in the set.
A shorted solenoid, relay coil, or computer
harness will not damage the ECM but will cause
the component to be inoperative.
J 34636 or BT-8405 testers or equivalent
provide a fast, accurate means of checking for a
shorted coil or a short to battery voltage.
ECM INPUTS
All of the sensors and input switches can be
diagnosed by the use of a Tech 1 scan tool. The
following is a short description of how the sensors and
switches can be diagnosed by the use of a Tech 1 scan
tool. The Tech 1 scan tool can also be used to compare
the values for a normal running engine with the
engine you're diagnosing.

A Tech 1 scan tool displays engine temperature in
degrees centigrade. After the engine is started, the
temperature should rise steadily to about 90C (194F)
then stabilize when the thermostat opens. If the
engine has not been run for several hours (overnight)
the engine coolant and intake air temperatures should
be within 5 of each other. A fault in the ECT sensor
circuit should set a DTC 14 or DTC 15. The Diagnostic
Trouble Code (DTC) charts also contain a "Diagnostic
Aid" chart to check for sensor resistance values
relative to temperature.

A Tech 1 scan tool displays temperature of the air
air temperature when the engine is cold, and rise as
underhood temperature increases. If the engine has
not been run for several hours (overnight) the IAT
temperature and engine coolant temperature should
read close to each other. A failure in the IAT sensor
circuit should set a DTC 23 or 25. The DTC charts also
contain a chart to check for sensor resistance values

A Tech 1 scan tool displays manifold pressure in
volts. Low pressure (high vacuum) reads a low voltage
while a high pressure (low vacuum) reads a high
voltage. A failure in the MAP sensor circuit should set
a DTC 33 or 34 and using the chart will find the cause
of the problem. A DTC 33 may be set if a rough or
unstable idle exists. CHART C-lD can also be used to
check MAP sensor.
Oxygen Sensor ( 025)

The Tech 1 scan tool has several positions that will
indicate the state of the exhaust gases, Oxygen Sensor
(028) right (Bank 1) and 028 left (Bank 2) voltages,
short term fuel trim Bank 1 and 2 and long term fuel
trim Bank 1 and 2. Refer to Tech 1 scan tool position
information in "Introduction," in SECTION 6E.
A problem in the Oxygen Sensor (02S) circuits, or
fuel system, should set a DTC 13 or 63 (open circuit),
DTC 44, 64 (lean indication), DTC 45, 65 (rich
indication). Refer to applicable chart if any of these
DTC(s) were stored in memory.

A Tech 1 scan tool displays throttle position in
volts. Voltage should increase at a steady rate as
throttle is moved toward WOT.
FRONT ENGINE COVER
24x CRANKSHAFT POSITION

SENSOR ASSEMBLY
BOLT(2) TORQUE 10 Nm (8 lb. ft.)
NS 15606
Figure C1-11 - High Resolution 24X Crankshaft Position Sensor
DRIVEABILITY AND EMISSIONS 3.4L {L32) {VIN S) {SFI) 6E3-C1-9

The ECM has the ability to auto-zero the TP sensor
voltage if it is between .29 volt (290 mV) and .98 volt
(980 mV). This means that any voltage between .29
and .98 volt will be determined by the ECM to be 0%
throttle. Tech 1 scan tools have the ability to read the
throttle angle and should display 0% when the throttle
is closed. A failure in the TP sensor or circuit should
set a DTC 21 or 22.
vss

The Tech 1 scan tool will display camshaft position
sensor data as "IGN Control Cam Signal." As the
sensor pulses the scan data will switch from O to 1. All
camshaft position sensor data should be checked at
idle. An error in the camshaft position sensor circuit
should set a OTC 17 and using the chart will find the
cause of the error.
A Tech 1 scan tool reading should closely match

with speedometer reading with drive wheels turning.
A failure in the VSS circuit should set a OTC 24.
PNPSwitch
A Tech 1 scan tool should read P-N when in park or
neutral, and R-0, L, when in drive or overdrive. This
display may vary with different makes of tools. Refer
to CHART C-lA for PNP switch diagnosis.
The Tech 1 scan tool will display 24X crankshaft

position sensor data as "IGN Control 24X Signal."
Data will be displayed in RPM. An error in the 24X
sensor circuit should set a DTC 36.
ON-VEHICLE SERVICE
ENGINE CONTROL MODULE {ECM)
Service of the ECM should normally consist of
either replacement of the ECM or reprogramming of
theEEPROM.
Crankshaft Position Sensor

The Tech 1 scan tool displays crankshaft position
sensor data as "IGN Control 3X Signal." A failure in
this circuit should set a DTC 82.
- --==--~
NS 15648
Figure C1-12 ECM Mounting
rn
rn
Data Link Connector (DLC), formerly ALDL,

must be secure.
2. Refer to up-to-date Techline terminal/equipment
user's instructions.
3. If ECM fails to program, do the following:
Check all ECM connections.
Check Techline terminal/equipment for latest
software version.
Try again to program the ECM. If it fails
again, replace the ECM. Replacement ECM
must be programmed.
4. If vehicle is equipped with an aftermarket antitheft system, it may require a reset procedure.
Refer to appropriate service manual/section.
Important
When replacing the production ECM with a
service ECM (controller), it is important to
transfer the broadcast code and production ECM
number to the service ECM label. Please do not
record on ECM cover. This will allow positive
identification ofECM parts throughout the service
life of the vehicle.
Important
. . .
To prevent internal ECM damage, the 1gmt10n
must be "OFF" when disconnecting or
reconnecting power to ECM (for example, battery
cable, ECM pigtail, ECM fuse,jumper cables, etc.).
ECM AND COMPONENTS REPLACEMENT
Functional Check
Use Techline terminal/equipment to perform the

"On-Board Diagnostic (OBD) System Check,"
Refer to "On-Board Diagnostic (OBD) System

Check," in "Engine Components/Wiring
Diagrams/Diagnostic Charts," Section "6E3-A" in
this service manual.
ECM
OR

circuit board.

1.
2.
3.
4.
5.
6.

ECM mounting hardware.
Connectors from ECM.
ECM from engine compartment.
ECM access cover.
Knock Sensor (KS) module.
rn
Important
The Knock Sensor (KS) module must be
transferred to the replacement ECM.
The replacement ECM is supplied without a
EEPROM program, the replacement ECM
must be programmed before the vehicle will
run.
IF ECM IS BEING REPLACED

1.
2.
New ECM from its packaging and check the

service number to make sure it is the same as the
defective ECM.
Access cover.
EEPROM PROGRAMMING
1.
Set-up:
Battery is charged.
Ignition is "ON."
Battery/cig. lighter connection secure.

1.
2.
3.
4.
5.
Knock Sensor (KS) module.

Access cover on ECM.
Connectors to ECM.
ECM located under hood.

SENSOR
Figure C1-13
NOTICE: Care must be taken when handling
sensor. Damage to sensor will affect proper
operation of the fuel injection system.

1. Relieve coolant pressure.
4. Carefully back out engine coolant temperature
sensor.

Coat threads (only) with sealer PIN 9985253 or
equivalent torque to 13 Nm (10 lb. ft.).
2. Sensor in engine. Locking tab on sensor assembly
must be located within area shown in Figure
Cl-13.
5. Refill lost coolant.
1.
EXHAUST OXYGEN SENSOR (025)
4-2-92
* 4S0078-6E
Figure C1-14- Oxygen Sensor (02S)
other contaminants. Also, avoid using cleaning

solvents of any type. Do not drop or roughly
handle the Oxygen Sensor (028).
2
NS 13751
Figure C1-13- Engine Coolant Temperature Sensor
INTAKE AIR TEMPERATURE {IAT) SENSOR

The IAT sensor is located in the rear air intake
duct.

1.
2.
3.
Electrical connecter.
Clamp.
Sensors.

1. Sensor.
2. Clamps.
OXYGEN SENSOR (025)
Figure C1-14
NOTICE: The Oxygen Sensors (028) use a
permanently attached pigtail and connector. This
pigtail should not be removed from the oxygen
sensor. Damage or removal of the pigtail or
connector could affect proper operation of the
oxygen sensor.
rn
Important
Take care when handling the Oxygen Sensor

(02S). The in-line electrical connector and
louvered end must be kept free of grease, dirt or
The oxygen sensors may be difficult to remove

when engine coolant temperature is below 48C
(120F).
Excessive force may damage threads in exhaust
manifold or exhaust pipe.
3. Carefully back out Oxygen Sensor (028) using tool
J 29533A/BT-8127.
rn
Important
A special anti-seize compound is used on the

Oxygen Sensor (028) 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 already have the

compound applied to the threads. If a sensor is
removed from an engine and if for any reason it is to be
reinstalled, the threads must have anti-seize
compound applied before reinstallation.
1. Coat threads of Oxygen Sensor (028) with antiseize compound PIN 5613695, or equivalent if
necessary.
2. Sensor, and torque to 41 Nm (30 lb. ft.).
MAP SENSOR CONNECTOR
MAP SENSOR
EGR CONNECTOR
OXYGEN SENSOR (025) PIGTAIL
NS 15649
Figure C1-15- MAP Sensor Service
MANIFOLD ABSOLUTE PRESSURE (MAP)

SENSOR
Figure C1-15

1.
2.
3.
4.
5.

MAP sensor electrical connector.
MAP sensor bolts/screws (2).
Inlet vacuum hose.
MAP sensor. Refer to Figure Cl-15.

MAP sensor to intake plenum. Refer to Figure
Cl-15.
3. Inlet vacuum hose.
1.
THROTTLE POSITION (TP) SENSOR

1. TP sensor electrical connector.
2. Remove TP sensor attaching screws and retainers.
3. Sensor.

With throttle valve in the normal closed idle
position, install throttle position sensor on throttle
body assembly (refer to Figure Cl-16).
2. Two TP sensor screws. Tighten to 2.0 N m (18.0
lb. in.).
3. TP sensor electrical connector.
1.
vss
Refer to SECTION 7 for transmission mounted
VSS.
PARK/NEUTRAL POSITION (PNP) SWITCH

Refer to "On-Vehicle Service," in SECTION 7A for
Park/Neutral Position (PNP) switch. "On-Vehicle
Service" and "Adjustment Procedures" are also listed
there.
SENSOR THROTTLE POSITION (TP)

2
SCREW ASSEMBLY TP SENSOR ATTACHING
9P 1074-AS
Figure C1-16 - Throttle Position (TP) Sensor Service
TRANSMISSION
POSITION SWITCH
{LOCATED IN CONSOLE)
ECM
................. -
.
:
ffe
De L
[!]---
. 0--
434 ORN/BLK
450 BLK/WHT
12V
-i
PNPSIGNAL
~
:

PARK/NEUTRAi:
POSITION {PNP)
SWITCH
CIRCUIT TO GROUND IN
PARK AND NEUTRAL
11-12-92
NS 15650
CHARTC-1A
PARK/NEUTRAL POSITION (PNP) SWITCH DIAGNOSIS
The Park/Neutral Position (PNP) switch contacts are a part of the transmission position switch and are closed
to ground in park or neutral, and open in drive ranges.
The ECM supplies ignition voltage through a current limiting resistor to CKT 434 and senses a closed switch
when the voltage on CKT 434 drops to less than 1 volt.
The ECM uses the PNP switch signal as one of the inputs to control:
Idle Air Control (!AC).
Vehicle Speed Sensor (VSS) diagnostics.
EGR.
IfCKT 434 indicates PNP switch is grounded while in a drive range, the EGR would be inoperative, resulting
in possible detonation.
If CKT 434 indicates drive (open), when the vehicle is actually in park or neutral, a dip in the idle may exist
when the gear selector is moved into a drive range.
1. Checks for a closed switch to ground in park
position. Different makes of scan tools will read
park/neutral position switch input differently.
Refer to tool operator's manual for type of display
used for a specific tool.
2.
3.
Checks for an open switch in drive range.

Be sure Tech 1 scan tool indicates drive even while
wiggling the shifter, to test for an intermittent or
misadjusted switch in drive or overdrive range.
DRIVEABILITY AND EMISSIONS 3.4L (VIN S) (SFI) 6E3-C1-15
CHARTC-1A
G)
(!)
WITH TRANSMISSION IN PARK,

INDICATE PARK OR NEUTRAL.
DOES IT?
SHIFT TRANSMISSION INTO DRIVE.

TECH 1 SCAN TOOL SHOULD DISPLAY A
CHANGE TO INDICATE DRIVE.
DOES IT?
DISCONNECT
TRANSMISSION POSITION
SWITCH HARNESS
CONNECTOR.
THIS SHOULD CAUSE SCAN
TOOL TO DISPLAY DRIVE
RANGE.
DOESIT?
FAULTY CONNECTION
OR
SWITCH MISADJUSTED
OR
FAUL TY SWITCH.
NO TROUBLE FOUND.
REFER TO
"INTERMITTENTS" IN
"SYMPTOMS,"
SECTION "B".
CKT 434 SHORTED

TO GROUND
OR
FAULTY ECM.
DISCONNECT TRANSMISSION POSITION SWITCH HARNESS

CONNECTOR.
JUMPER HARNESS CONNECTOR TERMINALS "A" AND "B".
SCAN TOOL SHOULD INDICATE PARK OR NEUTRAL.
DOESIT?
JUMPER HARNESS
CONN ECTOR {CKT 434)
TO ENGINE GROUND.
TECH 1 SCAN TOOL
SHOULD INDICATE
PARK OR NEUTRAL.
DOES IT?
FAUL TY SWITCH
CONNECTION
OR
SWITCH MISADJUSTED
OR
FAULTY SWITCH.
CKT4340PEN
OR
OR
ECM.
"AFTER REPAIRS," CONFIRM "'CLOSED LOOP" OPERATION AND NO MIL {SERVICE ENGINE SOON).
11-12-92
NS 16219
ECM
MANIFOLD ABSOLUTE
MANIFOLD
TO A/C EVAPO RA TOR

TEMPERATURE SENSOR
SENSOR GROUND
ABSOLUTE ---.._
PRESSURE-------""""
(VACUUM)
5 VOLT
REFERENCE
..., 111111 ~ -
TO A/C EVAPORATOR
TEMPERATURE SENSOR
9-8-92
NS 15613
CHARTC-10
MANIFOLD ABSOLUTE PRESSURE (MAP) OUTPUT CHECK
The Manifold Absolute Pressure (MAP) sensor measures the changes in the intake manifold pressure which
result from engine load (intake manifold vacuum) and RPM changes and converts these into a voltage output.
The ECM sends a 5 volt reference voltage to the MAP sensor. As the manifold pressure changes, the output
voltage of the sensor also changes. By monitoring the sensor output voltage, the ECM calculates the manifold
pressure. A lower pressure (low voltage) will be 1-2 volts at idle, while higher pressure (high voltage) output
voltage will be 4-4.8 volts at Wide Open Throttle (WOT). The MAP sensor is also used under certain conditions,
to measure barometric pressure, allowing the ECM to make adjustments for different altitudes. The ECM uses
the MAP sensor to control fuel delivery and ignition timing.
rn
Important
Be sure to use the same Diagnostic Test
Equipment for all measurements.
When comparing Tech 1 scan tool readings to a

known good vehicle, it is important to compare
vehicles that use a MAP sensor having the same
color insert or having the same "Hot Stamped"
number.
2. Applying 34 kPa (10 inch Hg) vacuum to the MAP
sensor should cause the voltage to be 1. 5 to 2.1
volts less than the voltage at Step 1. Upon
applying vacuum to the sensor, the change in
voltage should be instantaneous. A slow voltage
change indicates a faulty sensor.
1.
3. Check vacuum hose to sensor for leaking or

restriction. Be sure no other vacuum devices are
connected to the MAP sensor vacuum hose.
NOTICE: Make sure electrical connector

remains securely fastened.
4.

connection. Output changes greater than .1 volt
indicates a bad sensor.
CHART C-10
NOTICE: THIS CHART ONLY APPLIES TO MAP SENSORS

HAVING GREEN OR BLACK COLOR KEY INSERT (SEE BELOW}.
IF OTC 33 OR 34 IS SET, USE THOSE CHARTS FIRST.
IGNITION "'ON," ENGINE "OFF."
SCAN TOOL SHOULD INDICATE A MAP SENSOR VOLTAGE.
. COMPARE THIS READING WITH THE READING OF A KNOWN GOOD VEHICLE.
SEE FACING PAGE TEST DESCRIPTION, STEP 1.
VOLTAGE READING SHOULD BE WITHIN :t .4 VOLT.
ISIT?
DISCONNECT AND PLUG VACUUM SOURCE TO MAP SENSOR.

CONNECT A HAND VACUUM PUMP TO MAP SENSOR.
START ENGINE.
NOTE MAP SENSOR VOLTAGE.
APPLY 34kPa (10" Hg)OFVACUUM AND NOTE VOLTAGE CHANGE.
SUBTRACT SECOND READING FROM THE FIRST. VOLTAGE VALUE
SHOULD BE GREATER THAN 1.5 VOL TS.
ISIT?
NO TROUBLE FOUND. CHECK MAP SENSOR VACUUM

SOURCE FOR LEAKAGE OR RESTRICTION. BE SURE THIS
SOURCE SUPPLIES VACUUM TO MAP SENSOR ONLY.
CHECK MAP SENSOR CONNECTION.

IF OK, REPLACE MAP SENSOR.
HOT-STAMPED
NUMBER
LS 8963-6E
Figure 1 Coor Key Insert
LS 9045-6E
Figure 2 Hot Stamped Number
"AFTER REPAIRS,"' CONFIRM "'CLOSED LOOP" OPERATION AND NO MIL (SERVICE ENGINE SOON).
3-10-92
75 3162-6E
BLANK
SECTION C2
FUEL METERING SYSTEM

CONTENTS
General Description
Purpose
Modes of Operation
Starting Mode
Clear Flood Mode
Run Mode
Acceleration Mode
Fuel Cut-off Mode
Deceleration Mode
Catalytic Converter Protection
Mode
Battery Voltage Correction Mode
Fuel Metering System Components
Fuel Supply Components
Fuel Pump Electrical Circuit
Fuel Rail Assembly
Fuel Injector
Fuel Pressure Regulator Assembly
Throttle Body Assembly
. . . .. . . . . . . .
. . .. . . . . . . . .
C2-1
C2-1
C2-1
C2-1
C2-1
C2-2
C2-2
C2-2
C2-2
C2-2
C2-2
C2-2
C2-2
C2-2
C2-3
C2-3
C2-3
C2-4
GENERAL DESCRIPTION
PURPOSE
The function of the fuel metering system is to
deliver the correct amount of fuel to the engine under
all operating conditions.
Fuel is delivered to the engine by individual fuel
injectors mounted in the intake manifold near each
cylinder.
The main control sensor is the Oxygen Sensor
(02S), located in the exhaust manifold. The 02S tells
the Engine Control Module (ECM) how much oxygen
is in the exhaust gas, and the ECM changes the
air/fuel ratio to the engine by controlling the fuel
injectors. The best mixture to minimize exhaust
emissions is 14.7:1, which allows the Three-Way
Catalytic Converter (TWC) to operate most efficiently.
Because of the constant measuring and adjusting of
the air/fuel ratio, the fuel injection system is called a
"Closed Loop" system.
MODES OF OPERATION
The ECM monitors information from several
sensors to determine how much fuel to give the engine.
The fuel is delivered under one of several conditions
called modes. All the modes are controlled by the ECM
and are described below.
Idle Air Control (IAC) Valve

Assembly
Diagnosis
Fuel Pump Relay
On-Vehicle Service
Fuel Pump Relay
Port Fuel Injection Components
Fuel Pressure Relief Procedure
EngineFuelPipes
Fuel Rail Assembly
Fuel Pressure Connection
Fuel Injectors
Pressure Regulator Assembly

Throttle Body Replacement
C2-4
C2-5
C2-5
C2-5
C2-5
C2-6
C2-6
C2-6
C2-6
C2-6
C2-9
C2-10
C2-10
C2-11
C2-11
C2-12
C2-12
C2-14
C2-14
Starting Mode
When the ignition switch is turned to the "ON"
position (before engaging starter), the ECM energizes
the fuel pump relay for two seconds allowing the fuel
pump to build up pressure. 'l'he ECM then checks the
Engine Coolant Temperature (ECT) and Throttle
Position (TP) sensors and determines the proper
air/fuel ratio for starting. This ranges from 1.5: 1 at
-36C (-33F) to 14.7:1 at 94C (201F) running
temperature. The ECM controls the amount of fuel
delivered in the starting mode by changing how long
the injectors are energized. This is done by pulsing the
injectors for very shor times.
Clear Flood Mode

If the engine floods, it can be cleared by pushing
the accelerator pedal down all the way. The ECM
enables the clear flood mode and temporarily suspends
fuel delivery. The ECM maintains the clear flood
mode as long as the throttle stays wide open, and the
engine speed remains below 600 RPM. If the throttle
position becomes less than 62%, the ECM returns to
the starting mode.

Run Mode
Catalytic Converter Protection Mode
The run mode has two conditions called "Open

Loop" and "Closed Loop."
When the engine is first started and engine speed
is above 400 RPM, the system goes into "Open Loop"
operation. The ECM ignores the signal from the 028
and calculates the air/fuel ratio based on inputs from
the Engine Coolant Temperature (ECT) and Intake
Air Temperature (IAT) sensors.
The system stays in "Open Loop" until the
following conditions are met:
1. The 028 has varying voltage output, showing
that it is hot enough to operate properly. (This
depends on temperature.)
2. The ECT sensor is above a specified
temperature.
3. A specific amount of time has elapsed after
starting the engine.
The specific values for the above conditions vary
with different engines, and are stored in the
Programmable Read Only Memory (PROM) portion of
the ECM. When these values are met, the system goes
into "Closed Loop" operation. In "Closed Loop," the
ECM calculates the air/fuel ratio (injector on-time)
based on the signal from the 028. This allows the
air/fuel ratio to stay very close to 14.7:1.
The ECM constantly monitors engine operation,

and estimates conditions that could result in high
catalytic converter temperatures. If the ECM
determines the converter may overheat, it causes the
system to return to "Open Loop" operation and
enriches the fuel mixture.
Acceleration Mode
When the driver pushes on the accelerator pedal,
air flow into the cylinders increases rapidly, while fuel
flow tends to lag behind. To prevent possible
hesitation, the ECM increases the pulse width to the
injectors to provide extra fuel during acceleration. The
amount of fuel required is based on throttle position,
manifold air pressure, and engine speed.
Fuel Cut-off Mode

To prevent possible engine damage from overspeed, the ECM cuts-off fuel from the injectors when
engine speed is above 6000 RPM with the vehicle in
any forward gear position, or in reverse. The ECM
also cuts-off fuel to the injectors at vehicle speeds
above 108 mph to prevent tire damage.

When battery voltage is low, the ECM can
compensate for the weak spark by:
Increasing the amount offuel delivered.
Increasing the idle RPM.
Increasing ignition dwell time.

COMPONENTS
The fuel metering system consists of the following
parts:
Fuel supply components (fuel tank, pump,
lines).
Fuel pump electrical circuit .
Fuel rail assembly, including:
Fuel injectors.
Fuel pressure regulator.
Throttle body assembly, including:
Idle Air Control (IAC) valve.
Throttle Position (TP) sensor.
FUEL SUPPLY COMPONENTS

electric fuel pump, located in the fuel tank with the
gage sending unit, pumps fuel through an in-line fuel
filter to the fuel rail assembly. The pump is designed
to provide fuel at a pressure greater than is needed by
the injectors. The pressure regulator, part of the fuel
rail assembly, keeps fuel available to the injectors at a
regulated pressure. Unused fuel is returned to the fuel
tank by a separate line. (For further information see
SECTION 6C for replacement procedures covering the
fuel tank, fuel pump, in-line filter and fuel lines.)
Deceleration Mode
FUEL PUMP ELECTRICAL CIRCUIT
When the driver releases the accelerator pedal, air

flow into the engine is reduced. The corresponding
changes in throttle position and manifold air pressure
are relayed to the ECM, which reduces the injector
pulse width to reduce fuel flow. If the deceleration is
very rapid, or for long periods (such as long closed
throttle coast-down), the ECM shuts "OFF" fuel
completely to protect the catalytic converter.

the fuel pump relay for two seconds, causing the fuel
pump to pressurize the fuel system. If the ECM does
not receive ignition reference pulses (engine cranking
or running) within two seconds, it de-energizes the fuel
pump relay, causing the fuel pump to stop. If the fuel
pump relay fails, Diagnostic Trouble Code (DTC) 54 is
set in the ECM.
RETAINER - FUEL TUBE

2
INJECTOR ASSEMBLY - MFI FUEL
CONNECTION ASSEMBLY - FUEL PRESSURE
REGULATOR ASSEMBLY - FUEL PRESSURE
NA 1320-AS
SOLENOID ASSEMBLY
HOUSING - SPRAY
SPACER AND GUIDE

ASSEMBLY
SPRING - CORE
CORE SEAT
HOUSING SOLENOID
VALVE BALL
10
SOLENOID
SPRAY TIP
11
FILTER - FUEL INLET
PLATE - DIRECTOR
Figure C2-1 - Fuel Rail Assembly
FUEL RAIL ASSEMBLY

Figure C2-1
The fuel rail assembly, mounted in the engine
intake manifold, performs several functions. It
positions the injectors in the intake manifold,
distributes fuel evenly to the injectors, and integrates
the fuel pressure regulator into the fuel metering
system. The fuel rail also provides a threaded fitting
for connecting a pressure gage.
Fuel Injector
Figure C2-2
A fuel injector is a solenoid operated device,
controlled by the ECM, that meters pressurized fuel to
a single engine cylinder. The ECM energizes the
injector solenoid, which opens a ball valve, allowing
fuel to flow past the ball valve, and through a recessed
flow director plate. The director plate has six
machined holes that control the fuel flow, generating a
conical spray pattern of finely atomized fuel at the
injector tip. Fuel is directed at the intake valve,
causing it to become further atomized and vaporized
before entering the combustion chamber.
An injector that is stuck partly open would cause
loss of pressure after engine shut down. Consequently,
long cranking times would be noticed on some engines.
Dieseling also could occur because some fuel could be
9P0413-SY
Figure C2-2 - MFI Injector Assembly Cross-Sectional

View
delivered to the engine after the ignition is turned

"OFF."

Figure C2-3
The fuel pressure regulator is a diaphragmoperated relief valve with fuel pump pressure on one
side, and regulator spring pressure and intake
manifold vacuum on the other. The regulator's
function is to maintain a constant pressure differential
across the fuel injectors at all times. The pressure
regulator compensates for engine load by increasing
fuel pressure as engine vacuum drops.
With the ignition "ON" and engine "OFF" (zero
vacuum), fuel pressure at the pressure test connection
should be 284-325 kPa (41-47 psi). If the pressure is
too low, poor performance could result. If the pressure
is too high, excessive odor and a DTC 45 may result.
CHART A-7 has information on diagnosing fuel
pressure conditions.
6E3-C2-4 3.4L {L32) {VIN S) {SFI) DRIVEABILITY AND EMISSIONS
8
3
4
COVER ASSEMBLY
2
SPRING
RAIL ASSEMBLY - MFI FUEL
DIAPHRAGM
FUEL RETURN
SEAT
LEVER ASSEMBLY - THROTTLE
VALVE
TUBES - COOLANT
CONNECTION-VACUUM
RETAINER- SPRING
VALVE ASSEMBLY - IDLE AIR CONTROL (IAC)
3
BODY ASSEMBLY - THROTTLE
8P0968-AS
Figure C2-3 - Pressure Regulator Assembly
THROTTLE BODY ASSEMBLY
Figure C2-4
The throttle body assembly is attached to the
intake manifold air plenum, and is used to control air
flow into the engine, thereby controlling engine
output. The throttle valve within the throttle body is
opened by the driver through the accelerator controls.
During engine idle, the throttle valve is almost closed,
and air flow control is handled by the Idle Air Control
(IAC) valve, described below. To prevent throttle
valve icing during cool weather operation, engine
coolant is directed through the coolant cavity, on the
bottom of the throttle body.
The throttle body also provides the location for
mounting the TP sensor, for sensing changes in engine
vacuum due to throttle valve position. Vacuum ports
are located at, above, or below the throttle valve to
generate vacuum signals needed by various
components.
Idle Air Control {IAC) Valve Assembly

Figure C2-5
The purpose of the IAC valve assembly is to control
engine idle speed, while preventing stalls due to
changes in engine load.
The IAC valve, mounted in the throttle body,
controls bypass air around the throttle valve. By
moving a conical valve known as a pintle, IN toward
NA 1321-AS
Figure C2-4 Throttle Body Assembly
the seat (to decrease air flow); or OUT away from the
seat (to increase airflow), a controlled amount of air
moves around the throttle plate.
If engine speed is too low, more air is bypassed
around the throttle valve to increase RPM. If engine
speed is too high, less air is bypassed around the
throttle valve to decrease RPM.
The ECM moves the IAC valve in small steps,
called counts. These counts can be displayed on a scan
tool which plugs into the Data Link Connector (DLC).
During idle, the proper position of the IAC valve is
calculated by the ECM, based on battery voltage,
coolant temperature, engine load, and engine RPM. If
the RPM drops below specification and the throttle
valve is closed, the ECM senses a near stall condition
and calculates a new valve position to prevent stalling.
If the IAC valve is disconnected and reconnected
while the engine is running, the resulting idle RPM
may be wrong and resetting of the IAC valve will be
required.
After running the engine, the IAC valve resets
when the ignition is turned "OFF." When servicing
the IAC valve, it should only be disconnected or
connected with the ignition "OFF."
If the ECM is without battery power for any
reason, the programmed position of the IAC valve
pintle is lost, and is replaced with a default value.
Different shaped pintles are used for different IAC
valve applications.
DRIVEABILITY AND EMISSIONS 3.4l (L32) (VIN S) (SFI) 6E3-C2-5

For diagnosis of the fuel pump relay circuit, refer to
the Diagnostic Trouble Code (DTC) 54 chart.

2
VALVE-THROTTLE
PINTLE - IAC VALVE
ELECTRICAL INPUT SIGNAL
AIRINLET
NA0494-SY
Figure C2-5- IAC Valve Air Flow Diagram {Typical)
Be sure to use the correct part number, with the

correct pintle shape and diameter, when replacement
is required.
The IAC valve affects only the idle characteristics
of the vehicle. If it is fully retracted, too much air will
be allowed i~to the manifold and idle speed will be
high. If it is stuck closed, too little air will be allowed
in the manifold, and idle speed will be too low. If it is
stuck part way open, the idle may be rough, and will
not respond to engine load changes. A DTC 35 should
set ifa controlled idle cannot be maintained.

The nonadjustable TP sensor is mounted on the
side of the throttle body opposite the throttle lever. It
senses the throttle valve angle and relays that
information to the ECM. Knowledge of throttle angle
is needed by the ECM to generate the required injector
control signals (pulses). For further information, refer
to "Engine Control Module (ECM) and Sensors,"
Section "6E3-Cl".
DIAGNOSIS
FUEL PUMP RELAY
The fuel pump relay is mounted behind the driver
side kick panel/dead pedal (driver side left foot rest).
See illustration in "On-Vehicle Service."
Some failures of this system will result in an

"Engine Cranks But Won't Run Symptom." If this
condition exists, see CHART A-3. This chart will
determine if the problem is caused by the ignition
system, ECM, or fuel pump circuit. If it's determined
to be a fuel problem, CHART A-7 will be used. This
includes the injectors, pressure regulator, fuel pump,
and fuel pump relay.
If a problem occurs in the fuel metering system, it
usually results in either a rich or lean 028 signal.
This condition is sensed by the 028 and causes the
ECM to change the fuel calculation (injector pulse
width). The change made to the fuel calculation is
indicated by a change in the short and long term fuel
trim values which can be monitored with a scan tool.
A momentary change to the fuel calculation is
indicated by the short term fuel trim value, while a
prolonged change is indicated by the long term fuel
trim value. Average fuel trim values will be around
128, but will vary slightly from engine to engine.
rn
Important
When using a scan tool to observe fuel trim values,

remember that if the system is in control, no action
is required unless a driveability symptom is
present.
Listed below are examples of lean and ri~h 028

signals with the system in control and out of control.
A momentary lean 028 signal (system is in
control) will appear on the scan tool as:
Short term fuel trim value above 128 (adding
fuel).
Long term fuel trim value around 128.
A prolonged lean 028 signal (system is in control)
will appear on the scan tool as:
Short term fuel trim value around 128.
Long term fuel trim value above 128 (added
fuel).
A prolonged lean 028 signal (system is out of
Short term fuel trim value well above 128
(adding fuel).
Long term fuel trim value well above 128
(added fuel).
If both the short and long term fuel trim values are
fixed well above 128, see DTC 44 for items which can
cause a lean 028 signal.
A momentary rich 028 signal (system is in

Short term fuel trim value less than 128
(reducing fuel).

3.
Driver side kick panel/dead pedal (driver side left

foot rest).
4. Fuel pump relay from electrical connector.

1. Fuel pump relay.
2. Driver side kick panel/dead pedal (driver side left
foot rest).
3. Ignition "OFF."
PORT FUEL INJECTION COMPONENTS

CAUTION:
To reduce the risk of fire and
personal injury, relieve the fuel system
pressure before servicing fuel system
components.
small amount of fuel may be released
when servicing fuel lines or
connections. To reduce the chance of
personal injury, cover fuel line fittings
with a shop towel before disconnecting, to catch any fuel that may
leak out. Place the towel in an
approved container when disconnect
is completed.
LEFT DOOR JAM ("A" PILLAR)

2
DEAD PEDAL BRACKET
FUEL PUMP RELAY

NS 15279
Figure C2-6 - Fuel Pump Relay
A prolonged rich 028 signal (system is in control)

Long term fuel trim value less than 128
(reduced fuel).
A prolonged rich 028 signal (system is out of
control)
appear on the scan tool as:
Short term fuel trim value much less than 128
(reducing fuel).
Long term fuel trim value much less than 128
(reduced fuel).
If both the short and long term fuel trim values are
fixed well below 128, see OTC 45 for items which can
cause the system to run rich. If a driveability
symptom exists, refer to the particular symptom in the
"Symptoms," Section "6E3-B" for additional items to
check.
will
ON-VEHICLE SERVICE
FUEL PUMP RELAY
Figure C2-6
FUEL PRESSURE RELIEF PROCEDURE

Tool Required:
J 34730-1, Fuel Pressure Gage
1. Ignition "OFF."
2. Disconnect negative battery cable to avoid possible
start the engine.
3. Loosen fuel filler cap to relieve tank vapor
pressure.
4. Connect gage J 34730-1 or equivalent to fuel
pressure valve. Wrap a shop towel around fitting
while connecting gage to a void spillage.
container.
Engine Fuel Pipes

Figure C2-7

l++I Remove or Disconn~ct

1.
2.
Ignition "OFF."
Tools Required:
J 37088-A Fuel Line Release Tool Set

1.
2.
Ignition "OFF. "


3. Relieve fuel system pressure. (Refer to "Fuel
Pressure Re lief Procedure.")
4. Quick-connect fittings at engine fuel pipes.
5. Slide rubber dust covers from quick-connect
fittings at engine fuel pipes.
6. Grasp both sides of fitting. Twist female connector
1/4 turn in each direction to loosen any dirt within
fitting.
CAUTION: Safety glasses must be worn

when using compressed air, as flying dirt
8. Choose correct tool from J 37088-A or J 39504 tool
set for size of fitting. Insert tool into female
connector, then push/pull in ward to re lease
locking tabs.
ILI Clean and Inspect
NOTICE: If it is necessary to remove rust or

burrs from fuel pipe, use emery cloth in a
radial motion with the pipe end to prevent
damage to 0-ring sealing surface.
end.
required.
Engine fuel pipe retaining bolts (2).
Accelerator cable from routing clip.
Fuel tube retainer from fuel rail.
Engine fuel pipes.
0-rings from fuel rail and discard.
10.
11.
12.
13.
14.
BOLT
EVAPORATIVE EMISSION CANISTER PURGE
SOLENOID VALVE
INTAKE PLENUM
BRACE
FUEL RAIL ASSEMBLY
NS 15929
Figure C2-7 - Engine Fuel Pipes

I
1~.,.___2
t---3
I
Lubricate new 0-rings with clean engine oil and

install in fuel rail.
2. Engine fuel pipes to fuel rail.
3. Fuel tube retainer and retainer screw.
Finger tighten only.
4. Engine fuel pipe retaining bolts (2).
1.
l~I Tighten
Fuel tube retainer screw to 5 N m (45 lb. in.).
5. Quick-connect fittings to engine fuel pipes.
6. Apply a few drops of clean engine oil to the male
pipe end of engine fuel pipe, pressure gage adapter
or fuel line shut-off adapter.
7. Push both sides of fitting together to cause the
8. Once installed, pull on l;>oth sides of fitting to make
9. Slide dust covers over quick-connect fittings.
INJECTOR WIRING HARNESS

2
NUT
BOLT
FUEL RAIL
INTAKE PLENUM
STUD
Figure C2-8- Fuel Rail Removal
10. Accelerator cable into routing clip.

11. Tighten fuel filler cap.
NS 15924
-,--9
df!{"--10
RETAINER - FUEL TUBE
SCREW- FUEL TUBE RETAINER ATTACHING
BACKUP - 0-RING
0-RING - FUEL INLET TUBE
10
0-RING - LOWER INJECTOR (BROWN)
0-RING - FUEL OUTLET TUBE
11
SEAL- FUEL PRESSURE CONNECTION
RAIL ASSEMBLY - MFI FUEL
12
CONNECTION ASSEMBLY - FUEL PRESSURE
0-RING - UPPER INJECTOR (BLACK)
13
CAP - FUEL PRESSURE CONNECTION
CLIP- FUEL INJECTOR RETAINER
10-27-92
NA 0197-XV
Figure C29 Fuel Rail Assembly

12. Ignition "OFF."
IL! Inspect
Turn ignition switch to the "ON" position for two

seconds, then turn to the "OFF" position for ten
seconds. Again turn to the "ON" position and
check for leaks.
FUEL RAIL ASSEMBLY

Figures C2-8 through C2-10
The names of component parts appear in the
numbered list on the disassembled view.
An eight digit identification number is stamped on
the side of the fuel rail. Refer to this number if
servicing or part replacement is required.
IDENTIFICATION NUMBER
I //I / / / /
I
NOTICE:
Use care in removing the fuel rail assembly, to
prevent damage to the injector electrical connector
terminals and the injector spray tips. When
removed, support the rail to avoid damaging its
components.
Prevent dirt and other contaminants from
entering open lines and passages. Fittings should
be capped, and holes plugged, during servicing.
~ Clean
Before removal, the fuel rail assembly may be

cleaned with a spray type engine cleaner following
package instructions. Do Not immerse fuel rail in
liquid cleaning solvent.
!++!
Install or Connect

personal injury that may result from a
fuel leak, always install injector 0-rings in
the proper position. If the upper and
lower 0-rings are different colors {black
and brown), be sure to install the black 0ring in the upper position and the brown
0-ring in the lower position on the
injector. The 0-rings are the same size
but, are made of different materials.
SHIFT IDENTIFICATION
ASSEMBLY PLANT CODE

YEAR
DAY OF YEAR
NOT ALL PRODUCTION INFORMATION MAY BE SHOWN
NA 1319-AS
Figure C2-10 - Fuel Rail Assembly ldentififcation
!Lii'! Inspect
The fuel injector lower 0-ring uses a nylon collar,

called the 0-ring backup, to properly position the
0-ring on the injector. Be sure to reinstall the 0ring backup, or the sealing 0-ring may move on
the injector when installing the fuel rail and result
in a possible vacuum leak and driveability
complaints will occur.
1.
Fuel rail assembly in intake manifold.

Tilt rail assembly to install injectors.
Fuel rail attaching bolts.

1. Ignition "OFF."
Pressure Relief Procedure.")
4. Engine fuel pipes. (Refer to "Engine Fuel Pipes.")
5. Vacuum line harness from fuel rail.
6. Main electrical harness connector at fuel rail.
7. Fuel rail attaching bolts.
8. Fuel rail assembly.
1E-souRCECODE
'-v-' '--y---/
2.
!~J Tighten
Fuel rail attaching bolts to 25 N m (18 lb. ft.).
Engine fuel pipes to fuel rail.
Engine fuel pipes. (Refer to "Engine Fuel Pipes.")
Main electrical harness connector at fuel rail.
Rotate injector(s) as required to avoid
stretching wire harness.
6. Vacuum line harness connector from fuel rail.
8. Ignition "OFF."
3.
4.
5.
ILI Inspect

check for leaks.
FUEL PRESSURE CONNECTION

Figure C2-9
--~OCK . .
~ Clean
. ~~.~---->:
Area around fuel pressure connection with GM

X-30A or equivalent.
1
2
-;ELEASE

CLIP - INJECTOR RETAINER
9P 1063-AS
1. Ignition "OFF."
Pressure Re lief Procedure.")
4. Fuel pressure connection and seal.
Figure C211 MFI Fuel Injector

1. New seal on fuel pressure connection.
2. Fuel pressure connection in fuel rail.
l~I Tighten
Fuel pressure connection to 13 Nm (115 lb.

in.).
4. Ignition "OFF."
ILI Inspect

check for leaks.
FUEL INJECTORS
Figures C2-9, C2-11 and C2-12
NOTICE:
Use care in removing injectors to

prevent damage to the electrical connector pins on
the injector, and the nozzle. The fuel injector is
serviced as a complete assembly only. Since it is
an electrical component, Do Not immerse it in
cleaner.

1. Ignition "OFF."
4. Fuel rail assembly. (Refer to "Fuel Rail
Assembly.")
INJECTOR ASSEMBLY FUEL

A
PART NUMBER IDENTIFICATION
BUILD DATE CODE
MONTH 1-9 (JAN-SEPT) 0, N, D (OCT, NOV, DEC)
DAY
YEAR
MP 1222-AS
Figure C212 - Injector Part Number Location
1+1 Disassemble
1. Rotate injector retainer clip to release position.
2. Fuel injector.
3. Injector 0-ring seals from both ends of injector,
and discard.
4. Discard injector retainer clip.
rn
Important
When ordering new fuel injectors, be sure to order

the correct injector for the application being
serviced.
!+;+! Assemble
personal injury that may result from a
fuel leak, always install injector 0-rings in
the proper position. If the upper and
lower 0-rings are different colors (black
and brown), be sure to install the black 0ring in the upper position and the brown
0-ring in the lower position on t_he
injector. The 0-rings are the same size
but, are made of different materials.
!L! Inspect
1.
2.
3.
4.
The fuel injector lower 0-ring uses a nylon collar,

called the 0-ring backup, to properly position the
0-ring on the injector. Be sure to reinstall the 0ring backup, or the sealing 0-ring may move on
the injector when installing the fuel rail and result
in a possible vacuum leak and driveability
complaints will occur.
Lubricate new injector 0-ring seals with clean
engine oil, and install on injector.
New retainer clip onto injector.
Fuel injector into fuel rail injector socket with
electrical connectors facing outward.
Rotate injector retainer clip to lock position.

3. Ignition "OFF."
!Ll Inspect
The throttle body assembly repair procedures

cover component replacement with the unit on the
vehicle. However, throttle body replacement requires
that the complete unit be removed from the engine.
An eight digit part identification number is
stamped on the side of the throttle body casting. Refer
to this number if servicing, or part replacement is
required. For identification of parts during repair,
refer to the disassembled view.
NOTICE: The TP sensor and IAC valve should

NOT come in contact with solvent or cleaner, as
they may be damaged.
rn
Important
The pressure regulator and fuel rail are serviced as

a complete assembly only. Do not attempt to
remove the regulator cover from the fuel rail.
Clean
The throttle bore and valve deposits may be

cleaned on-vehicle, using carburetor cleaner and a
parts cleaning brush. Do Not use a cleaner that
contains methyl ethyl ketone, an extremely strong
solvent, and not necessary for this type of deposit.
The throttle body metal parts may be cleaned
following disassembly, in a cold immersion-type
cleaner such as GM X-55 or equivalent.

1.
2.
3.
4.
5.
6.
7.
81
9.
10.

check for leaks.
PRESSURE REGULATOR ASSEMBLY

Figures C2-13 through 15
Ignition "OFF."
Partially drain radiator, to allow coolant hoses at
throttle body to be removed.
Air inlet duct at throttle body, and crankcase vent
pipe at valve cover grommet.
TP sensor and IAC valve electrical connectors.
Vacuum harness connector from throttle body.
Throttle, T. V. (transmission control), and cruise
control cables.
Coolant hoses from throttle body.
Throttle body attaching bolts.
Throttle body assembly and flange gasket.
Discard gasket.
NOTICE:
Use care in cleaning old gasket

material from machined aluminum surfaces.
Sharp tools may damage sealing surfaces.
~ Clean
Gasket surface on intake manifold.

1.
2.
Throttle body assembly with new flange gasket.

6E3-C2-12 3.4L (L32} (VIN S} (SFI} DRIVEABILITY AND EMISSIONS

Refer to SECTION 6C, for additional
information on accelerator controls.
5.
6.
Vacuum harness connector.

TP sensor and IAC valve electrical connectors.
7. Air inlet duct to throttle body, and crankcase vent
pipe to valve cover grommet.
8. Refill radiator.
9. Ignition "OFF."
!L'i'! Inspect
NA 1322-AS
Figure C2-13 - Throttle Body Identification
With the engine "OFF," check to see that the

accelerator pedal is free:
Depress pedal to the floor and release.
THROTTLE POSITION (TP} SENSOR

Figure C2-15

1.
2.
3.
TP sensor attaching screws.
TP sensor.
NOTICE: The TP sensor is an c lectrical

component and must not be soaked in any liquid
cleaner or solvent, as damage may result.
L--
1.
2.
~,
With throttle valve closed, position TP sensor on

throttle shaft, then align with screw holes.
TP sensor attaching screws.
I~! Tighten
STUD
2
GASKET
INTAKE PLENUM
THROTTLE BODY
BOLT
3.
IDLE AIR CONTROL (IAC} VALVE

Figures C2-15 and C2-16
I+-+! Remove or Disconnect

NS 15925
Figure C2-14 - Throttle Body Removal
l~I Tighten
3.
4.
Throttle body attaching bolts to 27 Nm (20

lb. ft.).
Coolant hoses to throttle body.
Throttle, T. V., and cruise control cables.
rn
TP sensor attaching screws to 2.0 Nm (18 lb.

in.).
Important
Make sure throttle and cruise control linkage

does not hold throttle open.
1.
2.
3.
IAC valve attaching screws.
IAC valve assembly.
NOTICE: On [AC valves that have ben in

service: Do Not push or pull on the IAC valve
pintle. The force required to move the pintle may
damage the threads on the worm drive. Also, Do
Not soak IAC valve in any liquid cleaner or
solvent, as damage may result.
'<'
---~
9

2
GASKET - FLANGE
0-RING - IAC VALVE
SCREW - IDLE STOP
SCREW-TP SENSOR ATTACHING
SCREW- IA( VLAVE ATTACHING
11-09-92
NA 0198-XV
Figure C2-15 - Throttle Body Assembly

5. Reset IAC valve pintle position:
A. Turn ignition "ON" for five seconds ..
B. Turn ignition "OFF" for ten seconds.
C. Start engine and check for proper idle
operation.
THROTTLE BODY REPLACEMENT
DISTANCE OF PINTLE EXTENSION
DIAMETER OF PINTLE
IACV 0-RING
IACVATTACHING SCREW ASSEMBLY
llI Clean and Inspect
Important
If installing a new IAC valve, be sure to replace

with an identical part. IAC valve pintle shape and
diameter are designed for the specific application.
l@I Measure (If Installing a New IAC Valve)
Distance between tip of IAC valve pintle and

mounting flange.
If greater than 28 mm, use finger pressure to
slowly retract the pintle. The force required to
retract the pintle of a new valve will not cause
damage to the valve.

1.
2.
3.
Lubricate IAC valve 0-ring with clean engine oil.

IAC valve assembly.
Attaching screws.
l~I Tighten
75 3422-6E
Clean IAC valve 0-ring sealing surface, pintle

valve seat and air passage.
Use carburetor cleaner and a parts cleaning
brush to remove carbon deposits. Do Not use a
cleaner that contains methyl ethyl ketone, an
extremely strong solvent, and not necessary
for this type of deposit.
Shiny spots on the pintle or seat are normal,
and do not indicate misalignment or a bent
pintle shaft.
If air passage has heavy deposits, remove
throttle body for complete cleaning.
Inspect IAC valve 0-ring for cuts, cracks or
distortion. Replace if damaged.
rn
(Refer to
llI Inspect
Figure C2-16 Idle Air Control {IAC) Valve
Throttle body from intake plenum.

"Throttle Body Assembly.")
IAC valve attaching screws to 3.4 N m (30 lb.

in.).
Replacement throttle body for items to be

transferred from old unit.
l+t-+I Disassemble
Throttle body removed from engine, following

component repair procedures.
1-+}I Assemble
Replacement throttle body with transferred parts,

following component repair procedures.
Replacement throttle body to intake plenum.

(Refer to "Throttle Body Assembly.")
Fuel Tube Retainer
Fuel Rail Rail Attaching
Bolts
Fuel Pressure Connection
Throttle Body Attaching
Bolts
Throttle Position (TP)
Sensor
Idle Air Control Valve
5 Nm (45 lb. in.)
25 N m (18 lb. ft.)

13 Nm (115 lb. in.)
27 N m (20 lb. ft.)
2 N m (18 lb. in.)

3.4 Nm (30 lb. in.)
BLANK
CHARTC-2A
INJECTOR BALANCE TEST
The injector balance tester is a tool used to turn the injector on for a precise
amount of time, thus spraying a measured amount of fuel into the manifold.
This causes a drop in fuel rail pressure that we can record and compare between
each injector. All injectors should have the same amount of pressure drop ( 10
kPa). Any injector with a pressure drop that is 10 kPa (or more) greater or less
than the average drop of the other injectors should be considered faulty and
replaced.
STEP 1
Engine "cool down" period (10 minutes) is necessary to a void irregular
readings due to "Hot Soak" fuel boiling. With ignition "OFF" connect fuel gauge
J 347301 or equivalent to fuel pressure tap. Wrap a shop towel around fitting
while connecting gage to avoid fuel spillage.
Disconnect harness connectors at all injectors, and connect injector tester
J 34730-3, or equivalent, to one injector. Ignition must he "OFF" at least 10
seconds to complete ECM shutdown cycle. Fuel pump should run about 2 seconds
after ignition is turned "ON". At this point, insert clear tubing attached to vent
valve into a suitable container and bleed air from gauge and hose to insure
accurate gauge operation. Repeat this step until all air is bled from gauge.
STEP2
Turn ignition "OFF" for 10 seconds and then "ON" again to get fuel pressure
to its maximum. Record this initial pressure reading. Energize tester one time
and note pressure drop at its lowest point. (Disregard any slight pressure
increase after drop hits low point.) By subtracting this second pressure reading
from the initial pressure, we have the actual amount of injector pressure drop.
STEP3
Repeat Step 2 on each injector and compare the amount of drop. Usually, good
injectors will have virtually the same drop. Retest any injector that has a
pressure difference of 10 kPa, either more or less than the a vcrage of the other
injectors on the engine. Replace any injector that also fails the retest. [f the
pressure drop of all injectors is within 10 kPa of this average, the injectors
appear to he flowing properly. Reconnect them and review "Symptoms", Section
"6E3-B".
NOTICE:
The entire test should not be repeated more than once without
running the engine to prevent flooding. (This includes any retest on faulty
injectors.)

NOTICE: The entire test should NOT be repeated more
than once without running the engine to prevent
flooding. (This includes any retest on faulty injectors.)
CHARTC-2A
11
The fuel pressure test in Section "A" Chart A-7, should

be completed prior to this test.
Step 1. If engine is at operating temperature, allow a 10 minute "cool down" period then connect fuel
pressure gage and injector tester.
1. Ignition "OFF."
2. Connect fuel pressure gage and injector tester.
3. Ignition "ON."
4. Bleed off air in gage. Repeat until all air is bled from gauge.
Step 2. Run test:
1. Ignition "OFF" for 10 seconds.
2. Ignition "ON." Record gage pressure. (Pressure must hold steady, if not, see "fuel System
Diagnosis," CHART A-7, in Section "A").
3. Turn injector on, by depressing button on injector tester, and note pressure at the instant
the gauge needle stops.
Step 3.
1.
Repeat Step 2 on all injectors and record pressure drop on each. Retest injectors that
appear faulty (Any injectors that have a 10 kPa (1.5 psi) difference, either more or less, in
pressure from the average). If no problem is found, review "Symptoms" Section "B".
(INITIAL PRESSURE)
OUTPUT
POWER
ELECTRONIC FUEL
INJECTOR TESTER
TESTER
J 347303A
ACTIVATE
INJECTOR
/';:\
1 PULSE
\::,/ 50 PULSES
2ND
READING
(PRESSURE AFTER DROP)
lOOPULSES
INJECTOR
500 MS
10 MS
POS
NEG
BATTERY
SMS
CONNECTOR
EXAMPLE
1
1STREADING
293 kPa
(43 psi)
293 kPa
(43 psi)
293 kPa
(43 psi)
2NDREADING
131 kPa
(19 psi)
115 kPa
(17 psi)
145 kPa
(21 psi)
162 kPa
AMOUNT OF DROP (24 psi)
178 kPa
(26 psi)
148 kPa
(21 psi)
CYLINDER
OK
FAULTY, RICH FAULTY, LEAN

(TOO MUCH
(TOO LITTLE
FUEL DROP)
FUEL DROP)
5-9-92
MS 12020-6E
ECM
1 - - - - - - - - - 1747LT BLU/WHT
J - - - - - - - - - - 1748LTBLU/BLK
;:;~:::J::J.~
IACCOIL "A" HIGH

IACCOIL "A" LOW
1749 LTGRN/WHT
IAC COIL "B'" HIGH
J - - - - - - - - - - 444 LT GRN/BLK
IACCOIL "B" LOW

9-29-92
NS15616
CHART C-28
IDLE AIR CONTROL (IAC) CIRCUIT
11
The ECM controls engine idle speed with the IAC valve. To increase idle speed, the ECM retracts the IAC
valve pintle away from its seat, allowing more air to bypass the throttle bore. To decrease idle speed, it extends
the IAC valve pintle towards its seat, reducing bypass air flow. A Tech 1 scan tool will read the ECM commands
to the IAC valve in counts. Higher counts indicate more air bypass (higher idle). The lower the counts indicates
less air is allowed to bypass (lower idle).
System too lean (High Air/Fuel Ratio). - The
idle speed may be too high or too low. Engine
l. The Tech 1 RPM control mode is used to extend
speed may vary up and down and
and retract the IAC valve. The valve should move
disconnecting the IAC valve does not help.
smoothly within the specified range. If the idle
DTC 44/64 may be set. Tech 1 scan tool 028
speed is commanded (IAC extended) too low (below
voltage will be less than 300 m V (.3 volt).
700 RPM), the engine may stall. This may be
Check for low regulated fuel pressure, water in
normal and would not indicate a problem.
the fuel or a restricted injector.
Retracting the IAC beyond its controlled range
System too rich (Low Air/Fuel Ratio). - The
(above 1500 RPM) will cause a delay before the
idle speed will be too low. Tech 1 scan tool IAC
RPMs start dropping. This too is normal.
counts will usually be above 80. System is
2. This test uses the Tech 1 to command the IAC
obviously rich and may exhibit black smoke in
controlled idle speed. The ECM issues commands
exhaust.
to obtain commanded idle speed. The node lights
Tech 1 scan tool 02S voltage will be fixed
each should flash red and green to indicate a good
above 800 m V (.8 volt).
circuit as the ECM issues commands. While the
Check for high fuel pressure, leaking or
sequence of color is not important if either light is
sticking injector. Silicone contaminated 02S
"OFF" or does not flash red and green, check the
sensors Tech 1 scan tool voltage will be slow to
circuits for faults, beginning with poor terminal
respond.
contacts.
Throttle Body. - Remove [AC valve and inspect
Diagnostic Aids:
IAC Valve Electrical Connections. - IAC valve
connections should be carefully checked for
proper contact.
Crankcase Ventilation Valve. - An incorrect or
the IAC valve. Out of control range IAC Tech 1 scan
faulty valve may result in an incorrect idle
tool counts will be above 60 if idle is too low, and zero
speed.
counts if idle is too high. The following checks should
Refer to "Rough, Unstable, Incorrect Idle or
be made to repair a non-IAC system problem:
Vacuum Leak (High Idle). - If idle is too high,
If intermittent poor driveability or idle
stop the engine. Fully extend (low) IAC with
symptoms are resolved by disconnecting the
tester. Start engine. If idle speed is above 800
IAC, carefully recheck connections, valve
RPM, locate and correct vacuum leak
terminal resistance, or replace IAC.
including crankcase ventilation system. Also
check for binding of throttle blade or linkage.
CHARTC-28
'2' .
~
INSTALL TECH 1 SCAN TOOL,

ENGINE AT NORMAL OPERA TING TEMPERATURE
IN PARK/NEUTRAL WITH PARKING BRAKE SET.
A/C '"OFF.'"
SELECT RPM CONTROL. (MISC. TESTS)
CYCLE IAC THROUGH ITS RANGE FROM 700 RPM
UP TO 1500 RPM.
RPM SHOULD CHANGE SMOOTHLY.
DOESIT?
INSTALL IAC NODE LIGHT* IN IAC HARNESS.

ENGINE RUNNING. CYCLE IAC WITH TECH 1 SCAN TOOL.
EACH NODE LIGHT SHOULD CYCLE RED AND GREEN BUT
NEVER '"OFF.'"
DO THEY?
If CIRCUIT(S) DID NOT TEST RED AND

GREEN, CHECK FOR:
FAUL TY CONNECTOR TERMINAL
CONTACTS.
OPEN CIRCUITS INCLUDING
CONNECTORS.
CIRCUITS SHORTED TO GROUND OR
VOLTAGE.
FAULTY ECM CONNECTIONS OR
REPLACE ECM.
CHECKIAC
CONNECTIONS.
CHECKIAC
PASSAGES.
If OK, REPLACE IAC.
IDLE AIR CONTROL {IAC) CIRCUIT

USING THE IAC DRIVER* OR OTHER

CONVENIENT CONNECTOR, CHECK
RESISTANCE ACROSS IAC COILS.
SHOULD BE 40 TO 80 OHMS BETWEEN
IAC TERMINALS .. A .. TO '"B'" AND '"C'"
TO'"D'".

TERMINALS "B" AND '"C" AND
'"A'" AND"D'".
SHOULD BE INFINITE.
IDLE AIR CONTROL CIRCUIT OK.

REFER TO '"DIAGNOSTIC AIDS"
ON FACING PAGE.
REPLACE IAC
VALVE AND
RETEST.
REPLACE IAC
VALVE AND
RETEST.

J 37027 FROM: KENT-MOORE, INC.
CLEAR DIAGNOSTIC TROUBLE CODES, CONFIRM "CLOSED LOOP"

OPERATION, NO MALFUNCTION INDICATOR LAMP{MIL) "SERVICE
ENGINE SOON." PERFORM IAC RESET PROCEDURE PER APPLICABLE
SERVICE MANUAL AND VERIFY CONTROLLED IDLE SPEED IS CORRECT.
"AFTER REPAIRS," CONFIRM '"CLOSED LOOP'" OPERATION AND NO MIL (SERVICE ENGINE SOON).
10-14-92
9S 6034-GE
6E3-C2-20 3.4L (L32) {VIN S) {SFI) DRIVEABILITY AND EMISSIONS
BLANK
SECTION C3
EVAPORATIVE EMISSION (EVAP) CONTROL SYSTEM

CONTENTS
General Description
Purpose
EVAPCanister
Evaporative Emission (EVAP) Pressure
Control Valve

Results of Incorrect Operation
Diagnosis

Evaporative Emission (EVAP) Canister
Purge Solenoid Valve
C3-1
C3-1
C3-1
C3-1
C3-1
C3-2
C3-2
. . . . . ..
Visual Check of EVAP Canister

Functional Tests
Control Valve
On-Vehicle Service
EVAP Canister
EVAP Canister Purge Solenoid Valve
EVAP Caniste'r Hoses
C3-2
C3-2
C3-2
C3-2
C3-2
C3-2
C3-3
C3-3
C3-2
GENERAL DESCRIPTION
PURPOSE
The Evaporative Emission (EVAP) control system
used on all vehicles is the charcoal canister storage
method. This method transfers fuel vapor from the
fuel tank to an activated carbon (charcoal) storage
device (canister) to hold the vapors when the vehicle is
not operating. When the engine is running, the fuel
vapor is purg.ed from the carbon element by intake air
flow and consumed in the normal combustion process.
EVAP CANISTER
uses a rear mounted charcoal canister to absorb fuel
vapors from the gas tank.
When gasoline vapor builds enough to overcome
the spring tension of the EVAP pressure control valve,
the vapor will flow to the canister where it is absorbed
and stored by the charcoal. Under certain operating
conditions the ECM will command the purge solenoid
valve to open. This allows the vapor to flow into the
intake manifold for combustion.
17013138
17093194
TANK TUBE
2
AIR TUBE (FRESH AIR INLET)
PURGE TUBE
NA 1349-AS
EVAPORATIVE EMISSION SYSTEM

This system has a remote mounted canister purge
control solenoid valve. The ECM operates this
solenoid valve to control vacuum to the canister.
Under cold engine or idle conditions, the solenoid
valve is closed, which prevents vacuum from being
applied to the canister.
The ECM activates (or opens) the solenoid valve
and allows purge when:
Engine is warm.
After the engine has been running a specified
period of time.
Above a specified road speed.
Figure C3-1 - Evaporative Emission Canister
Above a specified throttle opening.
EVAPORATIVE EMISSION (EVAP) PRESSURE

CONTROL VALVE
This system uses an in-line EV AP pressure control
valve for pressure relief. Refer to diagram for
installation in system. When vapor pressure in the
tank exceeds approximately 5 kPa (. 7 psi) the
diaphragm valve opens, allowing vapors to vent to the
canister.

A 1.14 mm (0.045 inch) orifice in the passage leading
to the canister tube causes pressure to drop slowly,
preventing the valve from oscillating (buzzing). When
the tank pressure drops below 5 kPa (.7 psi), the valve
closes causing vapors to be held in the fuel tank.
RE SULTS OF INCORRECT OPERATION
Poor idle, stalling and poor driveability can be

caused by:
Inoperative purge solenoid valve.
Damaged canister.
Hoses split, cracked and, or not connected to
the proper tubes.
Evidence of fuel loss or fuel vapor odor can be
caused by:
Liquid fuel leaking from fuel lines.
Cracked or damaged canister.
Inoperative canister control valve.
Disconnected, misrouted, kinked, deteriorated
or damaged vapor hoses, or control hoses.
If the solenoid valve is open, or is not receiving
power, the canister can purge to the intake manifold at
the incorrect time. This can allow extra fuel during
warm-up, which can cause rough or unstable idle.
DIAGNOSIS
EVAPORATIVE EMISSION (EVAP) CANISTER
The Evaporative Emission (EVAP) canister purge
solenoid valve operation is covered in CHART C-3 at
the end of this section.
VISUAL CHECK OF EVAP CANISTER
Cracked or damaged, replace EVAP canister.
FUNCTIONAL TESTS
Control Valve
With a hand vacuum pump, apply approximately
38 cm Hg (15" Hg) to the control vacuum tube. After
ten seconds, there should be at least 13 cm Hg (5" Hg)
vacuum remaining. Be sure the hand vacuum pump
being used does not have an internal leak and the hose
connections to control vacuum tube and pump are
secure. If after 10 seconds there is less than 13 cm (5"
Hg) vacuum, the valve must be replaced.
With 38 cm Hg (15" Hg) vacuum still applied to the
control vacuum tube, attach a short piece of hose to the
valve's tank tube side. Blow into the tube. You should
feel the air pass through the valve. If air does not pass
through, the valve must be replaced.
ON-VEHICLE SERVICE
EVAP CANISTER
Figure C3-3

2. Raise vehicle.
3. Driver side rear wheel housing liner.
4. Hoses from canister.
5. Canister from canister bracket by releasing latch
on canister bracket.
6. Canister from vehicle.

1. Canister to vehicle.
2. Canister to canister bracket.
3. Hoses to canister.
5. Lower vehicle.
EVAP CANISTER PURGE SOLENOID VALVE
5
4
Figure C3-4

1.
2.
3.
RESTRICTION
CONTROL TUBE
DIAPHRAGM
TUBE TO CANISTER
DIAPHRAGM SPRING
TUBE TO FUEL TANK

MP0436-SY
Figure C3-2 - EVAP Pressure Control Valve

Electrical connector and hoses from solenoid valve.
Bracket and solenoid from intake manifold.

1.
Solenoid valve to intake manifold.
!~I Tighten
Bolt to intake manifold to 10 Nm (7 lb. in.).
FUEL TANK
-~11.,.-!VIEWA!
EVAPORATIVE EMISSION PRESSURE CONTROL VALVE
FUEL FILLER NECK

NS 15274
Figure C33 EVAP Canister Mounting
2. Electrical connector and hoses to solenoid valve.

EVAP CANISTER HOSES

Refer to "Vehicle Emission Control Information"
label for routing of EVAP canister hoses.
EV AP Canister Purge Solenoid
Valve Bolt 10 Nm (7 lb. ft.)
FUEL FEED AND RETURN PIPE ASSEMBLY
BOLT/SCREW
EVAPORATIVE EMISSION CANISTER PURGE

SOLENOID VALVE
NS15646
Figure C3-4 EVAP Canister Purge Solenoid Valve

Service
TO FUEL PRESSURE
REGULATOR VALVE
tl
TO MAP
SENSOR
[il
1t
DJ ---~~~ ~~~----.. . . .
----'0---.
"'x-$-~-~
+.---'- ~ - ~
TO CRANKCASE
VENTILATION
VALVE
...
DJ Purge
Evaporative Emission Canister
Solenoid Valve
[il
II)
[!] Fuel Tank
Throttle Body

(PressureNacuum Relief)
Remote Mounted
. [!}__ .__
II]
Evaporative Emission
Pressure Control Valve
[i]
Canister
10-8-92
NS 15846
Figure C3-5 - Evaporative Emissions Control System Schematic
BLANK
ECM
TO MANIFOLD
VACUUM
EVAP
CANISTER
PURGE
SOLENOID
VALVE
TO DIGITAL
EXHAUST GAS
RECIRCULATION
(EGR)VALVE
EVAP CANISTER
PURGE
CONTROL
DRIVER
L....------428 DK GRN/WHT
10-WA Y FWD LAMP
HARNESS CONNECTOR
(BLACK)
541 BRN
--0----r--
_
FUSE #6*
---1
TO IGNITION SWITCH .......:----"'-'e

10AMP
TO COOLING
CO~~~OL
RELAY
9-28-92
NS 15847
CHARTC-3
EVAPORATIVE EMISSION (EVAP) CANISTER PURGE SOLENOID VALVE CHECK
EVAP canister purge is controlled by a solenoid valve that allows manifold vacuum to purge the EVAP
canister when energized. The ECM supplies a ground to energize the solenoid valve.
If the diagnostic "test" terminal is grounded with the engine stopped and ignition "ON," or the following
conditions are met with the engine running, the EVAP canister purge solenoid valve will be energized (purge
"ON").
Engine run time after start more than 1 minute.
Engine coolant temperature above 60C (140F).
Vehicle speed above 1.3 mph.
Throttle off idle, above 6%.

1. Checks to see if the solenoid valve is opened or
closed. The solenoid valve is normally closed and
should open when the diagnostic "test" terminal is
grounded.
2. Completes functional check by grounding the
diagnostic "test" terminal. This should energize
the solenoid valve and allow the vacuum to drop
(purge "ON").
3. Checks for a complete circuit. Normally, there is
ignition voltage on CKT 541 and the ECM
provides a ground on CKT 428. A shorted solenoid
valve could cause an open circuit in the ECM.
Diagnostic Aids:
Normal operation of the EVAP canister purge
solenoid valve is described as follows:
With the ignition "ON," engine "OFF," diagnostic
"test" terminal grounded, the EVAP canister purge
solenoid valve should be energized.
CHARTC-3
EVAPORATIVE EMISSION (EVAP) CANISTER PURGE
SOLENOID VALVE CHECK
11
G).
IGNITION "ON." ENGINE STOPPED.

DISCONNECT VACUUM HOSES FROM EVAP CANISTER PURGE
SOLENOID VALVE.
AT THE SOLENOID VALVE, APPLY 34 kPa (10" Hg) OF VACUUM
TO THE MANIFOLD VACUUM SIDE OF PURGE SOLENOID
ABLE TO GET 34 kPa (10" Hg) OF VACUUM.
GROUND DIAGNOSTIC"TEST"
TERMINAL.
UNABLE TO GET 34 kPa (10" Hg) OF VACUUM.
DISCONNECT SOLENOID VALVE.

PROBE CKT 428 WITH A TEST
LIGHT TO 12 VOL TS.
NO DROP
WITH DIAGNOSTIC "TEST"

TERMINAL STILL GROUNDED
DISCONNECT EVAP CANISTER
PURGE SOLENOID VALVE.
BETWEEN
HARNESS CONNECTOR
TERMINALS.
NO TROUBLE FOUND.
CKT 428 SHORTED TO

GROUND OR FAUL TY ECM.
FAULTY SOLENOID
VALVE.
NO LIGHT
PROBE EACH HARNESS

CONNECTOR TERMINAL
WITH A TEST LIGHT TO
GROUND.
FAUL TY SOLENOID
VALVE OR
CONNECTOR.
LIGHT"ON"
ONE TERMINAL
LIGHT BOTH
TERMINALS
OPEN CKT428
OR
FAULTY
CONNECTION
OR
FAULTY ECM.
REPAIR SHORT TO
VOLTAGE IN CKT 428.
CHECK FOR OPEN IN IGNITION FEED

CIRCUIT TO SOLENOID VALVE.
10-27-92
NS 16196
BLANK
SECTION C4
ELECTRONIC IGNITION (El) SYSTEM

CONTENTS
General Description
Operation
System Components
24X and 3X Crankshaft
Position Sensors
Ignition Coils
Ignition Control Module
Circuits Affecting Ignition Control
How DTC 42 is Determined
C4-1
C4-1
C4-2
C4-2
C4-2
C4-2
C4-2
C4-3
C4-3
GENERAL DESCRIPTION
The Electronic Ignition (EI) system controls fuel
combustion by providing a spark to ignite the
compressed air/fuel mixture at the correct time. To
provide optimum engine performance, fuel economy,
and control of exhaust emissions, the ECM controls
spark advance of the ignition system. Electronic
ignition has several advantages over a mechanical
system:
No moving parts.
Less maintenance.
Remote mounting capability.
No mechanical load on the engine.
More coil cool down time between firing
events.
Elimination of mechanical timing
adjustments.
Increased available ignition coil saturation
time.
OPERATION
The electronic ignition system does not use the
conventional distributor and coil. The ignition system
consists of three ignition coils, an ignition control
module, a camshaft position sensor, a dual Hall-effect
crankshaft position sensor, an engine crankshaft
balancer with crankshaft position sensor interrupter
ring attached to the rear, related connecting wires,
and the ignition control and fuel metering portion of
the ECM.
Conventional ignition coils have one end of the
secondary winding connected to the engine ground. In
this ignition system, neither end of the secondary
winding is grounded. Instead, each end of a coil's
secondary winding is attached to a spark plug. Each
cylinder is paired with the cylinder that is opposite it
(1-4,2-5, 3-6).
Diagnosis
Diagnosis
On-Vehicle Service
Ignition Coi I
3X Crankshaft Position (CKP) Sensor
C4-3
C4-3
C4-4
C4-4
C4-4
C4-4
C4-4
C4-5
C4-5
These two plugs are on "companion" cylinders, i.e.,

on top dead center at the same time. When the coil
discharges, both plugs fire at the same time to
complete the series circuit. The cylinder on
compression is said to be the "event" cylinder and the
one on exhaust is the "waste" cylinder.
The cylinder on the exhaust stroke requires very
little of the available energy to fire the spark plug.
The remaining energy will be used as required by the
cylinder on the compression stroke. The same process
is repeated when the cylinders reverse roles. This
method of ignition is called a "waste spark" ignition
system.
Since the polarity of the ignition coil primary and
secondary windings is fixed, one spark plug always
fires with a forward current flow and its "companion"
plug fires with a reverse current flow. This is different
from a conventional ignition system that fires all the
plugs with the same direction of current flow. Since it
requires approximately 30% more voltage to fire a
spark plug backwards, the ignition coil design is
improved, with saturation time and primary current
flow increased. This redesign of the system allows
higher secondary voltage to be available from the
ignition coils - greater than 40 kilovolts (40,000 volts)
at any engine RPM. The voltage required by each
spark plug is determined by the polarity and the
cylinder pressure. The cylinder on compression
requires more voltage to fire the spark plug than the
one on exhaust.
It is possible for one spark plug to fire even though
a plug wire from the same coil may be disconnected
from its "companion" plug. The disconnected plug
wire acts as one plate of a capacitor, with the engine
being the other plate. These two "capacitor plates" are
charged as a spark jumps across the gap of the
connected spark plug. The "plates" are then
discharged as the secondary energy is dissipated in an
oscillating current across the gap of the still-connected
spark plug.

Secondary voltage requirements are very high with an
"open" spark plug or wire. The ignition coil has
enough reserve energy to fire the still-connected plug
at idle, but possibly not under high engine load. A
more noticeable misfire may be evident under load;
both spark plugs may then be misfiring.
must have the 3X signal to "fire" the correct ignition

coil.
The 24X interrupter ring and Hall-effect switch
react similarly. The 24X signal is used for better
resolution at a calibrated RPM.

SYSTEM COMPONENTS
24X and 3X Crankshaft Position Sensors
The 24X crankshaft position sensor, secured in an
aluminum mounting bracket and bolted to the front
side of the engine timing chain cover, is partially
behind the crankshaft balancer ("On-Vehicle Service,"
Figure C4-3).
A three wire harness connector plugs into the 3X
crankshaft position sensor, connecting it to the
ignition control module ("On-Vehicle Service," Figure
C4-3).
The 24X crankshaft position sensor contains a
Hall-effect switch. The magnet and Hall-effect switch
are separated by an air gap. A Hall-effect switch
reacts like a solid-state switch, grounding a lowcurrent signal voltage when a magnetic field is
present. When the magnetic field is shielded from the
switch by a piece of steel placed in the air gap between
the magnet and the switch, the signal voltage is not
grounded. If the piece of steel (called an interrupter) is
repeatedly moved in and out of the air gap, the signal
voltage will appear to go "ON-OFF-ON-OFF-ONOFF." Compared to a conventional mechanical
distributor, this "ON-OFF" signal is similar to the
signal that a set of breaker points in the distributor
would generate as the distributor shaft turned and the
points opened and closed.
In the case of the electronic ignition system, a
concentric interrupter ring mounted to the rear of the
crankshaft balancer has blades and windows that,
with crankshaft rotation, either block the magnetic
field or allow it to reach the Hall-effect switch. The
Hall-effect switch is called a 24X crankshaft position
sensor, because the interrupter ring has 24 evenlyspaced same-width blades and windows. The 24X
crankshaft sensor produces 24 "ON-OFF" pulses per
crankshaft revolution. The Hall-effect switch closest
to the crankshaft, the 3X crankshaft position sensor, is
so called because the interrupter ring has a special
wheel cast on the crankshaft that has seven machined
slots, six of which are equally spaced 60 apart. The
seventh slot is spaced 10 from one of the other slots.
As the interrupter ring rotates with the crankshaft,
the slots change the magnetic field. This will cause
the 3X Hall-effect switch to ground the 3X signal
voltage supplied from the ignition control module. The
ignition control module interprets the 3X "ON-OFF"
signals as an indication of crankshaft position, and
The camshaft position sensor ("On-Vehicle

Service," Figure C4-5) is located on the timing cover
behind the water pump near the camshaft sprocket.
As the camshaft sprocket turns, a magnet in it
activates the Hall-effect switch in the cam sensor.
When the Hall-effect switch is activated, it grounds
the signal line to the ECM, pulling the cam signal
line's applied voltage low. This is interpreted as a cam
signal.
The cam signal is created as piston #1 is on the
compression stroke.
When the cam signal is not received by the ECM
DTC 17 will be set.
Ignition Coils
Three twin-tower ignition coils are individually
mounted to the ignition control module (Figure C4-2).
Each coil provides spark for two plugs simultaneously
(waste spark distribution). Each coil is serviced
separately.
Two terminals connect each coil pack to the
module. Each coil is provided a fused ignition feed.
The other terminal at each coil is individually
connected to the module, which will energize one coil
at a time by completing and interrupting the primary
circuit ground path to each coil at the proper time.

The ignition control module performs several
functions:
It powers the 3X crankshaft sensor circuit.
It determines the correct ignition coil firing
sequence, based on 3X pulse. This coil
sequencing occurs at start-up. After the
engine is running, the module determines the
sequence, and continues triggering the
ignition coils in proper sequence.
It sends a "3X crankshaft reference" (fuel
control) signal to the ECM. The ECM
determines engine RPM from this signal. It is
also used by the ECM to determine crankshaft
position for ignition control spark advance
calculations. The signal sent to the ECM by
the ignition control module is an "ON-OFF"
pulse occurring 3 times per crankshaft
revolution.

Circuits Affecting Ignition Control
How OTC 42 is Determined
To properly control timing, the ECM relies on the

following information:
t
Engine temperature.
Intake air temperature.
Crankshaft position.
Engine speed (RPM).
The IC system consists of the ignition coil and
module assembly (ignition coils, electronic ignition
control module), the 3X crankshaft position sensor and
the 24X crankshaft position sensor, ECM and
connecting wires. The electronic Ignition Control
Module (ICM) connector terminals are lettered as
shown in Figure C4-1. These circuits perform the
following functions:
3X reference high - CKT 647. - The crankshaft
position sensor sends a signal to the electronic
ignition control module which generates a
reference pulse which is sent to the ECM. The
ECM uses this signal to calculate crankshaft
position and engine speed (also used to trigger
the injector).
3X reference low - CKT 453. - This wire is
grounded through the module and makes sure
the ground circuit has no voltage drop between
the ignition module and the ECM, which if
open, could affect performance.
Ignition control bypass - CKT 424. - During
initial cranking, the ECM will look for
syncronizing pulses from the camshaft and 3X
crankshaft position sensor indicating the
position of #1 piston and intake valve. 5 volts
is applied to the bypass circuit the instant
these signals are received by the ECM. This
generally occurs within 1 or 2 revolutions of
the crankshaft. An open or grounded bypass
circuit will set a DTC 42 and the engine will
run at base timing. A small amount of
advance is built into the ignition control
module to enhance performance.
IC - CKT 423. - The ECM uses this circuit to
trigger the electronic ignition control module.
The ECM uses the crankshaft reference signal
to base its calculation of the amount of spark
advance needed under present engine
conditions.
24X reference signal. - Additional to the
electronic ignition system is the 24X
crankshaft position sensor. It's function is to
increase idle quality and provide good low
speed driveability.
An open in the IC circuit while running will result

in the engine continuing to run although in a base
timing mode (module timing). The timing values are
stored in the ignition control module to allow for basic
engine performance.
If the IC circuit is shorted to ground, the MIL will
be turned "ON," and a OTC 42 will be set and the
engine will operate in module timing. Either
condition may cause poor performance and reduced
fuel economy.
If the bypass line is open or grounded, the ignition
control module will not switch to IC timing mode so
the IC voltage will be low and OTC 42 will be set.
If the IC circuit is grounded, the ignition control
module will switch to base timing and a OTC 42 will be
set and MIL illuminated.
DIAGNOSIS
If the engine cranks but will not run, CHART A-3
will be used to determine if the "El" system is the
cause of the problem or if it is another part of the fuel
injection system.
If OTC 42 is set, that OTC chart should be used for
diagnosis. If no OTC is set and the ignition system is
suspected, use CHART C4-F ("El" Misfire) for
diagnosis.

An open or ground in the ignition control or bypass
circuit will set a OTC 42. If a fault occurs in the
ignition control output circuit when the engine is
running, the engine may falter or quit running but
will restart and run in base timing mode once the
ignition has been cycled. A fault in either circuit will
force the ignition system to operate on base timing (10
BTDC), which will result in reduced performance and
fuel economy.
The ECM uses information from the engine
coolant temperature sensor in addition to RPM to
calculate the main spark advance values as follows:
High RPM
Cold engine
more advance
more advance
Low RPM
Hot engine
less advance
less advance
Therefore, detonation could be caused by high

resistance in the engine coolant temperature sensor
circuit. Poor performance could be caused by low
resistance in the engine coolant temperature sensor
circuit.
ECM
10-WAYFWDLAMP
HARNESS CONNECTOR
(BLACK)
FUSE #11 *
10 AMP
1t----V"1--- 239 PNK
IGNITION ....
G - - - - - - - - ' ~ T O HIGH RESOLUTION 24X

CRANKSHAFT POSITION
SENSOR AND CAMSHAFT
POSITION SENSOR.
B+
450BLK
GND
-i
LOW RESOLUTION
3X CRANKSHAFT
POSITION SENSOR
;:~ =ffi I
SIGNAL
MINIMUM
1--------- 424 TAN/BLK _ _ _ __.

1---------- 423 WHT -----1
ELECTRONIC
IGNITION
D
CONTROL
MODULE
E
(ICM)
.....__ _ ___. F
IGNITION CONTROL
BYPASS
IGNITION CONTROL
121 WHT ---TACH SIGNAL
-----1
3XREF HIGH
1--------- 453 RED/BLK -----1
3XREF LOW
647LTBLU/BLK
PRIMARY
WINDING
11-12-92
NS 15618
Figure C4-1 - El System with IC
DIAGNOSIS
If the Engine Cranks But Will Not Run or
immediately stalls, CHART A-3 must be used to
determine if the failure is in the ignition system or the
fuel system.
If a DTC 17, 36 or 82 is set, the appropriate OTC
chart must be used for diagnosis.
If the symptom is "Engine Miss" and the ignition
system is suspected, CHART C-4F will provide a
systematic diagnostic procedure.
ON-VEHICLE SERVICE
IGNITION COIL

1. Spark plug wires.
2. 2 screws securing coil to ignition control module.
3. Ignition coil. Refer to Figure C4-2.
It may be helpful to remove the throttle cable
bracket to gain access to coil pack 1-4.
l++f Install or Connect

1. Ignition coil.
2. 2 screws, torque to 4-5 Nm (40 lb. in.).
3. Spark plug wires.
IGNITION CONTROL MODULE

1.
2.
3.
4.
5.
6-way connector, 3-way connector and 2-way

connector at ignition control module.
Spark plug wires from ignition coils. Refer to
Figure C4-2.
6 screws securing ignition coils to ignition control
module.
Disconnect coils from ignition control module.
Ignition control module.

1.
2.
3.
4.
Ignition coils to ignition control module.

6 screws, torque to 4-5 Nm (40 lb. in.).
Plug wires.
6-way connector, 3-way connector and 2-way
connector to module.
f++I Remove or Disconnect

1.
2.
3.
4.

Serpentine belt from crankshaft pulley.
Using 18 mm socket, remove crankshaft harmonic
balancer retaining bolt.

1. Sensor harness connector at module.
2. Sensor to block bolt (1).
3. Sensor from engine.
ILI Inspect

NS 15844
Figure C4-2 - Ignition Contra Modu e and Co1

Assembly (Type II Shown)
5. Crankshaft harmonic balancer using special tool

(J 38197).
7. Sensor bolts (2). Refer to Figure C4-3.
8. Sensor.

1.
2.
3.
4.
5.
6.
7.
8.
Crankshaft position sensor with bolt (2). Refer to

Figure C4-3.
Torque bolts (2) to 10 Nm (8 lb. ft.).
Sensor electrical connector.
Balancer on crankshaft.
Apply thread sealer GM #1052080 or equivalent
to threads of crankshaft balancer bolt. Torque
bolt to 150 Nm (110 lb. ft.).
Lower vehicle.
Serpentine belt.
Sensor 0-ring for wear, cracks or leakage. Replace

if necessary. Lube new 0-ring with clean engine
oil before installing.

1. Sensor into hole in block.
2. Sensor to block bolt (1).
Torque to 8 Nm (71 lb. in.).
3. Sensor harness connnector at module.
Starter motor.
CAMSHAFT POSITION SENSOR

Figure C4-5
f+I Remove or Disconnect

1.
2.
3.
4.
5.

Throttle cable shield and bracket from TB.
Bolt (1). Refer to Figure C4-5.
Camshaft position sensor.

1.
2.
3.
4.
5.
Camshaft position sensor. Refer to Figure C4-4.

Bolt (1) torque to 10 Nm (8 lb. ft.).
Harness connector.
Throttle cable bracket and shield.
3X CRANKSHAFT POSITION (CKP) SENSOR

Figure C4-4
Disconnect negative battery cable.

Remove starter motor.
FRONT ENGINE COVER
24x CRANKSHAFT POSITION

SENSOR ASSEMBLY
BOLT (2) TORQUE 10 Nm (8 lb.
ft.)
NS 15606
Figure C4-3 - 24X Crankshaft Position Sensor
KNOCK SENSOR
2
BOLT/SCREW
NS 15845
Figure C4-4 3X Crankshaft Position Sensor
BOLT (1) TORQUE 10 Nm (8 lb. ft.)
NS 15091
Figure C4-5 Camshaft Position Sensor
BLANK
ECM
CONNECTOR (BLACK)
FUSE #11*
-----11 G .._________ TO CAMSHAFT POSITION SENSOR
I G N I T I O N ~ 239PNK
AND
10AMP
HIGH RESOLUTION 24X CRANKSHAFT
POSITION SENSOR
B+
SHIELD
SIGNAL
: ~ =ill.:. . .I__
LOW RESOLUTION 3X
t---------
424 TAN/BLK - - - - - 1 1
- - - - - - - - - - - 423 WHT - - - - - 1 1
ELECTRONIC
IGNITION
CONTROL
MODULE
(ICM)
IGNITION CONTROL
BYPASS
IGNITION CONTROL

D
E 1 - - - - - - - - - 647 LT BLU/BLK - - - - - 1 1
3XREF HIGH
' - - - - - - - I f - - - - - - - - - 453 RED/BLK - - - - - 1 1
3XREF LOW

9-2892
NS 15848
CHART C-4F
MISFIRE
The Electronic Ignition (EI) system uses a waste spark method of distribution. In this type of system, the
electronic ignition control module triggers the #1/4 coil pair resulting in both #1 and #4 spark plugs firing at the
same time. #1 cylinder is on the compression stroke at the same time #4 is on the exhaust stroke, resulting in a
lower energy requirement to fire #4 spark plug. This leaves the remainder of the high voltage to be used to fire
#1 spark plug. On this application, the low resolution 3X crankshaft position sensor is mounted to the engine
block and protrudes through the block to within approximately .050" of the crankshaft reluctor. Since the
reluctor is a machined portion of the crankshaft and the sensor is mounted in a fixed position on the block, timing
adjustments are neither possible or necessary.
plugs show no evidence of wear, damage or fouling,
an engine mechanical fault should be suspected.
Refer to "Cuts Out, Misses," in "Symptoms,"
1. Checks for voltage output of ignition system. The
Section "6E3-B".
companion cylinder spark plug cable in the circuit
3. Plug wires should be inspected for cuts or
must be connected to a good ground to create a
abrasions leading to shorts to ground or other
good spark and avoid overstressing the coil. Test
components. This would cause a weak or absent
each spark plug cable with the engine idling (the
spark yet the resistance valve when measured may
ignition must be cycled "OFF" when moving the
ST-125 tester to a different spark plug cable).
be correct.
4. If carbon tracking is evident replace coil and be
Keep disconnected spark plug leads away from
sure plug wires relating to that coil are clean and
sensors and other electronic components.
tight. Excessive wire resistance or faulty
Move quickly through this test. Don't leave
connections could have caused the coil to be
any spark plug lead disconnected for longer
than 15 seconds.
damaged.
5. If the no spark condition follows the suspected coil,
Let the engine run normally for 30 seconds
that coil is faulty. Otherwise, the electronic
between tests to avoid an excessive buildup of
ignition control module is the cause of no spark.
fuel.
This test could also be performed by substituting a
2. If the spark tester fires on all wires, the ignition
known good coil for the one causing the no spark
system, with the exception of the spark plugs, may
condition.
be considered in good working order. If the spark
CHART C-4F
MISFIRE
Cv
IGNITION "OFF."
INSTALL SPARK TESTER J-26792 (ST-125) TO ONE SPARK PLUG WIRE.
GROUND COMPANION CYLINDER PLUG WIRE.
IDLE ENGINE AND CHECK FOR SPARK AT TESTER.
REPEAT TEST ON ALL PLUG WIRES WHILE GROUNDING COMPANION PLUG WIRES.
DOES TESTER DISPLAY A CRISP BLUE SPARK ON ALL WIRES?
CHECK THE RESISTANCE OF EACH PLUG WIRE OF THE

COIL WHICH DISPLAYED AN INTERMITTENT OR
WEAK SPARK OR DID NOT FIRE THE SPARK TESTER.
IS WIRE RESISTANCE LESS THAN 30,000 OHMS EACH?
REMOVE AFFECTED COIL(S).

IS COIL(S) FREE OF CARBON TRACKING?
SWITCH POSITION OF COILS AT PROBLEM CYLINDER.

WILL SPARK JUMP TESTER GAP WHILE CRANKING
ENGINE?
G)
CHECK FOR:
FAULTY, WORN, OR DAMAGED SPARK PLUG(S).
PLUG FOULING, DUE TO ENGINE MECHANICAL FAULT.
IF PLUGS ARE OK, REFER TO SYMPTOMS, SECTION B;
CUTS OUT, MISSES.
FAULTY IGNITION COIL. ALSO CHECK FOR FAUL TY

PLUG WIRE CONNECTION{S) AND PLUG WIRE BOOT(S)
FOR CARBON TRACKING.
FAUL TY IGNITION COIL.
9-30-92
NS 15849
BLANK
DRIVEABILITY AND EMISSIONS 3.4L (L32) (VIN S) (SFI) 6E3-CS-1
SECTION CS
KNOCK SENSOR (KS) SYSTEM

CONTENTS
General Description
Purpose
Operation
Diagnosis

CS-1
CS-1
CS-1
CS-1
On-Vehicle Service
Knock Sensor
Knock Sensor (KS) Module
CS-1
CS-1
CS-2
GENERAL DESCRIPTION
PURPOSE
Varying octane levels in today's gasoline can cause
detonation in high performance engines. Detonation
is sometimes called spark knock.
To control spark knock, a Knock Sensor (KS)
system is used. This system is designed to retard
spark timing up to 10 to reduce spark knock in the
engine. This allows the engine to use maximum spark
advance to improve driveability and fuel economy.
SHUNT
RESISTOR
PIEZO
CRYSTAL
OPERATION
The KS system has two major components:
KS module (located in the ECM).
Knock sensor.
The Knock Sensor (KS) detects abnormal vibration
(spark knocking) in the engine. The sensor is mounted
in the engine block near the cylinders. The sensor
produces an AC output voltage which increases with
the severity of the knock. This signal voltage is
applied to ECM input. The ECM then adjusts the
Ignition Control (IC) timing to reduce spark knocking.
LS 8461-GE
t
t
Figure CS-1 Knock Sensor (KS)
DIAGNOSIS
The Tech 1 scan tool will have two positions to
check for diagnosing this circuit. The "knock signal"
parameter is used to monitor the input signal from the
knock sensor. This display position will display "Yes"
when knock is being detected. "Spark retard" is the
indication of how much the ECM is retarding the
spark.
DTC 43 is designed to diagnose the knock sensor
and wiring so problems encountered with this circuit
should set the DTC. However, if no DTC 43 was set
but the KS system is suspected because detonation was
the customer's complaint, refer to CHART C-5.
ON-VEHICLE SERVICE
KNOCK SENSOR
I+-+!
KNOCK SENSOR
BOLT/SCREW
NS 15845
Figure CS-2 - Knock Sensor Assembly

2.
3
4.
5.
Raise vehicle.
Starter motor.
KS wiring harness connector from knock sensor.
Knock sensor from engine block.

1.
Removal of the plug-in knock sensor module can be

accomplished by two methods as illustrated.
Method 1:
1.
Knock sensor into engine block. Be sure threads

are clean. Do not over tighten knock sensor. Over
torquing could damage the sensor.
Apply two opposing forces on either side of the

latch mechanism as shown below and pull unit up
from the header. Reinstallation is accomplished
by pushing the unit toward the header.
l~I Tighten
2.
3
4.
5.
Tighten to 19 Nm (14 lb. ft.).

KS wiring harness connector to the knock sensor.
Starter motor.
Lower vehicle.
METHOD1
KNOCK SENSOR (KS) MODULE
1+-+I Remove or Disconnect

Wiring harness from Engine Control Module
(ECM).
2. Mounting bracket from ECM.
3. Access cover from ECM.
1.
rn
Important
APPLY PRESSURE IN
DIRECTION OF ARROWS
NS 16216
Figure CS-4 Knock Sensor Module Removal
DO NOT remove any other screws.
Method 2:
2. Apply force toward the plug-in knock sensor

module with the thumb or forefinger with an
opposing force on the opposite side of the module as
shown below. Reinstallation is done as stated in
Method 1.
METHOD2
APPLY PRESSURE IN
DIRECTION OF ARROW
NS 16217
Figure CS-5 Knock Sensor Module Removal
NS 16215
Figure CS-3 - Knock Sensor (KS) Module
BLANK
ECM
KNOCK
SIGNAL
5V
5-9-92
NS 15039
CHARTC-5
KNOCK SENSOR (KS) SYSTEM CHECK
The Knock Sensor (KS) is used to detect engine detonation and the ECM will retard the ignition control
timing based on the signal being received. The circuitry within the knock sensor causes the ECMs 5 volts to be
pulled down so that under a no knock condition CKT 496 would measure about 2.5 volts. The knock sensor
produces an AC signal which rides on the 2.5 volts DC voltage. The amplitude and frequency are dependent upon
the knock level.
The ECM used with this engine contains a knock sensor module which contains the spark control logic that
retards spark timing which in turn reduces detonation.

1. With engine idling, there should not be a knock
signal present at the ECM, because detonation is
not likely under a no load condition.
2. Tapping on the engine lift hook bracket should
simulate a knock signal to determine if the sensor
is capable of detecting detonation. If no knock is
detected, try tapping on engine block closer to
sensor before replacing sensor.
3. If the engine has an internal problem which is
creating a knock, the knock sensor may be
responding to the internal failure.
4. This tests the integrity of the Knock Sensor (KS)

module.
Diagnostic Aids:
While observing knock signal on the Tech 1 scan
tool, there should be an indication that knock is
present when detonation can be heard. Detonation is
most likely to occur under high engine load conditions.
DRIVEABILITY AND EMISSIONS 3.4L (L32) (VIN S) (SFI) 6E3-CS-5
CHARTC-5
G)
G)
IF DIAGNOSTIC TROUBLE CODE {DTC)43 IS SET.USE THE DTCCHART.

ENGINE MUST BE IDLING AT NORMAL OPERATING TEMPERATURE.
USE TECH 1 TO OBSERVE KNOCK SIGNAL.
IS KNOCK INDICATED?
TAP ON ENGINE BLOCK WHILE OBSERVING KNOCK SIGNAL.
TECH 1 SHOULD INDICATE KNOCK WHILE TAPPING ON

ENGINE BLOCK.
DOESIT?
IF AN ENGINE KNOCK CAN BE HEARD, REPAIR THE

BASIC ENGINE PROBLEM. IF NO AUDIBLE KNOCK IS
HEARD, FOLLOW THE STEPS:
IGNITION "OFF.
CONNECT DVM TO KNOCK SENSOR AND
SET DVM ON 2 VOLT A.C. SCALE.

IGNITION "ON, ENGINE "ON."
ENGINE GROUND.
IS A SIGNAL INDICATED ON DVM?
G)
IGNITION "OFF."
CONNECT DVM TO KNOCK SENSOR AND
SET DVM ON 2 VOLT A.C. SCALE.
IGNITION "ON," ENGINE "ON."
ENGINE GROUND.
SYSTEM IS OPERATING
PROPERLY. REFER TO
"DIAGNOSTIC AIDS"
ON FACING PAGE.
CHECK CKT 496 FOR BEING

NEAR A SPARK PLUG WIRE
OR
A FAUL TY ECM CONNECTION
OR
FAULTY ECM.
TAP ON ENGINE BLOCK NEAR SENSOR.

IS A SIGNAL INDICATED ON DVM WHILE
TAPPING ON ENGINE BLOCK?
POOR CONNECTION AT KNOCK

SENSOR HARNESS CONNECTOR
OR
KNOCK SENSOR MODULE NOT
SEA TED PROPERLY
OR
FAUL TY KNOCK SENSOR MODULE.
"AFTER REPAIRS," CONFIRM "CLOSED LOOP" OPERATION AND NO Mil (SERVICE ENGINE SOON).
11-10-92
NS 16218
BLANK
SECTION C6
SECONDARY AIR INJECTION (AIR) SYSTEM

CONTENTS
General Description
C6-1
Purpose
C6-1
Operation of System Components

Operation
Diagnosis
Operational Checks

Al R Pump
C6-1
C6-1
C6-2
C6-2
C6-2
C6-2
Hoses and Pipes

Check Valve

On-Vehicle Service
AIR Pump
AIR Check Valve
AIR Pipes and Hoses
C6-3
C6-3
C6-4
C6-4
C6-4
C6-4
C6-4
GENERAL DESCRIPTION
PURPOSE
The Secondary Air Injection (AIR) system helps

reduce Hydrocarbon (HC), Carbon Monoxide (CO), and
Oxides of Nitrogen (NOx) exhaust emissions. It also
heats up the oxidation catalytic converter quickly on
engine start-up so conversion of exhaust gases can
occur sooner.
OPERATION OF SYSTEM COMPONENTS

The system (Figure C6-1) includes:
AIR Pump. - The AIR pump is located in the
left front of the underhood compartment and
supplies the air (oxygen) to the AIR system.
This electric air pump pressurizes air from the
engine air cleaner and pumps it through the
check valve and into the exhaust manifold.
The AIR pump is controlled by the ECM.
Battery voltage to the AIR pump is controlled
by the AIR pump relay. An integral stop valve
prevents air flow through the pump during
"OFF" periods. When the ECM provides a
ground circuit for the relay, battery voltage is
allowed to power up the AIR pump and
integral stop valve. The AIR pump motor is
protected by a 20 amp fuse and has its own
remote ground.
Check Valve. - The check valve prevents back
flow of exhaust gases into the pump in the
event of an exhaust backfire.
Necessary Plumbing. - As shown in Figure
C6-2.
AIR INJECTION PUMP

2
EXHAUST MANIFOLD
AIR INJECTION PIPE
INTAKE MANIFOLD
5
6
CHECK VALVE
AIR INJECTION HOSE (AIR TO EXHAUST
PORT)
AIR INJECTION HOSE (TO AIR CLEANER

ASSEMBLY)
10-12-92
NS 15887
Figure C6-1 - AIR System Operation
OPERATION
The AIR pump with integral stop valve is
controlled by the ECM. The ECM will turn "ON" the
AIR pump and opens the stop valve by providing the
ground to complete the circuit which energizes the AIR
pump relay. When air (oxygen) to the catalyst is
desired the ECM turns "ON" both the stop valve and
AIR pump.
6
7
HOSE ASSEMBLY
PIPE ASSEMLBY
10
PIPE ASSEMBLY
CLAMP
CHECK VALVE
AIR INJECTION PUMP HOSE
NUT
BOLT/SCREW
PIPE ASSEMBLY
INSTALL TO EXHAUST
MANIFOLD AS SHOWN
NS 15850
Figure C6-2 - AIR System
The ECM turns "ON" the AIR pump after start-up any
time engine coolant temperature is above about 12C
(55F). The AIR pump will operate for a maximum of
about 3 minutes, or until the system enters "Closed
Loop" operation. At the same time the ECM turns the
AIR pump "OFF," it also de-energizes the integral stop
valve solenoid so no air is directed to the exhaust ports.
The air system will be disabled under the following
conditions:
When the ECM recognizes a problem and sets
a diagnostic trouble code.
When the fuel system is operating in "Closed
Loop."
The AIR pump has been "ON" for about three
minutes.
RPM is greater than 3200 for greater than 5
seconds.
MAP is greater than 86 kPa.
MAP is less than 11 kPa.
Engine coolant temperature less than 12C
(55F).
Battery voltage is less than 10 volts or greater
than 16 volts.
Power Enrichment (PE) is detected .
RESULTS OF INCORRECT OPERATION

If no air (oxygen) flow enters the exhaust stream,
HC and CO emission levels will be too high during cold
start conditions.
Air flowing to the exhaust stream at all times
could increase temperature of the oxidation catalytic
converter.
DIAGNOSIS
The diagnosis of the AIR system is covered below,
and in CHART C-6 at the end of this section.
OPERATIONAL CHECKS
AIR Pump
The AIR pump is a regenerative turbine type
which is permanently lubricated and requires no
periodic maintenance.
If the vehicle has been sitting overnight, refer to
CHART C-6. If the engine is at or near normal
operating temperature use the following procedure:
Using the Tech 1 scan tool, select "Miscellaneous Test"
then "Output Test." Select "AIR System" in "Output
Test" directory. Observe oxygen sensor voltage for
right (Bank 1) oxygen sensor.

Using the t arrow enable the "Output Test" for the
AIR system. The "Output Test" will energize the AIR
pump for only about 5 seconds. When the "Output
Test" is enabled, the right (Bank 1) oxygen sensor
voltage should remain under 400 m V because air is
being directed to the right bank exhaust port. If the
voltage remains low during the "Output Test," the AIR
pump and integral stop valve are operating
satisfactorily.
If the voltage does not remain low when the
"Output Test" is commanded "ON," proceed as follows.
!L'l'I Inspect
1. For a seized AIR pump (refer to CHART C-6).
2. Hoses, tubes and all connections for leaks and
proper routing.
3. For air flow going to the exhaust manifold.
4. AIR pump for proper mounting.
Hoses and Pipes
!L'l'! Inspect
4. If a leak is suspected on the pressure side of the

system or if a hose or pipe has been disconnected
on the pressure side, the connections should be
checked for leaks with a soapy water solution.
With the AIR pump running, bubbles will form if a
leak exists.
Check Valve
!L'l'I Inspect
1. A check valve should be inspected whenever the
hose is disconnected from a check valve or
whenever check valve failure is suspected. (An
AIR pump that had become inoperative and had
shown indications of having exhaust gases in the
outlet port would indicate check valve failure.)
2. Remove the check valve and blow through the
check valve (toward the exhaust manifold), then
attempt to blow through the other side of the check
valve. Flow should only be in one direction
(toward the exhaust manifold). Replace valve
which does not operate properly.
1. Hose or pipe for deterioration or holes.

2. All hoses or pipe connections, and clamp tightness.
3. Hose or pipe routing. Interference may cause
wear.
ABS HYDRAULIC MODULA TOR
LEFT SIDE FRAME RAIL
AIR PUMP
AIR PUMP ELECTRICAL CONNECTOR
AIR BRACKET
HOSE TO AIR CLEANER

NS 15265
Figure C6-3 AIR Pump Service
ON-VEHICLE SERVICE
AIR CHECK VALVE
AIR PUMP
Figure C6-3

2. Raise vehicle.
3. Harness connector from AIR pump.
4. Outlet and inlet hoses.
5. Air pump mounting bolts (3) from bracket.

1. AIR pump to bracket.
2. Mounting bolts (3).
l~I Tighten
3.
4.
5.
6.
7.
Bolts to 12 N m (9 lb. ft.).

Outlet and inlet hoses to pump.
Harness connector to AIR pump.
Lower vehicle.
Check AIR system for proper operation (refer to
CHARTC-6).
Refer to Figure C6-2.

1. Check valve clamp.
2. Hose from check valve.
3. Left check valve pipe.
4. Unscrew check valve from AIR pipe.
I++( Install or Connect

1.
Screw check valve onto AIR pipe.
I~( Tighten
Check valve to AIR pipe 19 Nm (14 lb. ft.).
2. Air pipe to exhaust manifold.
3. Air hose to check valve.
AIR PIPES AND HOSES

For "On-Vehicle Service" procedures, refer to
Figure C6-2.
Check Valve
AIR Pump Bolts
19 Nm (14 lb. ft.)

12 Nm (9 lb. ft.)
BLANK
ECM

TO
FUSE #T*
I G N I T I O N ~ 4 4 1 BRN
SWITCH
20 AMP
SECONDARY AIR
INJECTION PUMP
RELAY CONTROL
SECONDARY
AIR INJECTION
PUMP
RELAY*
- - - - . E ---436BRN
t
10-WAY FORWARD
LAMP HARNESS
CONN ECTOR (BLACK)
.--------78 R E D - - - - '
.....---78 R E D - - - - ~
ELECTRIC AIR PUMP

FROM
AIR
CLEANER __.....
ASSEMBLY
TO
EXHAUST
PORTS
~-------78RED-----'
'----------~18RE0---~
10-13-92
NS 15883
CHARTC-6
SECONDARY AIR INJECTION (AIR) SYSTEM CHECK
11
11
3.4L (VIN S) F CARLINE (SFI)
During cold starts, above 12C (55F), the ECM completes the ground circuit to the air pump relay which
energizes the air pump and integral stop valve. Air is directed to the right side exhaust port whenever the engine
is started. Whenever the fuel system goes to "Closed Loop," or the air pump has been "ON" for more than
approximately 3 minutes, the ECM opens the ground circuit to the air pump relay, and the air pump is deenergized and integral stop valve closes.

1. This is a system performance test. If both the AIR
pump and AIR check valve are functioning
properly, the amount of fresh air flowing past the
028 will cause a false lean condition (low voltage).
Move quickly through these first two steps.
2. Checks the ECMs ability to shut "OFF" the AIR
pump. Once turned "OFF," the AIR pump should
stay "OFF" for at least 200 seconds.
3.
Checks for battery voltage for the energizing coil

and switching portions of the AIR pump relay.
4. Checks for an open control circuit. Grounding the
diagnostic "Test" terminal or using the Tech 1
"Output Test" will energize the AIR pump relay if
the ECM and circuits are normal.
CHART C-6
SECONDARY AIR INJECTION (AIR)

SYSTEM CHECK
CORRECT ANY ECM DTC(s) BEFORE ENTERING THIS

DIAGNOSTIC PROCEDURE.
COOLANT TEMPERATURE BETWEEN 20C AND 60C.
ENGINE IDLING IN OPEN LOOP.
IS AIR PUMP WORKING?
[$]
IGNITION "OFF."
CHECK UNDERHOOD ELECTRICAL CENTER
FUSE #7 FOR BEING OPEN.
FUSE OK?
ENGINE STILL OPERATING IN OPEN LOOP.

RUN ENGINE TO 3300 RPM.
AIR PUMP SHOULD TURN "OFF" AFTER
APPROXIMATELY S SECONDS.
DOESIT?
REMOVE AIR PUMP RELAY.

PROBE TERMINAL "E 1" AND "ES"
OF UNDERHOOD ELECTRICAL
CENTER WITH A TEST LIGHT
CONNECTED TO GROUND.
IS LIGHT "ON" IN BOTH CIRCUITS?
REPAIR SHORT
TO GROUND
IN CKTs 441 OR
78.
REMOVE AIR
PUMP RELAY .
DOES AIR PUMP
STOP?
IGNITION "ON,"
ENGINE "OFF."
DISCONNECT HOSE
GOING TO THE AIR
CHECK VALVE.
GROUND DIAGNOSTIC
"TEST" TERMINAL OR
INSTALL TECH 1 AND
ENTER AIR SYSTEM
"OUTPUT TEST." IS AIR
PRESENT AT THE END
OF THE HOSE THAT
WAS DISCONNECTED?
PROBE TERMINAL "E2" OF AIR

PUMP RELAY HARNESS WITH A
TEST LIGHT CONNECTED TO B +.
GROUND DIAGNOSTIC TEST
TERMINAL AT DLC.
DOES LIGHT ILLUMINATE?
REPAIR OPEN
IN CIRCUIT
THAT DID
NOT LIGHT.
PROBE CKT
436ATAIR
PUMP RELAY
HARNESS
WITHA TEST
LIGHT TO B+.
DOES LIGHT
ILLUMINATE?
$
IGNITION "OFF."
JUMPER TERMINAL "E4" TO
TERMINAL "E1" OF AIR PUMP RELAY
HARNESS USING A FUSED JUMPER.
IGNITION "ON."
IS AIR PUMP ON?
CKT4360PEN
OR
FAULTY
CONNECTIONS
OR
FAULTY ECM.
DISCONNECT AIR PUMP

CONNECTOR.
PROBE TERMINALS "A"
AND "B" WITH A TEST
LIGHT TO GROUND.
IS LIGHT ON?
[$]
REPAIR OPEN OR
SHORT TO GROUND
IN CIRCUIT THAT
DID NOT LIGHT.
OPEN GROUND
CIRCUIT OR
FAULTY AIR
PUMP MOTOR.
FAULTY RELAY
CONNECTION
OR
FAUL TV RE LAV.
$
CKT(S) 78
SHORTED
TOB+.
$
CKT436
GROUNDED
OR FAULTY
ECM.
FAULTY
AIR
PUMP
RELAY.
DISCONNECT
AIR PUMP
CONNECTOR.
PROBE
TERMINAL
"B" OFAIR
PUMP
ELECTRICAL
CONNECTOR
WITHA TEST
LIGHT TO
GROUND.
GROUND
DIAGNOSTIC
"TEST"
TERMINAL.
DOES LIGHT
ILLUMINATE?
[$]
FAULTY AIR
PUMP
ELECTRICAL
CONNECTION
OR
FAULTY AIR
PUMP.
NO
TROUBLE
FOUND.
[$
CKT78
OPEN.
11-10-92
NS 15933
6E3-C6~8 3.4L (L32) (VIN S) (SFI) DRIVEABILITY AND EMISSIONS
BLANK
SECTION C7
EXHAUST GAS RECIRCULATION (EGR) SYSTEM

CONTENTS
General Description
Purpose
Operation
Digital EGR Valve
EGR Control
C7-1
C7-1
C7-1
C7-1
C7-2
GENERAL DESCRIPTION
PURPOSE
The EGR system is used to lower NOx (Oxides of
Nitrogen) emission levels caused by high combustion
temperature. It does this by decreasing combustion
temperature.
SOLENOID & MOUNTING PLATE ASSEMBLY
EGR BASE PLATE
EGR BASE GASKET
INSULATOR GASKET
EGR BASE
ARMATURE ASSEMBLY
SCREW ASSEMBLY
Figure C71 Digital EGR Valve
9P 0161-XV
Diagnosis
Results of Incorrect EGR System
Operation
On-Vehicle Service
Digital EGR Valve
C7-2
C7-2
C7-2
The main element of the system is the digital EGR

valve.
The digital EGR valve feeds small amounts of
exhaust gas back into the intake manifold and then
into the combustion chamber.
OPERATION
Digital EGR Valve
The digital (EGR) valve is designed to accurately
supply EGR to an engine, independent of intake
manifold vacuum. The valve controls EGR flow from
the exhaust to the intake manifold through three
orifices which increment in size to produce seven
combinations. When a solenoid is energized, the
armature, with attached shaft and swivel pintle is
lifted, opening the orifice.
The flow accuracy is dependent on metering orifice
size only, which results in improved control.
The swivel pintle feature insures good sealing of
exhaust gas, reducing the need of critical assembly
alignment. In addition, the effects of EGR leakage on
idle quality are reduced because the shaft and seals
are exposed to exhaust pressure instead of manifold
vacuum. The shafts are sealed from the .exhaust
chamber by floating seals held in place by the seal
spring. These springs also hold the upper seals that
seal the armature cavity in the solenoids.
The solenoid coils are fastened together to
maximize reliability and to seal the coils from the
environment. T,he coils use a common power terminal
with individual ground terminals.
The digital EGR valve is opened by the ECM
"quad-driver," grounding each respective solenoid
circuit. This quad-driver activates the solenoid, raises
the pintle, and allows exhaust gas flow into the intake
manifold. The exhaust gas then moves with the
air/fuel mixture into the combustion chamber. If too
much exhaust gas enters, combustion will not occur.
For this reason, very little exhaust gas is allowed to
pass through the valve, with virtually none at idle.
The EGR valve is usually open under the following
conditions:
Warm engine operation.
Above idle speed.
ON-VEHICLE SERVICE
EGRCONTROL
To regulate EGR flow, the ECM controls the EGR
solenoids to vary the amount of EGR flow. The ECM
uses information from the following sensors to
regulate the solenoid:
Manifold Absolute Pressure (MAP).
DIGITAL EGR VALVE

2. Electrical connector at solenoid.
3. Two (2) base to flange bolt/screws.
4. Digital EGR valve. Refer to Figure C7-2.
DIAGNOSIS
An EGR flow check diagnosis of the digital EGR
system is covered in CHART C-7.
RESULTS OF INCORRECT EGR SYSTEM

OPERATION
With too much EGR flow at idle, cruise, or cold
operation, any of the following conditions may occur:
Engine stops after cold start.
Engine stops at idle after deceleration.
Car surges during cruise.
Rough idle.
Too little or no EGR flow allows combustion
temperatures to get too high. This could cause:
Spark knock (detonation).
Engine overheating.
Emission test failure.
EGR valve gasket with "UP" readable after

positioning on adaptor.
3. Two (2) bolt/screws finger tight.
1.
Important
When tightening digital EGR valve bolts, they

must be in the following sequence:
I~! Tighten
1. Torque each bolt/screw to 15 Nm (11 lb. ft.).
2. Apply additional torque to each bolt/screw to
30 Nm (22 lb. ft.).
\
SHIELD NUT
/:If,..
SHIELD
GASKET
DIGITAL EGR VALUE ASSEMBLY
BOLT/SCREW (2)
BOLT/SCREW (4)
TUBE ASSEMBLY
GASKET
BOLT/SCREW (4)
10
GASKET
11
ADAPTOR
12
STUD (2)
13
SHIELD
NS 16235
Figure C7-2 Digital EGR Valve Assembly
BLANK
TO EVAPCANISTER
PURGE
SOLENOID]
VALVE - - - - 541BRN
--++- 698 BRN
TO COOLING 7UNDERHOOD
FAN CONTROL
ELECTRICAL CENTER
RELAY
FUSE #6
10AMP
ECM
r::,
L.!.J1-----.. .~---~ IGNITION
-------------~699RED
"'-------,,,,=.,,.- 697 LT BLU - - - - - - - - - - - - - 6 9 7 LT 8LU

TOP VIEW OF EGR VAL VE AND
EGR VALVE CONNECTOR
10-20-92
NS 15638
CHARTC-7
EXHAUST GAS RECIRCULATION (EGR) FLOW CHECK
The digital (EGR) valve is designed to accurately supply EGR to an engine independent of intake manifold
vacuum. The valve controls EGR flow from the exhaust to the intake manifold through three orifices which
increment in size to produce seven combinations. When a solenoid is energized, the armature with attached shaft
and swivel pintle is lifted, opening the orifice.
The flow accuracy is dependent on metering orifice size only, which results in improved control.

1. DTC(s) should be diagnosed using appropriate
charts before preparing a functional check.
rn
2. This step activates each solenoid individually. As

you energize #1 or #2 solenoid, the engine RPM
should drop. #3 solenoid has the largest port and
may stall the engine when energized.
Important
If the digital EGR valve shows signs of excessive heat (a melted condition), check the exhaust system for
blockage (possibly a plugged converter) using the procedure found on CHART B-1. If the exhaust system is
restricted, repair the cause. One possibility is an injector which is open due to one of the following:
A. Stuck.
B. Grounded driver circuit.
C. Possibly defective ECM.
If this condition is found, the oil should be checked for possible fuel contamination.
CHARTC-7
EXHAUST GAS RECIRCULATION (EGR) FLOW CHECK
G)

CHECK TECH 1 SCAN TOOL FOR DIAGNOSTIC TROUBLE CODES.
IF DIAGNOSTIC TROUBLE CODES ARE PRESENT, REFER TO THOSE CHARTS FIRST.
G)
USING TECH 1 SCAN TOOL, SELECT EGR OUTPUT TEST (MISCELLANEOUS).

START ENGINE AND ALLOW IDLE TO STABILIZE.
ENERGIZE EGR SOL #1, RPM SHOULD DROP SLIGHTLY.*
ENERGIZE EGR SOL #2, ENGINE SHOULD HAVE A ROUGH IDLE.*
ENERGIZE EGR SOL #3, ENGINE SHOULD IDLE ROUGH OR STALL*
DID IDLE QUALITY RESPOND AS INDICATED FOR EACH SOLENOID?
EGR SYSTEM IS OK.

NO PROBLEM FOUND.
CHECK EGR VALVE, EGR TRANSFER TUBE, ADAPTOR, GASKETS,

FITTINGS AND ALL PASSAGES FOR DAMAGE, LEAKAGE OR
PLUGGING. IF OK, REPLACE EGR VALVE.
THESE STEPS MUST BE DONE VERY QUICKLY, AS THE ECM WILL

ADJUST THE IDLE AIR CONTROL VALVE TO CORRECT IDLE SPEED.
11-12-92
NS 16236
BLANK
SECTION
ca
TORQUE CONVERTER CLUTCH (TCC} SYSTEM

CONTENTS
General Description
Purpose
Operation
... ...... . ..... ....
C8-1
C8-1
C8-1
Automatic Transmission TCC System
Diagnosis
On-Vehicle Service
C8-1
C8-2
C8-2
GENERAL DESCRIPTION
PURPOSE
The Torque Converter Clutch (TCC) system uses a
solenoid operated valve in the automatic transmission
to couple the engine flywheel to the output shaft of the
transmission through the torque converter. This
reduces the slippage losses in the converter, which
increases fuel economy.
OPERATION
OJ
ITJ

For the Torque Converter Clutch (TCC) to apply,
two conditions must be met:
Internal transmission fluid pressure must be
correct. For information on internal
transmission operation, refer to SECTION 7A.
This section will cover only the electrical
operation of the TCC system.
The ECM grounds a switch internally to turn
"ON" the TCC solenoid in the transmission.
This moves a check ball which will allow the
torque converter clutch to apply, if the
hydraulic pressure is correct, as described
above.
The ECM controls the TCC solenoid by looking at
several sensors:
Vehicle Speed Sensor (VSS). Speed must be
above a certain value before the clutch can
apply.
The vehicle speed sensor is mounted in the
transmission. It replaces the conventional
speedometer driven gear and cable assembly,
and provides an electrical signal to the ECM.
The Vehicle Speed Sensor or VSS, is actually a
small Permanent Magnet (PM) generator. It
uses a gear driven by the transmission, to
generate voltage pulses at a rate of 4000 pulses
per mile.
SENSOR CONNECTOR
SPEEDO DRIVEN GEAR
VEHICLE SPEED SENSOR
MS 13244
Figure CS-1 Vehicle Speed Sensor (VSS)
Engine Coolant Temperature (ECT) Sensor.

Engine must be warmed up before the torque
converter clutch can apply about 60C (144F).
Throttle Position (TP) Sensor. After the torque
converter clutch applies, the ECM uses the
information from the TP sensor to release the
clutch when the vehicle is accelerating or
decelerating at a calibrated rate.
Gear Select Switch. A 4th gear switch is used
to send a signal to the ECM when the
transmission is in 4th gear. The ECM uses this
information to alter the conditions under
which the clutch applies or releases in 4th gear
only. The transmission need not be in 4th gear
to apply the clutch.
The brake switch is also part of the TCC circuit
as it will remove battery voltage to the TCC
solenoid when the brake pedal is depressed.
If the Torque Converter Clutch (TCC) is applied at
all times, the engine will stall immediately,just as in a
manual transmission with the clutch applied.
If the Torque Converter Clutch (TCC) does not
apply, fuel economy may be lower than expected. If
the vehicle speed sensor fails, the TCC will not apply.
If the 4th gear switch does not operate, the TCC may
not apply at the right time.
ON-VEHICLE SERVICE
TCC SOLENOID
2
CHECKBALLSEAT
CHECKBALL
4S0548-6E
Figure CS-2 - TCC Solenoid
DIAGNOSIS
The diagnosis of the TCC system is covered in
CHART C-8. If the ECM detects a problem in the VSS
system, a OTC 24 should set. In this case, refer to OTC
24chart.
Refer to SECTION 7A for further TCC diagnosis

and repair.
Refer to SECTION SA for VSS service procedures.
Refer to SECTION SA for wiring harness repair.
Refer to "Engine Control Module (ECM) and
Sensors," Section "6E3-Cl" if the ECM needs
reprogramming or replacement.
BLANK
SPEEDVEHICLE
SENSOR (VSS)
(TRANS MOUNTED)
O9
ECM
~ A B1 1 - - - - - - - - 4 0 0 YEL
VSS INPUT HIGH
- - - - - - - 4 0 1 PPL
VSS INPUT LOW
~r-'-111-----1~
INSTRUMENT
CLUSTER
817DKGRN/WHT

10-WAYINLINE
1/P CONNECTOR #1
(NATURAL)
MALFUNCTION
10 WAY INLINE 1/P
INDICATOR LAMP (MIL) CON ECTOR #2 (BLUE)
419BRN/WHT
MIL CONTROL
TO BRAKE
TRANSMISSION SHIFT
INTERRUPT {BTSI)
SOLENOID
4th GEAR
SWITCH
4th GEAR SWITCH
AUTOMATIC
TRANS TCC
SOLENOID
DATA LINK
CONNECTOR
(DLC)
F t----~
CLUTCH
ANTICIPATE/CRUISE
RELEASE SWITCH
1--------48GRY
451 BLK/WHT
CLUTCH ANTICIPATE
INPUT (MIT ONLY)
10-27-92
NS 15888
CHART C-8
(Page 1 of 2)
TORQUE CONVERTER CLUTCH (TCC) SYSTEM

The purpose of the automatic transmission Torque Converter Clutch (TCC) feature is to eliminate the power
loss of the torque converter stage, when the vehicle is in a cruise condition. This allows the convenience of the
automa~ic ~ransmission and the fuel economy of a manual transmission. The heart of the system is a solenoid,
located ms1de the automatic transmission, which is controlled by the ECM.
When the solenoid coil is activated "ON," the torque converter clutch is applied, which results in straight
through mechanical coupling from the engine to transmission. When the transmission solenoid is deactivated,
the Torque Converter Clutch (TCC) is released which allows the torque converter to operate in the conventional
manner (fluid coupling between engine and transmission).
T~e ECM tur~s "ON" the TCC when engine coolant temperature is above 60C (144F), TP sensor not
changmg, and vehicle speed above a calibrated value.
but this does not confirm that the TCC has engaged.
To determine if the TCC is functioning properly,
1. When a test light is connected from DLC terminal
engine RPM should decrease when the Tech 1 scan tool
"F" to ground, a test light "ON" indicates battery
indicates the TCC driver has turned "ON" while road
voltage is OK and the TCC solenoid is disengaged.
testing. To determine if the 4th gear switch is
2. When the diagnos~ic terminal is grounded, the
functioning properly, perform the checks in CHART CECM should energize the TCC solenoid and the
8 (Page 2 of 2). The switches will not prevent TCC
test light should go out.
from functioning, but will affect TCC lock and unlock
Diagnostic Aids:
points.
A Tech 1 scan tool only indicates when the ECM
has turned "ON" the TCC driver (grounded CKT 422),
CHART C-8
(Page 1 of 2)

USING A TECH 1 SCAN TOOL, CHECK THE FOLLOWING AND CORRECT IF NECESSARY.
COOLANT TEMPERATURE SHOULD BE ABOVE 60C.
TP SENSOR- BE SURE TP SENSOR SIGNAL IS NOT ERRATIC.
VSS - BE SURE TECH 1 SCAN TOOL DISPLAYS VSS WITH DRIVE WHEELS TURNING.
IF OTC 24 IS PRESENT, SEE OTC 24 CHART.
G)
MECHANICAL CHECKS, SUCH AS LINKAGE, OIL LEVEL, ETC., SHOULD BE

PERFORMED PRIOR TO USING THIS CHART.
IGNITION oN."
CONNECT TEST LIGHT TO DLC CONNECTOR TERMINAL "F" AND GROUND.
BULB SHOULD "LIGHT."
DOESIT?
DISCONNECT TCC ELECTRICAL CONNECTOR.

CONNECT TEST LIGHT BETWEEN TERMINALS" A" & "D".
BULB SHOULD NOT LIGHT.
DOESIT?
BRAKE SWITCH OUT

OF ADJUSTMENT OR
FAULTY
OR
CKT 422 SHORTED TO
VOLTAGE.

TERMINAL "A" TO GROUND.
BULB SHOULD LIGHT.
DOES IT?
CKT 422 SHORTED

TO GROUND
OR
FAULTY ECM.
OPEN CKT422
OR
FAULTY ECM.
GROUND DLC TERMINAL "F".

WITH TEST LIGHT CONNECTED
BETWEEN TRANSMISSION
CONNECTOR TERMINALS "A"
AND"D".
THE BULB SHOULD LIGHT.
DOESIT?
OPEN CKT 39, TCC BRAKE

SWITCH CIRCUIT
OR
ADJUST SWITCH.

LIGHT SHOULD GO OUT.
DOES IT?

RELEASE BRAKE PEDAL.
GROUND DIAGNOSTIC "TEST"
TERMINAL.
DOES IT?
TCC CIRCUIT OK. BE SURE VEHICLE IS

PROGRAMMED WITH THE CORRECT
CALIBRATION. TOCHECK4th GEAR
SWITCH, SEE CHART C-8 (2 OF 2).
FAULTY TCC CONNECTION

OR
TCC SOLENOID.
REPAIR OPEN CIRCUIT

BETWEEN TRANSMISSION
AND DLC TERMINAL "F".
11-10-92
8S4679-6E
VEHICLE
SPEED SENSOR (VSS)
(TRANS MOUNTED)
Oq
ECM
~ A B1 - - - - - - - - 4 0 0 Y E L
VSS INPUT HIGH
- - - - - - - - 4 0 1 PPL
VSS INPUT LOW
~-"-111-----1~
INSTRUMENT
CLUSTER
817DKGRN/WHT

10-WAY INLINE
1/P CONNECTOR #1
(NATURAL)
MALFUNCTION
10 WAY INLINE 1/P
INDICATOR LAMP (MIL) CON ECTOR #2 (BLUE)
r--,
1/P FUSE #9
SWITCH
TOIGN _ _ _ _ ___
419 BRN/WHT
L--J
(SERVICE ENGINE SOON) ,---:-- ---- -- - - -,
I
BRAKE SWITCH
I
:
ASSEMBLY
:
TO BRAKE
TRANSMISSION SHIFT
INTERRUPT (BTSI)
SOLENOID
39 PNK/8LK
A
~
583 LT BLU/BLK:
BRAKE II
ITCC
SWITCH :
L--------------.J
4th GEAR
SWITCH
..-~~~~-'!~-..--
..,..__ _ _ _ _ _ _ _ 583 LT BLU/BLK
- - - - - - - - - - - 4 4 6 LT BLU
AUTOMATIC
TRANS TCC
SOLENOID
DATA LINK
CONNECTOR
(DLC)
MIL CONTROL
CLUTCH
ANTICIPATE/CRUISE
RELEASE SWITCH
4th GEAR SWITCH
1----~
1--------48GRY
451 BLK/WHT
CLUTCH ANTICIPATE
INPUT (MIT ONLY)
10-27-92
NS 15888
CHARTC-8
(Page 2 of 2)

A 4th gear switch (mounted in the transmission) closes when the transmission shifts into 4th gear, and this
switch is used by the ECM to modify TCC lock and unlock points, when in a 4-3 downshift maneuver.
scan tool to display "YES," indicating the
transmission is in 4th gear.
1. Unless the switch or CKT 446 is closed, the Tech 1
Diagnostic Aids:
scan tool should display "NO," indicating the
transmission is not in 4th gear. The 4th gear
A road test may be necessary to verify the
switch should only be closed while in 4th gear.
2. Checks the operation of the 4th gear switch. When
customer complaint. If the Tech 1 scan tool indicates
TCC is turning "ON" and "OFF" erratically, check the
the transmission shifts into 4th gear, the switch
state of the 4th gear switch to be sure it is not changing
should close and the Tech 1 scan tool should
display "YES."
states under a steady throttle position. If the switch is
changing states, check connections and wire routing
3. Disconnecting the TCC connector simulates an
carefully. Also, if the 4th gear switch is always closed,
open switch to determine if CKT 446 is shorted to
the TCC may engage as soon as sufficient oil pressure
ground or the problem is in the transmission.
is reached.
4. This step determines if the ECM and wiring are
OK. Grounding CKT 446 should cause the Tech 1
CHARTC-8
(Page 2 of 2)

G)
CHECKS MADE ON THIS PAGE WILL NOT PREVENT THE TCC FROM WORKING,
BUT WILL AFFECT ENGAGEMENT OR DISENGAGEMENT POINTS.

DOES SCAN TOOL INDICATE
TRANSMISSION IS IN 4th GEAR?
RAISE DRIVE WHEELS.

START ENGINE.
SHIFT VEHICLE INTO OVERDRIVE.
INCREASE SPEED SLOWLY UNTIL TRANSMISSION SHIFTS
INTO 4th GEAR.
DOES SCAN TOOL INDICATE TRANSMISSION IS IN 4th
GEAR?
4th GEAR SWITCH

OK. REFERTO
"DIAGNOSTIC AIDS"
ON FACING PAGE.
DISCONNECT TCC ELECTRICAL

CONNECTOR.
JUMPER HARNESS TERMINAL "B"
{CKT 446) TO GROUND.
DOES SCAN TOOL INDICATE
FAULTY CONNECTION
OR
FAULTY 4th GEAR SWITCH
IN TRANSMISSION.

DISCONNECT TRANSMISSION ELECTRICAL CONNECTOR.
DOES SCAN TOOL INDICATE TRANSMISSION IS IN 4th
GEAR?
CKT 446 SHORTED

TO GROUND
OR
FAULTY ECM.
FAUL TY 4th GEAR SWITCH

OR
CKT 446 GROUNDED
INTERNALLY IN TRANSMISSION.
OPEN CKT 446, FAULTY CONNECTION

OR
FAULTY ECM.
3-4-92
9S6746-6E
BLANK
SECTION C10
A/C COMPRESSOR CLUTCH CONTROL

CONTENTS
General Description
Operation
Diagnosis
C10-1
C10-1
C10-1
GENERAL DESCRIPTION
In order to improve engine operation, and protect
the NC compressor and clutch during Wide Open
Throttle (WOT) performance, the NC compressor
operation is controlled by the ECM.
OPERATION
The A/C electrical system consists of an A/C
control head, A/C refrigerant low pressure cutoff
switch, an A/C refrigerant pressure sensor, an
evaporator temperature sensor, a control relay, the
compressor clutch, and the ECM.
When A/C is selected "ON" through the A/C
control head, a 12 volt signal is supplied to the NC
request input of the ECM. The ECM will poll the NC
refrigerant pressure sensor and A/C evaporator
temperature sensor before enabling the compressor
clutch control relay. If either switch detects a pressure
or temperature variation above or below a calibrated
acceptable range, the clutch relay will not be enabled.
When the ECM determines that the system
temperature and pressure are within acceptable
ranges, the A/C compressor clutch relay will be
enabled, allowing voltage to be applied to the A/C
clutch and NC status input of the ECM. The NC
status input informs the ECM that the relay has closed
and voltage is applied to the clutch, via the A/C
compressor low pressure cutoff switch. The A/C
compressor low pressure cutoff switch is closed when
there is sufficient system pressure (depending on
refrigerant charge and ambient temperature). The
ECM will also turn the cooling fan "ON" when NC is
requested. Refer to "Cooling Fan Control," Section
"6E3-C12" for more information on cooling fan
operation. NC is controlled by the ECM so that the
ECM can increase idle speed before turning "ON" the
clutch or disable the clutch during WOT or high
coolant temperatures.
DIAGNOSIS
The ECM will energize the NC clutch whenever
the engine is running and NC has been requested,
unless any of the following conditions are met:
Wide Open Throttle (WOT).
On-Vehicle Service
A/C Relay
C10-1
C10-1
NC head pressure greater than 492 psi or less

than 1 psi (as determined by the A/C
refrigerant pressure sensor).
Evaporator temperature sensor less than 1C
(33F).
Low ignition voltage.
IAT greater than 151C (304F).
Engine speed greater than 5200 RPM.
ECT greater than 124C (255F).
CHART C-10 should be used for diagnosing the
electrical portion of the NC circuit. SECTION lB of
the service manual should be used for diagnosing the
refrigerant portion of the system.
The Tech 1 will be used in diagnosing the system,
as it has the ability to monitor the NC request input to
the ECM, NC status, NC system pressure, as well as
displaying when the ECM has commanded the A/C
clutch "ON."
ON-VEHICLE SERVICE
A/CRELAY

2. Cover from underhood electrical center.
3. Relay from underhood electrical center.

1. Relay to underhood electrical center.
2. Cover to underhood electrical center.
For removal and replacement procedures of A/C
components, refer to SECTION lB of the service
manual.

AIR PUMP
RELAY
COOLANT FAN
RELAY, PRIMARY
ABS
RELAY
A/C COMPRESSOR
RELAY
~
~
~
~
INJECTOR
INJECTOR
IGNITION
A/C-CRUISE
LOW COOLANT
RELAY
FOG LIGHTS
RELAY
HIGH BLOWER
RELAY
TOP VIEW
#48
~#a!ZI
#7EJ
502
#200
#6EJ
#5~
641
#38
so
#18
G []}
J 84
H 004
84
~ E]2 E] ~ [[)2 sG ~ E]2 56 ~ B
2
81
B1
01
01
4
4
4
4
@E]
0
~
~
C8J
C8J EJsB 3
C8J
3 E]sEJ
3 B
2
2
2 s[i] 3 2
E ~1
c
;
D EL
B
1
81
#128
58
,....
C8J;
58
139
#118
3
#108
#98
BACK VIEW
NS 15595
Figure C10-1 -A/C Clutch Control Relay Location
DRIVEABILITY AND EMISSIONS 3.4l (L32) (VIN S) (SFI) 6E3-C10-3
BLANK
TOIATAND
MAP SENSOR
A/C
REFRIGERANT
PRESSURE
SENSOR
808BLK----------_,.------t
SENSOR GROUNDS
---------+-------.
A/C REFRIGERANT
PRESSURE SENSOR
SIGNAL
380 RED/BLK
416GRY-------,
A/C
EVAPORATOR
TEMPERATURE
SENSOR
808 BLK
-------+------'
732DKBLU------+----------,
1/P FUSE #3
ECM
416GRv------..---e----------.
A/C
~----,.,... TO TP AND
SELECT SWITCH
MAP SENSOR
TO ~ 2 4 1 BRN - - - - - - ~ - - - - - - - 7 6 2 LTGRN/BLK
IGNITION
25AMP
FUSE #12 *
SWITC~--~-------------.- ,.,,,,-- 139 PN K - - - ,
20AMP
A/C EVAPORATOR
TEMPERATURE SIGNAL
SV REFERENCE
A/CREQUEST
~-----""811--------J
A/C
COMPRESSOR
CLUTCH
CONTROL
RELAY*

CONNECTOR (BLACK)
.---,
I
1------------rt
459 DK GRN/WHT
-------+t
59DKGRN
L--_.
CLUTCH
A/C COMPRESSOR
CLUTCH RELAY
A/CSTATUS
~450BLKl
............. A/C COMPRESSOR LOW

11-1292
NS 15598
CHART C-10
(Page 1 of 2)
A/C COMPRESSOR CLUTCH CONTROL CIRCUIT DIAGNOSIS
The NC compressor clutch control relay is ECM controlled to delay NC clutch engagement after the A/C is
turned "ON." This allows the ECM to adjust engine RPM before the NC compressor clutch engages.
The ECM will engage the NC clutch any time NC has been requested unless any of the following conditions
exist:
High coolant temperature.
High engine RPM.
Low system pressure.
Wide open throttle.
High NC system pressure.
Any NC OTC set.
The ECM determines NC has been requested by receiving a voltage signal from the NC control head. When
the NC control switch closes, the NC request input has 12 volts applied to it. This is shown on the Tech 1 as NC
request "YES." A 3-wire NC refrigerant pressure sensor is used to monitor NC system pressure. If the NC
refrigerant pressure is greater than 430 psi or lower than Opsi, the NC clutch will not engage.
A faulty NC refrigerant pressure sensor will set a OTC 66 or 67. If the NC refrigerant pressure sensor signal
wire becomes open or shorted to ground, OTC 66 will set. If the signal circuit is shorted to voltage, a OTC 70 will
set. If the NC clutch engages and no pressure change is detected, a OTC 67 will set.
When a request for NC has been detected by the ECM, the ECM will ground the NC compressor clutch
control relay drive circuit, the relay contacts will close, and current will flow through the relay to the NC
compressor clutch.
Diagnostic Aids:

1. Checks the ECMs ability to control the NC clutch
control relay.
2. Checks for grounded CKT 459 to ECM.
Before using CHART C-10, be sure no OTC(s) are

stored. The ECM will not energize the NC compressor
clutch with a stored DTC.
CHART C-10
(Page 1 of 2)

CONTROL CIRCUIT DIAGNOSIS
3.4L (VIN S) ,.F,, CARLINE (SFI)
CHECK "A/C" FUSES.

ENGINE AT NORMAL OPERATING TEMPERATURE.
CORRECT ANY DIAGNOSTIC TROUBLE CODES.
A/C REFRIGERANT PRESSURE NORMAL.
ENGINE IDLING.
A/C "OFF."
IS A/C CLUTCH MECHANICALLY ENGAGED?
WITH ENGINE IDLING AT NORMAL OPERATING

TEMPERATURE, TURN A/C "ON" AND "OFF."
DOES A/C CLUTCH CYCLE "ON" AND "OFF"?
PLACE A/C SELECT IN A/C MODE.

TECH 1 SHOULD DISPLAY A/C
REQUEST "YES."
DOESIT?
NO TROUBLE
FOUND. A/C
CLUTCH
CIRCUIT OK.
ENGINE STILL RUNNING.

TECH 1 SHOULD DISPLAY A/C REQUEST "NO."
DOES IT?
DISCONNECT A/C
RELAY.
PROBE CKT 459 WITH
A TEST LIGHT TO B +.
IS TEST LIGHT "ON"?
CKT 762 SHORTED

TO VOLTAGE
OR
FAULTYA/C
CONTROL HEAD.
PROBE CKT 59 WITH

A TEST LIGHT TO
GROUND.
IS TEST LIGHT "ON"?
CKT 459 SHORTED TO

GROUND
OR
FAULTY ECM.
r-- -----,
I REFERTO
I
: CHARTC-10. :
I PAGE 2 OF 2. I
l..--------..1
1---------------------...
CHECKFORSHORTTO
GROUND IN CKT 241 OR 762.
CHECK FOR OPEN CKT

7620R241 OR
FAUL TY AC SELECT
SWITCH OR FAULTY
ECM CONNECTION OR
FAULTY ECM.
CKT590R603
SHORTED TO
VOLTAGE.
12-21-92
NS 16213
TOIATAND
MAP SENSOR
A/C
REFRIGERANT
PRESSURE
SENSOR
808BLK-------------------t
SENSOR GROUNDS
----------1-------1
A/C REFRIGERANT
PRESSURE SENSOR
SIGNAL
380 RED/BLK
416GRY-----~
A/C
EVAPORATOR
TEMPERATURE
SENSOR
ECM
808BLK-------+-----'
732DKBLU------+-----------t
1/P FUSE #3
416GRv---------------------t
A/C
'-----;~TO TP AND
SELECT SWITCH
MAP SENSOR
TO ~ 2 4 1 BRN - - - - - - ~ - - - - - - - 7 6 2 LTGRN/BLK
A/C EVAPORATOR
TEMPERATURE SIGNAL
5V REFERENCE
A/CREQUEST
IGNITION
25AMP
FUSE #12"
SWITC~~-- - - - - - - - - - - - ,..,,.- 139 PNK - - - ,
20AMP
A/C
COMPRESSOR
CLUTCH
CONTROL
RELAY"

CONN ECTOR (BLACK)
.---,
I
t-----------.-1
459 DK GRN/WHT
A/C COMPRESSOR
CLUTCH RELAY
A/CSTATUS
'---..J
CLUTCH
~450BLKl
.............. A/C COMPRESSOR LOW

" LOCATED IN UNDERHOOD ELECTRICAL CENTER
11-12-92
NS 15598
CHART C-10
{Page 2 of 2)
A/C COMPRESSOR CLUTCH CONTROL CIRCUIT DIAGNOSIS

The A/C clutch control relay is ECM controlled to delay A/C clutch engagement after the A/C is turned "ON."
This allows the ECM to adjust engine RPM before the A/C clutch engages.
The ECM will engage the A/C clutch any time A/C has been requested unless any of the following conditions
exist:
High engine RPM.
Low system pressure.
Wide open throttle.
High A/C system pressure.
Any AIC OTC set.
The ECM can determine AIC has been requested by a voltage signal received from the AJC control head.
When the AIC select switch closes, the AIC request voltage signal is applied to the ECM A/C request input. This
is shown on the Tech 1 as A/C request "ON." A 3-wire A/C refrigerant pressure sensor is used to monitor A/C
system pressure. If the AIC refrigerant pressure is greater than 430 psi or lower than O psi, the AIC clutch will
not engage.
The A/C refrigerant pressure sensor uses OTCs 66, 67 and 70 to indicate sensor or sensor circuit
malfunctions. If the AIC refrigerant pressure sensor signal wire becomes open or shorted to ground, OTC 66 will
set. If the signal line is shorted to voltage a OTC 70 is set. If the A/C clutch engages and no pressure change is
detected, a OTC 67 will set.
When a request for AIC has been detected by the ECM, the ECM will ground the A/C clutch control relay
drive circuit, the relay contacts will close, and current will flow through the relay to the AIC compressor clutch
via the AIC compressor low pressure cutoff switch.
CHART C-10
(Page 2 of 2)
r--------------,
: FROM CHART C-10 :
I
PAGE 1 OF 2
L,._

CONTROL CIRCUIT DIAGNOSIS
11
----------~
DOES TECH 1 DISPLAY A/C CLUTCH "ON?"
REFER TO APPROPRIATE DTC FOR DIAGNOSIS.
DISCONNECT A/C COMPRESSOR LOW

PRESSURE CUT "OFF" SWITCH.
JUMPER TERMINALS "B" TO "A".
DOES CLUTCH ENGAGE.
FAULTY
SWITCH OR
SWITCH
CONNECTION.
IGNITION "OFF."
DISCONNECT A/C
CLUTCH CONNECTOR.
IGNITION "ON"
ENGINE "ON."
PROBE "CKT 603"
GROUND.
IS LIGHT "ON"?
IGNITION "OFF."
REMOVE A/C RELAY.
IGNITION "ON."
USING A TEST LIGHT, PROBE BOTH IGNITION
FEED CIRCUITS CIRCUITS FROM A/C RELAY
HARNESS TO GROUND.
LIGHT"ON"BOTH
NO LIGHT ONE OR BOTH
JUMPER CKT 139 TO

CKTS9.
A/C STATUS "ON"?
CONNECT TEST
LIGHT BETWEEN
A/C COMPRESSOR
CLUTCH HARNESS
CONNECTOR
TERMINALS.
FAUL TY CLUTCH
CONNECTION
OR
FAULTY A/C
COMPRESSOR
CLUTCH COIL.
OPEN OR
SHORT TO
GROUND IN
CKT59 OR603
FROM SPLICE
TO CLUTCH.
OPEN CKT450
OR
FAULTY
GROUND
CONNECTION.
FAULTY ECM
CONNECTION
OR OPEN A/C
STATUS
CIRCUIT
FROM SPLICE
TO ECMOR
FAULTY ECM.
OPEN
A/C
CIRCUIT
FROM
RELAY
TO
SPLICE.
OPEN IN
CIRCUIT THAT
DID NOT
LIGHT.
IGNITION "ON."
GROUND
DIAGNOSTIC
"TEST" TERMINAL.
PROBE TERMINAL
"BS" (CKT 459) WITH
A TEST LIGHT TO
B+.
WITH A TEST LIGHT
TOB+.
FAULTY
A/C
RELAY.
OPEN OR SHORT
TO VOLTAGE IN
CKT459 OR
FAULTY ECM
CONN.QR
FAULTY ECM.
12-21-92
NS 16214
BLANK
SECTION C12
COOLING FAN CONTROL

CONTENTS
General Description
Operation
C12-1
C12-1
Diagnosis
On-Vehicle Service
C12-1
(12-1
GENERAL DESCRIPTION
ON-VEHICLE SERVICE
This vehicie utilizes an electric cooling fan for

engine and NC condenser cooling. The fan operates
under certain conditions as outlined below.
Cooling system component replacement can be

found in SECTION 6B.
OPERATION
The engine coolant fan is controlled by the ECM
via the coolant fan relay. A calibrated set of criteria
programmed into the ECM will energize the fan relay.
The following conditions control the fan:
Engine Coolant Temperature (ECT) sensor
signal indicating 109C (228F) or greater will
turn the coolant fan "ON."
Engine Coolant Temperature (ECT) sensor
signal indicating 98C or less will turn the fan
"OFF."
The fan will turn "ON" if NC is requested and
vehicle speed is less than 56 km/h (35 mph).
If vehicle speed is greater than 113 km/h (70
mph) the fan is disabled and will not turn
"ON."
If NC is requested and refrigerant pressure
sensor indicates approximately 20 psi or
greater the fan is turned "ON."
When the ECM is operating in backup the fan
will be "ON."
When any NC DTC is set the fan will be "ON."
DIAGNOSIS
The following C-12 circuits charts will diagnose
the ECM controlled cooling fans.
3
1
LEFT SIDE WHEELHOUSE
RELAY CENTER
HEADLAMP ACTUATOR MODULE

NS 15935
Figure C12-1 -Cooling Fan Relay
6E3-C12-2 3.4L (L32) (VIN S) (SFI) DRIVEABILITYAND EMISSIONS
ECM
B+
FUSE LINK
~402RED
10-WAYINLINE FWD
LAMP HARNESS
CONNECTOR (BLACK)
COOLING FAN CONTROL
335DKGRN
COOLING
FAN
CONTROL
RELAY*
409 LT BLU
150BL.K
TO IGN
TO DIGITAL EGR,
EVAP PURGE SOL VALVE
A/C
1/P FUSE #3
.
. SELECT SWITCH
TO ~ 2 4 1 B R N ~ - - - - - - - 7 6 2 L T G R N / B L K
IGNITION
25 AMP
SWITCH
A/C
REFRIGERANT
PRESSURE
SENSOR
808BLK_;_--------------t
380REDffiLK--------------t
416GRY _ _;___ _ _ _ _ _ _ _ _~ - - t
A/CREQUEST
SENSOR GROUND
SENSOR SIGNAL
5VREF
10-16-92
NS 15936
* LOCATE.DIN UNDERHOOD ELECTRICAL CENTER
CHART C-12
. (Page 1 of 2)
COOLING FAN CONTROL CIRCUIT DIAGNOSIS

3.4L (VIN S}l'F" CARLINE (SFI)
..
The electric cooling fan is controlled by the ECM, based on inputs from the Engine Coolant Temperature
(ECT) sensor, the AJC control switches, vehicle speed, and state of the AJC refrigerant pressure sensor. The ECM
controls the fan by grounding CKT 335 which energizes the fan control relay. Battery voltage is then supplied to
the fan motor.
The ECM grounds CKT 335 when engine coolant temperature is over about 109C (228F), or when A/C has
been requested and the A/C refrigerant pressure is about 1655 kPa (240 psi). Once the ECM turns the relay
"ON," it will keep it "ON" for a minimum of 30 seconds, or until vehicle speed exceeds 113 km/h (70 mph).
Also, if DTC 14 or 15 sets or the ECM is in back up, the primary fan will run at all time.

1. With the diagnostic terminal grounded, the
cooling fan control driver(s) will close, which
should energize the fan control relay(s).
2. If the AJC pressure is above 240 psi (1655 kPa) or
circuit is open, the fan would run whenever AJC is
requested.
3. With A/C clutch engaged and the AJC refrigerant
pressure sensor is functioning properly, the fan
should come "ON" when pressure exceeds about 20
psi. Under very cold ambient conditions, the fan
will remain "OFF." This signal should cause the
ECM to energize the cooling fan control relay.
4. This will determine if the A/C refrigerant pressure
sensor is faulty or if the ECM or circuitry is faulty.
Diagnostic Aids:
If the owner complained of an overheating
problem, it must be determined if the complaint was
due to an actual boilover, a hot light or temp. gage
indicated over heating.
If the gage or light indicates overheating, but no
boilover is detected, the gage circuit should be
checked.
CHART C-12

INDICATING LESS THAN 98C (208F).
IGNITION "ON,'" ENGINE "OFF," A/C "OFF."
COOLING FAN SHOULD BE "OFF."
ISIT?
(Page 1 of 2)

3.4L (VIN S) "F" CARLINE (MFI)
GROUND DIAGNOSTIC TEST TERMINAL, OR

SELECT COOLING FAN "OUTPUT" TEST ON TECH 1.
FAN SHOULD TURN "ON."
DOES IT?
r-"~~~~~~~~~~~~~-,r
UNGROUND DIAGNOSTIC TEST

TERMINAL OR EXIT OUTPUT TEST.
START AND IDLE ENGINE.
A/C "OFF.'"
FAN SHOULD BE "OFF" WHILE
TEMPERATURE IS UNDER 98C (208F)).
ISIT?
----,
REFER TO I
: CHART :
I
C-12
1
1 (2 OF 2) 1
I

LIGHT TO 12 VOLTS.
L------.l
CKT 335 SHORTED TO

FAN '"ON"
FAUL TY CALIBRATION OR ECM.
WITHOUT
A/C
,;-{"
ENGINE IDLING, A/C "OFF."

USE A TECH 1 SCAN TOOL AND CHECK A/C REFRIGERANT PRESSURE SENSOR.
DOES TECH 1 SCAN TOOL DISPLAY PRESSURE GREATER THAN 240 psi (1655 kPa)'?
----------------------,
ENGINE IDLING, A/C "ON.''
DISCONNECT A/C REFRIGERANT PRESSURE SENSOR.

DOES SCAN INDICATE ZERO A/C PRESSURE?
IF A/C IS INOPERATIVE SEE CHART :

~1~
FAN SHOULD TURN "ON" WHEN

A/C IS REQUESTED AND HEAD
PRESSURE EXCEEDS ABOUT
20psi.
:
I
:
I
----------------------~
NO TROUBLE
FOUND. REFER TO
"DIAGNOSTIC AIDS"
OF FACING PAGE.
OPEN CKT 808 OR FAUL TY

SENSOR CONNECTOR
OR FAUL TY SENSOR.

MEASURE VOLTAGE BETWEEN CONNECTOR TERMINAL "B" AND" A."
VOLTMETER SHOULD DISPLAY ABOUT 5 VOL TS.
DOES IT?
MEASURE VOLTAGE BETWEEN

CONNECTOR TERMINAL '"B" AND '"C."
VOLTMETER SHOULD READ 5 VOL TS.
DOESIT?
CKT 380 OPEN OR

SHORTED TO GROUND
OR FAULTY ECM
CONNECTION OR ECM.
MEASURE VOLTAGE BETWEEN CONNECTOR

TERMINAL "B" AND GROUND.
VOLTMETER SHOULD DISPLAY ABOUT 5 VOL TS.
DOES IT?
CKT8080PEN
OR FAULTY ECM
CONNECTION
ORECM.
CKT 416 OPEN OR

SHORTED TO GROUND
OR FAUL TY ECM
CONNECTION OR ECM.
'"AFTER REPAIRS," CONFIRM "CLOSED LOOP" OPERATION AND NO MIL (SERVICE ENGINE SOON).
12-21-92
NS 16220
6E3-C12-4 3.4L (L32) (VIN 4) (SFI) DRIVEABILITY AND EMISSIONS
ECM
B+
FUSE LINK
~402RED
10-WAY INLINE FWD
LAMP HARNESS
CONNECTOR (BLACK)
COOLING FAN CONTROL
33SDKGRN
COOLING
FAN
CONTROL
RELAY*
TOIGN
409 LT BLU
150 B L K - - - i - ,
TO DIGITAL EGR,
EVAPPURGESOLVALVE
1/P FUSE #3
TO ~
IGNITION
25 AMP
SWITCH
A/C
REFRIGERANT
PRESSURE
SENSOR
A/C
SELECT SWITCH
241 BRN ~ - - - - - - 7 6 2 LTGRN/BLK
808 BLK
----------------1
380 RED/BLK
--------------1
A/C REQUEST
SENSOR GROUND
SENSOR SIGNAL
416GRv-------------~
SVREF
10-1692
NS 15936
CHART C-12
(Page 2 of 2)


1. 12 volts should be available to CKT 541 and CKT
402 of the relay when the ignition is "ON."
2. This test checks the ability of the ECM to ground
CKT 335.
The Malfunction Indicator Lamp (MIL) "Service

Engine Soon" should also be flashing at this point.
If it isn't flashing, refer to CHART A-2.
3. If the fan does not turn "ON" at this point, CKT
409 or CKT 150 is open, or the cooling fan motor is
faulty.
DRIVEABILITY AND EMISSIONS 3.4L (L32) (VIN S) (SFI) 6E3-C12:.5
CHART C-12
I
(Page 2 of 2)
FROM
CHART
C-12
(1 OF 2)

. """l" . .
',\
~
REMOVE COOLING FAN CONTROL RELAY.

PROBE UNDERHOOD ELECTRICAL CENTER CAVITIES "01" AND "OS"
WITH A TEST LIGHT CONNECTED TO GROUND.
LIGHT "ON" BOTH
DIAGNOSTIC TEST TERMINAL GROUNDED.

PROBE CKTS 335 WITH A TEST LIGHT
CONNECTED TO 12 VOLTS.
REPAIR OPEN OR SHORT TO

GROUND IN CIRCUIT THAT DID NOT LIGHT.
JUMPER CAVITIES "01" AND "04" TOGETHER

USING A FUSED JUMPER.
FAN SHOULD RUN. DOES IT?
OPEN OR SHORT TO VOLTAGE IN CKT 335, OR

FAUL TY CONNECTION AT ECM OR A FAUL TY ECM.
WITH CAVITIES STILLJUMPERED, AS ABOVE,

CONNECT A TEST LIGHT ACROSS THE COOLING
FAN MOTOR HARNESS CONNECTOR "A" AND
"B" TERMINALS.
PROBE CKT 409 ON COOLING FAN MOTOR

HARNESS CONNECTOR WITH A TEST LIGHT
OPEN IN GROUND CKT 150.
FAUL TY MOTOR
REPAIR OPEN IN CKT 409 BETWEEN

RELAY AND COOLING FAN MOTOR.
11-12-92
NS 16221
BLANK
SECTION C13
CRANKCASE VENTILATION SYSTEM

CONTENTS
General Description
Operation
Diagnosis
C13-1
C13-1
C13-1
C13-2
GENERAL DESCRIPTION
A crankcase ventilation system is used to provide
scavenging of crankcase vapors. Fresh air from the air
cleaner is supplied to the crankcase, mixed with blowby gases and then passed through a crankcase
ventilation valve into the intake manifold (Figure
CI3-l).
Functional Check of Crankcase

Ventilation Valve
On-Vehicle Service
C13-2
C13-2
OPERATION
The primary control is through the crankcase
ventilation valve (Figure Cl3-2) which meters the flow
at a rate depending on manifold vacuum.
To maintain idle quality, this valve restricts the
flow when intake manifold vacuum is high. If
abnormal operating conditions arise, the system is
designed to allow excessive amounts of blow-by gases
to back flow through the crankcase vent tube into the
air inlet duct to be consumed by normal combustion.
CHECK VALVE
45 0068-6E
Figure C132 Crankcase Ventilation Valve Cross

Section

A plugged valve or hose may cause:
Rough idle.
Stalling or slow idle speed.
Oil leaks.
Oil in throttle body or plenum.
Sludge in engine.
A leaking valve or hose would cause:
Rough idle.
Stalling.
High idle speed.
c:::::> CLEAN AIR
-+
VOLATILE OIL FUMES
---- MIXTURE OF AIR AND FUMES
CRANKCASE VENTILATION VALVE
2
3
CRANKCASE VENT HOSE
CRANKCASE VENTILATION VALVE HOSE
TO INTAKE MANIFOLD
TO THROTTLE BODY
SS 1725-6E
Figure C131 Crankcase Ventilation Flow (Typical)
!VIEWA!
CRANKCASE VENTILATION VALVE HARNESS ASSEMBLY
2

NS 15884
Figure C13-3 - Crankcase Ventilation System Service
DIAGNOSIS
FUNCTIONAL CHECK OF CRANKCASE
VENTILATION VALVE
If an engine is idling rough, check for a clogged
crankcase ventilation valve or plugged hose. Check
valve part number to be sure the correct valve is
installed. Replace as required. Use the following
procedure:
1. Remove valve from rocker arm cover.
2. Run the engine at idle.
3. Place your thumb over end of valve to check for
vacuum. If there is no vacuum at the valve,
check for plugged hoses, manifold port or
valve. Replace plugged or deteriorated hoses.
4. Turn "OFF" the engine and remove valve.
Shake valve and listen for the rattle of check
needle inside the valve. If valve does not
rattle, replace valve.
With this system, any blow-by in excess of the

system capacity (from a badly-worn engine, sustained
heavy load, etc.) is exhausted into the inlet duct and is
drawn ipto the engine.
Proper operation of the crankcase ventilation
system is dependent upon a sealed engine.
If oil sludging or dilution is noted and the
crankcase ventilation system is functioning properly,
check engine for possible cause and correct to ensure
that system will function as intended.
ON-VEHICLE SERVICE
An engine which is operated without any
crankcase ventilation can be damaged. Therefore, it is
important to replace the valve at intervals shown in
SECTION OB.
Periodically, inspect the hoses and clamps and
replace any showing signs of deterioration.
ROCKER COVER ASSEMBLY
GROMMET
GROMMET
NS 15885
Figure C13-4- Crankcase Ventilation System Service
CRANKCASE VENT PIPE
AIR DUCT
CLAMP
NS 15886
Figure C13-5 - Crankcase Vent Pipe Installation
6E3-C13-4 3.4l (L32) (VIN S) (SFI) ORIVEABILITY AND EMISSIONS
BLANK
SECTION C14
AIR INTAKE SYSTEM

CONTENTS
General Description
Air Intake System
On-Vehicle Service
.... .... . .. ....

......... .... ..
C14-1
C14-1
C14-1
GENERAL DESCRIPTION
AIR INTAKE SYSTEM
Air intake system draws outside air in past the
louvered cover of the forward mounted air cleaner.
The air cleaner assembly is remotely mounted (refer to
Figure C14-2). The air then enters the engine by
flowing through the air intake duct throttle body and
into the intake manifold. The air is then directed into
the intake manifold runners, through the cylinder
heads and into the cylinder.
ON-VEHICLE SERVICE
NOTICE: When fasteners are removed, always
reinstall them at the same location from which
they were removed. If a fastener needs to be
replaced use the correct part number fastener for
that application. The correct torque value must be
used, as specified, during reassembly to assure
proper retention of all parts, or damage to the part
may result.
AIR CLEANER FILTER/AIR CLEANER
ASSEMBLY

1.
2.
3.
4.
5.
6.
7.
8.
Loosen clamp at rear air intake duct at throttle

body.
IAT sensor electrical connector.
Retainer from upper radiator support.
Crankcase vent pipe from rear air intake duct.
Loosen clamp that joins rear air intake duct to air
cleaner outlet duct and remove rear air intake
duct.
AIR intake hose.
Slide air cleaner housing and air cleaner outlet
duct up as a whole assembly.
Release latches from air cleaner housing.
Air cleaner filter.
Air Cleaner Filter/

Air Cleaner Assembly
C14-1
C14-1

1. Air cleaner filter into air cleaner housing.
2. Snap air cleaner latches into place.
3. Slide air cleaner assembly into retainers.
4. Rear air intake duct to throttle body and tighten
clamp.
5. IAT sensor electrical connector.
6. Retainer to upper radiator support.
7. Crankcase vent pipe to rear air intake duct.
8. AIR intake hose.
rn
Important
Clamp assembly tension adjustment screw

should be located on the side of the intake duct
for optimum clamp force. This is important for
proper sealing.
Clamp,
Rear Air Intake Duct
Clamp,
Air Cleaner Outlet Duct
3.5 Nm (31 lb. in.)
3.5 Nm (31 lb. in.)
REAR AIR INTAKE DUCT

(WITH INTAKE AIR TEMPERATURE SENSOR)
2
AIR CLEANER OUTLET DUCT
AIR CLEAN ER ASSEMBLY
FRONT AIR INTAKE DUCT
UPPER RADIATOR MOUNTING PANEL
NS 15934
Figure C14-1 Air Intake Components
DRIVEABILITY AND EMISSIONS 3.4L (L32) (VIN S) (SFI) INDEX-1

SECTION
PAGE
A
Acceleration Enrichment Mode
A/CClutch Circuit Diagnosis
General Description
Diagnosis
Chart C-10
On-Vehicle Service
A/C Request Signal
General Description
Diagnosis
Air Bypass Valve
Air Intake System
General Description
On-Vehicle Service
C2-2
C10-1
C10-1
C10-4
C10-1
C1-6
(10-4
C6-1
C14-1
C14-1
C14-1
........... . . . . . . ....
Backfire
Basic Procedure
Before Starting
B-17
A-1
C2-2
B-2
c
Camshaft Position Sensor C1-7, C4-2
Crankshaft Position Sensor (24X)
C1-7, C4-2
Crankshaft Position Sensor (3X)
C1-6, C4-2
EVAP Canister Hose
C3-3
ChartA-1:
No MIL (Service Engine Soon)
A-24
ChartA-3:
A-26
Engine Cranks But Will Not Run
ChartA-7:
Fuel System Diagnosis
A-28
Chart B-1:
Restricted Exhaust System Check
B-24
ChartC-1A:
Diagnosis C1-14
Chart C-1D:
MAP Output Check
C1-16
Chart C-2A:
C2-16
.. .........
SECTION
PAGE
Chart C-2B:
Idle Air Control (IAC) Valve Check
Chart C-3:
Check
Chart C-4F:
Misfire
Chart C-5:
Knock Sensor System Check
Chart C-6:
Secondary Air Injection System
Check
C2-18
C3-6
C4-8
.......
CS-4
C6-6
Chart C-7:
Exhaust Gas Recirculation (EGR) Flow
Check
Chart C-8:
System

Chart C-10:
A/C Compressor Clutch Control
Circuit Diagnosis
ChartC-12:
Cooling Fan Control
Circuit Diagnosis
. . .. . . . .. . . .
Chuggle
Clear Flood Mode

Closed Loop
Component Locations
Cooling Fan Control
General Description
Diagnosis
Service
Crankcase Ventilation System

General Description
Diagnosis
On-Vehicle Service
Cuts Out
... ...... . . . .........
C7-4
C8-4
C10-~
C12-2
B-6
C2-1
C2-1
A-3
C12-1
C12-1
C12-1
C13-1
C13-2
C13-2
B-10
. ... ... ..

Deceleration Mode
Detonation
Dieseling, Run On
DTC 13
A-10, 24
C2-2
B-8
B-16
A-34
2-INDEX 3.4L (L32) (VIN S) (SFI) DRIVEABILITY AND EMISSIONS

SECTION
............. ...
..............
. . . .. .. .
..
..
...
..
. . ......
.. . . ....
....
.. . . . .
. .. . . . .. . ...
..... . . ...
... . . .. .. .
..
.. ..... .. ... .
... . . .
...
.. . . . . .
.. .
..
.
.
.
.
.. .... .......
..
..
.. .. . .
.. .
. ... . . . . . .
.. . .
.. .. .
. . ..
.. . .
.......
..
.
.
. . . . . ...
..
.. . . . . . . . . . . . . . . .
. .. .
. .. .
. . .. . . ..
.. .
. . . . .... .
....
. . . . . . ..... .
.. .
..
.. . .
.... .
.. . .
. . ... .
. ...
.. . .
.. . . . . . .
... ..
. .. . . .. . . .
.. . .
.. . .
. . . ... . .... . . . . .
DTC14
DTC 15
DTC16
DTC17
DTC21
DTC22
DTC23
DTC24
DTC25
DTC33
DTC34
DTC35
DTC36
DTC39
DTC42
DTC43
DTC44
DTC45
DTC46
DTC51
DTC53
DTC54
DTC61
DTC63
DTC64
DTC65
DTC66
DTC67
DTC68
DTC69
DTC70
DTC71
DTC73
DTC75
DTC76
DTC77
DTC81
DTC82
DTC85
DTC86
DTC87
.. .
PAGE
SECTION
PAGE
A-36
A-38
A-40
A-42
A-44
A-46
A-48
A-50
A-52
A-54
A-56
A-58
A-60
A-62
A-64
A-66
A-68
A-70
Functional Check
EGR System
General Description
On-Vehicle Service
General Description
Diagnosis
Function
Functional Check
On-Vehicle Service
Engine Coolant Temperature Sensor
General Description
Diagnosis
On-Vehicle Service
EVAP Canister

EVAP Pressure Control Valve
General Description
Diagnosis

On-Vehicle Service
Exhaust Emissions Excessive (Odors)
Exhaust System Check Restricted
C1-10
A-72
A-111
A-74
A-76
A-78
A-80
A-82
A-84
A-86
A-88
A-90
A-92
A-94
A-96
A-98
A-100
A-102
A-104
A-108
A-108
A-111
A-112
A-111
. . . . .. . . .
A-10
A-21
C1-8
A-5
C1-2
C1-10
C7-1
C7-2
C1-1
C1-8
C1-1
C1-10
C1-9
C1-3
C1-8
C1-10
C3-1
C3-2
C3-1
C3-1
C3-2
C3-2
B-15
C7-1
B-18
. . . . . . . .. . . . . . . . .
Fan(s) Cooling
Fuel Injectors
General Description
Diagnosis
Fuel Pressure Connection Assy.

Fuel Pump Relay
Fuel Rail
Fuel System Pressure Check
........
. .. .
.. . .
...
C12-1
C2-3
C2-2
C2-5
C2-10
C2-6
C2-2
A-30
C2-3
A-32
A-36
H
Hard Start
Hesitation
E
ECM Connector Terminal End View
ECM Diagnostic Trouble Codes
ECM Inputs
ECM Wiring Diagram
EE PROM
General Description
On-Vehicle Service
. .. . . .
..
IAT Sensor
General Description
Diagnosis

On-Vehicle Service
Idle Air Control System Check
B-5
B-9
C1-4
C1-8
C1-11
C2-18
DRIVEABILITY AND EMISSIONS 3.4l (L32) (VIN S) (SFI) INDEX-3

PAGE
SECTION
General Description
Ignition Control (IC)
............
. .... ..... .. .
Incorrect Idle
Information Sensors
lntermittents
Introduction
C2-4
A-72, 74,
C4-1
B-12
Cl-3
C2-16
B-3
6E
K
Knock Sensor Module
.... ........

General Description
Diagnosis
On-Vehicle Service
. . . . . .. . .
Cl-10,
CS-2
SECTION
PAGE
Oxygen Sensor (025)

General Description
Diagnosis
On-Vehicle Service
Cl-4
Cl-8
Cl-11
p
General Description
Diagnosis
On-Vehicle Service
Poor Fuel Economy
Poor Performance . . . . . . . . . . . . . . . .
Pressure Regulator
Pump, AIR
CS-1
CS-1
CS-1
CS-4
Q
Quad-Drivers
. . . . . . . .. . .. . . . . .
Lack Of Power
Light, MIL (Service Engine Soon)
Light, One to Four
Long Term Fuel Trim
B-7
A-20
C8-2
Cl-2
Steady
Misses
Memory
Cl-4
Cl-8
Cl-12
Cl-16
A-24
B-10
Cl-2
C7-1
A-24
A-22
0
On-Board Diagnostic (OBD) System
Check
Cl-7
Reference Signal
Restricted Exhaust Check
Rough Idle
Run Mode
......... . . . ..... . ...
Cl-6
B-24
B-12
C2-2
B-16
N
Negative Backpressure EGR Valve
No DLC Data
... . . . . . . .. . . . . . .
R
Run On
MAP Sensor
General Description
Diagnosis
On-Vehicle Service
Output Check
MIL (Service Engine Soon) "On"
Cl-6
Cl-9
Cl-12
B-14
6E3-B
C2-4
C6-1
A-14
Sag
Scan Data
B-9
A-18

General Description
Diagnosis
On-Vehicle Service
Sensor Information
Sluggish
Spark Knock
Spongy
Stalling
Starting Mode
Stumble
Surges
System Voltage
Symptom Charts
C6-1
C6-2
C6-4
C6-4
Cl-3
B-7
B-8
B-7
B-12
C2-1
B-9
B-6
A-86
B-18
4-INDEX 3.4L (L32) (VIN S) (SFI) DRIVEABILITY AND EMISSIONS

SECTION
PAGE
T
Throttle Body Unit
General Description
On-Vehicle Service
General Description
Diagnosis
On-Vehicle Service
. ... . . ..... .


General Description
Diagnosis
C2-4
C2-14
C1-5
C1-8
C1-12,
C2-12
C8-1
C8-4
S.ECTION
PAGE
Typical Tech 1 Data Valves

A-16
A-18
u
Underhood Electrical Center
Unstable Idle
A-4
B-12
v
General Description
Diagnosis
On-Vehicle Service
C1-5
C1-9
C1-12
DRIVEABILITY AND EMISSIONS 5.7L (VIN P) 6E3-A-1
SECTION A
ENGINE COMPONENTS/WIRING DIAGRAMS/

DIAGNOSTIC CHARTS
ON-BOARD DIAGNOSTIC (OBD)
SYSTEM CHECK
To restore "Closed Loop" operation, run the engine at

part throttle several minutes and accelerate from idle
to part throttle a few times.
The "On-Board Diagnostic (OBD) System Check"

verifies the system is functioning correctly. Some
special considerations to keep in mind while making
the "On-Board Diagnostic (OBD) System Check" are:
Blocking Drive Wheels

The vehicle drive wheels must always be blocked
while checking the system.
BASIC PROCEDURE
If you have not reviewed the basic information on
how to use the diagnostic procedures, go to the
"Introduction" of this section. The facing page of each
chart in this section will provide a general circuit
description and in some instances, alternate diagnostic
steps or other diagnostic aids specific to that chart or
circuit.
Cold Oxygen Sensor (02S)

On this engine, the oxygen sensors may cool down
after only a short period of operation at idle. This will
put the system into "Open Loop."
CONTENTS
Component Locations
ECM Wiring Diagram (1 of 5)
. . . . . . . . . .. . . . . .. . . . . ... . . . . . . . . .
ECM Connector Terminal End View (1 of 4)

Tech 1 Data
No Malfunction Indicator Lamp (MIL) - ChartA-1
No DLC Data or Will Not Flash OTC 12; Malfunction Indicator Lamp (MIL) "ON"
Steady - Chart A-2
Engine Cranks But Will Not Run- ChartA-3 (1 of2)

Fuel Pump Relay Circuit- Chart A-5
Fuel System Diagnosis - Chart A-7 (1 of 3)

OTC 13 Bank 1 (Left) Oxygen Sensor (025) Circuit (Open Circuit)
OTC 14 Engine Coolant Temperature (ECT) Sensor Circuit (High Temperature Indicated)
OTC 15 Engine Coolant Temperature (ECT) Sensor Circuit (Low Temperature Indicated)
OTC 16 Distributor Ignition System (Low Resolution Pulse)

OTC 21 Throttle Position (TP) Sensor Circuit (Signal Voltage High)
OTC 22 Throttle Position (TP) Sensor Circuit (Signal Voltage Low)

OTC 23 Intake Air Temperature (IAT) Sensor Circuit (Low Temperature Indicated)
OTC 24 Vehicle Speed Sensor (VSS) Circuit

OTC 25 Intake Air Temperature (IAT) Sensor Circuit (High Temperature Indicated)
OTC 26 Quad-Driver Module (QOM) #1 Circuit
OTC 32 Exhaust Gas Recirculation (EGR) Circuit ( 1 of 2)
PageA-3
PageA-4
PageA-9
PageA-14
Page A-16
Page A-17
PageA-20
PageA-22
PageA-24
PageA-28
PageA-30
PageA-36
PageA-38
PageA-40
PageA-42
PageA-44
PageA-46
PageA-48
PageA-50
PageA-52
PageA-54
PageA-56
PageA-58
PageA-60
6E3-A-2 5.7L (VIN P) DRIVEABILITY AND EMISSIONS

DTC 33 Manifold Absolute Pressure (MAP) Sensor Circuit
(Signal Voltage High - Low Vacuum)
DTC 34 Manifold Absolute Pressure (MAP) Sensor Circuit
(Signal Voltage Low - High Vacuum)
DTC 36 Distributor Ignition System (Faulty High Resolution Pulse or
Extra Low Resolution Pulse Detected)
DTC 41 Ignition Control (IC) Circuit (Open or Shorted Circuit)
DTC 42 Ignition Control (IC) Circuit (Grounded Circuit)

DTC 43 Knock Sensor (KS) Circuit
DTC 44 Bank 1 (Left) Oxygen Sensor (025) Circuit (Lean Exhaust Indicated)
DTC 45 Bank 1 (Left) Oxygen Sensor (025) Circuit (Rich Exhaust Indicated)
DTC 46 Personal Automotive Security System (PASS-Key II) Circuit
DTC 51 PROM Error (Faulty or Incorrect PROM)
OTC 53 System Voltage
DTC 55 Fuel Lean Monitor
DTC 61 A/C System Performance
DTC 63 Bank 2 (Right) Oxygen Sensor (025) Circuit (Open Circuit)

DTC 64 Bank 2 (Right) Oxygen Sensor (025) Circuit (Lean Exhaust Indicated)
DTC 65 Bank 2 (Right) Oxygen Sensor (025) Circuit (Rich Exhaust Indicated)
DTC 66 A/C Refrigerant Pressure Sensor Circuit (Open or Shorted)

DTC 67 A/C Refrigerant Pressure Sensor Circuit (Pressure Sensor or A/C Clutch Circuit Problem)
DTC 68 A/C Relay Circuit (Shorted Circuit)

DTC 69 A/C Clutch Circuit
DTC 71 A/C Evaporator Temperature Sensor Circuit (Open or Shorted)

PageA-64
PageA-66
PageA-68
PageA-70
Page A-72
Page A-74
PageA-76
PageA-78
PageA-80
Page A-82
Page A-84
Page A-86
PageA-88
PageA-90
Page A-92
Page A-94
PageA-96
PageA-98
Page A-100
Page A-102
Page A-104
II
F" CARLINE
RPO:LT1
COMPUTER HARNESS
C1 Engine Control Module (ECM)

C2 Data Link Connector (DLC)
C3 Malfunction Indicator Lamp (MIL)
C4 Battery junction block
CS ECM harness grounds
C6 Fuse panel
CS Underhood electrical center
C9 Fuel pump "test" connector
C10 A/C compressor low pressure cut-off
switch
;:::: NOT ECM CONNECTED

N1 Crankcase ventilation valve
N7 Oil pressure sensor
N17 Evaporative emission canister (not
VIN CODE: P
D CONTROLLED DEVICES
1
2
5
8
9
10
12
15
18
19
20
Fuel injector
Idle Air Control (IAC) valve
connector
Fuel pump relay
Electric air pump
Ignition coil and ignition coil module
EGR solenoid valve
Evaporative emission canister purge
solenqid valve
Primary cooling fan
Secondary cooling fan
Reverse lockout solenoid (MIT only)
shown), located in left rear, near filler Exhaust Gas Recirculation (EGR) valve
tube
5.7L
VB MFI
INFORMATION SENSORS
A Manifold Absolute Pressure (MAP)

B Oxygen sensor (02S)
c Throttle Position (TP) sensor

D Engine Coolant Temperature (ECT)
sensor
F Vehicle Speed Sensor (VSS)
G Intake Air Temperature (IAT)
J Knock sensor
K A/C refrigerant pressure
L A/C evaporator temperature
SIR system components. Refer to
Section 9J of the service manual, for
"Cautions" and information on SIR
system components.
11-16-92
MS 12725
Figure A-1 - Engine Component Locations 5.7L (VIN P) "f" Carline
rec
ECM
(230
TO
SOLENOID
~- ---~ (A/T ONLY)
K:
r---------i---<"'-i,-----411--- 422 TAN/BLK

I
I
C ,'
.-------.-~""'E-=--i-----448WHT/BLK
r======i
I
Y
1
~BI
TORQUE CONVERTER CLUTCH

CONTROL (TCC) (A/T ONLY)
DIAGNOSTIC ENABLE
~ 451 BLK/WHT
ECMGROUND
451 BLKIWHT
ECMGROUND
~ 551 TAN/WHT
ECMGROUND
L.C21o_.....
-=DIAGNOSTIC
"TEST" TERMINAL
1455
BLK/WHT
A12
HD
,p------.~K,-----T---~~K~'--~SOOTAN
(200
(100
TO
DERM
040
TO KEYLESS
ENTRY RECEIVER
TO
EBCM
TO INSTRUMENT
CLUSTER
TO PASS-Key II
ECODER MODULE
BATTERY FEED
C
2
~~1002RED
TO B+
C200
___
........_ _ __
JUNCTION
BLOCK
10AMP
(1/P)
ENGINE COOLANT
ENGINE COOLANT
TEMPERATURE
(ECT) SENSOR
THROTTLE
POSITION (TP)
SENSOR
SERIAL DATA
______
1-----41..,________ 470 BLK

1 - - - - - - - - - - - 417 DK BLU
_.t - - - - - - - - - - - 4 7 4 G R Y
ECT AND TP SENSOR GROUND

THROTTLE POSITION
SENSOR SIGNAL
+ 5 VOLTS REFERENCE
. - - - - - - - - 808 BLK
A/C
EVAPORATOR
TEMPERATURE
SENSOR
1----------- 732 DK BLU
A/C EVAPORATOR
. - - - - ; , - - - - - - - 416 GRY
+ 5 VOL TS REFERENCE
MAP SIGNAL
MAP,IAT,A/C
AND A/C EVAPORATOR
TEMPERATURE SENSOR
GROUND
808BLK
, - - - - - - - - 808 BLK
INTAKE AIR
TEMPERATURE
(IAT) SENSOR
'-------11
1------------ 472 TAN
- - - - - - - - 808 BLK
808 BLK
A/C
REFRIGERANT
PRESSURE
SENSOR
INTAKE AIR TEMPERATURE

SENSOR SIGNAL
J
SENSOR SIGNAL
~--------416GRY
(1/P) = LOCATED IN INSTRUMENT PANEL FUSE BLOCK
Figure A-2 - ECM Wiring Diagram S.7L (VIN P) "F" Carline (1 of 5)
10-9-92
MS 12308

K
TODLC
TERMINAL "F" 4l
ECM
C230
T
TEMP SWITCH
c
c
s
422TAN/BLK
446LTBLU
11~
0
l
E
N
0
I
D
TORQUE CONVERTER
CLUTCH CONTROL
(TCC) (A/T ONLY)
4th GEAR SIGNAL
11HhGEAR
438 DK GRN/WHT
3rd GEAR SIGNAL
ll~dGEAR
232WHT
2nd GEAR SIGNAL
2nd GEAR
. - - - - - 583 l T BLU/BLK - - - - - '

C230~ H
TO OTHER
FANS/ACTR
CIRCUITS
.:-~~-~419BRNmHT
TO OTHER
GAGES FUSE
CIRCUITS
(SERVICE
FANS/ACTR
ENGINE SOON)
__.,___ _ _ 541BRN ~ T O I G N I T I O N
10AMP
(U/H)
c23o
REVERSE LOCKOUT SOLENOID
,____ _ _ _ 1652LT GRN
EVAP CANISTER
PURGE SOLENOID
VALVE CONTROL
- - - - - - - 435 GRY
EXHAUST GAS
RECIRCULATION
(EGR) SOLENOID
VALVE CONTROL
1-----------~ 436 BRN

C100
78RED
AIR PUMP
~ 3000RN
441 BRN
150BLK
_j_
20AMP
(U/H)
INTEGRAL STOP VALVE SOLENOID
SECONDARY AIR
INJECTION PUMP
RELAY CONTROL
~>-------..
82
2
C 00
TO IGNITION
444 l T GRN/BLK
SECONDARY
AIR
INJECTION
PUMP
REVERSE
LOCKOUT
SOLENOID
CONTROL
(MANUAL
TRANSMISSION
ONLY)
- - - - 428 DK GRN/WHT
AIR PUMP RELAY

78RED
Mil (SERVICE
ENGINE SOON)
CONTROL
1749 LT GRN/WHT
1748 LT BLU/BLK
1747 LT BLU/WHT
(U/H) = LOCATED IN UNDERHOOD ELECTRICAL CENTER.
(1/P) = LOCATED IN INSTRUMENT PANEL FUSE BLOCK.
Figure A-3 - ECM Wiring Diagram 5.7L (VIN P) "F" Carline (2 of 5)
IAC COIL "B" LOW

IAC COIL "B" HIGH
IAC COIL "A" LOW
IAC COIL "A" HIGH
10-15-92
MS 12309
I~ I
ECM
BANK 1 (LEFT) OXYGEN SENSOR
I~-1-
BLK --....;~(~~--- 1665PPL/WHT
~~g~:D
BANK 2 (RIGHT) OXYGEN SENSOR
BLK
11~--- 351 BLK/WHT
--<<-----
1666PPL
BANK 1 (LEFT) OXYGEN

SENSOR SIGNAL
OXYGEN SENSOR GROUND
BANK 2 (RIGHT) OXYGEN

SENSOR SIGNAL
1jl..._____ 451 BLK/WHT
ENGINE
GROUND
i--
TO HATCH RELEASE RELAY
A1------PARK/
NEUTRAL
POSITION
SWITCH
___
434 ORN/BLK
141 BRN
24 LT GRN
6 PPL - - - - - - T o STARTER SOLENOID
C230
434 ORN/BLK
20AMP
~
TURN B/U
PARK NEUTRAL POSITION

SIGNAL (A/T ONLY)
TO IGNITION
(1/P)
F
_........
575
TO BACK/UP LAMPS
DK GRN
TO PASS-KeyII RELAY
- - - - A N D BTSI SOLENOID
IM ;ill----------:::::~

SIGNAL
GROUND
TRANSMISSION MOUNTED TO INSTRUMENT

CLUSTER AND CRUISE-+-- 817 DK GRN/WHT
CONTROL MODULE
~ , - - - - - - - - - - 496 DK BLU
ll)
VSSOUTPUT
(4000K PULSE PER MILE)
KNOCK SENSOR SIGNAL
~NOCK
TO PASS-KeyII
DECODER MODULE
~ENSOR
C230
PASS-KeyII SIGNAL
(FUEL ENABLE)
Figure A-4- ECM Wiring Diagram 5.7L (VIN P) "F" Carline (3 of 5)
11-24-92
MS 12310
ECM
TO PASS-KeyII
DECODER
MODULE
ECM IGN
~ p 439 PNK
15,~~p
3 PNK
(I/P)
------------<41K;..._--- 439 PNK

C230
---l-- 465 DK GRN/WHT

e1 lc200
C220
TO FUEL
A1
PUMP~4l---~~:.-..._--t
C405
FUEL PUMP RELAY

CONTROL
451BLK/WHT ~
F
3PNK
IGNITION
SWITCH
TOB+
FUSE BLOCK
JUNCTION
INJECTOR
#10
7.5AMP
(U/H)
839 PNK
C100
--~))>----~.---
120GRY
C220
120 GRY
TO FUEL PUMP
TEST CONNECTOR
INJECTOR
#9
7.5AMP
(U/H)
639 PNK
:iJ.,----,-J.:
~
--------t 639PNK ~ 468DKGRN
B~
~-839PNK ~ 4 6 7 D K B L U
IGNITION SYSTEM
TEST CONNECTOR
. - - - - - - - - - - 632 BLK/PNK
632 PNK/BLK
DISTRIBUTOR
REFERENCE LOW
. - - - - - - - - - - - 631 YEL
631 RED
. - - - - - - - - 647 PPL/WHT
647 LT BLU/BLK
HIGH RESOLUTION
1---------- 453 RED/BLK
LOW RESOLUTION
. . - - - - - - - - 453 BLK/RED
II...._
r-- 450 BLK
C140
ENGINE I
GROUND
IGNITION
TO~
IGNITION
19 ~-M.P
BLK
~~~~E_C!~~
(U/H)
.\c
IGNITION FEED
IGNITION
COIL
MODULE
239
PNK
423WHT
IGNITION CONTROL
(U/H)
Figure AS ECM Wiring Diagram 5.7L {VIN P) "F" Carline (4 of 5)
11-3-92
MS 12311
6E3-A-8 5. 7L (VIN P) DRIVEABILITY AND EMISSIONS
ECM
J
,-------335DKGRN-----~~~K'-----~335DKGRN
C100
B~ P~l:,,~uy
~ - - 4 0 9 LT BLU
__r-150BLK
TO
OTHER
FANS/ACTR
FUSE CIRCUITS
PRIMARY COOLING
FAN RELAY CONTROL
COOLING
FAN
402 RED ~ B + JUNCTION

FANS/ACTR
~541
402
RED
1~.~-~p BRN
TO (U/H)
IGNITION
(FAN 2)
SECONDARY
COOLING
FAN
504BRN
r-150BLK
SECONDARY
COOLING
FAN RELAY
(W/C60)
TO OTHER
A/CCRUISE
FUSE CIRCUITS . . . . . _ - - - - - 4 7 3 DK BLU
H
((
A/C CRUISE c1oo
. - - - - - - - - - 1 3 9 PNK
3 PNK _ .
20AMP
(U/H)
HVAC
TOIGNITION~3000RN ~
2 ~~~p
TO
j
A/C
HVAC
(1/P)
241 BRN
RELAY
BLOWER -+- 66 LT GRN
SWITCH
-.rv----
139
PNK
473 DK BLU
SECONDARY COOLING
FAN RELAY CONTROL
TO IGNITION
TO REAR
DEFOG SYSTEM
HVAC
CONTROL
ASSEMBLY
A/CREQUEST
C100
.---...,
I
..___--~,~K'E-~:---------~459DKGRN/WHT
B4
- , . - - - -.......
~
59 DK GRN
I
1
~ 1 1 - - ,- - - - - - - - - - - - '- -
A/CCLUTCH
RELAY CONTROL
A/CSTATUS
..J
LOW PRESSURE
CUT-OFF SWITCH
~~603DKGRN
- ~
A/C
COMPRESSOR
CLUTCH
450BLK1
_
416GRY
A/C
EVAPORATOR
TEMPERATURE
SENSOR
- - - - 732 DK BLU
A/C EVAPORATOR
TEMPERATURE
SENSOR SIGNAL
TO MAP AND
IAT
TO MAP
A/C
REFRIGERANT
PRESSURE
SENSOR
808 BLK
380 RED/BLK
416 GRY
------1
(U/H) = LOCATED IN UNDERHOOD ELECTRICAL CENTER.

Figure A-6 - ECM Wiring Diagram 5. 7L (VIN P) "F" Carline (5 of 5)
A/C REFRIGERANT
PRESSURE SENSOR
SIGNAL
10-15-92
MS 12312
DRIVEABILITY AND EMISSIONS 5.7L {VIN P) 6E3-A-9
"F" CARLINE
22 PIN ECM CONNECTOR
5.7L {VIN P)
RPO: LT1
USE T-100 YELLOW BREAKOUT BOX {BOB)

ECM PIN/FUNCTION
--
BOB
PIN#
WIRE COLOR
CKT
VOLTAGE
"ON"
KEV
ENG
"RUN"
6E3 REFERENCE
A1
104
DKGRNNVHT
428
B+
B + (1)
SECTION C3
A2
EGR SOLENOID VALVE CONTROL
101
GRY
435
B+
B + (1)
SECTIONC7
(3)
(3)
SECTION C2
A3
112
A4 IACCOIL "A" HIGH
109
LTBLUNVHT
1747
AS IAC COIL "B" LOW
119
LTGRN/BLK
444
(3)
(3)
SECTION C2
BRNNVHT
419
O*
B+
CHARTS A-1, A-2
BRN
436
B + (1)
B + (1)
SECTIONC6
A6 MIL (SERVICE ENGINE SOON)

CONTROL
117
A7
103
AIR PUMP RELAY CONTROL
AB
102
A9
111
A10 IACCOIL "A" LOW
110
LT BLU/BLK
1748
(3)
(3)
SECTIONC2
A11 IACCOIL "B" HIGH
118
LTGRNNVHT
1749
(3)
(3)
SECTIONC2
A12 IGNITION CONTROL
108
WHT
423
O*
1.1 (3)
SECTION C4
A 13 ECT SIGNAL
105
VEL
410
1.8 (4)
1. 7 (4)
DTC(s)14, 15
A14
116
A15
113
A16
122
A17
120
A18
107
A19 PASS-KeyII
106
DKBLU
229
2.5
2.5
DTC46
A20
115
A21 PNP SIGNAL
114
ORN/BLK
434
* (5)
* (5)
CHARTC-1A
A22 A/C REQUEST
121
DKGRNNVHT
762
* (6)
* (6)
SECTION C10
NOTICE: DO NOT BACKPROBE ECM CONNECTORS!

This Chart may be used in conjunction with the T-100 Yellow Breakout Box (48921) to obtain volta~e
present for each circuit listed. Install the BOB between the ECM harness connectors and the EC ,
then probe the pin listed under "BOB PIN#". Voltage may var~ due to low battery charge or other
reasons, but should be very close. All voltages shown in the NG "RUN" column are typical with
engine at idle, closed throttle, normal operatini temperature, park or neutral, system in "Closed
Loop," all accessories "OFF," and scan tool not ins ailed.
DVM NEGATIVE (BLACK) LEAD MUST BE

CONNECTED TO A KNOWN GOOD GROUND.
1
(1)
(2)
(3)
(4)
(5)
(6)
LESS THAN .5 VOLT WHEN SYSTEM ENABLED.

12 VOLTS FOR FIRST TWO SECONDS WITH
IGNITION "ON."
VARIES.
VARIES WITH TEMPERATURE.
BA TTERV VOLTAGE WHEN IN GEAR.
BATTERY VOLTAGE WHEN SYSTEM IS ENABLED.
LESS THAN .5 VOLT .
LlLJLJOLJ
12
18
[]tJ~
GRAY ECM
CONNECTOR A
....__
6
11
000000
g,Ll Cl D L1 ..
17
22
~
.........
Figure A-7 - ECM Connector Terminal End View 5.7L (VIN P) "F" Carline (1 of 4)
~-
10-19-92
MS 12315

11
F" CARLINE
5.7L (VIN P)
RPO: LT1
USE T-100 YELLOW BREAKOUT BOX (BOB}

ECM PIN/FUNCTION
BOB
PIN#
WIRE COLOR
CKT
#
VOLTAGE
KEY
"ON"
* (2)
* (2)
SECTION CS
422
B+
B + (1)
SECTION CS
BLK
808
O*
O*
209
DKGRN
335
B+
B + (1)
SECTION C12
A/C CLUTCH CONTROL
219
DKGRN/WHT
459
B+
B + (1)
SECTION C10
ECMGROUND
217
BLK/WHT
451
O*
O*
DKBLU
473
B+
B + (1)
SECTION C12
LTBLU
446
B+
B + (1)
SECTION CS
O*
0.
SECTION B
DTC(s) AFFECTED
SECTION CS
0.
SECTION CS
O*
SECTION B
81

CONTROL (MANUAL TRANSMISSION)
204
LTGRN
1652
82
TCC (AUTOMATIC TRANSMISSION)
201
TAN/BLK
83
MAP, IA T, & A/C REFRIGERANT SENSOR

GND
212
84
PRIMARY COOLING FAN
BS
86
87
203
88
202
89
211
810 SECONDARY COOLING FAN (WITH C60)
210
811
218
812
208
813
205
814 4th GEAR SIGNAL
216
815
213
816
222
817 ECM GROUND
220
BLK/WHT
451
818 TP SENSOR, ECT GROUND
207
BLK
470
819 3rd GEAR SIGNAL
206
DKGRN/WHT
438
820 2nd GEAR SIGNAL
215
WHT
232
o
o
o
821
214
822 ECM GROUND
221
TAN/WHT
551

This Chart may be used in conjunction with the T-100 Yellow Breakout Box
b48921) to obtain voltage present for each circuit listed. Install the BOB
etween the ECM harness connectors and the ECM, then probe the pin listed
under "BOB PIN#". Voltage may vary due to low batte'?, charBe or other
reasons, but should be very close. All voltages shown in the NG "R N" column
are typical with engine at idle, closed throttle, normal operatin,9 temperature,
park or neutral, system in "Closed Loop," all accessories "OFF,' and scan tool
not installed.
LESS THAN .5 VOLT WHEN SYSTEM IS ENABLED.

BATTERY VOLTAGE ABOVE 5 MPH.
LESS THAN .5 VOLT.
DTC(s) AFFECTED
SECTION B
IL.-1~
-
r1
7
12
18

(1)
(2)
6E3 REFERENCE
ENG
"RUN"
O Ll Ll LI
-61:J-.
ddCJDCJ
000000
DODOO
.........
11
17
22
~
I.--.~
RED
ECM
CONNECTOR B
Figure A-8 - ECM Connector Terminal End View 5. 7L (VIN P) "F" Carline (2 of 4)
10-19-92
MS 12316
''F" CARLINE
USE T-100 YELLOW BREAKOUT BOX (BOB)

ECM PIN/FUNCTION
C1
5.7L (VIN P)
RPO: LT1
-
A/CSTATUS
VOLTAGE
BOB
PIN#
WIRE COLOR
304
DKGRN
CKT#
KEY
"ON"
ENG
"RUN"
59
0 (3)
C2
301
GRY
474
C3
TP SENSOR SIGNAL
312
DKBLU
417
.62
.62
6E3 REFERENCE
SECTIONC10
DTC(s) AFFECTED
DTC(s) 21, 22
309
C4
C5
LOW RESOLUTION
319
RED/BLK
453
1.00R
5.0
1.0(4)
C6
BATTERY FEED
317
ORN
340
B+
B+
C7
303
GRY
416
C8
KNOCK SENSOR SIGNAL
302
DKBLU
496
2.5
2.5
C9
REFERENCE LOW
311
PNK/BLK
632
SECTION C4
DTC(s) 66, 67
DTC16
CHART A-1
DTC(s) AFFECTED
OTC 43, SECTION CS
C10
310
C11 A/C REFRIGERANT PRESSURE

SENSOR SIGNAL
318
RED/BLK
380
.78
.6-1.0 (5)
C12 IGNITION FEED
308
PNK
439
B+
B+
C13
305
C14 HIGH RESOLUTION
316
LTBLU/BLK
647
0*
2.5 (4)
DTC36
C15
313
C16 A/C EVAPORATOR TEMPERATURE

SENSOR SIGNAL
322
DKBLU
732
1.4 (2)
1.4 (2)
CHART C-10
DTC71
C17 BATTERY FEED
320
ORN
340
B+
B+
CHART A-1
C18 DISTRIBUTOR IGNITION FEED
307
RED
631
B+
B+
SECTION C4
C19
306
C20 FUEL PUMP SIGNAL
315
GRY
120
O* (6)
B+
C21 MAP SIGNAL
314
LTGRN
432
4.8 (1)
1.2 (1)
DTC(s) 33, 34
C22 IA T SIGNAL
321
TAN
472
2.0 (2)
3.0 (2)
DTC(s) 23, 25

This Chart may be used in conjunction with the T-100 Yellow Breakout Box
(48921) to obtain voltage present for each circuit listed. Install the BOB
between the ECM harness connectors and the ECM, then probe the pin listed
under "BOB PIN#". Voltage may varYi due to low battery char~e or other
reasons, but should be very close. A I voltages shown in the NG "RUN"
column are typical with entne at idle, closed throttle, normal operating
temperature! park or neutra, system in "Closed Loop," all accessories "OFF,
and scan too not installed.
DVM NEGATIVE (BLACK) LEAD MUST
BE CONNECTED TO A KNOWN GOOD
GROUND.
CHART A-1
L-J.
,,,,...--
VARIES WITH ALTITUDE.

B + WHEN SYSTEM IS ENABLED.
VARIES.
WITH A/C "OFF"
B + WHEN FUEL PUMP IS ENABLED
LESS THAN .5 VOLT.
--.
1 ~ 6
CJ CJ !'.J D CJ
11
LJOCILlLILl
LlLlLlDLl
12
18
(1)
(2)
(3)
(4)
(5)
(6)
*
- ~
.........
17
22
....
I ,...,==-u_
GREEN ECM
CONNECTOR C
10-19-92
MS 12313
Figure A-9 - ECM Connector Terminal End View 5.7L (VIN P) "F" Carline (3 of 4)
''F" CARLINE
22 PIN 'ECM CONNECTOR
USE T-100 YELLOW BREAKOUTBOX (BOB)

ECM PIN/FUNCTION
01
CKT#
KEY
"ON"
ENG
"RUNU
404
PPL
401
0*
O*
DTC24
TAN
800
(1)
(1)
CHARTA2
401
03
412
409
05
6E3
REFERE~CE
WIRE COLOR
02
SERIAL DATA
VOLTAGE
BOB
PIN#
VSSGROUND
04
5.7L . (VIN P)
RPO: LT1
--
419
0
06
BANK 1 (LEFT) 025 SIGNAL
417
PPL/WHT
1665
.38 (1)
.1-.9 (1)
07
FUEL PUMP RELAY DRIVER
403
DKGRN/WHT
465
0 (2)
B+
CHART A5
08
VSS OUTPUT {4KPPM)
402
DKGRN/WHT
817
(3)
(3)
DTC24
DTC(s) 13, 44
09
411
010 INJECTOR DRIVER
410
DKGRN
468
B+
B+
CHARTA3
011 INJECTOR DRIVER
418
DKBLU
467
B+
B+
CHARTA3
012 VSS SIGNAL
408
YEL
400
(3)
(3)
DTC24
013
405
014
416
015
413
016 025 GROUND
422
BLKJWHT
351
O*
O*
017
420
018
407
019
406
020 DIAGNOSTIC ENABLE
415
WHT/BLK
448
021
414
022 BANK 2 (RIGHT) 025 SIGNAL
421
PPL
1666
.36
.1-.9 (1)
DTC(s) 13,63
CHARTA-2
DTC(s) 63, 64

This Chart may be used in conjunction with the T-100 Yellow Breakout Box (48921) to obtain volta~e
present for each circuit listed. Install the BOB between the ECM harness connectors and the EC ,
then probe the pin listed under "BOB PIN#". Voltage may var~ due to low battery charge or other
reasons, but should be very close. All voltages shown in the NG "RUN" column are typical with
engine at idle, closed throttle, normal operating temperature, park or neutral, system in "Closed
Loop," all accessories "OFF," and scan tool not installed.

BROWN
ECM
CONNECTOR D
(1)
(2)
(3)
*
VARIES.
B + FOR TWO SECONDS WITH IGNITION "ON."
VARIES DEPENDING ON POSITION OF DRIVE WHEELS.
LESS THAN .5 VOLT.
LILILlDOt:J
c'.JCJClC!CJ
c'.JCJi:'.JIJCJCJ
7
12
11
17
OODOO
.n.__..
18
"--
22
~
I- . ~
Figure A-10 - ECM Connector End View 5.7L (VIN P) "F" Carline (4 of 4)
10-992
MS 12314
BLANK
6E3-A-14 5.7L (VIN P} DRIVEABILITY AND EMISSIONS
~~.}2
TOB
~~
1002RED
C200
JUNCTION BLOCK
C210
L3PNK~439PNKB
15AMP
C230
BATTERY FEED
340 ORN
BATTERY FEED
439PNK
IGNITION FEED
TO PASS-Key II
DECODER MODULE
TO FUEL
TO OTHER GAGES
:~:ECrCUITS
3400RN
TO
(1/P)
INJECTORS
t,A
ECM
10 AMP
(1/P)
E~M /IGN
IGNITION SWITCH
TOB+.
~(---t-ECM/BAT
;- ~~3.9~
)/J)A_
PUMP RELAY
TOIGNITION~39PNK~419BRN/WHT : (( 8 :
1
I
10 AMP
(1/P)
KK :
419BRN/WHT
422 TAN/BLK
,----...,
451 BLK/WHT -
2-1( ) ~ 451 BLK/WHT
L.(
r---~
ciiio J
L.
TO DERM
DIAGNOSTIC ENABLE
ECMGROUND
ECMGROUND
r---~
I A12 I
I
DI
.__---;...-~._~-,-~:-c(~800TAN
DIAGNOSTIC
"TEST"
TERMINAL
TCCCONTROL
I I' I
.---------~~~~--4--448 WHT/BLK
'-----'
1
MIL (SERVICE ENGINE

SOON) CONTROL
L.
SERIAL DATA
c:100 ...
TO EBCM
10-12-92
MS 12492
ON-BOARD DIAGNOSTIC (OBD) SYSTEM CHECK

5.7L (VIN P) "F" CARLINE (MFI)
The On-Board Diagnostic (OBD) system check is an organized approach to identifying a problem created by
an engine control system malfunction. It must be the starting point for any driveability complaint diagnosis,
because it directs the service technician to the next logical step in diagnosing the complaint. Understanding the
chart and using it correctly will reduce diagnostic time and prevent the unnecessary replacement of good parts.

1. This step is a check for the proper operation of the
Malfunction Indicator Lamp (MIL) "Service
Engine Soon." The MIL should be "ON" steady.
2. No MIL at this point indicates that there is a
problem with the MIL circuit or the ECM control of
that circuit.
3. This test checks the ability of the ECM to control
the MIL. With the diagnostic terminal grounded,
the MIL should flash a DTC 12 three times,
followed by any Diagnostic Trouble Code (DTC)
stored in memory.
4. Most of the 6E procedures use a Tech 1 to aid
diagnosis, therefore, serial data must be available.
If a PROM error is present, the ECM may have
been able to flash DTC 12/51, but not enable serial
data.
5. Although the ECM is powered up, a "Cranks But
Will Not Run" symptom could exist because of an
ECM or system problem.
6.
This step will isolate if the customer complaint is a

MIL or a driveability problem with no MIL. An
invalid DTC may be the result of a faulty scan tool,
PROMorECM.
7. Comparison of actual control system data with the
typical values is a quick check to determine if any
parameter is not within limits. Keep in mind that
a base engine problem (i.e. advanced cam timing)
may substantially alter sensor values.
8. Installation of a scan tool will provide a good
ground path for the ECM and may hide a
driveability complaint due to poor ECM grounds.
9. If the actual data is not within the typical values
established, the charts in "Components Systems,"
Section "6E3-C" will provide a functional check of
the suspect component or system.
DRIVEABILITY AND EMISSIONS 5. 7l (VIN P) 6E3-A-15
ON-BOARD DIAGNOSTIC (080)

SYSTEM CHECK
5.7L (VIN P)
11
F" CARLINE (MFI)

NOTE MIL (SERVICE ENGINE SOON).
FLASHING OTC 12
STEADY LIGHT
G)
,...
USING TECH 1 PERFORM "080 SYSTEM CHECK."
OR
JUMPER "DLC" TERMINAL "B" TO" A".
DOES MIL (SERVICE ENGINE SOON) FLASH OTC 12?
---------,
: USE CHART A-1
CHECK FOR GROUNDED

DIAGNOSTIC TEST CKT 451.
USE WIRING DIAGRAM ON
CHART A-1.
,... ----------,
DOES TECH 1 DISPLAY ECM DATA?
: USE CHART A-2
DOES ENGINE START?
: USE CHART A-2
ARE ANY DTC(S) DISPLAYED?
: USE CHART A-3
REFER TO APPLICABLE OTC CHART.

START WITH LOWEST OTC.
'-------------'
---------
COMPARE TECH 1 DATA WITH TYPICAL VALUES

SHOWN ON FOLLOWING PAGE. ARE VALUES
NORMAL OR WITHIN TYPICAL RANGES?
REFER TO "SYMPTOMS"
IN SECTION "B".
REFER TO INDICATED
"COMPONENT(S) SYSTEM"
CHECKS IN SECTION "C".
3-10-92
7S 3227-6E
If after completing the on-board diagnostic system check and finding the Tech 1 diagnostics functioning
properly and no diagnostic trouble codes displayed, the "Typical Scan Values" may be used for comparison with
values obtained on the vehicle being diagnosed. The "Typical Data Values" are an average of display values
recorded from normally operating vehicles and are intended to represent what a normally functioning system
would typically display.
A SCAN TOOL THAT DISPLAYS FAULTY DATA SHOULD NOT BE USED, AND THE PROBLEM
SHOULD BE REPORTED TO THE MANUFACTURER. THE USE OF A FAULTY SCAN TOOL CAN
RESULT IN MISDIAGNOSIS AND UNNECESSARY PARTS REPLACEMENT.
Only the parameters listed below are used in this manual for diagnosing. If a scan tool displays other
parameters, the values are not recommended by General Motors for use in diagnosis. For more description on the
values and use of the scan tool to diagnose ECM inputs, refer to the applicable diagnosis section in Section "C". If
all values are within the range illustrated, refer to "Symptoms," Section "B".
TECH 1 DATA
Idle I Lower Radiator Hose Hot I Closed Throttle I Park or Neutral I Closed Loop I Accessories off
Refer To Section
Scan Position
"C1"and:
Units Displayed
Ty~icaf Data Value
Engine Speed
1 0 RPM from des1 red
RPM
Desired Idle
Eng Cool Temp.
Intake Air Temp.
ca;Fo
ca;Fo
MAP
BARO
Th rot Position
Throttle Angle
LefURight 025 Bnk 1 and 2
Loop Status
kPaNolts
kPaNolts
Volts
Percentage
Millivolts
Open/Closed
RPM
Short Term Fuel Trim Bnk 1 and 2

Long Term Fuel Trim Bnk 1 and 2
FuerTrim Cell
Fuel Trim Enable
Spark Advance
Mph/km/h
Knock Retard
Knock Signal
Lo Res. Signal
Hi Res. Signal
Injector P-ulse Width Bank 1 and 2
Idle Air Control
Learned IAC
EGR Duty Cycle
System Voltage
AIR Control
Fuel Evap Purge
QOM 1 QOM 2
QDM3
Knock Sensor
Current IC
Bnk 1 Injector Fault
Bnk 2 lnJector Fault
Fan 1 Fan 2
Counts
Counts
Cell Number
No/Yes
#of Degrees
Mph/km/h
Degrees of Retard
No/Yes
Milliseconds
Counts
Milliseconds
Counts
Counts
0-100%
Volts
Off/On
0-100%
Ok/Fault Ok/Fault
Ok/Fault
Ok/Not Ok
Ok/Not Ok
No/Yes
No/Yes
Off/On Off/On
A/C Request
A/CClutch
A/CStatus
A/C Ref Pressure
A/C EVAP Temperature
Pass Key
Reverse Inhibit Solenoid
Park/Neutral Position
TCC 2nd
No/Yes
Off/On
Off/On
Psi, Volts
3rd 4th
Calibration ID
Time From Start
Co/Fo
Disabled/Enabled
On/Off
P-N--/-R-DL
Off/On No/Yes
No/Yes No/Yes
0-9999
Hrs/Min/Sec
ECM commanded (based on temp)

85C-105C(185F-221F)
10C - 90C (50F - 194F)
(Depends on underhood temperature)
20 - 48/1-2 (Varies with altitude)
70 - 100/3.5-4.5 (Varies with altitude)
.3- .9
0%
10-1000 mV and varying
Closed Loop (may go open with
extended idle)
Varies
118 to 138
16 to 18 (depends on air flow & RPM)
No
Varies
0
0
No {Yes, when detonation is detected)

Vanes
Continuous counting
1.0-1.5
5- so
5- so
0%
13.5-14.5
Off
Ok
Ok
Ok
Ok
No
No
Depends on A/C refrigerant pressure,
and coolant
temperature
No
Off
Off
Varies (Depends on temp)
Varies (Depends on temp)
Enabled
On
P-N-No
Off
No
No
Varies
Varies (measures run time from
last start)
"C2"
"C2"
"C2"
"C4"
"C8"
"CS"
"CS"
"C4"
"C4"
"C2"
"C2"
"C2"
"C7"
"GD"
"CG"
"C3"
"CS"
"C4"
"C2"
"C2"
"C12"
"C10"
"C10"
"C10"
"C10"
"C8"
"C8"
"C8"
11-24-92
MS 12479

ECM DATA DESCRIPTION
A list of explanations for each data message
displayed on the Tech 1 scan tool begins below.
This information will assist in tracking down
emission or driveability problems, since the displays
can be viewed while the vehicle is being driven. See
the "On-Board Diagnostic System Check" for
additional information.
ENGINE SPEED - Range 0-9999 RPM - Engine speed is
computed by the ECM from the distributor reference

input. It should remain close to desired idle under
various engine loads with engine idling.
DESIRED IDLE - Range 0-3187 RPM - The idle speed
that is commanded by the ECM. The ECM will
compensate for various engine loads to keep the engine
at the desired speed.
ENG COOL TEMP - Range -40C to 151C, -40F to 304F
- The Engine Coolant Temperature (ECT) sensor is

mounted in the coolant pump and sends engine
temperature information to the ECM. The ECM
supplies 5 volts to the ECT sensor circuit. The sensor
is a thermistor which changes internal resistance as
temperature changes. When the sensor is cold
(internal resistance high), the ECM monitors a high
signal voltage which interprets it as a cold engine. As
the sensor warms (internal resistance decreases), the
voltage signal will decrease and the ECM will
interpret the lower voltage as a warm engine.
INTAKE AIR TEMP - Range -40C to 196C, -40F to
385F - The ECM converts the resistance of the intake
air temperature sensor to degrees. Intake Air

Temperature (IAT) is used by the ECM to adjust fuel
delivery and spark timing according to incoming air
density.
MAP - Range 11-105 kPa/0.00-5.10 Volts - The
Manifold Absolute Pressure (MAP) sensor measures
the change in the intake manifold pressure which
results from engine load and speed changes. As intake
manifold pressure increases, the air density in the
intake manifold also increases and additional fuel is
required.
BARO- Range 11-105 kPa/0.00-5.10 Volts - The BARO
reading displayed is measured from the MAP sensor at

key "ON," engine "OFF" and WOT conditions. The
BARO reading displayed represents barometric
pressure and is used to compensate for altitude.
THROT POSITION - Range 0-5.10 Volts - Used by the

ECM to determine the amount of throttle demanded by
the driver. Should read .36-.96 volt at idle to above 4
volts at wide open throttle.
THROTTLE ANGLE - Range 0-100% - Computed by the
ECM from TP sensor voltage (Throttle Position) and
should read 0% at idle and 100% at wide open throttle.
LEFT/RIGHT 02S Bank 1 and 2 - Range 0-996 mV Represents the exhaust oxygen sensor output voltage.
Should fluctuate constantly within a range between
1.00 m V (lean exhaust) and 1000 m V (rich exhaust)
when operating in "Closed Loop."
LOOP STATUS - Tech 1 Displays Open or Closed -
"Closed Loop" displayed indicates that the ECM is

controlling fuel delivery according to oxygen sensor
voltage. In "Open Loop," the ECM ignores the oxygen
sensor voltage and bases the amount of fuel to be
delivered on TP sensor, engine coolant temperature,
and MAP sensor inputs only.
SHORT TERM FUEL TRIM - Range 0-255 - Short term
fuel trim represents a short-term correction to fuel
delivery by the ECM in response to the amount of time
the oxygen sensor voltage spends above or below the
450 m V threshold. If the oxygen sensor voltage has
mainly remained below 450 m V, indicating a lean
air/fuel mixture, short term fuel trim will increase to
tell the ECM to add fuel. If the oxygen sensor voltage
stays mainly above the threshold, the ECM will reduce
fuel delivery to compensate for the indicated rich
condition.
LONG TERM FUEL TRIM Range 0-255 - Long term fuel
trim is derived from the short term fuel trim value and
is used for long-term correction of fuel delivery. A
value of 128 counts indicates that fuel delivery
requires no compensation to maintain a 14.7:1 air/fuel
ratio. A value below 128 counts means that the fuel
system is too rich and fuel delivery is being reduced
(decreased injector pulse width). A value above 128
counts indicates that a lean condition exists and the
ECM is compensating by adding fuel (increased
injector pulse width).
FUEL TRIM CELL - Range 0-255 - Fuel trim cell is
dependent upon engine speed and MAP sensor
readings. A plot of RPM vs. MAP is broken into 16
cells. Fuel trim cell indicates which cell is currently
active.

FUEL TRIM ENABLE - Tech 1 Displays "NO" or "YES" -
If the Fuel Trim Enable system is learning (YES) the

long term fuel trim is responding to the short term fuel
trim. If fuel trim enable displays "NO" then long term
fuel trim will not respond to changes in short term fuel
trim.
EGR DUTY CYCLE Range Oto 100% - The ECM cycles

the EGR solenoid valve "ON" and "OFF." The "ON"
time (duty cycle) of the EGR solenoid valve, expressed
as a percent, determines how much the exhaust gas is
recirculated.
SYSTEM VOLTAGE - Range 0.0 to 25.5 Volts - This
SPARK ADVANCE - Tech 1 Range -90 to 90 - This is a
display of the spark advance (IC) calculation which the

ECM calculates and then provides all spark advance to
the ignition system. The ECM computes the desired
spark advance using data such as engine temperature,
RPM, load, vehicle speed, and operating mode. There
is no adjustment for spark advance.
VEHICLE SPEED Range 0-255 km/h, 0-255 mph - The
vehicle speed sensor signal is converted into km/h and

mph for display.
KNOCK RETARD - Range 0 to 45 - Indicates the
amount of spark advance the ECM is removing from
IC in response to the Knock Sensor (KS) signal.
represents the system voltage measured by the ECM

at its ignition #1 feed.
AIR CONTROL - When the ECM enables the air pump,
the Tech 1 will indicate "ON." When the ECM

disables the air pump, the Tech 1 will indicate "OFF."
FUEL EVAP PURGE Tech 1 Range 0-100% - A
proportion.al signal used to control canister purge
func~ion. 0% implies the valve is commanded fully
closed while 100% implies that the valve is fully open.
QDM(S) - Tech 1 Displays "YES"/"NO" - Quad - Driver
modules are used to power various systems. The Tech
1 should display "OK" and switch to "Fault" if there is
a circuit problem.
KNOCK SIGNAL - Tech 1 Displays "YES" or "NO" -
Indicates whether or not a knock signal is being

detected by the ECM. Should read "NO" at idle.
LO RESOLUTION - Range 0-999.9 m/sec. - This signal is
generated by the ignition control module and should
display time between reference pulses received by the
ECM.
HI RESOLUTION - Range 0-255 Counts - This signal is
generated by the ignition control module and should

be incrementing with each reference pulse received by
theECM.
KNOCK SENSOR - Tech 1 will either display
Open/Grounded/OK. If a circuit problem is detected on

the knock sensor circuit, the Tech 1 will display either
open or grounded to identify a problem.
CURRENT IC - Tech
1 will either display

Open/Grounded/OK. If a circuit problem is detected on
the IC circuit, the Tech 1 will display either open or
grounded to identify the problem.
INJECTOR FAULTS - The Tech 1 will display "YES" if
the ECM has detected an improper voltage level on the

injector circuits.
INJECTOR PULSE WIDTH - Tech 1 Range 0.0 to 999.9 -
Indicates the "ON" time of the injectors in

milliseconds. When engine load is increased, injector
pulse width will increase.
FAN - When the ECM is commanding the coolant fans

"ON," the Tech 1 display will switch from "OFF" to
"ON."
IDLE AIR CONTROL - Range 0-255 - Displays the

commanded position of the idle air control pintle in
counts. The higher the number of counts, the greater
the commanded idle speed. Idle air control should
respond fairly quickly to changes in engine load to
maintain desired idle rpm.
A/C REQUEST - Tech 1 Displays "YES" or "NO" -
LEARNED IAC - Range O to 255 - Learned IAC is an

internal ECM parameter. Each time the vehicle is
driven the IAC system learns how many counts is
required to produce a given desired idle.
Represents the state of the A/C request from the

HVAC control assembly.
A/C CLUTCH - Tech 1 Displays "ON" or "OFF" -
Represents the commanded state of the A/C clutch

control relay. A/C clutch should be engaged when
"ON" is displayed.
DRIVEABILITY AND EMISSIONS 5.7L (VIN P) 6E3.-A-19

A/C STATUS - The Tech 1 will display "ON" if voltage
has been applied to the A/C compressor clutch.
A/C REF PRESSURE Range 0-459 psi I 0.00-4.90 Volts The Tech 1 will display the A/C refrigerant pressure
used by the ECM for cooling fan operation and A/C
diagnostic trouble codes.
A/C EVAP TEMP - -7C to 32C, 19F to 90F - The Tech
1 will display the A/C evaporator temperature and is
used by the ECM to cycle the A/C clutch. The
evaporator temperature sensor will also prevent
evaporator freeze.-up.
REVERSE INHIBIT SOLENOID - The Tech 1 will display
"ON" when all criteria have been met and the ECM is
mandating use of the reverse lockout solenoid.
PASS-Key - An input from the PASS-Key module
that tells the ECM to enable the injectors if the proper
signal is received. The Tech 1 will normally display
"Enabled." If the PASS-Key test has failed, the
display will switch to "Disabled" and the fuel system
may be disabled.
PARK/NEUTRAL POS - Tech 1 Displays - P-N-- or -R-DL P-N-- displayed indicates that the gear select lever is
in park or neutral.
TCC Tech 1 Displays "OFF" or "ON" - The Tech 1 only
indicates when the ECM has enabled the TCC driver
but this does not confirm that the TCC has engaged~
To determine ifTCC is operating properly, engine rpm
should decrease when TCC is enabled.
GEAR SWITCHES Tech 1 displays "VES"/"NO" - The
transmission gear switches are used by the ECM to
determine what gear the transmission is in. The ECM
also uses these inputs to control the TCC system.
CALIBRATION ID Range O to 9999 - The PROM
identification describes the particular PROM being
used in the ECM. The Tech 1 display number is not
the service part number.
TIME FROM START Range 0:00:00 to 18:12:15
HR/MIN/SEC - A measure of how long the engine has
been running. When the engine stops, it is reset to
zero.
11-24-92
MS 12724
6E3-A-20 5.7L {VIN P) DRIVEABILITY AND EMISSIONS
~
~C2
ECM/BAT
C
T O B + ~ ~ ~ 1002RED ~ ( ~ - - ~ - - 3400RN
1~l:P~P
C21 0
JUNCTION BLOCK
C200
"---- 340 ORN
IGNITION SWITCH
E~M /IGN
G
TOB+""'
L3PNK~439PNKB
439PNK
15AMP
C230
TO
(I/P)
TO PASS-Key II
INJECTORS
DECODER MODULE
TO OTHER GAGES
TO FUEL
FUSE CIRCUITS
PUMP RELAY
(230
,-----,
r.eAr.ers
TO IGNITION ~ 3 9 P N K ~ 4 1 9 BRN/WHT
10 AMP
(1/P)
: ((B:
I
I
I
419BRN/WHT
ECM
BATTERY FEED
BATTERY FEED
IGNITION FEED
MIL (SERVICE ENGINE

SOON} CONTROL
KI
422 TAN/BLK
TCCCONTROL
DIAGNOSTIC ENABLE
r-----,
1
451 BLK/WHT -
._C210 ~ 451 BLK/WHT
DIAGNOSTIC
"TEST"
TERMINAL
,----,
,-----,
..ciooJ
t . c:100 . .
I A12 I
I
D I
._.---;'r-<~1--~'---1T..--r:~<~sooTAN
TO DERM
ECMGROUND
ECMGROUND
SERIAL DATA
TOEBCM
11-3-92
MS 12492
CHART A-1
NO MALFUNCTION INDICATOR LAMP {MIL)

5.7L {VIN P) "F" CARLINE {MFI)
There should always be a steady MIL (Service Engine Soon) when the ignition is "ON" and engine stopped.
Ignition voltage is supplied directly to the light bulb. The Engine Control Module (ECM) will control the light
and turn it "ON" by providing a ground path through CKT 419 to the ECM.

1. Use J 35616-A tool kit to probe ECM harness
terminals, so that you do not damage them.
2. Using a test light connected to 12 volts, probe each
of the system ground circuits to be sure a good
ground is present. See ECM terminal end view in
front of this section for ECM pin locations of
ground circuits.
3. If the fusible link is open, determine short to
ground in CKT 1002.
4. Make sure to check CKT 439 if the ECM IGN fuse
is open and both 340 circuits if the ECM/Batt fuse
was open.
Check all 439 circuits if the ECM IGN fuse is open.
Refer to ECM wiring diagrams for information.
Diagnostic Aids:
Engine runs OK, check:
Faulty light bulb.
CKT 419 open.
Open gages fuse.
Engine cranks but will not run, check:
Continuous battery - fusible link open.
ECM Batt fuse open.
ECM IGN fuse open.
Battery CKTs 340 to ECM open.
Ignition CKT 439 to ECM open.
Poor connection to ECM.
Faulty ECM ground circuit(s).
PASS-KeyII circuit problem.
DRIVEABILITY AND EMISSIONS 5. 7L (VIN P) 6E3-A-21
CHART A-1
NO MALFUNCTION INDICATOR LAMP (MIL)
S.7L (VIN P) "F" CARLINE (MFI)
DOES THE ENGINE START?
IGNITION "OFF."
DISCONNECT ECM CONNECTOR "A".
IGNITION "ON."
PROBE CKT 419, WITH TEST LIGHT TO GROUND.
IS THE MALFUNCTION INDICATOR LAMP(MIL)
"SERVICE ENGINE SOON" "ON"?
FAULTYECM
CONNECTION
OR
ECM.
CHECK:
GAGES FUSE.
FAULTY BULB.
OPEN CKT 419.
CKT 419 SHORTED
TO VOLTAGE.
OPEN IGNITION
FEED TO BULB.
G)
G)
IGNITION "OFF."
DISCONNECT ECM
CONNECTOR "C".
IGNITION "ON."
PROBE BOTH 340 CKTs,
AND CKT 439, WITH TEST
LIGHT TO GROUND. TEST
LIGHT SHOULD BE "ON" AT
ALL CIRCUITS.
ISIT?
FAUL TY ECM GROUNDS

OR
ECM.
G)
G)
LOCATE AND
CORRECT SHORT TO
GROUND IN CIRCUIT.
REPAIR OPEN IN CIRCUIT

THAT DID NOT LIGHT THE
TEST LIGHT.
"AFTER REPAIRS.'' CONFIRM "CLOSED LOOP" OPERATION AND NO MIL (SERVICE ENGINE SOON).
10-6-92
MS 12080
ECM
L,C2
ECM/BAT
C
T O B + ~ ~ 1002RED ~ ( - - - ~ - - 3 4 0 0 R N
1~ 1p~P
JUNCTION BLOCK
C200
"'--ORN
C21 0
1
340
IGNITION SWITCH
E-'.M /IGN
G
TOB+
.L
3PNK~439PNKB
15 AMP
C230
TO
(1/P)
INJECTORS
BATTERY FEED
IGNITION FEED
439PNK
TO PASS-Key II
DECODER MODULE
TO FUEL
PUMP RELAY
TO OTHER GAGES
FUSE CIRCUITS
r:1\1:cs
BATTERY FEED
,...f~3_Q~
~I- 419 BRN/WHT
8
o IGNITION ~ 3 9 PNK~419BRN/WHT-1~t--K=
10 AMP
I
~;
c
~ - - - - - - - < ~ ~ i t - -~_..,'
+ -,-,...---,
422TAN/BLK
TCCCONTROL
448 WHT/BLK
DIAGNOSTIC ENABLE
451 BLK/WHT -
'-ci o~ 451 BLK/WHT

1
,...----,
I
I
DIAGNOSTIC
"TEST"
TERMINAL
A12
L---..J
T
f
C200
TODERM
86
ECMGROUND
817
ECMGROUND
,-----,
MIL (SERVICE ENGINE

SOON) CONTROL
DI
L~~-J
SOOTAN
SERIAL DATA
C100
TOEBCM
11-3-92
MS 12492
CHART A-2
NO DLC DATA OR WILL NOT FLASH DTC 12
11
MALFUNCTION INDICATOR LAMP (MIL) 0N" STEADY
5.7L (VIN P) "F'' CARLINE (MFI)
There should always be a steady MIL (Service Engine Soon) when the ignition is "ON" and engine stopped.
Ignition voltage is supplied to the light bulb. The Engine Control Module (ECM) will turn the light "ON" by
grounding CKT 419 in the ECM.
With the diagnostic "test" terminal grounded, the light should flash a OTC 12, followed by any diagnostic
trouble code(s) stored in memory.
A steady light with the diagnostic "test" terminal grounded suggests a short to ground in the light control
CKT 419 or an open in diagnostic CKTs 448 or 451.

1. If there is a problem with the ECM that causes a
Tech 1 to not display serial data, the ECM should
not flash a OTC 12. If OTC 12 is flashing, check
CKT 448 for a short to ground. If OTC 12 does
flash, make sure that the Tech 1 is working
properly on another vehicle.
2.
3.
4.
If the MIL goes "OFF," when the ECM connector is

disconnected, CKT 419 is not shorted to ground.
This step will check for an open diagnostic CKT
448.
At this point, the MIL (Service Engine Soon)
wiring is OK. The problem is a faulty ECM or
PROM. If DTC 12 does not flash, the ECM should
be replaced using the original PROM. Replace the
PROM only after trying an ECM, as a defective
PROM is an unlikely cause of the problem.
CHART A-2
NO DLC DATA OR WILL NOT FLASH OTC 12
MALFUNCTION INDICATOR LAMP (MIL) 0N" STEADY
5.7L (VIN P) F'' CARLINE (MFI)
11
11

IS THE Mil (SERVICE ENGINE SOON) "ON"?

DOES LIGHT FLASH DTC 12?
G)
IGNITION "OFF."
DISCONNECTECM CONNECTOR "A".
IGNITION "ON" AND NOTE Mil
(SERVICE ENGINE SOON).
r- - - - - - - ,
:
USE
:
I CHART A-1 1
L--------J
G)
IFPROBLEMWASNODLCDATA:
CHECK SERIAL DATA 800 CKT FOR
OPEN OR SHORT TO GROUND. IF OK,
IT IS A FAUL TY ECM OR PROM.
IGNITION "OFF."
JUMPER TERMINALS "A" TO "B" AT DLC CONNECTOR
DISCONNECT ECM CONNECTOR "D".
CONNECT TEST LIGHT BETWEEN ECM CONNECTOR
TERMINAL "020" AND B +.
REPAIR SHORT TO
GROUND IN CKT 419.
CHECK PROM FOR PROPER INSTALLATION.

IF OK, REPLACE ECM USING ORIGINAL PROM.
RECHECK FOR DTC 12.
REPLACE PROM.
CHECK FOR OPEN IN DLC DIAGNOSTIC

TERMINALS "A" AND "B" (CKT 448 AND
CKT 451), REPAIR AS NECESSARY.
SYSTEM OK.
6-9-92
MS 12460
INJECTOR
'i~'r..~p 639PNK~)1
TOFUELPUMPRELAY
IGNITION
SWITCH
t.
i
FUSE BLOCK
JUNCTION
3 PNK
TO B +
839 PNK
INJECTOR
# 10
. AMP
7 5
(U/H)
639PNK
~~~A
1A1
1
1
1
1
ECM
DK~iN
INJECTOR DRIVER
~;.
V':.'..--~
B~ I~~
t}~ 839 PNK
~~
~~-'-'-'-
467
DK BLU
~ t'YYY'\ ;.
V-,,, ~
C100
IGNITION SYSTEM
B
A
TEST CONNECTOR
I - - - - - - - - - - 632 PNK/BLK
632 BLK/PNK
, - - - - - - - - - - - 631 YEL
, - - - - - - - - 647 PPL/WHT
. . - - - - - - - - 453 BLK/RED
I-----------
631 RED
DISTRIBUTOR
REFERENCE LOW
IGNITION FEED
1--------- 647 LT BLU/BLK
HIGH RESOLUTIOIII
I - - - - - - - - - - 453 RED/BLK
LOW RESOLUTION
11j.-- 450 BLK
ENGINE
GROUND
IGNITION
TO~
IGNITION
1~ ~M.P
BLK
CONNECTOR
r
I
(U/H)
--------\
I
I
239
IGNITION
COIL
MODULE
PNK
423WHT
IGNITION CONTROL
I
I
IGNITION I
COIL
:
I
I
I
I
121
WHTI
~--------/-.J
BLK
(U/H)
= LOCA TEO IN UNDERHOOD ELECTRICAL CENTER
CONNECTOR
CHART A-3
TO..._j
INSTRUMENT
CLUSTER
11-3-92
MS 12476
{Page 1 of 2)

11
5.7L (VIN P) F" CARLINE (MFI)
1. Perform On-Board Diagnostic (OBD) system check
to determine if the ECM and the MIL (Service
Engine Soon) are functioning.
2. CHART C-4 will address all problems related to
the causes of a no spark condition.
3. The test light should blink, indicating the ECM is
controlling the injectors OK. All lights should
blink at the same brightness. If any injector light
blinks dimly an injector may be shorted. Compare
injector resistance values.
4. Use fuel pressure gage J 34730-1 or equivalent.
Wrap a shop towel around the fuel pressure tap to
absorb any small amount of fuel leakage that may
occur when installing the gage.
5. All injectors should be within 1.0 ohm of each
other and should not be less than 10 ohms at 21 C
(70F).
Diagnostic Aids:
An EGR valve sticking open can cause a low
air/fuel ratio during cranking.
Unless engine enters "Clear Flood" at the first
indication of a flooding condition, it can result in a
no start.
A defective MAP sensor may cause a no start or a
stall after start. Disconnect the sensor. The ECM
will use a default value for the sensor. If the
condition is corrected and the connections are OK
replace the sensor.
'
If above are all OK, refer to "Symptoms," Section
"6E3-B", "Hard Start."
PERFORM ON-BOARD DIAGNOSTIC SYSTEM CHECK.

CHECK THE FOLLOWING:
IF ECM DTC(s) 16,41, OR42 ARE STORED, USE THOSE
CHARTS FIRST.
CHECK PASS Key STATUS. IF NOT OK, REFER TO ECM
OTC 46 CHART FIRST.
ACTUAL ENGINE TEMPERATURE AND ECT TEMPERATURE
ON THE TECH 1 SHOULD BE CLOSE TO THE SAME, If NOT,
REFER TO OTC 1S.
TP SENSOR - If OVER 2.5 VOLTS AT CLOSED THROTTLE,
USE THE DTC 21 CHART.
IS RPM INDICATED ON TECH 1 DURING CRANKING?
USING A ST-125(SPARKCHECKER),
J 26792, CHECK FOR SPARK WHILE
CRANKING (CHECK TWO WIRES).
IS SPARK PRESENT?
0:
r-
DISCONNECT EACH
INJECTOR ONE AT A
TIME.
CONNECT TEST LIGHT
J 34730-2 TO EACH
INJECTOR HARNESS
CONNECTOR.
CHECK FOR BLINKING
LIGHT WHILE CRANKING.
(Page 1 of 2)

11
IGNITION "OFF."
DISCONNECT DISTRIBUTOR ELECTRICAL CONNECTOR.
IGNITION "ON."
PROBE TERMINAL "C" WITH A TEST LIGHT TO GROUND.
!SIT?
CHECK FOR CONTINUITY BETWEEN

DISTRIBUTOR CONNECTOR
TERMINAL "D" AND GROUND.
CIRCUIT SHOULD HAVE
CONTINUITY.
DOESIT?
------
BASIC
I IGNITION
: SYSTEM
: PROBLEM.
I REFER TO
: CHARTC-4.
L--------

OR
OPEN OR GROUNDED IGNITION
FEED CIRCUIT FROM
DISTRIBUTOR TO ECM
OR
FAULTY ECM.
FAULTY DISTRIBUTOR CONNECTION

OR
FAUL TY DISTRIBUTOR.
ALL LIGHTS BLINKING BRIGHTLY
CHART A-3

OR
OPEN GROUND CIRCUIT
FROM DISTRIBUTOR TO ECM
OR
FAULTY ECM.
USING TECH 1, ENABLE FUEL PUMP.

DOES FUEL PUMP OPERATE?
ANY LIGHTS BLINKING DIMLY
-----,
: USE
:
I CHART A-5. 1
L-------.J
0
4
r
--------,
: USE CHART A-3 :
1 (2 OF 2).
1
SHORTED INJECTOR, COMPARE

INJECTOR RESISTANCE VALUES.
L----------.J
IGNITION "OFF."
INSTALL FUEL PRESSURE GAGE AND NOTE
PRESSURE AFTER IGNITION "ON."
SHOULD BE (283-325 kPa)41-47 psi.
REVIEW THE "DIAGNOSTIC AIDS" ON FACING PAGE FOR ADDITIONAL

ITEMS TO CHECK. IF ALL ARE OK, MFI SYSTEM IS OK.
REFER TO "HARD START" IN "SYMPTOMS," SECTION "B".
------,
: USE
:
I CHART A-7. 1
L-------.J
6-6-92
MS 12493
INJECTOR
#9
7.SAMP
(U/H)
639 PNK
TO FUEL PUMP RELAY
t.
3PNK
FUSE BLOCK
~~
:A:
:
JUNC:l:NPNK
~~~
fYYY'\ , ; , _ ~
~ fYYY'\ ;..
~
639 PNK
~~
ECM
INJ 2,4,6,8 A
4
DK ~iN
INJECTOR DRIVER
B~
839PNK
~~~
Di:~u
INJECTOR
C100
~ l'YYT'\ ;..
r
~
#10
IGNITION SYSTEM
B
A
7.5 AMP
TEST CONNECTOR
TO B+
(U/H)
. . . . - - - - - - - - - 632 BLK/PNK
- - - - - - - - - 632 PNK/BLK
IGNITION
SWITCH ;
1-----------631RED
~ - - - - - - - - - 631 YEL
. - - - - - - - - - 647 PPL/WHT
A
- - - - - - - 453 BLK/RED
t--------- 647 LT BLU/BLK

1---------- 453 RED/BLK
DISTRIBUTOR
REFERENCE LOW
IGNITION FEED
HIGH RESOLUTION
LOW RESOLUTION
111---- 450 BLK
ENGINE
GROUND
IGNITION
TO~
IGNITION
1~ I\_M.P
j
(U/H)
BLK
239 PNK
~~~~E_C~~~ \
IGNITION
COIL
MODULE
423WHT
IGNITION CONTROL
! : !~NG::LK
IGNITION
COIL
II
I I
I ~NNECTOR
I I
I
I I
I
1
1
. - - - ,-<l:-,-'-A'--- 1847 WHT/BLK
L---(E--
L--------/-.J
A
BLK
(U/H) = LOCATED IN UNDERHOOD ELECTRICAL CENTER
121
WHTI
1848
WHT
TO__j
INSTRUMENT
CLUSTER
CONNECTOR
11-3-92
MS 12476
CHART A-3
(Page 2 of 2)

5.7L (VIN P} "F" CARLINE (MFI}
Test Description:
Number(s) below refer to circled

1. Checks for 12 volt supply to injectors. Due to the
injectors wired in parallel there should be a light
"ON" on both terminals.
2. Checks continuity of CKT 467 and CKT 468.
3. All checks made to this point would indicate that
the ECM is at fault. However, there is a possibility
of CKT 467 or CKT 468 being shorted to a voltage
source either in the engine harness or in the
injector harness.
To test for this condition:
Disconnect all injectors.
Ignition "ON."
Probe CKT 467 and CKT 468 on the ECM side

of injector harness with a test light connected
to ground. (Test one injector harness on each
side of engine.) There should be no light. If
light is "ON" repair short to voltage.
If OK, check the resistance of the injectors.
Should be 10 ohms or more.
Check injector harness connector. Be sure
terminals are not backed out of connector and
contacting each other.
If all OK, replace ECM.
CHART A-3
(Page 2 of 2)

11
r-----------,
: FROM CHART A-3 :

1
(PAGE 1 OF 2) 1
---------..1
G)
IGNITION "ON."
PROBE INJECTOR HARNESS TERMINALS
WITH A TEST LIGHT TO GROUND.
LIGHT SHOULD BE "ON" AT BOTH
TERMINALS.
CHECK INJECTOR DRIVER CIRCUIT WITH STEADY

LIGHT FOR SHORT TO GROUND.
IF CIRCUIT IS NOT SHORTED, CHECK RESISTANCE
ACROSS EACH INJECTOR IN THE CIRCUIT.
RESISTANCE SHOULD BE GREATER THAN 10 OHMS.

OR REPLACE ANY INJECTOR
THAT MEASURES UNDER 10
OHMS.
LIGHT "OFF" BOTH
G)
G)
RECONNECT INJECTOR(S)
IGNITION "OFF."
DISCONNECT ECM
IGNITION "ON."
PROBE TERMINALS "D1 O" AND "D11"
DUE TO INJECTORS WIRED IN PARALLEL,

THERE SHOULD BE A LIGHT ON BOTH
TERMINALS.
IF NOT, THE PROBLEM IS AN OPEN IN
THE HARNESS TO THE TESTED INJECTOR.
REPAIR OPEN IN INJECTOR

FEED CIRCUIT.
REFER TO FACING PAGE.
8-17-90
MS 10653
TO PASS-KeyII
DECODER
MODULE
ECMIGN
ECM
G
~439PNK
439PNK
C230
3 PNK
e1
(I/P)
J
--~r
c200
TO FUEL
PUMP.._
TO
IGNITION
465 DK GRN/WHT
C220
A1
~
C405
451 BLK/WHT
FUEL PUMP RELAY

CONTROL
-=:l._
~-----11----
120GRY
C220
120GRY
TO FUEL PUMP
TEST CONNECTOR
10-12-92
MS 12488
CHART A-5
FUEL PUMP RELAY CIRCUIT
11
pump. It will remain "ON" as long as the ECM is receiving ignition low resolution reference pulses from the
ignition system.
If there are no reference pulses, the ECM will shut "OFF" the fuel pump about 2-3 seconds after key "ON."
The pump will deliver fuel to the fuel rail and injectors, then to the pressure regulator, where the system
pressure is controlled to 284-325 kPa (41 - 47 psi). Excess fuel is then returned to the fuel tank.
When the engine is stopped, the fuel pump can be turned "ON" by using the Tech 1. Improper fuel system
pressure will result in one or all of the following symptoms:
Cranks but won't run.
DTC 44 and 64.
DTC 45 and 65.
Cuts out, may feel like ignition problem .
Poor fuel economy, loss of power .
Hesitation .

1. The fuel pump relay is located under the dead
pedal, (foot rest) on the driver's side of the vehicle.
Checks for 12 volt supply to the fuel pump relay.
Check ECM IGN fuse for being open. If fuse is
open, check CKT 439 for being grounded. If ECM
IGN fuse was OK, check CKT 439 for being open.
2. The test light should illuminate for 2 seconds when

the ignition was turned "ON."
A Tech 1 can also be used to enable the fuel pump
relay control circuit.
CHART A-5
: FROM CHART A-3 (1 OF 2). :
G)
FUEL PUMP RELAY CIRCUIT

11
DISCONNECTFUEL PUMP RELAY.

PROBE FUEL PUMP RELAY HARNESS TERMINAL
"C1" WITH A TEST LIGHT TO GROUND.
DOES TEST LIGHT ILLUMINATE?
USING A TEST LIGHT, PROBE FROM RELAY

HARNESS TERMINAL "C1" TO "A1".
IGNITION "OFF."
PROBE FUEL PUMP RELAY HARNESS TERMINAL
"C2" WITH A TEST LIGHT TO B +.
OBSERVE TEST LIGHT AS IGNITION IS BEING
TURNED"ON."
DOES TEST LIGHT ILLUMINATE FOR 2 SECONDS
WHEN IGNITION WAS TURNED "ON"?
USING A 15 AMP FUSED JUMPER WIRE, JUMP

TERMINALS "C1" AND" A2" OF RELAY HARNESS.
FUEL PUMP SHOULD RUN.
DOESIT?
CKT4650PEN
OR
OR
FAULTY ECM.
WITH "C1" AND" A2" STILL JUMPERED

RAISE VEHICLE.
DISCONNECT FUEL PUMP HARNESS CONNECTOR.
PROBE CKT 120 OF FUEL PUMP HARNESS (RELAY
SIDE) WITH A TEST LIGHT CONNECTED TO GROUND.
FAULTY RELAY CONNECTION

OR
FAULTY RELAY.
WITH "C1" AND" A2" STILL JUMPERED

USING A TEST LIGHT PROBE CKT 120 TO
FUEL PUMP GROUND CIRCUIT.
CKT 120 OPEN FROM FUEL

PUMP TO FUEL PUMP RELAY.
OPEN FUEL PUMP HARNESS

OR
FAULTY INTANK FUEL PUMP.
10-12-92
NS 15558

CAUTION:


RETURN LINE
J 37287
FUEL LINE
SHUT-OFF
ADAPTERS
FUEL PUMP AND

RESERVOIR ASSEMBLY
CHART A-7
(Page 1 of 3)

pump. It will remain "ON" as long as the engine is cranking or running, and the ECM is receiving reference
pulses. If there are no reference pulses, the ECM will shut "OFF" the fuel pump within 2 seconds after ignition
"ON" or engine stops.
Inside the fuel tank an electric fuel pump (within an integral reservoir), supplies fuel through an in-line filter
to the fuel rail assembly. The pump is designed to provide fuel at a pressure above the regulated pressure needed
by the injectors. A pressure regulator, attached to the fuel rail, keeps fuel available to the injectors at a regulated
pressure. Unused fuel is returned to the fuel tank by a separate line.
Leaking valve/seat within pressure regulator.
Leaking injector(s).
1. Connect fuel pressure gage as shown in
4. A leaking injector can best be determined by
illustration. Wrap a shop towel around the fuel
checking for a fouled or saturated spark plug(s). If
pressure connection to absorb any small amount of
a leaking injector can not be determined by a
fuel leakage that may occur when installing the
fouled or saturated spark plug, the following
gage. With ignition "ON" and fuel pump running,
procedure should be used.
pressure should be 284-325 kPa (41-47 psi). This
Remove fuel rail but leave fuel lines connected.
pressure is controlled by spring pressure within
Follow the procedures in "Fuel Metering
the regulator assembly.
System," Section "6E3-C2" of this manual.
2. When the engine is idling, manifold pressure is
Lift fuel rail out just enough to leave injector
low (high vacuum) and is applied to the pressure
nozzles in the ports.
regulator diaphragm. Vacuum will offset spring
pressure and result in lower fuel pressure. Fuel
personal injury that may result from fuel
pressure at idle will vary somewhat depending on
spray .on the engine, n:,al<e sure fuel rail is
barometric pressure but, should be less than
pressure noted in Step (1).
pqs1t1oned. qver _inJect~>r ports and
3. A system that does not hold pressure is caused by
inJector retaining chps are intact.
one of the following:
Leaking fuel pump check ball.
Pressurize the fuel system and observe injector
nozzles.
Leaking fuel pump feed hose.
CHART A-7
G)
INSTALL FUEL PRESSURE GAGE AS SHOWN ON FACING PAGE.

IGNITION "OFF" FOR 10 SECONDS. A/C "OFF."
IGNITION "ON." FUEL PUMP WILL RUN FOR ABOUT 2 SECONDS.
IT MAY BE NECESSARY TO CYCLE THE IGNITION "ON" MORE
THAN ONCE TO OBTAIN MAXIMUM PRESSURE.
NOTE FUEL PRESSURE WITH PUMP RUNNING, PRESSURE
SHOULD BE 284-325 kPa (41-47 psi). WHEN PUMP STOPS,
PRESSURE MAY VARY SLIGHTLY THEN SHOULD HOLD STEADY.
IS PRESSURE CORRECT AND DOES IT HOLD?
(Page 1 of 3)

5.7L (VIN P) ''F" CARLINE (MFI)
r-----------,
L----- -----.J
' FROM CHART A-3

r
-------------------------,
: IF FUEL PRESSURE IS WITHIN NORMAL

:
I RANGE BUT IS SUSPECTED OF DROPPING
I
: OFF DURING ACCELERATION, CRUISE OR
:
I HARD CORNERING, SEE CHART A-7 (2 OF 3). 1
~
FUEL PRESSURE
WITHIN SPEC., BUT
DOES NOT HOLD.
-------------------------~
r- - - - - - - - - - - - - - ,
I USE CHART A-5 TO
I
: DIAGNOSE FUEL PUMP :
: SEE CHART A-7 : ELECTRICAL CIRCUIT. __
1 (2 OF 3)
1
"----------"
DISCONNECT VACUUM HOSE

FROM PRESSURE REGULATOR
ASSEMBLY.
WITH ENGINE IDLING, APPLY 12
14 INCHES OF VACUUM TO
PRESSURE REGULATOR. FUEL
PRESSURE NOTED IN STEP (1)
SHOULD DROP APPROXIMATELY
21-69 kPa (3-10 psi).
DOES IT?
LOCATE AND
REPAIR LOSS
OF VACUUM
TO PRESSURE
REGULATOR.
FUEL
PRESSURE
OUT OF SPEC.
START ENGINE,ALLOWITTO IDLE AT

NORMAL OPERATING TEMPERATURE.
FUEL PRESSURE NOTED IN STEP{1)
SHOULD DROP APPROXIMATELY 21-69
kPa (3-10 psi).
DOESIT?
NO TROUBLE
FOUND,
REVIEW
"SYMPTOMS,"
SECTION "B".
PRESSURE
REGULATOR
IS FAULTY.
INSTALL J 37287 FUEL LINE

SHUT-OFF ADAPTORS, REFER TO
PAGES 3 OF 3 AND FACING PAGE
ILLUSTRATION.
MAKE SURE VALVES ARE OPEN.
IGNITION "OFF."
USING A 10 AMP FUSED JUMPER
WIRE, CONNECT FUEL PUMP
"TEST" CONNECTOR TO B +
AND WAIT FOR PRESSURE TO
BUILD.
CLOSE VALVE IN FUEL PRESSURE
LINE. PRESSURE SHOULD HOLD.
DOESIT?
CHECK FOR:
PLUGGED IN-LINE
FILTER.
RESTRICTED FUEL
PRESSURE LINE.
PLUGGED FUEL
PUMP STRAINER.
LEAKING FUEL
PUMP FEED HOSE.
OPEN VALVE IN FUEL

PRESSURE LINE.
RECONNECT PUMP "TEST"
JUMPER AND WAIT FOR
PRESSURE TO BUILD.
CLOSE VALVE IN FUEL
RETURN LINE. PRESSURE
SHOULD HOLD.
DOESIT?
CHECK FOR:
LEAKING FUEL
PUMP FEED HOSE.
LOCATE AND CORRECT LEAKING

INJECTOR(S}.
FUEL PUMP IS
FAULTY.
{LEAKING
CHECK BALL
INSIDE PUMP.)
PRESSURE
REGULATOR
IS FAULTY.
"AFTER REPAIRS," CONFIRM "CLOSED LOOP" OPERATION AND NO MIL{SERVICE ENGINE SOON).
11-30-92
NS 160516E

CAUTION:


RETURN LINE
FUEL PUMP AND

RESERVOIR ASSEMBLY
CHART A-7
(Page 2 of 3)

7.

5. Fuel pressure that drops off during acceleration,
cruise or hard cornering may cause a lean
condition and result in a loss of power, surging or
misfire. This condition can be diagnosed using a
Tech 1 scan tool. If the fuel system is very lean,
one or both oxygen sensors will stop toggling and
output voltage will drop below 300 m V. Also,
injector pulse width will increase.
rn
6.
NOTICE: Do not allow pressure to exceed 414

kPa (60 psi) as damage to the regulator may result.
Fuel pressure above 325 kPa (47 psi) may cause a
rich condition and may set a OTC 45/65.
(followed by black smoke) and a strong sulphur
smell in the exhaust.
9. This test determines if the high fuel pressure is
due to a restricted fuel return line or a faulty fuel
pressure regulator.
10. The pressure regulator filter screen is designed to
trap any contaminants introduced during engine
assembly. If dirty, it can be removed with a small
pick and discarded without potential harm to the
regulator.
8.
Important
Make sure system is not operating at "FuelCut-Off" which may cause false readings on
the scan tool.
Fuel pressure below 284 kPa (41 psi) may cause a

lean condition and may set a DTC 44/64.
cold, hesitation, poor driveability, lack of power,
surging or misfire.
Restricting the fuel return line causes fuel

pressure to build above regulated pressure. With
battery voltage applied to the pump "test"
connector, pressure should rise above 325 kPa (47
psi) as the valve in the return line is partially
closed.
CHARTA-7
(Page 2 of 3)

5.7L {VIN P) ,.F,. CARLINE {MFI)
r--------,
:
FROM
:
CHART A-7 I
: (1 OF 3) :
I
L-r-----J
~.----....__~~~~~~~~--, r':\
'2.) FUEL PRESSURE DROPS OFF
~
DURING ACCELERATION, CRUISE
DR HARD CORNERING.
I
CHECK FOR RESTRICTED IN-LINE

FUEL FILTER OR FUELPRESSURE
LINE. IS THERE A RESTRICTION?
FUEL PRESSURE LESS

THAN 284 kPa (41 psi).
SERVICE AS
REQUIRED
AND
RECHECK.
INSTALLJ 37287-2 FUEL

RETURN LINE SHUT-OFF
ADAPTER, REFER TO PAGES
3 OF 3 AND FACING PAGE
ILLUSTRATION.
MAKE SURE VALVE IS OPEN.
IGNITION "OFF."
USING A 10 AMP FUSED
JUMPER WIRE, CONNECT FUEL
PUMP "TEST" CONNECTOR
TOB+.
SLOWLY CLOSE SHUT-OFF
VALVE. PRESSURE SHOULD
RISE ABOVE 325 kPa (47 psi).
DO NOT EXCEED414 kPa (60
psi).
DOES PRESSURE RISE ABOVE
325 kPa (47 psi)?
FUEL PRESSURE ABOVE

325 kPa (47 psi).
Cv
DISCONNECT QUICK-CONNECT
FITTING AT ENGINE FUEL RETURN
PIPE, REFER TO PAGES 3 OF 3 AND
FACING PAGE ILLUSTRATION.
ATTACH A LENGTH OF FLEXIBLE
FUEL HOSE TO ENGINE FUEL
RETURN PIPE. PLACE OPEN END OF
HOSE INTO AN APPROVED
GASOLINE CONTAINER.
IGNITION "ON." NOTE FUEL
PRESSURE WITH PUMP RUNNING.
PRESSURE SHOULD BE 284-325 kPa
(41-47 psi).
IS IT?
CHECK FOR:
WRONG FUEL PUMP.
IFUEL PUMP IS FAULTY. I
PRESSURE
REGULATOR
IS FAULTY.
CHECK FOR
RESTRICTED ENGINE
FUEL RETURN PIPE.
IS THERE A
RESTRICTION?
LOCATE AND
CORRECT
RESTRICTION IN
FUEL RETURN LINE
TO FUEL TANK.
REMOVE PRESSURE
REGULA TOR AND
CHECK FOR
RESTRICTED FILTER
SCREEN (IF EQUIPPED).
I
IFOK
SERVICE AS
REQUIRED AND
RECHECK.
PRESSURE
REGULATOR IS
FAULTY.
11-30-92
NS 16052-6E
6E3-A-34 5. 7l (VIN P) DRIVEABILITY AND EMISSIONS
CHART A-7
(Page 3 of 3)
FUEL SYSTEM PRESSURE TEST

FUEL SYSTEM PRESSURE RELIEF PROCEDURE

Engines With Fuel Pressure Connection
(Must Be Performed Before Disconnecting Fuel Line Fittings)
CAUTION:
To reduce the risk of fire and personal injury, it is necessary to relieve fuel system
pressure before disconnecting fuel line fittings.
After relieving system pressure, a small amount of fuel may be released when
disconnecting fuel line fittings. In order to reduce the chance of personal injury,
cover fuel line fittings with a shop towel before disconnecting, to catch any fuel
that may leak out. Place the towel in an approved container when disconnect is
completed.
Tool Required: J 34 730-1 Fuel Pressure Gage
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
Ignition "OFF."
Disconnect negative battery cable to avoid possible fuel discharge if an accidental attempt is made to
start the engine.
Connect gage J 34730-1 to fuel pressure connection. Wrap a shop towel around fitting while connecting
Install bleed hose into an approved container and open valve to bleed system pressure. Fuel line fittings
are now safe for servicing.
Drain any fuel remaining in gage into an approved gasoline container.
Perform service required.
Ignition "OFF."
Connect negative battery cable.
Cycle ignition "ON" and "OFF" twice, waiting ten seconds between cycles, then check for fuel leaks.
11-11-92
NS 14624
DRIVEABILITY AND EMISSIONS 5.7L (VIN P} 6E3-A-35
CHART A-7
(Page 3 of 3)
FUEL SYSTEM PRESSURE TEST

11
rn
SERVICING QUICK-CONNECT FITIINGS

Important
In order to install fuel system diagnostic equipment on vehicles equipped with plastic quick-connect
fittings, fuel line separator tools must be used to disconnect the fittings. Using the separator tools to
release the fittings will cause the plastic retainer to remain inside the female connector allowing
diagnostic equipment to be connected.
Tools required:
J 37088-A tool set, fuel line quick-connect separator;
J 39504 tool set, fuel line quick-connect separator (restricted access).
I++!
1. Relieve fuel system pressure (see "Fuel System Pressure Relief').

2. If equipped, slide dust cover back to access quick-connect fitting.
3. Grasp both sides of fitting. Twist female connector 1/4 turn in each direction to loosen any dirt within
fitting.
CAUTION: Safety glasses must be worn when using compressed air, as flying dirt
5. Choose correct tool from J 37088-A or J 39504 tool set for size of fitting.
connector, then push/pull inward to release locking tabs.
Insert tool into female
IL! Clean and Inspect
NOTICE: If it is necessary to remove rust or burrs from fuel pipe, use emery cloth in a radial motion
with the pipe end to prevent damage to 0-ring sealing surface.
Using a clean shop towel, wipe off male pipe end.

Inspect both ends of fitting for dirt and burrs. Clean or replace components/assemblies as required.
!-++-!
Install or Connect
CAUTION: To Reduce the Risk of Fire and Personal Injury:

Before connecting fitting, always apply a few drops of clean engine oil to the
male pipe end of engine fuel pipe, pressure gage adapter or fuel line shut-off
adapter. This will ensure proper reconnection and prevent a possible fuel leak.
(During normal operation, the 0-rings located in the female connector will swell
and may prevent proper reconnection if not lubricated.)
Apply a few drops of clean engine oil to the male pipe end of engine fuel pipe, pressure gage adapter or
fuel line shut-off adapter.
2. Push both sides of fitting together to cause the retaining tabs/fingers to snap into place.
3. Once installed, pull on both sides of fitting to make sure connection is secure.
11-14-92
4. If equipped, reposition dust cover over quick-connect fitting.
l
NS 14628
ECM
BANK 1 (LEFT) 02S SIGNAL
~ , - - - - - - - 1666 PPL
BANK 2 (RIGHT) 02S SIGNAL
OXYGEN SENSOR (02S)
__' 351 BLK/WHT
-=-ENGINE
GROUND
EXHAUST
6-6-92
MS 12318
OTC 13
BANK 1 (LEFT) OXYGEN SENSOR (025) CIRCUIT
(OPEN CIRCUIT)
5. 7L (VIN P) "F" CARLINE (MFI)

The ECM supplies a voltage of about 450 m V between terminals "06" and "016". (If measured with a 10
megohm digital voltmeter, this may read as low as 320 m V). The oxygen sensor varies the voltage within a range
of about 1000 m V if a rich 028 signal is indicated, down through about 10 m V if a lean 028 signal is indicated.
circuit or cold sensor causes "Open Loop" operation.
1. OTC 13 will set:
Engine at normal operating temperature
(above 70C/158F).
At least 2 minutes engine run time after start.
028 signal voltage steady between 350 m V to

550 mV.
Throttle position sensor signal above 5%
(about .3 volt above closed throttle voltage).
All conditions must be met for about 60
seconds.
If the conditions for a OTC 13 exist, the system
will not go into "Closed Loop."
2. This will determine if the oxygen sensor is at fault,
or the wiring or ECM is the cause of the OTC 13.
3.
For this test use only a high impedance digital volt

ohmmeter (J 39200). This test checks the
continuity of CKT 1665 and CKT 351. If CKT 351
is open, the ECM voltage on CKT 1665 will be over
.6 volt (600 mV).
Diagnostic Aids:
Normal Tech 1 voltage readings vary between 10
mV to 1000 mV (.01 and 1.0 volt), while in "Closed
Loop." The system will go into "Open Loop" operation
when OTC 13 sets.
"6E3-B".
DTC 13
BANK 1 (LEFT) OXYGEN SENSOR (02S) CIRCUIT
(OPEN CIRCUIT)
5.7L (VIN P) .. F" CARLINE (MFI)
ENGINE AT NORMAL OPERA TING TEMPERATURE (ABOVE 80C/176F).

DOES TECH 1 TOOL INDICATE "CLOSED LOOP"?
[$]
[$

DTC(s) WERE STORED, REFER TO
DISCONNECT BANK 1 025.

TECH 1 SHOULD DISPLAY 025 VOLTAGE BELOW .2
VOLT(200 mV)WITH ENGINE RUNNING.
DOES IT?
[$]
[$
FAULTY 025 CONNECTION

OR
025.
REMOVE JUMPER.
CHECK VOLTAGE OF CKT 1665 (ECM SIDE) AT
025 HARNESS CONNECTOR USING A DVM .
.3 .6 VOLT (300 600 mV)
FAULTY ECM.
OVER .6 VOLT (600 mV)
OPEN CKT351
OR
FAULTY CONNECTION
OR
FAULTY ECM.
.
LESS THAN .3 VOLT (300 mV)
OPEN CKT 1665

OR
OR
FAULTY ECM.
6-6-92
MS 12484
ENGINE COOLANT
TEMPERATURE SENSOR
ECM
ECTSIGNAL
SENSOR
GROUND
TOTPSENSOR
6-6-92
MS 12319
DTC 14

The Engine Coolant Temperature (ECT) sensor uses a thermistor to control a signal voltage to the ECM. The
ECM applies a voltage on CKT 410 to the sensor. When the engine coolant is cold, the sensor (thermistor)
resistance is high, therefore, the ECM will sense a high signal voltage. As the engine coolant warms, the sensor
resistance becomes less, and the voltage drops. At normal engine operating temperature (85C - 95C or 185F 203F) the voltage will measure about 1.5 to 2.0 volts.

Signal voltage indicates an engine coolant
temperature above 130C (266F).
2. This test will determine if CKT 410 is shorted to
ground, which will cause the condition for a DTC
14.
Diagnostic Aids:
Check harness routing for a potential short to
ground in CKT410.
Tech 1 displays engine coolant temperature in
degrees celsius and fahrenheit. After engine is
started, the temperature should rise steadily, reach
normal operating temperature, and then stabilize
when thermostat opens.
"6E3-B".
OTC 14
5.7L (VIN P)
11
F" CARLINE (MFI)
DOES SCAN TOOL DISPLAY ENGINE COOLANT

TEMPERATURE OF 130C (266F) OR HIGHER?
DISCONNECT ENGINE COOLANT

TEMPERATURE SENSOR.
SCAN TOOL SHOULD DISPLAY ENGINE
COOLANT TEMPERATURE BELOW -30C
(-22F).
DOESIT?
DTC 14 IS INTERMITTENT. IF NO

OR
CKT 410 SHORTED TO SENSOR GROUND CIRCUIT
OR
FAULTY ECM.
DIAGNOSTIC AID
(APPROXIMATE)
'F
OHMS
100
90
212
194
176
158
140
122
113
104
95
86
77
68
59
50
41
32
23
14
5
-4
-22
-40
177
241
332
467
667
973
1188
1459
1802
2238
2796
3520
4450
5670
7280
9420
12300
16180
21450
28680
52700
100700
so
70
60
50
45
40
35
30
25
20
15
10
5
0
-5
-10
-15
-20
-30
-40
6-2-92
75 3055-6E
ENGINE COOLANT
TEMPERATURE SENSOR
ECM
ECTSIGNAL
SENSOR
GROUND
TOTPSENSOR
6-6-92
MS 12319
OTC 15

The Engine Coolant Temperature (ECT) sensor uses a thermistor to control the signal voltage to the ECM.
The ECM applies a voltage on CKT 410 to the sensor. When the engine coolant is cold, the sensor (thermistor)
resistance is high, therefore the ECM will sense a high signal voltage. As the engine coolant warms, the sensor
resistance becomes less, and the voltage drops. At normal engine operating temperature (85C - 95C or 185F 203F), the voltage will measure about 1.5 to 2.0 volts at the ECM.

ECT signal voltage indicates an engine coolant
temperature less than -49C (-56;2F).
2. This test simulates a DTC 14. If the ECM
recognizes the low signal voltage, (high
temperature) and the Tech 1 displays 130C
(266F) or above, the ECM and wiring are OK.
3. This test will determine ifCKT 410 is open. There
should be 5 volts present at sensor connector, if
measured with a DVM.
Diagnostic Aids:
A Tech 1 displays engine coolant temperature iri
started, the temperature should rise steadily, reach
normal operating temperature, and then stabilize
when the thermostat opens.
A faulty connection, or an open in CKT 410 or 470,
will result in a DTC 15.
If DTC 21 is also set, check CKT 470 for faulty
wiring or connections. Check terminals at sensor for
good contact.
"6E3-B".
DTC 15
5. 7L (VIN P) F" CARLINE (MFI)
0 .
DOES TECH 1 SCAN TOOL DISPLAY ENGINE COOLANT TEMPERATURE OF-30C (-22F) OR LESS?
DISCONNECT ENGINE COOLANT TEMPERATURE SENSOR.

JUMPER HARNESS TERMINALS TOGETHER.
TECH 1 SCAN TOOL SHOULD DISPLAY 130C (266F) OR MORE.
DOESIT?
ADDITIONAL DTC(S) WERE STORED, REFER
JUMPERCKT410TOGROUND.
TECH 1 SCAN TOOL SHOULD DISPLAY OVER 130C (266F).
DOES IT?
FAULTY CONNECTION OR ENGINE

COOLANT TEMPERATURE SENSOR.
OPEN ENGINE COOLANT TEMPERATURE SENSOR GROUND

CIRCUIT, FAULTY CONNECTION OR FAUL TY ECM.
OPEN CKT 410, FAUL TY

CONNECTION AT ECM, OR
FAULTY ECM.
DIAGNOSTIC AID
(APPROXIMATE)
OHMS
100
90
80
70
60
50
45
40
35
30
25
20
15
10
5
0
-5
-10
-15
-20
-30
40
212
194
176
158
140
122
113
104
95
86
177
241
332
467
667
973
1188
1459
1802
2238
2796
3520
4450
5670
7280
9420
12300
16180
21450
28680
52700
100700
77
68
59
50
41
32
23
14
5
-4
22
40
330-92
75 3261-6E

ECM
IGNITION SYSTEM
TEST CONNECTOR
r---------
.--------~632BLK/PNK
, - - - - - - - - - - - 631 YEL
- - - - - - - - - - 631 RED
. . . . - - - - - - - - 647 PPLJWHT
. . . - - - - - - - - 453 BLK/RED
632 PNK/BLK
DISTRIBUTOR
REFERENCE LOW
IGNITION FEED
- - - - - - - - 647 LT BLU/BLK
HIGH RESOLUTION
1---------- 453 RED/BLK
LOW RESOLUTION
!'-r-
C140
ENGINE I
GROUND
450 BLK
IGNITION
COIL
MODULE
IGNITION
TO
~
IGNITION
10 AMP
(U/H)
BLK
239 PNK
CONNECTOR
--------\
423WHT
IGNITION CONTROL
~B~1846PNKIBLK
I
IGNITION
COIL
p
R
II
GRY
CONNECTOR
I
I
..___,r-(1:--r'-.:..- 1847 WHT/BLK

121
WHTI
L----<1f- 1848
--------/.J
WHT
A
BLK
CONNECTOR
(U/H)
TO.._j
INSTRUMENT
CLUSTER
= LOCATED IN UNDERHOOD ELECTRICAL CENTER
11-3-92
MS 12328
OTC 16
DISTRIBUTOR IGNITION SYSTEM
(LOW RESOLUTION PULSE)
5.7L (VIN P}
11
11
F CARLINE (MFI}
The distributor ignition system supplies two timing inputs to the ECM, a high resolution signal (360 pulses
per one crankshaft revolution) and a low resolution signal (4 pulses per one crankshaft revolution). The ECM can
determine if one of the timing inputs is not being received by comparing the two inputs. If the ECM detects the
high resolution timing pulse without detecting the low resolution timing pulse, this DTC will set.
The reference signals toggle between O and 5 volts as the camshaft turns. Therefore, an open, a short to
voltage, a short to ground, or a defective sensor inside the distributor can prevent the voltage from pulsing at the
ECM.

720 high resolution timing pulses occur before
any low resolution pulses are detected.
2. This test will determine if the ECM is sending out
a signal to the distributor for processing. If this
signal is not available or is shorted to ground or
voltage, the distributor cannot ground it to
produce reference pulses.
Diagnostic Aids:
If DTC 16 does not reset and the vehicle still does
not start, refer to CHART A-3 "Engine Cranks But
Will Not Run."
DRIVEABILITY AND EMISSIONS 5. 7L (VIN P} 6E3-A-43
DTC 16
(LOW RESOLUTION PULSE}
CLEAR DTC(s).
CRANK ENGINE FOR 15 SECONDS.
DOES DTC 16 SET?
$
DTC 16 IS
INTERMITTENT.
REFER TO
"DIAGNOSTIC AIDS"
ON FACING PAGE.
IGNITION "OFF."
DISCONNECT IGNITION SYSTEM TEST CONNECTOR.
IGNITION "ON."
USING A DVM ON THE DC VOLTS SCALE.MEASURE VOLTAGE ON
TERMINAL" A" AT THE ECM SIDE OF THE IGNITION TEST
CONNECTOR.
I
I
LESS THAN .5 VOLTS
I
4 T06VOLTS
OVER 6 VOL TS
OPEN OR GROUNDED LOW

RESOLUTION SIGNAL
CIRCUIT FROM ECM TO TEST
CONNECTOR
OR
OR
FAULTY ECM.
I
IGNITION "OFF."
RECONNECT IGNITION SYSTEM
TEST CONNECTOR.
DISCONNECT DISTRIBUTOR
CONNECTOR.
IGNI.TION "ON."
MEASURE VOLTAGE ON TERMINAL
SHORT TO VOLTAGE
ON LOW
RESOLUTION SIGNAL
CIRCUIT FROM ECM
TO TEST
CONNECTOR.
"A".
I
LESS THAN .5 VOL TS
I
OPEN OR GROUNDED
LOW RESOLUTION
SIGNAL CIRCUIT FROM
TEST CONNECTOR TO
DISTRIBUTOR.
I
4 T06VOLTS
I
FAUL TY DISTRIBUTOR
CONNECTION
OR
FAUL TY DISTRIBUTOR.
I
OVER 6 VOL TS
I
SHORT TO VOLTAGE
ON LOW RESOLUTION
SIGNAL CIRCUIT FROM
TEST CONNECTOR TO
DISTRIBUTOR.
12-3-92
MS 10757
ECM
THROTTLE POSITION (TP)
SENSOR CONNECTOR
TO ECT SENSOR
SENSOR GROUND
THROTTLE
POSITION (TP)
SENSOR
IDLE
1---------------- 417 DKBLU

1----------------- 474GRY
sv
REFERENCE
6-6-92
MS 12320
DTC21

The Throttle Position (TP) sensor provides a voltage signal that changes, relative to the throttle blade
position. Signal voltage should vary from about .6 volt at idle to about 5 volts at Wide Open Throttle (WOT).
The TP sensor signal is one of the most important inputs used by the ECM for fuel control and for most of the
ECM controlled outputs.
TP sensor signal voltage is greater than 2.5
volts.
Engine at idle (less than 12 grams per second
calculated air flow).
OR
TP sensor signal voltage over 4.8 volts with

ignition "ON."
With throttle closed the TP sensor should display
between .3 and .9 volt. If it does not, check throttle
cable adjustment or for bent linkage.
2. With the TP sensor sensor disconnected, the TP
sensor voltage should go low, if the ECM and
wiring are OK.
3. Probing CKT 470 with a test light to 12 volts
checks the sensor ground. A faulty sensor ground
will cause a OTC 21.
Diagnostic Aids:
The Tech 1 displays throttle position in voltage
and percentage of throttle blade opening. With
ignition "ON" or at idle, TP sensor signal voltage
should read between .3 and .9 volt with the throttle
closed and increase at a steady rate as throttle is
moved toward Wide Open Throttle (WOT).
An open in CKT 470 will result in a DTC 21.
"6E3-B".
DTC21
THROTILE POSITION (TP) SENSOR CIRCUIT
5.7L (VIN P)
11
F" CARLINE (MFI)
THROTTLE CLOSED.
THROTTLE POSITION OVER 2.5 VOLTS?
DISCONNECT THROTTLE POSITION SENSOR.

THROTTLE POSITION BELOW .2 VOLT (200 mV).
DOES IT?
OTC 2115 INTERMITTENT. IF NO ADDITIONAL DTC(s) WERE

STORED, REFER TO "DIAGNOSTIC AIDS" ON FACING PAGE.
PROBE SENSOR GROUND CIRCUIT

BATTERY VOLTAGE.
TP SENSOR SIGNAL CIRCUIT SHORTED TO VOLTAGE

OR
FAULTY ECM.
FAULTY CONNECTION
OR
THROTTLE POSITION SENSOR.
OPEN SENSOR GROUND CIRCUIT

OR
FAULTY ECM.
3-26-92
7S 3057-6E
6E3-A-46 5.7l (VIN P) DRIVEABILITY AND EMISSIONS
ECM
THROTTLE POSITION {TP)
SENSOR CONNECTOR
THROTTLE
POSITION (TP)
SENSOR
TO ECT SENSOR
SENSOR GROUND
1---------------- 417 DK BLU

1----------------~474GRY
TP SENSOR SIGNAL
_.,,,,,,,,~ s v
REFERENCE
6-6-92
MS 12320
DTC22
THROTTLE POSITION (TP} SENSOR CIRCUIT
5. 7L (VIN P} "F" CARLINE (MFI}

The Throttle Position (TP) sensor provides a voltage signal that changes, relative to the throttle blade
position. Signal voltage should vary from about .6 volt at idle to about 5 volts at Wide Open Throttle (WOT).
The TP sensor signal is one of the most important inputs used by the ECM for fuel control and for most of the
ECM controlled outputs.
Test Description: Number(s).below refer to circled
1. OTC 22, will set if:
TP sensor signal voltage is less than about .23
volt.
The TP sensor has an auto zeroing feature. If the
voltage reading is within the range of about .3 to .9
volt, the ECM will use that value as closed
throttle. If the voltage reading is out of the auto
zero range at closed throttle, check for a binding
throttle cable or damaged linkage, if OK, continue
with diagnosis.
2. Simulates OTC 21: (high voltage) If the ECM
recognizes the high signal voltage, the ECM and
wiring are OK.
an open in CKT 417.
Diagnostic Aids:
The Tech 1 displays throttle position in voltage
and percentage of throttle blade opening.
With
ignition "ON" or at idl~, TP sensor signal voltage
should display between .3 and .9 volt with the throttle
closed and increase at a steady rate as throttle is
moved toward Wide Open Throttle (WOT).
An open or short to ground in CKT 474or CKT417
will result in a DTC 22.
"6E3-B".
DTC22
THROTTLE CLOSED.
DOES "TECH 1" DISPLAY TP SENSOR .2 VOLTS
(200 mv) OR BELOW?
DISCONNECT TP SENSOR.
JUMPER CKTS 474 & 417 TOGETHER.
"TECH 1" SHOULD DISPLAY TP SENSOR OVER
4.0 VOLTS (4000 mv).
DOESIH
PROBE CKT 417 WITH A TEST LIGHT

CONNECTED TO BATTERY VOLTAGE.
"TECH 1" SHOULD DISPLAY TP SENSOR
OVER 4.0 VOL TS (4000 mv).
DOES IT?
FAUL TY SENSOR CONNECTION

OR
FAUL TY SENSOR.
CKT 474 OPEN OR SHORTED TO GROUND

OR
FAUL TY CONNECTION
OR
FAULTY ECM.
IF NO ADDITIONAL DTCs WERE STORED, REFER TO
CKT 417 OPEN OR SHORTED TO GROUND, OR

SHORTED TO SENSOR GROUND CIRCUIT
OR
FAUL TV ECM CONNECTION
OR
FAULTY ECM.
6-6-92
95 7843-6E
ECM
INTAKE AIR
TEMPERATURE
SENSOR
IA T SENSOR SIGNAL
'------------472TAN
'-------------<11---- 808 BLK

TOMAP,A/C
REFRIGERANT PRESSURE,
AND A/C EVAPORATOR
TEMPERATURE SENSORS
6-8-92
MS 12321
DTC23

ECM applies a voltage (about 5 volts) on CKT 472. to the sensor. When the intake air is cold, the sensor
(thermistor) resistance is high, therefore, the ECM will sense a high signal voltage. If the intake air is warm, the
sensor (thermistor) resistance is low, therefore, the ECM will sense a low voltage.
A signal voltage indicates an intake air
temperature below-38C (-36F).
Engine idling (0% throttle).
No VSS (vehicle not moving).
All conditions met for 60 seconds,
OR
A signal voltage indicates an intake air

temperature below -38C (-36F).
DTC 14 or 15 present.
Engine run time greater than 60 seconds.
Engine idling (0% throttle).
No VSS (vehicle not moving)
2. A DTC 23 will set, due to an open sensor, wire, or
connection. This test simulates a DTC 25. If the
ECM recognizes the high signal voltage, (high
temperature) and the Tech 1 displays 130C
(266F) or above, the ECM and wiring are OK.
3. This will determine if the IAT sensor signal (CKT
472) or the IAT sensor ground (CKT 808) is open.
Diagnostic Aids:
The Tech 1 displays temperature of the air
entering the engine and should be close to ambient air
temperature when engine is cold, and rises as
Carefully check harness and connections for
possible open.
"6E3-B".
If the engine has been allowed to sit overnight, the
intake air temperature, and engine coolant
temperature values should be within a few degrees of
each other.
DTC23
5.7L___;(VIN
P) "F" CARLINE (MFI) ____
._______________
,____~----------------...!.,_---.!..
CD
0
~~-
DOES TECH 1 SCAN TOOL DISPLAY IAT-30C (22F) OR COLDER?
DISCONNECT SENSOR.
JUMPER HARNESS TERMINALS
ADDITIONAL DTC(S) WERE
TOGETHER.

13oc (266F).
DOESIT?
JUMPER CKT 472 TO GROUND.

130C (266F).
DOES IT?
DIAGNOSTIC AID
(APPROXIMATE)
"F
OHMS
100
90
80
70
60
50
45
40
35
30
25
20
15
10
212
194
176
158
140
122
113
104
95
86
177
5
0
-5
-10
-15
-20
-30
-40
77
68
59
50
41
32
23
14
-4
-22
-40
OPEN SENSOR
OPEN CKT 472,
GROUND CIRCUIT,
FAUL TY CONNECTION
FAUL TY CONNECTION
OR FAUL TY ECM.
OR FAULTY ECM.
241
332
467
667
973
1188
1459
1802
2238
2796
3520
4450
5670
7280
9420
12300
16180
21450
28680
52700
100700
3-17-92
75 3285-6E
ECM
<0
g,______: : :~
VSS SIGNAL
- - ' " " ' - 12V
PERMANENT MAGNET GENERATOR

(MOUNTED IN TRANSMISSION)
TO INSTRUMENT
CLUSTER AND
CRUISE CONTROL
MODULE
- - - - 8 1 7 DK GRN,WHT
VEHICLE SPEED OUTPUT

FOUR THOUSAND PULSES PER
MILE
6-6-92
MS 12329
DTC24
Vehicle speed information is provided to the ECM by the vehicle speed sensor, which is a Permanent Magnet
(PM) generator located in the transmission. The PM generator produces a pulsing voltage. The AC voltage level
and the number of pulses increases as the speed of the vehicle increases. The ECM then converts the pulsing
voltage to vehicle speed which is used for calculations. The vehicle speed can be displayed with a Tech 1.
The ECM supplies a signal, on CKT 817, to operate the speedometer and the odometer. The VSS signal is also
sent to the cruise control module.

1. DTC 24 will set if vehicle speed is less than 5 km/h
(3 mph) when:
Engine speed is between 1250 and 3000 RPM.
TP sensor is less than 2%.
Low load conditions.
MAP less than 22 kPa.
Above conditions met for 4 seconds.
These conditions are met during a road load
deceleration.
2. DTC 24 is being caused by a faulty ECM, faulty
PROM or an incorrect PROM.
Diagnostic Aids:
Check CKTs 400 and 401 for proper connections to
be sure they're clean and tight and the harness is
routed correctly.
DRIVE.ABILITY AND EMISSIONS 5.7L (VIN P) 6E3-A-51
DTC24
CD
IGNITION "OFF."
RAISE DRIVE WHEELS.
ENGINE IDLING.
WITH ENGINE IDLING IN GEAR, TECH 1 SHOULD DISPLAY VEHICLE
SPEED ABOVE 0.
DOES IT?
IGNITION "OFF."
DISCONNECT VSS HARNESS CONNECTOR AT TRANSMISSION.
CONNECT SIGNAL GENERATOR TESTER J 33431-B TO VSS HARNESS
CONNECTOR.
IGNITION "ON," TESTER "ON" AND SET TO GENERATE AVSS SIGNAL.
THE TECH 1 SHOULD DISPLAY VEHICLE SPEED ABOVE 0.
DOESIT?
IF NO ADDITIONAL DTC(s)
WERE STORED, REFER TO
"DIAGNOSTIC AIDS" ON
FACING PAGE.
CHECK PROM FOR

CORRECT APPLICATION.
IF OK, REPLACE ECM.
CKT 400 OR 401 OPEN,

SHORTED TO GROUND,
SHORTED TOGETHER,
FAULTY CONNECTIONS
OR
FAULTY ECM.
6-2-92
MS 12453
ECM
INTAKE AIR
TEMPERATURE
SENSOR
IAT SENSOR SIGNAL

~----------472TAN
....__ _ _ _ _ _ _ _ _ _ _ _ _ _ _ 808 BLK
TOMAP,A/C
REFRIGERANT PRESSURE,
AND A/C EVAPORATOR
TEMPERATURE SENSORS
6-8-92
MS 12321
DTC25
5. 7L (VIN P)
11
F11 CARLINE (MFI)
ECM applies a voltage (about 5 volts) on CKT 472 to the sensor. When intake air is cold, the sensor (thermistor)
resistance is high, therefore, the ECM will sense a high signal voltage. If the intake air is warm, the sensor
(thermistor) resistance is low, therefore, the ECM will sense a low signal voltage.

Signal voltage indicates an intake air
temperature greater than 150C (302F) for 12
seconds.
Time since engine start is 4 minutes or longer.
Vehicle speed is greater than 8 km/h (5 mph).
OR
Signal voltage indicates an intake air
temperature greater than 150C (302F).
No VSS (vehicle not moving).
Diagnostic Aids:
entering the engine and should display close to
ambient air temperature, when engine is cold, and rise
as underhood temperature increases.
Check harness routing for possible short to ground
inCKT472.
"6E3-B".
DTC25
G)

IAT OF 145C (293F) OR HOTTER?
DISCONNECT SENSOR.
TEMPERATURE BELOW -30( (-22F).
DOESIT?

DTC(S) WERE STORED, REFER TO

OR
TO SENSOR GROUND
OR
ECM IS FAULTY.
DIAGNOSTIC AID
(APPROXIMATE)
OF
OHMS
100
90
80
70
60
50
45
40
35
30
25
20
15
10
5
0
-5
-10
-15
-20
-30
-40
212
194
176
158
140
122
113
104
95
86
77
68
59
50
41
32
23
14
5
-4
-22
-40
177
241
332
467
667
973
1188
1459
1802
2238
2796
3520
4450
5670
7280
9420
12300
16180
21450
28680
52700
100700
2-25-92
75 3190-6E
ECM
EVAP CANISTER PURGE
SOLENOID VALVE
~ - - 541 BRN - - - - ~ - - - - 428 DK GRN/WHT
SENSE LINE
EGR SOLENOID
VALVE
~ - - - 541 BRN
- - - - - - , ~ i - - - - - - - - 435GRY
SENSE LINE
TO REVERSE
LOCKOUT SOLENOID
TO IGNITION
rr= c
AIR PUMP RELAY
TO SECONDARY
AIR INJECTION
PUMP
I
I
C100
78RED _ __..,,.
---~t-K-- 436 BRN
78RED
r--
I
I
SENSE LINE
I
441 BRN
-:=-
-r:F~~~; ~I~;--
(U/H)
441 BRN
TO IGNITION
(U/H)
10-7-92
MS 12463
= LOCATED IN UNDERHOOD ELECTRICAL CENTER.
DTC26
QUAD-DRIVER MODULE (QOM) #1 CIRCUIT
5.7L (VIN P) "F" CARLINE {MFI)
The ECM is used to control several components such as those illustrated above. The ECM controls these
devices through the use of a Quad-Driver Module (QDM). When the ECM is commanding a component "ON," the
voltage of the output circuit will be "low" (near O volts). When the ECM is commanding the output circuit to a
component "OFF," the voltage potential of the circuit will be "'high." (Near battery voltage.) The primary
function of the QDM is to supply the ground for the component being controlled.
Each QDM has a fault line which is monitored by the ECM. The fault line signal status can be displayed on
the Tech 1. The ECM will compare the voltage at the QDM. If the QDM fault detection circuit senses a voltage
other than what is expected, the fault line status will change and a OTC 26 will set.

I. DTC 26 will set if: the ECM detects the wrong
voltage potential for 20 seconds.
This test will begin to determine if the QOM
connected AIR pump can be controlled by the
ECM. If the relay appears to operate but the AIR
pump does not turn "ON," refer to "Secondary Air
Injection (AIR) System," Section "6E3-C6" for
further AIR diagnosis.
2. This check can detect a partially shorted coil which
would cause excessive current flow. Excessive
current flow to a QDM will be detected as a fault
and set this DTC. If excessive current flow is
detected, a circuit check will be performed to
isolate the device from the wiring.
3. The remaining checks will identify a circuit

problem that has caused an excessive current flow
or inoperative relay. If a QDM circuit check is
done on a relay, it is important to identify and test
the relay coil terminals of the harness connector to
avoid improper diagnosis.
Diagnostic Aids:
Engine should be idling while monitoring QDM
status. Using a Tech 1, monitor the QDM status while
moving related harness connectors, including ECM
harness. If the failure is induced, a fault will appear
on the Tech 1. This can help locate the intermittent.
Check for bent pins at ECM and ECM connector
terminals. If DTC reoccurs with no apparent
connector problem, replace ECM.
DTC26
11
G)
IF OTHER DIAGNOSTIC TROUBLE CODES {DTCs)

ARE STORED USE THOSE CHARTS FIRST.
IGNITION nON," ENGINE "OFF."
USING TECH 1 nMISC TEST," ACTIVATE AIR
PUMP RELAY.
DOES AIR PUMP RELAY OPERATE?
ACTIVATE EGR SOLENOID VALVE.

DOES EGR SOLENOID VALVE OPERATE?
ACTIVATE EVAP CANISTER PURGE SOLENOID

VALVE.
DOES EVAP CANISTER PURGE SOLENOID
VALVE OPERATE?
0 .
KEY UOFF."
DISCONNECTECM CONNECTOR" A".
KEY"ON."
USING DVM ON AMP SCALE, MEASURE
CURRENT FROM HARNESS TERMINALS" A 1"
"A2" AND"AS"TOGROUND.
EACH TERMINAL SHOULD MEASURE LESS
THAN .75 AMPS {BUT NOT "O").
DO THEY?
IGNITION "OFF."
DISCONNECT AFFECTED RELAY/SOLENOID VALVE
CONNECTOR.
CONNECT TEST LIGHT BETWEEN RELAY/SOLENOID
VALVE COIL CONNECTOR TERMINALS.
IGNITION "ON."
USING TECH 1 "MISC TEST" ACTIVATE AFFECTED
RELAY/SOLENOID VALVE.
ISIT?
CONNECT TEST LIGHT

FROM IGNITION FEED
CIRCUIT OF
RELAY/SOLENOID
VALVE TO GROUND.
LIGHT SHOULD BE
"ON."
ISIT?
FAULTY ECM
CONNECTION
OR
OPEN RELAY/
SOLENOID
VALVE
DRIVER
CIRCUIT
OR
FAULTY ECM.
OPEN
RELAY/
SOLENOID
VALVE
IGNITION
FEED
CIRCUIT.
AFTER 5 SECONDS
LIGHT SHOULD GO
"OFF."
DIDIT?
DISCONNECT
ECM
CONNECTOR
"A.
IS LIGHT
"ON"?

FAULTY RELAY/
SOLENOID VALVE
CONNECTION
OR
FAULTY RELAY/
SOLENOID.
RELAY/
SOLENOID VALVE
DRIVER CIRCUIT.
12-22-92
MS 12477
ECM
REVERSE LOCKOUT
SOLENOID
TO IGNITION, EGR AND
EVAPCANISTERPURGE..,_ 541 BRN ~ - - - - 1652LTGRN
SOLENOID VALVES
(MANUAL TRANSMISSION)
,---------------,
I
I
I
I
SENSE LINE
:
I
I
I
I
TODLC ~ ~ - - - - - - - ~ ~ r ~ K - - - - ,
TERMINAL "F"
C230
I
I
I
I
I
I
~ - _ ._ _ __..;.._ _ _ _ 422 TAN/BLK
~ ____ ~~S_E_L~N_Ef?_ J
t - - - - - - - - - - - - 446 LT BLU
i . - - - t - . - - - t C 1 - - - - - - - - - - 438 DK GRN/WHT
4th GEAR
SIGNAL
3rd GEAR
SIGNAL
2nd GEAR
SIGNAL
FAULT
LINE
TCC
APPLY SOLENOID
TO BRAKE SWITCH ASSEMBLY
AND IGNITION FEED~ 583 LT BLU/BLK
10-29-92
MS 12326
DTC27
devices through the use of a Quad-Driver Module (QDM). When the ECM is commanding a component "ON," the
component "OFF," the voltage potential of the circuit will be "high." (Near battery voltage.) The primary
function of the QDM is to supply the ground for the component being controlled.
Each QDM has a fault line which is monitored by the ECM. The fault line signal status can be displayed on
the Tech 1. The ECM will compare the voltage at the QDM. If the QDM fault detection circuit senses a voltage
other than what is expected, the fault line status will change and a DTC 27 will set if applicable.
A fault in QDM #2 will store a DTC 27 in the ECM memory but will not turn "ON" the MIL (Service Engine
Soon).
test the solenoid coil terminals of the harness
connector to avoid improper diagnosis.
1. DTC 27 will set if the ECM detects an improper
Diagnostic Aids:
This test will begin to determine if the QDM
connected devices can be controlled by the ECM.
If the reverse lockout solenoid or TCC are
inoperative, refer to "Torque Converter Clutch
(TCC) System (A/T), Automatic Transmission
Gear Switch System, Reverse Lockout System
Check for bent pins at ECM and ECM terminals. If
(MIT)," Section "6E3-C8" for further diagnosis.
OTC 27 reoccurs with no apparent connector problem,
replace ECM.
The QDM status should change when the brake is
applied on vehicles equipped with a torque converter
clutch.
3. The remaining checks will identify a circuit
or inoperative solenoid. If a QDM circuit check is
done on a solenoid, it is important to identify and
DTC27
QUAD-DRIVER MODULE (QDM) #2

CIRCUIT
IF OTHER DIAGNOSTIC TROUBLE CODES (DTCs) ARE STORED

USETHOSECHARTSFlRS~
USING TECH 1 "MISC TEST," ACTIVATE REVERSE LOCKOUT
SOLENOID (MIT) OR TCC SOLENOID (AJT}.
DOES SOLENOID OPERATE?
KEY "OFF."
DISCONNECT ECM CONNECTOR "B" .
KEY "ON."
USING DVM ON AMP SCALE, MEASURE CURRENT FROM HARNESS TERMINAL "82" OR "81 '' TO GROUND.
ECM TERMINAL "81" (MANUAL TRANSMISSION) SHOULD MEASURE LESS THAN 1.5 AMPS (BUT NOT "O").
ECM TERMINAL "82" (AUTOMATIC TRANSMISSION) SHOULD MEASURE LESS THAN .75 AMPS (BUT NOT "O").
DOES IT?
s
I
I
MANUAL
TRANSMISSION
AUTOMATIC
TRANSMISSION
IGNITION "OFF."
RAISE VEHICLE.
DISCONNECT REVERSE LOCKOUT
SOLENOID.
CONNECT TEST LIGHT BETWEEN SOLENOID
HARNESS CONNECTOR TERMINALS
IGNITION "ON."
IS IT?
IGNITION "OFF."
RAISE VEHICLE.
DISCONNECT TCC SOLENOID CONNECTOR.
CONNECT TEST LIGHT BETWEEN SOLENOID
HARNESS CONNECTOR TERMINALS.
IGNITION "ON."
GROUND DIAGNOSTIC TEST TERMINAL.
ISIT?
CONNECT TEST LIGHT

FROM IGNITION FEED
CIRCUIT OF SOLENOID
HARNESS TO GROUND.
LIGHTSHOULDBE"ON."
IS IT?
]
FAULTY ECM
CONNECTION
OR
OPEN
SOLENOID
DRIVER
CIRCUIT
OR
FAULTY ECM.
~
OPEN
SOLENOID
IGNITION
FEED
CIRCUIT.
GROUND
DIAGNOSTIC "TEST"
TERMINAL.
LIGHT SHOULD BE
"OFF."
IS IT?
@]
GlsJ
DISCONNECT
ECM
CONNECTOR
"B.,.
!SLIGHT
"ON"?
FAULTY
ECM.
CONNECT TEST LIGHT

FROM IGNITION FEED
CIRCUIT OF SOLENOID
TO GROUND.
ISIT?
UNGROUND DIAGNOSTIC
TEST TERMINAL.
LIGHT SHOULD BE "OFF."
IS IT?
FAULTY
SOLENOID
CONNECTION
OR
FAULTY
SOLENOID.
~
GROUNDED
SOLENOID
DRIVER
CIRCUIT.
FAULTY ECM
CONNECTION
OR
OPEN
SOLENOID
DRIVER
CIRCUIT
OR
FAULTY ECM.
Gb s
OPEN
SOLENOID
IGNITION
FEED
CIRCUIT.
DISCONNECT
ECM
CONNECTOR
"B'".
IS LIGHT
"ON"?
s
FAULTY
ECM.
EJ
FAULTY
SOLENOID
CONNECTION
OR
FAULTY
SOLENOID.
GROUNDED
SOLENOID
DRIVER
CIRCUIT.
11-2-92
MS 12456
. - - - - 59 DK GRN -
TO ECM AND LOW

PRESSURE CUTOFF
SWITCH
~B
ECM
1 - - - - - - < r t 1 - " - - - - - 459 DK GRN/WHT
C100
- - - 139PNK - - - -
J --~335DKGRN
- - - - - - < ~ ~ ~/L
--C100
1----
541BRN
--....
409 LT BLU
.....---.-Tos+
~~~~--
I
I
I
TO IGNITION
541 BRN
402 RED
I
I
I
FAN
2
- - - 504BRN
_rsoBLK
I
I
(WITH C60) (U/H)

~H
473DKBLU - - - - - - - - - - - ~ ~ ~ - - - - - - - 4 7 3 D K B L U
C100
I
I
I
I
I
I
I
-...-
I
__________
J1
SENSE
LINE
-=
L.-. FAULT LINE

(U/H)
10-19-92
MS 12446
= LOCATED IN UNDER HOOD ELECTRICAL CENTER.
DTC28
devices through the use of a Quad-Driver Module (QOM). When the ECM is commanding a component "ON," the
component "OFF," the voltage potential of the circuit will be "high." (Near battery voltage.) The primary
function of the QOM is to supply the ground for the component being controlled.
Each QOM has a fault line which is monitored by the ECM. The fault line signal status can be displayed on
the Tech 1. The ECM will compare the voltage at the QDM only when an A/C request signal is detected at the
ECM. If the QDM fault detection circuit senses a voltage other than what is expected, the fault line status will
change and a DTC 28 will set if applicable.
A QDM #3 fault will store a DTC 28 in the ECM memory but will not turn "ON" the MIL (Service Engine
Soon).

1. DTC 28 will set if the ECM detects an improper
These tests will begin to determine if the QDM
connected devices can be controlled by the ECM. If
a relay appears to operate but the device does not
activate, refer to "Electric Cooling Fan," Section
"6E3-Cl2" or "A/C Clutch Circuit Diagnosis,"
Section "6E3-Cl0" for further diagnosis.
3.
The remaining checks will identify a circuit

or inoperative relay. If a QDM circuit check is
done on a relay, it is important to identify and test
the relay coil terminals of the harness connector to
avoid improper diagnosis.
Diagnostic Aids:
Check for bent pins at ECM and ECM connector
terminals. If DTC reoccurs with no apparent
connector problem, replace ECM.
DTC28
QUAD-DRIVER MODULE (QDM) #3 CIRCUIT
IF OTHER DTCs ARE STORED USE THOSE CHARTS FIRST.

USING TECH 1 "MISC TEST," ACTIVATE FAN 1 RELAY.
DOES FAN 1 RELAY OPERATE?
ACTIVATEFAN2RELAY.
DOES FAN 2 RELAY OPERATE?
IGNITION "OFF."
DISCONNECT AFFECTED RELAY CONNECTOR.
CONNECT TEST LIGHT BETWEEN RELAY COIL
CONNECTOR TERMINALS.
IGNITION "ON."
GROUND DIAGNOSTIC TEST TERMINAL.
ISIT?
ACTIVATE A/C RELAY.

DOES A/C RELAY OPERATE?
KEY"OFF."
DISCONNECT ECM CONNECTOR "B".
KEY "ON."
USING DVM ON 2 AMP SCALE, MEASURE
CURRENT FROM HARNESS TERM.INALS "84",
"BS", "810" TO GROUND.
EACH TERMINAL SHOULD MEASURE LESS
THAN .75 AMPS (BUT NOT "O").
DO THEY?
DTC 28 IS INTERMITTENT. REFER TO

CONNECT TEST LIGHT

FROM IGNITION FEED
CIRCUIT OF
RELAY/SOLENOID VALVE
TO GROUND.
IS IT?
FAULTY ECM
CONNECTION
OR
OPEN RELAY/
SOLENOID
VALVE
DRIVER
CIRCUIT
OR
FAULTY ECM.
OPEN
RELAY/
SOLENOID
VALVE
IGNITION
FEED
CIRCUIT.
UNGROUND DIAGNOSTIC
TEST TERMINAL.
LIGHT SHOULD BE "OFF."
ISIT?
DISCONNECT
ECM
CONNECTOR
"B".
IS LIGHT
"ON"?
FAULTY RELAY/
SOLENOID
VALVE
CONNECTION
OR
FAULTY RELAY/
SOLENOID
VALVE.
VALVE DRIVER
CIRCUIT.
10-7-92
MS 10859
TO
IGNITION
ECM
EGR
SOLENOID
VALVE
N.C.
[l~TO
FANS/ACTR
10AMP
(U/H)
TO
OTHER FANS/ACTR
FUSE CIRCUITS
INTAKE
TO
EVAP CANISTER PURGE
SOLENOID VALVE AND
(U/H)
10-12-92
MS 12322
DTC 32 (Page 1 of 2)
EXHAUST GAS RECIRCULATION {EGR) CIRCUIT
5.7L {VIN P) F" CARLINE (MFI)
11
The_ Exhaust Gas Recirculation (EGR) valve vacuum is controlled by an ECM controlled solenoid valve. The
ECM will turn ~he EGR "ON" and "OFF" (Duty Cycle) by grounding CKT 435. The duty cycle is calculated by the
ECM based on mformation from the engine coolant temperature, air flow and engine RPM. There should be no
EGR when in park or neutral, TP sensor input below a specified value, or TP sensor indicating Wide Open
Throttle (WOT).
. Wit~ the ignition "ON" engine stopped, the EGR solenoid valve is de-energized and by grounding the
diagnostic "test" terminal, the solenoid valve is energized. The ECM will check EGR operation when:
Vehicle speed is above 50 mph.
MAP WITH KEY "ON"
MAP is as listed in table (depends on altitude).
ENGINE "OFF" (BARO)
Throttle angle is between 8% and 30%.
MAP
No more than .4% change in throttle position.
30
20
10
0
RANGE
FOR
TEST

1. Intake Passage: Shut oFF" engine and
remove the EGR valve from the manifold. Plug
the exhaust side hole with a shop rag or suitable
stopper. Leaving the intake side hole open,
attempt to start the engine. If the engine runs at a
very high idle (up to 3000 RPM is possible) or
starts and stalls, the EGR passages are not
restricted. If the engine starts and idles normally,
the EGR intake side passage in the intake
manifold is restricted.
Exhaust Passage: With EGR valve still
removed, plug the intake side hole with a suitable
stopper. With the exhaust side hole open, check for
the presence of exhaust gas. If no exhaust gas is
present, the EGR exhaust side passage in the
mtake manifold is restricted.
By grounding the diagnostic "test" terminal the
EGR solenoid valve should be energized and ;llow
vacuum to be applied to the gage. The vacuum at
the gage may or may not slowly bleed off. It is
important that the gage is able to read the amount
of vacuum being applied.
3. When the diagnostic "test" terminal is grounded,
the vacuum gage should bleed off through a vent in
4.
85
75
65
55
the solenoid valve. The pump gage may or may not

bleed off but this does not indicate a problem.
This test will determine if the electrical control
part of the system is at fault or if the connector or
solenoid valve is at fault.
Diagnostic Aids:
The EGR circuit can be inoperative if the PNP
switch is misadjusted or faulty. The EGR is disabled
when in park or neutral. To check the PNP switch,
refer to CHART C- lA.
Suction from shop exhaust hoses can alter
backpressure and may affect the operation of the EGR
valve during install testing.
The ECM also monitors left side short term fuel
trim during a OTC 32 test and must detect a change to
pass the test. If short term fuel trim is at a fixed value
(lean or rich) when a DTC 32 test is run, a DTC 32 may
set.
Vacuum lines should be thoroughly checked for
proper routing. Vacuum source goes to orifice side of
the EGR solenoid valve. Refer to "Vehicle Emissions
Control Information" label.
BEFORE USING THIS CHART, CHECK FOR MANIFOLD VACUUM TO

EGR SOLENOID VALVE, ALSO CHECK HOSES FOR LEAKS OR
RESTRICTIONS. SHOULD BE AT LEAST7" Hg VACUUM AT 2000 RPM.
DTC32
(Page 1 of 2)
EXHAUST GAS RECIRCULATION

(EGR) CIRCUIT
11
5. 7L (VIN P) F" CARLINE (MFI)
WITH ENGINE AT IDLE AND AT NORMAL OPERATING

TEMPERATURE, MANUALLY LIFT EGRVALVE DIAPHRAGM.
RPM SHOULD DECREASE OR ENGINE SHOULD STALL.
DOES IT?
DISCONNECT EGR VACUUM HARNESS AT SOLENOID VALVE. INSTALL A

VACUUM GAGE TO MANIFOLD SIDE OF HARNESS AND CHECK FOR
VACUUM SUPPLY TO SOLENOID VALVE.
VACUUM SHOULD BE AT LEAST 25 kPa (7" Hg) OF VACUUM AT 2000 RPM.
IS IT?
PLUGGED VACUUM PORT

ATINTAKE MANIFOLD.
LEAKING OR RESTRICTED
VACUUM SUPPLY LINE
TO EGR SOLENOID
VALVE.
ROTATE VACUUM HARNESS AND REINSTALL ONLY THE EGR VALVE SIDE, TO THE
SOLENOID VALVE.
INSTALL A VACUUM GAGE IN PLACE OF EGR VALVE.
INSTALL A HAND HELD VACUUM PUMP TO MANIFOLD SIDE OF EGR SOLENOID VALVE .
IGNITION "ON," ENGINE STOPPED .
APPLY 34 kPa (10" Hg) VACUUM AND OBSERVE GAGE .
GAGE SHOULD READ VACUUM APPLIED BY PUMP. DOES IT?
APPLY 34 kPa (10" Hg) VACUUM.

UNGROUND DIAGNOSTIC "TEST" TERMINAL.
VACUUM SHOULD BLEED OFF COMPLETELY AT GAGE .
DOES IT?
CONNECT VACUUM PUMP TO EGR VALVE SIDE OF HARNESS.

APPLY VACUUM AND OBSERVE GAGE.
GAGE SHOULD READ VACUUM APPLIED BY PUMP.
DOESIT?
s.
r
--------,
I
: REFER TO EGR
I
, CHART (2 OF 2). 1
~
DISCONNECT SOLENOID VALVE
ELECTRICAL CONNECTOR.
DOES VACUUM BLEED OFF
RAPIDLY AT GAGE?
L----------.J
GJ
ECMDRIVER
CIRCUIT OPEN
OR
FAULTY ECM.
REPLACE
SOLENOID
VALVE.
DISCONNECT EGR ELECTRICAL CONNECTOR.

CONNECT TEST LIGHT FROM TERMINAL "B"
OF EGR HARNESS CONNECTOR AND B +.
IS LIGHT "ON"?
~
0
FAULTY SOLENOID
VALVE
CONNECTION
OR
FAULTY SOLENOID
VALVE.
FAULTY
VACUUM
SUPPLY LINE
TO EGR VALVE.
DISCONNECT EGR ELECTRICAL CONNECTOR .

CONNECT TEST LIGHT BETWEEN HARNESS
DIAGNOSTIC "TEST" TERMINAL GROUNDED.
DOESIT?
6-20-91
MS 10833
CHECK FOR PLUGGED

EGR PASSAGES.
0.
GJ
GROUNDED
ECM DRIVER
CIRCUIT.
~
CONNECT TEST LIGHT BETWEEN
IGNITION FE ED CIRCUIT ANO GROUND.
NO LIGHT
REPAIR OPEN
IGNITION FEED
CIRCUIT.
LIGHT
OPEN ECM
DRIVER CIRCUIT
OR
FAULTY ECM.
TO
IGNITION
ECM
EGR
SOLENOID
VALVE
N.C.
FANS/ACTR
10AMP
{U/H)
TO
OTHER FANS/ACTR
FUSE CIRCUITS
TO
EVAP CANISTER PURGE
SOLENOID VALVE AND
REVERSE LOCKOUT SOLENOID (U/H)
10-12-92
MS 12322
DTC32
(Page 2 of 2)
EXHAUST GAS RECIRCULATION {EGR) CIRCUIT
11
5.7L {VIN P) F" CARLINE {MFI)
The Exhaust Gas Recirculation (EGR) valve vacuum is controlled by an ECM controlled solenoid valve. The
ECM will turn the EGR "ON" and "OFF" (Duty Cycle) by grounding CKT 435. The duty cycle is calculated by the
ECM based on information from the engine coolant temperature, air flow and engine RPM. There should be no
EGR when in park or neutral, TP sensor input below a specified value, or TP sensor indicating Wide Open
Throttle (WOT).
With the ignition "ON" engine stopped, the EGR solenoid valve is de-energized and by grounding the
diagnostic "test" terminal, the solenoid valve is energized. The ECM will check EGR operation when:
MAP WITH KEY "ON"
Vehicle speed is above 50 mph.
MAP is as listed in table (depends on altitude).
ENGINE "OFF" {BARO)
Throttle angle is between 8% and 30%.
MAP
20
10
30
0
No more than .4% change in throttle position.
RANGE
FOR
TEST

1. The remaining test checks the ability of the EGR
valve to interact with the exhaust system. This
system uses a negative backpressure EGR valve
which should hold vacuum with engine "OFF."
2. When engine is started, exhaust hackpressure at
the base of the EGR valve should open the valve's
internal bleed and vent the applied vacuum
allowing the valve to seat.
85
75
65
55
Diagnostic Aids:
The EGR circuit can be inoperative if the PNP
switch is misadjusted or faulty. The EGR is disabled
when in park or neutral. To check the PNP switch,
refer to CHART C- lA.
backpressure and may affect the operation of the EGR
valve during install testing.
The ECM also monitors left side short term fuel
trim during a DTC 32 test and must detect a change to
pass the test. If short term fuel trim is at a fixed value
(lean or rich) when a DTC 32 test is run, a DTC 32 may
set.
proper routing. Vacuum source goes to orifice side of
the EGR solenoid valve. Refer to "Vehicle Emissions
Control Information" label.
ORIVEABILITY ANO EMISSIONS 5.7L {VIN P) 6E3-A-63
DTC32
{Page 2 of 2)

r-------------,
: CONTINUED FROM :
I EGRCHART
I
: (1 OF 2).
:
L-
----------..J
IGNITION "OFF."
CONNECT A VACUUM PUMP TO EGR VALVE.
OBSERVE EGR DIAPHRAGM WHILE APPL YING VACUUM.
DIAPHRAGM SHOULD MOVE FREELY AND HOLD VACUUM
FOR AT LEAST 20 SECONDS.
DOESIT?
APPLY 34 kPa (10" Hg) VACUUM TO EGR VALVE.

START ENGINE AND IMMEDIATELY OBSERVE GAGE ON VACUUM PUMP.
EGR VALVE DIAPHRAGM SHOULD MOVE TO SEATED POSITION AND
VACUUM SHOULD DROP FROM PUMP GAGE WHILE STARTING ENGINE.
DOES IT?
REMOVE EGR VALVE.

CHECK FOR PLUGGED OR RESTRICTED EXHAUST PASSAGES.
EGR CIRCUIT IS OPERATING PROPERLY. REFER

TO SYMPTOMS (SECTION 6E3-B).
PASSAGES NOT OK
REPLACE EGR VALVE.
CLEAN PASSAGES.
RE-CHECK EGR VALVE.
10-9-90
MS 10854
MAP SENSOR
ff
f
A B C
ECM
TO A/C EVAPORATOR TEMPERATURE AND

A/C REFRIGERANT PRESSURE SENSORS
MANIFOLD
ABSOLUTE
PRESSURE
(VACUUM)
' - - - - - - - - - - - - - 416 GRY

' - - - - - - - - - - - - 432 LT GRN
.___ _ _ _ _ _ _ _ _ _ _ _ 808 BLK
TO IAT, A/C REFRIGERANT PRESSURE, AND

A/C EVAPORATOR TEMPERATURE SENSORS
10-7-92
MS 12081
DTC33

receives this information as a signal voltage that will vary from about 1-1.5 volts at idle to 4.0-4.8 volts at Wide
Open Throttle (WOT).
The Tech 1 displays manifold pressure in kPa of pressure and voltage. Low pressure (high vacuum) displays
a low voltage, while high pressure (low vacuum) displays a high voltage.
If the MAP sensor fails, the ECM will substitute a fixed MAP value and use the Throttle Position (TP) sensor
to control fuel delivery.

Less than 3% throttle.
MAP greater than 80 kPa.
MAP greater than 90 kPa with AJC "ON."
RPM greater than 500 RPM.
All above conditions met for 1 second.
Engine misfire or a low unstable idle may set DTC
33. Disconnect MAP sensor and system will go
into backup mode. If the misfire or idle condition
remains, see "Symptoms," Section "6E3-B".
2. If the ECM recognizes the low MAP signal, the
ECM and wiring are OK.
Diagnostic Aids:
If the idle is rough or unstable, refer to
"Symptoms," Section "6E3-B" for items which can
cause an unstable idle.
An open in CKT 808 will result in a DTC 33.
With the ignition "ON," and the engine "OFF," the
manifold pressure is equal to atmospheric pressure
is used by the ECM as an indication of vehicle altitude
and is referred to as BARO. Comparison of this BARO
reading with a known good vehicle with the same
sensor is a good way to check accuracy of a "suspect"
sensor. Reading should be the same, .4 volt.
Also CHART C- lD can be used to test the MAP
sensor.
"6E3-B".
DTC33
C)
IF ENGINE IDLE IS ROUGH, UNSTABLE, OR INCORRECT, CORRECT CONDITION

BEFORE USING CHART. SEE "SYMPTOMS" IN SECTION "B".
ENGINE IDLING.
DOES SCAN TOOL DISPLAY A MAP VOLTAGE OF4.0 VOLTS OR OVER?
IGNITION "OFF."
IGNITION "ON."
SCAN TOOL SHOULD READ A VOLTAGE OF 1 VOLT
OR LESS.
DOES IT?
IF NO ADDITIONAL DTC(s) WERE
PROBE SENSOR GROUND CIRCUIT WITH

A TEST LIGHT TO BATTERY VOLTAGE.
DOES IT?
MAP SIGNAL CIRCUIT SHORTED TO

VOLTAGE, SHORTED TO 5 VOLT
REFERENCE CIRCUIT
OR
FAULTY ECM.
VACUUM LEAK AT MAP SENSOR SEAL

OR
FAUL TY MAP SENSOR.
6-16-92
MS 12888
MAP SENSOR
ff
f
A B C
ECM

MANIFOLD
ABSOLUTE
PRESSURE
(VACUUM)
,___ _ _ _ _ _ _ _ _ _ 416 GRY

' - - - - - - - - - - - - 432 LT GRN
~ - - - - - - - - - - - - 808 BLK
TO IAT, A/C REFRIGERANT PRESSURE, AND

10-7-92
MS 12081
DTC34
(SIGNAL VOLTAGE LOW- HIGH VACUUM)

receives this information as a signal voltage that will vary from about 1-1.5 volts at idle to 4.0-4.8 volts at Wide
Open Throttle (WOT).
The Tech 1 displays manifold pressure in kPa of pressure and voltage. Low pressure (high vacuum) displays
a low voltage, while a high pressure (low vacuum) displays a high voltage.
If the MAP sensor fails, the ECM will substitute a fixed MAP value and use the Throttle Position (TP) Snsor
to control fuel delivery.

RPM less than 700 RPM.
OR

RPM greater than 700 RPM.
Throttle angle greater than 20%.
2. If the ECM recognizes the high MAP signal, the
ECM and wiring are OK.
3. The Tech 1 will not display 12 volts. The
important thing is that the ECM recognizes the
voltage as more than 4 volts, indicating that the
ECM and CKT 432 are OK.
Diagnostic Aids:
An intermittent open in CKT 432 or CKT 416 will
result in a DTC 34.
With the ignition "ON" and engine "OFF," the
manifold pressure is equal to atmospheric pressure
is used by the ECM as an indication of vehicle altitude
and is referred to as BARO. Comparison of this BARO
reading with a known good vehicle with the same
sensor is a good way to check accuracy of a "suspect"
sensor. Reading should be the same, .4 volt.
Also, CHART C-lD can be used to test the MAP
sensor.
"6E3-B".
DTC34
MANIFOLD ABSOLUTE PRESSURE {MAP) SENSOR CIRCUIT
{SIGNAL VOLTAGE LOW- HIGH VACUUM)
5.7L {VIN P) ''F" CARLINE {MFI)
ENGINE IDLING.
DOES SCAN TOOL DISPLAY MAP VOLTAGE BELOW .25 VOLT?
IGNITION "OFF."
DISCONNECT SENSOR ELECTRICAL CONNECTOR.
JUMPER HARNESS TERMINALS "B" TO "C".
IGNITION "ON."
MAP VOLTAGE SHOULD READ OVER 4.7 VOL TS.
DOES IT?

IGNITION "OFF."
REMOVE JUMPER WIRE.
PROBE TERMINAL "B" (CKT 432) WITH A TEST
LIGHT TO BATTERY VOLTAGE.
IGNITION "ON."
SCAN TOOL SHOULD READ OVER 4 VOLTS.
DOESIT?
.FAULTY CONNECTION
OR
SENSOR.
5 VOLT REFERENCE CIRCUIT OPEN

OR
SHORTED TO GROUND
OR
FAULTY ECM.
CKT432 OPEN
OR
OR
CKT 432 SHORTED TO SENSOR GROUND
OR
FAULTY ECM.
5-9-92
MS 10665

ECM
IGNITION SYSTEM
TEST CONNECTOR
, - - - - - - - - - - - 632 BLK/PNK
r-----------
631 YEL
. - - - - - - - - - - 647 PPUWHT
. . - - - - - - - - - 453 BLK/RED
t - - - - - - - - - - 632 PNK/BLK
1 - - - - - - - - - - - 631 RED
t - - - - - - - - - 647lT BLU/BLK
J---------- 453 RED/BLK
C140
ENGINE
GROUND
DISTRIBUTOR
REFERENCE LOW
IGNITION FEED
HIGH RESOLUTION
LOW RESOLUTION
I..___
1lr- 450BLK
IGNITION
COIL
MODULE
IGNITION
TO
~
IGNITION
10 AMP
(U/H)
BLK
2 3 9 PNK
CONNECTOR
--------\
423WHT
B
8
~ ~1846PNK/BLK
IGNITION CONTROl
IGNITION
COIL
I
I
II
GRY
CONNECTOR
.---;-<1,...;..:..:__ 1847 WHT/BLK

121
'----<if- 1848
~--------/.J
WHT
BLK
CONNECTOR
WHTJ
TO
INSTRUMENT
CLUSTER
11-3-92
MS 12328
DTC36
(FAULTY HIGH RESOLUTION PULSE OR EXTRA LOW RESOLUTION PULSE DETECTED)
5.7L (VIN P)
11
11
F CARLINE (MFI)
The distributor ignition system supplies two timing inputs to the ECM, a high resolution signal (360 pulses
per one crankshaft revolution) and a low resolution signal (4 pulses per one crankshaft revolution). The ECM can
determine if one of the timing inputs is not being received by comparing the two inputs. If the ECM detects one
timing pulse without detecting the other timing pulse, this DTC will set.
The reference signals toggle between O and 5 volts as the camshaft turns. Therefore, an open, a short to
voltage, a short to ground, or a defective sensor inside the distributor can prevent the voltage from pulsing at the
ECM.

If less than 60 high resolution pulses are
detected between each low resolution pulse.
Failure occurs 5 consecutive times.
2. This test will determine if the ECM is sending out
a signal to the distributor for processing. If this
signal is not available, or is shorted to ground or
voltage, the distributor cannot ground it to
produce reference pulses.
Diagnostic Aids:
The engine does not need the high resolution pulse
to operate. If a DTC 36 is present and the vehicle will
not start, check for DTC 16 and use that chart first. If
the engine will still not run, refer to CHART A-3
"Engine Cranks But Will Not Run."
DTC36
(FAULTY HIGH RESOLUTION PULSE OR
EXTRA LOW RESOLUTION PULSE DETECTED)
S.7L (VIN P)
11
F" CARLINE (MFI)
CLEAR DTC(s).
RUN ENGINE FOR 30 SECONDS .
DOES DTC 36 SET?
$
DTC361S
INTERMITTENT.
REFER TO
"DIAGNOSTIC AIDS"
ON FACING PAGE.
IGNITION "OFF."
DISCONNECT IGNITION "TEST" CONNECTOR.
IGNITION "ON."
USING A DVM (J 39200) ON THE DC VOLTS SCALE, MEASURE
VOLTAGE ON TERMINAL "B" AT THE ECM SIDE OF THE IGNITION
TEST CONNECTOR.
I
I
LESS THAN .5 VOL TS
I
4T06VOLTS
OVER 6 VOL TS
I
OPEN OR GROUNDED HIGH
RESOLUTION SIGNAL
CIRCUIT FROM ECM TO TEST
CONNECTOR
OR
OR
FAULTY ECM.
I
IGNITION "OFF."
RECONNECT IGNITION SYSTEM
TEST CONNECTOR.
CONNECTOR.
IGNITION "ON."
MEASURE VOLTAGE ON
TERMINAL "A".
I
I
LESS THAN .5 VOLTS
I
OPEN OR GROUNDED
HIGH RESOLUTION
SIGNAL CIRCUIT FROM
TEST CONNECTOR TO
DISTRIBUTOR.
I
4 T06VOLTS
SHORT TO VOLTAGE
ON HIGH
RESOLUTION SIGNAL
CIRCUIT FROM ECM
TO TEST CONNECTOR.
I
FAUL TV DISTRIBUTOR
CONNECTION
OR
FAULTY DISTRIBUTOR.
I
OVER 6 VOL TS
I
SHORT TO VOLTAGE
ON HIGH RESOLUTION
SIGNAL CIRCUIT FROM
TEST CONNECTOR TO
DISTRIBUTOR.
6-6-92
MS 10760
6E3-A-70 5.7L (VIN P) DRIVEABIUTY AND EMISSIONS

ECM
IGNITION SYSTEM
TEST CONNECTOR
- - - - - - - - - 632 PNK/BLK
DISTRIBUTOR
REFERENCE LOW
631 YEL
1-----------631RED
IGNITION FEED
. . . - - - - - - - 647 PPI.JWHT
1--------- 647 LT BLUIBLK
HIGH RESOLUTION
. . - - - - - - - - - - 453 BLK/RED
A 1 - - - - - - - - - - 453 RED/BLK -
LOW RESOLUTION
, - - - - - - - - - - - - 632 BLK/PNK
r----------
I...____
C140
ENGINE
450BLK
GROUND
1lr-
IGNITION
IGNITION
COIL
MODULE
TO
~
IGNITION
10 AMP
(U/H)
BLK
239 PNK
CONNECTOR
--------\
423 WHT
8
~ A1846PNK/BLK
IGNITION
COIL
I
I
I
II
IGNITION CONTROL
GRY
CONNECTOR
.---,r-<1:--,-'-'-- 1847 WHT/BLK

' - - - ~ - 1848
WHT
A
--------;/.J
BLK
CONNECTOR
121
WHT
TO.._j
INSTRUMENT
CLUSTER
11-3-92
MS 12328
DTC41
IGNITION CONTROL (IC) CIRCUIT
(OPEN OR SHORTED CIRCUIT)

The ignition system provides two timing inputs to the ECM, high resolution (360 pulses per crankshaft
revolution) and low resolution (4 pulses per crankshaft revolution). The ECM uses these two reference pulses to
determine individual ignition spark timing for each cylinder.
Once the ECM calculates ignition timing, the timing signal will be sent to the ignition coil module on the IC
circuit. Each timing pulse received by the ignition coil module, on the IC circuit, will trigger the ignition coil
module to operate the ignition coil. Secondary ignition voltage is induced and is then sent to the distributor for
distribution to each spark plug.
The IC signal voltage ranges from about .5 volt to 4.5 volts.
If a DTC 41 is detected, the ECM will disable the fuel injectors to prevent flooding of the engine.
DTC 41 will set if the IC circuit problem occurs during cranking.

Voltage on CKT 423 exceeds 4.6 volts.
Engine speed is less than 1500 RPM.
2. Without the engine running or cranking there
would be no voltage present on the IC line.
3. This check determines if the IC signal from the
ECM is available at the ignition coil module. The
IC circuit voltage should be between about .5 and
4.5 volts.
4.
5.
The remaining tests begin to check that the

ignition coil module circuitry is OK.
If all wiring and connections are OK, check the
ignition coil or the ignition coil voltage supply.
Diagnostic Aids:
Since the ignition coil module gets its power from
the coil, check the ignition feed circuit to the ignition
coil for opens.
DTC41
(D
CLEAR DTC(s}.
DOESDTC41 SET?
(OPEN OR SHORTED CIRCUIT)
5.7L (VIN P)
11
F" CARLINE (MFI)
IGNITION "OFF."
DISCONNECT IGNITION COIL MODULE CONNECTOR.
PROBE IGNITION COIL MODULE HARNESS CONNECTOR
TERMINAL "B" WITH A VOLTMETER TO GROUND.
IGNITION "ON."
IS MORE THAN .5 VOL TS PRESENT?

WITH VOLTMETER ON AC SCALE, CRANK ENGINE

AND OBSERVE VOLTAGE.
IS VOLTAGE BETWEEN 1 AND4 VOLTS?
IGNITION "OFF."
IGNITION "ON."
IS VOLTAGE PRESENT?
SHORT TO VOLTAGE
IN IC CIRCUIT.
IGNITION "OFF."
WITH TEST LIGHT TO B +, PROBE IGNITION COIL
MODULE HARNESS CONNECTOR TERMINAL "C".
LIGHT SHOULD BE ON,
IS IT?
OPEN IGNITION
COIL MODULE
GROUND CIRCUIT.
IGNITION "ON."
WITH TEST LIGHT TO GROUND,
PROBE IGNITION COIL MODULE
HARNESS CONNECTOR
TERMINALS "D" AND "A".
LIGHT SHOULD BE ON BOTH,
IS IT?
FAUL TY IGNITION COIL

MODULE CONNECTION
OR
FAUL TY IGNITION COIL MODULE.
FAULTY ECM.
IGNITION "OFF."
CHECK FOR CONTINUITY BETWEEN ECM
CONNECTOR TERMINAL "A12" AND IGNITION
COIL MODULE CONNECTOR TERMINAL "B".
IS CIRCUIT OPEN?

OR
FAULTY ECM.
OPEN IC CIRCUIT
BETWEEN ECM AND
IGNITION COIL
MODULE.
FAULTY CIRCUIT FROM IGNITION

COIL TO IGNITION COIL MODULE
ON CIRCUIT THAT DID NOT LIGHT.
10-7-92
MS 10758

ECM
IGNITION SYSTEM
TEST CONNECTOR
t---------
. - - - - - - - - - - 632 BLK/PNK
, - - - - - - - - - - - - 631 YEL
. - - - - - - - - - 647 PPL/WHT
. . . . . - - - - - - - - 453 BLK/RED
DISTRIBUTOR
REFERENCE LOW
632 PNK/BLK
1-----------631RED
IGNITION FEED
1--------- 647LTBLU/BLK
1---------- 453 RED/BLK
LOW RESOLUTION
I...__
C140
450 BLK
ENGINE 1
GROUND
HIGH RESOLUTION
lr-
IGNITION
COIL
MODULE
IGNITION
cu~~r
IGN
1i~~
....
BLK
:~~~E__C!~~\
239PNK
423WHT
~-----~~~ 1846PNKIBLK
IGNITION
COIL
i:
II
--------/.J
i~GRY
I
ANNECTOR
I
I
IA
121
WHT
A
TO.._j
BLK
CONNECTOR
{U/H)
IGNITION CONTROL
INSTRUMENT
CLUSTER
11-3-92
MS 12328
DTC42
(GROUNDED CIRCUIT)
5.7L (VIN P)
11
F" CARLINE (MFI)
The ignition system provides two timing inputs to the ECM, high resolution (360 pulses per crankshaft
revolution) and low resolution (4 pulses per crankshaft revolution). The ECM uses these two reference pulses to
determine individual ignition spark timing for each cylinder.
Once the ECM calculates ignition timing, the timing signal will be sent to the ignition coil module on the IC
circuit. Each timing pulse received by the ignition coil module on the IC circuit will trigger the ignition coil
module to operate the ignition coil. Secondary ignition voltage is induced and is then sent to the distributor for
distribution to each spark plug.
The IC signal voltage ranges from about .5 volt to 4.5 volts.
If DTC 42 is detected, the ECM will disable the fuel injectors to prevent flooding of the engine.
DTC 42 will set if the IC circuit problem occurs during cranking.
Engine speed below 3000 RPM.
Voltage on CKT 423 is below about .5 volt.
If the engine starts at this point, DTC 42 is
intermittent.
2. This check determines if the IC signal from the
ECM is available at the ignition coil module.
3. The remaining tests begin to check that the
ignition coil module circuitry is OK. If the ignition
coil module loses its voltage source, secondary
voltage will not be produced and a DTC 42 will set.
4.
5.
Since the ignition coil module gets its power from

the coil, check the ignition feed circuit to the
ignition coil for opens.
A DTC 42 will set if the high and low resolution
CKTs are shorted to each other. Before replacing
any components, make sure these circuits are not
shorted together.
ORIVEABILITY AND EMISSIONS 5.7L (VIN P) 6E3-A-73
DTC42
(GROUNDED CIRCUIT)
CLEAR DTC(s).
DOES OTC 42 SET?
IGNITION "OFF."
WITH A VOLTMETER ON AC SCALE, PROBE IGNITION COIL
MODULE CONNECTOR TERMINAL "B" TO GROUND.
CRANK ENGINE AND OBSERVE VOLTAGE.
IS VOLTAGE BETWEEN 1 AND4 VOLTS?

IGNITION "OFF."
WITH TEST LIGHT TO B +, PROBE IGNITION COIL
MODULE HARNESS CONNECTOR TERMINAL "C".
IS IT?
IGNITION "ON."
WITH TEST LIGHT TO GROUND,
PROBE IGNITION COIL MODULE
HARNESS CONNECTOR
TERMINALS "D" AND" A".
LIGHT SHOULD BE "ON" BOTH.
ISIT?
FAUL TY IGNITION COIL

MODULE CONNECTION
OR
FAUL TY IGNITION COIL MODULE.
OPEN IGNITION
COIL MODULE
GROUND CIRCUIT.
IGNITION "OFF."
DISCONNECT ECM CONNECTOR" A".
WITH TEST LIGHT TO B +, PROBE
ECM HARNESS TERMINAL "A12".
IS TEST LIGHT ON?

OR
FAULTY ECM.
GROUNDED IC CIRCUIT
BETWEEN ECM AND
IGNITION COIL MODULE.
FAULTY CIRCUIT FROM COIL TO

IGNITION COIL MODULE ON
CIRCUIT THAT DID NOT LIGHT.
6-6-92
MS 10759
ECM
KNOCK
SIGNAL
SV
, - - - - - - - 496 DK BLU
~~.".i.
7-7-92
NS 15347
DTC43
The knock sensor is used to detect engine detonation. The ECM will retard the spark timing based on the
signal being received from the knock sensor. The knock sensor produces an AC voltage which is sent to the ECM.
The amount of AC voltage produced by the knock sensor is determined by the amount of knock. The circuitry
within the knock sensor causes the ECM 5 volts to be pulled down so that under a no knock condition, CKT 496
would measure about 2.5 volts.
There is one internal ECM test ran on this circuit to determine it is operating correctly. If the test fails, a
DTC 43 will set.
If CKT 496 becomes open or shorted to ground, the voltage will either go above 4.12 volts or below .78
Test #1.
volt. If either of these conditions are met for about 5 seconds, a DTC 43 will be stored.

1. If the conditions for the test, as described above,
have been met, the Tech 1 will always indicate
"NO" when the knock signal position is selected. If
an audible knock is heard from the engine, repair
the internal engine problem, as normally no knock
should be detected at idle.
2. The ECM supplies 5 volts on CKT 496 which
should be present at the knock sensor terminal.
3. This test determines if the knock sensor is faulty
or if the IC portion of the PROM is faulty.
Diagnostic Aids:
Check CKT 496 for a potential open or short to
ground.
Also, check for proper installation of PROM.
"6E3-B".
\ ,DRIVEABILITY AND EMISSIONS 5.7L (VIN P) 6E3-A-75
DTC43
(0
G)
Ci)
INSTALL TECH 1.
ENGINE IDLING, ENGINE COOLANT TEMP ABOVE 67C.
DOES TECH 1 INDICATE A FIXED VALUE OF KNOCK
RETARD BETWEEN 4 AND 20 DEGREES?

IGNITION "ON."
USING A OVM, MEASURE VOLTAGE BETWEEN
HARNESS CKT 496 AND GROUND.
VOLTAGE SHOULD BE 4-6 VOLTS.
IS IT?
MEASURE RESISTANCE OF KNOCK SENSOR BY

CONNECTING OHMMETER BETWEEN SENSOR
TERMINAL AND ENGINE BLOCK.
SHOULD BE BETWEEN 3.3KO & 4.SKO.
ISIT?
CHECK HARNESS AND SENSOR CONNECTOR.

IFOK:
REMOVE ECM AND BE SURE PROM IS
PROPERLY SEATED INTO ECM.
IFOK:
REPLACE PROM.
OTC 43 IS INTERMITTENT. SEE "DIAGNOSTIC AIDS"

ON FACING PAGE.
LESS THAN 4 VOLTS

CHECK FOR CKT 496 BEING ROUTED TOO
CLOSE TO SECONDARY IGNITION WIRES
OR
OR
FAULTY ECM.
CKT 496 OPEN,

SHORTED TO GROUND
OR
FAULTY ECM.
REMOVE KNOCK SENSOR ANO ENSURE THAT THREADS ON

SENSOR AND BLOCK ARE CLEAN AND FREE OF CORROSION,
TEFLON TAPE, ANTI-SEIZE COMPOUNDS, OR SEALANTS. IF
OK, REPLACE FAULTY KNOCK SENSOR.
1-27-92
95 7767-6E
ECM
. . . . . - - - - - - - - 1666 PPL
OXYGEN S'ENSOR (02S)
__'
351 BLKJWHT
-::- ENGINE
GROUND
EXHAUST
6-6-92
MS 12318
DTC44
5.7L (VIN P)
11
F" CARLINE (MFI)
The ECM supplies a voltage of about 450 mV between terminals "D6" and "Dl6". (If measured with a 10
megohm digital voltmeter, this may read as low as 320 m V.) The oxygen sensor varies the voltage within a range
Test Description: ~umber(s) below refer to circled
Signal voltage remains below 200 m V for 50
seconds.
Diagnostic Aids:
Using the Tech 1, observe long term fuel trim
values at different RPM and air flow conditions. The
Tech 1 also displays the fuel trim cells, so the long
term fuel trim values can be checked in each of the
cells to determine when the DTC 44 may have been
set. If the conditions for DTC 44 exist, the long term
fuel trim values will be near 160.
Oxygen Sensor Wire. Sensor pigtail may be
manifold.
Check for intermittent ground in wire between
MAP Sensor. A Manifold Absolute Pressure
(MAP) sensor output that causes the ECM to sense
a higher than normal vacuum, will cause the
system to go lean. Disconnect the MAP sensor and
if the lean condition is gone, replace the sensor.
Lean Injector(s). Perform injector balance test

CHARTC-2A.
Fuel Contamination. Water, even in small
amounts, near the in-tank fuel pump inlet can be
delivered to the injectors. The water causes a lean
exhaust and can set a DTC 44.
Fuel Pressure. System will be lean if pressure is
too low. It may be necessary to monitor fuel
pressure while driving the vehicle at various road
speeds and/or loads to confirm. Refer to "Fuel
System Diagnosis," CHART A-7.
Exhaust Leaks. If there is an exhaust leak above
the oxygen sensor, the engine can cause outside air
to be pulled into the exhaust stream and flow past
the sensor causing a lean condition. Vacuum or
crankcase leaks can cause a lean condition.
AIR System. Make sure air is not being directed to
the exhaust ports while in "Closed Loop." If the
long term fuel trim value goes down while
squeezing air hose to left side exhaust ports, refer
to CHART C-6.
If the above are OK, the oxygen sensor may be at
fault.
DTC44
G)
RUN WARM ENGINE (75C/167f TO 95C/203f) AT 1200 RPM.

DOES TECH 1 INDICATE BANK1 025 VOLTAGE FIXED BELOW .35 VOLT {350 mV)?
DISCONNECT BANK1 025.

WITH ENGINE IDLING, TECH 1 SHOULD DISPLAY BANK1 025 VOLTAGE
BETWEEN .35 VOLT AND .55 VOLT (350 mV AND 550 mV).
DOESIT?
OTC 4415 INTERMITTENT. If NO ADDITIONAL

DTC(s) WERE STORED, REFER TO

OR
FAULTY ECM.
6-9-92
MS 12485
ECM
l.--------
1666 PPL
BANK 2 (RIGHT) 025 SIGNAL
OXYGEN SENSOR (025)
_"
351 BLK/WHT
-::-ENGINE
GROUND
EXHAUST
6-6-92
MS 12318
DTC45

The ECM suppHes a voltage of about 450 mV between terminals "06" and "016". (If measured with a 10
of about 1000 m V if a rich 028 signal is indicated down through about 10 m V ifa lean 02Ssignal is indicated.
The senlor is like an open circuit and produces no voltage when it is below 315C (600F). An open sensor

Signal voltage remains above 700 m V for 50
seconds.
Throttle angle is greater than 4%.
Diagnostic Aids:
values at different RPM and load conditions. The Tech
1 also displays the fuel trim cells, so the long term fuel
trim values can be checked in each of the cells to
determine when the DTC 45 may have been set. If the
conditions for OTC 45 exist, the long term fuel trim
values will be near 108.
Fuel Pressure. System will go rich if pressure is
too high. The ECM can compensate for some
increase. However, if it gets too high, a DTC 45
may be set. Refer to "Fuel System Diagnosis,"
CHARTA-7.
Rich Injector. Perform "Injector Balance Test,"
CHARTC-2A.
Leaking Injector. Refer to "Fuel System

Diagnosis,"CHART A-7.
Check for fuel contaminated oil.
EVAP Canister Purge. Check for fuel saturation.

If full of fuel, check canister control and hoses.
Refer to "Evaporative Emission (EVAP) Control
System," Section "6E3-C3".
MAP Sensor. An output that causes the ECM to
sense a lower than normal vacuum can cause the
system to go rich. Disconnecting the MAP sensor
will allow the ECM to set a fixed value for the
sensor. Substitute different MAP sensor if the rich
condition is gone while the sensor is disconnected.
Check for leaking fuel pressure regulator
diaphragm by checking vacuum line to regulator
for fuel.
TP Sensor. An intermittent TP sensor output will
cause the system to go rich, due to a false
indication of the engine accelerating.
EGR. An EGR staying open (especially at idle)
will cause the 028 to indicate a rich exhaust, and
this could result in a DTC 45.
DTC45
G).

DOES TECH 1 DISPLAY BANK1 025 VOLTAGE FIXED ABOVE .75 VOLT (750 mV)?
DISCONNECT BANK1 025 AND JUMPER HARNESS CKT 1665 TO GROUND.

TECH 1 SHOULD DISPLAY BANK1 025 BELOW .35 VOLT (350 mV).
DOESIT?
AFTER REPAIRS," REFER TO OTC CRITERIA ON FACING PAGE AND CONFIRM OTC DOES NOT RESET.
6-9-92
MS 12486
ECM
ECMBATT
TOB+
10AMP
(1/P)
c
PASS-KEYII
DECODER
MODULE
(1/P)
A1
BATTERY FEED
340 ORN
BATTERY FEED
C210
A3
~E
C230
229 DKBLU
PASS-KEYII SIGNAL
10-29-92
MS 12718
= LOCATED IN INSTRUMENT PANEL FUSE BLOCK
DTC46
PERSONAL AUTOMOTIVE SECURITY SYSTEM (PASS-Keyn) CIRCUIT
The PASS-Key I I system is designed to disable vehicle operation if the incorrect key or starting procedure is
used. The PASS-KeyII decoder module sends a signal to the ECM if the correct key is being used. If the proper
signal does not reach the ECM on CKT 229, the ECM will not pulse the injectors "ON" and thus not allow the
vehicle to be started.
DTC 46 will set, if the proper signal is not being received on CKT 229 by the ECM when the ignition is turned
"ON." A PASS-Key II fault will store a DTC 46 in the ECM memory.

1. If the engine cranks but doesn't start, it indicates
that the portion of the decoder module which
generates the signal to the ECM is not operating or
CKT 229 is open or shorted to ground. If the
decoder module is found to be OK, as determined
from SECTION 8A, the ECM may be at fault, but
this is not a likely condition.
2.
If DTC 46 is stored, and the engine will not crank,
it indicates that there is a PASS-KeyII problem

or an incorrect key or starting procedure is being
used.
DTC46
PERSONAL AUTOMOTIVE SECURITY SYSTEM (PASS-KeyII) CIRCUIT
11
IGNITION "ON."
DOES SCAN TOOL INDICATE PASS-KeyII STATUS AS "ENABLED"?
PROBLEM IS INTERMITTENT. IF NO
OTHER DTC(S) IS STORED, REFER TO
"INTERMITTENTS" IN SECTION "B".
G)
CHECK FOR OPEN OR SHORT TO GROUND IN CKT 229

OR
FAULTY PASS-KeyII DECODER MODULE
OR
OR
FAULTY ECM.
PASS-KeyII SYSTEM PROBLEM. REFER TO

PASS-KeyII DIAGNOSIS" IN SECTION "SA".
11-16-92
NS15561
PROM
ACCESS COVER
GASKET
J3
J2
J1
9S 6343-6E
OTC 51
PROM ERROR
(FAULTY OR INCORRECT PROM)
OTC 51
PROM ERROR
{FAULTY OR INCORRECT PROM)
5.7L (VIN P) ,.F,. CARLINE (MFI)
NOTICE:
TO PREVENT POSSIBLE ELECTROSTATIC DISCHARGE DAMAGE:

DO NOT TOUCH THE ECM CONNECTOR PINS OR SOLDERED COMPONENTS
ON THE ECM CIRCUIT BOARD.
WHEN HANDLING A PROM, DO NOT TOUCH THE COMPONENT LEADS,

AND DO NOT REMOVE INTEGRATED CIRCUIT FROM CARRIER.
NOTICE:
TO PREVENT POSSIBLE ELECTROSTATIC DISCHARGE DAMAGE TO THE

PROM, DO NOT TOUCH THE COMPONENT LEADS, AND DO NOT REMOVE
INTEGRATED CiRCUIT FROM CARRIER.
NOTICE:
TO PREVENT POSSIBLE ELECTROSTATIC DISCHARGE DAMAGE TO THE

ECM, DO NOT TOUCH THE CONNECTOR PINS OR SOLDERED COMPONENTS
ON THE CIRCUIT BOARD.
CHECK THAT ALL PINS ARE FULLY INSERTED IN THE SOCKET AND THAT PROM IS
PROPERLY LATCHED.
IF OK, REPLACE PROM, CLEAR MEMORY, AND RECHECK.
IF DTC 51 REAPPEARS, REPLACE ECM.
REFER TO SECTION "6E3 C1" FOR PROM AND ECM SERVICE PROCEDURES.
3-16-92
95 6345-6E
ECM
ECM
IGN
81
TO
....-<.-----<(~ 3PNK
IGNITION
C200
G
IGNITION FEED
15AMP
(IIP)
C230
TO FU EL PUMP RELAY
AND TO PASS-KEYII
DECODER MODULE
10-29-92
MS 12323
DTC53
SYSTEM VOLTAGE
DTC 53 will set when the engine is running and the ECM senses a voltage of more than 17 .1 volts or less than
8.0 volts on ECM terminal "Cl2". During the time the fault is present, all ECM outputs will be disengaged and
setting of additional DTCs may result.

1. Normal battery output is between 9.6 - 16.0 volts.
2. Checks to see if the high voltage reading is due to
the generator or ECM. With engine running,
check voltage at the battery.
If the voltage is above 12.1 volts, the ECM is OK.
3. Checks to see if generator is faulty under load
condition. If the voltage is below 8.0 volts, refer to
SECTION6D.
Diagnostic Aids:
During the time the failure is present, all ECM
outputs will be disengaged to protect the hardware.
The setting of additional DTCs may result.
OTC 53
SYSTEM VOLTAGE
ENGINE RUNNING ABOVE BOO.RPM.

NOTE BATTERY VOLTAGE ON TECH 1.
ABOVE 17.1 VOLTS
ABOVE 8.0 VOLTS AND BELOW17.1 VOLTS
ABOVE 17.1 VOLTS
REMOVE GENERATOR
FOR REPAIR.
SEE SECTION "6D."

HEADLAMPS AND HIGH BLOWER "ON."
NOTE BATTERY VOLTAGE VALUE.
BELOW17.1 VOLTS
REPLACE ECM
ABOVE 8.0 VOL TS
BELOW 8.0 VOL TS
FAULT IS NOT PRESENT

SEE "INTERMITTENTS" IN
"SYMPTOMS" (SECTION B).
REMOVE GENERATOR
FOR REPAIR.
SEE SECTION "6D."
3-23-90
95 7906-6E

CAUTION:


QUICK-CONNECT
,-,_----::::~ FITTINGS
RETURN LINE
J 37287
FUEL LINE
SHUT-OFF
ADAPTERS
FUEL PUMP AND

RESERVOIR ASSEMBLY
NS 16050
OTC 55
FUEL LEAN MONITOR
The ECMs internal circuitry can identify if the vehicle's fuel system is capable of supplying adequate
amounts of fuel during heavy acceleration (power enrichment). When a power enrichment mode of operation is
requested during "Closed Loop" operation (by heavy acceleration), the ECM will provide more fuel to the engine.
Under these conditions, the ECM should detect a "rich" condition. If this "rich" exhaust is not detected at this
time, a OTC 55 will set. A plugged fuel filter or restricted fuel line can prevent adequate amounts of fuel from
being supplied during power enrichment mode.
The ECM detects lean oxygen sensor voltage for 8
seconds during power enrichment modes of
operation.
Wrap a shop towel around the fuel pressure
connector to absorb any small amount of fuel
leakage that may occur when installing the gage.
Ignition "ON," pump pressure should be 284-325
kPa (41-47 psi). This pressure is controlled by
spring pressure within the regular assembly.
Pressure below 284 kPa (41 psi) may cause a lean
condition and may set a OTC 44 or 64. It could also
cause hard starting cold and poor driveability.
Low enough pressure will cause the engine not to
run at all.
Restricted flow may allow the engine to run at idle,

or low speeds, but may cause a surge and stall
when more fuel is required, as when accelerating
or driving at high speeds. Low fuel pressure under
heavy acceleration conditions may set a OTC 55.
2. Restricting the fuel return line allows the fuel
pressure to build above regulated pressure. With a
Tech 1 enable the fuel pump, pressure should rise
above 325 kPa (47 psi) as the valve in the return
line is partially closed.
Diagnostic Aids:
A restricted fuel filter can supply adequate
amounts of fuel at idle but may not be able to supply
enough fuel during heavy acceleration. A vapor lock
condition can cause a OTC 55.
DTCSS
FUEL LEAN MONITOR
IF DTC(s) 44 OR 64 ARE SET, REFER TO THOSE DTCs BEFORE

PROCEEDING WITH THIS CHART.
INSTALL FUEL PRESSURE GAGE, J 34730-1 .
START AND IDLE ENGINE AT NORMAL OPERATING TEMPERATURE.
DISCONNECT VACUUM LINE GOING TO FUEL PRESSURE REGULATOR.
NOTE FUEL PRESSURE WITH ENGINE RUNNING SHOULD BE 284-325 kPa
(41-47 psi).
I
NOTOK
CHECK FOR RESTRICTED FUEL LINES

OR
IN-LINE FILTER
NOTOK
IGNITION "OFF."
INSTALL J 37287-2 FUEL LINE ADAPTOR IN FUEL RETURN LINE.
REFER TO FUEL SYSTEM PRESSURE TEST CHART A-7, PAGE 3 OF
3 FOR FUEL PRESSURE RELIEF PROCEDURE AND FOR SERVICING
QUICK-CONNECT FITTINGS.
USING A TECH 1, ENABLE THE FUEL PUMP."
SLOWLY CLOSE VALVE IN RETURN LINE. PRESSURE SHOULD
RISE ABOVE 325 kPa (47 psi). DO NOT EXCEED 414 kPa (60 psi).
NO TROUBLE FOUND. IF NO ADDITIONAL

DTCs WERE STORED, REVIEW CIRCUIT
DESCRIPTION ON FACING PAGE.
REPLACE FILTER
OR
REPAIR FUEL LINE AND RECHECK.
I
I
ABOVE 325 kPa (47 psi)
PRESSURE BUT LESS THAN

284 kPa (41 psi)
I
CHECK FOR:
FAULTY FUEL PUMP
INCORRECT FUEL PUMP .
11-16-92
MS 12893

A/CCRUISE
, - - - - - - 1 3 9 P N K ~ 3PNK - T O IGNITION
....-----i.-
TO OTHER A/C CRUISE

FUSE CIRCUITS
20 AMP
(U/H)
TO IGNITION~ 300 ORN
A/C
~LAY
HVAC
~
25AMP
(1/P)
TO HVAC
~ 66 LT GRN
BLOWER SWITCH
139
PNK
ECM
> TO REAR
DEFOG SYSTEM
241
BRN
HVAC
CONTROL
ASSEMBLY
F
762 DK GRNtWHT ~
I
I
230
I :, B I
,___ _-r~~t--,1-----------459DKGRN/WHT
I
CI
59 DK GRN
LOW PRESSURE
CUTOFF SWITCH
TO OTHER
3DKGRN------<~
SOS CIRCUITS
C100
~--',-----------1--
450 BLK
A/C
COMPRESSOR
r:,::=:T:1
1 - - - - - - - - 8 0 8 BLK
PROBE
(INSERTED IN
EVAPORATOR)
BLK
A/C
EVAPORATOR
TEMPERATURE
SENSOR
A/CCLUTCH RELAY
CONTROL
A/CSTATUS
A/C
REFRIGERANT
PRESSURE
SENSOR
CLUTCH
A/C REQUEST
380 RED/BLK
416 GRY
416GRY
1 - - - - - - 7 3 2 DK BLU
808 BLK

-------1
SENSOR GROUND
A/C REFRIGERANT PRESS.
SENSOR SIGNAL
+ 5 VOLT REFERENCE
A/C EVAPORATOR
TEMPERATURE SENSOR
SIGNAL
SENSOR GROUND
TO OTHER 808 CIRCUITS
11-4-92
MS 12472
DTC61
11
The ECM monitors A/C refrigerant pressure and A/C evaporator temperature to determine if the A/C system
has adequate refrigerant (Rl34a) charge. The ECM will disable the A/C clutch whenever AJC refrigerant charge
drops below a predetermined value, to reduce the chance of compressor damage.
The ECM determines A/C charge based on A/C refrigerant pressure and. A/C evaporator temperature. The
ECM uses these two inputs to calculate A/C refrigerant charge.
If the ECM determines A/C refrigerant charge to be low, the A/C clutch will be disabled and Diagnostic
Trouble Code (DTC) 61 will be set. DTC 61 will store in ECM memory, but will not turn "ON" the MIL (Service
Engine Soon).

1. DTC 61could be caused by other DTCs, so refer to
those charts before proceeding with this diagnostic
chart.
2. If the A/C refrigerant pressure sensor is "slewed"
or "shifted" in value, the ECM could be detecting a
lower than normal pressure. Therefore, the ECM
would be sensing a low refrigerant change and
DTC 61 could result.
3. The conditions to set a DTC 67 could cause DTC 61
to set. DTC 67 will set if the ECM does not detect
an A/C refrigerant pressure change of more than 4
psi when the A/C clutch is cycled from "OFF" to
"ON."
4.
The NC performance test (refer to SECTION lBl)

must be performed, because A/C system hardware
(A/C compressor, thermal expansion valve etc.)
could cause a DTC 61.
Diagnostic Aids:
An AJC evaporator temperature sensor and/or an
A/C refrigerant pressure sensor that is "slewed"
(shifted in value) could cause a DTC 61.
DTC61
G)
G)
G)
IF ANY ECM A/C DTCS ARE STORED REFER TO THOSE CHARTS FIRST.
AMBIENT TEMPERATURE GREATER THAN 16C(60 F).
INSTALL A/C MANIFOLD GAGE SET (REFER TO SECTION 18).
IS A/C REFRIGERANT PRESSURE (LOW SIDE) GREATER THAN 45 PSI?
r-
USING A TECH 1, COMPARE A/C

REFRIGERANT PRESSURE TO TECH 1
A/C REFRIGERANT PRESSURE.
IS TECH 1 PRESSURE WITH IN 20 PSI
OF HIGH SIDE PRESSURE?
r-
L------------J
ENGINE IDLING, A/C

"OFF" FOR 10 SECONDS.
TURN A/C "ON" FOR 10
SECONDS.
DOES DIAGNOSTIC
TROUBLE CODE 67 SET?
DIDA/C
COMPRESSOR
CLUTCH
ENGAGE?
---------,
: REFER TO CHART :
I C-10 FOR A/C
I
: ELECTRICAL
:
I DIAGNOSIS.
I
L-----------J
r-
----------,
: REFER TO SECTION '

1 181 FOR FURTHER :
: A/C SYSTEM
:
I DIAGNOSIS.
I
---------,
REFER TO
I
: DIAGNOSTIC
:
I TROUBLE CODE
'
: (OTC) CHART 67. :
I
IGNITION "OFF."
JUMPER PRESSURE SENSOR CONNECTOR TERMINALS "B" AND "C".
IGNITION "ON."
DOES TECH 1 INDICATE PRESSURE SENSOR VOLTAGE ABOVE 4.SVOLTS?
USING DVM MEASURE VOLTAGE

FROM PRESSURE SENSOR
CONNECTOR "B" TO GROUND.
DOES DVM MEASURE ABOUT 5
VOLTS?
WITH A TEST LIGHT TO B +,

PROBE A/C REFRIGERANT
PRESSURE SENSOR
CONNECTOR TERMINAL "A".
IS TEST LIGHT "ON"?
L-----------J
0~
REFER TO SECTION
: 181 AND PERFORM
I A/C PERFORMANCE
: TEST.
FAULTY ECMS
VOLT REFERENCE
CONNECTION OR
OPEN OR
GROUNDEDS
:
VOLT REFERENCE
'
CIRCUIT OR
:
FAULTY ECM. __,
,__
L--------------1
____
FAULTY ECM
SIGNAL CIRCUIT
CONNECTION OR
OPEN OR
GROUNDED
PRESSURE SENSOR
SIGNAL WIRE OR
FAUL TY ECM. -
OPEN
PRESSURE
SENSOR
GROUND
CIRCUIT.
FAULTY
SENSOR
CONNECTION
OR FAULTY
SENSOR.
11-19-92
NS 16296
6E3-A-90 5.7L (VIN P) DRIVEABILITYAND EMISSIONS
ECM
~ - - - - - 1666PPL
OXYGEN SENSOR (02S)
_L
351 BLK,WHT
-=- ENGINE
GROUND
EXHAUST
6-6-92
MS 12318
DTC63
BANK 2 (RIGHT) OXYGEN SENSOR (025) CIRCUIT
(OPEN CIRCUIT)
5. 7L (VIN P) "F'' CARLINE (MFI)

The ECM supplies a voltage of about 450 m V between terminals "D16" and "D22". (If measured with a 10
megohm digital voltmeter, this may read as low as 320 mV.) The oxygen sensor varies the voltage within a range
of about 1000 m V if a rich 028 signal is indicated down through about 10 m V if a lean 02S signal is indicated.

1. DTC 63 will set:
Engine at normal operating temperature
(above 70C/158F).
At least 2 minutes engine running time after

start.
028 signal voltage steady between 350 m V to
550mV.
Throttle position sensor signal above 5%
(about .3 volt above closed throttle voltage).
All conditions must be met for about 60
seconds.
If the conditions for a DTC 63 exist, the system
will not go into "Closed Loop."
2. This will determine if the oxygen sensor is at fault,
or the wiring or ECM is the cause of the DTC 63.
3.
For this test use only a high impedance digital volt

ohmmeter (J 39200). This test checks the
continuity of CKT 1666 and CKT 351. If CKT 351
is open, the ECM voltage on CKT 1666 will be over
.6 volt (600 mV).
Diagnostic Aids:
Normal Tech 1 voltage readings vary between 10
mV to 1000 mV (.01 and 1.0 volt), while in "Closed
Loop." The system will go into "Open Loop" operation
when DTC 63 sets.
Refer to "Intermittents" in "Symptoms,'' Section
"6E3-B".
DTC63
(OPEN CIRCUIT)
5.7L (VIN P)
G)
11
F" CARLINE (MFI)
ENGINE AT NORMAL OPERATING TEMPERATURE (ABOVE 80C/176F).

DOES TECH 1 TOOL INDICATE "CLOSED LOOP"?
G)
DISCONNECTBANK202S.
TECH 1 SHOULD DISPLAY BANK 2 025 VOLTAGE BELOW .2
VOLT (200 mv) WITH ENGINE RUNNING.
DOES IT?
OTC 63 IS INTERMITTENT. IF NO ADDITIOl'4AL

REMOVE JUMPER.
CHECK VOLTAGE OF CKT 1666 (ECM SIDE) AT BANK 2 025
SENSOR HARNESS CONNECTOR USING A DVM .
FAULTY BANK 2 025 CONNECTION

OR
025.
.3-.6VOLT
(300 - 600 mV)
OVER .6 VOLT
(600 mV)
FAULTY ECM.
OPEN CKT 351

OR
FAULTY CONNECTION
OR
FAULTY ECM.
OPEN CKT 1666

OR
OR
FAULTY ECM.
6692
MS 12458
ECM
. . . - - - - - - - 1666 PPL
OXYGEN SENSOR (025)
351 BLKIWHT
--=- ENGINE
GROUND
EXHAUST
6-6-92
MS 12318
DTC64
BANK 2 (RIGHT) OXYGEN SENSOR (02S) CIRCUIT
5. 7L (VIN P)
11
F" CARLINE (MFI)
The ECM supplies a voltage of about 450 m V between terminals "016" and "022". (If measured with a 10
megohm digital voltmeter, this may read as low as 320 mV.) The Oxygen Sensor (028) varies the voltage within
a range of about 1000 m V if a rich 028 signal is indicated down through about 10 m V if a lean 028 signal is
indicated.

Signal voltage remains below 200 m V for 50
seconds.
Diagnostic Aids:
values at different RPM and air flow conditions. The
Tech 1 also displays the fuel trim cells, so the long
term fuel trim values can be checked in each of the
cells to determine when the OTC 64 may have been
set. If the conditions for OTC 64 exist, the long term
fuel trim values will be near 160.
Oxygen Sensor Wire. Sensor pigtail may be
manifold.
Check for intermittent ground in wire between
MAP Sensor. A Manifold Absolute Pressure
(MAP) sensor output that causes the ECM to sense
a higher than normal vacuum, will cause the
system to go lean. Disconnect the MAP sensor and
if the lean condition is gone, replace the sensor.
Lean Injector(s). Perform injector balance test

CHARTC-2A.
Fuel Contamination. Water, even in small
amounts, near the in-tank fuel pump inlet can be
delivered to the injectors. The water causes a lean
exhaust and can set a OTC 64.
Fuel Pressure. System will be lean if pressure is
too low. It may be necessary to monitor fuel
pressure while driving the vehicle at various road
speeds and/or loads to confirm. Refer to "Fuel
System Diagnosis," CHART A-7.
Exhaust Leaks. If there is an exhaust leak above
the oxygen sensor, the engine can cause outside air
to be pulled into the exhaust stream and flow past
the sensor causing a lean condition. Vacuum or
crankcase leaks can cause a lean condition.
AIR System. Make sure air is not being directed to
the exhaust ports while in "Closed Loop." If the
long term fuel trim value goes down while
squeezing air hose to right side exhaust ports, refer
to CHART C-6.
If the above are OK, the oxygen sensor may be at
fault.
DTC64
BANK 2 (RIGHT) OXYGEN SENSOR (02S) CIRCUIT
G).

DOES TECH 1 INDICATE BANK 2 025 VOLTAGE FIXED BELOW .35 VOLT (350 mV)?
DISCONNECT BANK 2 025.

WITH ENGINE IDLING, TECH 1 SHOULD DISPLAY
BANK2 025 VOLTAGE BETWEEN .35 VOLT AND .55
VOLT (350 mV AND 550 mV).
DOESIT?
DTC 64 IS INTERMITTENT.
IF NO ADDITIONAL DTC(s) WERE

OR
FAULTY ECM.
6-9-92
MS 12459
ECM
. - - - - - - - - - - - - - - - - - - - 1665 PPLWHT
~ , - - - - - - - 1666 PPL

OXYGEN SENSOR (025)
__"
351 BLK/WHT
-=- ENGINE
GROUND
EXHAUST
6-6-92
MS 12318
DTC65

The ECM supplies a voltage of about 450 mV between terminals "016" and "022". (If measured with a 10

Signal voltage remains above 700 m V for 50
seconds.
Throttle angle is greater than 4%.
Diagnostic Aids:
values at different RPM and load conditions. The Tech
1 also displays the fuel trim cells, so the long term fuel
trim values can be checked in each of the cells to
determine when the DTC 65 may have been set. If the
conditions for DTC 65 exist, the long term fuel trim
values will be near 108.
Fuel Pressure. System will go rich if pressure is
too high. The ECM can compensate for some
increase. However, if it gets too high, a DTC 65
may be set. Refer to "Fuel System Diagnosis,"
CHARTA-7.
Rich Injector. Perform "Injector Balance Test,"
CHARTC-2A.
Leaking Injector. See "Fuel System Diagnosis,"
CHARTA-7.
Check for fuel contaminated oil.

Canister Purge. Check for fuel saturation. If full
of fuel, check canister control and hoses. Refer to
''Evaporative Emission (EVAP) Control System,"
Section "6E3-C3".
MAP Sensor. An output that causes the ECM to
sense a lower than normal vacuum can cause the
system to go rich. Disconnecting the MAP sensor
will allow the ECM to set a fixed value for the
sensor. Substitute different MAP sensor if the rich
condition is gone while the sensor is disconnected.
Check for leaking fuel pressure regulator
diaphragm by checking vacuum line to regulator
for fuel.
TP Sensor. An intermittent TP sensor output will
cause the system to go rich, due to a false
indication of engine accelerating.
EGR. An EGR staying open (especially at idle)
will cause the 028 sensor to indicate a rich
exhaust, and this could result in a DTC 65.
DTC65

DO.ES TECH 1 DISPLAY BANK 2 025 VOLTAGE FIXED ABOVE .75 VOLT (750 mV)?
DISCONNECT BANK 2 025 AND JUMPER HARNESS CKT 1666 TO

GROUND.
TECH 1 SHOULD DISPLAY BANK 2 025 BELOW .35 VOLT (350 mV).
DOESIT?

6-9-92
MS 12457

A/C CRUISE
, - - - - - - 1 3 9 P N K ~ 3PNK - T O IGNITION
~------:i
TO OTHER A/C CRUISE

FUSE CIRCUITS
20 AMP
(U/H)
HVAC
TO IGNITION- 300 ORN ~

25AMP
(1/P)
TO HVAC
~ 66 LT GRN
241
BRN
BLOWER SWITCH
A/C
RELAY
C100
TO REAR
DEFOG SYSTEM
HVAC
CONTROL
ASSEMBLY
139
PNK
I
I
ECM
A/CREQUEST
BI
I
A/C CLUTCH RELAY

CONTROL
CI
59 DKGRN ~ - - - '1' - - - - - - - - - - - - - - - - LOW PRESSURE

CUTOFF SWITCH
~ r.l~~~
TOOTHER
3DKGRN----~
808CIRCUITS
450 BLK
A/C
COMPRESSOR
A/C
REFRIGERANT
PRESSURE
SENSOR
CLUTCH
PROBE
(INSERTED IN
EVAPORATOR)
BLK
A/C
EVAPORATOR
TEMPERATURE
SENSOR
t - - - - - - - - 8 0 8 BLK
380 RED/BLK
416GRY
416GRY
1 - - - - - - - 7 3 2 DK BLU

(U/H)
A/CSTATUS
SENSOR GROUND
SENSOR SIGNAL
+ 5 VOLT REFERENCE
A/C EVAPORATOR
TEMPERATURE SENSOR
SIGNAL
SENSOR GROUND
11-4-92
MS 12472
DTC66
{OPEN OR SHORTED)

The A/C system uses an A/C refrigerant pressure sensor mounted in the high side of the A/C system to
monitor AJC refrigerant pressure.
The ECM uses this information to turn "ON" the engine cooling fans when AJC pressure is high. The ECM
can prevent compressor damage by disabling the compressor clutch if head pressure gets too high.
The A/C refrigerant pressure sensor operates much like other 3-wire sensors. A 5 volt reference is supplied to
the sensor and returned to the ECM on the signal line. As the A/C refrigerant pressure increases or decreases,
the resistance of the sensor changes and varies the amount of signal returning to the ECM. The amount of signal
returned to the ECM is then converted to a pressure value which can be displayed on the Tech 1. A DTC 66 fault
will store a DTC in the ECM memory but will not turn "ON" the MIL (Service Engine Soon).

AJC refrigerant pressure sensor indicates A/C
refrigerant pressure is below -8 psi (.12 volt)
for 10 seconds.
4.
CKT 380 to 5 volts, checks the circuit, connections

andECM.
This step checks to see if the low voltage signal
was due to an open in the sensor circuit or the 5
volts reference circuit since the prior step
eliminated the pressure sensor.
OR
AJC refrigerant pressure sensor indicates A/C

refrigerant pressure is above 448 psi (4.86
volts) for 10 seconds.
2. Checks to see if the high voltage signal is from a
shorted sensor or a short to voltage in the circuit.
Normally, disconnecting the sensor would make a
normal circuit go to near zero volt.
3. Checks to see if low voltage signal is from the
sensor or the circuit. Jumpering the sensor signal
Diagnostic Aids:
DTC 66 sets when signal voltage falls outside the
or poor connections.
DRIVEABILITY AND EMISSIONS 5.7L (VIN P) 6E.3-A-97
DTC66
(OPEN OR SHORTED)
KEY "ON," ENGINE NOT RUNNING.

USING TECH 1, SCAN VOLTAGE
FOR A/C REFRIGERANT PRESSURE.
ABOVE 1.8 VOL TS
BELOW .1 VOLT
DISCONNECT A/C
SENSOR.
DOES SCAN DISPLAY LESS
THAN 1 VOLT?
A/C REFRIGERANT
PRESSURE SENSOR
SIGNAL CIRCUIT SHORTED
TO VOLTAGE
OR
FAULTY ECM.
FAULTY A/C
REFRIGERANT
PRESSURE SENSOR
CONNECTION
OR
OPEN 808 CKT
OR
FAULTY SENSOR.
~ETWEEN .1 VOL TS
AND 1.8 VOL TS
DISCONNECT A/C REFRIGERANT

PRESSURE SENSOR CONNECTOR.
JUMPER TERMINALS "B" AND "C".
DOES TECH 1 SCAN DISPLAY
ABOVE 4.6 VOLTS?
CODE 6615
INTERMITTE~T. SEE
"DIAGNOSTIC AIDS" OF
FACING PAGE.
REMOVE JUMPER.
CONNECT VOLTMETER FROM
TERMINAL "A" TO "B".
FAULTY A/C
SENSOR CONNECTION
OR
FAULTY AiC
SENSOR.
WITH TEST LIGHT TO B +,

PROBE PRESSURE SENSOR
IS LIGHT "ON"?
FAUL TY 380 CKT ECM

CONNECTION
OR
OPEN CKT 380
OR
FAULTY ECM.
6-9-92
MS 12478
A/CCRUISE
.....-----139 PNK ~ 3PNK
. - - - - - ~ TO OTHER A/C CRUISE
FUSE CIRCUITS
A/C
RELAY
20 AMP
(U/H)
TOIGNITION~3000RN
---+- TO IGNITION
HVAC
~
25AMP
(1/P)
TO HVAC
~ 6 6 LTGRN
BLOWER SWITCH
139
PNK
C100
ECM
> TO REAR
241
BRN
DEFOG SYSTEM
HVAC
CONTROL
ASSEMBLY
762 DK GRN/WHT
---4
B 1
230
I~
I
,__------.-~~._~,.------------459DKGRN/WHT
I
59 DK GRN
CI
--t-4---;:-----------1-LOW PRESSURE
A/CREQUEST
A/CCLUTCH RELAY
CONTROL
A/CSTATUS
CUTOFF SWITCH
~
3 DKGRN---~
450 BLK
A/C
COMPRESSOR
t - - - -.......- - 8 0 8
A/C
REFRIGERANT
PRESSURE
SENSOR
CLUTCH
PROBE
(INSERTED IN
EVAPORATOR)
TO OTHER
808CIRCUITS
BLK
A/C
EVAPORATOR
EMPERATURE
SENSOR
BLK
380 RED/BLK
416 GRY
416 GRY
1 - - - - - - 7 3 2 DK BLU
. (U/H) = LOCATED IN UNDERHOOD ELECTRICAL CENTER

SENSOR GROUND
SENSOR SIGNAL
+ 5 VOLT REFERENCE
A/C EVAPORATOR
TEMPERATURE SENSOR
SIGNAL
SENSOR GROUND
11-492
MS 12472
DTC67
(PRESSURE SENSOR OR A/C CLUTCH CIRCUIT PROBLEM)

The ECM can determine if the A/C compressor clutch is engaged or not engaged through the A/C clutch status
line. If the ECM has grounded the A/C relay, current can flow through the A/C relay to the A/C compressor clutch
and back to the ECM on the A/C status circuit.
When voltage is present at the ECM A/C clutch status terminal, A/C status "ON" will be displayed on the
Tech 1. As the ECM detects that the A/C clutch has cycled "OFF," the ECM will record A/C system pressure from
the A/C refrigerant pressure sensor. If the A/C refrigerant pressure does not increase more than 4 psi when the
A/C clutch is turned back "ON," a DTC 67 will set. This condition can occur if the A/C refrigerant pressure sensor
is fixed at one value, or if the A/C refrigerant pressure sensor ground is open. A DTC 67 will store in ECM
memory but will not turn "ON" the MIL (Service Engine Soon).

1. DTC 67 will set if: the ECM does not detect an A/C
refrigerant pressure change of more than 4 psi
when the A/C clutch has been cycled.
2. If the relay power feed CKT 139 is intermittent,
the A/C clutch status terminal may not detect
voltage when A/C is commanded "ON."
3. If the A/C clutch status line becomes
intermittently open or shorted while the
compressor is "ON," the ECM will be wrongly
detecting the A/C clutch going "ON" and "OFF."
When the ECM falsely detects the clutch cycling
from "ON" to "OFF" and the clutch is remaining
"ON," a DTC 67 will set since no pressure change
was detected.
4. If the A/C compressor clutch is disconnected or if

CKT 59 or CKT 603 or faulty low pressure cut-off
switch is open between the splice and the clutch,
the A/C compressor clutch will not engage, but the
ECM will detect voltage on the A/C status line
which will indicate the clutch is "ON." If the A/C
controls are cycled from "OFF" to "ON" at this
point, a DTC 67 will set since the clutch did not
engage and therefore no pressure change was
detected.
Diagnostic Aids:
An A/C system low on refrigerant (R134a) charge,
could cause a DTC 67 to set. Refer to SECTION lBl
for further A/C diagnosis.
DRIVEABILITY AND EMISSIONS 5.7l (VIN P) 6E3-A-99
DTC67
IF DTC(s) 66, 69 OR 71 ARE PRESENT

USE THOSE CHARTS FIRST.
CLEAR DTC(s).
START ENGINE.
TURNA/C"ON."
DID CLUTCH ENGAGE?

(PRESSURE SENSOR OR A/C CLUTCH CIRCUIT PROBLEM)
USING A SCAN TOOL, OBSERVE A/C REFRIGERANT PRESSURE.

A/C CLUTCH "OFF" FOR 10 SECONDS, THEN CYCLE A/C CLUTCH
"ON" FOR 10 SECONDS.
DID A/C REFRIGERANT PRESSURE INCREASE MORE THAN 4 psi
WHEN A/C CONTROLS WERE TURNED "ON"?
IGNITION "OFF."
DISCONNECT A/C
COMPRESSOR CLUTCH
CONNECTOR.
CONNECT A TEST
LIGHT BETWEEN A/C
CLUTCH HARNESS
CONNECTOR.
START ENGINE.
A/C"ON."
IS TEST LIGHT "ON"?
INTERMITTENT
A/CCLUTCH
CIRCUIT FROM
A/CRELAYTO
SPLICE. SEE
FACING PAGE.
PROBE A/C CLUTCH

TERMINAL" A" WITH TEST
LIGHT TO GROUND.
IS TEST LIGHT "ON"?
FAULTY A/C CLUTCH CONNECTION

OR
OPEN A/C CLUTCH COIL.
DISCONNECT A/CLOW
PRESSURE CUTOFF SWITCH.
PROBE A/CLOW PRESSURE
CUTOFF SWITCH HARNESS
TERMINAL" A" WITH A TEST
LIGHT CONNECTED TO
GROUND.
IS TEST LIGHT "ON"?
OPEN OR SHORTED A/C

CLUTCH CIRCUIT FROM LOW
PRESSURE CUTOFF SWITCH TO
SPLICE.
FAULTY SENSOR CONNECTION

OR
FAULTY SENSOR.

SEE "DIAGNOSTIC AIDS"
ON FACING PAGE.
CKT 603 OPEN OR SHORTED

OR
FAULTY LOW PRESSURE
CUTOFF SWITCH CONNECTION
OR
FAULTY LOW PRESSURE
CUTOFF SWITCH.
12-2-92
NS 15556
A/CCRUISE
r - - - - - - 1 3 9 P N K ~ 3PNK - T O IGNITION
TO OTHER A/C CRUISE
FUSE CIRCUITS
A/C
RELAY
20 AMP
(U/H)
HVAC
TO IGNITION--+-- 300 ORN ~

25AMP
(1/P)
TO HVAC
._66 LT GRN
241
BLOWER SWITCH
BRN
C100
I
TO REAR
DEFOG SYSTEM
HVAC
CONTROL
ASSEMBLY
139
PNK
ECM
A/CREQUEST
BI
A/C CLUTCH RELAY

CONTROL
CI
59 DK GRN ~ ~ - ' : - - - - - - - - - - - LOW PRESSURE
CUTOFF SWITCH
I
~ ~~
r:"l - - -
TO OTHER
SOS CIRCUITS
3 DK G R N - - - - - - 1 ~
450 BLK
A/C
COMPRESSOR
PROBE
(INSERTED IN
EVAPORATOR)
l - - - - - e - - - 8 0 8 BLK
A/C
REFRIGERANT
PRESSURE
SENSOR
CLUTCH
BLK
A/CSTATUS
380 RED/BLK
416 GRY
416GRY
A/C
EVAPORATOR
EMPERATURE
SENSOR
1 - - - - - - 7 3 2 DK BLU
808 BLK
--------t

SENSOR GROUND
SENSOR SIGNAL
+ 5 VOLT REFERENCE
'4./CEVAPORATOR
TEMPERATURE SENSOR
SIGNAL
SENSOR GROUND
11-4-92
MS 12472
DTC68
A/C RELAY CIRCUIT
(SHORTED CIRCUIT)
5.7L (VIN P)
11
F" CARLINE (MFI)
When the ECM detects that A/Chas been requested, the ECM will activate the A/C clutch relay. When the
relay is activated, voltage should be present at both the A/C compressor clutch and the AJC clutch status terminal
at the ECM.
If the ECM detects voltage on the AJC clutch status terminal when the AJC relay has not been commanded
"ON" by the ECM, a DTC 68 will set.
A short to voltage at any point in CKT 59 or CKT 603, a grounded relay control circuit or stuck A/C relay
contacts can set a DTC 68.
A DTC 68 fault will be stored in ECM memory but will not turn "ON" the MIL (Service Engine Soon).

Voltage is detected on the AJC status line for
more than 20 seconds after the ECM has
disengaged the AJC relay.
2. This will isolate the ignition feed portion of the
circuit from the clutch circuit.
3. If DTC 68 reappears at this step the ECM is
internally shorted to voltage.
DTC68
A/C RELAY CIRCUIT
{SHORTED CIRCUIT)
G)
IGNITION "OFF."
A/C "OFF."
DISCONNECT A/C COMPRESSOR CLUTCH.
IGNITION "ON."
PROBE CKT 603 WITH TEST LIGHT TO
GROUND.
IS TEST LIGHT "ON"?
G)
DISCONNECTA/CRELAY.
IS TEST LIGHT "ON"?
CKT 59 OR CKT 603

SHORTED TO VOLTAGE.
FAUL TY A/C RELAY

OR
CKT 459 SHORTED TO
GROUND
OR
FAULTY ECM.
IGNITION "OFF."
DISCONNECT A/C RELAY.
IGNITION "ON."
CLEAR ECM DTC(s).
START ENGINE AND RUN FOR 30
SECONDS.
DOES ECM OTC 68 REAPPEAR?
FAULTY ECM.
10-29-92
NS 15384
A/C CRUISE
.-----'----139 PNK ~ 3PNK ____.. TO IGNITION
.----.........._ TO OTHER A/C CRUISE
FUSE CIRCUITS
A/C
RELAY
20 AMP
(U/H)
TOIGNITION_.._ 3000RN
HVAC
~
25AMP
(1/P)
TOHVAC
~66LTGRN
BLOWER SWITCH
139
PNK
C100
ECM
241
BRN
HVAC
CONTROL
ASSEMBLY
TO REAR
DEFOG SYSTEM
762 DK GRN/WHT ~
I
B1
230
I~
I
1--------,-~~1--~,-----------459DKGRN/WHT
I
CI
59 DK GRN ~ 1 - - - !1- - - - - - - - - - - LOW PRESSURE

CUTOFF SWITCH
r-, _ _- r.l
TO OTHER
3DKGRN---~
808CIRCUITS
450 BLK
A/C
COMPRESSOR
A/C
REFRIGERANT
PRESSURE
SENSOR
CLUTCH
PROBE
(INSERTED IN
EVAPORATOR)
BLK
A/C
EVAPORATOR
EMPERATURE
SENSOR
1 - - - - - - - - 8 0 8 BLK
380 RED/BLK
416 GRY
416GRY
1 - - - - - - 7 3 2 DK BLU
808 BLK

-------1
A/C REQUEST
A/C CLUTCH RELAY
CONTROL
A/C STATUS
SENSOR GROUND
SENSOR SIGNAL
+ 5 VOLT REFERENCE
A/C EVAPORATOR
TEMPERATURE SENSOR
SIGNAL
SENSOR GROUND
DTC69
A/C CLUTCH CIRCUIT
11
When the ECM detects that A/C has been requested, the ECM will activate the A/C clutch relay. When the
relay has been activated, voltage should be present at both the A/C compressor clutch and the A/C clutch status
line terminal of the ECM.
If the ECM activates the A/C clutch relay but does not detect voltage present at the AJC clutch status
terminal for more than 20 seconds, a DTC 69 will set.
An open or short to ground at any point in CKT 59 or CKT 603 will cause DTC 69 to set.
A DTC 69 fault will be stored in the ECM memory but will not turn "ON" the MIL (Service Engine Soon).

ECM has commanded A/C "ON."
No voltage detected on AJC status line for more
than 20 seconds.
2. If the A/C clutch operates properly and the Tech 1
shows A/C clutch status "OFF," then an open
exists between the ECM and the splice to the
compressor.
DTC69
G)
A/C CLUTCH CIRCUIT

CLEAR ECM DTC(s).
START ENGINE.
CYCLE A/C CLUTCH CONTROLS TO "ON"
AND "OFF" WITHIN 20 SECONDS.
DOES A/C CLUTCH OPERA TE PROPERLY?
IGNITION "OFF."
IGNITION "ON."
PROBE RELAY HARNESS TERMINALS "81"
AND "82" WITH A TEST LIGHT TO GROUND.
OR
OPEN CKT 59 FROM SPLICE TO ECM
OR
FAULTY ECM.
LIGHT "ON" BOTH

PROBE RELAY HARNESS TERMINAL "BS"
WITH TEST LIGHT TO B +.
OPEN IN CKT 139 THAT DID NOT LIGHT.
JUMPER RELAY HARNESS

TERMINALS "84" TO "82".
DOES A/C CLUTCH ENGAGE?
OPEN A/C CLUTCH RELAY

CONTROL CIRCUIT
OR
OR
FAULTY ECM.
FAUL TY A/C RELAY CONNECTION

OR
FAUL TY A/C RELAY.
IS INTERMITTENT.
OPEN IN CKT 59 FROM RELAY TO SPLICE.
10-29-92
MS 12317
A/CCRUISE
...------139 PNK ~ 3PNK -----+- TO IGNITION

. . . . - - - - ~ TO OTHER A/C CRUISE
FUSE CIRCUITS
A/C
RELAY
20 AMP
(U/H)
TO IGNITION-+-- 300 ORN
HVAC
~
25AMP
(1/P)
TO HVAC
~ 66 LT GRN
BLOWER SWITCH
C100
59 DK GRN
TO REAR
DEFOG SYSTEM
Jo
241
BRN
HVAC
CONTROL
ASSEMBLY
139
PNK
I
I
ECM
A/CREQUEST
I
I
KB I
A/C CLUTCH RELAY

CONTROL
CI
A/CSTATUS
~ 1 - - - - '1' - - - - - - - - - - - - -
LOW PRESSURE
CUTOFF SWITCH
r:, - -
I.I
3DKGRN-----1~
450 BLK
A/C
COMPRESSOR
A/C
REFRIGERANT
PRESSURE
SENSOR
CLUTCH
PROBE
(INSERTED IN
EVAPORATOR)
BLK
A/C
EVAPORATOR
TEMPERATURE
SENSOR
TO OTHER
808CIRCUITS
1----------808 BLK
380 RED/BLK
416GRY
416 GRY
t - - - - - - - 7 3 2 DK BLU
SENSOR GROUND
SENSOR SIGNAL
+ 5 VOLT REFERENCE
A/C EVAPORATOR
TEMPERATURE SENSOR
SIGNAL
SENSOR GROUND

114-92
MS 12472
DTC71
(OPEN OR SHORTED)

The AJC system uses an AJC evaporator temperature sensor mounted in the AJC evaporator core to monitor
AJC temperature for use by the ECM. The ECM uses this information to cycle the AJC compressor clutch "ON"
and "OFF," so optimum cooling is attained. The A/C evaporator temperature sensor will also prevent A/C
evaporator core freeze up. The ECM will disable the A/C compressor clutch whenever A/C evaporator
temperature is below 2C (36F).
The AJC evaporator temperature sensor contains a two wire probe (thermistor) that is positioned in the center
of the evaporator core. The two wire probe is part of the A/C evaporator temperature sensor interface module.
The interface module works in conjunction with the ECM to determine AJC evaporator temperature. A OTC 71
fault will be stored in the ECM memory but will not turn on the MIL (Service Engine Soon).

AJC requested.
The ECM detects an open, short to ground or a
short to voltage in the A/C evaporator
temperature circuits.
2. With the A/C evaporator temperature sensor
harness disconnected, normal voltage on CKT 732
is near 5 volts. If a short to voltage is suspected,
reconnect sensor harness and back probe terminal
"B" of sensor harness using a OVM. If 5 volts or
more is indicated, then CKT 732 is shorted to
voltage.
Diagnostic Aids:
The A/C evaporator temperature sensor and
harness is located under the passenger side
instrument panel.
If A/C evaporator temperature sensor needs to be
replaced, refer to SECTION lB.
DRIVEABIUTY AND. EMISSIONS S..1L (VIN P) 6E3-A-105
OTC 71
(OPEN OR SHORTED)

USING A TECH 1, MONITOR A/C EVA PORA TOR TEMPERATURE.
IS A/C EVAPORATOR TEMPERATURE -7C (19F) OR 32C (90F).
DISCONNECT A/C EVAPORATOR TEMPERATURE SENSOR.

PROBE TERMINAL "C" OF A/C EVAPORATOR TEMPERATURE
SENSOR HARNESS WITH A TEST LIGHT TO B +.
RECONNECT SENSOR HARNESS.

BACK PROBE TERMINAL "B" OF
A/C EVAPORATOR
TEMPERATURE SENSOR
HARNESS WITH A DVM TO
GROUND.
IS 5 VOL TS OR MORE
INDICATED?
DISCONNECT A/C EVAPORATOR

TEMPERATURE SENSOR.
DOES TECH 1 DISPLAY A/C
OF 32C (90F}.
IGNITION "OFF."
DISCONNECT ECM
CONNECTOR "C".
PROBE TERMINAL "B" OF
A/C EVAPORATOR
TEMPERATURE SENSOR
HARNESS WITH A TEST
LIGHT TO B+.
DOES TEST LIGHT
ILLUMINATE?
FAULTY A/C
EVAPORATOR
TEMPERATURE
SENSOR.
DISCONNECT A/C
SENSOR.
MEASURE VOLTAGE AT
TERMINAL "B" OF A/C
SENSOR HARNESS.
FAULTY A/C EVAPORATOR

TEMPERATURE SENSOR
CONNECTION
OR
FAULTY A/C EVAPORATOR
TEMPERATURE SENSOR.
CKT 732 OPEN

OR
FAULTY ECM
CONNECTION
OR
FAULTY ECM.
"AFTER REPAIRS." REFER TO DTC CRITERIA ON FACING PAGE AND CONFIRM DTC DOES NOT RESET.
11-6-92
NS 15560
BLANK
DRIVEABILITY AND EMISSIONS S.7L (VIN P) 6E3-B-1
SECTION B
SYMPTOMS
CONTENTS
Important Preliminary Checks
. ..
...........
. . ..
Before Starting
Symptom
Visual/Physical Check
..
lntermittents ( 1 of 2)
Hard Start
...
Surges and/or Chuggles

Lack of Power, Sluggish or Spongy
Detonation/Spark Knock
. ..
......
.. .
. . .. . . . . . . . . . .
.....
. ..
...
....
.....
....
. ...
.....
... .... .
. . .. . . . .
. . . . . . . . .. . .
. .. . . . . . . . . . . . . . .
........
...
.. .....
. . . . . . . . . ..
...
.. . .
....
.......
. .... .... .
........
. ... . . . . . . . .. .
...
Page B-2
Page B-2
Page B-2
Page B-2
Page B-3
Page B-5
Page B-6
Page B-7
Page B-8
Hesitation, Sag, Stumble
Page B-9
Cuts Out, Misses (1 of 2)

Rough, Unstable, or Incorrect Idle, Stalling (1 of 2)
Poor Fuel Economy
Page B-10
Page B-12
Page B-14
Excessive Exhaust Emissions or Odors

Dieseling, Run-On
Backfire
Page B-16
Page B-17
Restricted Exhaust System Check - Chart B-1

ECM Connector "A" Symptom Chart
Page B-18
Page B-19
ECM Connector "B" Symptom Chart
Page B-20
Page B-21
Page B-22
ECM Connector "C" Symptom Chart

ECM Connector "D" Symptom Chart
Page B-15
6E3-B-2 5. 7L (VIN P) DRIVEABILITY AND EMISSIONS
IIMPORTANT PRELIMINARY CHECKS-]
BEFORE STARTING
Before using this section you should have performed the "On-Board Diagnostic (OBD) System
Check" and determined that:
1. The ECM and Malfunction Indicator Lamp (MIL) "Service Engine Soon" are operating
correctly.
2. There are no Diagnostic Trouble Codes (DTCs) stored, or if there is a DTC but no MIL
(Service Engine Soon).
SYMPTOM
Verify the customer complaint, and locate the correct symptom in the table of contents. Check
the items indicated under that symptom.
VISUAUPHYSICAL CHECK
Several of the symptom procedures call for a Careful Visual/Physical Check. The importance of
this step cannot be stressed too strongly - it can lead to correcting a problem without further checks
and can save valuable time. This check should include:
ECM grounds for being clean, tight and in their proper location.
Vacuum hoses for splits, kinks, and proper connections, as shown on "Vehicle Emission
Control Information" label. Check thoroughly for any type ofleak or restriction.
Air leaks at throttle body mounting area and intake manifold sealing surfaces.
Ignition wires for cracking, hardness, proper routing and carbon tracking.
Wiring for proper connections, pinches and cuts.
DRIVEABILITY AND EMISSIONS 5.7L {VIN P) 6E3-B-3
INTERMITTENTS
{Page 1 of 2)
Definition: Problem may or may not turn "ON" the
Malfunction Indicator Lamp (MIL) "Service
Engine Soon" or store a DTC.
DO NOT use the diagnostic trouble code charts in "Engine Components/Wiring

Diagrams/Diagnostic Charts," Section "6E3-A" for intermittent problems. The fault must be present
to locate the problem:
Most intermittent problems are caused by faulty electrical connections or wiring. Perform
careful visual/physical check as described at start of "Symptoms," Section "6E3-B". Check for:
Poor mating of the connector halves or a terminal not fully seated in the connector body
(backed out).
Improperly formed or damaged terminal. All connector terminals in the problem circuit
should be carefully reformed or replaced to insure proper contact tension.
Poor terminal to wire connection. This requires removing the terminal from the connector
body to check. Refer to SECTION SA for "Wiring Harness Service."
If a visual/physical check does not find the cause of the problem, the vehicle may be driven with a
voltmeter (J 39200) connected to a suspected circuit. A Tech 1 can also be used to help detect
intermittent conditions. An abnormal voltage, or scan reading, when the problem occurs,
indicates the problem may be in that circuit. If the wiring and connectors check OK, and a
diagnostic trouble code was stored for a circuit having a sensor, except for DTCs 43, 44, 45, 64,
and 65 substitute a known good sensor and recheck.
Loss of diagnostic trouble code memory. To check, disconnect MAP and idle engine until MIL
(Service Engine Soon) comes "ON." DTC 34 should be stored, and kept in memory when ignition
is turned "OFF." If not, the ECM is faulty.
An intermittent MIL (Service Engine Soon) with no stored DTC may be caused by:
Ignition coil shorted to ground and arcing at ignition wires or plugs.
MIL (Service Engine Soon) wire to ECM shorted to ground (CKT 419).
Diagnostic "test" terminal wire to ECM, shorted to ground (CKT 448).
ECM grounds, refer to ECM wiring diagrams.
6E3-B-4 5.7L (VIN P) DRIVEABILITY AND EMISSIONS
INTERMITTENTS
(Page 2 of2)
Definition:
Problem may or may not turn "ON" the

Malfunction Indicator Lamp I MIL) "Service
Engine Soon" or store a DTC.
--
Check for an electrical system interference caused by a defective relay, ECM driven solenoid, or
switch. They can cause a sharp electrical surge. Normally, the problem will occur when the
faulty component is operated.
Check for improper installation of electrical options such as lights, cellular phones, etc .
Ignition Control (IC) wires should be routed away from ignition wires, distributor, ignition coil
and generator. Wire from ECM to distributor (CKT 632) should have a good connection.
Check for open diode across NC compressor clutch, and for other open diodes (refer to wiring
diagrams).
If problem has not been found, refer to "ECM Connector Symptom" charts at the end of
DRIVEABILITY AND EMISSIONS 5.7L (VIN P) 6E3-B-5
HARD START
Definition:
Engine cranks OK, but does not start for a

long time. Does eventually run, or may start
but immediately stalls.
PRELIMINARY CHECKS
Make sure the driver is using the correct starting procedure.
SENSORS
CHECK: Engine Coolant Temperature (ECT) sensor using a Tech 1, compare engine coolant
temperature with ambient temperature on a cold engine.

If engine coolant temperature readings is 5 degrees greater than or less than
ambient air temperature on a cold engine, check resistance in ECT circuit or sensor
itself. Compare ECT resistance value to the "Diagnostic Aids" chart on DTC 15
chart.
CHECK: MAP sensor, use CHART C-lD.
CHECK: TP sensor for binding or a high TP sensor voltage with the throttle closed (should read
between ,l_ and .9 volt).
FUEL SYSTEM
CHECK: Fuel pump relay operation - pump should turn "ON" for 2 seconds when ignition is
turned "ON." Use CHART A-5.

CHECK: Both injector fuses (visual inspect).
NOTICE: A faulty in-tank fuel pump check valve will allow the fuel in the lines to drain back to
the tank after engine is stopped. To check for this condition, perform fuel system diagnosis
CHARTA-7.
IGNITION SYSTEM
CHECK: For proper ignition voltage output with spark tester J 26792 (ST-125).

CHECK: Bare or shorted ignition wires.
CHECK: Loose ignition coil ground.
ADDITIONAL CHECKS
CHECK: IAC operation - use CHART C-2C.
CHECK: Basic engine problem. Refer to SECTION 6A.
CHECK: For correct PROM. (Refer to Service Bulletins).
6E3-B-6 5. 7L (VIN P) DRIVEABILITY AND EMISSIONS
SURGES AND/OR CHUGGLES

Definition:
Engine power variation under steady

throttle or cruise. Feels like the vehicle
speeds up and slows down with no change in
the accelerator pedal.
PRELIMINARY CHECKS
Perform the careful visual/physical check as described at start of "Symptoms," Section ''6E3-B".
Be sure driver understands transmission torque converter clutch, and NC compressor operation
as explained in the owner's manual.
SENSORS
CHECK: Oxygen Sensors (028). The 028 should respond quickly to different throttle positions, if
they don't, check the Oxygen Sensors (028) for silicon or other contaminations from fuel,
or use of improper RTV sealant. The sensors may have a white powdery coating and
result in a high but false signal voltage (rich exhaust indication) The ECM will then
reduce the amount of fuel delivered to the engine, causing a severe driveability problem.
For more information, refer to "Engine Control Module (ECM) and Sensors," Section
"6E3-Cl".
FUEL SYSTEM
driven at the speed of the complaint. Monitoring long term fuel trim will help identify a
problem.
Lean - Long term fuel trim near 160. Refer to "Diagnostic Aids" on facing page of DTCs 44 and
64.
Rich - Long term fuel trim near 108. Refer to "Diagnostic Aids" on facing page of DTCs 45 and
65.
CHECK: Fuel pressure while condition exists, use CHART A-7.
CHECK: In-line fuel filter. Replace if dirty or plugged.
IGNITION SYSTEM
CHECK: For proper ignition voltage output using spark tester ,J 26792 (ST-125).

condition of distributor cap, rotor and ignition wires.
ADDITIONAL CHECKS
CH ECK:
CHECK:
CHECK:
CHECK:
ECM grounds for being clean, tight and in their proper location.
Vacuum lines for kinks or leaks.
EGR - There should be no EGR at idle, use CHART C-7.
Generator output voltage. Repair if less than 9 volts or more than 16 volts.
Also, check
DRIVEABILITY AND EMISSIONS 5. 7L (VIN P) 6E3-B-7
LACK OF POWER, SLUGGISH OR SPONGY

Definition:
Engine delivers less than expected power.

Little or no increase in speed when accelerator
pedal is pushed down part way.
PRELIMINARY CHECKS
Compare customer's vehicle to similar unit. Make sure the customer has an actual problem.
Remove and check air filter for dirt, or for being plugged. Replace as necessary.
FUEL SYSTEM
CHECK: Restricted fuel filter.
IGNITION SYSTEM
CHECK: Knock Sensor (KS) system for excessive spark retard activity. Refer to CHART C-5.
CHECK: Secondary voltage using a shop oscilloscope or a spark tester J 26792 (ST-125), to check
for a weak coil.
ADDITIONAL CHECKS
CHECK: ECM grounds for being clean, tight and in their proper locations. Refer to ECM wiring
diagrams.
CHECK: EGR operation for being open or partly open all the time.
Use CHART C-7.

CHECK: Generator output voltage. Repair ifless than 9 volts or more than 16 volts.
CHECK: Exhaust system for possible restriction, use CHART B-1.
Inspect exhaust system for damaged or collapsed pipes.

Inspect mufflers for heat distress or possible internal failure.
For possible plugged oxidation catalytic converter. Check back pressure by
removing AIR check valves near exhaust manifolds.
CHECK: Torque Converter Clutch (TCC) for proper operation. Refer to SECTION 7A.
ENGINE MECHANICAL
CHECK: Engine valve timing and compression. Refer to SECTION 6A.
CHECK: Engine for correct or worn camshaft. Refer to SECTION 6A.
DETONATION/SPARK KNOCK
Definition:
A mild to severe ping, usually worse under

acceleration. The engine makes sharp metallic
knocks that change with throttle opening.
PRELIMINARY CHECKS
Park/Neutral Position (PNP) signal. Be sure Tech 1 indicates drive with gear selector in drive or
overdrive, use CHART C-lA.
If Tech 1 readings are normal (refer to typical Tech 1 data) and there are no engine mechanical
faults, fill fuel tank with a premium gasoline that has a minimum' octane rating of 92 and reevaluate vehicle performance.
CHECK: EGR system for not opening, use CHART C-7.
CHECK: TCC operation, TCC applying too soon, use CHART C-8.
COOLING SYSTEM
Check for obvious overheating problems:

Low engine coolant.
Restricted air flow to radiator, or restricted water flow through radiator.
Inoperative electric cooling fan circuit, use CHART C-12.
Correct coolant solution should be a 50/50 mix of GM #1052753 or equivalent anti-freeze
coolant and water,
FUEL SYSTEM
driven at the speed of the complaint. Monitoring long term fuel trim will help identify problem.
Lean - Long term fuel trim near 160. Refer to "Diagnostic Aids" on facing page of DTCs 44 and 64.
Rich - Long term fuel trim near 108. Refer to "Diagnostic Aids" on facing page of DTCs 45 and 65.
IGNITION SYSTEM
CHECK: Spark plugs for proper heat range. Refer to "Owner's Manual."
CHECK: Knock sensor system for no retard, use CHART C-5.
ENGINE MECHANICAL
CHECK: For excessive oil in the combustion chamber.
Valve oil seals for leaking.

CHECK: Combustion chambers for excessive carbon build up.
Remove carbon with top engine

cleaner and follow instructions on can.
CHECK: Perform a cylinder compression test. Refer to SECTION 6A.
CHECK: For incorrect basic engine parts such as cam, heads, pistons, etc.
ADDITIONAL CHECKS
CHECK: For correct PROM. (Refer to Service Bulletins.)
DR1VEABILITY AND EMISSIONS 5. 7L (VIN P) 6E3-B-9
HESITATION, SAG, STUMBLE

Definition:
Momentary lack of response as the accelerator is

pushed down. Can occur at all vehicle speeds.
Usually more severe when first trying to make
the vehicle move, as from a stop sign. May cause
engine to stall if severe enough.
PRELIMINARY CHECKS
SENSORS
CHECK: TP sensor - Check TP sensor for binding or sticking. TP sensor signal voltage should
increase at a steady rate as throttle is moved toward Wide Open Throttle (WOT).
CHECK: MAPsensor-useCHARTC-lD.
FUEL SYSTEM
CHECK: Evaporative Emission (EVAP) canister purge system for proper operation, use
CHARTC-3.
CHECK: Fuel injectors. Perform injector balance test, use CHART C-2A.
IGNITION SYSTEM
CHECK: Spark plugs for being fouled, or for there being faulty secondary wiring.
CHECK: Ignition system ground.
ADDITIONAL CHECKS
CHECK:
CHECK:
CHECK:
CHECK:
For correct PROM. (Refer to Service Bulletins.)

EGRoperation, use CHART C.-7.
Engine thermostat functioning correctly and proper heat range.
Generator output voltage. Repair ifless than 9 or more than 16 volts.
6E3-B-10 5. 7L (VIN P) DRIVEABIUTY AND EMISSIONS
CUTS OUT, MISSES

(Page 1 of 2)
Definition:
Steady pulsation or jerking that follows engine

PRELIMINARY CHECKS
CYLINDER BALANCE TEST

Check for cylinder miss by:
1. Start engine, allow engine to stabilize, then disconnect IAC connector. Disconnect each
injector harness one at a time.
2. If there is an RPM drop on all cylinders (equal to within 50 RPM), go to "Rough, Unstable, or
Incorrect Idle, Stalling" symptom. Reconnect IAC connector.
3. If there is no RPM drop on one or more cylinders, or excessive variation in drop, check for
spark on the suspected cylinder(sl using a shop oscilloscope or with J 26792 (ST-125) spark
tester.
CHECK: Distributor cap for cracks. Refer to SECTION 6D.
With engine running, spray cap and ignition wires with fine water mist to check for
shorts.
CHECK: Ignition wires by connecting ohmmeter to ends of each wire being tested. If meter
displays over 30,000 ohms, replace wire(s).
If spark occurs:
CHECK: Spark plugs:
Insulator cracks.
Wear.
Improper gap.
Burned electrodes.
Heavy deposits.
CHECK: Injector drive circuits using J 34730-2C injector test light.
1. Disconnect harness from injectors.
2. Install injector test light and observe light while cranking.
3. If light fails to blink at any connector, it is a faulty injector drive circuit connector or
terminal or open harness. If injector drive circuit checks OK, perform injector
balance test. Refer to CHART C-2A.
CHECK: Fuel system - Plugged fuel filter, low pressure, use CHART A-7.
CUTS OUT, MISSES

(Page 2 of 2)
Definition: Steady pulsation or jerking that follows engine

ENGINE MECHANICAL
CHECK: Compression. Perform compression check on questionable cylinder(s). If compression is
low, repair as necessary. Refer to SECTION 6A.

CHECK: Base engine. Remove rocker covers, check for bent pushrods, worn rocker arms, broken
valve springs, worn camshaft lobes and valve timing, repair as necessary.
SECTION6A.
Refer to
ADDITIONAL CHECKS
CHECK: For electromagnetic interference.
An engine miss condition can be caused by

electromagnetic interference on the reference circuit. Electromagnetic interference can
usually be detected by monitoring engine RPM with a scan tool. A sudden increase in
RPM with little change in actual engine RPM indicates electromagnetic interference is
present. If the problem exists, check routing of secondary ignition wires, check
distributor ground circuit.
CHECK: Intake and exhaust manifold passage for casting flash.

STALLING
(Page 1 of 2)
Definition:
Engine runs unevenly at idle. If severe, the engine

or vehicle may shake. Engine idle speed may vary
in RPM. Either condition may be severe enough to
stall the engine.
PRELIMINARY CHECKS
Perform the careful visual/physical checks as described at start of"Symptoms,'' Section "6E3-B".

CHECK: ECM grounds for being clean, tight and proper routing. Refer to ECM wiring diagrams.
FUEL SYSTEM
NOTICE: Monitoring long term fuel trim will help identify the cause of the problem. If the
system is running lean (long term fuel trim near 160), refer to "Diagnostic Aids" on facing page
of DTCs 44 and 64. If the system is running rich (long term fuel trim near 108), refer to
"Diagnostic Aids" on facing page of DTCs 45 and 65.
CHECK: Incorrect minimum idle speed may be caused by foreign material accumulation in the
CHECK:
CHECK:
CHECK:
CHECK:
CHECK:
throttle bore, coking on the throttle valve or on the throttle shaft, or throttle body
tampering.
For injectors that are shorted internally. Compare injector resistance. Injector
resistance should be within one ohm of each other.
Injector balance, use CHART C-2A.
For fuel in pressure regulator hose. If fuel is present, replace regulator assembly.
Evaporative Emission (EVAP) control system, use CHART C-3.
The Oxygen Sensors (02S) should respond quickly to different throttle positions, if they
don't, check the Oxygen Sensors (02S) for silicon contamination from fuel, or use of
improper RTV sealant. The sensors will have a white powdery coating, and will result in
a high but false signal voltage (rich exhaust indication). The ECM will then reduce the
amount of fuel delivered to the engine, causing a severe driveability problem. Refer to
"Engine Control Module (ECM) and Sensors," Section "6E3-Cl" for more information.
IGNITION SYSTEM
CHECK: For proper ignition voltage output with spark tester J 26792 (ST-125).
ENGINE MECHANICAL
CHECK: Perform a cylinder compression check. Refer to SECTION 6A.
CHECK: For correct camshaft or weak valve springs. Refer to SECTION 6A.

STALLING
(Page 2 of 2)
Definition: Engine runs unevenly at idle. If severe, the engine
or vehicle may shake. Engine idle speed may vary

in RPM. Either condition may be severe enough to
stall the engine.
ADDITIONAL CHECKS
CHECK: MAP sensor, use CHART C-lD.
CHECK: Throttle linkage for sticking or binding.
CHECK: PNP switch circuit. Use CHART C-lA, or use Tech 1 and be sure scan tool indicates
vehicle is in drive with gear selector in drive or overdrive.

CHECK: IAC operation, use CHART C-2C.
CHECK: EGR valve. There should be no EGR at idle, use CHART C-7.
CHECK: AJC signal to ECM, Tech 1 should indicate AJC is being requested when ever A/C is
selected. If problem exists with AJC "ON," check AJC system operation, use CHART Cl 0.
CHECK: Check AIR system. There should be no AIR to exhaust ports while in "Closed Loop." Use
CHARTC-6.
CHECK: Crankcase ventilation valve for proper operation by placing finger over inlet hole in
valve end several times. Valve should snap back. If not, replace valve. Refer to
"Crankcase Ventilation System," Section "6E3-Cl3".

CHECK: For correct PROM (see Service Bulletins).
CHECK: For broken motor mounts.
CHECK: Generator output voltage. Repair if less than 9 or more than 16 volts.
6E3-B-14 5.7L (VIN P) ORIVEAlUUTY AND EMISSIONS

.
.
POOR FUEL ECONOMY.
Definition:
Fuel economy, as measured by an actual road

test, is noticeably lower. than expected. Also,
economy is noticeably lower than it was .on
this vehicl.e at one time, as previously shown
by an actual road test.
PRELIMINARY CHECKS
Perform the careful visual/physical check as described at start of"Symptoms," Section "6E3-B".
Visually (physically) check: Vacuum hoses for splits, kinks, and proper connections as shown on
"Vehicle Emission Control Information" label.
Check owner's driving habits.
- Is A/C "ON" full time (Defroster mode "ON")?
- Are tires at correct pressure?
- Are excessively heavy loads being carried?
- Is acceleration too much, too often?
Check air cleaner element (filter) for being dirty or plugged.
IGNITION SYSTEM
CHECK: Spark plugs.
Remove spark plugs, check for wet plugs, cracks, wear, improper gap,
burned electrodes, or heavy deposits. Repair or replace as necessary..
COOLING SYSTEM
CHECK: Engine thermostat for faulty part or for wrong heat range. Refer to SECTION 68.
ENGINE MECHANICAL
CHECK: Compression. Refer to SECTION 6A.
ADDITIONAL CHECKS
CHECK: TCC operation. Use CHART C-8. A Tech 1 should indicate an RPM drop, when the TCC
is commanded "ON."
CHECK: For exhaust system restriction, use CHART B-1.
CHECK: For proper calibration of speedometer.
CHECK: Air intake system and crankcase for air leaks.
EXCESSIVE EXHAUST EMISSIONS OR ODORS

Definition:
Vehicle fails an emission test. Vehicle has

excessive "rotten egg" smell. (Excessive odors do
not necessarily indicate excessive emissions.)
PRELIMINARY CHECKS
Perform "On-Board Diagnostic (OBD) System Check."

If emission test shows excessive CO and HC check items which can cause an engine to run RICH
(long term fuel trim near 108), refer to "Diagnostic Aids" on facing page of DTCs 45 and 65.
If emission test shows excessive NOx, check items which can cause an engine to run lean or too
hot.
COOLING SYSTEM
If the Tech l indicates a very high engine coolant temperature and the system is running lean:
- CHECK: Engine coolant level.
- CHECK: Engine thermostat for faulty part or for wrong heat range. Refer to SECTION GB.
- CHECK: Cooling fan operation, use CHART C-12.
FUEL SYSTEM
NOTICE: If the system is running rich (longterm fuel trim near 108), refer to "Diagnostic Aids"
on facing page of DTCs 45 and 65.
If the system is running lean (long term fuel trim near 160) refer to "Diagnostic Aids" on facing
page of DTCs 44 and 64.
CHECK:
CHECK:
CHECK:
CHECK:
For properly installed fuel cap.

Fuel pressure, use CHART A-7.
Injector balance test, use CHART C-2A.
EV AP canister for fuel loading, use CHART C-3.
IGNITION SYSTEM
CHECK: Spark plugs, ignition wires, and ignition components. Refer to SECTION 6D.
ADDITIONAL CHECKS
CHECK: EGR valve for not opening, use CHART C-7.
CH ECK: For lead contamination of oxidation catalytic converter (look for the removal of fuel filler
neck restrictor).
CHECK: Carbon build-up. Remove carbon with top engine cleaner. Follow instructions on can.
CHECK: Crankcase ventilation valve for being plugged, stuck or blocked crankcase ventilation
hose or fuel in the crankcase.

CHECK: For correct PROM (see Service Bulletins).
DIESELING, RUN-ON
Definition:
Engine continues to run after key is turned

"OFF," but runs very roughly. If engine runs
smoothly, check ignition switch and
adjustment.
PRELIMINARY CHECKS
FUEL SYSTEM
CHECK: Injectors for leaking. Refer to "Fuel System Diagnosis" CHART A-7.
BACKFIRE
Definition:
Fuel ignites in its intake manifold, or in

exhaust system, making loud popping
noise.
PRELIMINARY CHECKS
IGNITION SYSTEM
CHECK: Proper ignition coil output voltage with spark tester J 26792 (ST-125).

CHECK: Ignition wires for crossfire, also inspect distributor cap, ignition wires, and proper
routing of ignition wires.
NOTICE: If an intermittent condition exists in the distributor ignition system, refer to

"Distributor Ignition (DI) System," Section "6E3-C4" or SECTION 6D.
ENGINE MECHANICAL
CHECK: Compression - Look for sticking or leaking valves, worn camshaft lobe, refer to
SECTION6A.
CHECK: Valve timing, refer to SECTION 6A.
CHECK: Intake and exhaust manifold passages for casting flash.
FUEL SYSTEM
CHECK: Perform fuel system diagnosis check, use CHART A-7.
CHECK: Fuel injectors. Perform injector balance test, use CHART C-2A.
ADDITIONAL CHECKS
CHECK: EGR gasket for faulty or loose fit.
CHECK: EGR operation for being open all the time, use "Exhaust Gas Recirculation (EGR)"
CHARTC-7.
CHECK: Secondary air injection system, use CHART C-6.
CHECK: Intake and exhaust manifold for casting flash.
CHART 8-1
RESTRICTED EXHAUST SYSTEM CHECK
ALL ENGINES
Proper diagnosis for a restricted exhaust system is essential before any components are replaced.
CHECK AT AIR PIPE: (Left and Right Side AIR Pipes)

1.
2.
3.
Remove the rubber hose at the exhaust manifold AIR pipe check valve. Remove check valve.
Connect Exhaust Backpressure kit (with air adapter) J 35314-A.
Insert the nipple into the exhaust manifold AIR pipe.
DIAGNOSIS:
1.
2.
3.
4.
5.
With the engine idling at normal operating temperature, observe the exhaust system backpressure
reading on the gage. Reading should not exceed 8.6 kPa (1.25 psi).
Increase engine speed to 2000 RPM and observe gage. Reading should not exceed 20. 7 kPa (3 psi).
If the backpressure at either speed exceeds specification, a restricted exhaust system is indicated.
Inspect the entire exhaust system for a collapsed pipe, heat distress, or possible internal muffier failure.
If there are no obvious reasons for the excessive backpressure, the oxidation catalytic converter is
suspected to be restricted and should be replaced using current recommended procedures.
11-10-92
NS 16209
11
ECM PIN CONNECTOR A" SYMPTOM CHART

GRAY 22 PIN CONNECTOR
PIN FUNCTION
CKT
WIRE
COLOR
COMPONENT
CONNECTOR
CAVITY
DTC(s)
AFFECTED
POSSIBLE SYMPTOMS
FROM FAUL TY CIRCUIT
A1
EVAP CANISTER PURGE

CONTROL
428
DKGRN/
WHT
EVAP CANISTER
SOLENOID VALVE" A"
26 (3)
45 (2)
FUEL ODOR, ROUGH IDLE.
A2
EGR SOLENOID VALVE

CONTROL
435
GRY
EGR SOLENOID VALVE

"B"
26 (3)
32 (3)
DETONATION, STALL, ROUGH IDLE,

POOR PERFORMANCE.
A4
IACCOIL "A" HIGH
1747
LT BLU/
WHT
IAC VALVE" A"
(3)
INCORRECT IDLE, SURGE, STALLING.
AS
IAC COIL "B" LOW
444
LT GRN/
BLK
IAC VALVE "D"
(3)
A6
MIL (SERVICE ENGINE

SOON) CONTROL
419
BRN/
WHT
436
BRN
AIR RELAY "E2"
26(3)
INOPERATIVE AIR PUMP MOTOR, AIR

PUMP ON AT ALL TIMES.
A3
NOMIL
MIL "ON" ALL THE TIME.
A7
AS
A9
A10
IACCOIL "A" LOW
1748
LT BLU/
BLK
IAC VALVE "B"
(3)
A11
IAC COIL "B" HIGH
1749
LT GRN/
WHT
IAC VALVE "C"
(3)
A12
IGNITION CONTROL
423
WHT
IGNITION COIL
MODULE "B"
41,42(3)
A13
ECTSIGNAL
410
YEL
ECT "B"
14 (2)
15 (1)
PASS-KEYII
229
DKBLU
PASS-KEYII MODULE
"A3"
A21
PNPSIGNAL
434
ORN/BLK
PNP SWITCH "B"
A22
A/C REQUEST
762
DKGRN/
WHT
HVAC CONTROL
ASSEMBLY" A"
ENGINE CRANKS, BUT WILL NOT START.

HARD STARTING EXHAUST ODOR,
ROUGH IDLE, POOR FUEL ECONOMY,
LACK OF PERFORMANCE.
A14
A15
A16
A17
A18
A19
ENGINE CRANKS BUT WILL NOT START.
A20
(1)
(2)
(3)
POOR FUEL ECONOMY, STALL

INCORRECT IDLE.
(3)
A/C INOPERATIVE
OPEN CIRCUIT.
GROUNDED CIRCUIT.
OPEN/GROUNDED CIRCUIT.
REFER TO SECTION SA.
11-16-92
MS 12082
ECM Connector "A" Symptom Chart
ECM CONNECTOR "B" SYMPTOM CHART

RED 22 PIN CONNECTOR
COMPONENT
CONNECTOR
CAVITY
DTC(s)
AFFECTED
LTGRN
REVERSE LOCKOUT
SOLENOID "A"
27 (3)
UNABLE TO SHIFT INTO REVERSE OR WILL

GO INTO REVERSE AT ANY SPEED.
422
TAN/BLK
TCC SOLENOID "D"
27 (3)
POOR FUEL ECONOMY.

CHUGGLE.
808
BLK
MAP"A",IAT"A",
A/C REFRIGERANT
PRESSURE SENSOR
23 (1)
33 (1)
67 (1)
ROUGH IDLE, LACK OF PERFORMANCE.

EXHAUST ODOR, INOPERATIVE A/C.
PIN FUNCTION
CKT#
WIRE
COLOR
81
REVERSE LOCKOUT
SOLENOID
1652
82
TCC
83
MAP, IAT, & A/C

REFRIGERANT
PRESSURE SENSOR
GROUND
"A''
POSSIBLE SYMPTOMS
71
A/C EVAPORATOR
TEMPERATURE
SENSOR "C"
84
PRIMARY COOLING
FAN CONTROL
335
DKGRN
PRIMARY COOLING
FAN RELAY "02"
28 (3)
INOPERATIVE PRIMARY COOLING FAN.

PRIMARY COOLING FAN "ON" AT All
TIMES.
85
A/C CLUTCH RELAY

CONTROL (C60
OPTION)
459
DKGRN/WHT
A/C RELAY "85"
28 (3)
INOPERATIVE A/C CLUTCH ( 1 ).

A/C "ON" AT All TIMES (2).
86
ECMGROUND
451
BLK/WHT
ENGINE BLOCK
473
DKBLU
SECONDARY COOLING
FAN RELAY "F5"
446
LTBLU
TCC SOLENOID "B"
817- ECM GROUND
451
BLK/WHT
ENGINE BLOCK
818 TP SENSOR, ECT

GROUND
470
BLK
TP SENSOR "B", ECT

''A''
B 19 3rd GEAR SIGNAL
438
DKGRN/WHT
TCC SOLENOID "C"
POOR FUEL ECONOMY.
820 2nd GEAR SIGNAL
232
WHT
TCC SOLENOID "E"
POOR FUEL ECONOMY.
551
TAN/WHT
ENGINE BLOCK
87
88
89
810 SECONDARY COOLING
F.AN CONTROL (C60
OPTION)
28 (3)
INOPERATIVE SECONDARY COOLING FAN.

SECONDARY COOLING FAN "ON" AT ALL
TIMES.
811
812
813
814 4th GEAR SIGNAL
POOR FUEL ECONOMY.
815
816
ENGINE CRANKS BUT Will NOT START.
15 (1)
21 (1)
ROUGH IDLE.
821
822 ECM GROUND
(1)
(2)
(3)
ENGINE CRANKS BUT Will NOT START.
OPEN CIRCUIT.
GROUND CIRCUIT.
OPEN/GROUND CIRCUIT.
10-2092
MS 12461
ECM Connector "B" Symptom Chart
11
ECM CONNECTOR C" SYMPTOM CHART

GREEN 22 PIN CONNECTOR
PIN FUNCTION
CKT#
WIRE COLOR
COMPONENT
CONN ECTOR CAVITY
DTC(s)
AFFECTED
POSSIBLE SYMPTOMS
FROM FAULTY CIRCUIT
C1
A/C STATUS
59
DKGRN
A/C RELAY "84"

LOW PRESSURE
SWITCH
69 (1)
A/C INOPERATIVE.
C2
+ SVOLTS
REFERENCE
474
GRY
TPSENSOR"A"
22 (3)
HIGH IDLE, LACK OF PERFORMANCE.
C3
TP SENSOR SIGNAL
417
DKBLU
TP SENSOR"("
22 (3)
HIGH IDLE, LACK OF PERFORMANCE.
cs
LOW RESOLUTION
453
RED/BLK
DISTRIBUTOR" A"
16 (3)
(6
BATTERY FEED
340
ORN
(7
+ 5 VOLTS
REFERENCE
416
GRY
MAP "C", A/C REFRIG

PRESSURE SENSOR
"B", A/C EVAPTEMP
SENSOR "A"
34(3)
66(3)
ROUGH IDLE,
INOPERATIVE A/C.
(8
KNOCK SENSOR
SIGNAL
496
DKBLU
KNOCK SENSOR
43 (3)
C9
DISTRIBUTOR
REFERENCE LOW
632
PNK/BLK
DISTRIBUTOR "D"
C11 A/C REFRIGERANT

PRESSURE SIGNAL
380
RED/BLK
A/C REFRIGERANT
PRESSURE SENSOR "C"
C12 IGNITION FEED
439
PNK
647
LT BLU1BLK
DISTRIBUTOR "B"
36(3)
ENGINE SURGE, LACK OF PERFORMANCE.
C16 A/C EVAPORATOR

TEMPERATURE
SENSOR SIGNAL
732
DKBLU
A/C EVAPORATOR
TEMPERATURE
SENSOR "B"
71 (3)
INOPERATIVE A/C.
C17 BATTERY FEED
340
ORN
C18 DISTRIBUTOR
IGNITION FEED
631
RED
DISTRIBUTOR "C"
C20 FUEL PUMP SIGNAL
120
GRY
FUEL PUMP
RELAY "A2"
C21 MAP SIGNAL
432
LTGRN
MAP"B"
34(3)
ENGINE RUNS ROUGH, LACK OF POWER,

POOR PERFORMANCE.
C22 IA T SIGNAL
472
TAN
IAT"B"
23 (1)
25 (2)
POOR FUEL ECONOMY.
(4
ENGINE CRANKS BUT WILL NOT START (1).
C10
66(3)
INOPERATIVE A/C.
C13
C14 HIGH RESOLUTION
C15
C19
(1)
(2)
(3)
OPEN CIRCUIT.
GROUNDED CIRCUIT.
10-9-92
MS 12083
ECM Connector "C" Symptom Chart
ECM PIN CONNECTOR "D" SYMPTOM CHART

BROWN 22 PIN CONNECTOR
CKT#
WIRE
COLOR
COMPONENT
CONNECTOR
CAVITY
DTC(s)
AFFECTED
VSSGROUND
401
PPL
VSS "A"
24(1)
SERIAL DATA
800
TAN
06
BANK 1 (LEFT)
025 SIGNAL
1665
PPLNVHT
025
07
FUEL PUMP
RELAY DRIVER
465
DKGRN/WHT
FUEL PUMP
RELAY"C2"
08
VSSOUTPUT
(4KPPM)
817
DKGRN/WHT
1/P AND CRUISE

MODULE
010 INJECTOR
DRIVER
468
DKGRN
INJECTORS 2, 4, 6, 8
"A"
44 (1)
45(2)
POSSIBLE ENGINE CRANKS BUT WILL NOT START,

011 INJECTOR
DRIVER
467
DKBLU
INJECTORS 1, 3, 5, 7
"A"
44(1)
45 (2)
POSSIBLE ENGINE CRANKS BUT WILL NOT START,

012 VSS SIGNAL
400
YEL
VSS "B"
24(3)
INOPERATIVE SPEEDOMETER.
INOPERATIVE CRUISE CONTROL.
351
BLK/WHT
025
13 (1)
63 (1)
ROUGH IDLE, LEAN EXHAUST, POOR

448
WHT/BLK
DLC"B"
1666
PPL
025
PIN FUNCTION
01
POSSIBLE SYMPTOMS
INOPERATIVE SPEEDOMETER.
INOPERATIVE CRUISE CONTROL.
02
03
04
NO TECH 1 DATA.
05
13 (1)
44(2)
EXHAUST ODOR, POOR PERFORMANCE.

POOR FUEL ECONOMY, "OPEN LOOP."
LONG CRANK TIME BEFORE ENGINE STARTS.
INOPERATIVE CRUISE CONTROL AND
SPEEDOMETER.
09
013
014
015
016 025 GROUND
017
018
019
020 DIAGNOSTIC
ENABLE
NO TECH 1 DATA.
WILL NOT FLASH OTC 12.
021
022 BANK 2 (RIGHT)
025 SIGNAL
(1)
(2)
(3)
63 (1)
64(2)
EXHAUST ODOR, POOR PERFORMANCE.

POOR FUEL ECONOMY, "OPEN LOOP."
OPEN CIRCUIT.
GROUNDED CIRCUIT.
10-9-92
MS 12462
ECM Connector "D" Symptom Chart
ORIVEABILITY AND EMISSIONS 5.7L (VIN P) 6E3-B-23
BLANK
6E3-C-1 5.7L (VIN P) DRIVEABILITY AND EMISSIONS
SECTION C
COMPONENT SYSTEMS
correct part number fastener is not available, a fastener of equal size and strength (or stronger) may be used.
Fasteners that are not reused, and those requiring thread-locking compound will be called out. The correct
torque value must be used when installing fasteners that require it. If the above conditions are not followed,
parts or system damage could result.
Section "C" provides information on the following:
General description of components and systems.
On-Vehicle service.
Part names.
Diagnostic charts. These include a functional check of the system as well as diagnosis of any problem
found in the functional check.
For locations of components, wiring diagrams, and ECM terminal end view, refer to the front of the "A" section
of the engine being diagnosed.
Following are the sub-section identification and the system covered:
C1
C2
C3
C4
cs
CG
C7
CB
C10
C12
C13
C14
Engine Control Module (ECM) and Sensors Page C1-1

Fuel Metering System Page C2-1
Page C3-1
Distributor Ignition (DI) System Page C4-1
Page CS-I
Secondary Air Injection (AIR) System Page C6-1
Exhaust Gas Recirculation (EGR) System Page C7-1
Torque Converter Clutch (TCC) System (A/T), Automatic Transmission Gear Switch
System, Reverse Lockout System (MIT) Page C8-1
A/CClutchCircuitDiagnosis PageC10-1
Electric Cooling Fan(s) Page C12-1
Crankcase Ventilation System Page C13-1
Air Intake System PageC14-1
DIAGNOSTIC CHARTS
The diagnostic charts for each system are found after the on-vehicle service and parts information at the back of
each section. Following are the charts found in this section.
Park/Neutral Position (PNP) Switch Diagnosis
Chart C-1A
(Automatic Transmission Only)
Page C1-16
Chart C-1 D
Manifold Absolute Pressure (MAP) Output Check
PageC1-18
Chart C-2A
Page C2-16
Page C2-18
Chart C-2C
Chart C-3
Evaporative Emission (EVAP) Canister Purge Solenoid Valve Check Page C3-6
Chart C-4
Distributor Ignition System Check (1 of 2)
Page C4-4
Chart C-5
Knock Sensor (KS) System Check Page CS-4
Chart C-6
Secondary AIR Injection (AIR) System Check Page C6-6
Exhaust Gas Recirculation (EGR) System Check (1 of 2) Page C7-4
Chart C-7
Chart C-8A
Torque Converter Clutch (TCC) System (Electrical Diagnosis) (1 of 4) Page C8-6
Automatic Transmission 2nd Gear Switch (Electrical Diagnosis) (2 of 4)
Chart C-8A
Page C8-8
Automatic Transmission Jrd Gear Switch (Electrical Diagnosis) (3 of 4) Page C8-10
Chart C-8A
Automatic Transmission 4th Gear Switch (Electrical Diagnosis) (4 of 4) Page C8-12
Chart C-8A
Reverse Lockout System (Electrical Diagnosis) Page C8-14
Chart C-88
Chart C-10
A/C Clutch Circuit Diagnosis (1 of 3) Page Cl0-4
Electric Cooling Fan Control Circuit Diagnosis (1 of 2) Page C12-4
Chart C-12
DRIVEABILITY AND EMISSIONS 5.7L (VIN P) 6E3-C1-1
SECTION C1
ENGINE CONTROL MODULE (ECM) AND SENSORS

CONTENTS
General Description
PROM
ECM Function
Memory
ROM
RAM
PROM
long Term Fuel Trim
Speed Density System
Speed
Density
Information Sensors
Sensor
Knock Sensor
Sensor
Intake Air Temperature (IA T) Sensor
Oxygen Sensor (025)
A/C Evaporator Temperature
Sensor
A/CRequestSignal

(Automatic Only)

Reference Signal

Diagnosis
ECM
C1-1
C1-1
C1-1
C1-2
C1-2
C1-2
C1-2
C1-2
C1-2
C1-2
C1-3
C1-3
C1-3
C1-3
C1-3
C1-3
C1-4
C1-4
C1-4
C1-5
C1-6
C1-7
C1-7
C1-7
C1-7
C1-7
C1-7
C1-8
GENERAL DESCRIPTION
The Engine Control Module (ECM) (Figure Cl-1)
is the control center of the fuel injection system. It
constantly looks at the information from various
sensors, and controls the systems that affect vehicle
performance.
The ECM also performs a diagnostic function
check of the system. It can recognize operational
problems and alert the driver through the Malfunction
Indicator Lamp (MIL) "Service Engine Soon," and
store a DTC or DTCs which identify the problem areas
to aid the technician in making repairs. Refer to
"Introduction," SECTION 6E for more information on
using the diagnostic function of the ECM.
......................
PROM
ECM Inputs
Sensor
Knock Sensor
MAP Sensor
IAT Sensor
Oxygen Sensor (025)

Response Time
Oxygen Sensor Contaminants

A/C Request Signal
Reference Signal

On-Vehicle Service
ECM or PROM Replacement
If ECM is Being Replaced
Functional Check
Sensor
Sensor
Oxygen Sensor (025)
(Bank 1 or Bank 2)
Knock Sensor (KS)
(1-8
(1-8
(1-8
(1-8
(1-8
(1-8
(1-8
(1-8
(1-8
(1-9
(1-9
(1-9
(1-9
C1-9
(1-10
(1-10
(1-10
(1-11
(1-11
(1-11
(1-12
(1-12
(1-12
(1-13
(1-14
(1-14
(1-14
(1-14
For service, this ECM only consists of two parts: a

controller (the ECM without a PROM) and an
assembly called a PROM.
PROM
To allow one model of ECM to be used for many
different vehicles, a device called a calibrator or
Programmable Read Only Memory (PROM) is used.
The PROM is located inside the ECM and has
information on the vehicle's weight, engine,
transmission, axle ratio, and other items specific to
each vehicle. While an ECM part number can be used
by many vehicle lines, PROM is very specific and must
be used for the right vehicle. For this reason, it is very
important to check the latest parts book and service
bulletin information for the correct part number when
replacing a PROM.
6E3-C1-2 5.7l (VIN P) DRIVEABILITY AND EMISSIONS

PROM
ACCESS COVER
GASKET
RAM
Ran d o m Acce ss Mem ory (RAM) i s the
microprocessor "scratch pad." The processor can write
into, or read from this memory as needed. This
memory is erasable and needs a constant supply of
voltage to be retained. If the voltage is lost, the
memory is lost.
PROM
Programmable Read Only Memory (PROM) is the
portion of the ECM that contains the different engine
calibration information that is specific to year, model
and emissions.
The PROM is contained within the PROM
assembly and is removable from the ECM. The PROM
should be kept with the vehicle following ECM
replacement.
J3
J2
J1
9S 6343-6E
Figure C1-1 - Engine Control Module (ECM)

An ECM used for service (called a controller)
comes without a PROM. The PROM from the old ECM
must be carefully removed and installed in the new
ECM (refer to "On-Vehicle Service").
ECM Function
The ECM supplies 5 or 12 volts to power various
sensors or switches. This is done through resistances
in the ECM which are so high in value that a test light
will not light when connected to the circuit. In some
cases, even an ordinary shop voltmeter will not give an
accurate reading because its resistance is too low.
Therefore, the use of a 10 megohm input impedance
digital voltmeter (J 39200) is required to assure
accurate voltage readings.
Memory
There are three types of memory storage within
the ECM: ROM, RAM and PROM.
ROM
Read Only Memory (ROM) is a permanent memory
that is physically soldered to the circuit boards within
the ECM. The ROM contains the overall control
programs. Once the ROM is programmed, it cannot be
changed. The ROM memory is non-erasable, and does
not need power to be retained.
The short term fuel trim is an ECM erasable

memory register that will contain a number between 0
and 255. The neutral value for the short term fuel
trim is 128; any deviation from this value indicates the
short term fuel trim is changing the injector pulse
width. The amount of pulse width change depends on
how far the short term fuel trim value is from 128. The
short term fuel trim changes the pulse width by
varying the "Closed Loop" factor of the base pulse
width equation. As the ECM monitors the oxygen
sensor input, it is constantly varying the short term
fuel trim value. The value is updated very quickly,
therefore, the short term fuel trim only corrects for
short term mixture trends. The correction of long term
mixture trends is the function oflong term fuel trim.
Long Term Fuel Trim

The long term fuel trim is a matrix of cells
arranged by RPM and MAP. Each cell of the long term
fuel trim is a register like the short term fuel trim. As
the engine operating conditions change, the ECM will
switch from cell to cell to determine what "long term
fuel trim" factor to use in the base pulse width
equation.
While in any given cell, the ECM also monitors the
short term fuel trim. If the short term fuel trim is far
enough from 128, the ECM will change the long term
fuel trim value. Once the long term fuel trim value is
changed, it should force the short term fuel trim back
toward 128.
If the mixture is still not correct (as judged by the
02S), the short term fuel trim will continue to have a
large deviation from the ideal 128. In this case, the
long term fuel trim value will continue to change until
the short term fuel trim becomes balanced.
DRIVEABILITYAND EMISSIONS 5.7L (VIN P) 6E3-C1-3

Both the short term fuel trim and long term fuel
trim have limits which will vary with each PROM If
the mixture is off enough so that long term fuel trim
reaches the limit of its control and still cannot correct
the condition, the short term fuel trim would also go to
its limit of control in the same direction. If the
mixture is still not corrected by both short term fuel
trim and long term fuel trim at their extreme values,
an Oxygen Sensor (02S) DTC will likely result. Under
the conditions of power enrichment, the ECM sets the
short term fuel trim to 128 and freezes it there until
power enrichment is no longer in effect. This is done so
the "Closed Loop" factor and the long term fuel trim
will not try to correct for the commanded richness of
power enrichment.
HARNESS CONNECTOR
2
LOCKING TAB
SENSOR
55 1640-6EA
Figure C1-2 - Engine Coolant Temperature (ECT)

Sensor
The Multiport Fuel Injection (MFI) system is a

speed and air density system. The system is based on
"speed density" fuel management.
Three specific data sensors provide the EC:\1 with
the basic information for the fuel management portion
of its operation. That is, three specific signals to the
ECM establish the engine speed and air density
factors.
injector pulse width. Conversely, as manifold pressure

decreases, the amount of fuel is decreased.
The MAP sensor is mounted directly to the intake
manifold.
These three inputs :VIAP, IAT, and RPM are the
major determinants of the air/fuel mixture delivered
by the ::VIFI system.
The remaining sensors and switches provide
electrical inputs to the EC M which are used for
modification of the air/fuel mixture, as well as for
other EC:\1 controlled functions.
Speed
INFORMATION SENSORS
The engine speed signal comes from the distributor

ignition system module to the ECM on the low
resolution circuit. The ECM uses this information to
determine the "speed" or RPM factor for fuel and
ignition management.
SPEED DENSITY SYSTEM
Density
Two sensors contribute to the density factor, the
Intake Air Temperature (IAT) and the Manifold
Absolute Pressure (MAP) sensors.
The IAT sensor is a 2-wire sensor that measures
the temperature of the air entering the intake
manifold. The IAT sensor is a thermistor that changes
its resistance depending on the air temperature.
When the temperature is low, the resistance is high,
and when the temperature is high, the resistance is
low.
The Manifold Absolute Pressure (MAP) sensor is a
3-wire sensor that monitors the changes in intake
manifold pressure which results from changes in
engine loading. These pressure changes are supplied
to the ECM in the form of electrical signals.
As intake manifold pressure increases, the air
density in the intake manifold also increases, and
additional fuel is required. The MAP sensor sends this
pressure information to the ECM, and the EC'.VI
increases the amount offuel injected, by increasing the
The Engine Coolant Temperature (ECT) sensor is

a thermistor (a resistor which changes value based on
temperature) immersed in the engine coolant stream.
Low coolant temperature produces a high resistance,
while high temperature causes low resistance.
The ECM supplies a 5 volt signal to the ECT
through a resistor in the ECM and measures the
voltage. The voltage will be high when the engine is
cold, and low when the engine is hot. By measuring
the voltage, the ECM knows the engine coolant
temperature. Engine coolant temperature affects most
systems the ECM controls.
A failure in the ECT circuit should set either a
OTC 14 or DTC 15. Remember, these D'fCs indicate a
failure in the engine coolant temperature sensor
circuit, so proper use of the chart will lead to either
repairing a wiring problem or replacing the sensor to
properly repair a problem.
Knock Sensor
The knock sensor is mounted in the lower right
side of the engine block.
When abnormal engine vibrations (spark knock)
are present, the sensor produces a voltage signal which
is sent to the ECM.
6E3-C1-4 5. 7L (VIN P) DRIVEABILITY AND EMISSIONS

Refer to "Knock Sensor (KS) System," Section
"6E3-C5" for further information on the Knock Sensor
(KS) system.

The Manifold Absolute Pressure (MAP) sensor
(Figure Cl-4), is a pressure sensor that measures
changes in intake manifold pressure. The pressure
changes as a result of engine load and speed. The MAP
sensor converts this to a voltage output.
A closed throttle on engine coastdown would
produce a relatively low MAP output voltage, while a
wide-open throttle would produce a high MAP output
voltage. This high output voltage is produced because
the pressure inside the manifold is the same as outside
the manifold, so you measure 100% of outside air
pressure. Manifold Absolute Pressure (MAP) is the
OPPOSITE of what you would measure on a vacuum
gage. When manifold pressure is high, vacuum is low.
The MAP sensor is also used to measure barometric
pressure under certain conditions, which allows the
ECM to automatically adjust for different altitudes.
The ECM sends a 5 volt reference signal to the
MAP sensor. As the manifold pressure changes, the
electrical resistance of the MAP sensor also changes.
By monitoring the sensor output voltage the ECM
knows the manifold pressure. A higher pressure, low
vacuum (high voltage) requires more fuel, while a
lower pressure, higher vacuum (low voltage) requires
less fuel. The ECM uses the MAP sensor to control
fuel delivery and ignition timing.
A failure in the MAP sensor circuit should set a
DTC 33 or DTC 34.
KNOCK SENSOR (KS)
3S 0023-6E
Figure C1-3 - Knock Sensor
SENSOR
2
ELECTRICAL CONNECTOR
6S 2648-6E
Figure C1-4- Manifold Absolute Pressure (MAP]
MAP
kPa 100
10
Hg 29.6 26.6 23.7 20.7 17.7 14.8 11.8 8.9 5.9 2.9
4.9
90
4.4
80
3.8
70
3.3
60
50
2.7 2.2
40
1.7
30
1.1
20
0.6
0.3
0.3
HARNESS CONNECTOR

The Intake Air Temperature (IAT) sensor is a
temperature). It is mounted in the air intake duct.
Low temperature produces a high resistance and high
temperature causes low resistance.
The ECM supplies a 5 volt signal to the sensor
through a resistor in the ECM and measures the
voltage. The voltage will be high when the intake air
is cold, and low when the intake manifold air is hot. By
measuring the voltage, the ECM knows the intake air
temperature.
A failure in the IAT sensor circuit should set either
a OTC 23 or OTC 25.
LOCKING TAB
SENSOR
5S 1640-6EA
Figure C1-5 - Intake Air Temperature (IAT) Sensor
Oxygen Sensor(02S)
The Oxygen Sensor (02S) is essentially a small
variable battery; it has the ability to produce a low
voltage signal that feeds information on engine
exhaust oxygen content to the ECM.
The Oxygen Sensor (02S) is constructed from a
material (zirconia/platinum) that conducts electricity
under certain conditions. At operating temperature,
315 C (600 F'), the element becomes a semiconductor.

A platinum coating on the outer surface of the element
stimulates further combustion of the exhaust gases
right at the surface and this helps keep the element up
to the desired temperature. The oxygen sensor has an
inter cavity which is filled with atmospheric
(reference) air. The atmosphere has approximately
21 % oxygen in it. In this electrical circuit this inter
cavity is the positive ( +) terminal. The outer surface
of the element is exposed to the exhaust gas stream. It
is the negative (-) or ground terminal. The oxygen
concentration differences between the reference air
and exhaust gases produce small voltages (refer to
Figure Cl-6).
A rich exhaust (excessive fuel) has almost no
oxygen. When there is a large difference in the
amount of oxygen touching the inside and outside
surfaces, there is more conduction, and the sensor puts
out a voltage signal above 600 m V. With lean exhaust
(excessive oxygen) there is about two percent oxygen
in the exhaust. This is a smaller difference in oxygen
from the outside surfaces which results in less
conduction and a voltage signal below 300 m V. The
voltages are monitored and used by the ECM to "fine
tune" the air/fuel ratio to achieve the ideal mixture
desired.
The ECM sends a reference signal of 450 m V. The
reference signal serves to run the engine when it is in
"Open Loop" mode of operation. When the air/fuel
ratio is correct the ECM displays 450 m V. When the
engine is operating with a rich air/fuel ratio, there is a
reduction of free oxygen in the exhaust stream and the
oxygen voltage rises above the reference voltage.
When the engine is run lean, the voltage drops
below the reference voltage due to excess oxygen in the
exhaust stream. The oxygen sensor provides the
feedback information for the "Closed Loop" operating
mode of the fuel delivery system. The oxygen sensor
indicates to the ECM what is happening in the
exhaust. It does not cause things to happen. It is a
type of gage: Low voltage output = lean mixture =
high oxygen content in exhaust; high voltage output
= rich mixture = low oxygen content in the exhaust.
An open Oxygen Sensor (02S) circuit, should set a
OTC 13 or 63. A constant low voltage in the oxygen
sensor circuit should set a OTC 44 or 64. A constant
high voltage in the circuit should set a OTC 45 or 65.
OTCs 44, 45, 64, or 65 could also be set as a result of
fuel system problems. Refer to "OTC Charts" for
conditions that can cause a lean or rich system.

The Throttle Position (TP) sensor is a
potentiometer connected to the throttle shaft on the
throttle body. The TP sensor has one end connected to
5 volts from the ECM and the other to ECM ground. A
third wire is connected to the ECM to measure the
voltage from the TP sensor.
METAL GASKETCONNECTS TO
POSITIVE TERMINAL
INSIDE
SURFACE
POSITIVE
TERMINAL
CERAMIC
ZIRCON IA
ELEMENT
95 6326-6E
Figure C1-6- Oxygen Sensor (02S) Cutaway View

OXYGEN SENSOR ELEMENT
21%
21%
OXYGEN
OXYGEN
i
..
......
EXHAUST
GAS WITH
0%
OXYGEN
....
i
....
......
..
,
,,
,
,
,
,
0.6V
....
MORE CONDUCTION
0.3 V
EXHAUST
GAS WITH
2%
OXYGEN
LESS CONDUCTION
95 6325-6E
Figure C1-7 Oxygen Sensor Element
As the throttle valve angle is changed (accelerator

pedal moved), the voltage output of the 'TP sensor also
changes.
At a closed throttle position, the voltage output of
the TP sensor is low (approximately .5 volt). As the
throttle valve opens, the output increases so that at
wide-open throttle, the output voltage should be near 5
volts.
By monitoring the output voltage from the TP
sensor, the ECM can determine fuel delivery based on
throttle valve angle (driver demand).
6E3-C1-6 5.7L (VIN P) DRIVEABILITY AND EMISSIONS
RICH
0.60v
RICH
0.60v
ECM02S
REFERENCE
SIGNAL
0.4Sv
ECM02S
REFERENCE
SIGNAL
0.45v
LEAN
0.30v
LEAN
0.30v
NORMAL OPERATION
RICH TOO LONG - OTC 45 OR 65
RICH
0.60 v
RICH
0.60v
ECM02S
REFERENCE
SIGNAL
0.45 v
ECM02S
REFERENCE
SIGNAL
0.45v
LEAN
0.30v
LEAN
0.30v
LEAN TOO LONG - OTC 44 OR 64
BETWEEN 0.3-0.6v TOO LONG OTC 13 OR 63

3-19-92
95 6344-6E
Figure C1-8 - Normal Voltage and Abnormal Trends

--~~~~~~~~~...-~~--,
CONTROL
MODULE
THROTTLE VALVE
OJ
SENSOR CONNECTOR
[TI
SPEEDO DRIVEN GEAR
OJ

MS 13244
9P0394-SY
Figure C1-9 -Throttle Position (TP) Sensor
A broken or loose TP sensor can cause intermittent

bursts of fuel from the injector and cause an unstable
idle because the ECM detects the throttle is moving.
If the TP sensor circuit is open, the ECM will set a
DTC 22. If the TP sensor circuit is shorted, the ECM
will think the vehicle is at WOT, and a DTC 21 will be
set. A problem in any of the TP sensor circuits will set
either a DTC 21 or 22. Once a DTC is set, the ECM
will use a default value for TP sensor, and some
vehicle performance will return.
Refer to "On-Vehicle Service" for replacement of
TP sensor.
Figure C1-10 Vehicle Speed Sensor

(Automatic Transmission)

The Vehicle Speed Sensor (VSS) is a pulse counter
type input that informs the ECM how fast the vehicle
is being driven. The VSS system uses a Permanent
Magnet (PM) generator mounted at the output shaft of
the transmission. The VSS produces an AC voltage
signal that increases with vehicle speed. The ECM
processes this signal and sends it to the instrument
panel and cruise control module on CKT 817.
DRIVEABILITY AND EMISSIONS 5.7L (VIN P} 6E3-C1-7

This signal is used by the ECM to enable cooling
fans when head pressure reaches about 248 psi. If a
fault is present in the NC refrigerant pressure sensor
circuit, a DTC 66 and 67 will set, and the NC clutch
would be disabled.

This signal is used by the ECM to cycle the NC
clutch "ON" and "OFF." The EC:Vl will cycle the
clutch "ON" at 4C (39F) and "OFF" at 2C (36F). A
failure in the A/C evaporator temperature sensor
circuit will result in a DTC 71 and NC clutch would be
disabled.
A/C Request Signal

This signal tells the ECM that the NC selector
switch is turned "0).;." The ECM uses this
information to adjust the idle speed when the air
conditioning is working. If this signal is not available
to the EC:M, the NC compressor will not engage.

(Automatic Only)
The Park/:,,reutral Position (PNP) switch indicates
to the EC-11 when the transmission is in park, neutral,
or drive. This information is used for the TCC, EGR
and the IAC valve operation.
rn
Important
Vehicle should not be driven with park/neutral

position switch disconnected, as idle quality will be
affected and a possible false DTC 24 (VSS) may set.
Refer to SECTION 8A for more information on the

PNP switch, which is part of the neutral/start and
backup light switch assembly. Refer to CHART C- lA
for PNP switch check.
Reference Signal
The distributor ignition system sends a signal to
the ECM to tell it both engine RPM and crankshaft
position. Refer to "Distributor Ignition System,"
Section "6E3-C4" for further information.
DIAGNOSIS
To display diagnostic trouble codes, use a Tech 1,
or grounding the diagnostic "test" terminal with the
engine not running and the ignition "ON," will prompt
the Malfunction [ndicator Lamp ( MIL) "Service
Engine Soon" to flash DTC 12 three times and then
flash each DTC stored in memory three times.
All DTCs stored in memory would have been displayed

when DTC 12 was flashed again.No new DTCs can be
stored when in the "Diagnostics Mode" (diagnostic
lead is grounded). This eliminates confusion while the
system is being worked on.
To clear the DTCs from memory use the Tech 1 or:
Ignition "OFF."
Disconnect ECM BAT fuse (located in
instrument panel fuse block), for 30 seconds.
Since the ECM can have a failure which may affect
only one circuit, following the diagnostic procedures
in this section will determine which drcuit has a
problem and where it is.
If a diagnostic chart indicates that the ECM
connections or ECM is the cause of a problem, and the
ECM is replaced, but does not correct the problem, one
of the following may be the reason:
There is a problem with the EC:Vl terminal
connections. - The diagnostic chart will say
ECM connections or ECM. The terminals may
have to be removed from the connector in order
to check them properly.
The ECM, or PROM is not correct for the
application. - The incorrect components may
cause a malfunction and may or may not set a
DTC.
The problem is intermittent. - This means that
the problem is not present at the time the
system is being checked. In this case, refer to
the "Symptoms," Section "6E3-B" portion of
the manual and make a careful visual/physical
inspection of all portions of the system
involved.
Shorted solenoid, relav coil, or harness. Solenoids and relays are turned "ON" and
"OFF" by the ECM, using internal electronic
switches called "drivers." Each driver is part
of a group of four called "quad-drivers."
A shorted solenoid, relay coil, or harness will
not damage the ECM, but will cause the circuit
and controlled component to be inoperative.
When the circuit fault is not present or has
been repaired, the "quad-driver" will again
operate in a normal manner due to it's fault
protected design. If a fault has been repaired
in a circuit controlled by a "quad-driver," the
original ECM should be reinstalled and the
circuit checked for proper operation. ECM
replacement will not be necessary if the
repaired circuit or component now operates
correctly.
Circuit tester (,J 34636) provides a fast,
accurate means of checking for a shorted coil or
a short to battery voltage.
The PROM may be faulty. - Although these
rarely fail, it operates as part of the ECM.
Therefore, it could be the cause of the problem.
Substitute a known good PROM.
The replacement ECM may be faulty. - After

the ECM is replaced, the system should be
rechecked for proper operation. If the
diagnostic chart again indicates the ECM is
the problem, substitute a known good ECM.
Although this is a rare condition, it could
happen.
IAT Sensor
A faulty ECM can be determined in the diagnostic

charts, or by a OTC 51.

entering the engine and should be close to ambient air
temperature when engine is cold, and rise as
underhood temperature increases. If the engine has
not been run for several hours (overnight) the IAT
sensor temperature and ECT sensors should display
temperature readings close to each other. A failure in
the IAT sensor circuit should set a OTC 23 or 25. The
OTC charts also contain a chart to check for sensor
resistance values relative to temperature.
PROM
Oxygen Sensor (02S)
An incorrect or faulty PROM, which is part of the

ECM, may set a OTC 51. Also, make sure the PROM is
fully seated and latched in the socket.
The Tech I has several positions that will indicate

the state of the exhaust gases, oxygen sensor voltage,
short term fuel trim, and long term fuel trim.
Normal Tech 1 voltage varies between 10 mV to
1000 mV (.01 and 1.0 volt) while in "Closed Loop."
OTC 13 and 63 will set in one minute if voltage
remains between 350 mV and 550 mV, but the system
will go "Open Loop" in about 15 seconds.
The ECM self-diagnostic circuit looks for trends in
oxygen sensor voltage. If a trend is detected, the MIL
(Service Engine Soon) comes "ON."
A rich exhaust trend causes the sensor voltage to
stay above 700 m V for too long. This sets OTC 45 or
OTC 65.
Lean exhaust causes voltage to stay below 300 mV
for too long. This sets OTC 44 or 64. If voltage stays
between 350 m V and 550 m V for too long, the ECM
sets OTC 13 or f-3. This indicates an open oxygen
sensor circuit.
ECM
ECM INPUTS
All of the sensors and input switches can be
diagnosed by the use of a Tech 1. Following is a short
description of how the sensors and switches can be
diagnosed by the use of a Tech 1. The Tech 1 can also
be used to compare the values for a normal running
engine with the engine you are diagnosing.

The Tech 1 displays engine coolant temperature in
started, the temperature should rise steadily to about
90C (194F) then stabilize when the thermostat opens.
If the engine has not been run for several hours
(overnight), the ECT and IAT should be close to each
other. A fault in the Engine Coolant Temperature
(ECT) sensor circuit should set a OTC 14 or 15. The
OTC charts also contain a chart to check for Engine
Coolant Temperature (ECT) sensor resistance values
Knock Sensor
The Tech 1 will indicate when knock is present.
Refer to "Knock Sensor (KS) System," Section "6E3C5" for further information on the KS system.
MAP Sensor
The Tech I displays manifold absolute pressure
and will display volts and kPa of pressure. Key "ON,"
engine stopped (no vacuum), MAP will display high
voltage or pressure, while at idle (high vacuum), MAP
will display low voltage or pressure. Likewise, on
acceleration MAP will display high and on
deceleration will display low voltage.
A failure in the MAP sensor or circuit should
result in a OTC 33 or OTC 34.
Response Time
Not only is it necessary for the oxygen sensor to
produce a voltage signal for rich or lean exhaust, it is
also important to respond quickly to changes. The
ECM senses the response times. If the oxygen sensor
responds slowly, the customer may complain of poor
fuel economy, rough idle or lack of performance. It
may also set false ECM OTCs because the ECM uses
oxygen sensor voltages for system checks.
Oxygen Sensor Contaminants

Carbon
Black carbon or soot deposits result from over-rich
mixtures. However, carbon does not harm a sensor.
Deposits can be burned off in the engine by running it
at least part throttle for two minutes.
Silica
Certain RTV silicone gasket materials give off
vapors that contaminate the oxygen sensor.
DRIVEABILITY AND EMISSIONS 5.7l (VIN P) 6E3-C1-9

The sand-like particles from the RTV silica imbed in
the molecules of the sensor element and plug up the
surface. This results in ''lazy" oxygen sensor response
and engine control. The sensor will also have a whitelike appearance.
There is also a possibility of silica contamination
caused by silicone in the fuel. Careless fuel handling
practices with the transport containers can result in
unacceptable concentrations of silicone in the fuel at
the pump.
There is also a possibility of silica contamination
caused by silicon in lubricants used to install vacuum
hoses on fittings.
The Tech 1 has the ability to display the tnrottle angle

and should be 0% when the throttle is closed.
The Tech 1 should display "P-N" when in park or

neutral and "-R-DL" when in drive or reverse. Refer to
CHART C-lA for PNP switch diagnosis.
Lead
Reference Signal
Lead glazes sensors. It can be introduced when

regular, or leaded fuel, is burned. It is difficult to
detect lead contamination by visual inspection.
The Tech 1 will display this signal in RPM. Refer

to "Distributor Ignition System," Section "6E3-C4" for
more information on the distributor ignition system.
Other Substances
Oil deposits will ultimately prevent sensor

operation. The sensor will have a dark brown
appearance. Causes of high oil consumption should be
checked. The additives in ethylene glycol can also
affect sensor performance.
This produces a white-like appearance. If
antifreeze enters the exhaust system, you will likely
encounter other, more obvious, symptoms of cooling
system trouble.
The Tech 1 reading should closely match the

speedometer reading with drive wheels turning. A
failure in the VSS circuit should set a OTC 24.
A/C Request Signal

The Tech 1 should indicate NC request as "YES,"
when NC is requested.
PROM
ACCESS COVER
GASKET
Multiple Failures
If you encounter multiple or repeat oxygen sensor
failures on the same vehicle, consider contamination.
Leaded fuel, silica contamination from uncured,
low-grade (unapproved) RTV sealant, and high oil
consumption are possible.
A problem in the oxygen sensor circuit or fuel
system should set a OTC 13 or 63 (open circuit), OTC
44 or 64 (lean indication) or OTC 45 or 65 ( rich
indication). Refer to applicable chart if any of these
DTCs were stored in memory.

The Tech 1 displays throttle position in volts and
percentage of throttle blade opening. The value should
display between about .3-.9 volt, with throttle closed
and ignition "ON," or at idle. Voltage should increase
at a steady rate as throttle is moved toward WOT
(about 4.6 volts).
The ECM has the ability to auto-zero the TP sensor
voltage if it is between about .:3-.9 volt. This means
that any voltage in this window will be determined by
the ECM to be 0% throttle. A failure in the TP sensor
circuit should set a DTC 21 or 22.
J4
J2
Figure C111 - ECM
J1
95 6343-6E
ON-VEHICLE SERVICE
Service of the ECM should, normally, consist of
either replacement of the ECM or a PROM change.
If the diagnostic procedures call for the ECM to be
replaced, the PROM and ECM should be checked first
to see if they are the correct parts. If they are, remove
the PRO.M from the faulty ECM and install it in the
new service EC.M. THE SERVICE ECM WILL NOT
CONTAIN A PROM. DTC 51 indicates the PROM is
installed improperly or has malfunctioned. When
DTC 51 is obtained, check the PROM installation for
bent pins or pins not fully seated in the socket. If it is
installed correctly and DTC 51 still shows, replace the
PROM.
*65 25446E
Figure C1-13 - PROM Unit Socket
[I] Important
cable, ECM pigtail, ECM BAT fuse,jumper cables,

etc.).
When replacing the production ECM wit.h a

service EC:\I (controller), it is important to
transfer the Broadcast Code and production ECM
number to the service EC:Vl label.

Discharge damage to the PROM, Do Not touch the
component leads, and Do Not remove integrated
circuit from carrier.
[I] Important
To prevent internal EC:\I damage, the ignition

must be "OFF," when disconnecting or
reconnecting power to ECM (for example, battery
ECM OR PROM REPLACEMENT

Figures C1-12, 13

ECM mounting bolts (2).
3. ECM connector shield.
4. Connectors from ECM.
5. ECM mounting hardware if ECM 1s being
replaced.
6. PROM access cover.
7. PROM.
1.
2.
[I] Important

circuit board.
BRACKET
RIGHT SIDE WHEELHOUSING

NS 15273
Figure C1-12 - ECM Removal
Replacement ECM is supplied without a PROM, so

care should be used when removing it from the
defective ECM because it will be reused in the new
ECM.
Using two fingers, push both retaining clips back

away from the PROM. At the same time, grasp it at
both ends and lift it up out of the socket. Do Not
remove the cover of the PROM. Use of unapproved
PROM removal methods may cause damage to the
PROM or socket.
ll'l'I Inspect
For alignment notches of the PROM and carefully

set it aside. Do Not open the PROM.
IF ECM IS BEING REPLACED

circuit board.

1.
2.
New EC:\1 from its packaging and check the

service number to make sure it is the same as the
defective EC:\I.
Access cover.
MS 11147
Figure C1-14 PROM Unit Installation

circuit board.

Figure C1-14
1.
PROM in PRO:VI socket.
rn
2.
3.
4.
5.
6.
7.
Important
Gently press down on the ends of the PROM

until the clips are against the sides of the
PROM. DO NOT press on the ends of the
PROM until the clips snap into place, because
the ECM circuit board and/or clips may be
damaged. Press inward on the clips until they
snap into place.
PROM access cover on ECM.

ECM mounting hardware.
Connectors to ECM.
ECM connector shield.
ECM mounting bolts (2).
Functional Check
1.
2.
Turn ignition "ON."

Enter diagnostics.
A. Allow DTC 12 to flash four times to verify no
other DTCs are present. This indicates the
PROM is installed properly and the ECM is
functioning.
B. If DTC 51 occurs, or if the MIL (Service Engine
Soon) is "ON" constantly with no DTCs, the
PROM is not fully seated or is defective.
If it is necessary to remove the PROM,

follow the previous removal instructions.
[JJ
(I]
WATER PUMP
MS 12021
Figure C1-15- ECT Service

SENSOR
NOTICE: Care must be taken wnen handling
engine coolant temperature sensor. Damage to
engine coolant temperature sensor could affect
proper operation of the fuel injection system.

1.
2.
3.
4.
5.
Drain coolant. Refer to SECTION 68.

Raise vehicle.
ECT electrical connector.
Carefully back out engine coolant temperature
sensor from coolant pump.

1.
2.
Coat threads (ONLY) with sealer PN 1052080.

Engine coolant temperature sensor in coolant
pump.
f~I Tighten
Sensor to 23 Nm (17 lb. ft.).
4. Lower vehicle.
5. Fill coolant. Refer to SECTION 6B.
MANIFOLD ABSOLUTE PRESSURE (MAP)

SENSOR

3. Hold down bolts (2).
4. MAP sensor from intake manifold.
f++f Install or Connect

L
2.
3.
New MAP sensor seal (lightly coated with clean

engine oil).
MAP sensor to intake manifold.
Hold down bolts.
(]]
(]] 6 Nm (SO lb. in.)
f~I Tighten
4.
5.
MAP SENSOR CONNECTOR
Bolts to 6 N m (50 lb. in.).

(]]
MAP SENSOR
ECM HARNESS
MS 13213
Figure C1-16- MAP Sensor Service
INTAKE AIR TEMPERATURE (IAT) SENSOR
f++f Remove or Disconnect

1.
2.
3.

Carefully back out intake air temperature sensor
from air duct.

l.
2.
3.
Intake air temperature sensor into air duct.

OXYGEN SENSOR (025) (BANK 1 OR BANK 2)

NOTICE: The oxygen sensor uses a permanently
attached pigtail and connector. This pigtail should
not be removed from the oxygen sensor. Damage
or removal of the pigtail or connector could affect
proper operation of the oxygen sensor.
ELECTRICAL HARNESS
INTAKE AIR TEMPERATURE {IAT) SENSOR

NS 15277
Figure C1-17 - IAT Sensor
[I] Important
Take care when handling the oxygen sensor. The

in-line electrical connector and louvered end must
be kept free of grease, dirt, or other contaminants.
Also, avoid using cleaning solvents of any type. Do
Not drop or roughly handle the oxygen sensor.
The oxygen sensor may be difficult to remove when

engine temperature is below 48C (120F).
Excessive force may damage threads in exhaust
manifold or exhaust pipe.
2. Raise vehicle.
4. Carefully back out oxygen sensor.
EXHAUST MANIFOLD
2
2
OXYGEN SENSOR (025)

NS 15281
Figure C1-18- Bank 1 (Left) Oxygen Sensor (025)
rn
1.
Important
A special anti-seize compound is used on the

oxygen sensor 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 oxygen sensors will already have the
compound applied to the threads. If a sensor is
removed from an engine, and if for any reason
it is to be reinstalled, the threads must have
anti-seize compound applied before
reinstallation.
EXHAUST MANIFOLD
2
OXYGEN SENSOR (025)
STARTER
NS 15280
Figure C1-19 - Bank 2 (Right) Oxygen Sensor (025)
Coat threads of oxygen sensor with anti-seize

compound PIN 5613695 if necessary.
l~I Tighten
2.
3.
4.
Oxygen Sensor (02S) to 41 N m (30 lb. ft.).

Lower vehicle.

l
2.
3.
Two TP sensor attaching screws, lockwashers and
retainers.
Throttle position sensor.

l.
With throttle valve in the normal closed idle

position, install throttle position sensor on throttle
body assembly, making sure TP sensor pickup
SENSOR THROTTLE POSITION (TP)
SCREW TP SENSOR ATTACHING

MP 1224-AS
Figure C1-20 - Throttle Position (TP) Sensor Service
2.
lever lines up with tang on throttle actuator lever.

(Refer to Figure Cl-20.)
Retainers and two TP sensor screws.
6E3-C1-14 5.7L {VIN P) DRIVEABILITY AND EMISSIONS
l~I Tighten
TP sensor attaching screws to 2.0 Nm (18 lb. in.).
PARK/NEUTRAL POSITION {PNP) SWITCH

The park neutral position switch is part of the
transmission position switch assembly.
Refer to SECTION 7A for location of PNP switch.
On-vehicle service and adjustment procedures are also
listed there.
VEHICLE SPEED SENSOR {VSS)

For on-vehicle service procedures of the Vehicle
Speed Sensor (VSS); refer to ''Torque Converter Clutch
(TCC) System (Arr), Automatic Transmission Gear
Switch System, Reverse Lockout G"1/T)," Section "6E3C8".
KNOCK SENSOR {KS)

For On-vehicle service procedures of the knock
sensor, refer to "Knock Sensor (KS) System," Section
"6E3-C5".
Controller, ECM
ECT Sensor
MAP Sensor Bolt
Oxygen Sensor (02S)
TP Sensor Attaching Screws
3 Nm (26 lb. in.)

23 Nm (17 lb. ft.)
6 Nm (50 lb. in.)
41 Nm (30 lb. ft.)
2.0 Nm (18 lb. in.)
BLANK
c
PARK
NEUTRAL
POSITION
SWITCH
20AMP
141 BRN
24LTGRN
e'"v
TURN B/U
(1/P)
4340RN/BLK
~II
451 BLK.,WHT
L.RELEASE
TOHATCH
RELAY
575DKGRN
6 PPL
TO STARTER
SOLENOID
ECM
ENGINEGROUND
TO IGNITION
~ C230
TO BACKUP LAMPS
TO PASS KEY II
RELAY AND BTSI
SOLENOID
11-24-92
MS 12325
CHARTC-1A
(AUTOMATIC TRANSMISSION ONLY)

The Park/Neutral Position (PNP) switch contacts are a part of the neutral start switch, and are closed to
ground in park or neutral and open in drive ranges.
The ECM supplies ignition voltage through a current limiting resistor to CKT 434 and senses a closed switch
when the voltage on CKT 434 drops to less than one volt.
The ECM uses the PNP signal as one of the inputs to control:
Vehicle Speed Sensor (VSS) diagnostics.
If CKT 434 indicates PNP (grounded), while in drive range, the EGR would be inoperative, resulting in
possible detonation.
IfCKT 434 always indicates drive (open), a drop in the idle speed may exist when the gear selector is moved
into drive range.

1. Checks for a closed switch to ground in park
position.
2. Checks for an open switch in drive range.
3. Make sure the Tech 1 indicates drive, even while
wiggling shifter to test for an intermittent or
misadjusted switch in drive range.
DRIVEABILITY AND EMISSIONS 5.7L {VIN P) 6E3-C1-17
CHARTC-1A
{AUTOMATIC TRANSMISSION ONLY)
WITH TRANSMISSION IN PARK, SCAN TOOL

SHOULD INDICATE PARK OR NEUTRAL.
DOES IT?
SHIFT TRANSMISSION INTO DRIVE.

TECH 1 SCAN TOOL SHOULD DISPLAY A
CHANGE TO INDICATE DRIVE.
DOESIT?
DISCONNECT PNP SWITCH.

THIS SHOULD CAUSE SCAN
TOOL TO DISPLAY DRIVE
RANGE.
DOES IT?
FAUL TY PNP SWITCH

CONNECTION
OR
PNP SWITCH MISADJUSTED
OR
FAULTY PNP SWITCH.
NO TROUBLE
FOUND. REFER TO
"INTERMITTENTS"
IN "SYMPTOMS,"
SECTION "B".
CKT 434 SHORTED

TO GROUND
OR
FAULTY ECM.
DISCONNECT PARK/NEUTRAL POSITION SWITCH CONNECTOR.

JUMPER HARNESS CONNECTOR TERMINALS" A" AND "B".
SCAN TOOL SHOULD INDICATE PARK OR NEUTRAL.
DOES IT?
JUMPER HARNESS
CONNECTOR (CKT 434)
TO ENGINE GROUND.
SCAN TOOL SHOULD
INDICATE PARK OR
NEUTRAL.
DOESIT?
FAULTY PNP SWITCH CONNECTION

OR
PNP SWITCH MISADJU5TED
OR
FAULTY PNP SWITCH.
CKT4340PEN
OR
OR
ECM.
5-28-92
MS 12891
MAP SENSOR
ff
f
A B C
MANIFOLD
ABSOLUTE
PRESSURE
(VACUUM)
ECM

.____ _ __._ _ _ _ _ _ 416 GRV
' - - - - - - - - - - - - 432 LTGRN
.__________,.......----~soseLK
TO IA T, A/C REFRIGERANT PRESSURE, AND
10-7-92
MS 12081
CHARTC-10
11
The Manifold Absolute Pressure (MAP) sensor measures the changes in the intake manifold pressure which
result from engine load (intake manifold vacuum) and RPM changes; and converts these into a voltage output.
The ECM sends a 5 volt reference voltage to the MAP sensor. As the manifold pressure changes, the output
voltage of the sensor also changes. By monitoring the sensor output voltage, the ECM knows the manifold
pressure. A lower pressure (low voltage) output voltage will be about 1 - 2 volts at idle. While a higher pressure
(high voltage) output voltage will be about 4 - 4.8 at Wide Open Throttle (WOT). The MAP sensor is also used,
under certain conditions, to measure barometric pressure, allowing the ECM to make adjustments for different
altitudes. The ECM uses the MAP sensor to control fuel delivery and ignition timing.
3.
rn
1.
rn
Important
Be sure to use the same Diagnostic Test

Equipment for all measurements.
When comparing Tech 1 reading to a known good

vehicle, it is important to compare vehicles that
use a MAP sensor having the same color insert or
having the same "Hot Stamped" number. Refer to
figures on facing page.
If MAP sensor voltage is greater than 5 volts,
check for a short to voltage on the MAP sensor
signal circuit.
2. Applying 34 kPa (10" Hg) vacuum to the MAP
sensor should cause the voltage to change. Voltage
change should be greater than 1.5 volts. Upon
applying vacuum to the sensor, the change in
voltage should be instantaneous. A slow voltage
change indicates a faulty sensor.
Check for vacuum leaks or restrictions at intake

mounting surface.
4.
Important

securely fastened.
Remove sensor from intake manifold and twist

sensor by hand (only) to check for intermittent
connection. Output changes greater than .10 volt
would indicate a bad sensor. If OK, replace sensor.
CHARTC-10
NOTICE: THIS CHART ONLY APPLIES TO MAP SENSORS

HAVING GREEN OR BLACK COLOR KEY INSERT (SEE BELOW).
IF OTC 33 OR 34 IS SET, USE THOSE CHARTS FIRST.

SCAN TOOL SHOULD INDICATE A MAP SENSOR VOLTAGE.
COMPARE THIS READING WITH THE READING OF A KNOWN GOOD VEHICLE.
SEE FACING PAGE TEST DESCRIPTION, STEP 1.
VOLTAGE READING SHOULD BE WITHIN :t .4 VOLT.
ISIT?
REPLACE MAP SENSOR.
DISCONNECT AND PLUG VACUUM SOURCE TO MAP SENSOR.

CONNECT A HAND VACUUM PUMP TO MAP SENSOR.
START ENGINE.
NOTE MAP SENSOR VOLTAGE.
APPLY 34 kPa (10" Hg) OF VACUUM AND NOTE VOLTAGE CHANGE.
SUBTRACT SECOND READING FROM THE FIRST. VOLTAGE VALUE
SHOULD BE GREATER THAN 1.5 VOL TS.
ISIT?
NO TROUBLE FOUND. CHECK MAP SENSOR VACUUM

SOURCE FOR LEAKAGE OR RESTRICTION. BE SURE THIS
SOURCE SUPPLIES VACUUM TO MAP SENSOR ONLY.
CHECK MAP SENSOR CONNECTION.

If OK, REPLACE MAP SENSOR.
HOT-STAMPED
NUMBER
COLOR
KEYED INSERT
LS 9045-6E
LS 8963-6E
Figure 1 - Color Key Insert
Figure 2 - Hot Stamped Number
3-10-92
7S3162-6E
BLANK
SECTION C2

CONTENTS
General Description
Purpose
Modes of Operation
Starting Mode
Clear Flood Mode
Run Mode
Acceleration Mode
Deceleration Mode
Fuel Cutoff Mode
Fuel Metering System Components
Fuel Supply Components
Fuel Rail Assembly
Fuel Injectors
Diagnosis
Fuel Pump Relay
Fuel System Pressure Test
See Section 6E3, Chart A-7
C2-1
C2-1
C2-1
C2-1
C2-1
C2-1
C2-2
C2-2
C2-2
C2-2
C2-2
C2-2
C2-2
C2-2
C2-3
C2-3
C2-3
C2-4
C2-5
C2-5
C2-5
C2-5
GENERAL DESCRIPTION
PURPOSE
The function of the fuel metering system is to
deliver the correct amount of fuel to the engine under
all operating conditions. Fuel is delivered to the
engine by individual fuel injectors mounted in the
intake manifold near each cylinder.
The main control sensors are the Oxygen Sensors
(028) located in both exhaust manifolds. The 028
tells the Engine Control Module (ECM) how much
oxygen is in the exhaust gas. The ECM changes the
air/fuel ratio to the engine by controlling the fuel
injectors. The best mixture to minimize exhaust
emissions is 14.7 to 1, which allows the catalytic
converter to operate the most efficiently. Because of
the constant measuring and adjusting of the air/fuel
ratio, the fuel injection system is called a "Closed
Loop" system.
MODES OF OPERATION
The ECM looks at voltages from several sensors to
determine how much fuel to give the engine. The fuel
is delivered under one of several conditions called
modes. All modes are controlled by the ECM and are
described below.

See Chart C2-B
On-Vehicle Service
Service Information
Thread-Locking Material
Fuel Pump Relay

Multi port Fuel Injection Components
Fuel Rail Assembly
Engine Fuel Pipes
Fuel Injectors


IAC Valve/Coolant Cover Assembly
Chart C2-A- Injector Balance Test
Chart C2-C - Idle Air Control
(IAC) Valve Check
C2-6
C2-6
C2-6
C2-6
C2-6
C2-6
C2-7
C2-8
C2-8
C2-10
C2-11
C2-12
C2-12
C2-14
C2-14
C2-16
C2-18
Starting Mode
the fuel pump relay for two seconds allowing the fuel
pump to build up pressure. The ECM then checks the
Engine Coolant Temperature (ECT) Throttle Position
(TP), and Manifold Absolute Pressure (MAP) sensors
to determine the proper air/fuel ratio for starting. This
ranges from 1.5:1 at -36C (-33F) to 14.7:1 at 94C
(201 F) running temperature. The ECM controls the
amount of fuel delivered in the starting mode by
changing how long the injectors are energized. This is
done by pulsing the injectors for very short times.
Clear Flood Mode

If the engine floods, it can be cleared by pushing
the accelerator pedal down all the way. The ECM then
pulses the injectors at an air/fuel ratio of 20:1. The
ECM holds this injector rate as long as the throttle
stays wide open and the engine speed is below 600
RPM. If the throttle position becomes less than 80%,
the ECM returns to the starting mode.
Run Mode
The run mode has two conditions called "Open
Loop" and "Closed Loop."

When the engine is first started, and engine speed
is above 400 RPM, the system goes into "Open Loop"
operation. The ECM ignores the signal from the 02S
and calculates the air/fuel ratio based on inputs from
the ECT and Manifold Absolute Pressure (MAP)
sensors.
The system stays in "Open Loop" until the
following conditions are met:
1. Both 02S have varying voltage output,
showing that they are hot enough to operate
properly. (This depends on temperature.)
2. The ECT sensor is above a specified
temperature about 40C (104F).
3. A specific amount of time has elapsed after
starting the engine.
Specific values for the above conditions exist for
each different engine, and are stored in the
Programmable Read Only Memory (PROM). When
these values are reached, the system goes into "Closed
Loop" operation.
In "Closed Loop," the ECM calculates the air/fuel
ratio (injector on-time) based on the signal from
various sensors, but mainly the 02S. This allows the
air/fuel ratio to stay very close to 14.7:1.
Fuel Cutoff Mode

To prevent possible engine damage from overspeed, the ECM cuts off fuel from the injectors when
the engine speed is above approximately 5800 RPM.
To prevent tire damage on vehicles equipped with base
tires, the ECM also cuts off fuel from the injectors at
vehicle speeds above 108 mph. Also, see rapid
deceleration in "Deceleration Mode."
FUEL METERING SYSTEM COMPONENTS

The fuel metering system is made up of the
following parts:
Fuel supply components (fuel tank, pump,
lines).
Fuel pump electrical circuit.
Fuel rail assembly, including:
Fuel injectors.
Fuel pressure regulator assembly.
Throttle body assembly, including:
Idle Air Control (IAC) valve.
Acceleration Mode
FUEL SUPPLY COMPONENTS
When the driver pushes on the accelerator pedal,

air flow into the cylinders increases rapidly, while fuel
flow tends to lag behind. To prevent possible
hesitation, the ECM increases the pulse width to the
injectors to provide extra fuel during acceleration. The
amount of fuel required is based on throttle position,
coolant temperature, manifold air pressure, and
engine speed.

electric fuel pump, located in the fuel tank with the
fuel level sensor assembly, pumps fuel through an inline fuel filter to the fuel rail assembly. The pump is
designed to provide fuel at a pressure greater than is
needed by the injectors. The fuel pressure regulator,
part of the fuel rail assembly, keeps fuel available to
the injectors at a regulated pressure. Unused fuel is
returned to the fuel tank by a separate line. For
further information, refer to SECTION 6C for
replacement procedures covering the fuel tank, fuel
pump, in-line filter, and fuel lines.
Deceleration Mode
When the driver releases the accelerator pedal, air
flow into the engine is reduced.
The corresponding changes in throttle position and
manifold air pressure are relayed to the ECM, which
reduces the injector pulse width to reduce fuel flow. If
the deceleration is very rapid, or for long periods (such
as long closed throttle coast-down), the ECM shuts
"OFF" fuel completely to protect the catalytic
converter.

When battery voltage is low, the ECM
compensates for the weak spark delivered by the
distributor by:
Increasing the amount of fuel delivered;
Increasing the idle RPM; and
Increasing ignition dwell time.
FUEL PUMP ELECTRICAL CIRCUIT

the fuel pump relay for two seconds, causing the fuel
pump to pressurize the fuel system. If the ECM does
not receive ignition reference pulses (engine cranking
or running) within two seconds, it shuts "OFF" the fuel
pump relay, causing the fuel pump to stop.
FUEL RAIL ASSEMBLY

Figure C2-1
The fuel rail assembly is mounted to the engine
intake manifold, and performs several functions; it
positions the injectors in the intake manifold, it
distributes fuel evenly to the injectors, and it
integrates the fuel pressure regulator into the fuel
metering system.
DRIVEABILITY AND EMISSIONS 5. 7L {VIN P) 6E3-C2-3

2
REGULATOR ASSEMBLY -FUEL PRESSURE
INLET ASSEMBLY - FUEL

NA 1335-AS
SOLENOID ASSEMBLY
HOUSING -SPRAY
SPACER AND GUIDE

ASSEMBLY
SPRING - CORE
CORE SEAT
HOUSING -SOLENOID
VALVE - BALL
10
SOLENOID
SPRAY TIP
11
FILTER - FUEL INLET
PLATE - DIRECTOR
Fuel Injectors
Figure C2-2
The top-feed fuel injector assembly is a solenoidoperated device, controlled by the ECM, that meters
pressurized fuel to a single engine cylinder. The ECM
energizes the injector solenoid, which opens a ball
valve, allowing fuel to flow past the ball valve, and
through a recessed flow director plate. The director
plate has six machined holes that control the fuel flow,
generating a conical spray pattern of finely atomized
fuel at the injector tip.
Fuel is directed at the intake valve, causing it to
become further atomized and vaporized before
entering the combustion chamber.
An injector that is stuck partly open would cause
loss of pressure after engine shut down. Consequently,
long cranking times would be noticed on some engines.
Dieseling could also occur, because some fuel could be
delivered to the engine after the ignition is turned
"OFF."

Figure C2-3
The fuel pressure regulator is a diaphragmoperated relief valve with fuel pump pressure on one
side, and regulator spring pressure and intake
manifold vacuum on the other. The regulator's
function is to maintain a constant pressure differential
9P0413-SY
Figure C2-2 - Fuel Injector Assembly
across the injectors at all times. The pressure

regulator compensates for engine load by increasing
fuel pressure as engine vacuum drops.
With the ignition "ON" and engine "OFF" (zero
vacuum), system fuel pressure at the pressure test
connection should be 284-325 kPa (41-47 psi). If the
pressure is too low, poor performance could result. If
the pressure is too high, excessive odor and a
Diagnostic Trouble Code (DTC) 45/65 may result.
CHART A-7 has information on diagnosing fuel
pressure conditions.

Figure C2-4
The throttle body assembly is attached to the
intake manifold, and is used to control air flow into the
engine, thereby controlling engine output. The
throttle valves within the throttle body are opened by
the vehicle operator through the accelerator controls.
COVER
VACUUM CHAMBER
(VACUUM SOURCE TUBE NOT SHOWN)
SEAL - 0-RING
VALVE-FUEL PRESSURE REGULATOR
BASE ASSEMBLY
FILTER - SCREEN (IF EQUIPPED)
VALVE ASSEMBLY - IDLE AIR CONTROL
DIAPHRAGM
SPRING
VALVE ASSEMBLY -AIR VENT
NA 0493-SY
Figure C2-3 - Fuel Pressure Regulator Assembly

(Typical)
During engine idle, the throttle valves are almost

closed, and air flow control is handled by a fixed air
bypass orifice and the Idle Air Control (IAC) valve,
described below. To prevent throttle valve icing
during cool weather operation, engine coolant is
directed through the coolant cavity on the bottom of
the throttle body.
The throttle body also provides the location for
mounting the Throttle Position (TP) sensor and for
sensing changes in engine vacuum due to throttle
valve position.
Vacuum ports are located at, above, or below the
throttle valve to generate vacuum signals needed by
various components.

Figure C2-5
The purpose of the IAC valve assembly is to control
engine idle speed, while preventing stalls due to
changes in engine load.
The IAC valve, mounted in the throttle body,
controls a portion of the bypass air. An orifice located
between the throttle valves also supplies a constant
amount of bypass air. By moving a conical valve
known as a pintle, IN, towards the seat (to decrease air
flow); or OUT, away from the seat (to increase air
flow), a controlled amount of air can be bypassed. If
engine speed is too low, more air is bypassed to
MP 1301-AS
Figure C2-4 - Throttle Body Assembly
increase RPM. If engine speed is too high, less air is

bypassed to decrease RPM.
The ECM moves the IAC valve in small steps,
called counts. These can be measured and displayed
by a scan tool, which plugs into the Data Link
Connector (DLC).
During idle, the proper position of the IAC valve is
calculated by the ECM, based on battery voltage,
coolant temperature, engine load, and engine RPM. If
the RPM drops below specification and the throttle
valve is closed, the ECM senses a near stall condition
and calculates a new valve position to prevent stalling.
Engine idle speed is a function of total air flow into
the engine based on IAC valve pintle position +
crankcase ventilation valve flow + throttle valve
opening + bypass orifice air flow + calibrated
vacuum loss through accessories.
Controlled idle speed is programmed into the
ECM which determines the correct IAC valve
pintl; position to maintain the desired idle speed
for all engine operating conditions and loads.
The minimum idle air rate is set at the factory
with a stop screw. This setting allows enough air
flow by the throttle valves to cause the IAC valve
pintle to be positioned a calibrated number of steps
(counts), from the seat, during controlled idle
operation.


2
VALVE -THROTTLE
PINTLE - IAC VALVE
ELECTRICAL INPUT SIGNAL
rn
AIR INLET
NA 0494-SY
Figure C2-5 - IAC Valve Air Flow Diagram
Always start with the On-Board Diagnostic (OBD)

system check in the "Engine Components/Wiring
Diagrams/Diagnostic Charts," Section "6E3-A". This
will reduce diagnosis time and prevent unnecessary
parts replacement. Diagnosis of the "Fuel Metering
System," is covered in CHART A-3, "Engine Cranks
But Won't Run," and CHART A-7, "Fuel System
Diagnosis." These charts cover the diagnosis of the
injectors, pressure regulator, and the fuel pump.
A malfunction in the fuel metering system usually
results in either a rich or lean 02S signal. This signal
causes the ECM to change the fuel calculation (injector
pulse width). The change made to the fuel calculation
is indicated by a ~hange in the short and long term fuel
trim values which can be monitored with a scan tool.
A momentary change to the fuel calculation is
indicated by the short term fuel trim value, while a
prolonged change is indicated by the long term fuel
trim value. Average fuel trim values are around 128,
but vary slightly from engine to engine.
If the IAC valve is disconnected and reconnected

with the engine running, the idle speed may be
wrong. If this occurs, reset the IAC valve by
depressing the accelerator pedal slightly, start and
run engine for five seconds, then turn ignition
"OFF" for ten seconds.

The TP sensor is mounted on the side of the
throttle body opposite the throttle lever. It senses the
throttle valve angle and relays that information to the
ECM. Knowledge of throttle angle is needed by the
ECM to generate the required injector control signals
(pulses). Refer to "Engine Control Module (ECM) and
Sensors," Section "6E3-Cl".
DIAGNOSIS
FUEL PUMP RELAY
See illustration in "On-Vehicle Service." For
diagnosis of the fuel pump relay circuit, refer to
CHARTA-5.
Important
When using a scan tool to observe fuel trim values,

remember that if the system is in control, no action
is required unless a driveability symptom is
present. Listed below are examples of lean and
rich 02S signals with the system in control and out
of control.
A momentary lean 028 signal (system is in
Short term fuel trim value above 128 (adding
fuel).
A prolonged lean 028 signal (system is in control)
Long term fuel trim value above 128 (added
fuel).
A prolonged lean 028 signal (system is out of
Short term fuel trim value well above 128
(adding fuel).
Long term fuel trim value well above 128
(added fuel).
If both fuel trim values are fixed well above 128
refer to DTC 44 or 64 for items which can cause a lea~
02S signal.
A momentary rich 028 signal (system is in
Short term fuel trim value less than 128
(reducing fuel).
A prolonged rich 028 signal (system is in control)

Long term fuel trim value less than 128
(reduced fuel).
A prolonged rich 028 signal (system is out of
Short term fuel trim value much less than 128
(reducing fuel).
Long term fuel trim value much less than 128
(reduced fuel).
If the fuel trim values are fixed well below 128,
refer to DTC 45 or 65 for items which can cause the
fuel control system to run rich. If a driveability
symptom exists, refer to the particular symptom in the
"Symptoms," Section "6E3-B" for additional items to
check.
ON-VEHICLE SERVICE
SERVICE INFORMATION
Thread-Locking Material
rn
Important
The hardware used to attach the Throttle Position

(TP) sensor is coated with thread-locking adhesive.
If the TP sensor is removed for service, inspect the
attaching screw threads. There should be enough
thread-locking material (adhesive or compound)
on the threads to insure proper relocking. If not,
clean the threads and apply Loctite 262 to the
threads before reassembly. Replacement screws
are included in the service screw assortment
package. New attaching hardware is included in
the service packages.
LEFT DOOR JAM ("A" PILLAR)
CAUTION:
To reduce the risk of fire and personal
injury, relieve the fuel system pressure
before servicing fuel system components.
After relieving system pressure, a small
amount of fuel may be released when
servicing fuel lines or connections. To
reduce the chance of personal injury,
cover fuel line fittings with a shop towel
fuel
before disconnecting to catch
that may leak out. Place the towe in an
approved container when disconnect is
completed.
anr
FUEL PRESSURE RELIEF PROCEDURE

1.
2.
3.
4.
Fuel pump relay.

foot rest).
Ignition "OFF."
FUEL PUMP RELAY
MULTIPORT FUEL INJECTION COMPONENTS

4.
Figure C26 Fuel Pump Relay

Ignition "OFF."
foot rest).
Fuel pump relay from electrical connector.
DEAD PEDAL BRACKET
NS 15279
FUEL PUMP RELAY

Figure C2-6
1.
2.
3.
Tool Required:
Ignition "OFF."
Disconnect negative battery cable to avoid possible
start the engine.
3. Loosen fuel filler cap to relieve tank vapor
pressure.
1.
2.

MANUFACTURING
INFORMATION
c::r=[J
YEAR-!
DAY OF
YEAR
MODEL NUMBER
I I I I 111111111
'-.,-'
NA 1336-AS
Figure C2-7 - Fuel Rail Assembly Identification
Connect gage J 34730-1 to fuel pressure valve.

container.
4.
FUEL RAIL ASSEMBLY

Figures C2-7 through C2-9
Tools Required:
J 37088-A Fuel Line Release Tool Set
An eight digit identification number is stamped on
the fuel rail assembly. Refer to this model
identification number if servicing or part replacement
is required.
Names of component parts will be found on the
numbered list that accompanies the disassembled
view.
NOTICE:
Use care in removing the fuel rail assembly to
prevent damage to the injector electrical connector
terminals and the injector spray tips. When
removed, support the rail to avoid damaging its
components.
Prevent dirt and other contaminants from
entering open lines and passages. Fittings should
be capped, and holes plugged, during servicing.
~ Cleaning
Before removal, the fuel rail assembly may be

cleaned with a spray type engine cleaner, GM
X-30A or equivalent, following package
instructions. Do Not soak fuel rails in liquid
cleaning solvent.
FUEL RAIL ATTACHING BOLT

2
FUEL RAIL ASSEMBLY
INTAKE MANIFOLD
NS 15926
Figure C2-8 - Fuel Rail Removal and Installation
I+-+! Remove or Disconnect

1.
2.
3.
4.
5.
6.
Ignition "OFF."
Relieve fuel system pressure. (Refer to the "Fuel
Quick-connect fittings at engine fuel pipes.
Slide rubber dust covers from quick-connect
fittings at engine fuel pipes.
Grasp both sides of fitting. Twist female connector
1/4 turn in each direction to loosen any dirt within
fitting.
CAUTION: Safety glasses. must b~ worn

when using compresse~ a_,r, as flying dirt
particles may cause eye mJury.
8. Choose correct tool from J 37088-A tool set for size
of fitting. Insert tool into female connector, then
push/pull inward to release locking tabs.
IL! Clean and Inspect
NOTICE: Ifit is necessary to remove rust or burrs

from fuel pipe, use emery cloth in a radial motion
with the pipe end to prevent damage to 0-ring
sealing surface.

end.
required.
10. Vacuum line at pressure regulator.

11. Vacuum lines to gain access to fuel rail and engine
fuel pipes.
12. Electrical harness from routing clips on fuel rail.
13. Engine fuel pipe retaining bolt.
14. Injector electrical connectors.
15. Fuel rail attaching bolts.
lt:.WI ILI Cleaning and Inspection

NOTICE: If it is necessary to remove rust or
burrs from the engine fuel pipes: use emery cloth
in a radial motion with the tube end to prevent
damage to 0-ring sealing surface.
Using a clean shop towel, wipe off male tube
ends.
Inspect all connectors for dirt and burrs. Clean
or replace components/assemblies as required.
l+!+I Disassemble
Injector 0-ring seal from spray tip end of each

injector. Discard 0-ring seals.
l+;+I Assemble
Lubricate new injector 0-ring seals and install on

spray tip end of each injector.
11.
12.
13.
14.
Slide dust covers over quick-connect fittings.

Ignition "OFF."
ILf inspect

seconds, then turn "OFF" for ten seconds. Again
turn to "ON" position and check for fuel leaks.
ENGINE FUEL PIPES

Figure Cl-10

1.
2.
3.
4.
Ignition "OFF."
Relieve fuel system pressure.
Refer to the "Fuel Pressure Relief Procedure."
Fuel rail assembly.
Refer to the "Fuel Rail Assembly Removal
Procedure."
l+!+I Disassemble
1.
2.
3.
Engine fuel pipe retaining screw.

Engine fuel pipes from fuel rail.
0-rings from fuel inlet block and fuel pressure
regulator and discard.
l*+I Assemble
1.
2.
Lubricate new 0-rings with clean engine oil and

install in fuel inlet block and fuel pressure
regulator.
Push engine fuel pipes into fuel inlet block and
fuel pressure regulator.
Engine fuel pipe retainer and attaching screw.
3.
1.
2.
Fuel rail assembly in intake manifold.

Fuel rail attaching bolts.
l~I Tighten
l~I Tighten
Fuel rail attaching bolts to 20 N m (15 lb. ft.).

Injector electrical connectors.
Rotate injector(s) as required to avoid
stretching wire harness.
Engine fuel pipe retaining nut.
Electrical harness into routing clips on fuel rail.
Vacuum lines to intake manifold and fuel pressure
regulator.
Quick-connect fittings to engine fuel pipes.
Apply a few drops of clean engine oil to the male
pipe end of engine fuel pipe, pressure gage adapter
or fuel line shut-off adapter.
Push both sides of fitting together to cause the
Once installed, pull on both sides of fitting to make
l+f Install or Connect
3.
4.
5.
6.
7.
8.
9.
10.
1.
2.
3.
Engine fuel pipe retainer attaching screw to 9.5

Nm (84 lb. in.).
Fuel rail assembly.

Ignition "OFF."
ILf inspect

seconds, then turn "OFF" for ten seconds. Again
FUEL INJECTORS
Figures C2-11 and Cl-12
NOTICE: Use care in removing injectors to
prevent damage to the electrical connector pins on
the injector and the nozzle.
9
18
13
17
12
RAIL ASM LH MFI FUEL
12
REGULATOR ASM FUEL PRESSURE
ORING FUEL CROSSOVER TUBE
13
ORING FUEL OUTLET TUBE
CLIP FUEL CROSSOVER TUBE
14
SCREEN FILTER (IF SO EQUIPPED)
TUBEFUELCROSSOVER
15
ORING FUEL INLET FITTING
SCREW CROSSOVER TUBE RETAINER ATTACHING
16
SCREW FUEL INLET ASM ATTACHING
RETAINER FUEL CROSSOVER TUBE
17
INLET ASM FUEL
RAIL ASM RH MFI FUEL
18
0-RING FUEL INLET TUBE
0-RING FUEL INJECTOR
19
ORING FUEL INLET ASM
INJECTOR ASM MFI FUEL
20
RETAINER ASM FUEL TUBE
10
CLIP INJECTOR RETAINER
21
SCREW FUEL TUBE RETAINER ASM ATTACHING
11
SCREW PRESSURE REGULATOR ATTACHING

5-14-92
NA0199-XV
MP 1296-AS
Figure C2-11 - Fuel Injector and Retainer Clip
3.
4.
RETAINING NUT
2
ENGINE FUEL PIPE
FUEL RAIL
INTAKE MANIFOLD

NS 15927
Figure C2-10 - Engine Fuel Pipes
The fuel injector is serviced as a complete

assembly only. Since it is an electrical component,
Do Not immerse it in any cleaner.
1.
2.
3.
4.
4.
Ignition "OFF."
Refer to the "Fuel Pressure Relief Procedure."
Fuel rail assembly.
l+t+I Disassemble
1.
2.
3.
4.
Rotate injector retainer clip to release position.

Fuel injector assembly.
Injector 0-ring seals from both ends of injector,
and discard.
Injector retainer clip.
rn
Important
When ordering new fuel injectors, be sure to order

the correct injector for the application being
serviced.
!+~+I Assemble
1.
2.
Lubricate new injector 0-ring seals with clean

engine oil, and install on injector.
New retainer clip onto injector.
Fuel rail assembly.

Ignition "OFF."
!L'l'! Inspect

1.
2.
3.
Fuel injector assembly into fuel rail injector

socket, with electrical connector facing outward.
Rotate injector retainer clip to locking position.

seconds, then turn to "OFF" for ten seconds. Again
FUEL PRESSURE REGULATOR ASSEMBLY

Figure C2-9
rn
Important
The pressure regulator is serviced as a complete

assembly only.

1.
2.
3.
4.
Ignition "OFF."
Refer to "Fuel Pressure Relief Procedure."
Fuel rail assembly.
Refer to "Fuel Rail Removal."
!+t+! Disassemble
1.
2.
3.
Pressure regulator attaching screw.

Pressure regulator from fuel rail.
Pressure regulator 0-ring and discard.
!+~+I Assemble
1.
Lubricate new pressure regulator 0-ring with

clean engine oil and install on regulator.
DRIVEABILITY AND EMISSIONS 5. 7L (VIN P) 6E3-C2-11
DJ
GASKET
IT]
[I]
[I]
BOLT
IDLE AIR CONTROL {IAC) VALVE

THROTTLE POSITION SENSOR {TPS)
MS 12304-6E
Figure C213 Throttle Body Removal (Typical)
Refer to this number if servicing, or part replacement

is required. For identification of parts during repair,
refer to the disassembled view (Figure C2-15).
INJECTOR ASSEMBLY - FUEL

A
PART NUMBER IDENTIFICATION
BUILD DATE CODE
MONTH 1-9 (JAN-SEPT) 0, N, D {OCT, NOV, DEC)
DAY
YEAR
12) Cleaning
rn
MP 1222-AS
Figure C2-12 - Injector Part Number Location
2.
3.
Push pressure regulator into rail.

Pressure regulator attaching screw.
!~I Tighten
Pressure regulator attaching screw to 9.5 Nm

(84 lb. in.).
Refer to "Thread-Locking Material."
!+I Install or Connect

3. Ignition "OFF."
flitl Inspect

seconds, then turn to "OFF" for ten seconds. Again

Figure Cl-13
The throttle body assembly repair procedures
cover component replacement with the unit on the
vehicle. However, throttle body replacement requires
that the complete unit be removed from the engine.
An eight digit part identification number is
stamped on the throttle body casting as shown in
Figure C2-14.
Important
Do not soak the throttle body in cold

immersion type cleaner. The throttle valves
have a factory applied sealing compound (DAG
material is applied to outside edge of each
valve and throttle bore) to prevent air bypass
at closed throttle. Strong solvents or brushing
will remove the material. To clean the throttle
body following disassembly, use a spray type
cleaner such as GM X66-A or GM 1052626.
Use a shop towel to remove heavy deposits.
NOTICE: The TP sensor and IAC valve are

electrical components and should NOT come in
contact with solvent or cleaner, as they may be
damaged.

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
Ignition "OFF."
Partially drain cooling system to allow hoses at
throttle body to be removed. Refer to SECTION
6B.
Air intake duct. Refer to "Air Intake System,"
Section "6E3-Cl4".
Electrical connectors from TP sensor and IAC
valve.
Vacuum lines.
Coolant hoses from throttle body.
Accelerator cable shield.
Accelerator control cable(s).

Figure C2-15

2. TP sensor attaching screws.
3. TP sensor.
I I I Ir_
'--y--J
NOTICE: The TP sensor is an electrical

component and must not be soaked in any liquid
cleaner or solvent as damage may result.
YEAR
DAY
OF
YEAR
8 DIGIT
IDENTIFICATION
NUMBER
1.
MP1302-AS
Figure C2-14 - Throttle Body Identification
11. Throttle body assembly and flange gasket.

Discard gasket.
2.
~ Clean
l~I Tighten
NOTICE:
Use care in cleaning old gasket

material from machined aluminum surfaces as
sharp tools may damage sealing surfaces.
Gasket sealing surfaces.
1-++I Install or connect

1.
2.
Throttle body assembly with new flange gasket.

l~I Tighten
3.
4.
5.
6.
7.
8.
9.
10.
11.
Throttle body attaching bolts to 15 Nm

(11 lb. ft.).
Accelerator control cable(s).
Coolant hoses to throttle body.
Vacuum lines.
Electrical connectors to TP sensor and IAC valve.
Accelerator cable shield.
Air intake assembly. Refer to "Air Intake
System," Section "6E3-C14".
Refill radiator. Refer to SECTION 6B.
Ignition "OFF."
ll'l'I Inspect
With the engine "OFF," check to see that the

accelerator pedal is free.
Depress pedal to the floor and release.
A. Depress accelerator pedal slightly.
B. Start and run engine for five seconds.
C. Turn ignition "OFF" for ten seconds.
D. Restart engine and check for proper idle
operation.
With throttle valve in the closed position, install

the TP sensor on the throttle body assembly,
making sure TP sensor lever lines up with the TP
sensor drive lever on the throttle shaft.
TP sensor attaching screws coated with
appropriate thread-locking material.
Refer to "Thread-Locking Material."
TP sensor attaching screws to 2.0 Nm (18 lb.

in.).
IDLE AIR CONTROL (IAC) VALVE

Figures C2-15 and C2-16
Tool Required:
J 35632 IAC Removal Tool

1.
2.
3.
Electrical connectors from TP sensor IAT sensor

and IAC valve.
'
'
Air inlet assembly. Refer to "Air Intake System,"
Section "6E3-C14".
IAC valve assembly and gasket using J 35632
socket.
Discard gasket.
NOTICE: On IAC valves that have been in

service: Do Not push or pull on the IAC valve
pintle. The force required to move the pintle may
damage the threads on the worm drive. Also, do
not soak IAC valve in any liquid cleaner or
solvent, as damage may result.
ll"'I Cleaning and Inspection
Both original and replacement IAC valves have a

special factory applied thread-locking compound
applied to the screw threads. If the valve removed
from the throttle body it is being reinstalled. Do
Not remove the thread-locking compound that
may be on the threads.
Clean IAC valve gasket sealing surface, pintle
valve seat and air passage.
17
/,---9
16
~
11
GASKET - FLANGE
10
SCREW - IACV COVER ASSEMBLY TO

THROTTLE BODY ATTACHING
SPRING - IDLE STOP SCREW
11
GASKET- IA( VALVE ASSEMBLY
SCREW - IDLE STOP
12
PLUG - IDLE STOP SCREW
13
COVER ASSEMBLY - IACV/COOLANT
COVER - CLEAN AIR
14
GASKET - IACV/COOLANT COVER ASSEMBLY

TO THROTTLE BODY
SCREW - CLEAN AIR COVER ATTACHING
15
SEAL-STATIC
GASKET - CLEAN AIR COVER
16
17
SCREW-TP SENSOR ATTACHING
VALVE ASSEMBLY -AIR VENT

6-15-92
NA 0200-XV
Figure C21 S Throttle Body Assembly
rn
Use carburetor cleaner to remove carbon

deposits. Do Not use a cleaner that contains
methyl ethyl ketone, an extremely strong
solvent, and not necessary for this type of
deposit.
Shiny spots on the pintle or seat are normal,
and do not indicate misalignment or a bent
pintle shaft.
Important
c
If installing a new IAC valve, be sure to replace
with an identical part. IAC valve pintle shape and

diameter are designed for the specific application.
l~I Measure (If Installing a New IAC Valve)
Distance between tip of IAC valve pintle and

mounting surface.
If greater than 28 mm, use finger pressure to
slowly retract the pintle. The force required to
retract the pintle of a new valve will not cause
damage to the valve.

1.
IAC valve to 18 Nm (13 lb. ft.).

Using socket J 35632.
2. Air inlet assembly. Refer to "Air Intake System,"
Section "6E3-C14".
3. Electrical connectors to TP sensor, IAT sensor, and
IAC valve.
A. Depress accelerator pedal slightly.
B. Start and release accelerator pedal, run engine
for five seconds.
C. Turn ignition "OFF" for ten seconds.
D. Restart engine and check for proper idle
operation.
IDLE AIR CONTROL VALVE/COOLANT COVER

ASSEMBLY
Figure C2-15
Throttle body from intake manifold.

Refer to "Throttle Body Assembly."
+!+I Disassemble
1.
IAC valve
Refer to "Idle Air Control (IAC) Valve."
2. Idle air control valve/coolant cover assembly
screws.
3. Idle air control valve/coolant cover assembly and
gasket.
Discard gasket.
DISTANCE OF PINTLE EXTENSION
DIAMETER AND SHAPE OF PINTLE
IAC VALVE GASKET
9P 1058-AS
Figure C2-16 - Idle Air Control Valve Assembly
IAC valve assembly with new gasket.
l~I Tighten
ll"'I Cleaning and Inspection
Clean gasket sealing surface.

Inspect gasket sealing surface for corrosion or
damage that would cause a coolant leak. Replace
idle air control valve/coolant cover assembly or
throttle body if necessary.
I+~+! Assemble
1.
2.
3.
New gasket.
Idle air control valve/coolant cover assembly
assembly.
Idle air control valve/coolant cover assembly
screws.
I++! Install and Connect
Throttle body to intake manifold.

Refer to "Throttle Body Assembly."
Fuel Rail Attaching Bolts
Fuel Pressure Regulator
Attaching Screw
Engine Fuel Pipe Retainer
Attaching Screw
Throttle Body
Attaching Bolts
TP Sensor
20.0 Nm (15 lb. ft.)
9.5 Nm ( 84 lb. in.)

9.5 Nm (84 lb. in.)
15.0 Nm (11 lb. ft.)
2.0 Nm (18 lb. in.)
18.0 Nm (13 lb. ft.)
BLANK
CHARTC-2A
The injector balance tester is a tool used to turn the injector "ON" for a precise
amount of time, thus spraying a measured amount of fuel into the manifold.
This causes a drop in fuel rail pressure that we can record and compare between
each injector. All injectors should have the same amount of pressure drop ( 10
kPa). Any injector with a pressure drop that is 10 kPa (or more) greater or less
than the average drop of the other injectors should be considered faulty and
replaced.
STEP 1
Engine "cool down" period (10 minutes) is necessary to avoid irregular
readings due to "Hot Soak" fuel boiling. With ignition "OFF" connect fuel gauge
J 3470-1 to fuel pressure tap. Wrap a shop towel around fitting while connecting
gage to avoid fuel spillage.
Disconnect harness connectors at all injectors, and connect injector tester
J 34730-3A to one injector. Follow manufacturers instructions for use of adaptor
harness. Ignition must be "OFF" at least 10 seconds to complete ECM shutdown
cycle. Fuel pump should run about 2 seconds after ignition is turned "ON." At
this point, insert clear tubing attached to vent valve into a suitable container
and bleed air from gauge and hose to insure accurate gauge operation. Repeat
this step until all air is bled from gauge.
STEP2
Turn ignition "OFF" for 10 seconds and then "ON" again to get fuel pressure
to its maximum. Record this initial pressure reading. Energize tester one time
and note pressure drop at its lowest point (disregard any slight pressure increase
after drop hits low point). By subtracting this second pressure reading from the
initial pressure, we have the actual amount of injector pressure drop.
STEP3
Repeat Step 2 on each injector and compare the amount of drop. Usually, good
injectors will have virtually the same drop. Retest any injector that has a
pressure difference of 10 kPa, either more or less than the average of the other
injectors on the engine. Replace any injector that also fails the retest. If the
pressure drop of all injectors is within 10 kPa of this average, the injectors
appear to be flowing properly. Reconnect them and review "Symptoms," Section
"6E3-B".
NOTICE:
The entire test should not be repeated more than once without
running the engine to prevent flooding. (This includes any retest on faulty
injectors.)
NOTICE: The entire test should NOT be repeated more than

once without running the engine to prevent flooding. (This
includes any retest on faulty injectors.)
The fuel pressure test in Section "A" Chart A-7, should be
completed prior to this test.
CHARTC-2A
5.7L (VIN P) "F" CARLINE
(MFI)
Step 1. If engine is at operating temperature, allow a 10 minute "cool down" period then connect fuel
pressure gage and injector tester.
1. Ignition "OFF."
2. Connect fuel pressure gage and injector tester.
3. Ignition "ON."
4. Bleed off air in gage. Repeat until all air is bled from gauge.
Step 2. Run test:
1. Ignition "OFF" for 10 seconds.
2. Ignition "ON." Record gage pressure. (Pressure must hold steady, if not, see "Fuel System
Diagnosis," CHART A-7, in Section "A").
3. Turn injector on, by depressing button on injector tester, and note pressure at the instant
the gauge needle stops.
Step 3.
1.
Repeat Step 2 on all injectors and record pressure drop on each. Retest injectors that
appear faulty (Any injectors that have a 10 kPa (1.5 psi) difference, either more or less, in
pressure from the average). If no problem is found, review "Symptoms" Section "B".
(INITIAL PRESSURE)
OUTPUT
ACTIVATE
INJECTOR
I':\
1 PULSE
\:;;, 50 PULSES
(PRESSURE AFTER DROP)
ELECTRONIC FUEL
INJECTOR TESTER
TESTER
J 34730-lA
2ND
READING
POWER
100 PULSES
INJECTOR
500 MS
10 MS
POS
NEG
BATTERY
5 MS
CONNECTOR
EXAMPLE
CYLINDER
1STREADING
293 kPa
(43 psi)
293 kPa
(43 psi)
293 kPa
(43 psi)
2NDREADING
131 kPa
{19psi)
115 kPa
{17 psi)
145 kPa
(21 psi)
162 kPa
AMOUNT OF DROP (24 psi)
178 kPa
(26 psi)
148 kPa
{21 psi)
OK
FAULTY.RICH FAULTY, LEAN

(TOO MUCH
(TOO LITTLE
FUEL DROP)
FUEL DROP)
S-9-92
MS 12020-6E
ECM
t-----------~1747LTBLUMIHT
~:=;:=t::J.~1------------- 1748 LT BLU/BLK

1 - - - - - - - - - - - - 1749 LT GRNMIHT
1 - - - - - - - - - - - - - 444 LT GRN/BLK
IAC COIL" A" HI

IACCOIL "A"LO
IAC COIL "B" HI
IAC COIL "B" LO
11-20-92
NS 15658
CHARTC-2C
IDLE AIR CONTROL (IAC) VALVE CHECK
5.7L (VIN P) 11 F" CARLINE (MFI)
The ECM controls engine idle speed with the IAC valve. To increase idle speed, the ECM retracts the IAC
valve pintle away from its seat, allowing more air to bypass the throttle bore. To decrease idle speed, it extends
the IAC valve pintle towards its seat, reducing bypass air flow. The scan tool will display the ECM commands to
the IAC valve in counts. Higher the counts indicate more air bypass (higher idle). The lower the counts indicate
less air is allowed to bypass (lower idle).
RPM, locate and correct vacuum leaks
including crankcase ventilation system. Also,
1. The IAC tester is used to extend and retract the
check for binding of throttle blade or linkage.
IAC valve. Valve movement is verified by an
System too lean (High Air/Fuel Ratio) - The
engine speed change. If no change in engine speed
idle speed may be too high or too low. Engine
speed may vary up and down and
occurs, the valve can be retested when removed
from the throttle body.
disconnecting the IAC valve does not help.
2. This step checks the quality of the IAC movement
OTC 44 or 64 may be set.
in Step 1. Between 700 RPM and about 1500 RPM,
Tech 1 028 voltage will be less than 300 m V
(.3 volt). Check for low regulated fuel
the engine speed should change smoothly with
each flash of the tester light in both extend and
pressure, water in the fuel or a restricted
retract. If the IAC valve is retracted beyond the
injector(s).
control range (about 1500 RPM), it may take many
System too rich (Low Air/Fuel Ratio) - The idle
flashes in the extend position before engine speed
speed will be too low. Tech 1 IAC counts will
will begin to drop. This is normal on certain
usually be above 80. System is obviously rich
engines, fully extending IAC may cause engine to
and may exhibit black smoke in exhaust.
stall. This may be normal.
Tech 1 028 voltage will be fixed above 800 m V
3. Steps 1 and 2 verified proper IAC valve operation
(.8 volt). OTC 45 or 65 may set.
Check for high fuel pressure, leaking or
while this step checks the IAC circuits. Each lamp
sticking injector(s). Silicone contaminated
on the node light should flash red and green while
the IAC valve is cycled. While the sequence of
oxygen sensors will be slow to respond.
color is not important, if either light is "OFF" or
Throttle Body - Remove IAC valve and inspect
does not flash red and green, check the circuits for
IAC Valve Electrical Connections - IAC valve
faults, beginning with poor terminal contacts.
connections should be carefully checked for
Diagnostic Aids:
proper contact.
Crankcase Ventilation Valve - An incorrect or
faulty crankcase ventilation valve may result
the IAC valve. Out of control range IAC Tech 1 counts
in an incorrect idle speed.
will be above 60 if idle is too low, and zero counts if idle
Refer to "Rough, Unstable, Incorrect Idle or
is too high. The following checks should be made to
repair a non-IAC system problem:
If intermittent poor driveability or idle
symptoms are resolved by disconnecting the
Vacuum Leak (High Idle) - If idle is too high,
IAC, carefully recheck connections, valve
stop the engine. Fully extend (low) IAC with
tester. Start engine. If idle speed is above 800
terminal resistance, or replace IAC.
DRIVEABILITY AND EMISSIONS S.7L (VIN P) 6E3-C2-19
IGNITION "OFF,'" CONNECT IAC DRIVER* TO IAC VALVE.

SET PARKING BRAKE, BLOCK WHEELS, A/C "OFF."
IDLE ENGINE IN PARK (A/T) OR NEUTRAL (MIT).
INSTALL TECH 1 SCAN TOOL AND DISPLAY RPM.
WITH IAC DRIVER, EXTEND AND RETRACT IAC VALVE.
ENGINE RPM SHOULD DECREASE AND INCREASE AS IAC IS
CYCLED.
RPM CHANGES
IDLE AIR CONTROL (IAC) VALVE

CHECK
NO RPM CHANGE
RPM SHOULD CHANGE SMOOTHLY WITH EACH

FLASH OF THE IAC DRIVER LIGHT FROM 700 RPM
TO ABOUT 1500 RPM.
DOES IT?
CHECK IAC PASSAGES.

IF OK, REPLACE IAC.
INSTALL APPROPRIATE IAC NODE LIGHT* IN ECM

HARNESS.
CYCLE IAC DRIVER AND NOTE LIGHTS.
BOTH LIGHTS SHOULD CYCLE RED AND GREEN BUT
NEVER "OFF" AS RPM IS CHANGED OVER ITS
RANGE.
DO THEY?
CHECK IAC PASSAGES.

IF OK, REPLACE IAC.
USING THE OTHER CONNECTOR ON THE

IAC DRIVER PIGTAIL, CHECK RESISTANCE
ACROSS IAC COILS.
SHOULD BE 40 TO 80 OHMS BETWEEN IAC
TERMINALS "A" TO "B" AND "C" TO "D".
IF CIRCUIT(S) DID NOT TEST GREEN AND RED, CHECK

FOR:
FAUL TY CONNECTOR TERMINAL CONTACTS.
OPEN CIRCUITS INCLUDING CONNECTIONS.
CIRCUITS SHORTED TO GROUND OR VOLTAGE.
FAULTY ECM CONNECTION OR ECM.
CHARTC-2C

J 37027-A FROM: KENT-MOORE, INC.

TERMINALS "B" AND "C" AND" A"
AND"D".
SHOULD BE INFINITE.
IDLE AIR CONTROL VALVE AND

CIRCUIT OK. REFER TO "DIAGNOSTIC
REPLACE IAC VALVE

AND RETEST.
REPLACE IAC VALVE

AND RETEST.
6-4-92
95 7626-6E
BLANK
SECTION C3
EVAPORATIVE EMISSION (EVAP) CONTROL SYSTEM

CONTENTS
General Description
Pu ~pose
EVAP Canister
Control Valve

Diagnosis

Purge Solenoid Valve
C3-1
C3-1
C3-1
C3-1
C3-2
C3-2
C3-2
C3-2
C3-2
C3-2
Visual Check of EVAP Canister

Functional Tests
Control Valve
On-Vehicle Service
EVAP Canister
EVAP Canister Hoses
C3-2
C3-2
C3-2
C3-3
C3-3
C3-3
GENERAL DESCRIPTION
PURPOSE
The Evaporative Emission (EV AP) control system
used on all vehicles is the charcoal canister storage
method. This method transfers fuel vapor from the
fuel tank to an activated carbon (charcoal) storage
device (canister) to hold the vapors when the vehicle is
not operating. When the engine is running, the fuel
vapor is purged from the carbon element by intake air
flow and consumed in the normal combustion process.
EVAP CANISTER
uses a 1500 cc charcoal canister to absorb fuel vapors
from the gas tank.
When gasoline vapor builds enough to overcome
the spring tension of the EVAP pressure control valve,
the vapor will flow to the canister where it is absorbed
and stored by the charcoal. Under certain operating
conditions the ECM will command the purge solenoid
valve to open. This allows the vapor to flow into the
intake manifold for combustion.
17013138
17093194
TANK TUBE
2
AIR TUBE (FRESH AIR INLET)
PURGE TUBE
NA 1349-AS
EVAPORATIVE EMISSION SYSTEM

This system has a remote mounted canister purge
control solenoid valve. The ECM operates this
solenoid valve to control vacuum to the canister.
Under cold engine or idle conditions, the solenoid
valve is closed, which prevents vacuum from being
applied to the canister.
Figure C3-1 - Fuel Vapor Canister
The ECM activates (or opens) the solenoid valve

and allows purge when:
Engine is warm.
After the engine has been running a specified
period of time.
Above a specified road speed.
Above a specified throttle opening.

EVAPORATIVE EMISSION (EVAP) PRESSURE
CONTROL VALVE
This system uses an in-line EVAP pressure control
valve as a pressure relief valve. Refer to diagram for
installation in system. When vapor pressure in the
tank exceeds approximately 5 kPa (. 7 psi) the
diaphragm valve opens, allowing vapors to vent to the
canister. A 1.14 mm (0.045 inch) orifice in the passage
leading to the canister tube causes pressure to drop
slowly, preventing the valve from oscillating
(buzzing). When the tank pressure drops below 5 kPa
(.7 psi), the valve closes causing vapors to be held in
the fuel tank.
=/
7
17091151

Poor idle, stalling and poor driveability can be
caused by:
Inoperative purge solenoid valve.
Damaged canister.
Hoses split, cracked and, or not connected to
the proper tubes.
Evidence of fuel loss or fuel vapor odor can be
caused by:
Liquid fuel leaking from fuel lines.
Cracked or damaged canister.
Inoperative canister control valve.
Disconnected, misrouted, kinked, deteriorated
or damaged vapor hoses, or control hoses.
If the solenoid valve is open, or is not receiving
power, the canister can purge to the intake manifold at
the incorrect time. This can allow extra fuel during
warm-up, which can cause rough or unstable idle.
DIAPHRAGM
DIAGNOSIS
DIAPHRAGM SPRING
CONTROL TUBE
TUBE TO CANISTER
UMBRELLA VALVE
RESTRICTION
TUBE TO FUEL TANK

NA 1358-AS
Figure C3-2 - EVAP Pressure Control Valve
connections to control vacuum tube and pump are

secure. If after 10 seconds there is less than 13 cm (5"
Hg) vacuum, the valve must be replaced.
With 38 cm Hg (15" Hg) vacuum still applied to the
control vacuum tube, attach a short piece of hose to the
valve's tank tube side. Blow into the tube. You should
feel the air pass through the valve. If air does not pass
through, the valve must be replaced.
EVAPORATIVE EMISSION (EVAP) CANISTER

The Evaporative Emission (EVAP) canister purge
solenoid valve operation is covered in CHART C-3 at
the end of this section.
ON-VEHICLE SERVICE
EVAP CANISTER

Raise vehicle.
Driver side rear wheel housing liner.
Hoses from canister.
Canister from canister bracket by releasing latch
on canister bracket.
6. Canister from vehicle.
l.
VISUAL CHECK OF EVAP CANISTER
Cracked or damaged, replace EVAP canister.
FUNCTIONAL TESTS
Control Valve
With a hand vacuum pump, apply approximately
38 cm Hg (15" Hg) to the control vacuum tube. After
ten seconds, there should be at least 13 cm Hg (5" Hg)
vacuum remaining. Be sure the hand vacuum pump
being used does not have an internal leak and the hose
2.
3.
4.
5.
l++-1 Install or Connect

1. Canister to vehicle.
2. Canister to canister bracket.
3. Hoses to canister.
5. Lower vehicle.
n. Negative battery cable.
FUEL TANK
2
EVAPORATIVE EMISSION PRESSURE CONTROL VALVE
FUEL FILLER NECK

NS 15274
Figure C3-3 - EVAP Canister Mounting
EVAP CANISTER PURGE SOLENOID VALVE
I+..! Remove or Disconnect

1.
2.
3.
4.

Fastener from ignition test connector.
Electrical connector and hoses from solenoid valve.
Bracket and solenoid from intake manifold.
l,..+I Install or Connect

l.
Solenoid valve to intake manifold.
!~I Tighten
2.
3.
4.
Bolt to intake manifold to 5.8 Nm (52 lb. in.).

Electrical connector and hoses to solenoid valve.
Ignition test connector to bracket.
Negativebatterycable.
EVAP CANISTER HOSES

!VIEWA!
Refer to "Vehicle Emission Control Information"

label for routing of EV AP canister hoses.
BRACKET

INTAKE MANIFOLD
NS 15268
Figure C3-4 - EVAP Canister Purge Solenoid Valve

Service
EV AP Canister Purge Solenoid

Valve Bolt 5.8Nm(52lb.in.)
6E3-C3-4 5. 7l (VIN P) DRIVEABILITY AND EMISSIONS
[2J
IT]
[TI
THROTTLE BODY
FLOATING ROLL-OVER VALVE
SOLENOID VALVE (NORMALLY CLOSED)
[I]
FUEL TANK
EVAP EMISSION CANISTER
FUEL TANK VENT VALVE (PRESSURENACUUM
EVAP EMISSION PRESSURE CONTROL

VALVE WITH INTERNAL ORIFICE
RELIEF) REMOTE MOUNTED
Figure C3-5- Evaporative Emissions (EVAP) Control System Schematic
11-17-92
NS 15659
BLANK
6E3-C3-6 5. 7L (VIN P) DRIVEABILITY ANO EMISSIONS
TO CANISTER
-~~~--~~~~-
MANIFOLD
VACUUM
ECM
EVAP CANISTER PURGE

SOLENOID VALVE
N.C.
TO EGR,AND ._..__,_ _ 541 BRN

REVERSE LOCKOUT
SOLENOIDS
(U/H)
EVAP CANISTER
PURGE SOLENOID
VALVE DRIVER
--<----,-~
f
F
FANS/ACTR
C100
TO OTHER
FAN/ACTR FUSE
CIRCUITS
10AMP
(U/H)
> TO
IGNITION
10-20-92
MS 12487
CHARTC-3
EVAPORATIVE EMISSION (EVAP) CANISTER PURGE SOLENOID VALVE CHECK
EVAP canister purge is controlled by a solenoid valve that allows manifold vacuum to purge the EVAP
canister when energized. The ECM supplies a ground to energize the solenoid valve.
If the diagnostic "test" terminal is grounded with the engine stopped and ignition ''ON," or the following
conditions are met with the engine running, the EVAP canister purge solenoid valve will be energized (purge
"ON").
Vehicle speed above 2 mph.
Throttle off idle, above 1.6%.

1. Checks to see if the solenoid valve is opened or
closed. The solenoid valve is normally closed and
should open when the diagnostic "test" terminal is
grounded.
2. Completes functional check by grounding the
diagnostic "test" terminal. This should energize
the solenoid valve and allow the vacuum to drop
(purge "ON").
3. Checks for a complete circuit. Normally, there is
ignition voltage on CKT 541 and the ECM
provides a ground on CKT 428. A shorted solenoid
valve could cause an open circuit in the ECM.
Diagnostic Aids:
Normal operation of the EVAP canister purge
solenoid valve is described as follows:
With the ignition "ON," engine "OFF," diagnostic
"test" terminal grounded, the EV AP canister purge
solenoid valve should be energized.
CHARTC-3
EVAPORATIVE EMISSION (EVAP) CANISTER PURGE
SOLENOID VALVE CHECK
IGNITION "ON." ENGINE STOPPED.

DISCONNECT VACUUM HOSES FROM EVAP CANISTER PURGE
SOLENOID VALVE.
AT THE SOLENOID VALVE, APPLY 34 kPa (10" Hg) OF VACUUM
TO THE THROTTLE BODY SIDE OF PURGE SOLENOID VALVE.
ABLE TO GET 34 kPa (10" Hg) OF VACUUM.
UNABLE TO GET 34 kPa (10" Hg) OF VACUUM.
GROUND DIAGNOSTIC TERMINAL.

NOTE VACUUM.
DISCONNECT SOLENOID VALVE.

LIGHT TO 12 VOL TS.
NO DROP
WITH DIAGNOSTIC TERMINAL

STILL GROUNDED
DISCONNECT EVAPCANISTER
PURGE SOLENOID VALVE.
BETWEEN
HARNESS CONNECTOR
TERMINALS.
NO TROUBLE FOUND.
CKT 428 SHORTED TO

FAUL TY SOLENOID
VALVE.
NO LIGHT
PROBE EACH HARNESS

CONNECTOR TERMINAL
GROUND.
FAULTY SOLENOID
VALVE OR
CONNECTOR.
LIGHT"ON"
ONE TERMINAL
LIGHT BOTH
TERMINALS
OPEN CKT428
OR
FAULTY
CONNECTION
OR
FAULTY ECM.
REPAIR SHORT TO
VOLTAGE IN CKT 428 .
CHECK FOR OPEN IN IGNITION FEED

CIRCUIT TO SOLENOID VALVE.
"AFTER REPAIRS," CONFIRM "CLOSED LOOP" OPERATION AND NO MIL (SERVICE ENGINE SOON}.
6-1-92
MS 10661
BLANK
SECTION C4
DISTRIBUTOR IGNITION (DI) SYSTEM

CONTENTS
General Description
Purpose
Description

Operation
C4-1
C4-1
C4-1
C4-2
C4-2
Diagnosis
OTC 12
On-Vehicle Service
(4-2
(4-2
(4-2
(4-2
GENERAL DESCRIPTION
PURPOSE
The distributor ignition system controls fuel
combustion by providing a spark to ignite the
compressed air/fuel mixture at the correct time. To
provide improved engine performance, fuel economy,
and control of exhaust emissions, the ECM controls
distributor spark advance (timing) with an Ignition
Control (IC) system.
Only the IC system will be described here.
Additional information on the system is found in
SECTION 60.
To properly control ignition/combustion timing the
ECM needs to know:
Camshaft position.
Engine speed (RPM).
Engine coolant temperature.
The amount of detonation.
IGNITION COIL
DESCRIPTION
DISTRIBUTOR
The distributor ignition system is a net build

distributor (no timing adjustment) that provides angle
based timing information to the ECM for individual
cylinder spark timing. The ignition module is capable
of providing both 4X and 360X timing pulses each
crankshaft revolution. Using these timing pulses, the
ECM processes ignition spark timing and sends an IC
signal to the ignition coil module to activate the
secondary ignition system.
The ECM provides power, ground, and two 5 volt
reference voltages to the ignition control module. As
the camshaft turns (during crank or run), a slotted
two-track timing disk is rotated inside the ignition
control module. Each time a slot in either track of the
disk is properly aligned, the ignition control module
will pulse one of the 5 volt reference voltages to
ground.
IGNITION COIL WIRE

IGNITION COIL MODULE
NS 15346
Figure C4-1 - Distributor Ignition System
A reference signal is generated each time the ECM

detects that the reference voltages have been grounded
by the ignition control module. When the ECM detects
reference signals, ignition timing can be processed.
The ECM will also compare the 4X and the 360X
signals to each other to determine the location of the
number one cylinder and top dead center. In addition,
if only one signal is being received by the ECM a
Diagnostic Trouble Code (DTC) will be set. DTC 16
will be set if the 4X signal is missing and DTC 36 will
be set if the 360X signal is missing. The vehicle will
not run if the 4X (REFERENCE) signal is not
available at the ECM for processing.
6E3-C4-2 5.7L (VIN P) DRIVEABILITY AND EMISSJONS

OPERATION
The Ignition Control (IC) system consists of the
camshaft position sensor, ignition coil, ignition coil
module, and ECM. The connector terminals are
lettered as shown in CHART C-4.
These circuits perform the following functions:
Low Resolution Signal Reference (CKT 453). This provides the ECM with reference signals,
firing order, and camshaft position
information. If the low resolution signal
circuit becomes open or grounded, the engine
will not run because the ECM will not operate
the ignition coil module, fuel pump, or the fuel
injectors. A OTC 16 will set if the ECM
receives high resolution signal references
without the low resolution signals. If engine
cranks but will not start refer to CHART A-3.
High Resolution Signal Reference (CKT 647). This provides the ECM with detailed reference
signals and crankshaft position information.
If this circuit becomes open or grounded a OTC
36 will set and the engine will still run.
System Ground (CKT 631). - This circuit is
grounded at the ECM and provides ground for
the distributor to generate low and high
resolution signal reference signals. If this
circuit becomes open, the engine will not run
since there will be no reference information.
IC (CKT 423). - This circuit controls the
ignition coil "ON" and "OFF" time. It signals
the ignition coil module to begin primary coil
dwell current when the IC is high. The
ignition coil module shuts "OFF" ignition coil
current when the signal goes low. If this
circuit becomes open or grounded, the engine
will not start and a OTC 41 or 42 will set.

An open IC circuit will set a OTC 41. A grounded
IC circuit will set a OTC 42. An open or grounded IC
circuit will result in a engine cranks but will not run.
An open or ground in the low resolution signal
circuit will set a DTC 16 and the engine will not start.
If the high resolution signal circuit becomes open or
grounded a OTC 36 would set. This will cause reduced
performance and poor fuel economy.
The ECM uses information from the MAP and

engine coolant temperature sensor in addition to RPM
to calculate spark advance as follows:
Cold engine= More spark advance.
Engine under minimum load based on RPM
and low amount of air flow - More spark
advance.
Hot engine = Less spark advance.
Engine under heavy load based on RPM and
high amount of air flow - Less spark advance.
DIAGNOSIS
The description, operation and repair procedures of
the distributor ignition system components are found
in SECTION 60 of this manual. For an ignition
control check, refer to CHART C-4 at the end of this
section.
DTC 12
DTC 12 is used during the "On-Board Diagnostic
(OBD) System Check" procedure to test the DTC
display ability of the ECM. This OTC indicates that
the ECM is not receiving the engine RPM low
resolution (REFERENCE) signal. This occurs with
the ignition "ON" and the engine not running.
The reference signal also triggers the fuel injection
system. Without the reference signal the engine
cannot run. This signal can be checked by using a
Tech 1 which will help determine the cause of an
engine that cranks but will not start.
ON-VEHICLE SERVICE
For removal and replacement of the distributor
ignition system components, refer to SECTION 604,
"Distributor Ignition System."
Distributor Mounting
Bolts 11 Nm (8 lb. ft.)
Ignition Coil Mounting
Fasteners 2.8 Nm (25 lb. in.J
Ignition Coil Module
Fasteners 1.6 Nm (14 lb. in.)
BLANK
ECM
IGNITION SYSTEM
TEST CONNECTOR
. - - - - - - - - - - 632 BLK/PNK
. - - - - - - - - - - - 631 YEL
r--------
647 PPUWHT
. . - - - - - - - - - - 453 BLK/RED
DISTRIBUTOR
REFERENCE LOW
1---------- 632 PNK/BLK

1----------- 631 RED
1--------- 647LT BLU/BLK
A 1---------- 453 RED/BLK
C140
I..__
ENGINE 1lr-- 450BLK
GROUND
IGNITION
IGNITION FEED
HIGH RESOLUTION
LOW RESOLUTION
IGNITION
COIL
MODULE
TO
~
IGNITION
10 AMP
(U/H)
BLK
CONNECTOR
239 PNK
r
I
--------\
423WHT
I
I
I
I
t
IGNITION CONTROL
IGNITION
COIL
:
I
I
I
I
121
WHT
~--------/-.J
BLK
CONNECTOR
(U/H)
To....J
INSTRUMENT
CLUSTER
11-3-92
MS 12328
CHARTC-4
(Page 1 of 2)
DISTRIBUTOR IGNITION SYSTEM CHECK

The battery should be fully charged prior to any
tests.
1. To disconnect the tachometer lead, it will be
necessary to disconnect the gray ignition coil
connector from the ignition coil and jumper the "B"
terminal of the harness connector to the "B"
terminal of the ignition coil using a fused jumper
and terminal test adapter kit J 35616-A.
Checks for proper output from the distributor
ignition system. The spark tester requires a
minimum of25,000 volts to fire. This check can be
used in case of an ignition miss, because the
system may provide enough voltage to run the
engine but not enough to fire a spark plug under
heavy load.
2. This test will separate the distributor cap, rotor
and ignition wires from the ignition coil to help
identify a secondary ignition system problem.
3.
4.
5.
This will determine if the proper available voltage

exists in the primary ignition circuit.
This check will begin to determine if the ECM is
providing a signal to the ignition coil module or
not. If the ECM is not providing a signal to the
ignition coil module, the problem exists between
the distributor and ECM.
A grounded coil circuit will cause the ignition fuse
to open, and a no-start condition will occur.
Diagnostic Aids:
An ignition coil wire that is open or shorted to
ground can cause a no start condition.
I.JU
\?V\\\~k\l\. W'l-/f-Y>i1~ABILITY AND EMISSIONS
5.7L (VIN P) 6E3-C4-5
CHARTC-4
(Page 1 of 2)

PERFORM ON-BOARD DIAGNOSTIC (OBD) SYSTEM CHECK BEFORE PROCEEDING WITH THIS
TEST. (DISCONNECT TACHOMETER BEFORE PROCEEDING WITH THE TEST.)
CHECK SPARK AT PLUG WITH SPARK TESTERJ 26792 (ST-125)WHILE CRANKING (If NO SPARK
ON ONE WIRE, CHECK A SECOND WIRE) A FEW SPARKS AND THEN NOTHING IS CONSIDERED
NO SPARK.
I
I
NO SPARK
SPARK
I
CHECK FOR SPARK AT IGNITION COIL WIRE WITH TESTER
WHILE CRANKING. (LEAVE SPARK TESTER CONNECTED TO
IGNITION COIL WIRE FOR STEPS 3-6.)
CHECK FUEL, SPARK PLUGS,

ETC. SEE 6E3-B "SYMPTOMS."
I
I
NO SPARK
SPARK
I
INSPECT CAP FOR CRACKS, SECONDARY WIRES FOR OPENS;
SHORTS; OR POOR CONNECTIONS .
IF OK, REPLACE DISTRIBUTOR.

IGNITION "ON."
WITH DVM, CHECK VOLTAGE FROM HARNESS
TERMINALS "A" AND "D" TO GROUND.
I
I
BOTH TERMINALS 10 VOL TS OR MORE
WITH DVM ON AC SCALE, CONNECTED

FROM IGNITION COIL MODULE
CONNECTOR TERMINAL "B" TO
GROUND, CRANK ENGINE AND
OBSERVE VOLTAGE.
IS VOLTAGE BETWEEN 1 AND4
VOLTS?
BOTH TERMINALS UNDER 10 VOLTS
EITHER TERMINAL
UNDER 10 VOL TS
I
FAULTY IGNITION FEED(IRCUITTO

IGNITION COIL
OR
GROUNDED EXTERNAL COIL CIRCUIT
OR
FAULTY IGNITION COIL.
FAUL TY CIRCUIT FROM

TERMINAL TO COIL
OR
FAULTY COIL CONNECTION
OR
FAULTY COIL.
-------,
: TO CHART C-4
1 2 Of 2.
PROBE IGNITION COIL MODULE CONNECTOR

TERMINAL "C" WITH TEST LIGHT TO B +.
IS LIGHT ON?
I
I
I
L---------.J
~
OPEN IGNITION COIL MODULE GROUND CIRCUIT.
FAUL TY IGNITION COIL MODULE CONNECTION

OR
FAULTY IGNITION COIL MODULE.
6-17-92
MS 10860

ECM
IGNITION SYSTEM
TEST CONNECTOR
~ - - - - - - - - 632 BLK/PNK
~ - - - - - - - - - 631 YEL
. . . . . - - - - - - - 647 PPUWHT
~ - - - - - - 453 BLK/RED
1---------- 632 PNK/BLK
DISTRIBUTOR
REFERENCE LOW
11----------- 631 RED
IGNITION FEED
1--------- 647 LT BLU(BLK

1---------- 453 REDIBLK
C1E4,!1GINE
111---
HIGH RESOLUTION
LOW RESOLUTION
450 BLK
GROUND
IGNITION
COIL
MODULE
IGNITION
IGNITION
10 AMP
TO
~
BLK
CONNECTOR
r
I
--------\
(UfH)
239 PNK
B
423WHT
I
I
IGNITION CONTROL
I
I
I
IGNITION
COIL
:
I
I
I
I
121
WHT
~--------/-1
BLK
CONNECTOR
TO~
INSTRUMENT
CLUSTER
CHARTC-4
(Page 2 of 2)

1. If the ECM is detecting low resolution signal
pulses and no IC signal was available at the
ignition coil module, a problem exists with the
ECM or the circuit to the ignition coil module.
2. If the ECM does not detect low resolution signal
pulses the distributor or distributor to ECM
circuitry is most likely the problem. The
remaining tests will determine if the proper
signals are being sent and received from both the
distributor and ECM.
I
11-3-92
MS 12328
r-----------,
: FROM CHART C-4 :

1 1 OF 2.
1
L-
0
0
---------.J
CRANK ENGINE WHILE OBSERVING LOW

RESOLUTION SIGNAL ON TECH 1.
IS LOW RESOLUTION SIGNAL INDICATED?
CHARTC-4
(Page 2 of 2)
DISTRIBUTOR IGNITION SYSTEM CH ECK

IGNITION "OFF."
IGNITION "ON."
PROBE TERMINAL "C" WITH
A TEST LIGHT TO GROUND.
IS IT?
FAUL TV IGNITION CONTROL CONNECTION AT ECM

OR
OPEN IGNITION CONTROL CIRCUIT
OR
FAULTY ECM.
CHECK FOR CONTINUITY BETWEEN DISTRIBUTOR

CONNECTOR TERMINAL "D" AND GROUND.
CIRCUIT SHOULD HAVE CONTINUITY.
DOESIT?
FAUL TV ECM CONNECTION

OR
OPEN IGNITION FEED CIRCUIT FROM DISTRIBUTOR TO ECM
OR
FAULTY ECM.
USING A DVM ON DC SCALE, MEASURE VOLTAGE

AT DISTRIBUTOR CONNECTOR TERMINAL" A".
VOLTAGE SHOULD BE ABOUT 5 VOLTS.
IS IT?

OR
OPEN GROUND CIRCUIT FROM DISTRIBUTOR TO ECM
OR
FAULTY ECM.
MEASURE VOLTAGE AT DISTRIBUTOR

CONNECTOR TERMINAL "B".
VOLTAGE SHOULD BE ABOUTS VOLTS.
ISIT?
OR
FAUL TV LOW RESOLUTION SIGNAL
CIRCUIT FROM DISTRIBUTOR TO ECM
OR
FAULTY ECM.
FAUL TV DISTRIBUTOR CONNECTION

OR
FAUL TV DISTRIBUTOR.

OR
FAUL TV HIGH RESOLUTION SIGNAL
CIRCUIT FROM DISTRIBUTOR TO ECM
OR
FAULTY ECM.
6-1-92
MS 10861
BLANK
SECTION CS
KNOCK SENSOR (KS) SYSTEM

CONTENTS
General Description
Purpose
Operation
Diagnosis
CS-1
CS-1
CS-1
CS-1
On-Vehicle Service
Knock Sensor
PROM
. . . . . .. . . . . . . . . .
CS-1
CS-1
CS-2
CS-2
GENERAL DESCRIPTION
PURPOSE
Varying octane levels in today's gasoline can cause
detonation in high performance engines. Detonation
is sometimes called spark knock.
To control spark knock, a Knock Sensor (KS)
system is used. This system is designed to retard
spark timing up to 20 to reduce spark knock in the
engine. This allows the engine to use maximum spark
advance to improve driveability and fuel economy.
KNOCK SENSOR (KS)
3S0023-6E
OPERATION
Figure CS-1 Knock Sensor
The knock sensor detects abnormal vibration

(spark knocking) in the engine. The sensor produces
an AC output voltage which increases as the amount of
knock increases. This signal voltage is input to the
ECM. The ECM then adjusts the Ignition Control (IC)
to reduce spark knocking.
DIAGNOSIS
The Tech 1 has several positions to check for
diagnosing KS circuit. "Knock signal" is used to
monitor the input signal from the knock sensor. This
position should display "YES" to indicate when a
knock is being detected. "Knock retard" is the
indication of how much the ECM is retarding the
spark.
DTC 43 is designed to diagnose the knock sensor
circuit. Problems encountered with this circuit should
set DTC 43. However, if no DTC 43 was set but the KS
system is suspected, refer to CHART C-5.
LS 8461-6E
Figure CS-2 Knock Sensor Cutaway View
3.
4.
ON-VEHICLE SERVICE
CAUTION: Engine coolant may be hot.

The knock sensor is mounted in the
engine block cooling passage. Engine
coolant in the block will drain when the
knock sensor is removed.
KNOCK SENSOR

1.
2.

Drain coolant, refer to SECTION 68.
Raise vehicle.
Knock sensor wiring harness connector from
knock sensor.
5.
Knock sensor from engine block.
6E3-CS-2 5.7L (VIN P) DRIVEABILITY AND EMISSIONS

NOTICE: Do not apply thread sealant to sensor
threads. Sensor is coated at factory and applying
additional sealant will affect the sensor's ability to
detect detonation.
PROM
Refer to "Engine Control Module (ECM) and
Sensors," Section "6E3-Cl" for replacement procedure.
Knock Sensor
1.
Knock sensor into engine block. Be sure threads

are clean.
!~I Tighten
2.
3.
4.
5.
Sensor to 19 Nm (14 lb. ft.).

KS wiring harness connector to the knock sensor.
Lower vehicle.
Refill coolant. Refer to SECTION 6B.
19 Nm (14 lb. ft.)
BLANK
6E3-C5-4 5. 7L (VIN P) DRIVEABILITYAND EMISSIONS
ECM
KNOCK
SIGNAL
1.--------
SV
496 DK BLU
~:.?,~.
7-7-92
NS 15347
CHART C-5
The knock sensor system is used to detect engine detonation. The ECM will retard the spark timing based on
a signal being received from the knock sensor. The knock sensor produces an AC voltage which is sent to the
ECM. The amount of AC voltage produced by the sensor is determined by the amount of engine knock. The
circuitry within the knock sensor causes the ECMs 5 volts to be pulled down so that under a no engine knock
condition, CKT 496 would measure about 2.5 volts.

1. With engine idling, there should not be a knock
signal present at the ECM, because detonation is
not likely under a no load condition.
2. Tapping on the engines right exhaust manifold
should simulate a knock signal to determine if the
sensor is capable of detecting detonation. If no
knock is detected, try tapping on engine block
closer to sensor before replacing a sensor.
3. If the engine has an internal problem which is
creating a knock, the knock sensor may be
responding to the internal failure.
4. This test determines if the knock sensor is faulty

or if the KS portion of the PROM is faulty. If it is
determined that the PROM is faulty, be sure that
it is properly installed and latched into place. If
not properly installed, repair and retest.
Diagnostic Aids:
While observing knock signal on the Tech 1, there
should be an indication that knock is present when
detonation can be heard. Detonation is most likely to
occur under high engine load conditions.
DRIVEABILITY AND EMISSIONS 5. 7L (VIN P) 6E3-CS-5
CHARTC-5
IF OTC 43 IS SET, USE THE OTC CHART.

ENGINE MUST BE IDLING AT NORMAL OPERATING
TEMPERATURE.
USE SCAN TOOL TO OBSERVE KNOCK SIGNAL.
IS KNOCK INDICATED?
TAP ON RIGHT EXHAUST MANIFOLD

WHILE OBSERVING KNOCK SIGNAL
SCAN TOOL SHOULD INDICATE KNOCK
IF AN ENGINE KNOCK CAN BE HEARD, REPAIR THE

BASIC ENGINE PROBLEM. IF NO AUDIBLE KNOCK IS
HEARD, FOLLOW THE STEPS:
WHILE TAPPING ON MANIFOLD.
DOESIT?
CONNECT VOLTMETER TO KNOCK SENSOR AND
VOLTMETER ON AC SCALE.
IS A SIGNAL INDICATED ON VOLTMETER?
ENGINE GROUND.
SYSTEM IS OPERATING
CHECK CKT 496 FOR BEING
REPLACE KNOCK
CONNECT VOLTMETER TO
KNOCK SENSOR AND ENGINE
PROPERLY. REFER TO
"DIAGNOSTIC AIDS"
NEAR A SPARK PLUG WIRE
SENSOR.
OR
GROUND.
ON FACING PAGE.
A FAUL TY ECM CONNECTION
VOLTMETER ON AC SCALE.
OR
TAP ON ENGINE BLOCK NEAR
FAULTY ECM
SENSOR.
OR
IS A SIGNAL INDICATED ON
VOLTMETER WHILE TAPPING
PROM.
ON ENGINE BLOCK?
REPLACE
REPLACE KNOCK
PROM OR
ECM.
SENSOR.
""AFTER REPAIRS," CONFIRM "CLOSED LOOP" OPERATION AND NO MIL (SERVICE ENGINE SOON).
5-4-92
MS 9029-6E
6E3-CS-6 5.7l (VIN P) DRIVEABIUTY AND EMISSIONS
BLANK
SECTION C6
SECONDARY AIR INJECTION (AIR) SYSTEM

CONTENTS
General Description
Purpose
Operation of System Components
Operation

Diagnosis
Operational Checks
AIR Pump
Hoses and Pipes
CG-1
CG-1
CG-1
CG-1
CG-2
CG-2
CG-2
CG-2
CG-3
Check Valve
On-Vehicle Service
AIR Pump
AIR Check Valve
Left Side
Right Side
AIR Pipes and Hoses
CG-3
CG-4
CG-4
CG-4
CG-4
CG-4
CG-4
CG-5
GENERAL DESCRIPTION
PURPOSE
The Secondary Air Injection (AIR) system helps
reduce Hydrocarbon (HC), Carbon Monoxide (CO), and
Oxides of Nitrogen (NOx) exhaust emissions. It also
heats up the oxidation catalytic converter quickly on
engine start-up so conversion of exhaust gases can
occur sooner.
OPERATION OF SYSTEM COMPONENTS

The system (Figure C6-l) includes:
AIR Pump. - The AIR pump is located in the
left front of the underhood compartment and
supplies the air to the AIR system. The
electric air pump pressurizes air from the
engine air cleaner and pumps it to the check
valves near the exhaust manifolds.
The AIR pump is controlled by the ECM.
Battery voltage to the AIR pump is controlled
by the AIR pump relay. An integral stop valve
prevents air flow through the pump during
"OFF" periods. When the ECM provides a
ground circuit for the secondary AIR pump
relay, battery voltage is allowed to power up
the AIR pump and integral stop valve. The
AIR pump motor is protected by a 20 amp fuse
and has its own remote ground.
Check Valves. - The check valves prevent back
flow of exhaust gases into the pump in the
event of an exhaust backfire.
Necessary Plumbing. - As shown in Figure
C6-2.
CHECK VALVES
AIR INJECTION PIPES
AIR TO EXHAUST PORTS
TO AIR CLEANER ASSEMBLY
ELECTRIC AIR PUMP (ECM CONTROLLED)
EXHAUST MANIFOLD
INTAKE MANIFOLD
6-24-92
NS 15378
Figure C6-1 AIR System Operation
OPERATION
The AIR pump with integral stop valve is
controlled by the ECM. The ECM will turn "ON"
the AIR pump by providing the ground to complete
the circuit which energizes the AIR pump relay.
When air to the exhaust ports is desired, the ECM
turns "ON" both the integral stop valve and AIR
pump.
6E3-C6-2 5. 7l {VIN P) DRIVEABILITY AND EMISSIONS
TO SECONDARY AIR INJECTION PUMP

2
CHECK VALVE
RIGHT SIDE AIR PIPE
EXHAUST MANIFOLD
LEFT SIDE AIR PIPE

NS 15263
Figure C6-2 AIR System
The ECM turns "ON" the AIR pump after start-up

any time engine coolant temperature is above 15C
(59F). The AIR pump will operate for a maximum
of 240 seconds, or until the system enters "Closed
Loop" operation. At the same time the ECM turns
the AIR pump "OFF," it also de-energizes the
integral stop valve solenoid so no air is directed to
the exhaust ports.
The air system will be disabled under the
When the ECM recognizes a problem and
sets a diagnostic trouble code.
When the fuel system is operating in
"Closed Loop."
The AIR pump has been "ON" for 240
seconds.
RPM is greater than 2825.
MAP is greater than 96 kPa with VSS over
60mph.
MAP is less than 20 kPa.
ECT less than 15C (59F).
Oxidation catalytic converter over
temperature detected.
Oxygen voltage less than .248 volt or
greater than. 75 volt for 20 seconds.
Power enrichment is detected.

If no air (oxygen) flow enters the exhaust stream at
the exhaust ports, HC and CO emission levels will be
too high.
Air flowing to the exhaust ports at all times could
increase temperature of the oxidation catalytic
converter.
DIAGNOSIS
The diagnosis of the AIR system is covered in
CHART C-6 at the end of this section.
OPERATIONAL CHECKS
AIR Pump
The AIR pump is a regenerative turbine type
which is permanently lubricated and requires no
periodic maintenance.
The engine should be at normal operating
temperature in neutral at idle. Using the scan tool
select "Miscellaneous Test" then "Output Test." Select
"AIR System" in "Output Test" directory. Exit to
"Data List" and select oxygen sensor voltages for both
bank 1 and bank 2 oxygen sensors.
DRIVEABILITY AND EMISSIONS 5. 7l (VIN P) 6E3-C6-3

Enable the "Output Test" for the AIR system. The
"Output Test" will energize the AIR pump for only 5
seconds. When the "Output Test" is enabled, the
oxygen sensor voltages for both sensors should remain
under 400 m V because air is being directed to the
exhaust ports. If the oxygen sensor voltages remain
low during the "Output Test," the AIR pump and
integral stop valve are operating satisfactorily.
If the oxygen sensor voltage does not remain low
when the "Output Test" is commanded "ON," proceed
as follows.
If a leak is suspected on the pressure side of the

system or if a hose or pipe has been disconnected
on the pressure side, the connections should be
checked for leaks with a soapy water solution.
With the AIR pump running, bubbles will form if a
leak exists.
4.
Check Valve
!L'l'! Inspect
1.
A check valve should be inspected whenever the

hose is disconnected from a check valve or
whenever check valve failure is suspected. (An
AIR pump that had become inoperative and had
shown indications of having exhaust gases in the
outlet port would indicate check valve failure.)
Blow through the check valve (toward the cylinder
head) then attempt to suck back through the check
valve. Flow should only be in one direction
(toward the exhaust manifold). Replace valve
which does not operate properly.
!l'l'I Inspect
1.
2.
3.
4.
For a seized AIR pump (refer to CHART C-6).

Hoses, tubes and all connections for leaks and
proper routing.
For air flow going to the exhaust ports.
AIR pump for proper mounting.
2.
Hoses and Pipes
!l'l'I Inspect
1. Hose or pipe for deterioration or holes.
2. All hoses or pipe connections, and clamp tightness.
3. Hose or pipe routing. Interference may cause
wear.
ABS HYDRAULIC MODULATOR
LEFT SIDE FRAME RAIL
AIR PUMP
AIR PUMP ELECTRICAL CONNECTOR
AIR BRACKET
HOSE TO AIR CLEANER

NS 15265
Figure C6-3 - AIR Pump Service
ON-VEHICLE SERVICE
AIR PUMP
Figure C6-3
1. Screw check valve onto AIR pipe.

2. Raise vehicle.
3. Electrical connector from AIR pump.
4. Outlet and inlet hoses.
5. Air pump mounting bolts (3) from bracket.

1.
2.
l~I Tighten
Check valve to AIR pipe 23 Nm (17 lb. ft.).
2. Air pipe to exhaust manifold.
3. Air hose to check valve.
Right Side
AIR pump to bracket.

Mounting bolts (3).
1. Clamp and air hoses from AIR system right pipe.

2. Right check valve pipe.
3. Unscrew check valve from AIR pipe.
l~I Tighten
Bolts to 5.6 Nm (50 lb. in.).

3. Outlet and inlet hoses to pump.
4. Electric connector to AIR pump.
5. Lower vehicle.
7. Check AIR system for proper operation (refer to
CHARTC-6).

1.
Left Side
Screw check valve onto AIR pipe.
I~! Tighten
2.
3.
4.
AIR CHECK VALVE
Check valves 23 Nm ( 17 lb. ft.).

Right check valve pipe.
Hose and clamp to check valve.
Check AIR system for proper operation (see
CHARTC-6).
AIR PIPES AND HOSES

1.
2.
3.
4.
Check valve clamp.

Hose from check valve.
Left check valve pipe.
Unscrew check valve from AIR pipe.
For "On-Vehicle Service" procedures, refer to

Figures C6-2 and C6-4.
CHECK VALVE
2
INTAKE MANIFOLD
EXHAUST MANIFOLD
RIGHT SIDE AIR PIPE
GASKET
NS 15264
Figure C6-4 - AIR Check Valve and Pipe Service
AIR PUMP
RELAY
COOLANT FAN
RELAY, PRIMARY
(DRIVER SIDE)
ABS
RELAY
A/C COMPRESSOR
RELAY
~
~
INJECTOR
INJECTOR
YJ
IGNITION
~
A/C-CRUISE
U
I
COOLANT FAN
LOW COOLANT
PONTIAC : RELAY, SECONDARY
RELAY
I
1 (PASSENGER SIDE)
ONL y
L-------...1
FOG LIGHTS
RELAY
HIGH BLOWER
RELAY
NS 15660
Figure C6-5 - Air Pump Relay Location
Check Valves
AIR Pump
Right Side AIR Pipe
to Exhaust Manifold
Right Side AIR Pipe
to Intake Manifold
Left Side Air Pipe to
Exhaust Manifold
23 Nm (17 lb. ft.)

5.6 Nm (50 lb. in.)
24 Nm (18 lb. ft.)
24 Nm (18 lb. ft.)
34 Nm (25 lb. ft.)
ELECTRIC AIR PUMP
ECM
FROM
AIR
CLEANER-+ASSEMBLY
TO
EXHAUST
PORTS
AIR PUMP RELAY
---i------ 436 BRN
78RED
C100
78RED
AIR PUMP
~..------,~ TO IGNITION
441 BRN
20AMP
(U/H)
SECONDARY AIR
INJECTION
RELAY CONTROL
(U/H)
7-7-92
MS 12455
CHARTC-6
SECONDARY AIR INJECTION (AIR) SYSTEM CHECK
During cold starts, above 15C (59F), the ECM completes the ground circuit to the air pump relay which
enables the air pump and integral stop valve. Air is directed to the exhaust ports whenever the engine is started.
Whenever the fuel system goes to "Closed Loop," or the air pump has been "ON" for greater than 240 seconds, the
ECM opens the ground circuit to the air pump relay, and the air pump is de-energized and the integral stop valve
closes.

1. The ECM should energize the air pump when
engine coolant temperature is greater than 15C
(59F) and fuel system not in "Closed Loop." If any
Diagnostic Trouble Codes (DTCs) are present the
ECM will not energize the AIR pump.
2. The ECM should de-energize the air pump relay
when engine speed exceeds 2825 RPM.
3. Air pump relay is located in the underhood
electrical center.
4.
Selecting "Miscellaneous Test" then outputs and

then AIR system on the Tech 1 with the ignition
"ON" and the engine not running should enable
the AIR pump and integral stop valve.
There is a possibility that the AIR pump motor will
be operating, but no air is being distributed to the AIR
system. The integral stop valve may not be opening or
a restriction in the AIR hoses or pipes may be the
cause.
','
\.:_J
f3'
\:..)
CHARTC-6
CORRECT ANY ECM DTC(s) BEFORE

ENTERING THIS DIAGNOSTIC
PROCEDURE.
COOLANT TEMPERATURE BETWEEN 20c
AND60C.
ENGINE IDLING IN OPEN LOOP.
IS AIR PUMP WORKING?
SECONDARY AIR INJECTION (AIR)

SYSTEM CH ECK
11
r:;'I
V
IGNITION "OFF."
CHECK AIR PUMP FUSE FOR BEING OPEN.
FUSE OK?
REMOVE AIR PUMP RELAY.

PROBE TERMINAL "E1" AND "ES"
OF AIR PUMP RELAY HARNESS
GROUND.
IS LIGHT "ON" IN BOTH CIRCUITS?
PROBE TERMINAL "E2" OF AIR

PUMP RELAY HARNESS WITH A
USING TECH 1, "MISC TEST"
(OUTPUTS), ACTIVATE AIR SYSTEM.
DOES LIGHT ILLUMINATE?
REPAIR
SHORT TO
GROUND IN
AIR PUMP
FUSE CIRCUIT.
ENGINE STILL OPERATING IN OPEN

LOOP.
RUN ENGINE TO 2850 RPM.
AIR PUMP SHOULD TURN "OFF."
DOESIT?
REMOVE AIR PUMP

RELAY.
DOES AIR PUMP
STOP?
fi0
V
REPAIR OPEN
IN CIRCUIT
THAT DID
NOT LIGHT.
PROBECKT
436AT AIR
PUMP RELAY
HARNESS
WITH A TEST
LIGHT TO B +.
DOES LIGHT
ILLUMINATE?
CKT(S) 78
SHORTED
TOB+.
IGNITION "OFF."
JUMPER TERMINAL "E4" TO
TERMINAL" E1" OF AIR PUMP RELAY
HARNESS USING A FUSED JUMPER.
IGNITION "ON."
IS AIR PUMP ON?
CKT4360PEN
OR
FAULTY ECM
CONNECTION
OR
FAULTY ECM.
CKT 436
GROUNDED
OR FAULTY
ECM.
FAULTY AIR
PUMP
RELAY.
DISCONNECT AIR PUMP

CONNECTOR.
PROBE TERMINALS A"
AND "B" WITH A TEST
LIGHT TO GROUND.
IS LIGHT ON?
REPAIR OPEN OR
SHORT TO GROUND
IN CIRCUIT THAT
DID NOT LIGHT.
OPEN GROUND
CIRCUIT OR
FAULTY AIR
PUMP MOTOR.
FAUL TY RELAY
CONNECTION
OR
FAULTY RELAY.
IGNITION "ON," ENGINE

"OFF."
DISCONNECT HOSE
GOING TO THE AIR
CHECK VALVE,
USING TECH 1, "MISC
TEST" (OUTPUTS),
ACTIVATE AIRSYSTEM.
IS AIR PRESENT AT THE
END OF THE HOSE THAT
WAS DISCONNECTED.
DISCONNECT
AIR PUMP
CONNECTOR.
PROBE
TERMINAL
"B" OFAIR
PUMP
ELECTRICAL
CONNECTOR
WITH A TEST
LIGHT TO
GROUND.
USINGTECH
1, "MISC
TEST"
(OUTPUTS),
ACTIVATE
AIR SYSTEM.
DOES LIGHT
ILLUMINATE?
NO
TROUBLE
FOUND.
FAULTY AIR
PUMP
ELECTRICAL
CONNECTION
OR
FAULTY AIR
PUMP.
11-20-92
NS 15379
BLANK
SECTION C7
EXHAUST GAS RECIRCULATION (EGR) SYSTEM

CONTENTS
General Description
Purpose
Operation
EGR Control
EGR Valve Identification
.. . . . . ... .. . . . . .. ..
C7-1
C7-1
C7-1
C7-1
C7-1
C7-2
C7-2
GENERAL DESCRIPTION.
PURPOSE
The Exhaust Gas Recirculation (EGR) system is
used to lower NOx (Oxides of Nitrogen) emission levels
caused by high combustion temperature and excessive
oxygen. It does this by decreasing combustion
temperature and displacing oxygen.
The main element of the system is the EGR valve
mounted on the intake manifold and operated by
vacuum.
The EGR valve feeds small amounts of exhaust gas
back into the combustion chamber as shown in (Figure
C7-1).
.....................
Diagnosis
On-Vehicle Service
EGR Valve
EGR Manifold Passage
EGR Solenoid Valve
C7-2
C7-2
C7-2
C7-2
C7-3
C7-3
For this reason, very little exhaust gas is allowed to

pass through the EGR valve. The EGR valve is
usually open, during warm engine operation and when
the vehicle is above idle speed.
EGR CONTROL
The EGR vacuum control has a vacuum solenoid
valve that is controlled by pulse width modulation.
This means the ECM turns the solenoid valve "ON"
and "OFF" many times a second and varies the
amount of "ON" time ("pulse width") to vary the
amount of vacuum applied to the EGR valve.
The ECM uses RPM and information from the
following sensors to regulate the EGR solenoid valve:
Intake Air Temperature CIAT) sensor.
Manifold Absolute Pressure (MAP) sensor.
Park/Neutral Position (PNP) switch.
Vehicle Speed Sensor (VSS).
Grounding the DLC diagnostic "test" terminal,
with the ignition "ON" and the engine not running,
will energize the solenoid valve and allow vacuum to
the EGR valve.
NEGATIVE BACKPRESSURE EGR VALVE
EGR VALVE
INTAKE AIR
EXHAUST GAS
EGR VACUUM PORT

45 0001-6E
Figure C7-1 - Exhaust Gas Recirculation
OPERATION
The EGR valve is opened by vacuum to let exhaust
gas flow into the intake manifold. The exhaust gas
then moves with the air/fuel mixture into the
combustion chamber. If too much exhaust gas enters,
combustion will not occur.
The EGR valve used on this engine is a negative

backpressure valve. It varies the amount of exhaust
gas flow into the manifold depending on manifold
vacuum and variations in exhaust backpressure.
The diaphragm on this EGR valve (shown in
Figure C7-2) has an internal vacuum bleed hole which
is held closed by a small spring when there is no
exhaust backpressure. The amount of vacuum to the
valve is controlled by an ECM contrDlled solenoid
valve.
Engine vacuum opens the EGR valve against the
pressure of a large spring. When vacuum combines
with negative exhaust backpressure, the vacuum
bleed hole opens and the EGR valve closes.

When replacing an EGR valve, always check for
correct part number in the parts catalog or
supplemental bulletin.

Too much EGR flow dilutes the fresh intake
air/fuel mixture, causing the engine to run roughly or
stall. With too much EGR flow (at idle, cruise, or cold
operation) tends to weaken combustion and may result
in any of the following conditions:
Engine stops after cold start.
Engine stops at idle after deceleration.
Vehicle surges during cruise.
Rough idle.
Too little or no EGR flow allows combustion
temperatures to get too high during acceleration and
load conditions. This could cause:
Spark knock (detonation).
Engine overheating.
Emission test failure.
2
1
EGRVALVE
EXHAUST GAS
SMALL SPRING
INTAKE AIR
LARGE SPRING
VACUUM PORT
DIAPHRAGM
AIR BLEED HOLE
45 0113-6E
DIAGNOSIS
Diagnosis of the EGR system is covered in CHART
C-7 at the end of this section, if DTC 32 was not set.
Figure C7-2 - Negative Backpressure EGR Valve
ON-VEHICLE SERVICE
EGRVALVE
ASSEMBLY
1.
2.
3.
4.
5.

Hose from AIR check valve.
Vacuum line.
Retaining nuts.
EGR valve.
EGR Manifold Passage

TYPE OF VALVE:
P = POSITIVE BACKPRESSURE
N =NEGATIVE BACKPRESSURE
BLANK= PORTED VALVE
!L'l'I Inspect
LP 1203
Figure C7-3 - EGR Valve Identification
EGR VALVE IDENTIFICATION
Negative backpressure EGR valves will have an

"N" stamped on the top side of the valve after the
part number.
Positive backpressure EGR valves will have a "P"
stamped on the top side of the valve, after the part
number.
Port EGR valves have no identification stamped
after the part number.
If EGR passages in the inlet manifold indicate

excessive build-up of deposits, the passages should
be cleaned. Care should be taken to ensure that all
loose particles are completely removed to prevent
them from clogging the EGR valve or from being
ingested into the engine.
~
1.
2.
3.
Clean
With a wire wheel, buff the exhaust deposits from

the mounting surface and around the valve.
Look for exhaust deposits in the valve outlet.
Remove deposit build-up with a screwdriver.
Clean mounting surfaces of intake manifold and
valve assembly.
EGR VALVE
2
GASKET
INTAKE MANIFOLD
NS 15267
Figure C7-4 - EGR Valve Service

1.
2.
3.
4.
EGR valve on intake manifold using new gasket.
EGR SOLENOID VALVE
l~I Tighten
EGR
VACUUM HOSE HARNESS
Bolts to 22 Nm (16 lb. ft.).

Vacuum hose to valve.
Hose to AIR check valve.
EGR SOLENOID VALVE

l.
2.
3.
4.

Electrical connector at solenoid valve.
Vacuum hoses.
Nut and solenoid valve.

1. Solenoid and bracket.
l~I Tighten
2.
3.
4.
INTAKE MANIFOLD
Nut to 34 Nm (25 lb. ft.).

Vacuum hoses.
NS 15266
Figure C7-5 EGR Solenoid Valve
EGR Valve Bolts to
Intake Manifold
Solenoid Valve and Bracket,
Nut to Intake Manifold
22 Nm (16 lb. ft.)

34 N m (25 lb. ft.)
MANIFOLD
VACUUM
TO
IGNITION
ECM
EGR
SOLENOID
VALVE
N.C.
FANS/ACTR
tOAMP
(U/H)
EXHAUST
TO
EVAP CANISTER PURGE
SOLENOID VALVE AND
REVERSE LOCKOUT SOLENOID (U/H) = LOCATED IN UNDERHOOD ELECTRICAL CENTER
TO
OTHER FANS/ACTR
FUSE CIRCUITS
10-1:.l-92
MS 1:.l322
CHARTC-7
(Page 1 of 2)
EXHAUST GAS RECIRCULATION (EGR) SYSTEM CHECK

The Exhaust Gas Recirculation (EGR) valve is controlled by a normally closed solenoid valve. The ECM
turns the solenoid valve "ON" to allow vacuum to pass to the EGR, and turns the solenoid valve "OFF" to prevent
EGR operation.
The duty cycle is calculated by the ECM based on information from the ECT, IAT, TP sensor, and MAP
sensors. Also, engine RPM and the PNP switch input affect EGR. There should be no EGR when in park or
neutral, TP sensor below a calibrated value, or TP sensor indicating WOT.
With the ignition "ON" and engine "OFF," the EGR solenoid valve is de-energized. The solenoid valve,
however, should be energized, if the diagnostic "test" terminal is grounded with the ignition "ON" and engine
"OFF."

1. Intake Passage: Shut "OFF" engine and
remove the EGR valve from the manifold. Plug
the exhaust side hole with a shop rag or suitable
stopper. Leaving the intake side hole open,
attempt to start the engine. If the engine runs at a
very high idle (up to 3000 RPM is possible) or
starts and stalls, the EGR passages are not
restricted. If the engine starts and idles normally,
the EGR intake side passage in the intake
manifold is restricted.
Exhaust Passage: With EGR valve still
removed, plug the intake side hole with a suitable
stopper. With the exhaust side hole open, check for
the presence of exhaust gas. If no exhaust gas is
present, the EGR exhaust side passage in the
intake manifold is restricted.
2. The vacuum at the gage may or may not slowly
bleed off. It is important that the gage is able to
read the amount of vacuum being applied.
3.
4.
When the diagnostic "test" terminal is grounded,

the vacuum gage should bleed off through a vent in
the solenoid valve. The pump gage may or may not
bleed off but this does not indicate a problem.
This test will determine if the electrical control
part of the system is at fault or if the connector or
solenoid valve is at fault.
Diagnostic Aids:
proper routing. Refer to "Vehicle Emission Control
Information" label.
backpressure and may affect the functional check of
the EGR valve.
CHART C-7
BEFORE USING THIS CHART, CHECK FOR MANIFOLD VACUUM TO

EGR SOLENOID VALVE, ALSO CHECK HOSES FOR LEAKS OR
RESTRICTIONS. SHOULD BE AT LEAST 7" Hg VACUUM AT 2000 RPM.
EXHAUST GAS RECIRCULATION

(EGR) SYSTEM CHECK
WITH ENGINE AT IDLE ANO AT NORMAL OPERATING

TEMPERATURE, MANUALLY LIFT EGR VALVE DIAPHRAGM.
RPM SHOULD DECREASE OR ENGINE SHOULD STALL.
DOES IT?
{Page 1 of 2)
GJ
(2)
CHECKFORPLUGGED
EGR PASSAGES.
DISCONNECT EGR VACUUM HARNESS AT SOLENOID VALVE. INSTALL A

VACUUM GAGE TO MANIFOLD SIDE OF HARNESS AND CHECK FOR
VACUUM SUPPLY TO SOLENOID VALVE.
VACUUM SHOULD BE AT LEAST 25 kPa {7" Hg) OF VACUUM AT 2000 RPM.
IS IT?
0.
.
~
PLUGGED VACUUM PORT

AT INTAKE MANIFOLD.
LEAKING OR RESTRICTED
VACUUM SUPPLY LINE
TO EGR SOLENOID
VALVE.
ROTATE VACUUM HARNESS ANO REINSTALL ONLY THE EGRVALVE SIDE, TO THE
SOLENOID VALVE.
INSTALL A VACUUM GAGE IN PLACE OF EGR VALVE.
INSTALL A HAND HELD VACUUM PUMP TO MANIFOLD SIDE OF EGR SOLENOID VALVE.
IGNITION "ON," ENGINE STOPPED.
APPLY 34 kPa (10" Hg)VACUUM AND OBSERVE GAGE .
GAGE SHOULD READ VACUUM APPLIED BY PUMP. DOES IT?
[;]
APPLY 34 kPa (10" Hg)VACUUM.

UNGROUND DIAGNOSTIC "TEST" TERMINAL.
VACUUM SHOULD BLEED OFF COMPLETELY AT GAGE .
DOESIT?
: REFER TO EGR
CHART (2 OF 2).
CONNECT VACUUM PUMP TO EGR VALVE SIDE OF HARNESS.

APPLY VACUUM AND OBSERVE GAGE.
GAGE SHOULD READ VACUUM APPLIED BY PUMP.
DOESIT?
~-------,
I
I
I
1
l.----------...1
DISCONNECT SOLENOID VALVE

DOES VACUUM BLEED OFF
RAPIDLY AT GAGE?
GJ
ECM DRIVER
CIRCUIT OPEN
OR
FAULTY ECM.
REPLACE
SOLENOID
VALVE.
DISCONNECT EGR ELECTRICAL CONNECTOR.

CONNECT TEST LIGHT FROM TERMINAL "8"
OF EGR HARNESS CONNECTOR AND 8 +.
IS LIGHT "ON"?
DISCONNECT EGR ELECTRICAL CONNECTOR .

CONNECT TEST LIGHT BETWEEN HARNESS
DIAGNOSTIC "TEST" TERMINAL GROUNDED.
DOES IT?
FAULTY SOLENOID
VALVE
CONNECTION
OR
FAUL TY SOLENOID
VALVE.
"AFTER REPAIRS," CONFIRM "CLOSED LOOP" OPERATION

ANO NO MIL (SERVICE ENGINE SOON).
FAULTY
VACUUM
SUPPLY LINE
TO EGR VALVE.
GJ
GJ
6-20-91
MS 10833
GiJ
GROUNDED
ECMDRIVER
CIRCUIT.
r;i
IGNITION FEED CIRCUIT AND GROUND.
NO LIGHT
REPAIR OPEN
IGNITION FEED
CIRCUIT.
. I
LIGHT
OPEN ECM
DRIVER CIRCUIT
OR
FAULTY ECM.
TO
IGNITION
ECM
EGR
SOLENOID
VALVE
I ,:~
N.C.
. ~TO
INTAKE
FANS/A CTR
10AMP
(U/H)
TO
EVAP CANISTER PURGE
SOLENOID VALVE AND
REVERSE LOCKOUT SOLENOID (UIH) = LOCATED IN UNDERHOOD ELECTRICAL CENTER
TO
OTHER FANS/ACTR
FUSE CIRCUITS
10-12-92
MS 12322
CHARTC-7
(Page 2 of 2)

11
The Exhaust Gas Recirculation (EGR) valve is controlled by a normally closed solenoid valve. The ECM
turns the solenoid valve "ON" to allow vacuum to pass to the EGR, and turns the solenoid valve "OFF" to pre-vent
EGR operation.
The duty cycle is calculated by the ECM based on information from the TP sensor, ECT, IAT, and MAP
sensors. Also, engine RPM and the PNP switch input affect EGR. There should be no EGR when in park or
neutral, TP sensor below a calibrated value, or TP sensor indicating WOT.
With the ignition "ON" and engine "OFF," the EGR solenoid valve is de-energized. The solenoid valve,
however, should be energized, if the diagnostic "test" terminal is grounded with the ignition "ON" and engine
"OFF."
Diagnostic Aids:

1 The remaining test checks the ability of the EGR
valve to interact with the exhaust system. This
system uses a negative backpressure EGR valve
which should hold vacuum with engine "OFF."
2. When engine is started, exhaust backpressure at
the base of the EGR valve should open the valve's
internal bleed and vent the applied vacuum
allowing the valve to seat.

backpressure and may affect the functional check of
the EGR valve.
During normal EGR valve operation, the
movement of the EGR pintle is small. It is important
to determine whether the valve pintle moves and not
how much it moves.
DRIVEABILITY AND EMISSIONS S.7L (VIN P) 6E3-C7-7
CHARTC-7
(Page 2 of 2)

r-------------..,
: CONTINUED FROM :
I EGRCHART
:' -(1
- OF
__
2).
________ j 1
IGNITION "OFF."
CONNECT A VACUUM PUMP TO EGR VALVE.
OBSERVE EGR DIAPHRAGM WHILE APPLYING VACUUM.
DIAPHRAGM SHOULD MOVE FREELY AND HOLD VACUUM
FOR AT LEAST 20 SECONDS.
DOESIT?
APPLY 34kPa (10" Hg)VACUUMTO EGRVALVE.

START ENGINE AND IMMEDIATELY OBSERVE GAGE ON VACUUM PUMP.
EGR VALVE DIAPHRAGM SHOULD MOVE TO SEATED POSITION AND
VACUUM SHOULD DROP FROM PUMP GAGE WHILE STARTING ENGINE.
DOES IT?
REPLACE EGR VALVE.
REMOVE EGR VALVE.

CHECK FOR PLUGGED OR RESTRICTED EXHAUST PASSAGES.
EGR CIRCUIT IS OPERA TING PROPERLY. REFER

TO SYMPTOMS (SECTION 6E3-B).
PASSAGES NOT OK
REPLACE EGR VALVE.
CLEAN PASSAGES.
RE-CHECK EGR VALVE.
10-9-90
MS 10854
BLANK
SECTION CS
TORQUE CONVERTER CLUTCH (TCC) SYSTEM (AJT)

AUTOMATIC TRANSMISSION GEAR SWITCH SYSTEM
REVERSE LOCKOUT SYSTEM (MIT)
CONTENTS
General Description
Purpose
Operation

Operation
Manual Transmission Reverse
Lockout Solenoid

Vehicle Speed Sensor (Automatic
Transmission)
C8-1
C8-1
C8-1
C8-1
C8-2
C8-2
C8-2
Vehicle Speed Sensor (Manual

Transmission)
On-Vehicle Service
Reverse Lockout Solenoid (MIT Only)

Internal Transmission Components
(8-2
(8-2
(8-2
(8-2
(8-4
(8-4
GENERAL DESCRIPTION
PURPOSE
The Torque Converter Clutch (TCC) system uses a
solenoid operated valve in the automatic transmission
to couple the engine flywheel to the output shaft of the
transmission through the torque converter. This
reduces the slippage losses in the converter, which
increases fuel economy.
OPERATION

TCC SOLENOID
For the Torque Converter Clutch (TCC) to apply,

two conditions must be met:
Internal transmission fluid pressure must be
correct. For information oh internal
transmission operation, refer to SECTION 7 A.
This section will cover only the electrical
operation of the TCC system.
The ECM grounds a switch internally to turn
"ON" the TCC solenoid in the transmission.
This moves a check ball which will allow the
torque converter clutch to apply, if the
hydraulic pressure is correct, as described
above.
The ECM controls the TCC solenoid by looking at
several sensors:
Vehicle Speed Sensor (VSS). Vehicle speed
must be above a certain value before the clutch
can apply.
The vehicle speed sensor is mounted in the
transmission. It replaces the conventional
speedometer driven gear and cable assembly,
and provides an electrical signal to the ECM.
The Vehicle Speed Sensor or VSS, is actually a
small Permanent Magnet (PM) generator.
CHECK BALL SEAT
CHECK BALL
4S0548-6E
Figure CS-1 - TCC Solenoid
It uses a gear driven by the transmission,

(automatic transmission) or a coil type speed
sensor with a tooth rotor mounted to the
output shaft of the transmission (manual
transmission) to generate voltage pulses at a
rate of 4000 pulses per mile.
Engine Coolant Temperature (ECT) Sensor .
Engine must be warmed up before the torque
converter clutch can apply about 50C (122F).
Throttle Position (TP) Sensor. After the torque
converter clutch applies, the ECM uses the
information from the TP sensor to release the
clutch when the vehicle is accelerating or
decelerating at a certain rate.
Gear Select Switch. A 4th gear switch is used
to send a signal to the ECM when the
transmission is in 4th gear. The ECM uses this
information to vary the conditions under
which the clutch applies or releases in 4th gear
only. The transmission need not be in 4th gear
to apply the clutch.
The brake switch is also part of the TCC circuit

as it will remove battery voltage to the TCC
solenoid when the brake pedal is depressed.
OPERATION
Manual Transmission Reverse Lockout
Solenoid
The reverse lockout system has one major
component:
Reverse Lockout solenoid.
The reverse lockout solenoid is mounted to the
right side of the transmission.
The ECM uses vehicle speed to determine when
the reverse lockout solenoid is enabled. When vehicle
speed is above 5 mph, the reverse lockout solenoid will
be disengaged and the transmission will XOT be able
to be placed in to reverse. When vehicle speed is below
5 mph, the ECM will ground CKT 1652 and the
reverse lockout solenoid will be energized. When the
solenoid is energized, it will overcome the reverse
lockout solenoid spring and will allow the
transmission to be shifted into reverse.


(Manual Transmission)
The Vehicle Speed Sensor (VSS) is made up of a
coil mounted on the transmission and a tooth rotor
mounted to the output shaft in the transmission. As
each rotor tooth nears the coil, the coil produces an AC
voltage pulse. As the vehicle speed increases the
number of AC voltage pulses per second increases.
The ECM then converts this information to miles per
hour/kilometers per hour and sends a signal to the
instrument cluster and cruise control module via CKT
817.
ON-VEHICLE SERVICE

1.
2.
3.
4.
5.

Electrical connector from sensor.
Retainer bolt.
Vehicle speed sensor and 0-ring from
transmission.
The ECM receives vehicle speed input from the

Vehicle Speed Sensor (VSS). The Vehicle Speed
Sensor (VSS) is a small Permanent Magnet (PM)
generator mounted in the transmission. It uses a gear,
driven by the transmission, to generate voltage pulses
at a rate of 4000 pulses per mile. The ECM then
converts this information to miles per hour/kilometers
per hour and sends a signal to the instrument cluster
and cruise control module via CKT 817.
1.
2.
3.
4.
0-ring on sensor. Coat with clean transmission

fluid before installing.
Speed sensor gear on sensor. (Automatic
transmission.)
Sensor assembly into transmission. Make sure
sensor is fully seated.
Retainer and retainer bolt.
l~I Tighten
5.
6.
7.
8.
BolttolONm(89lb.in.).
Lower vehicle.
Check transmission fluid level, refer to "Fluid
Level and Checking Information" in SECTION 7A
for Automatic Transmission and SECTION 7B for
Manual Transmission.
REVERSE LOCKOUT SOLENOID (MIT ONLY)
OJ
SENSOR CONNECTOR
l}J
SPEEDO DRIVEN GEAR
[I]
MS 13244
Figure CS-2 - Vehicle Speed Sensor (Automatic

Transmission)
1.
2.
3.
4.

Bolt and solenoid from transmission.
ILitl Inspect
Solenoid seal for cuts, nicks, swelling or distortion.

Replace if necessary.
!VIEWA!
TRANSMISSION
2
BACK-UP LAMP SWITCH
REVERSE LOCK-OUT SOLENOID
VEHICLE SPEED SENSOR (VSS)

NS 15276
Figure CS-3 - Vehicle Speed Sensor and Reverse Lockout Solenoid Location (Manual Transmission)
DRIVER GEAR
TRANSMISSION

NS 15269
Figure CS-4 - Vehicle Speed Sensor Service (Automatic Transmission)

1.
2.
Solenoid seal and lubricate with clean

transmission fluid.
Solenoid to transmission.
3.
4.
5.
Solenoid bolt to 25 Nm (18 lb. ft.).

Electrical connector to solenoid.
Lower vehicle.
f~I Tighten
INTERNAL TRANSMISSION COMPONENTS

For replacement of internal transmission switches,
refer to SECTION 4L60.
VSS Retainer Screw Bolt
Reverse Lockout Solenoid
Bolt
10 );-m (89 lb. in.)
25~m(18lb.ft.)
BLANK
K
TODLC
~
TERMINAL "F" - ~
C230
D
1------------ 422 TAN/BLK
TEMP SWITCH
II
B - - - - - - - - - - - 446LTBLU
11~
4TH GEAR
11
h3RDGEAR
2ND GEAR
c
E
1---------- 438 DK GRN/WHT

1------------ 232 WHT
:rec
I
BRAKE:
SWITCH I
I
I
I
I
BRAKE
SWITCH :
ASSEMBLY,
-----c--
GAGES
T01--IGNITION
10AMP
(1/P)
I
I
39PNK
4TH GEAR SIGNAL

3Ro GEAR SIGNAL
2ND GEAR SIGNAL
Tc
230
: 583 LT BLU/BLK
1
I
I
.__....,,__
L.------...1
...-- 400YEL
TO
VEHICLE SPEED
SENSOR ....-- 401 PPL
_.
--~TO. OTHER GAGES

FUSE CIRCUITS
(1/P)
TORQUE CONVERTER
CLUTCH CONTROL
(TCC) (A/T ONLY)
,--------.
TCC
APPLY SOLENOID
ECM
CHART C-SA
SPEED SENSOR
INPUT
SPEED SENSOR
GROUND
10-15-92
MS 12327
(Page 1 of 4)


The purpose of the automatic transmission Torque Converter Clutch (TCC) feature is to eliminate the power
loss of the torque converter stage, when the vehicle is in a cruise condition. This allows the convenience of the
automatic transmission and the fuel economy of a manual transmission. The heart of the system is a solenoid,
located inside the automatic transmission, which is controlled by the ECM.
When the solenoid coil is activated "ON," the torque converter clutch is applied, which results in 100%
mechanical coupling from the engine to transmission. When the transmission solenoid is deactivated, the torque
converter clutch is released which allows the torque converter to operate in the conventional manner (fluid
coupling between engine and transmission).
The ECM turns "ON" the TCC when engine coolant temperature is above 50C (122F), TP sensor not
changing, and vehicle speed above a specified value.

1. Confirms 12 volt supply as well as continuity of
TCC circuit.
2. Grounding the diagnostic "test" terminal with
engine "OFF," should energize the TCC solenoid.
3. TCC solenoid coil resistance must measure more
than 20 ohms. Using an ohmmeter, check the
solenoid coil resistance of all ECM controlled
solenoids and relays before installing a
replacement ECM. Replace any solenoid or relay
that measures less than 20 ohms.
Diagnostic Aids:
A Tech 1 only indicates when the ECM has turned
"ON" the TCC driver (grounded CKT 422) but this
does not confirm that the TCC has engaged. To
determine if the TCC is functioning properly, engine
RPM should decrease when the Tech 1 indicates the
TCC driver has turned "ON." To determine if the gear
switches are functioning properly, perform the checks
in this section. The switches will not prevent the TCC
from functioning, but will affect TCC lock and unlock
points. If the 4th gear switch circuit is always open,
is reached.
CHARTC-8A
ti\
\.:_.,/
USING A TECH I SCAN TOOL CHECK THE

FOLLOWING AND CORRECT IF NECESSARY.
COOLANT TEMPERATURE SHOULD BE
ABOVE 70C (156F).
TP SENSOR - BE SURE TP SENSOR SIGNAL IS
NOT ERRATIC.
VSS - BE SURE "SCAN" DISPLAYS VSS WITH
DRIVE WHEELS TURNING. IF OTC 24 IS
PRESENT, SEE OTC CHART 24.
(Page 1 of 4)

MECHANICAL CHECKS, SUCH AS LINKAGE, OIL LEVEL, ETC. SHOULD BE

PERFORMED PRIOR TO USING THIS CHART.
IGNITION "ON."
CONNECT TEST LIGHT TO DLC TERMINAL "F" AND GROUND.
DOES IT?

DOES IT?
IGNITION "ON," ENGINE

"OFF."
RELEASE BRAKE PEDAL.
GROUND DIAGNOSTIC
TERMINAL.
DOES IT?
BRAKE SWITCH OUT

OF ADJUSTMENT OR
FAUL TY, OR CKT 422
SHORTED TO
VOLTAGE.
DISCONNECT TCC ELECTRICAL CONNECTOR.

CONNECT TEST LIGHT BETWEEN TERMINAL" A & D".
BULB SHOULD NOT "LIGHT."
DOESIT?
-
CONNECT TEST LIGHT

FROM TERMINAL "A" TO
GROUND.
DOES IT?
DISCONNECT ECM
CONNECTOR "B".
NOTE LIGHT.
CKT 422
SHORTED
TO
GROUND.
r- ------------,
TCC CIRCUIT OK. BE

SURE VEHICLE IS
EQUIPPED WITH THE
CORRECT PROM. TO
CHECK 4th GEAR
SWITCH, SEE CHART
C-8 (4th GEAR
SWITCH
L, DIAGNOSIS).
_ _ _ _ _ _ _ _ _ _ _ _ _ ..J
IGNITION "OFF."
DISCONNECT ECM
CONNECTOR "B".
CONNECT OHMMETER
BETWEEN ECM
TERMINAL "82" AND
DLC TERMINAL "F"
IS THERE CONTINUITY?
GROUNDDLC
TERMINAL "F".
WITH TEST LIGHT
CONNECTED BETWEEN
TRANSMISSION
CONNECTOR
TERMINALS "A & D".
THE BULB SHOULD
"LIGHT."
DOESIT?
FAULTYTCC
SOLENOID
VALVE
CONNECTION
OR
TCC SOLENOID
VALVE.
REPLACE
ECM.
OPEN IN IGNITION
FEED CIRCUIT
TCCBRAKE
SWITCH CIRCUIT,
OR
ADJUST SWITCH.
REPAIR OPEN
CIRCUIT BETWEEN
TRANSMISSION &
DLC TERMINAL "F."
6-6-92
MS 10835
K
TOOLC
~
TERMINAL "F" - ~
(230
1 - - - - - - - - - - - 422 TAN/BLK
TEMP SWITCH
'
II11~4TH GEAR
~RD GEAR
11 2ND GEAR
1 - - - - - - - - - - - - 446 LT BLU
c 11--------- 438 DK GRN/WHT
E J-----------~232WHT
:rec
I
I
I
TORQUE CONVERTER
CLUTCH CONTROL
{TCC) {A/T ONL V)
4TH GEAR SIGNAL
3RD GEAR SIGNAL
2ND GEAR SIGNAL
r------""'
I
I
TCC
APPLY SOLENOID
ECM
BRAKE:
SWITCH I
Tc
230
I
I
BRAKE
SWITCH :
: 583 LT BLU/BLK
ASSEMBL Y1 ......--t
GAGES
ro---
1GN1T10N
400YEL
TO
VEHICLE SPEED
SENSOR ~ 401 PPL
L-------..J
10AMP
(1/P)
'----'_ro OTHER GAGES

FUSE CIRCUITS
(1/P)
SPEED SENSOR
INPUT
SPEED SENSOR
GROUND
10-1592
MS 12327
CHARTC-8A
(Page 2 of 4)
AUTOMATIC TRANSMISSION 2nd GEAR SWITCH


A 2nd gear switch (mounted in the transmission) is normally closed and opens when the transmission shifts
into 2nd gear. The ECM utilizes this signal to identify what gear position the transmission is in.

1. Unless the switch is stuck open or CKT 232 is
open, the Tech 1 should display "NO," indicating
the transmission is not in 2nd gear. The 2nd gear
switch should only be open while in 2nd gear.
2. This checks the operation of the 2nd gear switch.
When the transmission shifts into 2nd gear the
switch should open and the Tech 1 should display
"YES."
to display "YES," indicating the transmission is in
2nd gear.
4.
Disconnecting the TCC connector simulates a open

switch to determine if CKT 232 is shorted to
Diagnostic Aids:
If the 2nd gear switch is changing states, check
connections and wire routing carefully.
Sorne vehicles are equipped with a first gear
lockout (no manually selectable 1st gear position is
provided on the gear shift). Under certain driving
conditions these vehicles may start in 2nd gear which
would cause 2nd gear status to be "YES" with no
vehicle speed. If the vehicle starts out from second
gear, the second gear switch, which is normally closed,
would be open and the Tech 1 would display second
gear as "YES."
CHARTC-8A
(Page 2 of 4)
AUTOMATIC TRANSMISSION 2nd GEAR SWITCH

5. 7L (VIN P)
11
F" CARLINE (MFI)
CHECKS MADE ON THIS PAGE WILL NOT

PREVENT THE TCC FROM WORKING, BUT
WILL AFFECT ENGAGEMENT OR
DISENGAGEMENT POINTS.

DOES "SCAN" INDICATE TRANSMISSION IS IN 2nd GEAR?
RAISE DRIVE WHEELS.

START ENGINE.
INCREASE SPEED SLOWLY UNTIL TRANSMISSION SHIFTS
INTO 2nd GEAR.
DOES "SCAN" INDICATE TRANSMISSION IS IN 2nd GEAR?
2nd GEAR SWITCH

OK. REFERTO
"'DIAGNOSTIC
AIDS" ON FACING
PAGE.
DISCONNECT TCC ELECTRICAL

CONNECTOR.
DOES "SCAN" INDICATE
TRANSMISSION IS IN 2nd GEAR?
GROUNDED INTERNALLY IN
TRANSMISSION
OR
FAULTY 2nd GEAR SWITCH IN
TRANSMISSION.

DISCONNECTTRANSMISSION
JUMPER HARNESS TERMINAL 'T"
TO GROUND.
DOES "SCAN'' INDICATE
TRANSMISSION IS IN 2nd GEAR?
FAULTY ECM
CONNECTION
OR
CKT232 OPEN
OR
FAULTY ECM.
FAUL TY 2nd GEAR SWITCH

OR
CKT 232 OPEN INTERNALLY
IN TRANSMISSION.
GROUNDED CKT 232

OR
FAULTY ECM.
"AFTER REPAIRS," CONFIRM "CLOSED LOOP" OPERATION AND NO MIL(SERVICE ENGINE SOON).
6-26-92
MS 12324
ECM
TODLC
~
TERMINAL "F'' - ~
(230
1----------- 422 TAN/BLK
TORQUE CONVERlER
CLUTCH CONTROL
(TCC) (A/T ONLY)
1------------ 446 LT BLU
4TH GEAR SIGNAL
t - - - - - - - - - 438 OK GRN/WHT
3Ro GEAR SIGNAL
0
TEMP SWITCH
,1~4TH GEAR
,
1
HRDGEAR
,1
2NDGEAR
TCC
APPLY SOLENOID
E t-----------~232WHT
2No GEAR SIGNAL
,-------...,
:rec
BRAKE:
SWITCH I
I
I
I
I
BRAKE
SWITCH :
ASSEMBLY1
I
Tc
230
: 583 LT BLU/BLK
1
I
GAGES
I
I
1
1
TO~-- - - 39 PNK
'---- - - '
IGNITION
1..-------1
..,.__ 400 YEL

TO
VEHICLE SPEED
SENSOR . . _ 401 PPL
"----lTO OTHER GAGES

FUSE CIRCUITS
(1/P)
SPEED SENSOR
INPUT
SPEED SENSOR
GROUND
10-15-92
MS 12327
CHARTC-8A
(Page 3 of 4)
AUTOMATIC TRANSMISSION 3rd GEAR SWITCH

5.7L (VIN P)
11
F" CARLINE (MFI)
A 3rd gear switch (mounted in the transmission) is normally closed and opens when the transmission shifts
into 3rd gear. The ECM utilizes the 3rd gear switch signal for scheduling of the torque converter clutch
engagement.

1. Unless the switch is stuck open or CKT 438 is
open, the Tech 1 should display "NO," indicating
the transmission is not in 3rd gear. The 3rd gear
switch should only be open while in 3rd gear.
2. This checks the operation of the 3rd gear switch.
When the transmission shifts into 3rd gear the
switch should open and the Tech 1 should display
"YES."
to display "NO," indicating the transmission is not
in 3rd gear.
4.
Disconnecting the TCC connector simulates an

Diagnostic Aids:
If the 3rd gear switch is changing states, check
connections and wire routing carefully.
CHARTC-8A
(Page 3 of 4)
AUTOMATIC TRANSMISSION 3rd GEAR SWITCH

(ELECTRICAL DIAGNOSIS}
5. 7L (VIN P)
11
F" CARLINE (MFI)

IGNITION "ON.'" ENGINE "OFF."

DOES "SCAN" INDICATE TRANSMISSION IS IN 3rd GEAR?
RAISE DRIVE WHEELS.

START ENGINE.
INCREASE SPEED SLOWLY UNTIL TRANS.
SHIFTS INTO 3rd GEAR.
DOES "SCAN" INDICATE TRANSMISSION
IS IN 3rd GEAR?
3rd GEAR SWITCH OK.

REFER TO
"DIAGNOSTIC AIDS"
ON FACING PAGE.
DISCONNECT
TRANSMISSION
TRANSMISSION IS IN 3rd
GEAR?
GROUNDED INTERNALLY IN
TRANSMISSION
~

DISCONNECTTRANSMISSION
JUMPER HARNESS TERMINAL"('"
TO GROUND.
DOES "SCAN'" INDICATE
TRANSMISSION IS IN 3rd GEAR?
FAULTY ECM
CONNECTION
OR
CKT438 OPEN
OR
FAUL TY ECM.
FAUL TY 3rd GEAR SWITCH

OR
CKT 438 OPEN INTERNALLY
IN TRANSMISSION.
GROUNDED CKT 438

OR
~UUYEC~
FAUL TY 3rd GEAR SWITCH IN

TRANSMISSION.
7-8-92
MS 12464
ECM
K
TODLC
~
TERMINAL "F'" ~
C230
D
I--------....- - 422 TAN/BLK
TEMP SWITCH
II
11~
11
1------------ 446 LT BLU

1--------- 438 DK GRN/WHT
3Ro GEAR SIGNAL
E t-----------~232WHT
2ND GEAR SIGNAL
4TH GEAR
~RD GEAR
2NDGEAR
TORQUE CONVERTIR
CLUTCH CONTROL
(TCC) (A/T ONLY)
4TH GEAR SIGNAL
TCC
APPLY SOLENOID
-+--- 400YEL
SPEED SENSOR
INPUT
SENSOR - - - 401 PPL
SPEED SENSOR
GROUND
TO
VEHICLE SPEED
~__,._TO OTHER GAGES
FUSE CIRCUITS
(1/P)
10-1 S-92
MS 12327
CHARTC-8A
{Page 4 of 4)
AUTOMATIC TRANSMISSION 4th GEAR SWITCH

{ELECTRICAL DIAGNOSIS}
A 4th gear switch (mounted in the transmission) is normally open and closes when the transmission shifts
into 4th gear. This switch is used by the ECM to modify TCC lock and unlock points, when in a 4-3 downshift
maneuver. The temperature switch is normally open. Transmission must be in 4th gear for the temperature
switch to apply TCC to cool transmission fluid. Temperature switch locks at about 155C (279F) and unlocks
about 143C (259F).

1. Unless the switch is stuck closed or CKT 446 is
shorted to ground, the Tech 1 should display "NO,"
indicating the transmission is not in 4th gear. The
4th gear switch should only be closed while in 4th
gear.
2. This checks the operation of the 4th gear switch.
When the transmission shifts into 4th gear the
switch should close and the Tech 1 should display
"YES."
3. Disconnecting the TCC connector simulates an
4.
This step determines if the ECM and wiring are

to display "YES," indicating the transmission is in
4th gear.
Diagnostic Aids:
A road test may be necessary to verify the
customer complaint. If the Tech 1 indicates TCC is
turning "ON" and "OFF" erratically, check the state of
the 4th gear switch to be sure they're not changing
states under a steady throttle position. If the switch is
changing states, check connections and wire routing
carefully. Also, if the 4th gear switch is always closed,
is reached.
CHARTC-8A
(Page 4 of 4)
AUTOMATIC TRANSMISSION 4th GEAR SWITCH



DOES "SCAN" INDICATE TRANSMISSION IS IN 4th GEAR?
RAISE DRIVE WHEELS.

START ENGINE.
INCREASE SPEED SLOWLY UNTIL
TRANSMISSION SHIFTS INTO 4th GEAR.
DOES "SCAN" INDICATE TRANSMISSION IS
IN 4th GEAR?
4th GEAR SWITCH OK.
REFER TO
.. DIAGNOSTIC AIDS"
ON FACING PAGE.
DISCONNECT TCC
JUMPER HARNESS
TERMINAL "B" (CKT 446)
TO GROUND.
TRANSMISSION IS IN 4th
GEAR?
FAULTY CONNECTION
OR
FAUL TY 4th GEAR SWITCH IN
TRANSMISSION.

DISCONNECT TRANSMISSION
ELECTRICAL CONNECTOR
CKT 446 SHORTED TO

GROUND
OR
FAULTY ECM.
FAULTY 4th GEAR

SWITCH
OR
CKT 446 GROUNDED
INTERNALLY IN
TRANSMISSION.
OPEN CKT 446,

FAULTY CONNECTION
OR
FAULTY ECM.
6-27-92
MS 12471
ECM
REVERSE LOCKOUT
SOLENOID
REVERSE LOCKOUT
SOLENOID CONTROL
(M/TONLY)
. - - - - - 541 BRN - - - ~ - - - - - 1652 LTGRN
J_
MOUNTED TO
TRANSMISSION
TO OTHER
FANS/ACTR CIRCUITS
----<~--- 541 BRN
FANS/ACTR
---------.
. - - - - - ' ~ TO IGNITION
C100
10AMP
(U/H)
.___ _ _ _ __.TO EGR SOLENOID VALVE AND EVAP

CANISTER PURGE SOLENOID VALVE
(U/H)
10-12-92
NS 15380
CHARTC-88
REVERSE LOCKOUT SYSTEM
{ELECTRICAL DIAGNOSIS)
5. 7L (VIN P)
11
F" CARLINE (MFI)
The reverse lockout solenoid will be energized when the ECM grounds CKT 1652, which will allow the
transmission to be shifted into reverse. The ECM will enable the reverse lockout solenoid whenever vehicle speed
is below 4 mph. When vehicle speed is above 5 mph, the ECM will de-energize the reverse lockout solenoid, which
will prohibit the transmission from being shifted into reverse.

1. The reverse lockout solenoid will be enabled
whenever vehicle speed is below 5 mph. If there is
a fault in the vehicle speed sensor circuit and the
ECM is not receiving VSS signal, the reverse
lockout solenoid would be enabled at speeds above
5 mph (8 km/h) and the shifter could be placed into
reverse.
2. Selecting "Field Service Mode" on the Tech 1 or
grounding the diagnostic "test" terminal at the
DLC with the ignition ''ON" and engine not
running, will de-energize the reverse lockout
solenoid indicating normal system operation.
NOTICE: Do Not keep the diagnostic "test"

terminal grounded for more than 1 minute, as
damage could result to ECM driven solenoids.
3.
Raise the vehicle enough to gain access to the

reverse lockout solenoid electrical harness and
still be able to turn the ignition "ON."
4. Disconnecting the ECM will determine if the ECM
is internally shorted or CKT 1652 is shorted to
ground causing the reverse lockout solenoid to be
enabled.
CHARTC-88
REVERSE LOCKOUT SYSTEM
G:
IF OTC 24 IS PRESENT, USE THAT OTC CHART FIRST .

IGNITION "OFF."
FULLY DEPRESS CLUTCH PEDAL.
CAN TRANSMISSION BE SHIFTED INTO REVERSE?
[$]
FAUL TY REVERSE LOCKOUT SOLENOID
OR
INTERNAL TRANSMISSION PROBLEM.

FULLY DEPRESS CLUTCH PEDAL.
[$
[$]
CLUTCH PEDAL DEPRESSED.

SELECT "FIELD SERVICE" MODE ON TECH 1.
G).
G).
IGNITION "OFF."
RAISE VEHICLE .
DISCONNECT ELECTRICAL HARNESS FROM
REVERSE LOCKOUT SOLENOID.
PROBE TERMINAL" A" OF REVERSE
LOCKOUT SOLENOID ELECTRICAL HARNESS
WITH A TEST LIGHT TO B +.
IGNITION "ON."
SELECT "FIELD SERVICE" MODE ON TECH 1.
[$
G).
NORMAL SYSTEM
OPERATION. EXIT
"FIELD SERVICE"
MODE ON TECH 1.
IGNITION "OFF."
DISCONNECT ECM CONNECTOR "B" .
IGNITION "ON."
PROBE TERMINAL "A" OF REVERSE
LOCKOUT SOLENOID WITH A TEST
LIGHT CONNECTED TO B +.
IS TEST LIGHT "ON"?
FAUL TY REVERSE
LOCKOUT
SOLENOID
OR
INTERNAL
TRANSMISSION
PROBLEM.
IGNITION "OFF."
RAISE VEHICLE.
DISCONNECT ELECTRICAL HARNESS
FROM REVERSE LOCKOUT
SOLENOID.
PROBE TERMINAL "B" OF REVERSE
LOCKOUT SOLENOID ELECTRICAL
HARNESS WITH A TEST LIGHT TO
GROUND.
IGNITION "ON."
[$]
PROBE TERMINAL "A" OF

ELECTRICAL HARNESS WITH A
~
FAULTY CONNECTION AT REVERSE
LOCKOUT SOLENOID
OR
FAULTY REVERSE LOCKOUT
SOLENOID.
[$
ICKT 541 OPEN.
CKT 1652 OPEN

OR
FAULTY ECM
CONNECTION
OR
FAULTY ECM.
$
CKT 1652 SHORTED
TO GROUND.
[$
I FAULTY ECM. I
11-2-92
NS 15381
BLANK
SECTION C10
A/C CLUTCH CIRCUIT DIAGNOSIS

CONTENTS
GeneralDescription
Operation
Diagnosis
On-Vehicle Service
A/C Relay
A/C Evaporator Temperature
Sensor
C10-1
(10-1
(10-1
C10-1
GENERAL DESCRIPTION
In order to improve engine operation, the A/C
compressor operation is controlled by the ECM.
OPERATION
This system consists of a HV AC control assembly,
AIC compressor low pressure cut-off switch an A/C

refrigerant pressure sensor, an A/C ev;porator
temperature sensor, a control relay, the compressor
clutch and the EC:'.\1.
The A/C compressor low pressure cut-off switch is
closed when there is sufficient system pressure
(depending on refrigerant charge (R134A) and
ambient temperature). If a low charge is present, the
AIC compressor low pressure cut-off switch will open
so AIC compressor damage does not occur.
When the HVAC control assembly is placed in the
AIC mode, a request signal is sent to the ECM. The
ECM will then energize the A/C clutch relay, unless
abnormally high or low A/C pressure is detected by the
A/C refrigerant pressure sensor. The ECM also
monitors the A/C evaporator temperature sensor to
cycle the A/C clutch "ON" and "OFF." If the ECM
detects an A/C evaporator temperature less than 2C
(36F), the A/C clutch will be prohibited from being
enabled. The ECM will also energize the cooling fans
"ON" when A/C is requested. Refer to "Electric
Cooling Fan," Section "6E3-C12". The A/C control
relay is controlled by the ECM so that the ECM can
increase idle speed before turning "ON" the clutch or
disable the clutch when high engine coolant
temperature is detected or high engine RPM is
detected.
DIAGNOSIS
The ECM will energize the A/C clutch whenever
the engine is running less than 4100 RPM and A/Chas
been requested, unless any of the following conditions
are met:
AIC head pressure greater than 414 psi (2854
kPa) or less than 38 psi (262 kPa) (as
determined by the A/C refrigerant pressure
sensor).
(10-1
(10-1
(10-1
A/C evaporator temperature less than 2C

(36F).
Low ignition voltage.
Engine speed greater than 4700 RPM for 6
seconds.
ECT greater than 125C (257F).
CHART C-10 should be used for diagnosing the
electrical portion of the A/C circuit. SECTION lB of
the service manual should be used for diagnosing the
refrigerant portion of the system.
The Tech 1 will be used in diagnosing the system,
as it has the ability to read the A/C request input to
the ECM, A/C compressor status, A/C system pressure,
A/C evaporator temperature, as well as displaying
when the ECM has commanded the A/C clutch "ON."
ON-VEHICLE SERVICE
A/C RELAY

2. Cover from underhood electrical center.
3. Relay from underhood electrical center.

1.
2.
3.
Relay to underhood electrical center.

Cover to underhood electrical center.

For removal and replacement procedures, refer to
SECTION lB of the service manual.

1.
2.
3.

Carefully back out A/C refrigerant pressure
sensor.
AIR PUMP
RELAY
COOLANT FAN
RELAY, PRIMARY
(DRIVER SIDE)
ABS
RELAY
A/C COMPRESSOR
RELAY
~
INJECTOR
C,O
INJECTOR
~
IGNITION
00
A/C-CRUISE
I
U
COOLANT FAN
LOW COOLANT
RELAY
I
1 (PASSENGER SIDE)
ONLY
L-------...l
FOG LIGHTS
RELAY
HIGH BLOWER
RELAY
NS 15660
Figure C10-1 - A/C Clutch Control Relay Location

A/C refrigerant pressure sensor to NC refrigerant
line.
components, refer to SECTION lB of the service
manual.
1.
DRIVEABILITY AND EMISSIONS 5. 7l {VIN P) 6E3-C10-3
BLANK
A/CCRUISE
. - - - - - - 1 3 9 P N K ~ 3 P N K -TOIGNITION
~-------- TO OTHER A/C CRUISE
FUSE CIRCUITS
20 AMP
(U/H)
TO IGNITION- 300 ORN
A/C
RELAY
HVAC
~
25AMP
(1/P)
TO HVAC
BLOWER SWITCH
139
PNK
ECM
66 LT GRN
241
BRN
TO REAR
DEFOG SYSTEM
HVAC
CONTROL
ASSEMBLY
F
762 DK GRN/WHT ~
I
I
230
I ~BI
,.._---....~~~~,,------------459DKGRN/WHT
(100
CI
59DKGRN--f-4~~,-----------t..-LOW PRESSURE
CUTOFF SWITCH
r:'l - -
a.l
3DKGRN---~
450 BLK
A/C
COMPRESSOR
A/C
REFRIGERANT
PRESSURE
SENSOR
CLUTCH
PROBE
(INSERTED IN
EVAPORATOR)
BLK
A/C
EVAPORATOR
EMPERA TURE
SENSOR

A/C REQUEST
A/C CLUTCH RELAY
CONTROL
A/C STATUS
TO OTHER
SOB CIRCUITS
- - - - - - - - 8 0 8 BLK
380 RED/BLK
416 GRY
416GRY
- - - - - 7 3 2 DK BLU
SENSOR GROUND
SENSOR SIGNAL
+ 5 VOLT REFERENCE
A/C EVA PORA TOR
TEMPERATURE SENSOR
SIGNAL
SENSOR GROUND
10-15-92
MS 12472
CHART C-10 (Page 1 of 3)

The AJC clutch control relay is ECM controlled to delay NC clutch engagement after the NC is turned "ON."
This allows the ECM to adjust engine RPM before the NC clutch engages.
The ECM will engage the NC clutch any time NC has been requested unless any of the following conditions
exist:
Low battery voltage.
Low evaporator temperature.
High engine RPM.
Low NC system pressure.
When the HVAC control assembly is placed in the NC mode, A 12 volt signal is sent to the ECM. When the
ECM receives this signal the ECM will ground CKT 459 to energize the NC relay. This will be displayed on the
Tech 1 as NC request "YES." A 3-wire NC refrigerant pressure sensor is used to monitor NC system pressure.
If the AJC refrigerant pressure is greater than 414 psi or lower than 38 psi, the NC clutch will not engage.
The AJC refrigerant pressure sensor uses ECM DTCs 66 and 67. If the NC refrigerant pressure sensor signal
wire becomes open, shorted to ground or shorted to voltage, DTC 66 will set. If the NC clutch engages and no
pressure change is detected, a DTC 67 will set.
The ECM also monitors AJC evaporator temperature. The ECM utilizes this information to cycle the NC
clutch. If NC evaporator temperature is out of range (high or low), the ECM will disable the NC clutch relay.
The AJC evaporator temperature sensor uses ECM DTC 71. If the NC evaporator temperature sensor circuits
becomes open, shorted to ground or shorted to voltage, OTC 71 will set.
When a request for AJC has been detected by the ECM, the ECM will ground the NC clutch control relay
driver circuit, the relay contacts will close, and current will flow through the relay to the NC compressor clutch.
When AJC request has been detected by the ECM, the cooling fan(s) will be turned "ON" unless vehicle speed
is too high.
Diagnostic Aids:
1. Checks the ECMs ability to control the NC clutch
Before using CHART C-10, be sure no ECM
control relay.
DTC(s) are stored. The ECM will not activate the NC
2. Checks for grounded CKT 459 to ECM.
clutch with a stored DTC.
3. Before replacing C60 A/C control components,
refer to SECTION lB for further diagnostics.
CORRECT ANY DIAGNOSTIC TROUBLE CODES (DTCs) BEFORE

PROCEEDING WITH THIS CHART.
CHECK A/C CRUISE FUSE AND HVAC FUSE FOR BEING OPEN .
ENGINE COOLANT AT NORMAL OPERATING TEMPERATURE .
A/C REFRIGERANT PRESSURE NORMAL.
A/C EVAPORATOR TEMPERATURE NORMAL.
ENGINE IDLING,A/C "OFF."
IS A/C CLUTCH ENGAGED?
]
r'
~
PLACE A/C SELECTOR
INTO
A/C MODE.
DOES TECH 1
DISPLAY A/C
STATUS "ON"?
---------.,
I
I
I
L------------j
.
]
DISCONNECT HVAC
CONTROL ASSEMBLY.
PROBE TERMINAL "C"
OF HVAC CONTROL
ASSEMBLY HARNESS
WITH A TEST LIGHT
CONNECTED TO
GROUND.
r---~-,
REFER TO
I
: CHARTC-10 :
I PAGE 2 OF 3. 1
L.--------.J
FAULTY
CLUTCH
CONN OR
FAULTY A/C
COMPRESSOR
CLUTCH COIL
CKT590R603
SHORTED TO VOLTAGE.

FROM TERMINAL "A" TO
"C" OF HVAC CONTROL
ASSEMBLY HARNESS.
TECH 1 SHOULD DISPLAY
A/C REQUEST AS "YES."
DOES IT?
OPEN
CKT450
OR
FAULTY
GROUND
CONN.
11 FAULTY RELAY.
I LIGHT "OFF" I
CKT 241
OPEN.
I
~
IGNITION 'OFF,"
IGNITION "ON."
USING A TEST LIGHT, PROBE
BOTH IGNITION FEED
CIRCUITS FROM A/C RELAY
HARNESS TO GROUND.
G)
FAULTY HVAC CONTROL

ASSEMBLY CONNECTION OR
FAULTY HVAC CONTROL
ASSEMBLY.
NO LIGHT ONE OR BOTH
1 JUMPER CKT 50 TO CKT 59. I
A/C STATUS "ON"?
~
CKT603
OPEN OR
FAULTY LOW
PRESSURE
CUT-OFF
SWITCH OR
SYSTEM LOW
ON CHARGE.
CKT 762 OPEN OR

OR FAUL TY ECM.
I LIGHT "ON" BOTH I

DISCONNECT LOW PRESSURE
CUT-OFF SWITCH.
PROBE CKT 59 AT LOW
HARNESS WITH A TEST LIGHT
TO GROUND.
LIGHT
"OFF"
EJ
5J
I II
CKT 459 SHORTED

TO GROUND OR
FAULTY ECM.
PROBE CKT 59 AT RELAY HARNESS

IS TEST LIGHT "ON"?
LIGHT"ON"
CONNECT
TEST LIGHT
BETWEENA/C
COMPRESSOR
CLUTCH
HARNESS
CONNECTOR.
LIGHT
"ON"
CIRCUIT 762 SHORTED TO VOLTAGE

OR FAULTY HVAC CONTROL
ASSEMBLY OR FAUL TY ECM.

PROBE CKT 459 WITH A
TEST LIGHT TO B + .
IS TEST LIGHT "ON"?
DISCONNECT
A/CCLUTCH
CONNECTOR.
PROBE
TERMINAL "A"
WITH A TEST
LIGHT TO
GROUND.
IS TEST LIGHT
"ON"?
ENGINE STILL RUNNING .

TECH 1 SHOULD INDICATE A/C REQUEST AS "NO."
DOESIT?
DOES TECH 1
DISPLAY A/C
CLUTCH "ON"?
: REFER TO CHART
I C-10 PAGE 3 OF 3.
DOES TECH 1 INDICATE

A/C REQUEST AS "YES."

11
CYCLE A/C CLUTCH "ON" & "OFF."

DOES A/C CLUTCH ENGAGE?
CHART C-10 (Page 1 of 3)
l;J
CKT59
OPEN
FROM
SPLICE TO
LOW
PRESSURE
CUT-OFF
SWITCH.
FAULTY ECM
CONNOR
OPEN A/C
STATUS
CIRCUIT FROM
SPLICE TO
ECMOR
FAULTY ECM.
OPEN IN CIRCUIT THAT

DID NOT LIGHT.
IS THE A/CCLUTCH
COIL "ON"?
eJ
OPEN A/C
CIRCUIT
FROM
RELAY TO
SPLICE.
IGNITION "ON."
GROUND DIAGNOSTIC
"TEST" TERMINAL.
PROBE RELAY HARNESS
CONNECTOR, CKT 459 WITH
A TEST LIGHT TO B +.
LIGHT "ON"
FAUL TY A/C RELAY
I LIGHT
. "OFF"
OPEN OR SHORT
TO VOLTAGE IN
CKT459 OR
FAULTY ECM
CONN.OR
FAULTY ECM.
11-4-92
NS 15559
A/CCRUISE
, - - - - - - 1 3 9 P N K ~ 3 P N K __.,..TOIGNITION
. - - - - - - - . TO OTHER A/C CRUISE
FUSE CIRCUITS
20 AMP
(U/H)
HVAC
TO IGNITION~ 3000RN ~
25AMP
(1/P)
TO HVAC
...._ 66 LT GRN
241
BLOWER SWITCH
BRN
A/C
RELAY
(100
I
I
TO REAR
DEFOG SYSTEM
Jo
HVAC
CONTROL
ASSEMBLY
139
PNK
I
ECM
A/CREQUEST
BI
A/C CLUTCH RELAY

CONTROL
I
CI
59DKGRN~~~:-----------tt--LOW PRESSURE
CUTOFF SWITCH
r:"1 - -
..-i.. ..
3 DK G R N - - - ~
450 BLK
A/C
COMPRESSOR
A/C
REFRIGERANT
PRESSURE
SENSOR
CLUTCH
PROBE
(INSERTED IN
EVAPORATOR)
BLK
A/C
EVAPORATOR
EMPERATURE
SENSOR
A/CSTATUS
TO OTHER
SOS CIRCUITS
- - - - - - - - - 8 0 8 BLK
380 RED/BLK
416 GRY
416GRY
t - - - - - - 7 3 2 DK BLU
(U/H) = LOCATED IN UNDER HOOD ELECTRICAL CENTER

SENSOR GROUND
SENSOR SIGNAL
+ 5 VOLT REFERENCE
A/C EVAPORATOR
TEMPERATURE SENSOR
SIGNAL
SENSOR GROUND
10-15-92
MS 12472
CHARTC-10
(Page 2 of 3)

The AJC clutch control relay is ECM controlled to delay NC clutch engagement after the NC is turned "ON."
This allows the ECM to adjust engine RPM before the NC clutch engages.
The ECM will engage the AJC clutch any time NC has been requested unless any of the following conditions
exist:
Low evaporator temperature
High engine RPM.
Low NC system pressure.
When the HVAC control assembly is placed in the NC mode, a 12 volt signal is sent to the ECM. When the
Tech 1 as A/C request "YES." A 3-wire NC refrigerant pressure sensor is used to monitor NC system pressure.
If the AJC refrigerant pressure is greater than 414 psi or lower than 38 psi, the NC clutch will not engage.
The AJC refrigerant pressure sensor uses ECM OTCs 66 and 67. If the NC refrigerant pressure sensor signal
wire becomes open, shorted to ground or shorted to voltage, OTC 66 will set. If the NC clutch engages and no
pressure change is detected, a OTC 67 will set.
The ECM also monitors NC evaporator temperature. The ECM utilizes this information to cycle the NC
clutch. If NC evaporator temperature is out ofrange (high or low), the ECM will disable the NC clutch relay.
The AJC evaporator temperature sensor uses ECM OTC 71. If the NC evaporator temperature sensor circuits.
becomes open, shorted to ground or shorted to voltage, OTC 71 will set.
When a request for A/C has been detected by the ECM, the ECM will ground the NC clutch control relay
driver circuit, the relay contacts will close, and current will flow through the relay to the NC compressor clutch.
is too high.
CHART C-10
(Page 2 of 3)

,--------------.
: FROMCHARTC-10 :
PAGE 1 OF3
L,,
_ _ _ _ _ _ _ _ _ _ _ ....
INSTALL A/C MANIFOLD GAGE SET. REFER TO SECTION 1B.

IGNITION "ON.H
USING TECH 1, COMPARE A/C GAGE SET PRESSURE TO TECH 1 PRESSURE.
IS TECH 1 PRESSURE WITHIN 20 psi OF HIGH SIDE OF PRESSURE?
ENGINE IDLING, A/C "ON ...

USING A TECH 1, MONITOR A/C
EVAPORATOR TEMPERATURE.
IS A/C EVAPORATOR TEMPERATURE
GREATER THAN 2C (36F).
IGNITION "OFF."
JUMPER PRESSURE SENSOR CONNECTOR TERMINALS "B" AND"(".
IGNITION "ON."
DOES TECH 1 INDICATE PRESSURE SENSOR VOLTAGE ABOVE 4.8 VOL TS?
DISCONNECT A/C
EVAPORATOR
TEMPERATURE SENSOR.
DOES A/C EVA PORA TOR
TEMPERATURE
INDICATE-7C(19F)?
USING DVM MEASURE VOLTAGE

FROM PRESSURE SENSOR
CONNECTOR "B" TO GROUND.
DOES DVM MEASURE ABOUTS
VOLTS?
FAULTY A/C
EVAPORATOR
TEMPERATURE
SENSOR.
HIGH RESISTANCE
IN CIRCUIT 732
OR
FAULTY ECM.
FAULTY ECMS
VOLT REFERENCE
CONNECTION OR
OPEN OR
GROUNDEDS
VOLT REFERENCE
CIRCUIT OR
FAULTY ECM.
FAULTY ECM
SIGNAL CIRCUIT
CONNECTION OR
OPEN OR
GROUNDED
PRESSURE SENSOR
SIGNAL WIRE OR
FAUL TY ECM. -
WITH A TEST LIGHT TO B +,

PROBE A/C REFRIGERANT
PRESSURE SENSOR
CONNECTOR TERIIAINAL "A".
IS TEST LIGHT "ON"?
OPEN
PRESSURE
SENSOR
GROUND
CIRCUIT.
FAULTY
SDI SOR
CONNECTION
OR FAULTY
SE'-ISOR.
11-18-92
NS 15570
A/CCRUISE
. - - - - - - - 1 3 9 PNK ~ 3PNK -
, - - - + - ~ TO OTHER A/C CRUISE
20 AMP
(U/H)
FUSE CIRCUITS
TO IGNITION
ECM
HVAC
TO IGNITION~ 300 ORN ~

25AMP
(1/P)
TO REAR
TO HVAC
~ 66 LT GRN
DEFOG SYSTEM
241
BLOWER SWITCH
BRN
A/C
RELAY
HVAC
CONTROL
ASSEMBLY
139
PNK
762 DK GRN/WHT ~
I
Bl
230
I :,
I
......_----.~~~-~,- - - - - - - - - - 4 5 9 D K G R N / W H T
C100
CI
-----------1...--
59 DK GRN ~ -.....1
450 BLK
r:, ----
..----L
A/C
REFRIGERANT
PRESSURE
SENSOR
CLUTCH
PROBE
(INSERTED IN
EVAPORATOR)
BLK
A/C CLUTCH RELAY

CONTROL
A/CSTATUS
LOW PRESSURE
CUTOFF SWITCH
~~
3 DKGRN------.~
A/C
COMPRESSOR
A/CREQUEST
A/C
EVAPORATOR
EMPERATURE
SENSOR
TO OTHER
SOS CIRCUITS
- - - - - - - 8 0 8 BLK
380 RED/BLK
416GRY
416GRY
- - - - - 7 3 2 DK BLU

SENSOR GROUND
SENSOR SIGNAL
+ 5 VOLT REFERENCE
A/C EVAPORATOR
TEMPERATURE SENSOR
SIGNAL
SENSOR GROUND
10-15-92
MS 12472
CHART C-10
{Page 3 of 3)

11
The A/C clutch control relay is ECM controlled to delay NC clutch engagement after the AJC is turned "ON."
This allows the ECM to adjust engine RPM before the AJC clutch engages.
The ECM will engage the AJC clutch any time AJC has been requested unless any of the following conditions
exist:
High A/C system pressure.
Low evaporator temperature.
High engine RPM.
Low A/C system pressure.
When the HVAC control assembly is placed in the AJC mode, a 12 volt signal is sent to the ECM. When the
Tech 1 as A/C request "YES." A 3-wire AJC refrigerant pressure sensor is used to monitor NC system pressure.
If the A/C refrigerant pressure is greater than 414 psi or lower than 38 psi, the AJC clutch will not engage.
The A/C refrigerant pressure sensor uses ECM DTCs 66 and 67. If the AJC refrigerant pressure sensor signal
wire becomes open, shorted to ground or shorted to voltage, DTC 66 will set. If the NC clutch engages and no
pressure change is detected, a DTC 67 will set.
The ECM also monitors A/C evaporator temperature. The ECM utilizes this information to cycle the AJC
clutch. If A/C evaporator temperature is out of range (high or low), the ECM will disable the NC clutch relay.
The AJC evaporator temperature sensor uses ECM DTC 71. If the NC evaporator temperature sensor circuits
becomes open, shorted to ground or shorted to voltage, DTC 71 will set.
When a request for AJC has been detected by the ECM, the ECM will ground the NC clutch control relay
driver circuit, the relay contacts will close, and current will flow through the relay to the AJC compressor clutch.
is too high.
Test Description: Number(s) below refer to circled This would cause A/C clutch to be engaged at all times
when A/C is requested.
1. If 5 volt reference is not present at the A/C
evaporator temperature sensor, the A/C
evaporator temperature would be at a fixed value.
CHART C-10
(Page 3 of 3)

r------------,
: FROMCHARTC-10 :
t PAGE 1 OF3.
1
L
----------.J
IGNITION "OFF."
DISCONNECT A/C EVAPORATOR TEMPERATURE SENSOR.
IGNITION "ON."
USING A DVM{J 39200}MEASURE VOLTAGE AT TERMINAL
"A" OFA/C EVAPORATOR TEMPERATURE SENSOR
HARNESS.
IS 5 VOL TS INDICATED ON DVM?
5 VOL TS REFERENCE
CIRCUIT OPEN.
OR
SHORTED TO GROUND.
10-30-92
NS 16198
6E3-C10-10 5.7L (VIN P} DRIVEABILITY AND EMISSIONS
BLANK
SECTION C12
ELECTRIC COOLING FAN(S)

CONTENTS
General Description
Operation
Primary Cooling Fan (Fan 1)
Secondary Cooling Fan (Fan 2)
(WithC60)
C12-1
C12-1
C12-1
On-Vehicle Service
Primary and Secondary Cooling Fan
Relay
C12-1
C12-1
C12-1
GENERAL DESCRIPTION
The electric cooling fan(s) are used to cool engine
coolant flowing through the radiator. They are also
used to cool the refrigerant flowing through the lVC
condenser.
OPERATION
The electric cooling fan(s) are controlled by the
ECM. The EC~I controls the ground path for the
cooling fan relay(s).
The relay(s) are used to control the high current
flow to power the cooling fan motors. The ECM
determines operation of the independent fans based on
various sensor inputs.
The ECM will turn the secondary cooling fan "ON"

when any of the following conditions exist at idle:
Certain ECM Diagnostic Trouble Codes
(DTCs) set.
ECT above l 13C (235F).
AJC head pressure above 248 psi.
Once the secondary fan has been turned "ON" by
the ECT, the ECM will turn the fan "OFF" when that
temperature has dropped about 3C (5F). If the
secondary cooling fan has been turned "ON" by high
NC head pressure, the ECM will turn the fan "OFF"
when the pressure has dropped to 208 psi. The
minimum "ON" time for the secondary cooling fan is
30 seconds.
ON-VEHICLE SERVICE
Primary Cooling Fan (Fan 1)
PRIMARY AND SECONDARY COOLING FAN

RELAY
The primary cooling fan is controlled by the ECM

based on inputs from the A/C system, Engine Coolant
Temperature (ECT) sensor, Vehicle Speed Sensor
(VSS).
The ECM will turn the primary cooling fan "ON"
when any of the following conditions exist at idle.
Certain ECM Diagnostic Trouble Codes (DTCs)
set.
ECT above 108C (226F).
AJC head pressure above 248 psi.
Once the primary fan has been turned "ON" by the
Engine Coolant Temperature (ECT) sensor, the ECM
will turn the fan "OFF" when that temperature has
dropped about 3C (5F). If the primary cooling fan has
been tumed "ON" by high A/C head pressure, the
ECM will turn the fan "OFF" when the pressure has
dropped to 200 psi. The minimum "ON" time for the
primary cooling fan is 50 seconds.
Secondary Cooling Fan (Fan 2) (With C60)

The secondary cooling fan is controlled by the
ECM based on inputs from the A/C system, Engine
Coolant Temperature (ECT) sensor, Vehicle Speed
Sensor (VSS).
1.
2.
3.

Cover from underhood electrical center.
Relay from underhood electrical center.

1.
2.
3.
Relay to underhood electrical center.

Cover to under hood electrical center.
Cooling system component replacement can be
found in SECTION 6B.
components, refer to SECTION lB.
PRIMARY COOLING FAN MOTOR
RADIATOR
SECONDARY COOLING FAN MOTOR
LOWER RADIATOR SUPPORT
NS
15383
Figure C12-1 - Cooling Fan (CGO) Location
AIR PUMP
RELAY
COOLANT FAN
RELAY, PRIMARY
(DRIVER SIDE)
ABS
RELAY
A/C COMPRESSOR
RELAY
0.0
INJECTOR
~
INJECTOR
00
IGNITION
~
A/C-CRUISE
I
U
COOLANT FAN
LOW COOLANT
RELAY
1
ONLY
(PASSENGER SIDE)
L--------l
I
I
FOG LIGHTS
RELAY
HIGH BLOWER
RELAY
NS
Figure C12-2 - Cooling Fan Relay Location
15660
BLANK
ECM
J
. - - - - - - 3 3 5 DK GRN - - - - - - . t ~ ' # - K - - - - - 3 3 5 DK GRN
C100
. - - - - 409 LT BLU
r150BLK
TO
OTHER
FANS/ACTR
FUSE CIRCUITS
PRIMARY COOLING
FAN RELAY CONTROL
P~,~~UY
COOLING
FAN
402 R E D ~ B+ JUNCTION
FANS/ACTR
~541
402
RED
1~ !\_~P BRN
TO (U/H)
IGNITION
504BRN
_r-150BLK
SECONDARY COOLING
FAN RELAY (W/C60}
(FAN2)
SECONDARY
COOLING
FAN
' - - - - - - - 4 7 3 DK BLU - - - - - - - < 1 ~ ' . ~ - - - - 4 7 3 DK BLU

C100
(U/H}
SECONDARY COOLING
FAN RELAY CONTROL
CHART C-12
10-20-92
MS 12084
(Page 1 of 2)
ELECTRIC COOLING FAN CONTROL CIRCUIT DIAGNOSIS

11
The cooling fans are controlled by the ECM based on various inputs. Battery voltage is supplied to the
primary fan relay on terminals "Dl" and "F4" of the secondary fan relay. Ignition voltage is supplied to terminal
"D5" of the primary fan relay and "F2" of the secondary fan relay. Grounding CKT 335 (relay terminal "D2") will
energize the primary cooling fan relay (Fan 1) and supply battery voltage to the primary cooling fan motor.
Grounding CKT 473 (relay terminal "F5") will energize the secondary cooling fan relay (Fan 2) and supply
battery voltage to the secondary fan motor.
When certain Diagnostic Trouble Codes (DTCs) are set, the ECM will enable the cooling fans.

1. With the diagnostic "test" terminal grounded, the
cooling fan control driver(s) will close, which
should energize the fan control relay(s).
2. The cooling fans should come "ON" anytime A/C
system is operating.
3. Comparing Tech 1 pressure and manifold gage set
pressure will determine if the A/C refrigerant
pressure sensor is out of range. An out of range
A/C refrigerant pressure sensor can cause the
cooling fans to operate at the wrong times.
Diagnostic Aids:
due to an actual boil over, or the warning indicator
light, or engine coolant temperature gage indicated

overheating.
The gage accuracy can also be checked by
comparing the Engine Coolant Temperature (ECT)
sensor reading using a Tech 1 and comparing its
reading with the gage reading.
If the engine is actually overheating and the gage
indicated overheating, but the cooling fan is not
coming "ON," the Engine Coolant Temperature (ECT)
sensor has probably shifted out of calibration and
should be replaced.
If the engine is overheating and the cooling fans
are "ON," the cooling system should be checked, refer
to SECTION 68.
The ECM will command fan 1 "ON" at 108C
(226F) and "OFF" at 105C (221F) and, fan 2 "ON" at
113C (235F) and "OFF" at 110C (230F).
CHART C-12
(Page 1 of 2)
IGNITION "ON," ENGINE "OFF," A/C "OFF."

DO BOTH FANS TURN "ON"?
ELECTRIC COOLING FAN CONTROL

CIRCUIT DIAGNOSIS
5. 7L (VIN P) "F" CARLINE MFI
If ANY ECM DTCs ARE SET REFER TO DTC(s) CHART FIRST.

BE SURE COOLING SYSTEM IS OK.
ENGINE COOLANT BELOW 100C (212F).
IGNITION "ON," ENGINE "OFF," A/C "OFF."
ARE BOTH COOLING FANS "OFF"?
r-
START ENGINE, A/C "OFF.

ARE FAN(S) "ON"?
DISCONNECT FAN CONTROL RELAY FOR

COOLING FAN THAT IS OPERA TING.
DID THE FAN STOP?
IGNITION "ON."
PROBE FAN RELAY HARNESS
CONNECTOR TERMINAL
"02" PRIMARY OR "Fs
SECONDARY WITH A TEST
LIGHT TO B +.
IS TEST LIGHT ON?
------------,
: REFER TO CHART C-12 :

1
(PAGE 2 OF 2).
1
L--------------J
CIRCUIT{S) FROM RELAY

TO FAN IS St,ORTED TO
VOLTAGE.
FAULTY PRIMARY FAN

RELAY
OR
FAULTY SECONDARY
FAN RELAY.
A/C REQUEST CIRCUIT
SHORTED TO
VOLTAGE
OR
FAULTY HVAC
CONTROL ASSEMBLY.
OR
FAULTY ECM.
INSTALL A/C MANIFOLD GAGE SET. REFER TO

SECTION 18.
USING TECH 1, COMPARE MANIFOLD GAGE
SET PRESSURE TO TECH 1 A/C REFRIGERANT
PRESSURE.
IS TECH 1 A/C REFRIGERANT PRESSURE WITHIN
20 psi OF HIGH SIDE PRESSURE?
PRIMARY FAN (FAN 1)
SECONDARY FAN (FAN 2)
PRIMARY COOLING FAN RELAY

CONTROL CIRCUIT SHORTED TO
GROUND
OR
FAULTY ECM.
SECONDARY COOLING
FAN RELAY CONTROL
CIRCUIT SHORTED TO
GROUND
OR
FAULTY ECM.
----------~
: REFER TO SECTION :
I C-10 FOR FURTHER I
: DIAGNOSIS OF
I THE A/C CIRCUIT.
'-------------.J
ENGINE IDLING, A/C "ON."

IS TECH 1 A/C REFRIGERANT PRESSURE
WITHIN 20 psi OF HIGH SIDE PRESSURE?
NO TROUBLE FOUND. REFER TO "DIAGNOSTIC

11-16-92
MS 12489
ECM
J
.---------335 DK GRN - - - - - - ' l l ! ~ ~ K - - - - - 3 3 5 DK GRN
C100
. - - - - 409 LT BLU
r150BLK
TO
OTHER
FANS/ACTR
FUSE CIRCUITS
PRIMARY COOLING
FAN RELAY CONTROL
P~1t1UY
COOLING
FAN
402 RED ~ B + JUNCTION

FANS/ACTR
~541
402
RED
1~~-~p BRN
TO (U/H)
IGNITION
504BRN
r150BLK
SECONDARY COOLING
FAN RELAY (W/C60)
(FAN 2)
SECONDARY
COOLING
FAN
L . . . - - - - - - 4 7 3 DK BLU - - - - - - - . ~ c : , K - - - - - 4 7 3 DK BLU
C100
SECONDARY COOLING
FAN RELAY CONTROL
10-20-92
MS 12084
CHART C-12
{Page 2 of 2)
.
The cooling fans are controlled by the ECM based on various inputs. Battery voltage is supplied to the
primary fan relay on terminals "01" and "F4" of the secondary fan relay. Ignition voltage is supplied to terminal
"05" of the primary fan relay and "F2" of the secondary fan relay. Grounding CKT 335 (r(jlay terminal "02") will
energize the primary cooling fan relay (Fan 1) and supply battery voltage to the primary cooling fan motor.
Grounding CKT 473 (relay terminal "F5") will energize the secondary cooling fan relay (Fan 2) and supply
battery voltage to the secondary fan motor.
The ECM will enable the cooling fans, when certain Diagnostic Trouble Codes (DTCs) are set.
Diagnostic Aids:
due to an actual boil over, the warning indicator light,
or engine coolant temperature gage indicated
overheating.
The gage accuracy can also be checked by
comparing the Engine Coolant Temperature (ECT)
sensor reading using a Tech 1 and comparing its
reading with the gage reading.
If the engine is actually overheating and the gage

indicated overheating, but the cooling fan is not
coming "ON," the Engine Coolant Temperature (ECT)
sensor has probably shifted out of calibration and
should be replaced.
If the engine is overheating and the cooling fans
are "ON," the cooling system should be checked, refer
to SECTION 68.
The ECM will command fan 1 "ON" at 108C
(226F) and "OFF" at 105C (221F) and an 2 "ON" at
113C (235F) and "OFF" at 110C (230F).
r--------,
I
I
I
I
I
FROM
CHARTC-12
(1 OF 2)
CHART C-12
I
I
1
I
I

5. 7L {VIN P) "F" CARLINE {MFI)
L--r----.J
.
PRIMARY
SECONDARY W/C60
IGNITION "OFF."
DISCONNECT PRIMARY COOLING FAN RELAY
IGNITION "ON."
PROBE FAN RELAY HARNESS TERMINALS "D1" AND
"D5" WITH A TEST LIGHT CONNECTED TO GROUND .
LIGHT "ON" BOTH
USING TECH 1 SELECT

"FIELD SERVICE MODE."
PROBE HARNESS TERMINAL
"02" WITH A TEST LIGHT
CONNECTED TO B +.
IS TEST LIGHT "ON"?
LIGHT "OFF"
ONE OR BOTH
I
REPAIR OPEN OR
SHORT TO GROUND
IN CIRCUIT THAT
DID NOT LIGHT.
[$
USING A FUSED JUMPER

WIRE, JUMPER FAN RELAY
HARNESS TERMINALS "01"
AND "04" TOGETHER.
DOES FAN OPERATE?
REPAIR OPEN OR
SHORTTO VOLTAGE
IN CIRCUIT 335.
OR
FAULTY ECM
CONNECTION OR
FAULTY ECM.
@]
IGNITION "OFF."
DISCONNECT PRIMARY COOLING
FAN ELECTRICAL CONNECTOR
IGNITION "ON."
JUMPER WIRE STILL INSTALLED
AT RELAY HARNESS.
CONNECT A TEST LIGHT ACROSS
COOLING FAN ELECTRICAL
IS TEST LIGHT "ON".
FAULTY RELAY
CONNECTION
OR
FAULTY RELAY.
LIGHT "ON" BOTH
USING TECH 1 SELECT

"FIELD SERVICE MODE."
PROBE HARNESS TERMINAL
"F5" WITH A TEST LIGHT
CONNECTED TO B +.
IS TEST LIGHT "ON"?
PROBE COOLING FAN MOTOR

HARNESS CONNECTOR
TERMINAL "B" WITH A TEST
LIGHT CONNECTED TO GROUND.
IS TEST LIGHT "ON"?
~
FAUL TY FAN MOTOR
CONNECTION
OR
CIRCUIT 150 OPEN.
USING A FUSED JUMPER

WIRE, JUMPER FAN RELAY
HARNESS TERMINALS "F4"
AND "F1" TOGETHER.
DOES FAN OPERATE?
.
LIGHT "OFF"
ONE OR BOTH
REPAIR OPEN OR
SHORT TO
GROUND IN
CIRCUIT THAT DID
NOT LIGHT.
FAULTY CONNECTION
AT FAN MOTOR
OR
FAUL TY FAN MOTOR.
IGNITION "OFF."
DISCONNECT SECONDARY COOLING
FAN ELECTRICAL CONNECTOR
IGNITION "ON."
JUMPER WIRE STILL INSTALLED AT
RELAY HARNESS.
CONNECT A TEST LIGHT ACROSS
COOLING FAN ELECTRICAL
IS TEST LIGHT "ON".
PROBE COOLING FAN MOTOR

HARNESS CONNECTOR
TERMINAL "B" WITH A TEST
LIGHT CONNECTED TO GROUND.
IS TEST LIGHT "ON"?
~
OPEN IN CIRCUIT 409
BETWEEN RELAY
AND COOLING FAN
MOTOR.
[$
REPAIR Of>EN OR
SHORT TO VOLTAGE
IN CIRCUIT 473.
OR
FAULTY ECM
CONNECTION OR
FAULTY ECM.
[$]
IGNITION "OFF."
DISCONNECT SECONDARY COOLING FAN RELAY
IGNITION "ON."
PROBE FAN RELAY HARNESS TERMINALS "F2" AND
"F4" WITH A TEST LIGHT CONNECTED TO GROUND.
(Page 2 of 2>
$
FAUL TY FAN MOTOR
CONNECTION
OR
CIRCUIT 150 OPEN.
FAULTY RELAY
CONNECTION
OR
FAULTY RELAY.
~
FAULTY CONNECTION
AT FAN MOTOR
OR
FAUL TY FAN MOTOR.
s
OPEN IN CIRCUIT 504
BETWEEN RELAY
AND COOLING FAN
MOTOR.
10-29-92
NS 15382
BLANK
SECTION C13
CRANKCASE VENTILATION SYSTEM

CONTENTS
GeneralDescription
Operation
Diagnosis
C13-1
C13-1
C13-1
C13-2
GENERAL DESCRIPTION
A "closed" crankcase ventilation system is used to
provide a more complete sea venging of crankcase
vapors. Fresh air from the air cleaner is supplied to
the crankcase, mixed with blow-by gases and then
passed through a crankcase ventilation valve into the
intake manifold (Figure C13-1).
Functional Check of Crankcase Ventilation

Valve ..
Functional Check of Crankcase
Ventilation Valve System

On-Vehicle Service
Cl 3-2
C13-2
C13-2
OPERATION
The primary control is through the crankcase
ventilation valve (Figure C13-2) which meters the flow
at a rate depending on manifold vacuum.
To maintain idle quality, the crankcase
ventilation valve restricts the flow when intake
manifold vacuum is high. If abnormal operating
conditions arise, the system is designed to allow
excessive amounts of blow-by gases to back flow
through the crankcase vent tube into the engine air
inlet to be consumed by normal combustion.
CHECK VALVE
45 0068-6E
Figure C13-2 Crankcase Ventilation Valve Cross

Section

A plugged valve or hose may cause:
Rough idle.
Stalling or slow idle speed.
Oil leaks.
Sludge in engine.
A leaking valve or hose would cause:
Rough idle.
Stalling.
High idle speed.
c::> CLEAN AIR
-+ VOLATILE OIL FUMES

----- MIXTURE OF AIR AND FUMES
TO THROTTLE BODY
3
4
CRANKCASE VENT HOSE

CRANKCASE VENTILATION VALVE HOSE
TO INTAKE MANIFOLD
SS 1725-6E
Figure C13-1 Crankcase Ventilation Valve Flow

{Typical)
OJ
CRANKCASE VENTILATION HOSE
[Ij
THROTTLE BODY
I]]
'41
INTAKE MANIFOLD
CRANKCASE VENTILATION
t.=..J VALVE
MS 12022-6E1
Figure C133 Crankcase Ventilation System
DIAGNOSIS
VENTILATION VALVE
If an engine is idling rough, check for a clogged
crankcase ventilation valve or plugged hose. Replace
as required. Use the following procedure:
1. Remove crankcase ventilation valve from
rocker arm cover.
2. Run the engine at idle.
3. Place your thumb over end of valve to check for
vacuum. If there is no vacuum at the valve,
check for plugged hoses or manifold port, or
crankcase ventilation valve. Replace plugged
or deteriorated hoses.
4. Turn "OFF" the engine and remove crankcase
ventilation valve. Shake valve and listen for
the rattle of check needle inside the valve. If
valve does not rattle, replace valve.
With this system, any blow-by in excess of the
system capacity (from a badly-worn engine, sustained
heavy load, etc.) is exhausted into the intake manifold
and is drawn into the engine. Proper operation of the
crankcase ventilation system is dependent upon a
sealed engine. If oil sludging or dilution is noted, and
the crankcase ventilation system is functioning
properly, check engine for possible cause and correct to
ensure that system will function as intended.

VENTILATION VALVE SYSTEM
1. Check crankcase ventilation valve for correct
application.
2. Engine at normal operating temperature.
3. Block off crankcase ventilation system fresh air

intake passage.
4. Remove engine oil dipstick and install a vacuum
gage on dipstick tube.
5. Run engine at 1500 RPM for 30 seconds then read
vacuum gage while at 1500 RPM.
If vacuum is present the crankcase ventilation
system is functioning properly. No vacuum
indicated the engine may not be sealed and/or is
drawing in outside air. Check valve cover, oil pan
gasket for leaks. If the vacuum gage registers a
pressure or the vacuum gage is pushed out of the
dipstick tube, check for the correct crankcase
ventilation valve, a plugged hose or excessive
engine blow-by.
ON-VEHICLE SERVICE
An engine which is operated without any
crankcase ventilation can be damaged. Therefore, it is
important to replace the crankcase ventilation valve
at intervals shown in SECTION OB.
Periodically, inspect the hoses and clamps and
replace any showing signs of deterioration.
SECTION C14
AIR INTAKE SYSTEM

CONTENTS
General Description
Air Intake System
On-Vehicle Service
. . . .. . .. . . . . . ..
(14-1
(14-1
(14-1
GENERAL DESCRIPTION
AIR INTAKE SYSTEM
Air intake system draws outside air in past the air
filter element. The air cleaner assembly is remotely
mounted (refer to Figure Cl4-1). The air then enters
the engine by flowing through force air intake duct to
throttle body into the intake manifold. The air is then
directed into the intake manifold runners, through
cylinder heads and into the cylinder.
ON-VEHICLE SERVICE
AIR FILTER ELEMENT/AIR CLEANER
ASSEMBLY

1.
2.
3.
4.
5.
6.
7.
8.
Loosen clamp at air intake duct at throttle body.

IAT electrical connector.
Retainers (2) from upper radiator support.
Hose from air intake duct.
Disconnect air intake duct from throttle body.
Slide air cleaner housing up and air intake duct as
a whole assembly.
Release latches from air cleaner housing.
Air filter element.
Air Filter Element/Air Cleaner
Assembly
(14-1
!+I Install or Connect

1.
2.
3.
4.
5.
6.
7.
Air filter element into air cleaner housing.

Snap air cleaner latches into place.
Slide air cleaner assembly into retainers.
Air intake duct to throttle body and tighten clamp.
IAT electrical connector.
Retainers (2) to upper radiator support.
Hose to air intake duct.
rn
Important
Clamp assembly tension adjustment screw

should be located on the side of the intake duct
for optimum clamp force. This is important for
proper sealing.

(WITH INTAKE AIR TEMPERATURE SENSOR)
2
AIR CLEANER ASSEMBLY
FRONT AIR INTAKE DUCT
UPPER RADIATOR MOUNTING PANEL
NS 15275
Figure C14-1 -Air Intake Components
DRIVEABILITY AND EMISSIONS 5.7L (VIN P) INDEX-1

SECTION
PAGE
A
Acceleration Enrichment Mode
A/C Clutch Circuit Diagnosis
General Description
Diagnosis
Chart C-10
On-Vehicle Service
A/C Compressor Low Pressure Cutoff
Switch

A/C Request Signal
General Description
Diagnosis
Chart C-10
Air Intake System
General Description
On-Vehicle Service
C2-2
C10-1
C10-1
Cl0-4
Cl0-1
Cl0-4
A-104
A-96, 98
Cl-7
Cl-9
Cl0-4
C14-1
C14-1
. . . . .. . . . . .. . . . . . . . . .
Backfire
Basic Procedure
Before Starting
8-17
A-1
C2-3
B-2
c
Chart A-1:
ChartA-2:
No DLC Data, Or Will Not Flash OTC 12,
Or MIL (Service Engine Soon)
"ON" Steady
ChartA-3:
Engine Cranks But Will Not Run
Chart A-5:
Fuel Pump Relay Circuit
Chart A-7:
Chart 8-1:
Restricted Exhaust System Check
Chart C-1A:
Diagnosis
Chart C-10:
MAP Output Check
ChartC-2A:
. . . .. . . . . ...
A-20
A-22
A-24
SECTION
PAGE
Chart C-2C:
Chart C-3:
Check
C2-18
ChartC-4A:
Distributor Ignition System Check
Chart C-5:
Chart C-6:
Check
Chart C-7:
Exhaust Gas Recirculation (EGR)
Check ~
ChartC-8A:
System
Chart C-88:
Reverse Lockout System
Chart C-10:
A/C Clutch Circuit Diagnosis
Chart C-12:
Electric Cooling Fan Control
Circuit Diagnosis
Chuggle
Clear Flood Mode
Closed Loop
Component Locations
Cooling Fan Control
General Description
Diagnosis
Service
Crankcase Ventilation System
General Description
Diagnosis
Service
Cuts Out
...
.........
.....................
C3-6
C4-4
CS-4
C6-6
C7-4
C8-6
C8-14
C10-4
C12-4
8-6
C2-2
C2-1
A-3
C12-1
C12-4
C12-1
C13-1
C13-2
C13-2
8-10
A-28
D
A-30
C1-18

Deceleration Mode
Detonation
Dieseling, Run On
Distributor
Distributor Ignition (DI) System
Distributor Ignition System Check
C2-16
DTC 12
DTC 13
8-18
C1-16
A-14, 22
C2-2
B-8
B-16
C4-1
C4-1
C4-4
A-14
A-36
2-INDEX 5. 7L (VIN P) DRIVEABILITY AND EMISSIONS

SECTION
DTC14
DTC 15
DTC 16
DTC 21
DTC22
DTC23
DTC24
DTC25
DTC26
DTC27
DTC28
DTC32
DTC33
DTC34
DTC36
DTC41
DTC42
DTC43
DTC44
DTC45
DTC46
DTC 51
DTC53
DTC55
DTC61
DTC63
DTC64
DTC65
DTC66
DTC67
DTC68
DTC69
DTC 71
.. .. . . . . . . . ... . . . .. . ..
. . . . . . . . . . . ... . . . .. .. .
. ... . . . . . . . ... . . . ... . .
. .. . .. . . . . . . . . . . . . . . . .
. .. .. . . . . . . ... . . . . . . . .
. . . . .. . . . . . . . . . . . . . . . .
. . . . .. . . . . . . .. . . . . . . . .
......................
. ... . . . . . . .. . . .. . . . . . .
. .. . . . .. . . . . . . . . . . .. . .
. . . . . . .. . . . . . . . . . . . . . .
.. . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . .. . . . . . . . .
.... .. .. . . ... . . . . . . . . .
. .. . . . . . . . . . . . . . . . . . . .
. . . . . . .. . . . .. . .. . . . . . .
. .. . . . . .. . . . . . . . . . . . . .
. .. . . . . . . . . . .. .. . . . .. .
. . . . . . . .. . . . .. . . . . . . . .
.. . . . . . .. . .. . . . . . ...
. . . . . . . .. . . . .. . . . . . .. .
.. ..... . . . . ... ... . . . . .
. . . . . . . . . . . . . . .. . . . . . .
. .. . . . .. . . . .. . . . . . . . . .
. . .. . . . .. . . . .. . . . . . .. .
. . . . . . . .. . .. .. . . . . . . . .
. .. . . . . . . . . .. . . . . . . . . .
.................. - ...
. ... . . . . . . . . . . . . . . . . . .
. . . . .. . . . . . . . . . . . . . . . .
. .. . . . . . . . . . . . . . . . . . . .
.... . . . . . . . . . . . . . . . . . .
. .. . . . . . . . . . . . . . . . . . . .
~
PAGE
A-38
A-40
A-42
A-44
A-46
A-48
A-50
A-52
A-54
A-56
A-58
A-60
A-64
A-66
A-68
A-70
A-72
A-74
A-76
A-78
A-80
A-82
A-84
A~86
A-88
A-90
A-92
A-94
A-96
A-98
A-100
A-102
A-104
Engine Coolant Temperature Sensor

General Description ,
C1-3
DTC 14and 15
A-40, 42
Diagnosis C1-8
On-Vehicle Service
C1-11
EVAP Canister
C3-1
EVAP Canister f-;lose
C3-3
C3-2
EVAP Pressure Control Valve
C3-2
General Description
C3-1
Diagnosis C3-2
On-Vehicle Service
C3-2
Evaporator Temperature Sensor (Al()
A-104
Exhaust Emissions Excessive (Odors)
B-15
Cl-1
Exhaust System Check Restricted
B-18
F
Fan(s) Cooling
Fuel Injectors
General Description
Diagnosis
Fuel Pressure Connection Assy.
Fuel Pump Relay
Fuel Pump Test Connector
Fuel Rai I
Fuel System Pressure Check
E
ECM Connector Terminal End View
ECM Inputs
ECM Wiring Diagram
EGR System
General Description
On-Vehicle Service
General Description
Diagnosis
Function
Functional Check
On-Vehicle Service
P~GE
SECTION
C12-1
C2-3
C2-1
C2-6
C2-10
C2-7
C2-3
A-28 ~
A-3
C2-3
A-30
A-34
H
A-9
C1-8
A-4
Cl-1
Cl-2
C1-1
A-14
C1-8
C1-2
C.1-11
C1-10
Hard Start
Hesitation
IATSensor
General Description
Diagnosis
Service
Idle Air Control System Check

General Description
Ignition Control (IC)
B-5
B-9
C1-4
C1-8
C1-13
C2-18
C2-5
A-70, 72,
C4-1
DRIVEABILITY AND EMISSIONS 5. 7L (VIN P) INDEX-3

SE(:JION
PAGE
Incorrect Idle
Information Sensors
lntermittents
Introduction
B-12
C1-3
C2-16
B-3
GE
K
(1-3,
A-74
Knock Sensor
General Description
Diagnosis
On-Vehicle
C5-1
(5-1
(5-1
C5-4
SECTION
PAGE
p
General Description
Diagnosis

On-Vehicle Service
Poor Fuel Economy
Poor Performance
Pressure Regulator
PROM
General Description
Diagnosis .
On-Vehicle Service
Functional Check
Error
Pump.AIR
.....................
. .. . . . . . . .. . . . . . . . . .
C1-7
C1-7
C1-14
B-14
6E3-B
C2-4
C1-1
C1-8
C1-10
C1-11
A-82
C6-1
Q
Lack of Power
Light, MIL (Service Engine Soon)

Long Term Fuel Trim
Low Pressure Cutoff Switch
(A/C Compressor)
B-7
A-20
C1-2
Steady
Misses
Memory
(10-4
C1-4
(1-8
C1-12
(1-18
A-22
B-1 O
C1-2
N
No DLC Data
C7-1
A-22
A-20
0
On-Board Diagnostic (OBD) System
Check
Oxygen Sensor (025)

General Description
Diagnosis
A-14
C1-4
C1-8
On-Vehicle Service
C1-7
M
MAP Sensor
General Description
,.'.!": Diagnosis
On-Vehicle Service
Output Check
MIL (Service Engine Soon) "On"
Quad-Drivers
Cl-12
Reference Signal
Refrigerant Pressure Sensor (A/C)
Rough Idle
Run Mode
Run On
C1-7
A-96, 98
C8-14
8-12
C2-2
8-16
s
Sag
........................
Scan Data
B-9
A-16

General Description
Diagnosis
Chart C-6
On-Vehicle Service
Sensor Information
Sluggish
Spark Knock
Spongy

Stalling
Starting Mode
Stumble
Surges
C6-1
C6-2
(6-6
C6-4
C6-5
C1-3
B-7
B-8
B-7
8-12
C2-1
8-9
B-6
4-INDEX 5.7L (VIN P) DRIVEABILITY AND EMISSIONS

SECTION
PAGE
System Voltage
A-84
C1-2
T
Throttle Body Unit
General Description
Service
General Description
Diagnosis
On-Vehicle Service
General Description
Diagnosis
C2-4
C2-12
Unstable Idle
. . . . .. . . . . . . . . . . .
PAGE
v
General Description
DTC 24
Diagnosis
On-Vehicle Service
C1-6
A-SD
C1-9
C1-14
W
C1-5
C1-9
C1-13,
C2-14
C8-1
C8-6
u
SECTION
C6-5,
(10-2,
(12-2
B-12
Will Not Flash DTC 12
.. ... . . .. . . . .
A-22
EXHAUST SYSTEM 6F-1
SECTION 6F
EXHAUST SYSTEM
~OTICE: All new GM vehicles are certified by the United States Environmental Protection Agency as conforming to the requirements of the regulations for the control of air pollution from new motor vehicles. This certification
is contingent on certain adjustments being set to factory standards, thus, these adjustment points either have been
permanently sealed and/or made inaccessible to prevent indiscriminate adjustment in the field. For this reason, the
factory procedure for temporarily removing plugs, caps, etc., for the purpose of servicing the product must be
strictly followed and, where practical, returned to the original intent of the design.
NOTICE: Exhaust system components must have enough clearance from the underbody to prevent overheating of
the floor panel assembly and possible damage to the passenger compartment, insulation and trim materials.
result.
CONTENTS
General Description . . . . . . . . . . . . . . . . . . . . . . . . 6F-1
Exhaust Crossover Pipe Assembly . . . . . . . . . . 6F- l
Catalytic Converter Assembly . . . . . . . . . . . . . . 6F-1
Exhaust Muffler Assembly ................ 6F-2
Hangers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6F-2
Clamps and Welded Connections . . . . . . . . . . . 6F-2
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6F-2
Testing for Restricted
Exhaust . . . . . . . . . . . . . . . . . Refer to Section 6E2
On-Vehicle Service ........................ 6F-3
Component Replacement .................. 6F-3
Exhaust Crossover Pipe Assembly . . . . . . . . . . 6F-3
Catalytic Converter Assembly .............. 6F-4
Exhaust Pipe Assembly . . . . . . . . . . . . . . . . . . . 6F-5
Exhaust Muffler Assembly . . . . . . . . . . . . . . . . 6F-6

Exhaust Tailpipe Extension Assembly
(5.7L LTl Engine) ..................... 6F-6
Catalytic Converter Hanger Assembly . . . . . . . 6F-7
Exhaust Muffler Hanger Assemblies . . . . . . . . . 6F-9
Exhaust Muffler Interior Bracket
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 6F-10
Catalytic Converter Heat Shield . . . . . . . . . . . 6F-11
Exhaust Heat Shield . . . . . . . . . . . . . . . . . . . . . 6F-11
Exhaust Pipe Heat Shield Assembly and
Exhaust Muffler Heat Shield . . . . . . . . . . . . 6F-12
Exhaust System Clearance Dimensions . . . . . . 6F-13
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6F-16
Fastener Tightening Specifications . . . . . . . . . 6F-16
GENERAL DESCRIPTION
muffler assembly must be replaced whenever a new

exhaust muffler assembly is installed.
NOTICE: When inspecting or replacing exhaust

system components, make sure there is adequate
clearance from all points on the underbody to prevent overheating of the floor panel assembly and
possible damage to the passenger compartment,
insulation and trim materials.
. Periodic maintenance of the exhaust system is not
req~1red. If the vehicle is raised for other service, it is
advisable to check the condition of the complete exhaust
system.
Check complete exhaust system, nearby body areas
and rear compartment lid for broken, damaged, missing or
mispositioned parts, open seams, holes, loose connections
or other deterioration that could permit exhaust fumes to
seep into the rear compartment or passenger compartment. Dust or water in the rear compartment may indicate
a problem in one of these areas. Any faulty areas should
~e c~rrected immediately. To help ensure continued
mtegnty, the exhaust system pipe rearward of the exhaust
EXHAUST CROSSOVER PIPE ASSEMBLY

On the 3.4L L32 engine, the exhaust crossover pipe
assembly can be removed from the catalytic converter
assembly. On the 5.7L LTl engine, the exhaust crossover
pipe and catalytic converter assembly must be replaced as
a complete assembly.
CATALYTIC CONVERTER ASSEMBLY

Figure 1
CAUTION: Prolonged operation with a
misfiring or flooded engine may cause
the catalytic converter to overheat.
This could cause damage either to the
catalyst itself or the operating vehicle
and possible personal injury.
NOTICE: When jacking or lifting vehicle from
frame side rails, be certain lift pads do not contact
6F-2 EXHAUST SYSTEM

catalytic converter or damage to catalytic converter
may result.
The catalytic converter assembly is an emission
control device added to the exhaust system to reduce
pollutants from the exhaust gas stream.
NOTICE: The catalytic converter requires the use

of unleaded fuel only, or damage to the catalyst may
result.
A single bed monolith catalytic converter is used in
combi~ati~n with two different types of catalyst. These
are oxidation catalyst and three-way (reduction/oxidation) catalyst.
The catalysts have coatings that contain platinum
and palladium. The oxidation catalyst lowers the level of
hydrocarbons (HC) and carbon monoxide (CO). The
three-way catalyst lowers the levels of oxides of nitrogen
(N03) as well as HC and CO.
EXHAUST MUFFLER ASSEMBLY

The muffler assembly is a tri-flow design. The muffler assembly has a slot in the inlet pipe. The slot indexes
to~ ke~ (ta'?) welded on the exhaust pipe assembly to help
mamtam alignment.
HANGERS
[I] Important
The installation of exhaust system supports is very
important, as improperly installed supports can
cause annoying vibrations that can be difficult to
diagnose.
Two types of hangers are used to support the exhaust
system. One type is a conventional rubber strap. The
second type is a "rubber block." The rubber block type
provides a rigid hanger along with a feature that continues
to support the exhaust system if a rubber insulator block is
broken.
CLAMPS AND WELDED CONNECTIONS

CAUTION: Coat slip joints with exhaust
system sealer before assembly to prevent exhaust from entering the vehicle
and causing personal injury.
Two methods are used for connecting exhaust
system slip joints: clamps and welds. When servicing a
welded connection it should be cut and the new connection clamped when installing replacement parts.
Three types of clamps are used for connecting
exhaust system slip joints: guillotine, saddle/U-bolt and
single nut compression.
DIAGNOSIS
CONDITION
POSSIBLE CAUSE
CORRECTION
Leaking Exhaust Gases
Leaks at pipe joints.
Tighten nuts or bolts/screws at leaking

joints to specifications.
Exhaust Noises
1.
Exhaust pipes contacting heat

shields, or loose heat shields. Inspect
when cold and after warmup.
2.
Leaks at manifold assembly or pipe

connections.
Burned or blown-out muffler
assembly.
Burned or rusted out exhaust pipe
assembly.
Leaking exhaust crossover pipe
assembly at manifold flange.
Cracked or broken manifold
assembly.
Leak between manifold assembly
and cylinder head.
1. Tighten heat shield bolts/screws to

2.0 Nm (18 lb. in.). Align exhaust
system if necessary. Refer to
"Exhaust System Clearance
Dimensions" in this section.
2. Tighten clamps at leaking
connections to specifications.
3. Replace muffler assembly.
3.
4.
5.
6.
7.
4.
Replace exhaust pipe assembly.
5. Tighten exhaust crossover pipe nuts

to 35 Nm (26 lb. ft.).
6. Replace manifold assembly.
7. Tighten manifold-to-cylinder head
stud nuts or bolts/screws to specifications. Refer to SECTION 6A2A
or 6A3A.
EXHAUST SYSTEM 6F3

CONDITION
POSSIBLE CAUSE
Exhaust Vibrations
1. Transmission shims are between cat-
1. Reposition shims so they are

alytic converter assembly and transbetween transmission assembly and
catalytic converter bracket.
mission support assembly.
2. Inadequate clearance, less than 3 mm 2. Replace transmission support
(1/8 inch), between transmission
assembly. Refer to SECTION 11.
support assembly and floor panel
assembly.
3. Inadequate clearance, less than 3 mm 3. Loosen catalytic converter hanger
(1/8 inch), between catalytic
bolts/screws and reposition catalytic
converter hanger assembly and
converter hanger assembly.
transmission support assembly.
Loss of Engine Power and/or

Internal Rattles in Muffler
Assembly
Dislodged turning tubes and/or baffles in

muffler assembly, catalytic converter
assembly or exhaust pipe assembly.
CORRECTION
EXHAUST CROSSOVER PIPE ASSEMBLY
ON-VEHICLE SERVICE
3.4L L32 Engine
COMPONENT REPLACEMENT
Exhaust system service includes replacement of the
following items:
Exhaust crossover pipe assembly (3.4L L32 engine)
Catalytic converter assembly (with crossover pipe
for 5.7L LTl engine)
Exhaust pipe assembly
Exhaust muffler assembly (with tailpipe(s))
Complete exhaust system
Catalytic converter and exhaust muffler hanger
assemblies
Catalytic converter heat shield
Exhaust heat shield
Exhaust pipe heat shield assembly
Exhaust muffler heat shield
Replace muffler assembly, catalytic

converter assembly or exhaust pipe
assembly.
Figures 1 and 2

2. Exhaust crossover pipe nuts (2).
3. Exhaust crossover pipe assembly (4) from studs on
exhaust manifold assembly ( 1).
4. Lower exhaust system.
5. Exhaust crossover pipe seal (3) from exhaust manifold assembly ( 1).
6. Support catalytic converter assembly (7) and
exhaust system.
7. Catalytic converter clamp assembly (8).
8. Catalytic converter assembly (7) from exhaust
crossover pipe assembly (4).
A
A
B
C
1
2
3
4
RIGHT SIDE
4
LEFT SIDE
STUD
NUT, EXHAUST CROSSOVER PIPE, 35 Nm (26 LB. FT.)
SEAL, EXHAUST CROSSOVER PIPE
PIPE ASSEMBLY, EXHAUST CROSSOVER
Figure 1 - Exhaust Manifold Attachments (3.4L L32 Engine)
PC0001-6Ff-RP
6F-4 EXHAUST SYSTEM
9--
11
31
lVIEWA
4 PIPE ASSEMBLY, EXHAUST CROSSOVER

7 CONVERTER ASSEMBLY, CATALYTIC
8 CLAMP ASSEMBLY, CATALYTIC CONVERTER,
68 Nm (50 LB. FT.)
11 BOLT/SCREW, EXHAUST PIPE, 20 Nm (15 LB. FT.)
12 PIPE ASSEMBLY, EXHAUST
30 HANGER ASSEMBLY, CATALYTIC CONVERTER
31 BOLT/SCREW, CATALYTIC CONVERTER HANGER,
41 Nm (30 LB. FT.)
11
PC00036fFRP
Figure 2 - Catalytic Converter Assembly (3.4L L32 Engine)
l++I
CATALYTIC CONVERTER ASSEMBLY

Install or Connect

section.
1. Exhaust crossover pipe assembly (4) to catalytic
converter assembly (7).
2. Catalytic converter clamp assembly (8).
l~I
Tighten
Catalytic converter clamp assembly (8) to 68

Nm (50 lb. ft.).
3. Exhaust crossover pipe seal (3).
4. Raise exhaust crossover pipe assembly (4).
5. Exhaust crossover pipe assembly (4) to studs on
exhaust manifold assembly (1).
l~I
Tighten
Exhaust crossover pipe nuts (2) evenly to 35

Nm (26 lb. ft.).
7. Lower vehicle.
5.7L LT1 Engine

The crossover pipe is welded to the catalytic converter assembly. The crossover pipe and catalytic converter assembly are replaced as a unit. Refer to "Catalytic
Converter Assembly" in the following procedure.
3.4L L32 Engine
Figure2
l++I

2. Catalytic converter clamp assembly (8) at exhaust
3. Exhaust pipe bolts/screws (11).
4. Exhaust pipe assembly (12) from catalytic converter
assembly (7).
5. Catalytic converter hanger bolts/screws (31 ).
6. Catalytic converter assembly (7).
l++I
Install or Connect

1. Catalytic converter assembly (7) to catalytic converter hanger assembly (30).
2. Catalytic converter hanger bolts/screws (31 ).
l~I
Tighten
Catalytic converter hanger bolts/screws (31) to

41 Nm (30 lb. ft.)
3. Exhaust pipe assembly (12) to catalytic converter
assembly (7).
4. Exhaust pipe bolts/screws (11 ).
EXHAUST SYSTEM 6F5
l~I
Tighten
Exhaust pipe bolts/screws ( 11) to 20 Nm ( 15

lb. ft.).
5. Catalytic converter clamp assembly (8) at exhaust
l~I
Tighten
Catalytic converter clamp assembly (8) to 68

Nm (50 lb. ft.).
6. Lower vehicle.
5.7L LT1 Engine
Figures 3 and 4
3. Exhaust crossover pipe from studs on exhaust manifold assembly (5).

4. Exhaust pipe bolts/screws ( 13 ).
5. Catalytic converter assembly ( 10) from exhaust pipe
assembly (14).
6. Catalytic converter hanger bolts/screws (40).
7. Catalytic converter assembly (10).

1. Catalytic converter assembly (10) to catalytic converter hanger assembly (35).
2. Catalytic converter hanger bolts/screws (40).
l~I

l. Raise and suitably support vehicle. Refer to SEC-
TION OA.
Catalytic converter hanger bolts/screws (40) to

41 Nm (30 lb. ft.).
3. Exhaust pipe assembly (14) to catalytic converter
assembly (10).
4. Exhaust pipe bolts/screws (13).
l~I
FRTJ
Tighten
Tighten
Exhaust pipe bolts/screws (13) to 20 Nm (15

lb. ft.).
5. Exhaust crossover pipe to studs on exhaust manifold
assembly (5).
l~I Tighten
Exhaust crossover pipe nuts (2) to 35 Nm (26

lb. ft.).
7. Lower vehicle.
2
EXHAUST PIPE ASSEMBLY


c
A
B
C
D
2
5
RIGHTSIDE
LEFT SIDE
STUD
PIPE, EXHAUST CROSSOVER
NUT, EXHAUST CROSSOVER PIPE, 35 Nm (26 LB. FT.)
PC0002-6F-F-RP
Figure 3 - Exhaust Manifold Attachments (5.7L LT1 Engine)

2. Exhaust pipe bolts/screws ( 11 or 13) at catalytic converter assembly (7 or 10).
3. Exhaust pipe hanger nut (19 or 22).
4. Muffler clamp assembly ( 17 or 23).
5. Exhaust pipe assembly (12 or 14) from exhaust muffler assembly (15 or 20).
6. Exhaust pipe assembly (12 or 14), sliding it out of
exhaust pipe hanger bracket assembly (18 or 21).

NOTICE: See "Notice" on page 6F-l of this
section.
1. Exhaust pipe assembly (12 or 14) to exhaust pipe
hanger bracket assembly (18 or 21).
6F-6 EXHAUST SYSTEM
A
10
13
14
35
40

CONVERTER ASSEMBLY, CATALYTIC
BOLT/SCREW, EXHAUST PIPE, 20 Nm (15 LB. FT.)
PIPE ASSEMBLY, EXHAUST
HANGER ASSEMBLY, CATALYTIC CONVERTER
BOLT/SCREW, CATALYTIC CONVERTER HANGER,
41 Nm (30 LB. FT.)
14
PCOCJ04..6F-F-RP
Figure 4 - Catalytic Converter Assembly (5.7L LT1 Engine)
2. Exhaust pipe assembly (12 or 14) to exhaust muffler

assembly (15 or 20).
l++I
3. Muffler clamp assembly (17 or 23).
l~I

section.
Tighten
Muffler clamp assembly (17 or 23) to 68 Nm

(50 lb. ft.).
l~I
Tighten
Exhaust pipe hanger nut (19 or 22) to 15 Nm

(11 lb. ft.).
1. Exhaust muffler assembly (15 or 20).

2. Tailpipe to exhaust muffler hanger assembly (16 or
24).
3. Exhaust pipe assembly (12 or 14) at exhaust muffler
assembly ( 15 or 20).
l~I
5. Exhaust pipe bolts/screws (11 or 13) to catalytic

converter assembly (7 or 10).
l~I
Tighten
EXHAUST MUFFLER ASSEMBLY

Figures 5 and 6
++I

2. Exhaust muffler hanger nut (26), if equipped.
4. Exhaust pipe assembly (12 or 14) at exhaust muffler
5. Tailpipe from exhaust muffler hanger assembly (16
or 24).
6. Exhaust muffler assembly (15 or 20).
Tighten
Muffler clamp assembly (17 or 23) to 68 Nm

(50 lb. ft.).
5. Exhaust muffler hanger nut (26), if equipped.
l~I
Exhaust pipe bolts/screws ( 11 or 13) to 20 N m

(15 lb. ft.).
6. Lower vehicle.
Install or Connect
Tighten
Exhaust muffler hanger nut (26) to 25 Nm (18

lb. ft.).
6. Lower vehicle.
EXHAUST TAILPIPE EXTENSION ASSEMBLY

(5. 7L LT1 ENGINE)
f++I
1. Loosen exhaust tailpipe extension clamp assembly.
2. Exhaust tailpipe extension assembly from tailpipe.
f++I
Install or Connect

1. Exhaust tailpipe extension assembly to tailpipe until
stop position is reached.
EXHAUST SYSTEM 6F-7
12
16
IVIEWB I
A
12
15
16
17
18
19
TAILPIPE
MUFFLER ASSEMBLY, EXHAUST
HANGER ASSEMBLY, EXHAUST MUFFLER
CLAMP ASSEMBLY, MUFFLER, 68 Nm (50 LB. FT.)
BRACKET ASSEMBLY, EXHAUST PIPE HANGER
NUT, EXHAUST PIPE HANGER 15 Nm (11 LB. FT.)
12
PC~007-6FF-RP
Figure 5 - Exhaust Muffler Assembly (3.4L L32 Engine)
2. Align exhaust tailpipe extension assembly to rear

fascia assembly and tighten exhaust tailpipe extension clamp assembly.
l~I Tighten
Exhaust tailpipe extension clamp assembly to
70 Nm (52 lb. ft.).
CATALYTIC CONVERTER HANGER

ASSEMBLY
Figures 7 and 8

2. Support catalytic converter assembly (7 or 10).
3. Catalytic converter hanger bolts/screws (31 or 40).
4. Rear axle torque arm outer bracket bolt/screw (34),

if equipped.
5. Rear axle torque arm bracket nuts (29 or 39) from
rear axle torque arm inner bracket bolts/screws (28
or 36).
6. Catalytic converter hanger bracket assembly (32, 33
or 38) with catalytic converter hanger assembly (30
or 35) away from rear axle torque arm inner bracket
7. Catalytic converter hanger assembly (30 or 35) from
catalytic converter hanger bracket assembly (32, 33
or 38).

NOTICE: See "Notice" on page 6F-l of this section.
1. Catalytic converter hanger assembly (30 or 35) to
catalytic converter hanger bracket assembly (32, 33
or 38).
6F-8 EXHAUST SYSTEM
20
14
24
21
!VIEWS!
24
A TAILPIPE
14 PIPE ASSEMBLY, EXHAUST
20 MUFFLER ASSEMBLY, EXHAUST
21 BRACKET ASSEMBLY, EXHAUST PIPE HANGER
22 NUT, EXHAUST PIPE HANGER, 15 Nm (11 LB. FT.)
23 CLAMP ASSEMBLY, MUFFLER, 68 Nm (50 LB. FT.)
24 HANGER ASSEMBLY, EXHAUST MUFFLER
26 NUT, EXHAUST MUFFLER HANGER, 25 Nm (18 LB. FT.)
PC0008-6F-F-RP
Figure 6 - Exhaust Muffler Assembly (5.7L LT1 Engine)
EXHAUST SYSTEM 6F-9

A WITH MANUAL FIVE-SPEED TRANSMISSION
ASSEMBLY
B WITH AUTOMATIC TRANSMISSION ASSEMBLY
BRACKET
41 Nm (30 LB. FT.)
41 Nm (30 LB. FT.)
32 BRACKET ASSEMBLY, CATALYTIC CONVERTER
HANGER
HANGER
34 BOLT/SCREW, REAR AXLE TORQUE ARM OUTER
B
30
~ 7
PC0009-6F-F-RP
Figure 7 - Catalytic Converter Hanger Assembly to Transmission Assembly (3.4L L32 Engine)
2. Catalytic converter hanger bracket assembly (32, 33

or 38) with catalytic converter hanger assembly (30
or 35) to rear axle torque arm inner bracket assembly
(27 or 37).
3. Rear axle torque arm bracket nuts (29 or 39) to rear
axle torque arm inner bracket bolts/screws (28 or
36).
l~I
Tighten
Rear axle torque arm bracket nuts (29 or 39) to

41 Nm (30 lb. ft.).
4. Rear axle torque arm outer bracket bolt/screw (34),
if equipped.
l~I
Tighten
Rear axle torque arm outer bracket bolt/screw

(34) to 27 Nm (20 lb. ft.).
5. Catalytic converter hanger bolts/screws (31 or 40).
l~I
Tighten
Catalytic converter hanger bolts/screws (31 or

40) to 41 Nm (30 lb. ft.).
6. Remove support from catalytic converter assembly
(7 or 10).
7. Lower vehicle.
EXHAUST MUFFLER HANGER ASSEMBLIES

Figures 5, 6 and 9
3.4L L32 Engine
l++I

2. Support exhaust muffler assembly ( 15).
3. Exhaust muffler hanger bracket bolts/screws (42)
4. Exhaust muffler hanger assembly (16) by sliding it
off of tailpipe.
6F-10 EXHAUST SYSTEM

6. Exhaust muffler hanger assembly (57).
l++I
Install or Connect

2. Exhaust muffler hanger bracket bolts/screws (41).
l~I
Tighten
Exhaust muffler hanger bracket bolts/screws

(41) to 15 Nm (11 lb. ft.).
4. Exhaust muffler hanger nut (26).
l~I
37

BRACKET
HANGER
41 Nm (30 LB. FT.)
41 Nm (30 LB. FT.)
PC0011-6F-F-RP
Figure 8 - Catalytic Converter Assembly to Transmission

Assembly (5.7L LT1 Engine - Manual Transmission
Assembly Shown, Automatic Transmission Assembly Similar)
1++1
Install or Connect

1. Exhaust muffler hanger assembly (16 or 24) to tail-
pipe and underbody.

l~I
Tighten
Exhaust muffler hanger bracket bolts/screws

(42) to 15 Nm (11 lb. ft.).
3. Remove support from exhaust muffler assembly
(15)
4. Lower vehicle.
5.7L LT1 Engine
++f

2. Support exhaust muffler assembly (20).
3. Exhaust muffler hanger nut (26).
Tighten
Exhaust muffler hanger nut (26) to 25 Nm (18

lb. ft.).
5. Remove support from exhaust muffler assembly
(20).
6. Lower vehicle.
EXHAUST MUFFLER INTERIOR BRACKET

ASSEMBLY
Figures 5, 6 and 9
!++I

2. Support exhaust muffler assembly (15 or 20) and
exhaust pipe assembly (12 or 14).
4. Exhaust pipe hanger bracket assembly (18 or 21).
5. Exhaust muffler interior hanger bolts/screws (44).
6. Exhaust muffler interior bracket assembly (43).
!++I
Install or Connect

1. Exhaust muffler interior bracket assembly (43).
2. Exhaust muffler interior hanger bolts/screws (44).
I~!
Tighten
Exhaust muffler interior hanger bolts/screws

(44) to 15 Nm (11 lb. in.).
3. Exhaust pipe hanger bracket assembly (18 or21).
I~!
Tighten
Exhaust pipe hanger nut (19 or 22) to 15 Nm

(11 lb. in.).
5. Remove support from exhaust muffler assembly (15
or 20) and exhaust pipe assembly (12 or 14).
6. Lower vehicle.
EXHAUST SYSTEM 6F-11
B
I
A
B
C
15
16
20
41
42
43
44
57
UNDERBODY
5.7L LT1 ENGINE
3.4L L32 ENGINE
j
B
VIEW
BOLT/SCREW, EXHAUST MUFFLER HANGER BRACKET,
15 Nm (11 LB. FT.)
BOLT/SCREW, EXHAUST MUFFLER HANGER BRACKET,
15 Nm (11 LB. FT.)
BRACKET ASSEMBLY, EXHAUST MUFFLER INTERIOR
BOLT/SCREW, EXHAUST MUFFLER INTERIOR
HANGER, 15 Nm (11 LB.FT.)
PC0012-6F-F-RP
Figure 9 - Installing Exhaust Muffler Hanger Assemblies to Underbody
CATALYTIC CONVERTER HEAT SHIELD
l~I
Figure 10
I++( Remove or Disconnect

1. Catalytic converter assembly. Refer to "Catalytic
Converter Assembly" under "On-Vehicle Service"
in this section.
2. Catalytic converter heat shield bolts/screws (46).
3. Catalytic converter heat shield (45).
I++( Install or Connect

1. Catalytic converter heat shield (45).
2. Catalytic converter heat shield bolts/screws (46).
Tighten
Catalytic converter heat shield bolts/screws

(46) to 2.0 Nm (18 lb. in.).
3. Catalytic converter assembly. Refer to "Catalytic
Converter Assembly" under "On-Vehicle Service"

in this section.
EXHAUST HEAT SHIELD

Figure 10
l++I
1. Exhaust crossover pipe assembly (3.41 L32 engine).

Refer to "Exhaust Crossover Pipe Assembly" under
47
45 SHIELD, CATALYTIC CONVERTER HEAT

46 BOLT/SCREW, CATALYTIC CONVERTER HEAT SHIELD,
2.0 Nm (18 LB. IN.)
47 SHIELD, EXHAUST HEAT
48 BOLT/SCREW, EXHAUST HEAT SHIELD, 2.0 Nm
(18 LB. IN.)
46
PC0014-6F-F,RP
Figure 10 - Catalytic Converter and Exhaust Heat Shields
2. Catalytic converter assembly (5.7L LTI engine).

Refer to "Catalytic Converter Assembly" under
EXHAUST PIPE HEAT SHIELD ASSEMBLY

AND EXHAUST MUFFLER HEAT SHIELD
3. Exhaust heat shield bolt/screw (48).
Figure 11
4. Exhaust heat shield (47).

1. Exhaust heat shield (47).
1. Exhaust muffler assembly. Refer to "Exhaust Muffler Assembly" under "On-Vehicle Service" in this
section.
2. Exhaust pipe assembly. Refer to "Exhaust Pipe
2. Exhaust heat shield bolt/screw (48).
3. Exhaust pipe heat shield bolts/screws (50).
l~I Tighten
Exhaust heat shield bolt/screw (48) to 2.0 Nm
(18 lb. in.).
3. Catalytic converter assembly (5.7L LTl engine).
Refer to "Catalytic Converter Assembly" under
4. Exhaust crossover pipe assembly (3.4L L32 engine).
Refer to "Exhaust Crossover Pipe Assembly" under
4. Exhaust pipe heat shield assembly {49).
5. Exhaust muffler heat shield bolts/screws (51).

6. Exhaust muffler heat shield (52).

1. Exhaust muffler heat shield (52).
2. Exhaust muffler heat shield bolts/screws (51).
l~I
Tighten
Exhaust muffler heat shield bolts/screws (51)

to 2.0 Nm (18 lb. in.).
3. Exhaust pipe heat shield assembly (49).
4. Exhaust pipe heat shield bolts/screws (50).
l~I

6. Exhaust muffler assembly. Refer to "Exhaust Muffler Assembly" under "On-Vehicle Service" in this
section.
EXHAUST SYSTEM CLEARANCE

DIMENSIONS
Figures 12 and 13
Tighten
Exhaust pipe heat shield bolts/screws (50) to

2.0 Nm (18 lb. in.).
5. Exhaust pipe assembly. Refer to "Exhaust Pipe
All checking dimensions are to be made on a cold

exhaust system.
If dimensions cannot be met, it indicates a quality
deficiency in a component part that must be corrected.
A
B
C
49
50
UNDERBODY
EXTERIOR RAIL COMPARTMENT
BRACKET
SHIELD ASSEMBLY, EXHAUST PIPE HEAT
BOLT/SCREW, EXHAUST PIPE HEAT SHIELD,
2.0 Nm (18 LB. IN.)
51 BOLT/SCREW, EXHAUST MUFFLER HEAT SHIELD,
2.0 Nm (18 LB. IN.)
52 SHIELD, EXHAUST MUFFLER HEAT
PC0015-6F-F-RP
Figure 11 - Exhaust Pipe Heat Shield Assembly and Exhaust Muffler Heat Shield
F
1Bmml0.71~
7
16 mm (0.63")
!VIEW A I
~12
jv1EWG
12 mm (0.47") min ..
8~~
27 mm (1.06") max.
22 mm (0.87") min.
53
25 mm (0.98") min.
jv1Ewe
15 mm (0.59") max.
9 mm (0.35") min.
jv1EWE
>
18 mm (0.71") max.
13 mm (0.51") min.
22 mm (0.87") max.
18.5 mm (0.73") min.
IVIEWJ!
I
18 mm (0.71")
22 mm (0.87") max.
17 mm (0.67") min.
~
A
19 mm 10.75") max.
t 4 mm (0.55") min.
E
jv1EWF
A
A
B
C
D
E
F
4
7
8
12
15
45
53
UNDERBODY
FRAME BRACKET AND SCREW
PANEL, DASH FRONT
FRAME
TAILPIPE
EXTENSION, EXHAUST HEAT SHIELD
PIPE ASSEMBLY, EXHAUST CROSSOVER
CLAMP ASSEMBLY, CATALYTIC CONVERTER,
68 Nm (50 LB. FT.)
SHIELD, CATALYTIC CONVERTER HEAT
PAN ASSEMBLY, OIL
29.5 mm (1.16") max.

24.5 mm (0.96") min.
15
Figure 12 - Exhaust System Clearance Dimensions (3.4L L32 Engine)
PC0016-6f.F-RP
A,~,
19 mm (0.75") max.
~ ~ 14 mm (0.55") min.
jv1EwHj
12.5 mm (0.50") max.

7.5 mm (0.30") min.
~J__
--c
,f~~ ~-
J 29.5mm(1.16")max.
_. ~ 2 4 . 5 mm (0.96") min.
~,_,~5
27 mm (1.07")
14~
jv1ewAj
10-
~====-jv1EWE
~FRT
/E
\;f::im;,
21 mm (0.82") max.
SECTION L-L
--===-==~--r
15 mm (0.60") max.
10 mm (0.40") min.
30.5 mm (1.20") max.

25.5 mm (1.0") min.
55
/ ( , , mm (0.52") max.
8 mm (0.32") min.
IVIEW BI
29.5 mm (1.16") max.

24.5 mm (0.96") min.
SEC M-M/N-N
21.5 mm (0.85") max.

16.5 mm (0.65") min.
58
0 ~
u
29.5 mm (1.16") max.

24.5 mm (0.96") min.
26.5 mm (1.04") max.

21.5 mm (0.85") min.
26.5 mm (1.04") max.
B
21.5 mm (0.85") min. ~~::::;...,~-
'\/
14
~7")
24mm (0.95") max._/'

19mm(0.75")m;,.
!VIEWG!
A
A
B
C
D
E
10
14
20
45
49
54
55
56
58
IVIEWP!
UNDERBODY
CROSSMEMBER
TAILPIPE
SPARE TIRE WHEEL WELL ASSEMBLY PINCH
SHIELD, CATALYTIC CONVERTER HEAT
SHIELD ASSEMBLY, EXHAUST PIPE HEAT
PAN ASSEMBLY, OIL
PIPE ASSEMBLY, TRANSMISSION OIL COOLER
TRANSMISSION ASSEMBLY
SOLENOID, EXHAUST PRESSURE REGULATOR VALVE
PC0017-6F-F-RP
Figure 13 - Exhaust System Clearance Dimensions (5.?L LT1 Engine)
6F16 EXHAUST SYSTEM
SPECIFICATIONS
Catalytic Converter Clamp Assembly ................................... 68 Nm (50 lb. ft.)
Catalytic Converter Hanger Bolt/Screw .................................. 41 Nm (30 lb. ft.)
Catalytic Converter Heat Shield Bolt/Screw ............................. 2.0 Nm (18 lb. in.)
Exhaust Crossover Pipe Nut ........................................... 35 Nm (26 lb. ft.)
Exhaust Heat Shield Bolt/Screw ....................................... 2.0 Nm (18 lb. in.)
Exhaust Muffler Hanger Bracket Bolt/Screw .............................. 15 Nm (11 lb. ft.)
Exhaust Muffler Hanger Nut ........................................... 25 Nm (18 lb. ft.)
Exhaust Muffler Heat Shield Bolt/Screw ................................ 2.0 Nm (18 lb. in.)
Exhaust Muffler Interior Hanger Bolt/Screw .............................. 15 Nm (11 lb. ft.)
Exhaust Pipe Bolt/Screw .............................................. 20 Nm (15 lb. ft.)
Exhaust Pipe Hanger Nut ............................................. 15 Nm (11 lb. ft.)
Exhaust Pipe Heat Shield Bolt/Screw ................................... 2.0 Nm (18 lb. in.)
Exhaust Tailpipe Extension Clamp Assembly ............................. 70 Nm (52 lb; ft.)
Muffler Clamp Assembly ............................................. 68 Nm (50 lb. ft.)
Rear Axle Torque Arm Bracket Nut ..................................... 41 Nm (30 lb. ft.)
Rear Axle Torque Arm Outer Bracket Bolt/Screw .......................... 27 Nm (20 lb. ft.)
AUTOMATIC AND MANUAL TRANSMISSION 7-1
SECTION 7
AUTOMATIC AND MANUAL TRANSMISSION

result.
CONTENTS
General Description .......................... 7-1
Description of Section 7 ...................... 7-1
Section 7A - Automatic Transmission
On-Vehicle Service ...................... 7-1
Section 7A-15A- HYDRA-MATIC 4L60
Automatic Transmission Diagnosis
(RPO MD8) .......................... 7-1
Section 7A-15B- HYDRA-MATIC 4L60
Automatic Transmission Unit Repair
(RPO MD8) .......................... 7-1
Section 7B - Manual Transmission

On-Vehicle Service ......................
Section 7B-6B - Borg-Warner (T5) 5-Speed
Manual Transmission Unit Repair
(RPO M49) ..........................
Section 7B-10B - Borg-Warner (T56) 6-Speed
Manual Transmission Unit Repair
(RPO M28 and M29) ...................
Section 7C- Clutch ........................
GENERAL DESCRIPTION
SECTION 7A-158 - HYDRA-MATIC 4L60

AUTOMATIC TRANSMISSION UNIT REPAIR
(RPO MD8)
Section 7 contains both on-vehicle service and unit

repair, as well as diagnosis procedures for the HYDRAMATIC 4L60 automatic transmission assembly, the BorgWarner 5-speed manual transmission assembly and the
two Borg-Warner 6-speed manual transmission assemblies.
7-1
7-1
7-2
7-2
This section contains the disassembly, inspection,

overhaul and assembly procedures for the mechanical
components on the automatic transmission. It also
includes information on gaging certain components,
proper use of special tools, and torque specifications
required for assembly.
DESCRIPTION OF SECTION 7
SECTION 7A - AUTOMATIC TRANSMISSION
ON-VEHICLE SERVICE
SECTION 78 - MANUAL TRANSMISSION

ON-VEHICLE SERVICE
This section contains information for automatic

transmission assembly identification, automatic transmission fluid level checking procedures and specific information for servicing some components while the automatic
transmission assembly is in the vehicle. This section also
contains procedures for removing and installing the automatic transmission assembly.
This section contains information on the BorgWarner 5-Speed (RPO M49) manual transmission and
both Borg-Warner 6-Speed (RPO M28 and M29) manual
transmissions. It includes information on transmission
identification, fluid level checking procedures and specifics on servicing some components while the transmission
is in the vehicle. This section also contains procedures for
the removal and installation of the transmission from the
vehicle.
SECTION 7A-15A - HVDRA-MATIC 4L60

AUTOMATIC TRANSMISSION DIAGNOSIS
(RPO MD8)
SECTION 78-68 - BORG-WARNER (T5)

5-SPEED MANUAL TRANSMISSION UNIT
REPAIR (RPO M49)
This section contains information to assist in diagnosing automatic transmission operating conditions when
the unit is in the vehicle. The diagnosis covers: road test
procedures, diagnosis charts, fluid flow diagrams, electrical wiring diagrams, automatic transmission oil passage
identification and torque converter clutch diagnosis.
This section covers the disassembly, inspection,

overhaul and assembly procedures for the Borg-Warner
5-Speed Manual Transmission. Also included is information on the gaging of certain components, proper use of
special tools, and torque specifications required for
assembly.
72 AUTOMATIC AND MANUAL TRANSMISSION

SECTION 78-108- BORG-WARNER (T56)
6-SPEED MANUAL TRANSMISSION UNIT
REPAIR (RPO M28 and M29)
nents, proper use of special tools, and torque specifications required for assembly.
This section covers the disassembly, inspection,

overhaul and assembly procedures for both versions of the
Borg-Warner 6-Speed Manual Transmission. Also
included is information on the gaging of certain compo-
This section contains clutch assembly diagnosis, onvehicle service of the hydraulic system, pressure plate/
clutch disc removal and installation procedures, torque
specifications and special tools required.
SECTION 7C - CLUTCH
AUTOMATIC TRANSMISSION ON-VEHICLE SERVICE 7A-1
SECTION 7A
ON-VEHICLE SERVICE
result.
CONTENTS
General Information ........................ 7A-2
Transmission Assembly Identification
Information .......................... 7A-2
Transmission Assembly Definitions . . . . . . . . . 7 A-2
Throttle Positions ...................... 7A-2
Shift Conditions . . . . . . . . . . . . . . . . . . . . . . . 7A-2
Noise Conditions . . . . . . . . . . . . . . . . . . . . . . 7 A-3
Preliminary Checking Procedure . . . . . . . . . . . . 7A-3
Line Pressure Check ... Refer to Section 7A-15A
Noise and Vibration Analysis . . . . . . . . . . . . . . 7A-3
Transmission Fluid Level Information ....... 7 A-4
Transmission Fluid Checking Procedure . . . . . . 7A-4
General Service Procedures . . . . . . . . . . . . . . . . . . 7A-4
No Air Tool Recommendation .............. 7A-4
Parts Cleaning, Inspection and
Replacement .......................... 7A-4
Flywheel Assembly{forque Converter
Clutch Vibration Test Procedure . . . . . . . . . . 7A-6
Fluid Leak Diagnosis . . . . . . . . . . . . . . . . . . . . . 7 A-6
Methods for Locating Leak . . . . . . . . . . . . . . 7A-6
Repairing the Leak . . . . . . . . . . . . . . . . . . . . . 7 A-8
Possible Points of Fluid Leaks . . . . . . . . . . . . 7A-8
Transmission Case Porosity Repair . . . . . . . . 7 A-8
Torque Converter Clutch Electrical Controls . . 7 A-9
Torque Converter Clutch Diagnosis . . . . . . . . . . 7 A-9
On-Vehicle Service . . . . . . . . . . . . . . . . . . . . . . . . 7A-9
Automatic Transmission Range Selector
Lever Cable Assembly . . . . . . . . . . . . . . . . . . 7 A-9
Automatic Transmission Control Assembly . . . 7A-9
Automatic Transmission Park Lock
Cable Assembly . . . . . . . . . . . . . . . . . . . . . . 7 A-10
Brake Transmission Shift Interlock
System Diagnosis ....... Refer to Section 8A-138
Automatic Transmission Control
Lever Solenoid ....................... 7 A-12
Park/Neutral Position Switch Assembly ..... 7A-12
Park/Neutral Position Switch Assembly
Adjustment Using Old Switch
Assembly ....................... 7A-13

Adjustment Using New Switch
Assembly .......................
Automatic Transmission TV Cable
Assembly System .....................
Assembly System Diagnosis ............
Line Pressure Checks ..................
Checking Line Pressure Regulation .......
Checking Lifter and Check Ball
"Fail-Safe" System .................
Inspection of Automatic Transmission
TV Cable Assembly System Parts ......
Assembly ...........................
Setting Automatic Transmission TV Cable
Assembly ...........................
Changing Transmission Fluid and Automatic
Transmission Oil Filter Assembly ........
Automatic Transmission Oil Cooler Upper
Pipe and Upper and Lower Hose
Assemblies . . . . . . . . . . . . . . . . . . . . . . . .
Oil Cooler Flushing Procedure . . . . . . . . . . . .
Serviceable Components ...................
Transmission Fluid Filler Tube Assembly ....
Vehicle Speed Sensor (VSS) and Speedometer
Driven Gear .........................
Speedometer Drive Gear and Automatic
Transmission Case Extension ...........
Governor Assembly . . . . . . . . . . . . . . . . . . . . .
Accumulator Assembly ..................
2-4 Band Servo Assembly ................
Transmission Converter Cover ............
Pressure Regulator Valve .................
Auxiliary Valve Body Assembly ...........
Control Valve Assembly .................
Converter Clutch Solenoid Valve Assembly
and Wiring Harness Replacement ........
Electrical Connector and Seal .............
Case Extension Oil Seal Assembly .........
7A-13
7A-13
7A-14
7A-15
7A-16
7A-16
7A-16
7A-16
7A-17
7A-17
7A-18
7A-19
7A-20
7A-20
7A-21
7A-22
7A-22
7A-23
7A-23
7A-24
7A-25
7A-25
7A-26
7A-29
7A-30
7A-30
7A-2 AUTOMATIC TRANSMISSION ON-VEHICLE SERVICE

Automatic Transmission Assembly Removal
and Installation ....................... 7A-30
Specifications ............................ 7A-33
GENERAL INFORMATION
IDENTIFICATION INFORMATION
Figures 1 and 2
The HYDRA-MATIC 4L60 transmission assembly
was formerly designated the THM 700-R4 transmission
assembly.
All automatic transmission assemblies have a metal
identification nameplate attached to the transmission case
exterior or a stamped identification number on the transmission oil pan rail. This is shown in Figure 1. The identification information will help in servicing the unit and
ordering necessary parts through a GM parts catalog.
Additional transmission assembly identification is
provided on the service parts identification label as shown
in Figure 2.
This label contains information on the regular production options (RPO) as well as standard and mandatory
options. This label is affixed to the inside of each vehicle
at the assembly plant. Refer to SECTION OA for label
location and additional information.
TRANSMISSION ASSEMBLY DEFINITIONS

The following definitions are provided to establish a
common language and assist the user in describing transmission assembly related conditions. Some of these terms
or conditions are used in the transmission assembly diagnosis section of this service manual.
Throttle Positions
Minimum Throttle - least amount of throttle opening required for an upshift.
Light Throttle - approximately 1/4 of accelerator
pedal travel.
Medium Throttle - approximately 1/2 of accelerator pedal travel.
Heavy Throttle - approximately 3/4 of accelerator
pedal travel.
HYDRA-MA TIC 4L60 AUTOMATIC TRANSMISSION
ASSEMBLY IDENTIFICATION INFORMATION
TOLEDO, OHIO
Fastener Tightening Specifications ......... 7A-33

Speedometer Gear Chart ................. 7A-33
Special Tools ............................ 7A-34
Wide Open Throttle - full travel of accelerator

pedal.
Full Throttle Detent Downshift - quick application of accelerator pedal to its full travel, forcing a
downshift.
Zero Throttle Coastdown - full release of accelerator pedal while vehicle is in motion in drive range.
Engine Braking- condition where engine is used to
slow vehicle by manually downshifting during zero
throttle coastdown.
Shift Conditions
Bump- sudden and forceful application of clutch or
band.
Chuggle - bucking or jerking condition that may be
engine related. May be most noticeable when the
torque converter clutch is engaged. Similar to the
feel of towing a trailer.
Delayed - condition where shift is expected but
does not occur for a period of time. Examples of this
condition could be described as clutch or band
engagement that does not occur as quickly as
expected during part throttle or wide open throttle
application of accelerator, or when manually downshifting to lower range. Also defined as "late" or
"extended."
Double Bump - two sudden and forceful applications of clutch or band. Also defined as "double
feel."
Early - condition where shift occurs before vehicle
has reached proper speed and tends to labor engine
after upshift.
End Bump - firmer feel at end of shift as compared
to feel at start of shift. Also defined as "end feel" or
"slip bump."
Firm - noticeable quick application of clutch or
band that is considered normal with medium to
heavy throttle shift. Should not be confused with
"harsh" or "rough."
JULIAN DATE
(OR DAY OF THE YEAR)
HYDRA-MATIC 4L60
CALENDAR
YEAR
SOME MODELS
(2 = 1992)
(3 = 1993)
3 YD M
TRANSMISSION I.D.
LOCATION
MO~z
SHIFT BUILT
A & B = FIRST SHIFT
C & H = SECOND SHIFT
PC6001-7A-D-RP
Figure 1 -'-Automatic Transmission Assembly Identification Information

Flare - quick increase in engine RPM accompanied
with momentary loss of torque. This most generally
occurs during a shift. Also defined as "slipping."
Harsh - more noticeable application of clutch or
band as compared to "firm." This condition is considered undesirable at any throttle position. Also
defined as "rough."
Hunting. - repeating quick series of upshifts and
downshifts causing noticeable change in engine
RPM. An example could be described as a 4-3-4
shift pattern. Also defined as "busyness."
Initial Feel - distinct firmer feel at start of shift as
compared to finish of shift.
Late - shift that occurs when engine is at higher than
normal RPM for given amount of throttle.
Shudder - repeating jerking sensation similar to
"chuggle" but more severe and rapid in nature. This
condition may be most noticeable during certain
ranges of vehicle speed. May also be used to define
the condition after torque converter clutch engagement.
Slipping - noticeable increase in engine RPM without vehicle speed increase. Slip usually occurs during or after initial clutch or band engagement.
Soft - slow, almost unnoticeable clutch application
with very little shift feel.
Surge-repeating engine related feeling of acceleration and deceleration that is less intense than
"chuggle."
Tie-Up- condition where two opposing clutches are
attempting to apply at the same time causing the
engine to labor with noticeable loss of engine RPM.
Noise Conditions
Gear Noise - whine, most noticeable in first gear
and reverse that is related to vehicle speed. A gear
noise condition may become less noticeable or go
away after an upshift.
M- INDICATES TRANSMISSION
TYPE IN OPTION LIST. (SPECIFIC
MODEL CODE IS FOUND ON THE
TRANSMISSION NAMEPLATE)
MOB- DESIGNATES HYDRA-MATIC 4L60
SERVICE PARTS IDENTIFICATION
MX - DESIGNATES
ASSEMBLY
MXD- DESIGNATES 4 SPEED
DO NOT REMOVE
1 G 3 A R 4 7 Y X E 5 1 0 DO O 1
C90 C95 DF3 D3C 033 D 8 E Z EID FFL F40 661 GW9 660 GU2 689
JA1 JA4 KOS K22 K99 LV21MDBIMXOfNA5 NB1 NK1 NK2 N33 N67 GJW
T87 UJ3 U23 U35 VOS V10 WC3 WG2 YT9 Y56 OIL SSC 428 421 420
42T 409 788 BWT 9WT 11A 9DA
PRINTED IN U.S.A.
PART NO. 14065987

PC6002-7A-D-RP
Figure 2 - Service Parts Identification Label
Pump Noise - high-pitched whine increasing in

intensity with engine RPM. This condition may also
be noticeable in "PARK" and "NEUTRAL" operating ranges with the vehicle stationary.
PRELIMINARY CHECKING PROCEDURE

Transmission assembly performance may be
influenced by one or more of the following items. These
items should be checked and corrected if necessary,
before attempting transmission assembly diagnosis.
High or low fluid level.
Engine performance. Refer to SECTION 6 and
SECTION 6E.
TV cable assembly setting.
Manual linkage adjustment.
Internal fluid leaks. Refer to SECTION 7A-15A.
Electrical system. Refer to SECTION 6D and SECTION 8A.
Transmission assembly or other mechanical component. Refer to SECTION 7A-15A.
NOISE AND VIBRATION ANALYSIS

A noise or vibration noticeable when the vehicle is
in motion, may not be caused by the transmission assembly.
If a noise or vibration is noticeable in "PARK" and
"NEUTRAL" with engine at idle, but is less noticeable as
RPM increases, the cause may be poor engine performance.
lll 1nspect
Tire and wheel assemblies for:
- Uneven wear.
- Imbalance.
- Mixed sizes.
- Mixed radial and bias ply. Refer to SECTION
3E.
Suspension components for:
- Alignment and wear.
- Loose fasteners. Refer to SECTION 3C.
Engine and transmission assembly mounts for:
- Damage.
- Loose bolts/screws.
Transmission case mounting holes for:
- Missing bolts/screws, nuts, studs.
- Stripped threads.
- Cracks.
Flywheel assembly for:
- Missing or loose bolts/screws.
- Cracks.
- Imbalance.
Torque converter clutch for:
- Missing or loose bolts/screws or lugs.
- Missing or loose balance weights.
- Imbalance.
TRANSMISSION FLUID LEVEL

INFORMATION
Checking fluid level, color and condition at regular
intervals will provide early diagnosis information about
the transmission assembly. This information may be used
to correct conditions that could cause major transmission
assembly repairs if not detected early.
When adding or changing fluid, use only DEXRON-IIE. Refer to SECTION OB for maintenance information and servicing intervals.
NOTICE: Do not overfill. Overfilling will cause
foaming, loss of fluid and possible damage to transmission assembly.
Fluid level can be checked when transmission
assembly reaches normal operating temperatures of
82 to 93C (180 to 200F). This temperature is
reached after approximately 24 km (15 miles) of
highway driving.
Fluid level can also be checked when transmission
assembly is cold (before driving vehicle). Fluid level
should be within cold range.
New fluid is red in color.
[I] Important
When new, fluid is red in color. The red dye is
added so the assembly plant can identify it as
transmission fluid and distinguish it from
engine oil or anti-freeze. The red dye is not a
quality indicator, and is not permanent. As the
vehicle is driven, the fluid will turn darker in
color. The color may eventually turn light
brown.
Inaccurate fluid level readings will result if the fluid
is checked immediately after the vehicle has been
operating under certain conditions.
- In high ambient temperatures above 32C
(90F).
At sustained high speeds.
- In heavy city traffic during hot weather.
- As a towing vehicle.
- In commercial service.
TRANSMISSION FLUID CHECKING

PROCEDURE
Figure3
The fluid level must be checked with the vehicle at
normal operating temperature, 82 to 93C (180 to
200F). Temperature will greatly effect fluid level. If the
vehicle is not at normal operating temperature or the
proper checking procedures are not followed, the fluid
level indicator assembly reading could be false, causing
an improper fluid level adjustment. Improper fluid level
may cause poor transmission assembly performance and
damage.
Wait at least 30 minutes before checking fluid level
if vehicle has been driven:
When outside temperatures are above 32C (90F).
In heavy traffic, especially in hot weather.

While pulling a trailer.
A cold check of the fluid level can be made if the
vehicle has not been operated for at least eight hours. The
cold check should be used as a reference only. A hot check
must be performed if fluid is added during a cold check.
1. Start engine.
Hot check - operate vehicle for minimum of 24
km (15 miles) or until normal operating temperature has been reached.
Cold check - let engine run at low idle for 5
minutes if outside temperature is 10C (50F)
or above. If outside temperature is below l0C
(50F), the engine may have to run longer.
2. Park vehicle on level ground.
3. Move transmission control lever assembly to
"PARK."
4. Apply parking brake and block tire and wheel
assemblies.
5. Press brake pedal assembly.
6. Move transmission control lever assembly through
each gear range.
A. Pause approximately 3 seconds in each range.
B. Return transmission control lever assembly to
"PARK" position.
7. Let vehicle idle for 3 minutes with accessories off.
8. Check fluid level, color and condition.
A. Check both sides of fluid level indicator
assembly.
Use lowest level.
B. If fluid level is low, add only to "COLD" area
for cold check or "HOT" area for hot check.
DO NOT OVERFILL.
C. Recheck level after adding fluid.
GENERAL SERVICE PROCEDURES

NO AIR TOOL RECOMMENDATION
NOTICE: It is not recommended to use air powered
tools to disassemble or assemble transmission
assemblies. Improper bolt torques can contribute to
transmission assembly repair conditions, and this
information vital to diagnosis can only be detected
when using hand tools.
PARTS CLEANING, INSPECTION AND

REPLACEMENT
Use appropriate safety equipment such as:
- Safety glasses.
- Safety shoes.
- Gloves.
Keep work areas and tools clean.
Clean transmission assembly exterior before removing parts.
Do not use wipe cloths or rags.
Do not use solvents on:
- Rubber seals.
HYDRA-MATIC 4L60
CHECK IN PARK, ENGING IDLING, VEHICLE LEVEL.

TRANS HOT MUST BE IN CROSSHATCH.
DO NOT OVERFILL.
DEXRON-IIE FLUID ONLY.
I
I
CHECK AUTOMATIC
TRANSMISSION FLUID LEVEL
I
HIGH
,dJ
CHECK AUTOMATIC
TRANSMISSION FLUID COLOR
l
I
LOW
rl
FOAM
NON TRANSPARENT
PINK
REPLACE COOLER
LT. BROWN
NOTICE: AU10MATIC
TRANSMISSION
FLUID MAY TURN DARK
WITH NORMAL USE
AND DOES NOT ALWAYS
INDICATE CONTAMINATION
OR OXIDATION
I
REMOVE EXCESS
AUTOMATIC
TRANSMISSION
FLUID
AUTOMATIC
TRANSMISSION
FLUID LEVEL
HIGH
ADD AUTOMATIC
TRANSMISSION
FLUID TO
OBTAIN PROPER
LEVEL
DRAIN AUTOMATIC
TRANSMISSION FLUID TO
DETERMINE SOURCE
OF CONTAMINATION
CHECK FOR EXTERNAL

LEAKS !REFER TO
'' AUTO MA TIC TRANSMISSION
FLUID LEAK DIAGNOSIS"
CORRECT LEAK
CONDITION
DRAIN AUTOMATIC
TRANSMISSIO~ FLUID TO
DETERMINE IF THERE IS
CONTAMINATION
CONTAMINANTS
IN AUTOMATIC
TRANSMISSION
FLUID
REMOVE EXCESS
AUTOMATIC
TRANSMISSION
FLUID
NOTICE: A VERY SMALL

AMOUNT OF IIIATERIAL
IN THE BOTTOM PAN IS
A NORMAL CONDITION
CHANGE AUTOMATIC
TRANSMISSION FLUID
AND FILTER
ASSEMBLY OVERHAUL
REQUIRED !REFER
TO "UNIT REPAIR
SECTION")
LARGE PIECES OF
MET AL OR OTHER
MA TERI AL IN THE
BOTTOM PAN
ADD NEW AUTOMATIC

TRANSMISSION FLUID
ASSEMBLY OVERHAUL
REQUIRED !REFER TO
"UNIT REPAIR SECTION")
CHECK AUTOMATIC
TRANSMISSION FLUID
LEVEL
ADD NEW AUTOMATIC
TRANSMISSION FLUID
PERFORM ROAD TEST

(REFER TO AUTOMATIC
DIAGNOSIS SECTION)
CHECK AUTOMATIC
TRANSMISSION FLUID
LEVEL
PC00017A-F-RP
Figure 3 - Checking Automatic Transmission Fluid Color, Level and Condition

- Plastic{feflon thrust washers or spacers.
Blow out all passages with compressed air.
Clean out small passages with fine wire.
Handle parts carefully to prevent damage.
NOTICE: The assembly of some components will
require use of an assembly lube. It is recommended
that J 36850 Transjel , or equivalent, be used during assembly. Do not use any type of grease to retain
parts during assembly of this unit. Lubricants other
than the recommended assembly lube will change
fluid characteristics and cause undesirable shift
conditions and/or oil filter clogging.
When installing bolts/screws or studs into aluminum, always dip the threads in Transjel or equivalent.
Recondition damaged or stripped aluminum threads
with thread inserts.
Replace all gaskets and 0-ring seals.
- Do not use gasket cement or sealers.
Replace Teflon and rubber lip seals only when necessary and install using the appropriate seal installer.
TM,
ll'l'I Inspect
Manual linkage for:
- Bent or broken links and rods.
All seals, gaskets, 0-ring seals and mating surfaces
for:
- Nicks.
- Cuts.
- Damage.
Snap rings for:
- Expansion or compression.
- Distortion.
- Nicks.
- Proper ring-to-groove fit.
Bearings and thrust surfaces for:
- Wear.
- Scoring.
- Pitting.
FLYWHEEL ASSEMBLY/TORQUE
CONVERTER CLUTCH VIBRATION TEST
PROCEDURE
NOTICE: Some engine/transmission assembly
combinations cannot be balanced in this manner due
to limited clearances between the torque converter
clutch bolts/screws and the engine. Be sure bolts/
screws do not bottom out in lug nuts or the transmission converter cover could be dented and cause
internal damage.

1. Start engine.
2. With engine at idle speed and transmission assembly
in "PARK" or "NEUTRAL," observe vibration.
3. Shut off engine.

5. Transmission converter cover bolts/screws.
6. Flywheel bolts/screws.
Discard flywheel bolts/screws.
7. Rotate torque converter clutch 120 degrees (1/3
turn).

1. Flywheel bolts/screws.
Hand start flywheel bolts/screws.
- Use new flywheel bolts/screws with
retaining compound removed from first
three threads.
l~I Tighten
Flywheel bolts/screws to 63 Nm (46 lb. ft.).
2. Transmission converter cover bolts/screws.
l~I Tighten
Transmission converter cover bolts/screws to
10 Nm (89 lb. in.).
3. Lower vehicle.
4. Start engine and check for vibration.
If vibration still exists repeat this procedure
until best possible balance is obtained.
FLUID LEAK DIAGNOSIS

Figure4
The cause of most external leaks generally can be
located and repaired with the transmission assembly in the
vehicle.
Methods for Locating Leak

General Method
1. Verify leak is transmission fluid.
2. Thoroughly clean suspected leak area.
3. Operate vehicle for about 24 km (15 miles) or until
normal operating temperatures are reached.
4. Park vehicle over clean paper or cardboard.
5. Shut off engine and look for fluid spots on paper.
6. Make necessary repairs.
Powder Method
1. Thoroughly clean suspected leak area with solvent.
2. Apply aerosol type powder (foot powder) to suspected leak area.
3. Operate vehicle for about 24 km (15 miles) or until
normal operating temperatures are reached.
4. Shut off engine.
5. Inspect suspected leak area and trace leak path
through powder to find source.
A
K
A AUTOMATIC TRANSMISSION OIL PAN GASKET

B AUTOMATIC TRANSMISSION. CASE
C TRANSMISSION OIL COOLER CONNECTORS AND PIPE
PLUGS
D AUTOMATIC TRANSMISSION TV CABLE SEAL
E 2-4 SERVO COVER SEAL
F TRANSMISSION FLUID FILLER TUBE SEAL
G AUTOMATIC TRANSMISSION OIL PUMP SEAL ASSEMBLY
H AUTOMATIC TRANSMISSION OIL PUMP-TO-HOUSING
SEAL (0-RING)
J TORQUE COVERTER ASSEMBLY

VENT
ELECTRICAL CONNECTOR SEAL
MANUAL SHAFT SEAL
GOVERNOR COVER SEAL
SPEEDOMETER SEAL
Q 0-RING (ELECTRICAL CONNECTOR) SEAL
R PROPELLER SHAFT OIL SEAL ASSEMBLY
S TRANSMISSION OIL LINE PRESSURE TAP
K
L
M
N
P
Figure 4 - Automatic Transmission Fluid Leak Points
PC0002-7A-F-RP
7A8 AUTOMATIC TRANSMISSION ON-VEHICLE SERVICE

Dye and Black Light Method

A fluid dye and black light kit is available from various tool manufacturers.
1. Follow manufacturer's recommendations for
amount of dye to use.
2. Detect leak with black light.
Repairing the Leak

Once the leak has been pinpointed and traced back to
its source, the cause of the leak must be determined for it
to be properly repaired. For example, if a gasket is
replaced, but the sealing flange is bent, the new gasket
will not repair the leak. The bent flange also must be
repaired.
The following conditions may cause a leak. Before
attempting to repair a leak, these conditions should be
checked and corrected if necessary.
Gaskets
ll'l'I
Inspect
Fluid level/pressure too high.

Plugged vent or drain-back holes.
Improperly torqued fasteners, dirty or damaged
threads.
Warped flanges or sealing surface.
Scratches, burrs or other damage to sealing surface.
Damaged or worn gasket.
Cracking or porosity of component.
Improper sealant used, where applicable.
Incorrect gasket.
Seals
ll'l'I
Inspect
Fluid level/pressure too high.

Plugged vent or drain-back holes.
Damaged seal bore.
Damaged or worn seal.
Improper installation.
Cracks in component.
Scratched, nicked or damaged, manual or output
shaft surface.
Loose or worn bearing causing excess seal wear.
Possible Points of Fluid Leaks

Oil Pan
ll'l'I
Inspect
Incorrectly tightened oil pan bolts/screws.

Improperly installed or damaged oil pan gasket.
Damaged oil pan.

Incorrect oil pan gasket.
Oil Case Leak
lll
1nspect
Damaged or missing transmission filler tube seal.

Mislocated filler tube bracket.
Missing, damaged, or improperly installed TV cable
seal.
Damaged or missing engine speed governor cover
and 0-ring seals.
Damaged speedometer driven gear/vehicle speed
sensor seal.
Damaged manual shaft seal.
Loose or damaged oil cooler connector fittings.
Worn or damaged propeller shaft oil seal.
Loose parking pawl shaft cup plug, if equipped.
Loose engine speed governor pressure pipe plug.
Loose line pressure pipe plug.
Porous casting.
Leak at Torque Converter End
lll
1nspect
Torque converter seal damaged.

- Torque converter seal lip cut. Check torque
converter hub for damage.
- Bushing moved forward and damaged.
- Garter spring missing from seal.
Torque converter leak in weld area.
Porous casting of transmission case or oil pump.
Leak at Vent Pipe of Fluid Filler Tube Assembly
ll'l'I
Inspect
Over-filled system.
Water or coolant in fluid. Fluid will appear milky.
Transmission case porous.
Incorrect fluid level indicator assembly.
Plugged vent.
Plugged drain-back holes.
Mispositioned oil pump-to-case gasket, if equipped.
Transmission Case Porosity Repair

1. Clean leak area with solvent and air dry.
CAUTION: Epoxy cement may cause
skin irritations and eye damage. Read
and follow all information on container
label as provided by manufacturer.
2. Mix sufficient amount of epoxy cement, GM PIN
1052533, or equivalent, following manufacturers'
recommendations.
3. While transmission case is hot, apply epoxy cement
with clean, dry soldering acid brush.

4. Allow epoxy cement to cure for three hours before
starting engine.
5. Repeat fluid leak diagnosis procedures to determine
if leak is fixed.
TORQUE CONVERTER CLUTCH

ELECTRICAL CONTROLS
The torque converter clutch (TCC) system uses controls that are both internal and external to the transmission
assembly. For internal control components of the TCC
system, refer to SECTION 7A-15A for wiring diagrams
and switch locations.
The external control components of the TCC system
include:
Cruise Control Release Switch Assembly - To
avoid stalling the engine when braking, the TCC is
released any time the brake pedal assembly is
applied.
Engine Control Module (ECM) - Receives input
signals and grounds TCC solenoid to apply clutch
when proper operating conditions are met.
Throttle Position Sensor - Sends throttle position
information to ECM.
Manifold Absolute Pressure (MAP) Sensor Sends engine vacuum (load) information to ECM.
Vehicle Speed Sensor (VSS) - Sends vehicle speed
information to ECM.
Engine Coolant Temperature Sensor - Sends
engine coolant temperature information to ECM.
TORQUE CONVERTER CLUTCH DIAGNOSIS

To properly diagnose the torque converter clutch
(TCC) system, perform all electrical testing first and then
hydraulic testing. Refer to SECTION 6E3 and SECTION
7A-15A for additional TCC information.
ON-VEHICLE SERVICE
AUTOMATIC TRANSMISSION RANGE
SELECTOR LEVER CABLE ASSEMBLY
Figure 5

3. Cable assembly (806) from bracket (800).
4. Cable Assembly (806) from lever assembly (809).
5. Lower vehicle.
6. Front floor console trim plate assembly. Refer to
SECTION 8C.
7. Cable assembly (806) from control assembly (805).
8. Grommet on cable assembly (806) from base of control assembly (805), pulling cable assembly (806)
through hole in front compartment floor pan assembly.

1.
2.
3.
4.
NOTICE: See "Notice" on page 7A-J of this section.

Grommet on cable assembly (806) to base of control
assembly (805) by feeding cable assembly (806)
through hole in front compartment floor pan assembly.
Cable assembly (806) to control assembly (805).
Front floor console trim plate assembly. Refer to
SECTION 8C.
Place control assembly (805) in "NEUTRAL" position.
Important
5.
6.
7.
8.
9.
10.
11.
Control assembly must remain in "NEUTRAL" position until cable assembly installation is completed.
Cable assembly (806) to bracket (800) with adjustment button unlocked.
Place lever assembly (809) in "NEUTRAL" position by rotating lever assembly counterclockwise
from "PARK" through "REVERSE" and into
"NEUTRAL."
Cable assembly (806) to lever assembly (809).
Lock adjustment button on cable assembly (806) to
bracket (800) by turning counterclockwise.
Lower vehicle.
AUTOMATIC TRANSMISSION CONTROL

ASSEMBLY
Figures 5 and 6

2. Automatic transmission range selector lever cable
assembly. Refer to "Automatic Transmission Range
Selector Lever Cable Assembly" in this section.
3. Park/neutral position switch assembly. Refer to
"Park/Neutral Position Switch Assembly" in this
section.

7A-10 AUTO!IIATIC TRANSMISSION ON-VEHICLE SERVICE
A GROMMET
800 BRACKET, AUTOMATIC TRANSMISSION RANGE
SELECTOR LEVER CABLE
803 NUT, AUTOMATIC TRANSMISSION RANGE SELECTOR
LEVER, 20 Nm (15 LB. FT.)
805 CONTROL ASSEMBLY, AUTOMATIC TRANSMISSION
806 CABLE ASSEMBLY, AUTOMATIC TRANSMISSION
RANGE SELECTOR LEVER
808 BOLT/SCREW, AUTOMATIC TRANSMISSION CONTROL,
4.5 Nm (40 LB. IN.)
809 LEVER ASSEMBLY, AUTOMATIC TRANSMISSION
RANGE SELECTOR
~~
'
-I
'ii0;.a
b
I,
'1
11 ' l[
I
800
Figure 5 - Automatic Transmission Range Selector Lever Cable Assembly
l~I Tighten
3. Park/neutral position switch assembly. Refer to
"Park/Neutral Position Switch Assembly" in this
section.
AUTOMATIC TRANSMISSION PARK LOCK

CABLE ASSEMBLY
Figure 7
806
806 CABLE ASSEMBLY, AUTOMATIC TRANSMISSION
RANGE SELECTOR LEVER
808 BOLT/SCREW, AUTOMATIC TRANSMISSION CONTROL,
4.5 Nm 140 LB. IN.)
810 KNOB/HANDLE, AUTOMATIC TRANSMISSION
CONTROL LEVER
811 RETAINER, AUTOMATIC TRANSMISSION CONTROL
LEVER HANDLE
PC0004-7AFRP
Figure 6 -Automatic Transmission Control Assembly

(Typical)

1.
2.
3.
4.

CAUTION: Refer to "Caution" on page
7A1 of this section.
Disable the SIR system. Refer to SECTION 9J.
Place automatic transmission control assembly in
"PARK."
Tum ignition key to "RUN" position.
812
813
A SPRING, AUTOMATIC TRANSMISSION PARK LOCK
CABLE
B BRACKET, AUTOMATIC TRANSMISSION PARK LOCK
CABLE
812 CABLE ASSEMBLY, AUTOMATIC TRANSMISSION PARK
LOCK
813 CLIP, AUTOMATIC TRANSMISSION PARK LOCK CABLE
814 NUT, AUTOMATIC TRANSMISSION PARK LOCK CABLE
815 BUTTON; AUTOMATIC TRANSMISSION PARK LOCK
CABLE LOCK
PC0005-7A-F-RP
Figure 7 - Automatic Transmission Park Lock Cable Assembly (Typical)
Do not proc~ed to next step with ignition key

in any other position.
5. Left-hand instrument panel sound insulator assembly, instrument panel driver knee bolster assembly,
and instrument panel driver knee bolster deflector.
8C.
7. Nut (814).
8. Clip (813).
9. Cable assembly (812) from bracket.
10. Move button (815) to "UP" position.
11. Unsnap cable terminal from park lock lever pin.

12. Lower steering column assembly. Refer to SECTION 3F.
13. Unsnap cable assembly (812) from steering column
assembly (816).

1. Make sure ignition key is in '!RUN" position and
automatic transmission control assembly is in
"PARK."
Do not proceed to next step with ignition key
in any other position.
2. Snap cable terminal to park lock lever pin.
3. Push cable connector forward to remove slack.
4. With no load applied to connector, press .button

(815) down.
5. Cable assembly (812) to bracket.
A. Push bracket housing against adjusting spring.
B. Drop cable assembly (812) through slot in
bracket and seat housing to automatic transmission control assembly.
6. Push button (815) down.
7. Snap cable assembly (812) into steering column
assembly (816).
8. Raise steering column assembly. Refer to SECTION
3F.
9. Clip (813).
10. Nut (814).
8C.
12. Left-hand instrument panel sound insulator assembly, instrument panel driver knee bolster assembly,
and instrument panel driver knee bolster deflector.
13. Turn ignition key to "OFF" position.
15. Enable the SIR system. Refer to SECTION 9J.
ILl tnspect
Functional operation.
A. With automatic transmission control assembly
in "PARK" and the igniti~rikey in "LOCK"

position, make sure control assembly cannot
be moved to different position. Ignition key
should be removable from steering column
assembly.
B. With ignition key in "RUN" and automatic
transmission control assembly in "NEUTRAL," make sure key cannot be turned to
"LOCK."
C. If above conditions are met, system is properly
adjusted. Proceed to step E.
D. If above conditions are not met, put button
(815) back to "UP" position, and readjust as
above. Then push button (815) down and
recheck operation.
E. If key cannot be removed in "PARK" position,
move button (815) to "UP" position and move
cable connector nose rearward until ignition
key can be removed.
F.
Snap button (815) down.
G. Reinstall cable assembly (812) into clip (813)

to ensure correct routing.
AUTOMATIC TRANSMISSION CONTROL

LEVER SOLENOID
The automatic transmission control lever solenoid is
part of the brake transmission shift interlock system
(BTSI). The solenoid prevents the operator from shifting
the automatic transmission control assembly out of
"PARK" unless the brake pedal is depressed.
!VIEWA
A
B
C
804
RETAINER, PLASTIC
STUD
SOLENOID, AUTOMATIC TRANSMISSION CONTROL
LEVER
Figure 8
lI
PC0006-7A-F-RP

Cable Assembly" in section OA.
SECTION 8C.
3. Wiring harness electrical connector from automatic
transmission control lever solenoid (804).
4. Automatic transmission control lever solenoid (804)
by unsnapping retainers.
l++I
Install or Connect
1. Automatic transmission control lever solenoid (804)

by snapping retainers into place.
2. Wiring harness electrical connector to automatic
transmission control lever solenoid (804).
SECTION 8C.
Figure 8 - Automatic Transmission .Control Lever Solenoid

(Typical)
PARK/NEUTRAL POSITION SWITCH

ASSEMBLY
r
The park/neutral position switch assembly prevents
starter motor operation when the automatic traq.smission
control assembly is in any gear by breaking .]he starter
motor circuit. When the automatic transmission control
assembly is in reverse (engine running), the park/neutral
position switch completes the backup lamp circuit, lighting the backup lamps.
Figure9
l++I

8C.

in "PARK" or "NEUTRAL." If engine will start
with ignition key in any other position, readjust
park/neutral position switch assembly.

Adjustment Using New Switch Assembly
l++I
Install or Connect
1. Place automatic transmission control assembly
(805) in "NEUTRAL."
2. Tang (818) on switch assembly (817) into slot on
automatic transmission control assembly (805).
3. Bolts/screws (819) to automatic transmission case.
l~I
818
A NEUTRAL NOTCH
B PARK NOTCH
C TANG SLOT
D PIN, GAGE
817 SWITCH ASSEMBLY, PARK/NEUTRAL POSITION
818 TANG, PARK/NEUTRAL POSITION SWITCH CARRIER
819 BOLT/SCREW, PARK/NEUTRAL POSITION SWITCH,
2.2 Nm (19 LB. IN.)
825 DETENT PLATE, PARK/NEUTRAL POSITION SWITCH
PC0007-7A-F-RP
Figure 9 - Park/Neutral Position Switch Assembly
4. Switch assembly (817).

Adjustment Using Old Switch Assembly
I++!
1.
2.
3.
4.
Install or Connect

Place automatic transmission control assembly
(805) in "NEUTRAL."
Tang (818) on switch assembly (817) into slot on
automatic transmission control assembly (805).
Bolts/screws (819) to automatic transmission case,
loosely.
Insert 2.34 mm (3/32-inch) gage pin into service
adjustment hole, and rotate switch assembly (817)
until gage pin drops to 15 mm (19/32-inch) depth.
l~I
Tighten
Tighten

8C.
[I] Important
After park/neutral position switch assembly adjustment, verify engine will only start with ignition key
[I] Important
If park/neutral position switch bolt/screw holes
will not align with automatic transmission control assembly, verify automatic transmission
control assembly is in "NEUTRAL" position.
Do not rotate park/neutral position switch
assembly. If switch assembly has been rotated
and the pin is broken, the switch assembly can
be adjusted using the procedure under "Park/
Neutral Position Switch Assembly Adjustment
Using Old Switch" in this section.
8C.
AUTOMATIC TRANSMISSION TV CABLE

ASSEMBLY SYSTEM
The TV cable assembly (826) used on the HYDRAMATIC 4L60 automatic transmission assembly controls
line pressure, shift points, shift feel, part throttle downshifts and detent downshifts. The TV cable assembly
(826) operates the throttle lever (831) in the control valve
assembly.
The TV cable assembly (826) serves two basic functions:

1. To transfer throttle lever movement to the TV
plunger in the control valve assembly. This causes
TV pressure and line pressure to increase according
to engine throttle opening and controls part throttle
and detent downshifts.
2. To prevent the automatic transmission assembly
from operating at low (idle) pressures, if the TV
cable assembly (826) should be broken or disconnected.
If the TV cable assembly (826) is properly connected, the TV lifter rod will remain in its normal position, holding the TV exhaust check
ball off its seat.
If the TV cable assembly (826) is broken, disconnected or out of adjustment, the TV lifter
824
826
830
831
~f~1
826
8\ 3 ~
/ ('
r,
ti
~826
!VIEWA!
64
824
826
827
LINK, TV CABLE
PLENUM ASSEMBLY
CABLE ASSEMBLY, AUTOMATIC TRANSMISSION TV
BOLT/SCREW, AUTOMATIC TRANSMISSION TV CABLE,
10 Nm (89 LB. IN.)
828 SEAL, AUTOMATIC TRANSMISSION TV CABLE (0-RING)
830 BRACKET, AUTOMATIC TRANSMISSION TV CABLE
831 LEVER.THROTTLE
PCOCJOB.7AfR~
Figure 1O- Automatic Transmission TV Cable Assembly (L32)
rod will drop down to allow the TV exhaust

check ball to seat.
ll"'I
Inspect
With automatic transmission oil pan removed, pull

down on TV exhaust valve lifter rod. Spring should
return rod to its normal up position.
- If throttle lever (831) and bracket (830) or
lifter rod cannot lift exhaust check ball off its
seat, high line pressure and delayed upshifts
will result.
- TV lifter rod will not function properly if bent.

ASSEMBLY SYSTEM DIAGNOSIS
CAUTION: To avoid possible personal
injury and/or damage to the vehicle, the
vehicle parking brake assembly must
be applied at all times during all diagnosis procedures.
ll'l'I
Inspect
The following conditions possibly are caused by the

automatic transmission TV cable assembly system:
- Delayed or harsh upshifts.
- Early and slipping upshifts.
- High or low line pressure.
- No upshifts.
- Chatter on takeoff.
- 1-2 shift at full throttle only.
- No full throttle or part throttle detent downshifts.
- Intermittent second gear starts.
The above conditions can be caused by an automatic
transmission TV cable assembly that is:
- Improperly set.
- Kinked or binding.
- Disconnected.
AUTOMATIC TRANSMISSION ON-VEHICLE SERVICE 7A15

826
!VIEWA
64 LINK, TV CABLE
826 CABLE ASSEMBLY, AUTOMATIC TRANSMISSION TV
827 BOLT/SCREW, AUTOMATIC TRANSMISSION TV CABLE,
10 Nm (89 LB. IN.)
828 SEAL, AUTOMATIC TRANSMISSION TV CABLE (0-RING)
830 BRACKET, AUTOMATIC TRANSMISSION TV CABLE
831 LEVER.THROTTLE
836 TUBE ASSEMBLY, TRANSMISSION FLUID FILLER
PC0009-7A-F-RP
Figure 11 - Automatic Transmission TV Cable Assembly (LT1)
- Broken.
- Wrong part.
Make sure the engine fuel, electrical and mechanical
systems are performing properly before attempting transmission diagnosis. Transmission performance can be
affected by a problem existing in another system.
Do not attempt to correct a condition by changing
the automatic transmission TV cable assembly setting
from its proper adjustment. Apparent improvement as a
result of changing the setting indicates further diagnosis is
required to identify the real cause of the condition (such as
engine performance or control valve assembly).
Line Pressure Checks

1. Install oil pressure gage.
2. Install engine tachometer.
3. Warm up engine to normal operating temperature.
4. Run engine at 1000 rpm.

5. Make sure parking brake assembly is applied.
6. Place automatic transmission control assembly in
"PARK." Note oil pressure.
7. Place automatic transmission control assembly in
"DRIVE." Oil pressure should be equal to or not
more than 69 kPa (10 psi) higher than in "PARK."
8. Increase engine speed to 1400 rpm. If oil pressure
does not increase, set automatic transmission TV
cable assembly. Refer to "Setting Automatic Transmission TV Cable Assembly" in this section.
ll'l'I Inspect
Automatic transm1ss1on TV cable assembly for
kinked, binding, disconnected or broken condition.

Automatic transmission TV cable assembly for correct part number.
Checking Line Pressure Regulation
IL'l'I Inspect
l. Oil pressure gage while manually pulling out full
length of automatic transmission TV cable assembly. Oil pressure should increase as cable assembly
is pulled out.
Do not increase engine's throttle opening while
performing this test.
If oil pressure does not increase, refer to
"Inspection of Automatic Transmission TV
Cable Assembly System Parts" in this section.
2. Oil pressure gage as automatic transmission TV

cable assembly is returned to its original position.
Oil pressure should decrease smoothly as automatic
transmission TV cable assembly is returned.
If oil pressure does not decrease smoothly,
refer to "Inspection of Automatic Transmission TV Cable Assembly System Parts" in this
section.
Checking Lifter and Check Ball "Fail-Safe"

System
1. Run engine.
2. Disconnect automatic transmission TV cable assembly at throttle linkage.
3. Read oil pressure gage.
Line pressure should increase to maximum. If
line pressure does not increase, refer to
"Inspection of Automatic Transmission TV
Cable Assembly System Parts" in the following procedure.
4. Connect automatic transmission TV cable assembly
at throttle linkage.
5. Set automatic transmission TV cable assembly as
described in "Setting Automatic Transmission TV
Cable Assembly" in this section.
6. Repeat line pressure checks in "PARK" and
"DRIVE" as described in "Line Pressure Checks"
in this section.
If automatic transmission TV cable assembly
system does not come out of "fail-safe" mode
(pressure remains high), refer to "Inspection
of Automatic Transmission TV Cable Assembly System Parts" in the following procedure.
Inspection of Automatic Transmission TV

Cable Assembly System Parts
- TV exhaust lifter rod is not distorted and not

binding in control valve assembly or spacer
plate.
- TV exhaust check ball moves up and down as
lifter does.
- Lifter spring holds lifter rod up against bottom
of control valve assembly.
- TV plunger does not stick at any position of
travel.
Replace or clean parts as necessary.

ASSEMBLY

1. Air cleaner. Refer to SECTION 6E3-C14.
NOTICE: Do not pry on plastic cable terminal to
disconnect automatic transmission TV cable assembly from throttle lever. Prying on cable terminal may
cause breakage of terminal or kinking of automatic
transmission TV cable assembly. Pull automatic
transmission TV cable assembly toward front of the
vehicle.
2. Cable terminal from throttle lever (831) at throttle
body.
3. TV cable assembly (826) from bracket (830) by
compressing locking tangs.
4. Routing clips or straps, if necessary.
6. Bolt/screw (827) and washer securing TV cable
assembly (826) to automatic transmission assembly.
7. Seal (828) from hole in automatic transmission case,
and discard.
8. TV cable assembly (826) from link (64).

1. New seal (828) into hole in automatic transmission
case.
2. Transmission end of TV cable assembly (826) to
link (64) and to automatic transmission case with
bolt/screw (827) and washer.
l~I Tighten
3.
4.
5.
ILl 1nspect
Throttle lever and automatic transmission TV cable
bracket. Make certain:
6.

Lower vehicle.
Routing clips or straps, if necessary.
Pass TV cable assembly (826) through bracket (830)
and engage locking tangs of TV cable assembly
(826) on bracket (830).
Cable terminal to throttle lever (831) at throttle
body.
11 Adjust
Automatic transmission TV cable assembly.
Refer to "Setting Automatic Transmission TV
Cable Assembly" in the following procedure.
7. Air cleaner. Refer to SECTION 6E3-Cl4.
SETIING AUTOMATIC TRANSMISSION TV

CABLE ASSEMBLY
Figure 12
The automatic transm1ss1on TV cable assembly
must be set by rotating the throttle lever at the throttle
body. Do not use the accelerator pedal assembly to rotate
the throttle lever.
1. Stop engine.
2. Hold down tab (832) at engine end of TV cable
assembly (826).
3. Move slider (834) until it stops against fitting (833).
4. Release tab (832).
5. Rotate throttle lever to "full travel" position.
6. Slider (834) must move (ratchet) toward throttle
lever when throttle lever is rotated to its "full
travel" position.
lll 1nspect
Check that TV cable assembly (826) moves freely.
The TV cable assembly (826) may appear to function properly with engine stopped and cold. Recheck
after engine is hot.
Road test vehicle.
CHANGING TRANSMISSION FLUID AND

AUTOMATIC TRANSMISSION OIL FILTER
ASSEMBLY
Figures 13 and 14
l~+I Remove or Disconnect

1. Raise and suitably support vehicle. Refer to SEC-
2.
3.
4.
5.
lll 1nspect
Fluid color and condition. Refer to Figure 3.
6. Remaining bolts/screws (74), oil pan (73) and gasket
(72).
7. Filter assembly (71) and seal (70).
Seal (70) may be stuck in automatic transmission case.
li,I Clean
Automatic transmission case and gasket surfaces
with solvent, and air dry. All traces of gasket material must be removed.
832
l.
2.
3.
~c
4.
834
A
B
C
826
832
833
834
SLIDER AGAINST FITIING (ZERO OR RESET POSITION)

RESET DIRECTION
DIRECTION OF CABLE ACTUATING LEVER
CABLE ASSEMBLY, AUTOMATIC TRANSMISSION TV
TAB, AUTOMATIC TRANSMISSION TV CABLE RESET
FITIING, AUTOMATIC TRANSMISSION TV CABLE
SLIDER, AUTOMATIC TRANSMISSION TV CABLE
PC0010-7AFRP
Figure 12 - Setting Automatic Transmission TV Cable

Assembly (Part Rotated 90 Degrees)
TION OA.
Place drain pan under oil pan (73).
Bolts/screws (74) from front and sides only.
Loosen rear bolts/screws (74) approximately four
turns.
NOTICE: When removing automatic transmission
oil pan bolts/screws, use caution in order not to damage the automatic transmission case or automatic
transmission oil pan sealing surfaces.
Lightly tap oil pan (73) with rubber mallet or pry to
allow fluid to drain.

Coat new seal (70) with small amount of Transjel
or equivalent.
New seal (70) to filter assembly (71).
Filter assembly (71) and seal (70) into automatic
transmission case.
,
New gasket (72), oil pan (73) and bolts/screws (74).
NOTICE: Automatic transmission oil pan bolt/
screw and washer assembly must not be reused if
conical washer is reversed. Failure to replace the
bolt/screw and washer may result in improper fas
tening of system components.
TM ,
l~I Tighten
5. Lower vehicle.
6. Fill automatic transmission fluid to proper level.
7. Check "COLD" fluid level reading for initial fill
only. Refer to "Transmission Fluid Checking Procedure" in this section.
Do not overfill.

NOTICE: Allow sufficient clearance to transmission oil cooler pipe and hose assemblies to prevent
damage or wear which may cause fluid loss.
!+,.I Remove or Disconnect

1. Fitting on radiator end of oil cooler upper hose
assembly (860).
2. Fitting on radiator end of oil cooler lower hose
assembly (857).
5. Rear axle torque arm assembly. Refer to SECTION
3D.
70 SEAL, AUTO MATIC TRANSMISSION OIL FILTER (0-RING)

71 FILTER ASS EMBLY, AUTOMATIC TRANSMISSION OIL
72 GASKET, AUTOMATIC TRANSMISSION OIL PAN
73 PAN, AUTOMATIC TRANSMISSION OIL
74 BOLT/SCREW, AUTOMATIC TRANSMISSION OIL PAN,
16 Nm (12 LB. FT.)
93 MAGNET, AUTOMATIC TRANSMISSION OIL PAN
PC6010-7A-D.flP
Figure 13 - Automatic Transmission Oil Pan and Automatic

Transmission Oil Filter Assembly
6. Catalytic converter hanger assembly. Refer to SECTION 6F.

7. Support automatic transmission assembly with a
transmission stand.
8. Transmission support member assembly. Refer to
SECTION 10-3.
9. Lower the transmission stand slightly, to allow
access to oil cooler. fittings at the transmission
assembly.
10. Fitting on transmission assembly end of upper pipe
assembly (856).
11. Fitting on transmission assembly end of lower hose
assembly (857).
12. Upper pipe assembly (856) and lower hose assembly
(857) from engine clip (858) and pipe clip (859).
!..+I Install or Connect
A AUTOMATIC TRANSMISSION OIL PAN BOLT/SCREW

AND CONICAL WASHER ASSEMBLY IS REUSABLE
B AUTOMATIC TRANSMISSION OIL PAN BOLT/SCREW
AND CONICAL WASHER ASSEMBLY IS NOT REUSABLE
PC6011-7A-0-RP
Figure 14 - Automatic Transmission Oil Pan Bolt/Screw and

Conical Washer Assembly
NOTICE: See "NOTICE" on page 7A-1 of this

section.
1. Upper pipe assembly (856) and lower hose assembly
(857) to engine clip (858) and pipe clip (859).
2. Fitting on transmission assembly end of lower hose
assembly (857).
l~I
Tighten
Fitting on transmission assembly end of lower
hose assembly (857) to 27 Nm (20 lb. ft.).
3. Fitting on transmission assembly end of upper pipe
assembly (856).
l~I
ILl 1nspect
Gasket (72) for leaks.
AUTOMATIC TRANSMISSION OIL COOLER

UPPER PIPE AND UPPER AND LOWER
HOSE ASSEMBLIES
Figure 15
If replacement of automatic transmission oil cooler
pipe and hose assemblies is required, use only doublewrapped and brazed steel tubing meeting GM specification 123 Mor equivalent. Tubing should be double flared.
4.
5.
6.
7.
8.
Tighten
Fitting on transmission assembly end of upper
pipe assembly (856) to 27 Nm (20 lb. ft.).
Raise the transmission assembly.
Transmission support member assembly. Refer to
SECTION 10-3.
Remove transmission stand.
Catalytic converter hanger assembly. Refer to SECTION 6F.
Rear axle torque arm assembly. Refer to SECTION
3D.
856
859
856
856 PIPE ASSEMBLY, TRANSMISSION OIL COOLER UPPER

857 HOSE ASSEMBLY, TRANSMISSION OIL COOLER
LOWER
858 CLIP, ENGINE
859 CLIP, TRANSMISSION OIL COOLER PIPE
860 HOSE ASSEMBLY, TRANSMISSION OIL COOLER UPPER
862 CLAMP, TRANSMISSION OIL COOLER UPPER HOSE
~59
857
!VIEWA!
PC0011-7AF-RP
Figure 15 - Transmission Oil Cooler Pipe and Hose Assemblies
l 0. Lower vehicle.
11. Fitting on radiator end of oil cooler lower hose
assembly (857).
!~I Tighten
Fitting on radiator end of oil cooler lower hose
assembly (857) to 27 Nm (20 lb. ft.).
12. Fitting on radiator end of oil cooler upper hose
assembly (860).
!~I Tighten
1.
2.
Fitting on radiator end of oil cooler upper hose

assembly (860) to 27 Nm (20 lb. ft.).
OIL COOLER FLUSHING PROCEDURE

Figure 15
Tools Required:
J 35944-A "Transmission" Oil Cooler and
Line Flusher
J 35944-20 Cooler Flushing Fluid
NOTICE: The automatic transmission oil cooler
flushing procedure must be performed whenever a
transmission assembly is removed for service to
remove existing oil which may be contaminated and
to prevent contamination of new oil. The flushing
procedure must be performed before installation of
the overhauled or replacement transmission assembly.
3.
4.
5.
6.
NOTICE: Flushing tool is designed for use with

only J 35944-20 flushing fluid. Use of any other
fluid can result in damage to the tool, automatic
transmission oil cooler components or improper
flushing of the cooler.
Remove fill cap on J 35944-A and fill with 0.6 liters
(20 to 21 ounces) of J 35944-20.
Do not overfill tool.
Follow manufacturer's suggested procedures
for handling fluid.
Replace cap on J 35944-A and pressurize to 550 to
700 kPa (80 to 100 psi).
NOTICE: Shop air supply must be equipped with a
water/oil filter and pressure should not exceed 825
kPa (120 psi). Failure to use a water/oil filter can
allow residual moisture to cause corrosion of components. Excessive air pressure can cause damage to
components.
Install J 35944-A to undercarriage of vehicle with
hook provided, and attach hose from flushing tool to
upper pipe assembly (856) attaching to top fitting at
transmission assembly end of oil cooler.
Install discharge hose to lower hose assembly (857)
attaching to bottom fitting at transmission assembly
end of oil cooler. Clip opposite end of discharge
hose to oil drain container.
With water valve on tool in "OFF" position, attach
water supply to J 35944-A.
Turn water supply on at faucet.

7. Flush transmission fluid by opening water valve on
tool to "ON" position for about 10 seconds.
If water does not flow through cooler (system
is completely plugged), do not complete flushing procedure. Turn water off immediately and
inspect oil cooler and pipes for restriction.
Replace cooler and/or pipes as required.
8. Turn water valve on tool to "OFF" position and clip

discharge hose to 5-gallon pail. Cover pail with shop
cloth to prevent splash.
9. Turn water valve on tool to "ON" position and
depress trigger to mix flushing fluid into water flow.
Use bale clip to hold trigger down.
10. Flush oil cooler with water and fluid for two minutes.
Every 15 to 20 seconds during flushing procedure, attach air supply to air valve on
J 35944-A and leave in place for 3 to 5 seconds
to create surging action for complete cleaning.
ll..'l'I Inspect
A. Fluid flow through cooler feed lines during 30
second running period. Minimum of 1.8 liters
(2 quarts) of fluid should flow during this time.
B. If fluid flow is insufficient, check flow by disconnecting feed line at cooler and observe flow
with engine running at idle.
Insufficient Flow: Inspect transmission
for causes.
Sufficient Flow: Inspect cooler pipes,
hoses and fittings and repeat cooler flushing procedure. If the flow through cooler
is still insufficient after second flushing
procedure, replace cooler.
25. Disconnect discharge hose.
26. Connect oil cooler return pipe to fitting.
[el Adjust
Transmission fluid level.
11. Release trigger and turn water valve on tool to

"OFF" position.
12. Disconnect discharge hose from lower hose assembly (857).
13. Install hose from J 35944-A to lower hose assembly
(857) attaching to bottom fitting of oil cooler.
14. Connect discharge hose to upper pipe assembly
(856) attaching to top fitting of oil cooler.
Reversing hoses creates back-flush.
15. Repeat steps 9 and 10.
16. Release trigger and allow water only to rinse the oil
cooler for one minute.
17. Turn water valve on tool to "OFF" position and turn
water supply off at faucet.
18. Attach air supply to air valve on J 35944-A and dry
system out with dry compressed air for at least two
minutes. Be sure no moisture can be seen leaving
hose.
19. Remove J 35944-A and discharge hose from oil
cooler/hoses.
SERVICEABLE COMPONENTS
TRANSMISSION FLUID FILLER TUBE
ASSEMBLY
Figure 16

1. Indicator assembly (837).
3. Bolt/screw (835) retaining tube assembly (836) to
transmission assembly (838).
4. Loosen tube assembly (836) from transmission
assembly (838).
5. Place drain pan under transmission assembly (838).
6. Lower vehicle.
7. Tube assembly (836) and seal (901) from vehicle by
pulling out from top.
20. Connect oil cooler feed hose to automatic transmission assembly.

Feed hose is lower hose assembly (857)
attached to bottom connection at transmission
end of system.
21. Attach discharge hose to oil cooler return pipe.
I.
2.
3_.
Return pipe is upper pipe assembly (856)

attached to top connection at transmission end
of system.
4.
22. Attach opposite end of discharge hose to oil drain

container.
5.
23. Fill automatic transmission assembly with fluid.

24. Start engine and run for 30 seconds to remove any
residual moisture from cooler.

Seal (901) and tube assembly (836) through top of
vehicle.
Insert seal (901) into automatic transmission case
hole.
Tube assembly (836) to transmission assembly
(838).
Bolt/screw (835) attaching tube assembly (836) to
l~I Tighten
lVIEWA
835
A
B
835
836
837
838
901
5.7L LT1 ENGINE

3.4L L32 ENGINE
BOLT/SCREW, TRANSMISSION
TUBE ASSEMBLY, TRANSMISSION FLUID FILLER
INDICATOR ASSEMBLY, TRANSMISSION FLUID LEVEL
SEAL, TRANSMISSION FLUID FILLER TUBE
835
!VIEWS
PC0012-7A-F-RP
Figure 16 - Transmission Fluid Filler Tube and Transmission Fluid Level Indicator Assemblies
6. Lower vehicle.
7. Indicator assembly (837).
VEHICLE SPEED SENSOR (VSS) AND

SPEEDOMETER DRIVEN GEAR
l~I Tighten
3. Electrical connector to sensor (99).
4. Lower vehicle.
Figure 17
10
44
2. Electrical connector from sensor (99).

3. Bolt/screw ( 100).
4. Sensor (99) and gear (44) from automatic transmission case (10).
Separate sensor (99) and gear (44).
ll'l'I
Inspect
Seal (42) and automatic transm1ss10n case (10).

Replace seal (42) if necessary.

1. Sensor (99) to gear (44 ), and then to automatic transmission case (10).
-~
42
100
10 CASE, AUTOMATIC TRANSMISSION
42 SEAL, VEHICLE SPEED SENSOR, (0-RING)
44 GEAR, SPEEDOMETER DRIVEN
99 SENSOR, VEHICLE SPEED
100 BOLT/SCREW, VEHICLE SPEED SENSOR RETAINING,
10 Nm (89 LB. IN.)
PC60147A-0-RP
Figure 17 - Vehicle Speed Sensor and Speedometer

Driven Gear
SPEEDOMETER DRIVE GEAR AND

AUTOMATIC TRANSMISSION CASE
EXTENSION
Figure 18

30.
5. Vehicle speed sensor and speedometer driven gear.
Refer to "Vehicle Speed Sensor (VSS) and
Speedometer Driven Gear" in the previous procedure.
7. Extension (36), with seal (35). Discard seal (35).
8. Sleeve (690) and seal (691), if necessary.
9. Drive gear (689) and clip (688).
ll'l'I Inspect
Speedometer drive gear. Refer to SECTION
7A-15B for disassembly and inspection procedures.

1.
2.
3.
4.

Drive gear (689) and clip (688).
Sleeve (690) and seal (691 ), if removed.
New Seal (35) and extension (36).
Bolts/screws (37).
l~I Tighten
5.
6.
7.
8.
9.

Vehicle speed sensor and speedometer driven gear.
Refer to "Vehicle Speed Sensor (VSS) and
Speedometer Driven Gear" in the previous procedure.
30.
Propeller shaft assembly. Refer to SECTION 4A.
Lower vehicle.
GOVERNOR ASSEMBLY
Figure 19

10
35
36
37
39
45
46
687
688
689
690
691
CASE, AUTOMATIC TRANSMISSION

SEAL, AUTOMATIC TRANSMISSION CASE EXTENSION
EXTENSION, AUTOMATIC TRANSMISSION CASE
BOLT/SCREW, AUTOMATIC TRANSMISSION CASE
EXTENSION, 35 Nm (26 LB. FT.)
SEAL ASSEMBLY, CASE EXTENSION OIL
GOVERNOR ASSEMBLY
COVER, GOVERNOR
SHAFT, OUTPUT
CLIP, SPEEDOMETER DRIVE GEAR
GEAR, SPEEDOMETER DRIVE
SLEEVE, OUTPUT SHAFT
} NOT USED ON
SEAL, OUTPUT SHAFT SLEEVE. ALL MODELS
PC0013-7AfRP
Figure 18 - Speedomete'r Drive Gear and Automatic

Transmission Case Extension

30.
5. Support automatic transmission assembly with a
transmission stand.
SECTION 10-3.
7. Lower the transmission stand slightly, to allow
access to governor assembly.
8. Cover (46).
A. Tap around cover flange with punch to remove.
B. Do not damage cover (46).
9. Governor assembly (45) from governor bore.
!l'l'I Inspect
Governor assembly (45).

1. Governor assembly (45) into governor bore.
2. Cover (46).
Apply sealant, such as Loctite Cup Plug Sealant II, or equivalent, to cover flange before
installing cover (46).
3. Raise transmission assembly.
~FRT
A APPLY SEALANT ON THIS FLANGE BEFORE

INSTALLATION
45 GOVERNOR ASSEMBLY
46 COVER,GOVERNOR
PC0014-7AfRP
Figure 19 - Governor Cover

SECTION 10-3.
63
59
60
61
62
63
30.
8. Remove transmission stand.
9. Lower vehicle.
11 Adjust
ACCUMULATOR ASSEMBLY
PC6019-7A-D-RP
Figure 20 - 1-2 Accumulator Assembly
If spring (59) is conical in shape, larger end is

installed in piston (61 ).
2. Cover and pin assembly (62).
3. Bolts/screws (63) attaching cover and pin assembly
(62) to transmission case.
l~I Tighten
Figure20

1. Automatic transmission oil pan and automatic transmission oil filter assembly. Refer to "Changing
Transmission Fluid and Automatic Transmission Oil
Filter Assembly" in this section.
2. Bolts/screws (63) attaching cover and pin assembly
(62) to transmission case.
3. Cover and pin assembly (62).
4. Piston (61), ring (60), and spring (59).
Piston (61) and ring (60) may remain inside
cover and pin assembly (62).
ll'l'I Inspect
Accumulator assembly. Refer to SECTION 7A-15B
for disassembly and inspection procedures.

1. Spring (59), ring (60), and piston (61 ).
SPRING, 12 ACCUMULATOR
RING, OIL SEAL ( 1-2 ACCUMULATOR PISTON)
PISTON, 1-2 ACCUMULATOR
COVER AND PIN ASSEMBLY, 1-2ACCUMULATOR
BOLT/SCREW, 1-2ACCUMULATORCOVER
11 Nm (97 LB. IN.)

2-4 BAND SERVO ASSEMBLY

Figures 21 and 22

1.
2.
3.
4.
Tool Required:
J 29714-A Servo Cover Depressor
Exhaust crossover pipe assembly and catalytic converter hanger assembly. Refer to SECTION 6F.
30.
5. Support automatic transmission assembly with
transmission stand.

6. Transmission support. Refer to SECTION 10-3.
7. Catalytic converter heat shield. Refer to SECTION
6F.
8. Lower automatic transmission assembly.
9. Two automatic transmission oil pan bolts/screws
from below servo cover ( 15).
10. Install J 29714-A on automatic transmission oil pan
rail.
11. Reinstall automatic transmission oil pan bolts/
screws.
12. Depress servo cover (15) and remove retaining ring
(13).
13. J 29714-A.
14. Servo cover ( 15).
If unable to remove by hand, use slip joint pliers.
0-ring seal may remain in automatic transmission case.
15. 2-4 band servo assembly (16).
!l'l'I
Inspect
15 COVER, 2-4 BAND SERVO

16 SERVO ASSEMBLY, 2-4 BAND
PC6018-7A-D-RP
Figure 22 - 2-4 Band Servo Assembly
4. Depress servo cover ( 15).

6. Remove J 29714-A.
2-4 band servo assembly. Refer to SECTION

7A-15B for disassembly and inspection procedures.
!~I
!++I Install or Co~nect

section.
1. 2-4 band servo assembly (16).
2. Servo cover ( 15).
Replace 0-ring seal on servo cover ( 15).
3. Install J 29714-A on automatic transmission oil pan
rail.
7.
8.
9.
10.
11.
12.
i3.
14.
Tighten
Automatic transmission oil pan bolts/screws to

16 Nm (12 lb. ft.).
Raise automatic transmission assembly.
Catalytic converter heat shield. Refer to SECTION
6F.
Transmission support. Refer to SECTION 10-3.
Remove tool supporting automatic transmission
assembly.
3D.
Exhaust crossover pipe assembly and catalytic converter hanger assembly. Refer to SECTION 6F.
Lower vehicle.
TRANSMISSION CONVERTER COVER

Figure23

2. Converter cover bolts/screws (840).
3. Converter cover (839) from automatic transmission
assembly (838).

13 RING, 2-4 BAND SERVO COVER RETAINING
15 COVER, 2-4 BAND SERVO
PC601 7 -7AD-RP
Figure 21 - 2-4 Band Servo Cover
NOTICE: See "Notice" on page 7A-l of this

section.
1. Converter cover (839) to automatic transmission
assembly (838).
2. Converter cover bolts/screws (840).
217
u----218
lliii---- 219
,\----220
t=::
@
840
838 TRANSMISSION ASSEMBLY, AUTOMATIC
839 COVER, TRANSMISSION CONVERTER
840 BOLT/SCREW, TRANSMISSION CONVERTER COVER,
10 Nm (89 LB. IN.)
224
217
218
219
220
221
222
PUMP ASSEMBLY, AUTOMATIC TRANSMISSION OIL

VALVE, PRESSURE REGULATOR
SPRING, PRESSURE REGULATOR VALVE
VALVE, REVERSE BOOST
BUSHING, REVERSE BOOST VALVE
VALVE, TV BOOST
223 BUSHING, TV BOOST VALVE
224 RING, TV BOOST VALVE BUSHING RETAINER
__ _J>C0019-7 A-F-RP
PC0018-7A-F-RP
Figure 23 - Transmission Converter Cover
!~I Tighten
Transmission converter cover bolts/screws
(840) to 10 Nm (89 lb. in.).
3. Lower vehicle.
Figure 24 - Pressure Regulator Valve Assembly

1. Regulator valve (218) into pump cover bore.
2. Spring (219).
3. Reverse boost valve (220) into bushing (221 ).
Small end first. Retain with Transjel
or
equivalent.
4. Bushing (221) with reverse boost valve (220) into
pump cover bore.
5. TV boost valve (222) into bushing (223).
Insert long land of TV boost valve (222) into
largest hole of bushing (223). Retain with
Transjel or equivalent.
6. Bushing (223) with TV boost valve (222) into pump
cover bore.
7. Compress TV boost valve bushing and related components (223 through 218).
8. Retainer ring (224).
9. Automatic Transmission oil pan. Refer to "Changing Transmission Fluid and Automatic Transmission
Oil Filter Assembly" in this section.
TM ,
PRESSURE REGULATOR VALVE

Figure24

1. Automatic transmission oil pan. Refer to "Changing
2. Compress TV boost valve bushing and related components (223 through 218) with small screwdriver.
4. Slowly release spring pressure.
5. Regulator valve (218).
6. Spring (219).
7. Reverse boost valve (220) and bushing (221).
8. TV boost valve (222) and bushing (223).
ll'l'I
TM,
AUXILIARY VALVE BODY ASSEMBLY

Figure25
Inspect
Pressure regulator valve assembly. Refer to SECTION 7A-15B for disassembly and inspection procedures.

A WASHER, WIRE RETAINING

B CONNECTOR, ELECTRICAL
96 TUBE, AUTOMATIC TRANSMISSION REAR CLUTCH
ACCUMULATOR
97 RETAINER. AUXILIARY CONTROL VALVE BODY TUBE
374 BOLT (M6X1X16), SPECIAL HEX WASHER HEAD,
11 Nm (97 LB. IN.)
375 BOLT (M6X1X35), HEX HEAD, 11 Nm (97 LB. IN.)
376 BOLT (M6X1X45), HEX HEAD, 11 Nm (97 LB. IN.)
377 BODY, AUXILIARY VALVE
710 BRACKET, PARKING PAWL ACTUATOR
715 BOLT, PARKING LOCK BRACKET
PC6021-7AD-RP
Figure 25 - Auxiliary Valve Body Assembly
2.
3.
4.
5.
6.
7.
ll'l'I

Two bolts (M6xlx45) (376) attaching accumulator
tube (96) to control valve assembly and auxiliary
valve body (377).
Two retainers (97).
Accumulator tube (96).
Gently pry loose from transmission oil pump
assembly first, then from auxiliary valve body
(377).
Two bolts (M6xlx35) (375) and bolt (M6xlxl6)
(374) attaching auxiliary valve body (377) to transmission case.
Auxiliary valve body (377).
Number 12 check ball.
Number 12 check ball may be retained within
auxiliary valve body (377) or on control valve
body spacer plate gasket.
Inspect
Auxiliary valve body. Refer to SECTION 7A-15B

for disassembly and inspection procedures.

NOTICE: See "Notice" on page 7A-l of this section.
1. Number 12 check ball in auxiliary valve body (377).
If necessary, use Transjel , or equivalent to
hold in place.
2. Auxiliary valve body (377).
3. Two bolts (M6xlx35) (375) and bolt (M6xlx16)
(374) attaching auxiliary valve body (377) to transmission case.
l~I
Tighten
Bolts (M6xlx35) (375) and bolt (M6xlxl6)
(374) to 11 Nm (97 lb. in.).
4. Accumulator tube (96).
Lightly tap into auxiliary valve body (377)
first, then into transmission oil pump assembly.
6. Bolts (M6xlx45) (376) attaching accumulator tube
(96) to control valve assembly and auxiliary valve
body (377).
!~I
Tighten
Bolts (M6xlx45) (376) to 11 Nm (97 lb. In.).

CONTROL VALVE ASSEMBLY


1. TV cable assembly from throttle lever. Refer to
"Automatic Transmission TV Cable Assembly" in
this section.
3. Two bolts (M6xlx45) (376) attaching accumulator
tube (96) to control valve assembly (67) and auxiliary valve body (377).
~~_J
51~
56
55A
558
55C
91
359
377
BALL, #2 CHECK (3RD CLUTCH ACCUMULATOR)

BALL, #12 CHECK (FORWARD CLUTCH)
BALL, #6 CHECK (DRIVE 3)
BALL, #10 CHECK (TV EXHAUST) (COPPER FLASH)
CUP PLUG, ORIFICE
BODY, AUXILIARY VALVE
PC00217AFRP
Figure 27 - Control Valve Body Check Balls
A CONNECTOR, ELECTRICAL
34 SEAL, AUTOMATIC TRANSMISSION WIRING
CONNECTOR (0-RING)
49 SEAL, CONVERTER CLUTCH SOLENOID VALVE (0-RING)
50 VALVE ASSEMBLY, CONVERTER CLUTCH SOLENOID
51 BOLT/SCREW, CONVERTER CLUTCH SOLENOID VALVE,
11 Nm (97 LB. IN.)
56 PLATE, VALVE BODY SPACER
67 VALVE ASSEMBLY, CONTROL
70 SEAL, AUTOMATIC TRANSMISSION OIL FILTER
(0-RING)
71 FILTER ASSEMBLY, AUTOMATIC TRANSMISSION OIL
72 GASKET, AUTOMATIC TRANSMISSION OIL PAN
73 PAN, AUTOMATIC TRANSMISSION OIL
74 BOLT/SCREW, AUTOMATIC TRANSMISSION OIL PAN,
16 Nm (12 LB. FT.)
88 GASKET, SPACER PLATE-TO-CASE
89 GASKET, SPACER PLATE-TO-VALVE BODY
93 MAGNET, AUTOMATIC TRANSMISSION OIL PAN
96 TUBE, AUTOMATIC TRANSMISSION REAR CLUTCH
ACCUMULATOR
377 BODY, AUXILIARY VALVE
PC00207 AFRP
Figure 26 -Automatic Transmission Case and Attaching Parts
47A SCREEN ASSEMBLY, GOVERNOR OIL

478 SCREEN ASSEMBLY, CONVERTER CLUTCH SOLENOID
VALVE
55E BALL (3-4 CLUTCH/3-2 EX.), #4 CHECK
55F BALL (2ND/1-2). #8 CHECK
55G BALL (4TH ACCUMULATOR), #1 CHECK
55H BALL (PART THROTTLE/DRIVE 3), #3 CHECK
106 RETAINER AND BALL ASSEMBLY, DOUBLE ORIFICE
PC6027-7A-DRP
Figure 28 - Transmission Case Check Balls and Filters
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
Bolts (M6x 1x45) (376) are painted yellow for

identification.
Two retainers (97).
Gently pry loose from oil pump assembly first,
then from auxiliary valve body (377).
Bolt/screw attaching clip (66).
Solenoid wire harness connectors from pressure
switch and temperature switch.
Bolt/screw attaching temperature switch to control
valve assembly (67).
Temperature switch.
Loosen bolt/screw attaching wire retainer washer to
control valve assembly (67).
Solenoid wire harness connector from transmission
wiring electrical connector assembly.
A. Gently pry back locking tabs.
B. Allow harness to be suspended from solenoid
Bolt/screw (75).
Manual shift detent assembly (709).
Bolts/screws (69) attaching TV lever assembly (65)
to control valve assembly (67).
TV Lever assembly (65).
Link (64).
Loosen remaining bolts/screws (69) completely.
Bolts/screws (69) should remain in control
valve assembly (67) to aid in reassembly.
Manual valve link assembly (705).
Pick up control valve assembly (67) while
holding manual valve link assembly (705) and
rotate control valve assembly (67) to disconnect manual valve link assembly (705) from
manual valve (340).
19. Control valve assembly (67).

20. Numbers 2, 6 and 10 check balls (55A, 55C, and 91).
May be retained within control valve assembly
(67) or gasket (89).
l~I
Clean
Control valve assembly components.
lll
1nspect
Control valve assembly. Refer to SECTION 7A-15B

for disassembly and inspection.

NOTICE: See "Notice" on page 7 A-1 of this section.
1. Numbers 2, 6 and 10 check balls (55A, 55C and 91)
into control valve assembly (67).
2.
3.
4.
5.
6.
7.
Use Transjel , or equivalent, to hold in place.

Manual valve link assembly (705).
Rotate control valve assembly (67) while holding manual valve link assembly (705) to install
manual valve link assembly (705) to manual
valve (340).
Position over gasket (89) and raise into place.
Tighten any bolts/screws (69) left in control valve
assembly (67), finger tight only, at this time.
Link (64).
TV lever assembly (65) and bracket.
Bolts/screws (69) attaching TV lever assembly (65)
to control valve assembly (67).
Finger tighten only, at this time.
75
A RETAINER, WASHER WIRE

50 VALVE ASSEMBLY, CONVERTER CLUTCH SOLENOID
51 BOLT/SCREW, CONVERTER CLUTCH SOLENOID VALVE,
11 Nm (97 LB. IN.)
63 BOLT/SCREW, 1-2 ACCUMULATOR COVER, 11 Nm
(97 LB. IN.)
66 CLIP, AUTOMATIC TRANSMISSION ELECTRICAL WIRING
69 BOLT/SCREW, CONTROL VALVE BODY, 11 Nm (97 LB. IN.)
75 BOLT/SCREW, MANUAL SHIFT DETENT, 22 Nm
(16 LB. FT.)
92 CONDUIT, AUTOMATIC TRANSMISSION WIRING
97 RETAINER, AUXILIARY CONTROL VALVE BODY TUBE
374 BOLT (M6 x 1 x 16), SPECIAL HEX WASHER HEAD,
63
11 Nm (97 LB. IN.)
375 SOLT (M6 x 1 x 35), HEX HEAD, 11 Nm (97 LB. IN.)
376 BOLT (M6 x 1 x 45l.. HEX HEAD, 11 Nm (97 LB. IN.)
51
69
PC6025 7ADRP
Figure 29 - Control Valve Body Bolt Screw Locations

8. Manual shift detent assembly (709).
9. Bolt/screw (75).
!~I
l 0.
11.
12.
13.
14.
15.
16.
17.
18.
Tighten
703

Solenoid wire harness connector to tra)lsmission
wiring electrical connector assembly.
Temperature switch.
Tighten bolt.screw attaching wire retainer washer to
control valve assembly (67), finger tight only.
Place conduit (92) beneath washer before
tightening.
Bolt/screw attaching temperature switch to control
Finger tight only, at this time.
Solenoid wire harness connectors to pressure switch
and temperature switch.
The wire connectors are color coded to correspond to the information in the wiring diagram. On switches which take two connectors,
the terminals are reversible. To correctly route
and install the wire connectors, refer to SECTION 7A-15A.
Bolt/screw attaching clip (66).
Lightly tap into auxiliary valve body (377)
first, then into oil pump assembly.
Two retainers (97).
Two bolts (M6x l x45) (376) attaching accumulator
tube (96) to control valve assembly (67) and auxiliary valve body (377).
--T
709
340
340
703
705
709
VALVE, MANUAL
LEVER, MANUAL SHIFT DETENT
LINK ASSEMBLY, MANUAL VALVE
DETENT ASS EMBLY, MANUAL SHIFT
PC6023-7 A-D-RP
Figure 31 - Manual Shift Detent Assembly
NOTICE: Torque auxiliary valve body cover bolts/

screws in a spiral pattern starting from the center. If
auxiliary valve body cover bolts/screws are torqued
at random, auxiliary valve bores may be distorted
and inhibit auxiliary valve operation.
l~I
Tighten
Bolts/screws (69) and bolts (M6xlx45) (376)

to 11 Nm (97 lb. in.).
20. Automatic transmission TV cable assembly at
throttle lever.
21. Set automatic transmission TV cable assembly.
11
Adjust
Automatic transmission fluid level.
CONVERTER CLUTCH SOLENOID VALVE

ASSEMBLY AND WIRING HARNESS
REPLACEMENT
Figures 26 and 29
l++I
64 LINK, TV CABLE
65 LEVER ASSEMBLY, TV
69 BOLT/SCREW, CONTROL VALVE BODY,
11 Nm (97 LB. IN.)
PC6024- 1 A-D-RP
Figure 30 - TV Lever Assembly
2. Bolt/screw attaching clip (66) to control valve
assembly (67).
7A30 AUTOMATIC TRANSMISSION ON-VEHICLE SERVICE

3. Loosen bolt/screw attaching wire retainer washer to
control valve assembly (67).
4. Solenoid wire harness connectors from pressure
switch and temperature switch.
5. Solenoid wire harness connector from transmission
wiring electrical connector.
Gently pry back locking tabs.
6. Conduit (92).
7. Two bolts/screws (51).
8. Solenoid valve assembly (50) and seal (49) from

ILl
1nspect
ELECTRICAL CONNECTOR AND SEAL

Figure26

1. Oil pan and automatic transmission oil filter assembly. Refer to "Changing Transmission and Automatic Transmission Oil Filter Assembly" in this
section.
2. Internal and external electrical wires from electrical
connections.
3. Electrical connector and seal (34) from automatic
4. Seal (34) from electrical connector.
Discard old seal (34).
Converter clutch solenoid valve assembly and converter clutch solenoid valve seal. Refer to SECTION
7A-15A for inspection procedures.

1. Seal (49) and solenoid valve assembly (50) into
2. Two bolts/screws (51)
l~I Tighten
Bolts/screws (51) to 11 N m (97 lb. in.).
ll.l
1nspect
Automatic transm1ss1on sealing surface for

damage or corrosion.

1. New seal (34) to electrical connector.
2. Electrical connector and new seal (34) to automatic
3. Internal and external electrical wires to electrical
connectors.
4. Oil pan and automatic transmission oil filter assembly. Refer to "Transmission Fluid and Automatic
Transmission Oil Filter Assembly" in this section.
3. Conduit (92).
Slide into place under wire retainer washer.
4. Solenoid wire harness connector to transmission
wiring electrical connector.
5. Solenoid wire harness connectors to pressure switch
and temperature switch.
Solenoid wire harness connectors are color
coded to correspond to information in wiring
diagram. On switches which take two solenoid
wire harness connectors, the terminals are
reversible. To correctly route and install solenoid wire harness connectors, refer to SECTION 7A-15A.
l~I Tighten
Solenoid wire harness retainer washer-to-control valve assembly bolt/screw to 11 Nm
(97 lb. in.).
6. Bolt/screw attaching clip (66) to control valve
assembly (67).
l~I Tighten
Bolt/screw to 11 Nm (97 lb. in.).
7. Automatic Transmission oil pan and automatic
transmission oil filter assembly. Refer to "Changing
CASE EXTENSION OIL SEAL ASSEMBLY

Figure 18
Tool Required:
J 21426 Output Shaft Sleeve and Case Extension Oil Seal Installer

2. Oil seal assembly (39) with screwdriver.

1. Oil seal assembly (39). Tap into place with J 21426.
Adjust
Automatic transmission fluid level.
AUTOMATIC TRANSMISSION ASSEMBLY

REMOVAL AND INSTALLATION
A pressure test should be performed before automatic transmission assembly removal to aid in diagnosis.
NOTICE: Transmission oil cooler flushing must be
performed when an automatic transmission assembly is removed for service. The flushing procedure

should be performed after the installation of the
overhauled or replacement assembly. Failure to
flush the system may cause damage to the system
and its components.
l.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
Tool Required:
J 21426 Output Shaft Sleeve and Case Extension Oil Seal Installer
Automatic transmission TV cable assembly at
throttle lever.
Mark position of propeller shaft assembly to pinion
yoke.
Support transmission assembly (838).
Washer (853) and nut (852) from support (850) and
Bolts/screws (854) from support (850) and rail
assembly (846).
Support (850) from transmission assembly (838)
and rail assembly (846).
Rear axle torque arm. Refer to SECTION 30.
Bolts/screws (840) from cover (839).
Cover (839) from transmission assembly (838).
Bolts/screws (842) from converter assembly (1).
Flywheel assembly (841) from converter assembly
1 CONVERTER ASSEMBLY, TORQUE

842 BOLT/SCREW, TRANSMISSION TORQUE CONVERTER,
63 Nm (46 LB. FT.)
PC00227 AFRP
Figure 32 - Torque Converter Assembly-to-Flywheel

Assembly
l. Raise transmission assembly (838) into vehicle.

2. Transmission oil cooler lines.
3. Automatic transmission TV cable assembly a[ transmission assembly (838).
4. Align transmission assembly (838) to engine block.
5. Transmission fluid level indicator assembly.
6. Bolts/screws (843 or 845).
846
(1).
16. Move catalytic converter heat shield as necessary.

18. Transmission oil cooler pipe assemblies from transmission oil cooler pipe clips.
19. Electrical connectors at transmission assembly
(838).
20. Bolts/screws (843 or 845).
21. Transmission fluid level indicator assembly.
22. Separate transmission assembly (838) from engine
block.
23. Automatic transmission TV cable assembly at transmission assembly (838).
24. Transmission oil cooler lines.
25. Lower transmission assembly (838) from vehicle.

~ ...
838
846
850
852
853
854

RAIL ASSEMBLY, ENGINE COMPARTMENT INNER SIDE
SUPPORT, TRANSMISSION
NUT, TRANSMISSION MOUNT, 47 Nm (35 LB. FT.)
WASHER, TRANSMISSION MOUNT
BOLT/SCREW, TRANSMISSION SUPPORT
PC0023-7A-F-RP
Figure 33 - Automatic Transmission Assembly Mounting
l~I
7.
8.
9.
10.
11.
12.
845
Tighten

Electrical connectors to transmission assembly
(838).
Transmission oil cooler pipe and hose assemblies to
transmission oil cooler pipe clips.
Automatic transmission range selector lever cable
Reposition catalytic converter heat shield. Refer to
SECTION 6F.
Flywheel assembly (841) to converter assembly (I).
Bolts/screws (842) to converter assembly (1).
l~I
Tighten

13. Converter cover (839) to transmission assembly
(838).
14. Bolts/screws (840) to cover (839).
l~I
Tighten

16. Rear axle torque arm. Refer to SECTION 3D.
17. Support (850) to transmission assembly (838) and
rail assembly (846).
18. Bolts/screws (854) to support (850) and rail assembly (846).

844 ENGINE ASSEMBLY
845 BOLT/SCREW, TRANSMISSION, 95 Nm (70 LB. FT.)
PC00257A-FRP
Figure 35 - Automatic Transmission Assembly-to-Engine

19. Washer (853) and nut (852) to support (850) and

l~I
20.
21.
22.
23.
24.
843
Tighten
Nut (852) to 47 Nm (35 lb. ft.).

Remove support from transmission assembly (838).
Propeller shaft assembly, using marks made during
removal. Refer to SECTION 4A.
Lower vehicle.
Automatic transmission TV cable assembly at
throttle lever.
15!1 Clean
NOTICE: Transmission oil cooler flushing must be
performed when a transmission assembly is
removed for service. The flushing procedure should
be performed after the installation of the overhauled
or replacement assembly. Failure to flush the system
may cause damage to the system and its components.
Transmission oil cooler and oil cooler pipe and hose
assemblies. Refer to "Oil Cooler Flushing Procedure" in this section.
11 Adjust
844 ENGINE ASSEMBLY
PC0024-7A-F-RP
Figure 34 - Automatic Transmission Assembly-to-Engine

Assembly (5.7 LT1 Engine)
Automatic transm1ss10n shift control lever cable

Set automatic transmission TV cable assembly.
SPECIFICATIONS
Automatic Transmission Case Extension Bolt/Screw ....................... 35 Nm (26 lb. ft.)
Automatic Transmission Control Bolt/Screw ............................. 4.5 Nm (40 lb. in.)
Automatic Transmission Oil Cooler Pipe and Hose Assembly Fittings .......... 27 Nm (20 lb. ft.)
Automatic Transmission Oil Pan Bolt/Screw .............................. 16 Nm (12 lb. ft.)
Automatic Transmission Range Selector Lever Cable Bracket Bolt/Screw ....... 24 Nm (18 lb. ft.)
Automatic Transmission Range S.elector Lever Nut ......................... 20 Nm (15 lb. ft.)
Automatic Transmission TV Cable Bolt/Screw ............................ 10 Nm (89 lb. in.)
Control Valve Body Bolt/Screw ........................................ 11 Nm (97 lb. in.)
Converter Clutch Solenoid Valve Bolt/Screw .............................. 11 Nm (97 lb. in.)
Flywheel Bolt/Screw ................................................. 63 Nm (46 lb. ft.)
Hex Head Bolt (M6X1X35) ........................................... 11 Nm (97 lb. in.)
Hex Head Bolt (M6X1X45) ........................................... 11 Nm (97 lb. in.)
Manual Shift Detent Bolt/Screw ........................................ 22 Nm (16 lb. ft.)
1-2 Accumulator Cover Bolt/Screw ..................................... 11 Nm (97 lb. in.)
Park/Neutral Position Switch Bolt/Screw ................................ 2.2 Nm (19 lb. in.)
Special Hex Washer Head Bolt (M6X1Xl6) .............................. 11 Nm (97 lb. in.)
Transmission Bolt/Screw (3.4L L32 Engine) .............................. 95 Nm (70 lb. ft.)
Transmission Bolt/Screw (5.7L LTl Engine) .............................. 47 Nm (35 lb. ft.)
Transmission Converter Cover Bolt/Screw ............................... 10 Nm (89 lb. in.)
Transmission Mount Nut .............................................. 47 Nm (35 lb. ft.)
Transmission Torque Converter Bolt/Screw ............................... 63 Nm (46 lb. ft.)
Vehicle Speed Sensor Retaining Bolt/Screw .............................. 10 Nm (89 lb. in.)
SPEEDOMETER GEAR CHART
TIRE SIZE
P235/55R16
P245/50ZR 16
P215/60R16
P215/60HR16
P235/55R16
P245/50ZR16
DRIVEN GEAR
DRIVE GEAR
AXLE
RATIO
COLOR
TEETH
COLOR
TEETH
2.73
RED
37
RED
17
3.23
BROWN
BROWN
BROWN
DARK GREY
18
18
18
44
PURPLE
PURPLE
PURPLE
RED
7
7
7
17
PC0026-7 AFRP
SPECIAL TOOLS
1.
2.
3.
J 21426
~
~
J29714-A
5.
J 35944-20
1. CONVERTER HOLDING STRAP

2. OUTPUT SHAFT SLEEVE AND CASE EXTENSION OIL
SEAL INSTALLER
3. SERVO COVER DEPRESSOR
4. OIL COOLER AND LINE FLUSHER "TRANSMISSION"
5. COOLER FLUSHING FLUID
PC00277AFRP
4L60 AUTOMATIC TRANSMISSION DIAGNOSIS
7A-15A-1
SECTION/HVDRA-MATIC 4L60
AUTOMATIC TRANSMISSION DIAGNOSIS

RPO MD8
CONTENTS
General Description ................................... 7A-15A-1
Diagnosis Information ............................... 7 A-15A-l
Road Test Procedure ............................... 7A-15A-l
Shift Speed Charts .................................. 7A-15A-3
Diagnosis ............................................ 7A-15A-4
Line Pressure Check ............................... 7A-15A-4
GENERAL DESCRIPTION
Figure 1
The HYDRA-MATIC 4L60 is a fully automatic

transmission for rear wheel drive vehicles which
provides four forward gear ranges and a reverse.
Torque Converter Evaluation ................. 7A-15A-4

Line Pressure Check Procedure ............. 7A-15A-6
Clutch Application Chart ........................ 7A-15A-7
Diagnosis Charts ..................................... 7A-15A-8
Fluid Flow and Circuit Description ..... 7A-15A-18
Electrical Wiring Diagrams .................. 7A-15A-42
Fluid Passages ...................................... 7A-15A-45
The major components of this transmission are:
Torque Converter Clutch Asm.
Vane Type Pump
2-4 Band Asm.
Five Multiple Disc Clutches
Two Planetary Gear Sets
One Sprag Clutch
One Roller Clutch
Valve Body Asm.
VANE TYPE
PUMP ASSEMBLY
LO ROLLER
CLUTCH
ASSEMBLY
TURBINE~~~~~~~~~~~~~~~~~~~~~~~~c:::==~~~~~~~~
SHAFT
CONVERTER
PUMP
OUTPUT
SHAFT
CONTROL
VALVE
ASSEMBLY
LH0001-4L60
Figure 1 HYDRA-MATIC 4L60 Transmission
7A-15A-2
The oil pressure and shift points are controlled

by throttle opening via a throttle valve cable. (See
Section 7Al for T.V. cable information).
The transmission can be operated in any one of
the following seven modes:
P - Park position prevents the vehicle from
rolling either forward or backward. (For safety
reasons the parking brake should be used in
addition to the park position).
R - Reverse allows the vehicle to be operated
in a rearward direction.
N - Neutral allows the engine to be started and
operated without driving the vehicle. If necessary
this position may be selected if the engine must
be restarted with the vehicle moving.
@- Overdrive is used for all normal driving
conditions. It provides four gear ratios plus
converter clutch operation. Downshifts are
available for safe passing by depressing the
accelerator.
D - Drive position is used for city traffic, hilly
terrain, and trailer towing. It provides three gear
ranges. Again, downshifts are available by
depressing the accelerator.
2 - Manual second is used to provide
acceleration and engine braking. This range may
be selected at any vehicle speed.
1 - Manual Lo is used to provide maximum
engine braking. This range may also be selected
at any vehicle speed.
DIAGNOSIS INFORMATION
ROAD TEST PROCEDURE
Perform the road test following the sequence

given.
Km/h (mph) shift points will vary with actual
throttle position and driver habits.
Not all possible throttle positions and
corresponding mph shift point information have
been provided.
Compare the results of the test with shift speed
chart information. Use these results with the
diagnosis information contained in this Automatic
Transmission Diagnosis Section to evaluate the
transmission.
This test should only be performed when traffic
and road conditions permit.
Observe all traffic safety regulations.
Drive and Reverse Engagement Shift Check

1. Start engine
2. Depress brake pedal
3. Move gear selector:
"Park" (P) to "Reverse" (R)
"Reverse" (R) to "Neutral" (N) to "Drive"
(D)
Drive and/or Reverse engagement, may take

from 1-2 seconds at normal operating
temperatures (80 to 90C/180 to 200F).
Engagement should not be harsh.
Upshifts and Torque Converter Clutch (TCC)

Apply
Figure2
With gear selector in "Overdrive" @

1. Accelerate using a steady increasing throttle
pressure
2. Note the shift speed point gear engagements for:
2nd gear
3rd gear
Overdrive
3. Note the speed shift point for TCC apply. This
should occur while in third gear or overdri\le. If
the apply is not noticed, refer to the Torque
Converter Clutch Diagnosis information
contained in this section of the Service Manual.
[I]
Important
The torque converter clutch will not engage

if engine coolant has not reached a minimum
operating temperature of approximately
54C (130F).
Part Throttle Downshift

At vehicle speeds of 64 to 88 km/h (40 to 55
mph) quickly depress the accelerator to a half open
position and observe:
rec release
Transmission downshift to 3rd gear
immediately
Full Throttle (Detent) Downshift

At vehicle speeds of 77 to 88 km/h (48 to 55
mph) quickly depress the accelerator to a wide open
position and observe:
TCC release
Transmission downshift to 2nd gear
immediately
Manual Downshift
1. At vehicle speeds of 64 to 88 km/h (40 to 55
mph) release the accelerator pedal while moving
the gear selector to "Third" (D) gear and observe:
TCC release
Transmission downshift to 3rd gear should
be immediate
Engine should slow vehicle down
2. Move gear selector to "Overdrive" (D) and
accelerate to 64 to 72 km/h (40 to 45 mph).
Release the accelerator pedal while moving the
gear selector to "Second" (2) gear and observe.
rec release
7A-15A-3
1993 HYDRA-MATIC 4L60 SHIFT SPEED CHART
NOTES: 1.
2.
3.
4.
MODEL
12MIN
THROTILE
23MIN
THROTILE
3-4MIN
THROTILE
12
W.O.T.
4-3 COAST
DOWN
32COAST
DOWN
AAM
11-14
23-26
36-46
ADM
13-15
23-26
36-45
AFM
15-18
26-31
ASM
11-13
22-28
BAM
12-15
BBM
14-18
BCM
21 COAST
DOWN
27-30
25-29
13-20
6-8
40-44
30-38
18-26
9-12
38-52
34-39
28-33
16-24
9-12
36-47
27-30
25-29
13-20
6-8
22-28
32-41
30-36
22-26
13-21
9-11
26-33
40-52
36-43
25-29
14-24
9-11
13-18
26-28
43-53
36-42
25-29
14-24
9-11
BFM
13-16
24-28
38-52
30-40
25-29
14-21
8-11
BHM
12-15
22-28
33-43
30-36
21-25
12-20
7-9
10-13
BRM
16-19
28-31
35-48
36-50
24-31
15-23
BWM
13-18
25-31
38-51
36-42
25-29
14-24
9-11
CPM
13-20
23-29
49-53
33-39
35-46
15-22
11-13
FDM
15-19
26-33
42-51
40-47
28-35
16-24
11-13
FFM
10-13
18-21
33-46
34-42
17-20
10-16
4-7
FMM
13-21
21-23
31-43
34-42
19-24
13-20
8-10
HBM
13-16
24-28
43-51
31-41
25-34
14-22
9-12
HDM
13-16
26-29
40-48
31-38
28-34
15-24
10-12
HJM
14-18
18-31
50-55
31-41
31-47
16-27
11-13
HLM
14-17
26-34
56-63
34-43
40-51
15-25
10-13
8-10
LHM
13-14
22-25
48-53
24-27
35-47
13-21
SAM
13-15
18-25
48-50
28-35
37-47
10-18
9-12
SFM
10-13
18-23
43-51
29-35
36-45
13-19
8-10
YAM
12-14
21-26
31-46
45-52
21-26
12-21
9-11
YCM
12-14
21-26
31-40
42-52
21-26
12-21
9-11
YDM
14-16
24-28
38-51
35-44
23-29
13-22
9-11
ALL SPEEDS INDICATED ARE IN MILES PER HOUR. CONVERSION TO km/h = MPH x 1.609.
SHIFT POINTS WILL VARY SLIGHTLY DUE TO ENGINE LOADS AND VEHICLE OPTIONS.
SPEEDS LISTED WITH + EXCEED 65 MPH.
SPEEDS ARE BASED ON TPS OF 10 TO 20. USE A SCAN TOOL TO MEASURE CORRECT TPS.
PH0002-4l60
Figure 2 Shift Speed Chart
Downshift to second gear should be

immediate
3. Move gear selector to "Overdrive" @ and
accelerate to 40 km/h (25 mph). Release the
accelerator pedal while moving the gear selector
to "First" (1) gear and observe:
TCC release
Transmission downshift to 1st gear should
be immediate
Coastdown Downshift
1. With the transmission range selector in
"Overdrive" @ accelerate to 4th gear and TCC
apply.
2. Release the accelerator pedal and lightly apply
the brakes to observe:
TCC release
Shift points for downshifts
Manual Gear Range Selection

Manual Third (D)
1. With vehicle stopped, place transmission
range selector in "Third" (D) and accelerate
to observe:
The first to second gear shift point
The second to third gear shift point
Manual Second (2)

range selector in "Second" (2) and accelerate
to observe:
The first to second gear shift point
2. Accelerate to 40 km/h (25 mph) and observe:
That a second to third gear shift does
not occur
That TCC does not engage
7A-15A-4
Manual First (1)

range selector in "First" (1) and accelerate
to 24 km/h (15 mph) and observe:
That no upshift occurs
That TCC does not engage
Reverse
range selector in "Reverse" (R) and slowly
accelerate to observe reverse gear operation.
TORQUE CONVERTER CLUTCH (TCC)

DIAGNOSIS
The Torque Converter Clutch is applied by fluid
pressure which is controlled by a solenoid located inside
the Automatic Transmission assembly. The solenoid is
energized by completing an electrical circuit through a
combination of switches and sensors.
Functional Check Procedure
IL"'!
Inspect
1. Install a tachometer or scan tool.

2. Drive the vehicle until proper transmission
operating temperature is reached.
3. Drive the vehicle at 80 to 88 km/h (50 to 55
mph) with light throttle (road load).
4. Maintaining throttle, lightly touch the brake pedal
and check for release of the TCC and a slight
increase in engine rpm.
5. Release the brake, slowly accelerate and check
for a re-apply of the TCC and a slight decrease
in engine rpm.
To properly diagnose the Torque Converter Clutch
(TCC) system, perform all electrical testing first and
then test the hydraulic system.
For diagnosis of electrical or emission control

related components of the TCC, refer to the
specific vehicle section in Driveability and
Emissions.
For diagnosis of TCC hydraulic controls, refer

to the Fluid Flow and Circuit Description, and
Wiring Diagrams provided in this section.
Section 8A, Electrical Diagnosis, shows vehicle

wiring diagrams if additional information is
necessary.
NOTICE: Use only high impedence type

ohmmeters for electrical testing on the TCC circuit.
If another type of ohmmeter is used, damage to
the TCC solenoid may occur.
NOTICE: Do not bench test the TCC solenoid
using an automotive type battery. Accidentally
crossed wires will damage the internal diode of
the solenoid.
A completed circuit does not indicate that the

solenoid will actually apply.
LINE PRESSURE CHECK

Figure3
The next step in diagnosing the Automatic

Transmission is to do a line pressure check. This is a
valuable tool in diagnosis since line pressure controls
the hydraulic functions of the transmission.
Refer to figure 3 for the Line Pressure Check
Procedure and line pressure chart.
TORQUE CONVERTER EVALUATION

The torque converter should be replaced under
any of the following conditions:
External leaks in the hub weld area
Torque converter hub is scored or damaged.
Torque converter pilot is broken, damaged or

fits poorly into crankshaft.
Steel particles are found after flushing the cooler

and cooler lines.
Pump is damaged or steel particles are found in

the converter.
Vehicle has TCC shudder and/or no TCC apply.

Replace only after all hydraulic and electrical
diagnoses has been made. (Torque converter
clutch material may be glazed.)
Torque converter has an imbalance which cannot

be corrected. (Refer to Torque Converter
Vibration Test Procedure in the Transmission Unit
Repair Section.)
Torque converter is contaminated with engine

coolant containing antifreeze.
Internal failure of stator roller clutch
Excess end play
Heavy clutch debris due to overheating (blue

torque converter)
Steel particles or clutch lining material found in

fluid filter or on magnet when no internal parts
in unit are worn or damaged - indicates that
lining material came from torque converter.
Noise
Torque converter whine is usually noticed when
the vehicle is stopped and the transmission is in "Drive"
or "Reverse". The noise will increase when engine
rpm is increased. The noise will stop when the vehicle
is moving or when the torque converter clutch is applied
because both halves of the converter are turning at the
same speed.
Perform a stall test to make sure the noise is
actually coming from the converter:
1. Place foot on brake.
2. Put transmisison range selector in "Drive".
3. Depress accelerator pedal to approximately 1200
rpm for no more than six seconds.
NOTICE: If the accelerator pedal is depressed for

more than six seconds, damage to the transmission
may occur.
A torque converter noise will increase under this
load.
IT]
Important
This noise should not be confused with pump

whine noise which is usually noticeable in
"Park", "Neutral" and all other gear ranges.
Pump whine will vary with pressure ranges.
Torque Converter Stator

The torque converter stator roller clutch can
malfunction in two different ways. It can either remain
locked up at all times or freewheel in both directions.
If the stator is freewheeling at all times, the vehicle
tends to have poor acceleration from the standstill.
The car may act normal at speeds above 50 to 55 km/h
(30 to 35 mph). If poor acceleration is noted, it should
first be determined that the exhaust system is not
blocked, the engine timing is correct, and the
transmission is in "First" ( 1) gear when starting out.
If the engine accelerates freely to high rpm in
"Neutral" (N), it can be assumed that the engine and
exhaust system are normal. Checking for poor
performance in "Drive" (D) and "Reverse" (R) will
help determine if the stator is freewheeling at all times.
7A-15A-5
If the stator is locked up at all times, performance

from a standstill appears normal. Engine rpm and
acceleration is restricted or limited, however, at high
speeds. The engine may overheat with this condition.
Visual examination of the converter may reveal a blue
color from overheating.
If the torque converter has been removed from
the vehicle, the. stator roller clutch can be checked by
inserting a finger into the splined inner race of the
roller clutch and trying to turn the race in both
directions. The inner race should turn freely clockwise,
but not turn or be very difficult to turn
counterclockwise.
The Torque Converter should not be replaced if:
The oil has an odor, is discolored, and there
is no evidence of metal or clutch facing
particles.
The threads in one or more of the converter
bolt holes are damaged.
- Correct with thread insert. (Refer to
Section 6A.)
Transmission failure did not display evidence
of damaged or worn internal parts, steel
particles or clutch plate lining material in
unit and inside the fluid filter.
Vehicle has been exposed to high mileage
(only). The exception may be where the
torque converter clutch dampener plate
lining has seen excess wear by vehicles
operated in heavy and/or constant traffic,
such as taxi, delivery or police use.
7A-15A-6
LINE PRESSURE CHECK PROCEDURE

CHECK TRANSMISSION FLUID LEVEL
CHECK AND ADJUST T.V. CABLE
CHECK OUTSIDE MANUAL LINKAGE AND CORRECT
CHECK ENGINE TUNE
INSTALL PRESSURE GAGE
CONNECT TACHOMETER TO ENGINE
CHECK PRESSURE AS FOLLOWS:
Minimum T.V. Line Pressure Check
Set the T.V. cable to specification; and with the brakes applied, take the line pressure readings in the ranges and at the engine
R.P.M. indicated in the chart below.
Full T.V. Line Pressure Check
Full T.V. line pressure readings are obtained by tying or holding the T.V. cable to the full extent of its travel; and with the brakes
applied, take the line pressure readings in the ranges and at the engine R.P.M. indicated in the chart below.
*NOTICE:
Total running time combination not to exceed 2 minutes.
CAUTION:
Brakes must be applied at all times.

1993 HVDRA-MATIC 4L60 TRANSMISSION PRESSURES
RANGE
PARK,
NEUTRAL,
OVERDRIVE&
MANUAL3RD
@1000RPM
REVERSE
@1000RPM
MANUAL2ND
&MANUAL LO
@1000RPM
MODEL
AAM
ADM
AFM,BWM
ASM
BAM
BBM
BCM
BFM
BHM
BRM
CPM
FDM
FFM,FMM
LHM
SAM
SFM
YAM, YCM, YDM
AAM
ADM
AFM,BWM
ASM
BAM
BBM
BCM
BFM
BHM
BRM
CPM
FDM
FFM,FMM
LHM
SAM
SFM
YAM YCM, YDM
AAM, ADM, AFM, ASM, BBM, BCM, BHM, BRM, BWM
BAM, CPM, FDM, FFM, FMM, SAM, SFM, YAM, YCM, YDM
BFM,LHM
NORMAL PRESSURE
AT MINIMUM T.V.
PSI
kPa
75-85
518-587
518-587
75-85
518-587
75-85
75-85
518-587
65-75
451-518
75-85
518-587
518-587
75-85
518-587
75-85
518-587
75-85
75-85
518-587
451-515
65-75
451-515
65-75
451-515
65-75
518-587
75-85
451-515
65-75
451515
6575
451-515
65-75
738-836
107121
738-836
107121
738-836
107121
738-836
107121
742-847
108-123
738-836
107121
738-836
107-121
665-754
96-109
107-121
738836
738-836
107-121
742-847
108123
580-662
8496
580-S62
8496
665-754
96-109
84-96
580-S62
580-S62
8496
58Q-662
84-96
162-184
11211269
1127-1286
163-187
12931465
188-212
NORMAL PRESSURE
ATFULL T.V.
kPa
PSI
147-171
1016-1183
174-201
1197-1389
1028-1192
149-173
952-1105
138-160
944-1105
137-160
965-1126
140-160
931-1067
135-155
1421-1689
206-245
943-1085
137-157
1061-1227
135-178
158-184
1090-1273
983-1142
142-166
1311-1533
190-222
1402-1669
203-242
894-1038
130150
137-160
948-1104
1354-1617
196-235
14481685
210244
1706-1979
247287
1465-1698
212-246
1356-1575
196228
1551-1816
225-263
1375-1605
199232
1326-1520
192-220
1825-2169
264314
13431545
195-224
1511-1748
219253
17922092
260-303
12631467
183213
1684-1969
244286
261-311
18012144
1148-1333
166-193
12171417
176-205
1739-2077
252301
11211269
162184
11271286
163-187
12931465
188212
Line pressure is basically controlled by pump output and the pressure regulator valve. In addition, line pressure is boosted in
Reverse, Second and Lo by the reverse boost valve.
Also, in the Neutral, Drive, Intermediate and Reverse positions of the selector lever, the line pressure should increase with throttle
opening because of the T.V. system. The pressure is controlled by the T.V. cable, the throttle lever and bracket assembly and the
T.V. link, as well as the control valve assembly.
The main line pressure tap plug is located on the left side of the transmission above the outside manual lever.
Figure 3 Line Pressure Check Procedure
PH00034L60
HYDRA-MATIC 4L60
FIRST
SECOND
THIRD
RANGE
GEAR
2-4
BAND
REVERSE
INPUT
CLUTCH
- GEAR RATIOS
~.06
1.62
1.00
OVERRUN
CLUTCH
FOURTH
REVERSE
FORWARD
CLUTCH
FORWARD
SPRAG CL.
ASSEMBLY
APPLIED
HOLDING
APPLIED
HOLDING
APPLIED
HOLDING
7A-15A-7
.70
2.29
3.4
CLUTCH
LO-ROLLER
CLUTCH
LDREV.
CLUTCH
P-N
1st
2nd
APPLIED
D
3rd
4th
APPLIED
APPLIED
APPLIED
HOLDING
APPLIED
APPLIED
HOLDING
3rd
APPLIED
APPLIED
HOLDING
1st
APPLIED
APPLIED
HOLDING
APPLIED
APPLIED
HOLDING
APPLIED
APPLIED
HOLDING
2nd
2nd
1st
REVERSE
APPLIED
APPLIED
APPLIED
APPLIED
APPLIED
1st
HOLDING
APPLIED
HOLDING
APPLIED
HOLDING
HOLDING
APPLIED
APPLIED
LH0004-4L60
Figure 4 Clutch Application Chart
7A-15A-8
CONDITION
OIL PRESSURE HIGH OR
LOW
(Verify With Gage- Refer
To Line Pressure Check
Procedure)
FOR CAUSE
INSPECT COMPONENT
Oil Pump Assembly (7)
Oil Filter (71)
HIGH OR LOW SHIFT

POINTS
Pressure regulator valve (218) stuck.

Pressure regulator valve spring (219)
damaged.
Rotor guide (213) omitted or misassembled.
Rotor (214) cracked or broken.
T.V. boost valve (222), reverse boost
valve (220) or sleeve (221) stuck, damaged or incorrectly assembled.
Orifice hole in pressure regulator valve
(218) plugged.
Sticking slide (206) or excessive rotor
clearance.
Pressure relief ball (231 ) not seated or
damaged.
Porosity in pump cover or body.
Wrong pump cover.
Pump faces not flat.
Excessive rotor clearance.
Intake pipe restricted by casting flash.

Cracks in filter body or intake pipe.
"O" ring seal (70) missing, cut or damaged.
Wrong grease used on rebuild.
T. V. Exhaust Ball (91)
Stuck or damaged.
Throttle Lever & Bracket

Assembly (65)
Misassembled, binding or damaged.
Throttle Link (64)
Valve Body (67)
Manual valve (340) scored or damaged.

Spacer plate (56) or gaskets (88 & 89)
incorrect, misassembled or damaged.
Face not flat.
Throttle valve (326) sticking.
T. V. limit valve (332) sticking.
Modulated downshift valve (301) stuck.
Line bias valve (336) stuck.
2-3 Shift valve (316) stuck.
Checkballs omitted or misassembled.
Case ( 10)
Case to valve body face not flat.
T.V. Cable
Binding or not correctly adjusted.
T. V. Exhaust Ball (91)
Stuck or damaged.

Assembly (65)
ALL ILLUSTRATION NUMBERS REFERENCE HYDRA-MATIC 4L60 UNIT REPAIR SECTION

LH0005-4L60-R 1
Figure 5 Diagnosis Chart A
CONDITION
HIGH OR LOW SHIFT
POINTS (Continued)
FOR CAUSE
INSPECT COMPONENT
Valve Body Assembly (67)
Case (10)
1ST GEAR RANGE ONLY

- NO UPSHIFT
Governor Assembly (45)
7A-15A-9
Stuck pressure regulator valve (218) or

T.V. boost valve (222).
Sticking pump slide (206).
Sticking throttle valve (326) or plunger
(324).
Modulated T.V. up or down valves (301 &
303) sticking.
T.V. limit valve (332) sticking.
misassembled, damaged or incorrect.
Line bias valve (336) sticking.
Porous or damaged valve body pad.
Governor filter (4 7 A) restricted or damaged.
2-4 Servo Assembly (13-31)
a. 2-4 accumulator porosity.
b. Damaged servo piston seals.
c. Apply pin damaged or improper length.
2-4 Band Assembly (602)
a. Burned.
b. Anchor pin not engaged.
Governor valve (107) sticking.

Governor driven gear (83) loose or damaged:
a. Wear on bottom of gear indicates pin
is not pressed in deep enough.
b. Wear of corner of gear indicates pin
is missing.
c. Wear resembles an apple core if wrong
gear is used, or there is a burr on the
output shaft.
d. Wear on one side of gear indicates output shaft snap ring is missing or the
governor has seized in the bore.
Governor driven gear retaining pin (82)
missing.
Nicks or burrs on output shaft (687).
Nicks or burrs on governor sleeve ( 106)
or case bore.
Governor support pin in case too long or
short.
Governor weights ( 108 & 109) or springs
( 110 & 111 ) missing, binding or damaged.
Valve Body (67)
1-2 Shift valve (322) sticking.

mispositioned or damaged.
Case (10)
Case to valve body face not flat or damaged.

Governor filter (47A) restricted or damaged.
NH0006-4L60
Figure 6 Diagnosis Chart B
7A-15A-10
CONDITION
1 ST GEAR RANGE ONLY

- NO UPSHIFTS
(Continued)
SLIPS IN 1ST GEAR
INSPECT COMPONENT
FOR CAUSE
2-4 Servo Assembly

(13-31)
Restricted or blocked apply passages in

case.
Nicks or burrs on servo pin (29) or pin
bore in case.
4th Servo piston ( 16) in backwards.
2-4 Band (602) worn or damaged.

Band anchor pin not engaged.
Forward Clutch Assembly
Clutch plates (649) worn.

Porosity or damage in forward clutch
piston (630).
Forward clutch piston inner and outer
seals (629) missing, cut or damaged.
Input housing to forward clutch housing
"O" ring seal (622) missing, cut or damaged.
Damaged forward clutch housing (628).
Forward clutch housing retainer and ball
assembly (627) not sealing or damaged.
Forward Clutch
Accumulator
Piston seal (369) missing, cut or damaged.

Piston (367) out of its bore.
Porosity in the piston or auxiliary valve
body (377).
Stuck abuse valve (360).
Oil Pump (7)
Auxiliary accumulator valve tube (96)

leaks, not seated in pump cover or
missing.
Input Housing & Shaft

Assembly (621)
Turbine shaft seals (619) missing, cut or

damaged.
Valve Body (67)
1-2 Accumulator valve (333) stuck.

Face not flat, damaged lands or interconnected passages.
incorrect, mispositioned or damaged.
T.V. Cable
Binding or broken.
Low Roller Clutch (678)
Damage to lugs or inner ramps.

Rollers not free moving.
Inadequate spring tension
Damage to inner splines.
Lube passage plugged.
Torque Converter ( 1)
Stator roller clutch not holding.

LH0007-4L60-R1
Figure 7 Diagnosis Chart C
CONDITION
SLIPS IN 1ST GEAR

(Continued)
INSPECT COMPONENT
1-2 Accumulator Assembly

(59-63)
FOR CAUSE
Porosity in piston (61) or 1-2 accumulator

cover and pin assembly (62).
Damaged ring grooves on piston.
Piston seal (60) missing, cut or damaged.
Valve body to spacer plate gasket (89)
at 1-2 Accumulator cover, missing or
damaged.
Leak between piston and pin.
Broken 1-2 accumulator spring ( 59).
Oil Pressure
(See Causes of High or Low Oil Pressure.)
2-4 Servo Assembly

(13-31 l
4th Servo piston ( 16) in backwards.
T.V. Cable
Binding or broken.
Not correctly adjusted.
1-2 SHIFT SPEED - HIGH

OR LOW

Assembly (65)
Valve Body (67)
Oil Pump Assembly (71) or

Case (10)

Assembly (65)
Face not flat.
Incorrectly installed or damaged.

T. V. cable broken or binding.
Throttle valve (326) sticking.

1-2 Shift valve train (317-322) stuck.
Gaskets (88 & 89) or spacer plate (56)
Line bias valve (336) stuck.
1-2 Accumulator valve (333) stuck.
T. V. limit valve (332) stuck.
Face not flat.
2nd Accumulator (59-63)

T. V. link missing, binding or damaged.
2-4 Servo Assembly

( 13-31)
(See 1st Gear Range Only - No Upshift.)
T. V. exhaust checkball (91) stuck.

T. V. plunger (324) sticking.
Face not flat.
SLIPPING OR ROUGH 1-2

SHIFT
7A-15A11
Apply pin (29) too long or too short.

2nd servo apply piston seal missing, cut
or damaged.
Restricted or missing oil passages.
Servo bore in case damaged.
Porosity in 1-2 accumulator housing (62)
or piston (61 ).
Piston seal or groove damaged.
Nicks or burrs in 1-2 accumulator housing.
Missing or restricted oil passage.
LH0008-4L60
Figure 8 Diagnosis Chart D
7A-15A-12
INSPECT COMPONENT
CONDITION
SLIPPING OR ROUGH 1-2

SHIFT (Continued)
NO 2-3 SHIFT OR 2-3

SHIFT SLIPPING, ROUGH
OR HUNTING
FOR CAUSE
2-4 Band (602)
Worn or mispositioned.
Oil Pump Assembly (7) or

Case (10)
Faces not flat.
Converter ( 1 )
Internal damage.
Valve (107) stuck.

Drive gear retaining pin (82) missing or
loose.
Governor weights ( 108 & 109) binding.
Governor driven gear (83) damaged.
Governor support pin in case too long or
too short.
Oil Pump (7)
Valve Body (67)
Stator shaft (216) sleeve scored or off

location.
2-3 Valve train (313-316) stuck.

Accumulator valve (333) stuck.
Spacer plate (56) or gaskets (88& 89)
Throttle valve (326) stuck.
T.V. limit valve (332) stuck.
Input Housing Assembly

(621)
NO 3-4 SHIFT/SLIPPING
OR ROUGH 3-4 SHIFT
Clutch plates worn [3-4 (654) or forward

(649)].
Excessive clutch plate travel.
Cut or damaged piston seals [3-4 (624)
or forward (629)].
Porosity in input clutch housing (621) or
piston (623).
3-4 Piston checkball (620) stuck, damaged or not sealing.
Restricted apply passages.
Forward clutch piston retainer and ball
assembly (627) not seating.
Sealing balls loose or missing.
Case (10)
3rd Accumulator retainer and ball assembly (80) not seating.
2-4 Servo Assembly

(13-31)
2nd Apply piston seals (23 & 24) missing,

cut or damaged.
Governor (45)
Governor weights (108 & 109) binding.

Governor valve (107) stuck.
Governor driven gear retaining pin (82)
missing or loose.
Governor driven gear (83) damaged.
Governor support pin in case too long
or too short.
LH0009-4L60
Figure 9 Diagnosis Chart E
INSPECT COMPONENT
CONDITION
NO 3-4 SHIFT/SLIPPING
OR ROUGH 3-4 SHIFT
(Continued)
FOR CAUSE
Faces not flat.

- Pump cover retainer and ball assembly
omitted or damaged.
2-4 Servo Assembly

(13-31)
'
Case (10)
Valves stuck.
2-3 Shift valve (313-316) train .
Accumulator valve (333).
Throttle valve (326).
T.V. limit valve (332).
1-2 Shift valve train (317-322) .
3-2 Control valve (339) .
Manual valve link (64) bent or damaged.
Incorrect band apply pin (29).
Missing or damaged servo seals (14 & 17).
Porosity in pistons, cover or case.
Damaged piston seal grooves.
Plugged or missing orifice cup plug (86).
3rd Acpumulator retainer and ball assembly (80) leaking.

Porosity in 3-4 accumulator piston (52)
or bore.
3-4 Accumulator piston seal (53) or seal
grooves damaged.
Plugged or missing orifice cup plug (81 ).
Restricted oil passage.
NO REVERSE OR SLIPS IN
REVERSE
7A-15A-13

(621 l
Refer to Slipping 2-3 Shift.
Worn or misassembled.
3-4 Apply ring (625) stuck in applied

position.
Forward clutch not releasing.
Turbine shaft seals (619) missing, cut or
damaged.

(621)
Manual Valve Link (705)
Disconnected.
Retainer and ball assembly missing or

damaged.
Stator shaft seal rings (233) or ring
grooves damaged.
Stator shaft sleeve scored or damaged.
Reverse boost valve (220) stuck, damaged or misassembled.
Cup plug missing.
Faces not flat.
Converter clutch valve (227) stuck.

Figure 10 Diagnosis Chart F
LH0010-4L60
7A-15A-14
CONDITION
INSPECT COMPONENT
NO REVERSE OR SLIPS IN
REVERSE (Continued)
2-3 Shift valve (316) stuck.

Manual linkage (64) not adjusted.
Spacer plate (56) and gaskets (88 & 89)
Reverse Input Clutch

Assembly (605)
Clutch plate (612) worn.

Reverse input housing and drum assembly
(605) cracked at weld.
Clutch plate retaining ring out of groove.
Return spring assembly retaining ring
(610) out of groove.
Seals (608) cut or damaged.
Restricted apply passage.
Porosity in piston (607).
Belleville plate (611) installed incorrectly.
Excessive clutch plate travel.
Auxiliary Valve Body (377)
Lo overrun valve (364) stuck.

Orificed cup plug (359) restricted, missing
or damaged.
Lo And Reverse Clutch
Clutch plates (682) worn.

Porosity in piston (695).
Seals (696) damaged.
Return spring assembly retaining ring
(693) mispositioned.
Restricted apply passage.
T.V. Cable
Loose or incorrectly installed.
T. V. Bracket Assembly (65)
Bent.
2-4 Servo Assembly

(13-31)
Servo cover retaining ring (13) omitted

or misassembled.
4th Apply piston ( 16) . damaged or misassembled.
Servo inner housing (22) damaged or misassembled.
Governor weights (108 & 109) binding.

Governor valve ( 107) stuck.
Valves stuck.
Throttle valve (326)
3-2 Control valve (339)
T.V. modulated downshift (301)
4-3 Sequence valve body channel
blocked.
NO PART THROTTLE OR
DELAYED DOWNSHIFTS
FOR CAUSE

NH0011-4L60
Figure 11 Diagnosis Chart G
CONDITION
NO OVERRUN BRAKING
- MANUAL 3-2-1
INSPECT COMPONENT
FOR CAUSE
External Linkage
Not adjusted properly.
Valves stuck.
4-3 Sequence valve (329)
Throttle valve (326)
Checkball #3 mispositioned.
Spacer plate (56) and gaskets (88 & 89)
incorrect, damaged or mispositioned.
Input Clutch Assembly

(621)
NO CONVERTER CLUTCH
APPLY
7A-15A-15
Turbine shaft oil passages plugged or not

drilled.
Turbine shaft seal rings (619) damaged .
....,. Turbine shaft sealing balls loose or
missing.
Porosity in forward (630) or overrun clutch
piston (632).
Overrun piston seals (631) cut or damaged.
Overrun piston checkball (633) not
sealing.
Electrical
12 Volts not supplied to transmission.

Outside electrical connector damaged.
Inside electrical connector, wiring harness or solenoid damaged.
Electrical short (pinched solenoid wire).
Solenoid not grounded.
Incorrect or damaged pressure switches.
Temperature switch damaged.
Converter ( 1l
Internal damage.
Converter clutch valve (227) stuck or

assembled backwards.
Converter clutch valve retaining ring
(225) mispositioned.
Pump to case gasket (9) mispositioned.
Orifice cup plug (240) restricted or damaged.
Solenoid "O" ring seal (49) cut or damaged.
High or uneven bolt torque (pump body
to cover).
Input Housing and Shaft

(621)
Turbine shaft "O" ring seal (618) cut or

damaged.
Turbine shaft retainer and ball assembly
(617) restricted or damaged.
TCC shift valve stuck.

TCC apply valve stuck.
Solenoid o-ring leaking.
Solenoid Screen (4 78)
Blocked.
ALL ILLUSTRATION NUMB~S REFERENCE HYDRA-MATIC 4L60 UNIT REPAIR SECTION

LH0012-4L60-R1
Figure 12 Diagnosis Chart H
7A-15A-16
CONDITION
CONVERTER SHUDDER
FOR CAUSE
INSPECT COMPONENT
Torque Converter
Assembly ( 1)
Internal damage.

Oil Filter (71)
Crack in filter body.

Flash restricting filter neck.
"O" ring seal (70) cut or damaged.
Miscellaneous
Low oil pressure.

Engine not tuned properly.
Input Housing and Shaft

Assembly (621 I
Turbine shaft "O" ring (618) cut or damaged.

Turbine shaft retainer and ball assembly
(6171 restricted or damaged.
NO CONVERTER CLUTCH
RELEASE
DRIVES IN NEUTRAL
2ND GEAR START

(DRIVE RANGE)
NO PARK
Solenoid
External ground.
Clogged exhaust orifice.
Converter ( 1 )
Internal damage.
Converter clutch apply valve stuck in

apply position.
ECM
External ground.
Forward Clutch
Not releasing.
Manual Valve Link (705)
Disconnected.
Case (10)
Face not flat.

Internal leakage.
Valve ( 107) stuck.

Governor support pin too long or missing.
Forward Clutch Sprag

Assembly (642)
Sprag assembly installed backwards.
Parking Linkage (701-715)
Actuator rod assembly (701) bent or

damaged.
Actuator rod spring binding or improperly
crimped.
Actuator rod not attached to inside detent lever (703).
Parking lock bracket (710) damaged or
not torqued properly.

LHOO 13-4L60-R 1
Figure 13 Diagnosis Chart I
CONDITION
7A-15A-17
FOR CAUSE
INSPECT COMPONENT
NO PARK (Continued)
Parking Linkage (Cont.)
Inside detent lever (703) not torqued

properly.
Detent roller and spring assembly (709)
mispositioned or not torqued properly.
Parking pawl (711) binding or damaged.
RATCHETING NOISE
Parking Pawl (711)
Parking pawl return spring (714) weak,

damaged or misassembled.
OIL OUT THE VENT
Oil Pump (7)
Chamfer in pump body rotor pocket too

large.
Valve Body (67)
T. V. limit valve (332) stuck.
Miscellaneous
Fluid level - overfilled.
VIBRATION IN REVERSE
AND WHINING NOISE IN
PARK
Oil Pump (7)
Broken vane rings (212).
NO DRIVE IN ALL
RANGES
Converter to flex plate bolts missing.
NO DRIVE IN DRIVE
RANGE
Stator roller clutch not holding.

Converter not bolted to flex plate.
FRONT OIL LEAK
Welded seam leaking.

Damaged converter hub.
Torque Converter Seal (2)
Damaged seal assembly.

Missing garter spring.
DELAY IN DRIVE AND

REVERSE
Converter drainback.

LH0014-4L60-R 1
Figure 14 Diagnosis Chart J
7A-15A-18
PARK
PRESSURES
INTAKE & DECREASE
EI!! CONVERTER & LUBE
MAINLINE
c::J T.V. FEED
~
C::JT.V.
i:::rz:I MODULATED T.V. (M.T.V.I
c:::::J M.T.V. UP
c:::::J M.T.V. DOWN
c:::::J GOVERNOR
c:::::J ACCUMULATOR
Figure 15 Park- Engine Running
7A-15A-19
PARK- ENGINE RUNNING

2-4 BAND - RELEASED
3-4 CLUTCH - RELEASED
CONVERTER CLUTCH - RELEASED
LO AND REVERSE CLUTCH - RELEASED
REVERSE INPUT CLUTCH - RELEASED
LO ROLLER CLUTCH - NOT HOLDING
FORWARD CLUTCH - RELEASED
OVERRUN CLUTCH - RELEASED
FORWARD SPRAG CLUTCH - NOT HOLDING
With the selector lever in the Park (Pl position, oil from the pump is directed to the following:
1.
Pressure Regulator Valve
2.
Release Side of the Converter and the Lubrication System
3.
Decrease Side of the Pump Slide
4.
Manual Valve
5.
T.V. System (Limit Valve, Throttle Valve, Line Bias Valve, M.T.V. Up Valve and M.T.V. Down Valve)
6.
Pressure Relief Valve
7.
Line Pressure Tap
Oil flows from the pump to the pressure regulator valve which regulates the pump pressure. When
the pump output exceeds the demand of line pressure, oil from the pressure regulator valve is directed
to the converter clutch apply valve. The converter clutch apply valve directs oil to the release side
of the converter clutch. Converter return oil is directed to the transmission cooler by the converter
clutch apply valve. Oil from the cooler is directed to the transmission lubrication system.
Oil is also directed from the pressure regulator valve to the pump slide to decrease pump output in
relation to the combined pressure of M.T.V. oil and regulator valve spring force. Line pressure acts
on the pressure relief valve which will exhaust any oil above 2,240 to 2,520 kPa (320 to 360 psi).
Line pressure at the manual valve is available for use in other drive ranges.
Line pressure at the T.V. limit valve is limited to 620 kPa (90 psi). This limited pressure is directed
to the throttle valve where it is regulated to a variable pressure called throttle valve (T.V.) pressure.
T.V. pressure increases with carburetor opening and is directed to the line bias, M.T.V. up and M.T.V.
down valves.
At the line bias valve, T.V. pressure is modulated to M.T.V. pressure. M.T.V. pressure helps to control
line pressure at the pressure regulator valve and accumulator pressure at the accumulator valve.
T.V. pressure at the M.T.V. up valve and M.T.V. down valve is available for use when accelerating in
other ranges.
SUMMARY
The converter is filled from the release side; all clutches and the band are released. The manual linkage
has the parking pawl engaged in the reaction internal gear lugs. At idle, there is not sufficient T.V.
pressure to open the M.T.V. up or M.T.V. down valves.
LH0017-4L60
Figure 16 Park- Engine Running -
Legend
7A-15A-20
NEUTRAL- ENGINE RUNNING
PRESSURES
1:5:51 INTAKE & DECIIEASf

! I ! ] CONYERTEII & LUBE
MAINLINE
T.V. FEED
c:::::JT.V.
c::J MODULAltD T.V. IM.T.V.)

c::::::JM.T.V. UP
c::::::JM.T.V. DOWN
c::::::J GOVERNOR
c::::::J ACCUMULATOR
OIL COOLER
Bl!EDDiflCE
LH0018-4L60
Figure 17 Neutral -
Engine Running
7A-15A-21
NEUTRAL-ENGINE RUNNING
3-4 CLUTCH - RELEASED

REVERSE INPUT CLUTCH - RELEASED
FORWARD CLUTCH - RELEASED
2-4 BAND - RELEASED
LO AND REVERSE CLUTCH - RELEASED

LO ROLLER CLUTCH - NOT HOLDING
OVERRUN CLUTCH - RELEASED
When the selector lever is moved to the Neutral (Nl position, the line pressure is directed to the same
areas as in Park, except in Neutral (Nl the manu~I valve directs oil into the Reverse, Neutral, Drive
4, Drive 3 (RND4D3) oil is directed to the 2-3 shift valve which directs RND4D3 oil to the 3-4 relay
valve through the servo feed passage. Oil at these valves is available for use in other ranges.
SUMMARY
The converter is filled from the release side; all clutches and the band are released. At idle, there is
not sufficient T.V. pressure to open the M.T.V. up or M.T.V. down valves.
LH0019-4L60
Figure 18 Neutral - Engine Running -
Legend
7A-15A-22
D-4 FIRST GEAR
PIIESSUIIES
IS:!liiJ INTAKE & DECIIEASE

1!:!:!J CONVEIITTR & LUBE
MAINLINE
T.V. FEED
c:::::nv.
c:::J MODULATED T.V. (M.T.V.)
liiil M.T.V. UP
IIlIID M.T.V. DOWN
-
GOVERNOR
ACCUMULATOR
OIL COOLER
BlHOORlflCE
"
PRESSURE
RELIEF
VALVE
..
a! a!
~ l!i
l!i
LH0020-4L60
Figure 19 D4 -
First Gear
7A-15A-23
D-4- FIRST GEAR

FORWARD CLUTCH - APPLIED
FORWARD SPRAG CLUTCH - HOLDING
LO ROLLER CLUTCH - HOLDING
When the selector lever is moved to the Drive (D) position, the manual valve is repositioned to allow
line pressure to enter the Drive 4 (D4) passage. Drive 4 oil then flows to the following:
1.
Forward Clutch Accumulator, Forward Clutch and Abuse Valve
2.
Governor Valve
3.
1-2 Shift Valve
4.
Accumulator Valve
5.
3-4 Shift Valve
BASIC CONTROL
Drive 4 oil is directed to the forward clutch accumulator where the #12 checkball seats, routing
forward clutch feed through an orifice. This combines with the forward clutch accumulator to cushion
the forward clutch apply.
During "Rock Cycle" conditions (stuck in mud or snow and "Rocking" out), an abuse valve routes
04 oil to forward clutch feed oil to quicken the apply of the forward clutch,
Drive 4 oil is directed to the 1-2 and 3-4 shift valves. Drive 4 oil is directed to the accumulator valve
and is regulated to a pressure called accumulator pressure; this pressure is directed to the 1-2 and
3-4 accumulator pistons to act as a cushion for the band apply in second gear and overdrive.
Drive 4 oil is orificed into the governor passage, and is regulated to a variable pressure called governor
pressure. Governor pressure increases with vehicle speed and acts against the 1-2, 2-3, 3-4, and the
3-2 control valve springs.
In first gear, there could be sufficient throttle valve plunger travel to increase T.V. pressure enough
to open the M.T.V. up and the M.T.V. down valves. In first gear, M.T.V. up exerts pressure against governor
pressure at the 1-2, 2-3, and 3-4 valves. M.T.V. down pressure is stopped by a land at the 2-3 and
3-4 throttie valves.
SUMMARY
The converter clutch is released, the forward sprag clutch is holding, the forward clutch is applied;
the transmission is in Drive (D) Range - First Gear.
LH0021-4L60
Figure 20 04 -
First Gear -
Legend
7A-15A-24
D-4 SECOND GEAR
PRESSURES
!SS INTAKE & DECIIEASE

1!:!:!1 CONVERTER & LUBE
-
MAINLINE
c:::J T.Y. FEED

c:::::::JT.Y.
[=:I MODULATED T.Y. (M.T.Y.I
E::,31 M.T.Y. UP
lllIID M.T.Y. DOWN
GOVERNOR
ACCUMULATOR
CIINVSIG
LH0022-4L60
Figure 21 04 -
Second Gear
7A-15A-25
D-4-SECOND GEAR
2-4 BAND - APPLIED
As both vehicle speed and governor pressure increase, the force of the governor oil acting on the 1-2
shift valve overcomes the pressure of M.T.V. up oil and the force of the 1-2 throttle valve spring. This
allows the 1-2 shift valve to open and Drive 4 (04) oil to enter the second (2nd) oil passage. This
oil is called second (2nd) oil. Second oil from the 1-2 shift valve is directed to the following:
1.
1-2 Shift Checkball (8)
2.
2-4 Servo
3.
1-2 Accumulator Piston
4.
Solenoid Assembly (Converter Clutch)
5.
3-4 Relay Valve
BASIC CONTROL
Second oil from the 1-2 shift valve will seat the 1-2 shift checkball (8) forcing 2nd oil through an orifice.
Second oil is then directed to the 2-4 servo to apply the 2-4 band. At the same time, 2nd oil moves
the 1-2 accumulator piston against accumulator pressure and the accumulator spring to maintain a
controlled build-up of pressure on the servo during the 1-2 shift for a smooth band apply. 2nd oil at
the 3-4 relay valve is available for use in other ranges.
Second oil is rerouted into converter clutch signal oil above the 1-2 shift valve. Converter signal oil
exhausts at this solenoid until a signal is received from the vehicles E.C.M.
SUMMARY
The converter clutch is released, the 2-4 band is applied, the forward clutch is applied, and the forward sprag clutch is holding; the transmission is in Drive (D) Range - Second Gear.
LH0023-4L60
Figure 22 04 -
Second Gear -
Legend
7A-15A-26
D-4 THIRD GEAR

(CONVERTER CLUTCH APPLIED)
PRESSURES
cs:SI INTAKE & DECREASE

1!:]31 CDNYERnR & LUBE
Cli::::I MAINUNE
C::::JT.V. FEED
c:::n.v.
c::::JMODULATED T.V. (M.T.V.)
l!:I!I M.T.V. UP
CllIDM.T.V. DOWN
GOVERNOR
ACCUMULATOR
OIL COOLER
BlEIOOR~ICE
LH0024-4L60
Figure 23 D4 - Third Gear -
Converter Clutch Applied
7A-15A-27
D-4-THIRD GEAR
( Converter Clutch Applied)
CONVERTER CLUTCH - APPLIED

3-4 CLUTCH - APPLIED
As both vehicle speed and governor pressure increase, the force of governor oil acting on the 2-3
shift valve overcomes the force of the 2-3 T.V. spring and M.T.V. up oil. This allows the 2-3 shift valve
to open and allows RND4D3 oil to enter the 3rd clutch passage.
Third clutch oil from the 2-3 shift valve is directed to the following:
1.
3-2 Exhaust Checkball (4)
2.
3-4 Clutch Piston
3. Third Clutch Accumulator Checkball (2)

4. Third Accumulator Exhaust Checkball (7)
5.
2-4 Servo (Release Side)
6.
3-2 Control Valve
BASIC CONTROL
Third clutch oil from the 2-3 shift valve flows past the 3-2 exhaust checkball (4), to the 3-4 clutch
piston. At the same time, third clutch oil is directed past the third clutch accumulator checkball (2),
seats the third accumulator exhaust check ball (7), and then into the release side of the 2-4 servo.
This third clutch accumulator pressure combined with the servo cushion spring, moves the second
apply piston, in the 2-4 servo, against second oil and acts as an accumulator for a smooth 2-4 band
release and 3-4 clutch apply.
Third clutch oil is present at the 3-2 control valve in preparation of a third gear to second gear shift.
Once the solenoid receives a signal from the vehicles controls and solenoid is on, converter clutch
signal oil will shift the converter clutch apply valve, and redirect converter feed oil into the apply passage.
The apply oil flows between the stator shaft and converter hub to charge the converter with oil and
push the converter pressure plate against the converter cover, causing a mechanical link between
the engine and the turbine shaft. The rate of apply is controlled by the orifice checkball capsule in
the end of the turbine shaft.
At the same time the converter clutch apply valve will direct converter feed oil through an orifice to
the transmission cooler. Cooler oil is directed to the transmission lubrication system.
SUMMARY
The converter clutch is applied*, the forward clutch is applied, the forward sprag clutch is holding,
the 3-4 clutch is applied and the 2-4 band is released; the transmission is in Drive (D) Range - Third
Gear (direct drive).
*The converter clutch may or may not be applied, depending on shift calibration and solenoid operation.
LH0025-4L60
Figure 24 D4 - Third Gear - Converter Clutch Applied -
Legend
7A-15A-28
D-4 OVERDRIVE
l't!ESSURES
li::'5:!I INTAIIE DECIIEASf

&:i3 CONVERTER LUBE
MAINLINE
T.V. FUD
c::::JT.V.
r::::J MODULATED T.V. IM.T.V.)
e::DI M.T.V. UP
IIIIIll M.T.V. DOWN
-
GOVERNOR
ACCUMULATOR
LH0026-4L60
Figure 25 04 -
Overdrive
7A-15A-29
D-4- OVERDRIVE
CONVERTER CLUTCH - APPLIED

2-4 BAND - APPLIED

As both vehicle speed and governor pressure increase, the force of governor oil acting on the 3-4
shift valve overcomes the force of the 3-4 T.V. spring and M.T.V. up oil. This opens the 3-4 shift valve
sending Drive 4 (D4) into the fourth signal passage. Fourth signal oil will overcome the 4-3 sequence
valve spring and open the 3-4 relay and the 4-3 sequence valves, allowing second oil to enter the
servo feed passage.
Servo feed oil is directed to the following:
1.
2-3 Shift Valve

a.
Which directs oil to the:

1) 3-4 Accumulator
2) 4-3 Sequence Valve
2.
4-3 Sequence Valve

a.
Which directs oil to the:

1) 4th Apply Piston (in the 2-4 servo)
BASIC CONTROL
Servo feed oil passes through the 4-3 sequence valve and becomes fourth oil. Fourth oil then enters
the 2-4 servo, applies pressure on the fourth apply piston, and applies the 2-4 band.
SUMMARY
The converter clutch*, 2-4 band, forward clutch, the 3-4 clutch are applied, and the forward sprag
clutch is overrunning; the transmission is in Drive (D) Range - Overdrive.
*The converter clutch may or may not be applied, depending on solenoid operation.
LH0027-4L60
Figure 26 D4 - Overdrive -
Legend
7A-15A-30
PART THROTTLE
4-3 AND MODULATED DOWNSHIFTS
PRESSURES
ai;:JJ INTAKE & DECIIEASE
e:!:!J CONVEl!TER & LUBE

MAINLINE
C:::::JT.Y. FUD
C::::JT.Y.
c::::J MODULATED T.Y. IM.T.Y.I
IL!3 M.T.Y. UP
IDilll M.T.Y. DOWN
-
GOVERNOR
ACCUMULATOR
LH0028-4L60
Figure 27 Part Throttle 4-3 and Modulated Downshifts
7A-15A-31
PART THROTTLE 4-3 AND MODULATED DOWNSHIFTS

(Valves In Third Gear Position)
CONVERTER CLUTCH - APPLIED*

A part throttle 4-3 downshift can be accomplished by depressing the accelerator pedal far enough
to move the throttle valve (T.V.) plunger to allow the T.V. oil to enter the part throttle (P.T.) passage.
This oil, called part throttle (P.T.) oil, is then routed to the 3-4 throttle valve.
Part throttle oil and the 3-4 throttle valve spring force will close the 3-4 shift valve against governor
pressure, shutting off 04 oil to the fourth signal passage. Fourth accumulator oil will push the 3-4
relay valve closed and hold the 4-3 sequence valve open while it exhausts at an orifice at the T.V.
limit valve. Fourth oil will pass through the 4-3 sequence valve to the servo feed passage to the 2-3
shift valve to the fourth accumulator passage. When fourth accumulator pressure is low enough, the
4-3 sequence valve spring will close the 4-3 sequence valve and the remaining fourth and fourth
accumulator oil will exhaust at the 4-3 sequence valve.
A type of part throttle downshift can be accomplished in some ranges (4-3, and 3-2, shifts) by
depressing the accelerator pedal far enough to raise M.T.V. down pressure. This pressure when combined with the throttle valve spring pressure can overcome governor pressure and cause a modulated
downshift.
*The converter clutch will be released for the 4-3 downshift and may or may not be reapplied depending on shift calibration
and solenoid operation.
LH0029-4L60
Figure 28 Part Throttle 4-3 and Modulated Downshifts - Legend
7A-15A-32
DETENT DOWNSHIFTS
PRESSURES
C!ii:!I INTAICE & DECREASE
!!:!:!! CONVERTER & LUBE

IIE!!!!I MAINUNE
C:Z] T.V. FEED
c::::JT.V.
c::::J MODULATED T.V. (M.T.V.I
E:!:!) M.T.V. UP
l!IIlI] M.T.V. DOWN
GOVERNOR
l!!!!!!B ACCUMULATOR
LH0030-4L60
Figure 29 Detent Downshifts
7A-15A-33
DETENT DOWNSHIFTS
(Valves In Second Gear Position)
2-4 BAND - APPLIED

While operating at speeds below approximately 60 mph (96 km/h), a forced or detent 3-2 downshift
is possible by depressing the accelerator pedal fully. This will position the throttle valve (T.V.)
plunger to allow T.V. oil to enter the detent passage. This oil, called detent oil, is then routed to
the following:
1.
Line Bias Valve
2.
2-3 Throttle Valve
3.
1-2 Throttle Valve
4.
Converter Clutch Throttle Valve (Non E.C.M. Controlled Vehicles Only)
Detent oil from the T.V. plunger flows to the line bias valve to boost modulated T.V. (M.T.V.) pressure.
M.T.V. oil acting on the T.V. boost valve will boost line pressure approximately 70 kPa (10 psi).
The E.C.M. will discontinue the signal provided to the solenoid to release the converter clutch.
Detent oil from the T.V. plunger flows to the 2-3 throttle valve. Detent and M.T.V. down oil, acting
on separate areas of the 2-3 throttle valve, will close the 2-3 shift valve against governor oil and allow
3rd clutch and 3rd accumulator oil to pass through an orifice and exhaust at the 2-3 shift valve.
At vehicle speeds above approximately 50 mph (80 km/h), governor oil acting on the 3-2 control valve
will close it. Now the exhausting 3rd clutch accumulator oil from the intermediate servo will seat the
3rd clutch accumulator checkball (2) and flow through another orifice controlling the intermediate
band apply for a smooth 3-2 shift at high speed.
A detent 2-1 downshift can be accomplished at speeds below approximately 30 mph (48 km/h),
because detent oil pressure and the 1-2 spring force acting on the 1-2 throttle valve will close the
1-2 shift valve, shifting the transmission to first gear.
LH0031-4L60
Figure 30 Detent Downshifts -
Legend
7A-15A-34
MANUAL THIRD
PRESSURES
~
INTAKE & DECREASE

l!I3 CONVERTER & LUBE
MAINLINE
c::::::JT.V. FEED
c:::JT.V.
c::::::J MODULATED T.V. (M.T.V.I
c:::J M.T.V. UP
c:::=i M.T.V. DOWN
GOVERNOR
ACCUMULATOR
LH0032-4L60
Figure 31 Manual Third
7A-15A-35
MANUAL THIRD
OVERRUN CLUTCH - APPLIED
CONVERTER CLUTCH - RELEASED*
A forced 4-3 downshift can be accomplished by moving the selector lever from Drive (D) Range to
Third (3rd) Gear. When the selector lever is moved to the Third (3rd) Gear position, 03 oil from the
manual valve is directed to the following:
1.
4-3 Sequence Valve
2.
Part Throttle and Drive 3 (03) Checkball (3)
3.
3-4 Shift Valve
03 oil will close the 3-4 shift valve and allow the 4th signal oil to exhaust.
03 oil combined with the 4-3 sequence valve spring force will close the 4-3 sequence valve to allow
the fourth and fourth accumulator oil to exhaust and release the band. 03 oil then flows into the overrun clutch passage where it applies the overrun clutch to keep the forward sprag clutch from overrunning when engine braking is needed.
The forward and 3-4 clutches are applied. The 2-4 band is released. The transmission is in Manual
Third, direct drive. The overrun clutch is applied to allow engine braking.
In manual 3rd, the converter is shown released, and there is no M.T.V. up or M.T.V. down pressure.
This is assuming the throttle is released. If the throttle is opened sufficiently, the E.C.M. could signal
the solenoid to apply the converter clutch and the M.T.V. up and M.T.V. down valves could open.
LH0033-4L60
Figure 32 Manual Third -
Legend
7A-15A-36
MANUAL SECOND
PRESSURES
C!i31 INTAKE & DECIIEASE

I!:!:!) CONVERTER & LUBE
MAINLINE
liiii T.V. FEED
c:::::n.v.
c:::J MODULATED T.V. (M.T.V.)

c:J M.T.V. UP
c:J M.T.V. DOWN
iiiil GOVERNOR
-
ACCUMULATOR
LH0034-4L60
Figure 33 Manual Second
7A-15A-37
MANUAL SECOND
2-4 BAND - APPLIED
CONVERTER CLUTCH - RELEASED*
A forced 3-2 downshift can be accomplished by moving the selector lever from Third (3rd) Gear to
Second (2nd) Gear position.
When the selector lever is moved to the Second (2nd) Gear position, RND403, 3rd clutch, and 3rd
accumulator oil will exhaust at the manual valve. With no pressure to apply the 3-4 clutch, or release
the 2-4 band, the transmission will shift to second gear.
The manual valve will also direct line pressure into the 02 passage. Drive 2 (02) oil will act on the
reverse boost valve to boost line pressure to 1206 kPa (175 psi) which is required to prevent the 2-4
band and forward clutch from slipping.
SUMMARY
The forward clutch and 2-4 band are applied. The transmission is in second gear. Also, the overrun
clutch is still applied to allow engine braking when needed.
LH0035-4L60
Figure 34 Manual Second - Legend
7A-15A-38
MANUAL LO
PRESSURES
i.::s::!1 INTAXE & DECIIEASE

c.:::.:3 CONVERTER & LUBE
MAINLINE
i;;;;;::;J T.V. FUD
c:::::nv.
r:::::J MODULATED T.V. IM.T.V.)

c::::J M.T.V. UP
c::::J M.T.V. DOWN
-
GOVERNOR
ACCUMULATOR
LH0036-4l60
Figure 35 Manual Lo
7A-15A-39
MANUAL LO
LO ROLLER CLUTCH - APPLIED
Maximum downhill braking can be obtained at speeds below 30 mph (48 km/h) with the selector
in Lo (1st) range. Lo/1st oil pressure, which is 1206 kPa (175 psi), is the same as second (2nd) oil pressure
because second (D2) oil is still present.
Lo oil from the manual valve is directed to the following:
1.
1-2 Shift Valve Train
2.
Lo and Reverse Clutch
3.
Lo Overrun Valve
Lo oil at the 1-2 T.V. valve combined with the 1-2 throttle valve spring force will close the 1-2 shift
valve at speeds approximately 35 mph (56 km/h) or below. This allows 2nd oil to exhaust, releasing
the 2-4 band, and lo oil to apply the lo and reverse clutch.
Lo/1st oil coming off the 1-2 T.V. valve is directed toward the lo overrun valve that regulates lo/reverse
oil. This smoothes the 2-1 manual downshift for maximum engine braking.
SUMMARY
The forward clutch is applied. The lo and reverse, and the overrun clutch are applied to allow engine
braking. The 2-4 band is released, the transmission is in Lo Range - First Gear.
LH0037-4L60
Figure 36 Manual Lo - Legend
7A-15A-40
REVERSE
PRESSURES
1ii:!iiJ INTAKE & DECREASE

li:.:3 CONVERTER & LUBE
. . . MAINLINE
T.V. FEED
c:::n.v.
c:::J MODULATED T.V. IM.T.V.)
EI!! M.T.V. UP
l!IIlll M.T.V. DOWN
c::::::IGOVERNOR
c::::::J ACCUMULATOR
OIL COOLER
BLEED ORIFICE
LH0038-4L60
Figure 37 Reverse
7A-15A-41
REVERSE
REVERSE INPUT CLUTCH - APPLIED
LO AND REVERSE CLUTCH - APPLIED
When the selector lever is moved to the Reverse (R) position, the manual valve is repositioned to allow
line pressure to enter the reverse passage which directs oil to the following:
1.
Lo and Reverse Clutch
2.
Reverse Input Clutch
3.
Reverse Boost Valve
4.
Lo Overrun Valve
Reverse oil is orificed at the retainer and ball assembly, and regulated at the lo overrun valve to apply
the lo and reverse clutch.
Reverse oil is orificed into the reverse input clutch and orificed out of the reverse input piston for a
smooth apply of the reverse input clutch during the shift.
Reverse oil acting on the reverse boost valve in the pressure regulator will boost line pressure to
approximately 670 kPa (100 psi). M.T.V. oil from the line bias valve acting on the T.V. boost valve,
in the pressure regulator, will further boost line pressure from 670 kPa (100 psi) at idle to 1690 kPa
(245 psi) at full throttle.
SUMMARY
The reverse input clutch is applied. The lo and reverse clutch is applied. The transmission is in
Reverse (R).
LH0039-4L60
Figure 38 Reverse - Legend
7A-15A-42
4-3 PULSE
(N.C.) ~.C.C. SOL
(N.O. OIL PATH)
0.5 AMPSi~+ 12V
~>I
----\--i
---.
0.010 AMPS I B
+12V
--?~
I
I
GROUND~to--
IL __. ________ JI
O'
.4-3 DOWNSHIFT SW
I: (COLOR ID-BLACK BODY)
2 TERMINALS
, 4TH CL TERMINAL
'(COLOR ID-BLUE)
0,
0
"=====----
_;. ---_,_
.. _,.
I,
NORMALLY OPEN (N.O.)

NORMALLY CLOSED (N.C.)
1 I 4TH CLUTCH SW
\ : (COLOR ID-METALLIC
~ti t,%~~'1';~~1NAL
-------------------=
NEG. SOL TERMINAL
TO TERMINAL D
(CCC GROUND)
(COLOR ID-BLACK)
4TH DISCREET
SW (N.C.)
OPTIONAL 4TH CL SW
(COLOR ID-METALLIC
& BLACK)
TYPE 4
1993 MODEL: LHM
PH0040-4L60
Figure 39 Wiring Diagram - Type 4
TERMINAL A TO
SOL POS. SIDE
(COLOR ID-RED)
TERMINAL B TO
4TH CLUTCH SWITCH
(COLOR ID-WHITE)
4TH CL TERMINAL
(COLOR ID-BLUE)
4TH CLUTCH SW
(COLOR ID-METALLIC
AND WHITE)
1 TERMINAL
'~-
1---------\
0.5 AMPS IA
+ 12V
--1
----?,:...,.__ _ _~v-v,.
I
0.010 AMPS 18
~>=-.------i
+ 12V
!_ \
rh
GROUND~~
L___
I
I
_____
4TH DISCREET
SW(N.C.)
NORMALLY OPEN (N.O.)
NORMALLY CLOSED (N.C.)
POS. SOL TERMINAL

(COLOR ID-RED)
TYPE9
1993 MODEL: FFM,
FMM
PH0042-4L60
I
I
I
OPTIONAL 4TH CL SW
(COLOR ID-METALLIC
& BLACK)
t-
NEG. SOL TERMINAL

TO TERMINAL D
(CCC GROUND)
(COLOR ID-BLACK)
T.C.C. SOL
(N.O. OIL PATH)
JI
7A-15A-43
CCC PATTERN
SHIFT 4TH CLUTCH B
SIGNAL
'
4TH CLUTCH TERMINAL

(COLOR I.D. BLUE)
PIPE PLUG
"' 3 REO' D
'' ~-,'
SOLENOID
ASM. COMPLETE
(COLOR I.D.
LGT. BROWN)
~===;:::=-=---=--~==i=~~-
TYPE 18
1993 MODELS: AAM, ADM, AFM, ASM,
BAM, BBM, BCM, BFM, BHM, BJM,
BRM, BWM, DDM, FDM,
'
-1_
NEGATIVE SOLENOID
TERMINAL TO TEMP
SWITCH (COLOR I.D.
BLACK)
4TH CLUTCH SWITCH

SIGNAL TERMINAL
(COLOR I.D. BLACK)
PH0043-4L60
Figure 41 Wiring Diagram -Type 18
SOLENOID ASM.
COMPLETE
(COLOR I.D.
LT. GREEN)
NEGATIVE SOLENOID
TERMINAL TO TEMP
SWITCH (COLOR I.D.
BLACK)
4 TH CLUTCH SWITCH
SIGNAL TERMINAL
(COLOR I.D. BLACK)
TYPE 19
1993 MODEL: SAM
PH0044-4L60
7A-15A-44
TRANSMISSION
I -------------------------,
T.C.C. SOLENOID
~~
'
:'
:
'
'
TO ECM-T.C.C. D :
DRIVER
:
:
T~iP.
,
TO ECM 4TH GEAR B :
DISCRETE INPUT
'
''
TO ECM 2ND GEAR E :

DISCRETE INPUT
SWITCH
TO ECM JRD GEAR C:

DISCRETE INPUT
:
'
'
4TH CL.
SWITCH N.O.
(CLOSED IN 4TH)
l
'
:
i
'
JRD CL.;~CH N.C.!EN IN JRD)
:
:
2ND CL. SWITCH N.C. !OPEN IN 2~D)

1
''
rh--------.J'
,' ____ --- - ------ --SOLENOID ASM.
COLOR 1.0. BLACK
OST
SO
I IVE
LENOID
TERMINAL TO 4-3
SWITCH COLOR 1.0. RED
NEGATIVE SOLENOID
TERMINAL TO TEMP.
SWITCH COLOR 1.0. BLACK
4TH CL. SWITCH

COLOR 1.0.
METALLIC &
BLACK
TEMP. SWITCH ASM.

CONNECTOR
COLOR 1.0.
BLACK
4TH CL.
TERMINAL
COLOR 1.0.
BLUE
2ND CL. SWITCH

COLOR 1.0.
METALLIC &
BLACK
TYPE 22
1993 MODELS:
YAM, YCM,
YDM
PH0045-4L60
7A-15A-45
ILL.
ILL.
ILL.
NO.
DESCRIPTION
1 LINE
2 04
3 02
4 LO
5 REVERSE
6 GOVERNOR
7 LO - 1ST FEED
9 3RD ACCUMULATOR
10 T.V.
11 M.T.V.
12 ACCUMULATOR
13 4TH SIGNAL
14 2ND CLUTCH
15 3-4 ACCUMULATOR
NO.
DESCRIPTION
16 T.V.F.
17 OVERRUN CLUTCH
18 T.V. EX.
19 03/PART THROTTLE
20 PART THROTTLE
21 03
22 4TH CLUTCH
23 C.C. SIG.
24 MOD. UP
25 MOD. DOWN
26 DETENT
27 3-4 CLUTCH
29 RND4-3
30 3RD CLUTCH
NO.
DESCRIPTION
31 IDENTIFICATION
32 VOID
33 EXHAUST
34 SF
35 4-3
42 04 ABUSE
43 3RD FEED
44 3-2 HIGH SPEED
45 2ND FEED
46 3RD CL. EXHAUST
47 4TH FEED
48 1-2 ACCUMULATOR
LH0046-4L60
Figure 44 Valve Body Passages
7A-15A-46
350
ILL.
NO.
DESCRIPTION
301 VALVE, T.V. MODULATOR DOWNSHIFT
302 SPRING, T.V. MODULATOR DOWNSHIFT
VALVE
303 VALVE, T.V. MODULATOR UPSHIFT
304 SPRING, T.V. MODULATOR UPSHIFT VALVE
309 SLEEVE, 3-4 THROTTLE VALVE
310 SPRING, 3-4 THROTTLE VALVE
311 VALVE, 3-4 THROTTLE
312 VALVE, 3-4 SHIFT
323 SLEEVE, THROTTLE VALVE PLUNGER
324 PLUNGER, THROTTLE VALVE
325 SPRING, THROTTLE VALVE
326 VALVE, THROTTLE
328 VALVE, 3-4 RELAY
329 VALVE, 4-3 SEQUENCE
ILL.
NO.
330
331
332
333
334
335
336
337
338
339
340
341
342
343
344
350
351
352
DESCRIPTION
SPRING, 4-3 SEQUENCE VALVE
SPRING, T.V. LIMIT VALVE
VALVE, T.V. LIMIT
VALVE, 1-2 ACCUMULATOR
SLEEVE, 1-2 ACCUMULATOR VALVE
SPRING, 1-2 ACCUMULATOR VALVE
VALVE, LINE BIAS
SPRING, LINE BIAS VALVE
SPRING, 3-2 CONTROL
VALVE, 3-2 CONTROL
VALVE, MANUAL
PIN, COILED SPRING
PIN, COILED SPRING
RETAINER, SPRING (SLEEVE)
PLUG, VALVE BORE
BODY, CONTROL VALVE
PLUG, T.V. LIMIT
PLUG, VALVE BORE (12.5 - O.D.)
LH0047-4L60
Figure 45 Valve Trains
7A-15A-47
9o
26
010
Q11
27
0
2
015
026
Ao
10
0
23
ILL.
NO.
27
Os
23
11
2o
0.
11
16
15
0 0 0
21
16
10
0
10
DESCRIPTION
1 LINE
2 D4
3 D2
4 LO
5 REVERSE
6 GOVERNOR
7 LO - 1 ST FEED
8 LO/REVERSE
9 3RD ACCUMULATOR
10 T.V.
11 M.T.V.
12 ACCUMULATOR
13 4 TH SIGNAL
11
14
01
20
0
12 0
13
oa
so
120
07
12
0
12
~-
22
10

012
Oo
0
5
17
('.]
024
07
Oy,
0
26
4~
10
13
017
50
06
Do
0
6
26
24
25
sO
(:)14
.46
17
06
045
20
017
06
14
26
110 10
07
02
4Q
30
44
30 04
0
1
1
260 0
9CJ
43
0
290
15
012
015
D
19
18
ILL.
NO.
14
15
16
17
18
19
20
21
22
23
24
25
26
.048
DESCRIPTION
2ND CLUTCH
3-4 ACCUMULATOR
T.V.F.
OVERRUN CLUTCH
T.V. EX.
D3/PART THROTTLE
PART THROTTLE
D3
4TH CLUTCH
C.C. SIG.
MOD. UP
MOD. DOWN
DETENT
ILL.
NO.
27
29
30
31
42
43
44
45
46
47
48
DESCRIPTION
3-4 CLUTCH
RND4-3
3RD CLUTCH
IDENTIFICATION
D4 ABUSE
3RD FEED
3-2 HIGH SPEED
2ND FEED
3RD CL. EXHAUST
4TH FEED
1-2 ACCUMULATOR
LH0048-4L60
Figure 46 Typical Spacer Plate
7A-15A-48
05
43
~ooo
30.
29
o
011
11
10
40 0
Q..P Os
~o
17
10
02
26
23
oe
11
11
l)
10
22
24
15
t?
012
012
16
15
@).
QJ G
O
120
15
o ~
0
16
42
5
07 0
08
05
08
--
13
12n
140
10
G
o
CJ
OD
,..,
0 Du
O
D
26
Q5
CJ7
~a
011
13
09
100
14
14
.~~o
0
0
006
10
!:::)
SJ<J
~
0 0
D
10
Os
\ ) 26
c:=::J11
ILL.
NO.
26
30
c=Jo
023
DoG
10
4Q
26
16
0 0
10 10
010
DESCRIPTION
1 LINE
2 04
3 02
4 LO
5 REVERSE
6 GOVERNOR
7 LO - 1ST FEED
8 LO/REVERSE
9 3RD ACCUMULATOR
10 T.V.
11 M.T.V.
12 ACCUMULATOR
13 4TH SIGNAL
c::::J
19
0
19
0
18
ILL.
NO.
14
15
16
17
18
19
20
21
22
23
24
25
26
DESCRIPTION
2ND CLUTCH
3-4 ACCUMULATOR
T.V.F.
OVERRUN CLUTCH
T.V. EX.
03/PART THROTTLE
PART THROTTLE
03
4TH CLUTCH
C.C. SIG.
MOD. UP
MOD. DOWN
DETENT
ILL.
NO.
27
29
30
31
42
43
44
45
46
47
48
DESCRIPTION
3-4 CLUTCH
RND4-3
3RD CLUTCH
IDENTIFICATION
04 ABUSE
3RD FEED
3-2 HIGH SPEED
2ND FEED
3RD CL. EXHAUST
4TH FEED
1-2 ACCUMULATOR
LH0049-4L60
Figure 47 Spacer Plate to Valve Body Gasket
Os
50
03
003
01
29C=:)
~Doo
CJ
26
010
c::i
010
c::::J
017
O O
10
27
D
26
130
13
011
02
10
c=J
11
0(
2
017
10
0
10
o1
08
so
'--026
23
22
16
0
09
OB
10
100
ILL.
DESCRIPTION
1 LINE
2 04
3 02
4 LO
5 REVERSE
6 GOVERNOR
7 LO - 1ST FEED
8 LO/REVERSE
9 3RD ACCUMULATOR
10 T.V.
11 M.T.V.
12 ACCUMULATOR
13 4TH SIGNAL
_ _ _ _ _o_--,14
o~
14
ILL.
NO.
14
15
16
17
18
19
20
21
22
23
24
25
26
012
14
01
22
so
0 9 Deo
024
25
06
12
26
d'i] 024
230
NO.
09
011
023
0.
4Q
027
110
nD
7A-15A-49
DESCRIPTION
2ND CLUTCH
3-4 ACCUMULATOR
T.V.F.
OVERRUN CLUTCH
T.V. EX.
D3/PART THROTTLE
PART THROTTLE
D3
4TH CLUTCH
C.C. SIG.
MOD. UP
MOD. DOWN
DETENT
0
15
15
12
0012
ILL.
NO.
27
29
30
31
42
43
44
45
46
47
48
DESCRIPTION
3-4 CLUTCH
RND4-3
3RD CLUTCH
IDENTIFICATION
04 ABUSE
3RD FEED
3-2 HIGH SPEED
2ND FEED
3RD CL. EXHAUST
4TH FEED
1-2 ACCUMULATOR
LH0050-4L60
Figure 48 Spacer Plate to Case Gasket
7A-15A-50
PASSAGES
1 LINE
2 D4
3 D2
4 LO
5 REVERSE
6 GOVERNOR
7 LO - 1 ST FEED
8 LO/REVERSE
9 3RD ACCUMULATOR
10 T.V.
11 M.T.V.
12 ACCUMULATOR (4TH)
13 4TH SIGNAL
14 2ND CLUTCH
15 3-4 ACCUMULATOR
16 T.V.F.
17 OVERRUN CLUTCH
18 T.V. EX.
19 D3/PART THROTTLE
20 PART THROTTLE
21 D3
22 4TH CLUTCH
23 C.C. SIG.
24 MOD. UP
25 MOD. DOWN
26 DETENT
27 3-4 CLUTCH (3-2 EX)
29 RND4-3
42 04 ABUSE
43 3RD FEED
44 3-2 HIGH SPEED
45 2ND FEED
46 3RD CL. EXHAUST
47 4TH FEED
48 1-2 ACCUMULATOR
47A
106
478
COMPONENTS
47A GOVERNOR FILTER LOCATION
478 CONVERTER CLUTCH FILTER LOCATION
55E #4 CHECK BALL (3-4 CLUTCH/3-2 EX.)
55F #8 CHECK BALL (2ND/1-2)
55G #1 CHECK BALL (4TH ACCUMULATOR)
55H #3 CHECK BALL (PART THROTTLE/DRIVE 3)

106 RETAINER & BALL ASM. (DOUBLE-ORIFICE)
LH0051-4L60
Figure 49 Case Passages and Checkball Locations
CASE OIL PASSAGES

1
3
5
11
17
23
LINE
DR-2
REVERSE
M.T.V.
O.R. CLUTCH
CONV. CL. SIG.
27
32
36
39(a)
39(b)
49
3-4 CLUTCH
VOID
VENT
LUBE TO COOLER
LUBE FROM COOLER
PRESSURE TAP
A
B
C
D
80
86
2-4 SERVO BORE

SERVO EXHAUST HOLE
2ND & 4TH BAND APPLY PASSAGE
3RD ACCUM. PRESSURE TAP PASSAGE
RETAINER & BALL ASSEMBLY, 3RD ACCUM.
PLUG, CASE SERVO
LH0053-4L60
LH0052-4L60
Figure 50 Pump to Case Passages
Figure 51 Servo Passages
A
B
C
D
E
F
14
15
16
17
4TH OIL
3RD ACCUMULATOR OIL
VALVE BODY FACE
OIL PAN FLANGE
EXHAUST
2ND OIL
SEAL, "O" RING (2-4 SERVO COVER)
COVER, 2-4 SERVO
PISTON, 4TH APPLY
RING, OIL SEAL (4TH APPLY PISTON)
(OUTER)
18 RING, RETAINER (APPLY PIN)
19 WASHER, SERVO APPLY PIN
20 SPRING, SERVO APPLY PIN
21
22
23
24
25
26
27
28
29
31
80
86
7A-15A-51
SEAL, "O" RING

HOUSING, SERVO PISTON (INNER)
RING, OIL SEAL (2ND APPLY PISTON) (INNER)
RING, OIL SEAL (2ND APPLY PISTON) (OUTER)
PISTON, 2ND APPLY
SPRING, SERVO CUSHION
RETAINER, SERVO CUSHION SPRING
RING, RETAINER (2ND APPLY PISTON)
PIN, 2ND APPLY PISTON
SPRING, SERVO RETURN
PLUG, CASE SERVO
LH0054-4L60
Figure 52 Servo Assembly
7A-15A~52
1
3
5
11
17
23
23(a)
27
32
33
33(a)
33(b)
36
37
37(a)
38
39
39(a)
39(b)
40
41
41 (a)
LINE
02
REVERSE
MODULATED T.V.
OVERRUN CLUTCH
CONVERTER CLUTCH SIGNAL
39a
(ORIFICE CUP PLUG)
3-4 CLUTCH
VOID
EXHAUST
EXHAUST (T.C.C. RELEASE)
EXHAUST (PRESS. REG.)
VENT
DECREASE
DECREASE AIR BLEED
(ORIFICE CUP PLUG)
SEAL DRAIN
LUBE
LUBE TO COOLER
LUBE FROM COOLER
CONVERTER CLUTCH RELEASE
CONVERTER CLUTCH FEED
CONVERTER CLUTCH FEED TO COOLER
(ORIFICE CUP PLUG)
27
LH0055-4L60
Figure 53 Pump Cover Passages
LINE
02
5
11
17
23
27
32
33
33(a)
33(b)
36
37
38
39
39(a)
39(b)
40
41
REVERSE
MODULATED T.V.
OVERRUN CLUTCH
3-4 CLUTCH
VOID
EXHAUST
EXHAUST (T.C.C. RELEASE)
EXHAUST (PRESS. REG.)
VENT
DECREASE
SEAL DRAIN
LUBE
LUBE TO COOLER
LUBE FROM COOLER
CONVERTER CLUTCH RELEASE
CONVERTER CLUTCH FEED
33b
33
LH0056-4L60
Figure 54 Pump Body Passages
4L60 AUTOMATIC TRANSMISSION UNIT REPAIR
7A-15B-1
SECTION/HYDRA-MATIC 4L60
AUTOMATIC TRANSMISSION UNIT REPAIR

RPO MD8
correct part number is not available, a fastener of equal size and strength (or stronger) may be used. Fasteners
that are not reused, and those requiring thread locking compound will be called out. The correct torque value
must be used when installing fasteners that require it. If the above conditions are not followed, parts or system
damage could result.
CONTENTS
Transmission Disassembly ........................... 7A-15B-2
General Service Information ..................... 7A-15B-2
2-4 Servo Assembly .................................. 7A-15B-2
Servo Pin Length ...................................... 7A-15B-2
Governor Cover and Governor ................. 7A-15B-4
Speed Sensor/Speedometer and
Case Extension ..................................... 7A-15B-4
Pan and Filter Assembly ........................... 7A-15B-5
Valve Body and Wiring Harness ............... 7A-15B-5
Transmission End Play Check .................. 7 A-15B-8
Oil Pump Assembly .................................. 7A-15B-8
2-4 Band, Reverse Input Clutch,
Input Clutch and Input Gear Set ........... 7A-15B-9
Reaction Gear Set ................................... 7A-15B-10
Lo and Reverse Clutch Parts ................... 7A-15B-11
Int1er Manual Linkage ............................. 7A-15B-12
Manual Shaft Seal Replacement ............. 7A-15B-12
Component Repair and
Transmission Reassembly ....................... 7 A-15B-13
Case Assembly ........................................ 7A-15B-13
Case ..................................................... , ... 7A-15B-13
Third Accumulator Retainer and
Ball Assembly ..................................... 7A-15B-14
Retainer and Ball Assembly Leak
Check Procedure ................................. 7 A-15B-14
Replacement Procedure - Third Accumulator
Retainer and Ball Assembly ............... 7 A-15B-14
Lo and Reverse Clutch Piston ................. 7A-15B-15
Parking Pawl ........................................... 7A-15B-16
Reaction Internal Gear and
Carrier Assembly ................................ 7A-15B-16
Reaction Internal Gear and Support ....... 7A-15B-17
Lo and Reverse Clutch Spacer Plate
Selection ............................................. 7A-15B-17
Lo and Reverse Clutch Support
Assembly ............................................ 7 A-15B-20
Reaction Sun Gear and Shell .................. 7A-15B-21
Input Internal Gear and
Reaction Shaft.. ................................... 7A-15B-21
Internal Transmission Speed Sensor
Rotor ................................................... 7A-15B-22
Input Internal Gear and Output Shaft ..... 7A-15B-22

Input Carrier and Sun Gear ..................... 7A-15B-23
Input Clutch Assembly ........................... 7A-15B-24
Check Valve Retainer and Ball
Assembly-Replacement Procedures 7A-15B-25
Forward Clutch Sprag Assembly ............ 7A-15B-31
Forward Clutch Piston Travel Check ...... 7A-15B-33
3-4 Clutch Assembly ............................... 7A-15B-34
3-4 Clutch Piston Travel Check .............. 7A-15B-34
Clutch Air Check .................................... 7A-15B-34
Turbine Shaft Seals ................................. 7A-15B-35
Reverse Input Clutch Assembly .............. 7 A-15B-36
Reverse Input Clutch Backing Plate
Selection ............................................. 7A-15B-38
Reverse Input and Input Clutches ........... 7 A-15B-39
2-4 Band Assembly ................................. 7A-15B-40
Oil Pump Assembly ................................ 7A-15B-40
Oil Pump Body ....................................... 7A-15B-40
Oil Pump Cover (Disassemble) .............. 7A-15B-41
Oil Pump Body (Assemble) .................... 7A-15B-43
Oil Pump Cover (Assemble) ................... 7A-15B-43
Oil Pump Cover and Body ...................... 7 A-15B-44
Transmission End Play Check ................ 7 A-15B-45
Valve Body and Associated Parts ........... 7A-15B-48
Control Valve Assembly ......................... 7 A-15B-49
Auxiliary Accumulator Valve
Body Assembly ................................... 7A-15B-51
2-4 Servo Assembly ................................ 7 A-15B-55
Governor and Governor Cover ............... 7A-15B-58
Speed Sensor/Speedometer and
Case Extension ................................... 7A-15B-59
Torque Converter Assembly ................... 7 A-15B-59
Disassembled Views .................................. 7 A-15B-62
Seal and Bearing Locations ....................... 7 A-15B-68
Torque Specifications and
Bushing Locations .................................. 7A-15B-69
Bushing Replacement Procedure ............... 7 A-15B-70
Governor Bore Repair Procedure ............... 7 A-15B-73
Special Tools .............................................. 7A-15B-74
7A-15B-2
TRANSMISSION DISASSEMBLY
2-4 Servo Assembly

Figures 2 and 3
General Service Information
Tool Required:
J 29714 Servo Cover Compressor
Figure 1
Tool Required:
J 8763-02 Holding Fixture and Base
NOTICE: It is not recommended to use air

powered tools to disassemble or assemble
transmissions/transaxles. Improper bolt torques
can contribute to transmission repair conditions
and this information, vital to diagnosis, can only
be detected when using hand tools.
Teflon Oil Seal Rings

If any seal rings are damaged, cut, or do not
rotate freely in their groove be certain to check
the ring groove for debris, burrs, or damage.
,...., Remove or Disconnect
1.
2.
3.
4.
Install J 29714.
Servo cover retaining ring (13).
Servo cover and 0-ring seal (14 and 15).
2-4 servo assembly (16-31).
1 5 2-4 SERVO COVER
Thrust Washer Surfaces

The thrust washer and thrust bearing surfaces
may appear to be polished. This is a normal
condition and should not be considered damage.
~ Clean
Thoroughly clean the exterior of the transmission.
15
LH0058-4L60
Torque Converter (1).

Figure 2 Servo Cover Removal
,...., Install or Connect
1. J 8763-02 onto the transmission case.

2. Holding fixture into the base.
Drain the transmission fluid out case extension

by rotating transmission so bell housing is up.
LH0057-4L60-R1
Figure 1 Holding Fixture
Servo Pin Length

Figures 3, 4 and 5
Tools Required:
J 33037 Band Apply Pin Tool
J 22269-01 Piston Compressor
As a diagnostic aid, the servo pin length should
now be checked. If the pin length is too short or too
long, be certain to inspect the 2-4 band and reverse
input drum for damage or wear when disassembled.
l@I
7A-15B-3
Measure
Figure 4
1. Install J 33037 as shown with apply pin (29).

2. Install servo cover retaining ring (13) to secure
tool.
3. Apply 11 Nm (98 lb. in.) torque.
4. If white line "A" appears in gage slot "B" pin
length is correct.
5. Use pin selection chart to determine correct pin
length if new pin is needed.
14
J 33037
A WHITE LINE
B GAGE SLOT
PIN IS PRESET AT FACTORY AND MUST NOT BE
READJUSTED
2-4 SERVO PIN SELECTION

PIN LENGTH
PINI.D.
INCH
MM
65.82-66.12
2.59-2.60
1 GROOVE
67. 23-67. 53
2.65-2.66
2 GROOVES
68.64-68.94
2.70-2.71
NO GROOVE
PH0102-4L60-E
Figure 4 Servo Pin Length

13
14
15
16
17
18
19
20
21
22
23
24
25
26
26A
27
28
29
31
RING, SERVO COVER RETAINING

COVER, 2-4 SERVO
PISTON, 4TH APPLY
RING, OIL SEAL {4TH APPLY PISTON - OUTER}
RING, RETAINER {APPLY PIN}
WASHER, SERVO APPLY PIN
SPRING, SERVO APPLY PIN
SEAL, "O" RING
HOUSING, SERVO PISTON {INNER)
RING, OIL SEAL {2ND APPLY PISTON - INNER}
RING, OIL SEAL {2ND APPLY PISTON - OUTER}
PISTON, 2ND APPLY
SPRING, SERVO CUSHION ASSIST {CORVETTE ONLY}
RING, RETAINER {2ND APPLY PISTON}
NH0059-4L60
Figure 3 Servo Assembly
1....1 Remove or Disconnect

Figures 3 and 5
1. 4th apply piston (16).

2. Servo return spring (31).
3. Servo pin retainer ring (18), washer (19) and
apply pin spring (20).
4. 2nd apply piston pin (29).
5. Install J 22269-01.
7. Cushion spring retainer (27) and cushion spring
(26).
7A-15B-4
25 SECOND APPLY PISTON ASM.
LH0062-4L60
LH0061-4L60
Figure 5 Second Servo Piston Retaining Ring Removal
Figure 6 Speed Sensor Removal
Governor Cover and Governor

Figures 6 and 7
l+--+I
1. Governor cover (46)

Tap around the cover flange with a punch
to remove.
[I]
Important
Do not damage the governor cover.

2. Governor assembly (45).
Speed Sensor/Speedometer and Case

Extension
Figures 6 and 7
Tool Required:
J 38417 Speed Sensor Remover and
Installer
Mechanical Speedometer:
1. Bolt and washer assembly (41) and retainer (40).
2. Speedometer driven gear assembly (43), speedo
driven gear (44) and 0-ring seal (42).
Internal Transmission Speed Sensor (I. T.S.S.):
3. Speed sensor retaining bolt (100).

4. Speed sensor assembly (99) and 0-ring seal
(42) with J 38417.
5. Case extension bolts (37), case extension (36)
and extension seal ring (35).
6. Output shaft sleeve (690) and output shaft 0ring seal (691).
ILL.
NO.
10
35
36
37
39
40
41
42
43
44
45
46
99
1 00
687
688
689
690
691
699
DESCRIPTION
CASE, TRANSMISSION
SEAL, CASE EXTENSION TO CASE
EXTENSION, CASE
BOLT, CASE EXTENSION TO CASE
RETAINER, SPEEDO DRIVEN GEAR FITTING
BOLT & WASHER ASSEMBLY
SEAL, 0-RING (SPEEDO FITTING TO
CASE EXTENSION)
FITTING ASSEMBLY, SPEEDO DRIVEN GEAR
GEAR, SPEEDO DRIVEN
GOVERNOR ASSEMBLY
COVER, GOVERNOR
SPEED SENSOR, INTERNAL TRANSMISSION
BOLT, SPEEDO SENSOR RETAINING
SHAF~ OUTPUT
CLIP, SPEEDO DRIVE GEAR
GEAR, SPEEDO DRIVE
SLEEVE, OUTPUT SHAFT NOT USED ON
SEAL, OUTPUT SHAFT
ALL MODELS
ROTOR, INTERNAL TRANSMISSION SPEED SENSOR
LH0063-4L60-R 1
Not all models use an output shaft sleeve

and seal.
Figure 7 Extension and Associated Parts
!+--+!
7A-15B-5
Figure 7
73
Models with Mechanical Speedometer

72
1. Speedometer drive gear (689) and clip (688).

Use care not to damage the speedo gear.
Push tab of retaining clip and tap
speedometer gear off the output shaft.
71
Pan And Filter Assembly

10
Figure 8
~ Clean
!+--+!
Exposed ends of bottom pan screws and spray

with penetrating oil.
1. Screws (74), oil pan (73) and gasket (72).

2. Oil filter (71) and filter seal (70).
Filter seal may be stuck in.the pump.
!L"'!
10
70
71
72
73
74
93
CASE, TRANSMISSION
SEAL, FILTER
FILTER ASSEMBLY, TRANSMISSION OIL
GASKET, TRANSMISSION OIL PAN
PAN, TRANSMISSION OIL
SCREW, SPEC. HEX WASHER HEAD (PAN)
MAGNET, CHIP COLLECTOR
Inspect
Filter (71 ), open filter by prying the metal

crimping away from the top of the filter
(black) and pull apart. The filter may
contain evidence for root cause diagnosis.
LH0064-4L60-R 1
Figure 8 Pan, Filter and Seal Remove
- Clutch material.
- Bronze slivers indicating bushing wear.
- Steel particles.
3. Outside electrical connector (33) and 0-ring
97
seal (34) from inside the case.

Gently pry apart the locking tabs.
Valve Body And Wiring Harness

!+-..!
376
51
50
Figures 9 and 10
I. Electrical connections from switches.

Refer to wiring diagrams in the Diagnosis
Section for specific model applications.
2. Solenoid bolts (51) and solenoid assembly (50)
with 0-ring seal (49) and wiring harness.
3. Accumulator cover bolts (63) and 1-2
accumulator cover and pin assembly (62).
4. 1-2 accumulator piston (61) and seal (60).
5. Spring (59).
A
50
51
63
66
69
75
92
97
374
WASHER WIRE RETAINER

SOLENOID ASSEMBLY
BOLT, HEX WASHER HEAD (SOLENOID)
BOLT, ACCUMULATOR COVER
CLIP, ELECTRICAL WIRE
BOLT, VALVE BODY
BOLT, MANUAL DETENT SPRING
CONDUIT, SOLENOID WIRE
CLAMP, AUXILIARY TUBE
BOLT, SPEC. HEX WASHER HEAD
(M6 X 1 X 18)
375 BOLT, HEX HEAD (M6 X 1 X 35)
LH0065-4L60
Figure 9 Valve Body Bolt Locations
7A-15B-6
88
5. Spacer plate (56) and spacer plate gaskets (88

and 89).
6. Checkballs (55A, 55C and 91) spring (54),
piston (52), seal (53) and pin.
Three checkballs are located under the
valve body: one is in the auxiliary valve
body and four are located in the case. The
large copper flash colored ball is #10
checkball (91).
52 PISTON, 3-4 ACCUMULATOR

53
54
56
59
60
61
62
63
77
88
89
RING, OIL SEAL (3-4 ACCUMULATOR PISTON)

SPRING, 3-4 ACCUMULATOR
PLATE, VALVE BODY SPACER
RING, OIL SEAL (1-2 ACCUM. PISTON)
COVER & PIN ASSEMBLY, 1-2 ACCUM.
PIN, ACCUMULATOR PISTON
GASKET, SPACER PLATE TO CASE
GASKET, SPACER PLATE TO VALVE BODY
LH0066-4L60
340
703
705
709
VALVE, MANUAL
LEVER, DETENT (INNER)
LINK, MANUAL VALVE
SPRING ASSEMBLY, MANUAL DETENT
LH0067-4L60
Figure 10 Accumulator Assembly

Figure 11 Manual Valve Link
l~-+I
1. Bolt (75) and manual detent spring assembly

(709).
2. Electrical wire clips (66).
3. Auxiliary tube clamps (97) and auxiliary
accumulator valve tube (96).
4. Wiring harness retaining washer (A).
5. Bolts (69) and T.V. lever and bracket assembly
(65).
6. T.V. link (64).
l~-+I
1.
2.
3.
4.
Remaining valve body bolts (69).

Manual valve link (705).
Bolts (374-375), auxiliary valve body (377) and
checkball (55B).
64 LINK, THROTTLE LEVER TO CABLE

65 LEVER & BRACKET ASSEMBLY, THROTTLE
69 BOLTS, CONTROL VALVE ASSEMBLY
LH0068-4L60
Figure 12 T.V. Lever and Bracket
ILL.
NO.
A
33
96
97
374
375
376
377
710
715
DESCRIPTION
WASHER, WIRE RETAINING
TUBE, AUXILIARY ACCUMULATOR VALVE
BOLT, SPECIAL HEX HEAD (M6 X 1 X 16)
BOLT, HEX HEAD (M6 X 1 X 35)
AUXILIARY ACCUM. VALVE BODY ASM.
BRACKET, PARKING LOCK
BOLT, PARKING LOCK BRACKET
55A
558
55C
551
91
395
7A-15B-7
#2 CHECK8ALL (3RD CLUTCH ACCUM.)

#12 CHECK8ALL (FORWARD CLUTCH)
#6 CHECK8ALL (DRIVE 3)
#11 CHECKBALL (REVERSE)
#10 CHECK8ALL (T.V. EXHAUST)
CUP PLUG - ORIFICE
LH0069-4L60
LH0071-4L60-R 1
Figure 13 Removing Auxiliary Valve Body Assembly
Figure 15 Valve Body Checkball Locations
67
0
34
33~
10
33
34
56
67
88
89
96
377
CASE, TRANSMISSION
SEAL, "O" RING (ELECTRICAL CONNECTION)
VALVE ASSEMBLY, CONTROL BODY
AUXILIARY ACCUMULATOR VALVE
BODY ASSEMBLY
LH0070-4L60
Figure 14 Control Valve, Auxiliary Valve Body, Spacer

Plate and Gaskets
ILL.
NO.
4 7A
4 78
55E
55F
55G
55H
106
DESCRIPTION
GOVERNOR FILTER LOCATION
CONVERTER CLUTCH FILTER LOCATION
#4 CHECK BALL (3-4 CLUTCH/3-2 EX.)
#8 CHECK BALL (2ND/1-2)
#1 CHECK BALL (4TH ACCUMULATOR)
#3 CHECK BALL (PART THROTTLE/DRIVE 3)
RETAINER & BALL ASM. (DOUBLE ORIFICE)
LH0072-4L60
Figure 16 Case Checkballs and Filters
7A-15B-8
Transmission End Play Check

Figures 17 and 18
Tools Required:
J 24773-A Oil Pump Remover
J 25022-A End Play Adaptor (245 mm)
J 34725 End Play Adaptor (298 mm)
J 25025-7A Post
Dial indicator
As a diagnostic aid, transmission end play should
be checked prior to removing the internal parts. If the
end play is not within specifications, you should watch
for possible worn or misassembled parts during
disassembly.
f@I
A DIAL INDICATOR
B 278mm (11 ") BOLT
C LOCK NUT
LH007 4-4L60
Measure
1. Remove an oil pump bolt (5) and install a 278

mm ( 11 inch) bolt and locknut or J 25025-7A.
2. Install J 25022-A or J 34725 as shown.
3. Install J 24773-A as shown.
4. Install dial indicator.
A. Set to zero.
B. Pull up on J 24773-A.
C. End play should be 0.13 to 0.92 mm (0.005
to 0.036 inch).
Figure 18 End Play Check
Oil Pump Assembly

Figures 19 and 20
Tools Required:
J 37789-A Oil Pump Remover and Installer
139119 Adapter
l+--+I
1. 0-ring seal (618).

2. All oil pump bolts (5) and 0-rings (6).
3. Slide J 39119 over stator shaft until it locks
under splines.
4. Oil pump assembly (7) with J 37789-A.
5. Oil pump to case seal (8) and gasket (9).
6. Reverse input clutch to oil pump thrust washer
(601).
A 298mm TURBINE SHAFT

B 245mm TURBINE SHAFT
THE SOLENOID ASM. AND OIL FILTER MUST BE REMOVED

BEFORE OIL PUMP REMOVAL
NH0075-4L60
LH0073-4L60
Figure 17 End Play Tool
Figure 19 Oil Pump Removal
7A-15B-9
2-4 Band, Reverse Input Clutch, Input Clutch

And Input Gear Set
Tools Required:
J 29837 Output Shaft Support Fixture
J 34627 Snap Ring Pliers
Figures 20 and 22
1. Reverse input clutch (605) and input clutch (62)
together.
Grasp the turbine shaft and lift.
2. Band assembly pin (48).
3. The 2-4 band assembly (602).
4. Input sun gear (658).
Figures 21 and 22
J 29837 as shown.
[I]
Important
Output shaft (687) may fall free when

retaining ring (661) is removed if J 29837
is not used.
J 29837
10 CASE, TRANSMISSION
687 SHAF~ OUTPUT
ILL.
NO.
5
6
7
8
9
10
48
601
602
605
621
658
DESCRIPTION
BOLT, PUMP TO CASE
0-RING, PUMP TO CASE BOLT
PUMP ASSEMBLY, OIL
SEAL, OIL (PUMP TO CASE)
GASKET, PUMP COVER TO CASE
CASE, TRANSMISSION
PIN, BAND ANCHOR
WASHER, THRUST (PUMP TO DRUM)
BAND ASSEMBLY, 2-4
HOUSING & DRUM ASM., REVERSE INPUT CLUTCH
HOUSING & SHAFT ASSEMBLY, INPUT
GEAR, INPUT SUN
LH0076-4L60
Figure 20 Input Clutch Removal
LH0077 -4L60
Figure 21 Output Shaft Support Fixture
I+-,.!
Figure22
1. Retaining ring (661) with J 34627. Do not
overexpand the ring.

2. Input carrier assembly (662).
7A-158-10
3. J 29837 and output shaft (687).
rn
Reaction Gear Set
Important
Figure23
The manufacturer assembles the output

shaft and reaction internal gear with
adhesive for ease of assembly. If these parts
have not become separated during use, the
output shaft will come out later along with
the reaction internal gear.
4. Thrust bearing assembly (663).
661
662
663
10
10
661
662
663
CASE, TRANSMISSION
RET., OUTPUT SHAFT TO INPUT CARRIER
CARRIER ASSEMBLY, INPUT (COMPLETE)
BEARING ASSEMBLY, THRUST (INPUT CARRIER TO
REACTION SHAFT)
LH0078-4L60
Figure 22 Input Carrier Removal
1. Input internal gear (664) and reaction carrier

(666).
2. Reaction sun shell (670) and thrust washer
(669).
3. Reaction sun shell to inner race thrust washer
(674).
4. Lo and reverse support to case retainer ring
(676).
5. Lo and reverse clutch support retainer spring
(680).
6. Reaction sun gear (673).
7. Lo and reverse inner race (675), roller assembly
(678), support assembly (679) and reaction
carrier assembly (681).
8. Lo and reverse clutch plates (682).
9. Reaction internal gear (684) and thrust bearing
assembly (683).
10. Reaction gear support to case bearing (692).
7A-15B-11
Lo And Reverse Clutch Parts

Figures 24,..25 and 27
Tools Required:
J 34627 Snap Ring Remover/Installer
J 23327 Clutch Spring Compressor
670
E3
1. Bolts (715) and parking lock bracket (710).
6828
II]
682A
Important
Due to interference, the parking pawl may

have to be removed before removing or
installing the low and reverse piston.
A. Parking pawl shaft plug (713) with a
#4 screw extractor.
B. Parking pawl pivot shaft (712) with a
magnet.
C. Parking pawl (711) and return spring
(714).
Install tool J 23327.
Lo and reverse clutch retainer ring (693) with
J 34627.
Lo and reverse clutch spring assembly (694).
Lo and reverse clutch piston (695).
Apply air pressure in the case apply
passage.
684
68 5 ----'"<!l,iiii\.~,
692-----R;-~,
676
679
678
2.
3.
697
ILL.
NO.
10
664
666
669
670
673
674
675
676
678
679
680
681
682A
6828
682C
6820
683
684
685
692
693
694
695
697
DESCRIPTION
CASE, TRANSMISSION
GEAR, INPUT INTERNAL
SHAFT, REACTION CARRIER
WASHER, THRUST (REACTION SHAFT/SHELL)
SHELL, REACTION SUN
GEAR. REACTION SUN
WASHER, THRUST (RACE/REACTION SHELL)
RACE, LO & REVERSE ROLLER CLUTCH
RING, LO & REVERSE SUPPORT TO CASE RETAINER
CLUTCH ASM., LO & REVERSE ROLLER
SUPPORT ASM., LO & REVERSE CLUTCH
SPRING, TRANSMISSION (LO & REVERSE
CLUTCH SUPPORT RETAINER)
CARRIER ASSEMBLY, REACTION
PLATE, LO & REVERSE CLUTCH (WAVED)
PLATE, LO & REVERSE CL. (SELECTIVE)
PLATE ASM., LO & REVERSE CLUTCH (FIBER)
PLATE, LO & REVERSE CLUTCH (FLAT STEEL)
BEARING ASSEMBLY, THRUST (REACTION
CARRIER/SUPPORT)
GEAR, INTERNAL REACTION
SUPPORT, INTERNAL REACTION GEAR
BRG., REACTION GEAR SUPPORT TO CASE
RING, LO & REVERSE CLUTCH RETAINER
SPRING ASM., LO & REVERSE CLUTCH
PISTON, LO & REVERSE CLUTCH
DEFLECTOR, OIL (HIGH OUTPUT MODELS ONLY)
LH0079-4L60
Figure 23 Reaction Gear Set Removal
4.
5.
695
694
693
L....---10
10
693
694
695
CASE, TRANSMISSION
SPRING ASSEMBLY, LO & REVERSE CLUTCH_
LH0080-4L60
Figure 24 Lo and Reverse Snap Ring Removal
7A-15B-12
(A)
APPLY AIR PRESSURE HERE TO REMOVE LO &

REVERSE PISTON FROM THE CASE
LH0081-4l60
Figure 25 Lo and Reverse Piston Removal
A GOV. COVER
FACE SURFACE
B- DOWEL
710
701
702
703
705
706
707
708
709
710
711
712
713
714
715
~e
-712
713
ACTUATOR ASSEMBLY, PARKING LOCK

NUT, HEX HEAD
LEVER, INSIDE DETENT
LINK, MANUAL VALVE
RETAINER, MANUAL SHAFT
SHAFT, MANUAL
SEAL, MANUAL SHAFT
MANUAL DETENT ROLLER & SPRING ASM.
PAWL, PARKING BRAKE
SHAFT, PARKING BRAKE PAWL
PLUG, STEEL CUP
SPRING, PARKING PAWL RETURN
LH0083-4L60
Figure 27 Parking Linkage
LH0082-4L60
Figure 26 Governor Bore Pin Location
Inner Manual Linkage

Figure27
l+-..1 Remove or Disconnect

1. Inside manual shaft nut (702).
2. Manual shaft (707) and manual shaft retainer
(706).
3. Parking lock actuator assembly (701) and inside
detent lever (703).
Manual Shaft Seal Replacement

Figure28
Manual shaft seal (708).

- Pry out with a screwdriver.
,....., Install or Connect
New manual shaft seal (708).

- Tap into place using a 14 mm socket.
7A-158-13
10
10
ILL.
NO.
DESCRIPTION
707 SHAFT, MANUAL
708 SEAL, MANUAL SHAFT
11 VENT ASSEMBLY, TRANSMISSION
LH0084-4L60
Figure 28 Manual Shaft Seal
!L'l'I
Inspect
Figure27
!-++-!
Figure 29 Case Vent Assembly
Case
Actuator rod (701) for damage.

Inside detent lever (703) for damage or cracks.
Manual shaft (707) for damage or burrs.
Manual detent spring assembly (709) for roller
freeness or damage.
!L!
Install or Connect
Figure 27
Parking lock actuator (701) onto inside detent

lever (703).
Manual shaft (707) into case ( 10) and inside
detent lever (703).
Inside manual shaft nut (702) onto manual shaft
(707).
!~I
Tighten
Nut (702) to 31 Nm (23 lb. ft.)

Manual shaft retainer (706) onto manual shaft
(707).
COMPONENT REPAIR AND

TRANSMISSION REASSEMBLY
The assembly of some components will require
use of an assembly lube. It is recommended that
TRANSJEL J 36850 or equivalent be used during
assembly.
NOTICE: Do not use any type of grease to retain
parts during assembly of this unit. Greases other
than the recommended assembly lube will change
transmission fluid characteristics and cause
undesirable shift conditions and/or filter clogging.
Case Assembly
&!!
LH0085-4L60
Clean
Thoroughly with solvent.

Air dry.
- Do not wipe with cloth.
Inspect
Case (10) exterior for cracks or porosity.

Case to valve body face for damage,
interconnected oil passages and flatness.
- Face flatness can be checked by inspecting
the spacer plate to case gasket for proper
land impressions.
Vent assembly ( 11) for damage.
Air check all oil passages.
- See diagnosis section for oil passage
identification.
2-4 servo bore for:
- Damage, porosity, or burrs.
- Any sharp edges (i.e. - oil passages, slots
for retaining ring removal - remove if
found).
Orifice cup plug (86) in servo bore for debris
or damage.
Third accumulator bore for:
- Porosity, damage, or burrs.
- Pin damage (77).
- Orifice cup plug (81) damaged or plugged.
Speedometer bore for:
- Damage.
- Sharp edges.
- Porosity.
All bolt holes for thread damage
- Heli-coil to repair.
Cooler connectors (12) for:
- Damage.
- Proper torque 38 Nm (28 lb. ft.).
7A-15B-14
Case interior for:

- Damaged ring grooves or casting flash.
- Clutch plate lugs worn or damaged.
- Bushing (767) scored, worn, or damaged
(see Bushing Replacement).
- Governor support pin installation depth.
(Incorrect installation depth will cause
governor driven gear damage and shift
problems.)
Third Accumulator Retainer and Ball Assembly

Figure 32
!L'I'!
Inspect
Ball for:
- Presence.
- Sticking or leaking.
Retainer for:
- Presence.
- Loose.
- Incorrect seating.
- Restricted feed slots.
Retainer and Ball Assembly Leak Check

Procedure
Figure32
1. Install the servo assembly (16-31) into the servo

bore.
2. Install the servo cover (15) and retainer (13).
3. Pour a suitable solvent into the accumulator
bore.
!L'I'!
A
B
C
D
80
86
Inspect
Watch for leakage inside the case.

If leakage is observed, replace the third
accumulator retainer and ball assembly.
Replacement Procedure - Third Accumulator

Retainer and Ball Assembly
2-4 SERVO BORE

SERVO EXHAUST HOLE
2ND & 4TH BAND APPLY PASSAGE
3RD ACCUM. PRESSURE TAP PASSAGE
PLUG, CASE SERVO
Figures 32 and 33
Tools Required:
6.3 mm (#4) Screw Extractor
9.5 mm (3/8 inch) diameter metal rod
LH0053-4l60
Figure 30 2-4 Servo Bore
!+--+!
Third accumulator retainer and ball assembly

(80).
!-++-!
Use 6.3 mm (#4) screw extractor.
Install or Connect
Figures 32 and 33
LH0087-4L60
Figure 31 Third Accumulator Bore
A new third accumulator retainer and ball

assembly.
- Oil feed slots in the retainer must line up
with oil passage in the servo bore. To be
certain of correct installation depth, scribe
a mark at 42.0 mm (1.653 inch) on the 9.5
mm (3/8 inch) diameter metal rod. Use it
to seat the third accumulator and ball
assembly as shown. When the scribed line
is flush with the case face, installation depth
is correct.
!-++-!
7A-15B-15
Install or Connect
Figure35
A
C
D
80
3RD ACCUMULATOR BORE

CASE INTERIOR
2-4 SERVO BORE
LH0088-4L60
Figure 32 Leak Check - 3rd Accumulator
1. Piston seals (696) onto the piston (695).

Lubricate with TRANSJEL J 36850 or
equivalent.
2. Piston (695) into the case.
Index the piston with the notch in the
bottom of the case.
3. Spring assembly (694) onto the piston.
Flat side of the retainer upward.
4. J 23327 over the spring assembly.
Compress the spring assembly past the ring
groove in the case hub.
5. Retainer ring (693) into the case hub ring groove
with J 34627.
LH0089-4L60
Figure 33 Third Accumulator Retainer and Ball Asm. Installation
Lo and Reverse Clutch Piston

Figures 34 and 35
Tools Required:
J 34627 Snap Ring Remover/Installer
J 23327 Clutch Spring Compressor
!l"'!
CASE, TRANSMISSION
SPRING ASM., LO & REVERSE CLUTCH
SEALS, LO & REVERSE CLUTCH
Inspect
Figure 34
10
693
694
695
696
Lo and reverse piston (695) for:

- Porosity or damage.
- Ring groove damage.
Piston seals (696) for nicks or cuts.
Spring assembly (694) for damage.
Retainer ring (693) overstressed.
LH0090-4L60
Figure 34 Lo and Reverse Piston
7A-15B-16
4l60 AUTOMATIC TRANSMISSION UNIT REPAIR
,....., Install or Connect
Figure36
695
694
693
1----10
10
693
694
695
CASE, TRANSMISSION
SPRING ASSEMBLY, LO & REVERSE CLUTCH
LH0080-4L60
Figure 35 Installing Lo and Reverse Snap Ring
1. Parking pawl (711) and parking pawl return

spring (714) into the case.
2. Parking pawl pivot shaft (712) into the parking
pawl (711) and the case.
Check for proper operation.
3. Retaining plug (713) into the case.
Coat the plug with Loctite sealant or
equivalent and install it with a hammer and
punch.
Reaction Internal Gear and Carrier Assembly

IL'l'I
Parking Pawl
Figure36
ILI
Inspect
Parking paw1 (711) for cracks, burrs, or damage.

Parking pawl return spring (714) for distortion
or damage.
Parking pawl pivot shaft (712) for damage and
freeness of fit with the parking pawl.
LH0092-4L60
Figure 36 Parking Pawl Installation
Inspect
Reaction internal gear (684) and support (685)

for:
- Proper assembly.
- Stripped splines.
- Cracks.
- Teeth or lug damage.
- Thrust bearing assemblies (683 and 692)
for damage.
Lo and reverse clutch plates (682) for:
- Composition material wear, heat damage,
or delamination.
- Heat damage or surface finish damage to
steel plates.
Reaction carrier assembly (681) for:
- Pinion gear damage.
- Excessive pinion washer wear.
- End play exceeding 0.61 mm (0.024 inch).
- Proper pinion staking.
- Keystoned pinion gears (pinions must tum
freely).
- Damaged or worn thrust bearing.
- To check the captive thrust bearing in the
carrier for wear, place a bushing or an
output shaft sleeve on the bearing race (do
not contact the pinion gears) and turn it
with the palm of your hand. Any
imperfections will be felt through the
bushing.
7A-15B-17
Retain with TRANSJEL J 36850 or

equivalent.
2. Reaction internal gear and support (684 and
685) onto the bearing as shown.
3. Reaction carrier to support thrust bearing
assembly (683) onto the support (685).
Outer bearing race goes toward the support.
4. Reaction carrier (681) onto the thrust bearing.
A
A PINION GEAR END PLAY .20mm/.60mm (.008"/.024")

LH0093-4L60
Figure 37 Pinion End Play Check
681 CARRIER ASSEMBLY, REACTION
683 BEARING ASSEMBLY, THRUST (REACTION
CARRIER/SUPPORT)
685 SUPPORT, INTERNAL REACTION GEAR
692 BRG., REACTION GEAR SUPPORT TO CASE
697 DEFLECTOR, OIL (HIGH OUTPUT
MODELS ONLY)
662 CARRIER ASSEMBLY, INPUT 690 SLEEVE, OUTPUT SHAFT
COMPLETE
LH0095-4L60
LH0094-4L60
Figure 38 Captive Thrust Bearing Check
Reaction Internal Gear and Support

Figure 44
1-+ ..I Install or Connect

1. Reaction gear support to case bearing (692) onto
the case hub as shown.
Outside bearing race goes toward case hub.
Figure 39 Reaction Internal Gear and Carrier Bearing

Locations
Lo and Reverse Clutch Spacer Plate Selection

Tools Required:
Scale
Straight edge
7A-15B-18
679
679
.----INSTALL THE APPROPRIATE SELECTIVE

SPACER PLATE TO THE FINAL
ASSEMBLY AFTER DIMENSION "D"
IS OBTAINED. IDENTIFICATION SIDE UP.
682(A)
ILL.
DESCRIPTION
NO.
679
682
682(A)
682(8)
STACK UP FOR
MEASURING
SUPPORT ASSEMBLY, LO & REVERSE CLUTCH

PLATE ASSEMBLY, LO & REVERSE CLUTCH
SPACER PLATE, LO & REVERSE CL. (SELECTIVE)
WAVE PLATE, LO & REVERSE CLUTCH
LH0097-4L60
Figure 40 Measuring For Spacer Plate Selection
f@!
Measure
1. To measure for proper selective spacer plate,

stack the lo and reverse assembly on a flat
surface in the following order:
A. One waved plate (682B).
B. Five composition and four steel plates
(682), starting with one composition plate
and alternating with steel.
C. Lo and reverse clutch support (679).
2. Apply an evenly distributed load to the top of
the lo and reverse support assembly (679). Light
pressure (approximately 22 Nor 5 lbs.) on the
lo and reverse support assembly (679) will
provide the correct dimension for measurement.
NOTICE: Excessive pressure will start to flatten

the wave plate resulting in an inaccurate
measurement.
3. Measure the height of the clutch pack from the

work surface to the top of the lo and reverse
clutch support (dimension D).
4. Use dimension D to select the proper thickness
of the selective spacer plate for assembly.
5. Install the proper selective spacer plate between
the wave plate and the first composition clutch
plate with the identification side up.
6. The overall height for dimension D with the
selective spacer plate included should be 30.515
to 31.401 mm (1.20 to 1.24 inch).
LO AND REVERSE CLUTCH
QTY.
THICKNESS
PLATE - WAVED
2.42mm
(.096")
PLATE - SELECTIVE
SEE FIG. 39
PLATE - COMP. FACED
2.25mm
(.088")
PLATE - FLAT STEEL
1.75mm
(.069")
PHO 135-4L60-E
Figure 41 Lo and Reverse Clutch Plate Chart
7A-15B-19
LO AND REVERSE CLUTCH SPACER PLATE SELECTION CHART

USE THIS SELECTIVE PLATE
IF GAGE DIMENSION "D" IS

FROM
TO
IDENTIFICATION
PLATE THICKNESS
29.559mm
(1.164")
28.844mm
(1.136")
NONE
1.684mm
(.066")
1.829mm
(.072")
30.087mm
(1.185")
29.347mm
(1.155")
1.314mm
(.052")
1.168mm
(.046")
29.057mm
(1.144")
28.317mm
( 1.115")
2.198mm
(.087'')
2.344mm
(.092")
PHO 136-4L60-E
Figure 42 Lo and Reverse Spacer Plate Selection Chart
lul
Install or Connect
Figures 41 and 43
1. Waved plate (682A).

2. Correct selective spacer plate (682B), from
selection procedure.
3. Lo and reverse clutch plates (682) into case
lugs.
Start with a composition plate and alternate
with steel.
Index with the splines of the reaction carrier
and the case as shown.
682 PLATE ASSEMBLY,
LO & REVERSE CLUTCH
LH0099-4L60
Figure 43 Lo and Reverse Clutch Plates Properly

Installed
10
681
682
682A
6828
683
684
685
692
697
CASE, TRANSMISSION
CARRIER ASSEMBLY, REACTION
PLATE ASSEMBLY, LO & REVERSE CLUTCH
PLATE, LO & REVERSE CLUTCH (WAVED)
PLATE, LO & REVERSE CL. (SELECTIVE)
BEARING ASSEMBLY, THRUST (REACTION
CARRIER/SUPPORT)
GEAR, INTERNAL REACTION
SUPPORT, INTERNAL REACTION GEAR
BRG., REACTION GEAR SUPPORT TO CASE
DEFLECTOR, OIL (HIGH OUTPUT
MODELS ONLY)
LH0100-4L60
Figure 44 Reaction Internal Gear and Carrier Assembly

Installation
7A-15B-20
Lo and Reverse Clutch Support Assembly

l+-,.1
Support assembly for:

- Cracks or damaged lugs.
Figure 45
1. Inner race (675) from the support assembly.

2. One retainer ring (677).
3. Roller clutch assembly (678).
1. Roller clutch assembly (678) into the cam and

support assembly (679).
2. Support and roller assembly into the case with
the hub down.
3. Inner race (675) into the roller assembly.
Turn inner race (675) while inserting.
A. Push down for full engagement.
B. Bottom tangs will be flush with carrier
hub when properly installed.
C. Check for proper operation by rotating
the inner race as shown in Figure 45.
4. Support retainer spring (680) into the case.
Insert between the case lug and the one
open notch in the support.
ALIGN WIDE NOTCH

WITH WIDE CASE LUG.
680 ~---
LH0102-4L60
Figure 46 Lo and Reverse Support and Roller Asm.

Installation
A
B
675
677
LOCKED UP
FREE WHEELS
RACE, LO & REVERSE ROLLER CLUTCH
RING, LO & REVERSE RETAINER (ROLLER
ASSEMBLY /CAM)
678 CLUTCH ASSEMBLY, LO & REVERSE ROLLER
679 SUPPORT ASSEMBLY, LO & REVERSE CLUTCH
680 SPRING, TRANSMISSION LO & REVERSE CLUTCH
SUPPORT RETAINER
680
LH0101-4L60
Figure 45 Lo and Reverse Clutch Support Assembly
ll'l'I
679
Inspect
10
Figure 45
Inner race (675) for damage and surface finish.

Roller clutch assembly (678) for:
- Damaged rollers.
- Broken springs.
Carn for:
- Loose cam.
- Surface finish.
10
678
679
680
CASE, TRANSMISSION
CLUTCH ASSEMBLY, LO & REVERSE ROLLER
SUPPORT ASM., LO & REVERSE CLUTCH
SPRING, TRANSMISSION (LO & REVERSE
CLUTCH SUPPORT RETAINER)
LH0103-4L60
Figure 47 Support Spring - Installed
7A-15B-21
Reaction Sun Gear and Shell
Figure48
IL'I'!
!u!
_.669
Inspect
Reaction sun gear (673) for:

- Nicked, scored, or worn bushing (See
Bushing Replacement).
- Damaged spline or teeth.
Loose or weak retaining ring (do not
remove this ring, except to replace it.).
Reaction sun shell (670) for:
- Stripped or worn splines.
- Broken hub.
- Bent tangs.
Lo and reverse inner race to reaction sun gear
shell thrust washer (674) for wear or damage.
Reaction shaft to reaction sun gear shell bronze
thrust washer (669) for wear or damage.
Install or Connect
Figure 48
1. Reaction sun gear retainer ring (671) onto the

reaction sun gear, if previously removed.
2. Reaction sun gear (673) into the reaction carrier.
Index the teeth with the pinion gears.
3. Thrust washer (674) onto the lo and reverse
support inner race.
Index the four locating ears into the inner
race.
4. Reaction sun gear shell (670) onto the reaction
sun gear.
5. Bronze thrust washer (669) onto the reaction
sun gear shell.
Index tangs into the shell.
669 WASHER, THRUST (REACTION SHAFT/
SHELL)
670 SHELL, REACTION SUN
671 RING, REACTION SUN GEAR RETAINER
673 GEAR, REACTION SUN
674 WASHER, THRUST (RACE/REACTION SHELL)
675 RACE, LO & REVERSE ROLLER CLUTCH
676 RING, LO & REVERSE SUPPORT TO CASE
RETAINER
LH0105-4L60
Figure 48 Reaction Sun Gear and Shell Installation
IL'I'!
Inspect
Figures 49 and 50
Input Internal Gear and Reaction Shaft

Figures 49 and 50
Figure 49
1. Retainer ring (668) from input internal gear

(664).
2. Reaction carrier shaft (666) from the input
internal gear.
Reaction carrier shaft (666) for:

- Scored, damaged, or worn bushings (see
Bushing Replacement).
- Cracked shaft.
- Damaged spline or gear teeth.
- Under cut around the shaft from
interference with the sun gear.
7A-15B-22
Input internal gear (664) for:

- Cracks.
Input carrier to reaction shaft thrust bearing
(663) for wear or damage.
Output shaft (687) for:
- Plugged or restricted lube passages.
- Damaged splines or ring groove.
- Damaged governor drive gear teeth.
- Burrs or damage to the front of the shaft at
seal area. (Polish with crocus cloth if
necessary).
- Burrs or damage to bearing journals.
E3
Install or Connect
Figure50
1. Place new rotor over output shaft.

2. Place J 36352-4 in groove on output shaft.
3. Place J 36352-6 on shaft and press to make
contact with J 36352-4.
REMOVAL
INSTALLATION
J 21427-01
687 SHAF~ OUTPUT
699 ROTOR, INTERNAL TRANSMISSION SPEED
SENSOR
LH0107-4L60
664 GEAR, INPUT INTERNAL

666 SHAFT, REACTION CARRIER
668 RING, REACTION SHAFT/INTERNAL GEAR
Figure 50 Internal Transmission Speed Sensor Rotor
RETAINER
LH0106-4L60
Figure 49 Input Internal Gear and Reaction Shaft
Internal Transmission Speed Sensor Rotor
Input Internal Gear and Output Shaft

Figures 51 and 52
Tool Required:
J 29837 Output Shaft Support Fixture
Figure 50
Tools Required:
J 21427-01 Speedometer Gear Puller
Adapter
J 8433 Speedometer Gear Puller
J 36352-6 "C" Washer
J 36352-4 Rotor Installer
Mechanical press
llI
l-+I
If rotor is damaged, replace it. Do not reuse a

rotor that has been removed.
Figure50
2.
3.
4.
Speed sensor rotor on output shaft for tooth

damage.
[[) Important
1.
Inspect
Figure50
I-+!
Install J 21427 with J 8433 and remove rotor.
5.
6.
Install or Connect
Reaction shaft (666) into the input internal gear

(664)_
Retainer ring (668) into the input internal gear.
Input internal gear and shaft assembly into the
sun gear shell.
Index the shaft spline into the reaction
carrier.
Thrust bearing (663) onto the reaction carrier
shaft.
Outer race goes toward the reaction carrier
shaft.
Output shaft (687) into the transmission.
Index the splines with the mating parts.
J 29837 onto the case.
Position upwards as far as possible to
support the output shaft.
7A-15B-23
Input Carrier and Sun Gear

Figure 53
664
~663
~__)
6661{
Tool Required:
J 34627 Snap Ring Pliers
&TIITo
!l'I'!
'
'
668--<D
10
Figure 51 Input Internal Gear Installation
!u!
Inspect
Input carrier assembly (662) for:

- Pinion gear damage.
- Excessive pinion washer wear - end play
should be 0.20 to 0.61 mm (0.008 to 0.024
inch).
Proper pin stake.
- Keystoned pinion gears (pinion gears must
rotate freely).
- Damaged or worn thrust bearing.
To check the captive thrust bearing in
the carrier for wear, place a bushing or
an output shaft sleeve on the bearing
race (do not contact the pinion gears)
and tum it with the palm of your hand.
Any imperfections will be felt through
the bushing.
Input sun gear (658) for:
- Bushing damage or wear (see Bushing
Replacement Procedure).
- Cracks.
Install or Connect
Figure 53
J 29837
687 SHAFT, OUTPUT
LH0077-4L60
Figure 52 Output Shaft - Installation
1. Input carrier assembly (662) onto the output

shaft.
2. Retainer ring (661) into the output shaft ring
groove.
Use care not to overexpand the ring during
installation.
Do not reuse the old retainer ring if it has
been overexpanded.
3. Remove J 29837.
4. Input sun gear (658) into the input carrier.
Rotate the sun gear teeth into the pinion
gear teeth.
7A-158-24
a-----658
!
'
10
658
661
662
3.
4.
5.
6.
7.
The 3-4 clutch plates (654).

Five 3-4 clutch boost spring assemblies (600).
The 3-4 clutch apply plate (653).
The 3-4 clutch ring retainer plate (652).
Forward clutch backing plate retainer ring (651)
and backing plate (650).
8. Forward clutch sprag assembly (638-648).
CASE, TRANSMISSION
GEAR, INPUT SUN
RET., OUTPUT SHAFT TO INPUT CARRIER
CARRIER ASSEMBLY, INPUT (COMPLETE)
LH0111-4L60
Figure 53 Input Carrier and Sun Gear - Installation
Input Clutch Assembly
605 HOUSING & DRUM ASSEMBLY, REVERSE

INPUT CLUTCH
615 BEARING ASSEMBLY, STATOR SHAFT/
SELECTIVE WASHER
616 WASHER, THRUST (SELECTIVE)
621 HOUSING & SHAFT ASSEMBLY, INPUT
Tools Required:
J 23456 Clutch Spring Compressor Press
J 23327-1 Clutch Spring Compressor
J 25018-A Clutch Spring Compressor
Adaptor
l+--+I
Figures 54 and 56
l.,t+I
Reverse input clutch assembly (605) from the

input clutch assembly (621).
Oil pump to selective washer thrust bearing
(615).
Selective washer (616).
Disassemble
Figures 55 and 56
1. Place the input clutch assembly (621) on the

bench with the turbine shaft through the bench
hole.
2. The 3-4 clutch plate retainer ring (656) and the
backing plate (655).
LH0112-4L60
Figure 54 Reverse Input and Input Clutches
l..t+I
Disassemble
Figure 56
1.
2.
3.
4.
5.
6.
l..t+I
Input sun gear bearing assembly (637).

Input housir.g to output shaft lip seal (636).
Forward clutch plates (649).
Forward wave plate (648).
Forward clutch apply plate (646).
Overrun clutch plates (645).
Disassemble
Figure 55
1. Install J 23456 and J 23327-1 with J 25018-A.

Compress overrun clutch spring assembly
(634).
2. Overrun clutch retainer ring (635).
3. Overrun clutch spring assembly (634).

4. Overrun clutch piston (632).
Inner and outer lip seals (631 ).
5. Forward clutch piston assembly (630).
Inner and outer lip seals (629).
6. Forward clutch housing (628).
7. The 3-4 clutch spring assembly (626).
8. The 3-4 clutch apply ring (625) and piston (623).
Inner and outer lip seals (624) from piston.
9. Forward clutch to input housing 0-ring seal
(622).
10. Four turbine shaft oil seal rings (619).
621 INPUT HOUSING &

SHAFT ASSEMBLY
Tools Required:
6.3 mm (#4) Screw extractor
9.5 mm (3/8 inch) diameter metal rod
6.35 mm (1/4 inch) diameter rod or drift
hammer
J 23456 Clutch Spring Compressor Press
Adaptor
J 29882 Overrun Clutch Inner Seal
Protector
J 29883 Forward Clutch Inner Seal
Protector
LH0113-4L60
Inspect
Figures 57 and 58
Input housing for porosity or damage

Input housing and shaft assembly (621) for:
- Spline wear or damage.
- Three turbine shaft check balls.
A. The balls must not be loose or leaking.
B. The open hole is the lube oil passage
which feeds the output shaft.
Presence of orificed cup plug ( 698).
Cracks at lube holes.
Four turbine shaft oil seal ring grooves for
damage or burrs.
- Seals must fit freely into the ring grooves.
Check valve retainer and ball assembly (617)

for:
- Damage.
- The ball must move freely in the retainer.
- The retainer must be tight in the turbine
shaft.
Feed passages for:
- Obstructions - blow air through passages.
Check Valve Retainer and Ball Assembly Replacement Procedures
Figure 55 Overrun Clutch Retainer Ring - Removal
IL"l'I
7A-15B-25

Figure 58
1. Straighten the tangs of the retainer and remove

the ball.
2. Check valve retainer.
Use 6.3 mm (#4) Screw extractor.
1....1 Install or Connect

Figure 58
New check valve retainer and ball assembly

(617).
A. Use the 9.5 mm (3/8 inch) metal rod.
B. Seat the retainer 3.0 mm (1/8 inch) below
top surface of the turbine shaft.
C. Be certain the ball is loose.
7A-15B-26
615 616
617
623
625
626
628
652 653 654C 654A
6548
ILL.
NO.
600
615
DESCRIPTION
SPRING ASM., 3-4 CLUTCH BOOST (5)
BEARING ASSEMBLY, STATOR SHAFT/
SELECTIVE WASHER
617 RETAINER & BALL ASSEMBLY, CHECK VALVE
620 RETAINER & CHECK BALL ASSEMBLY
623 PISTON, 3RD & 4TH CLUTCH
625 RING, 3RD & 4TH CLUTCH APPLY
626 SPRING ASSEMBLY, 3RD & 4TH CLUTCH
627 RETAINER & BALL ASSEMBLY, FORWARD
CLUTCH HOUSING
628 HOUSING, FORWARD CLUTCH
630 PISTON, FORWARD CLUTCH
632 PISTON, OVERRUN CLUTCH
633 BALL, OVERRUN CLUTCH
634 SPRING ASSEMBLY, OVERRUN CLUTCH
635 SNAP RING, OVERRUN CLUTCH SPRING RETAINER
636 SEAL, INPUT HOUSING TO OUTPUT SHAFT
645A PLATE ASSEMBLY, OVERRUN CLUTCH (FIBER)
6458 PLATE, OVERRUN CLUTCH (STEEL)
A FORWARD CLUTCH SPRAG ASSEMBLY
637 BEARING ASSEMBLY, INPUT SUN GEAR
638 SNAP RING, OVERRUN CL. HUB RET.
639 HUB, OVERRUN CLUTCH
641 RETAINER & RACE ASSEMBLY, SPRAG
642 FORWARD SPRAG ASSEMBLY
643 RETAINER RINGS, SPRAG ASSEMBLY
644 RACE, FORWARD CLUTCH (OUTER)
ILL.
NO.
646
648
649A
6498
650
651
DESCRIPTION
PLATE, FORWARD CLUTCH APPLY
PLATE, FORWARD CLUTCH (WAVED)
PLATE ASSEMBLY, FORWARD CLUTCH (FIBER)
PLATE, FORWARD CLUTCH (STEEL)
PLATE, FORWARD CLUTCH BACKING (SEL.)
RING, FORWARD CLUTCH BACKING PLATE
RETAINER
652 PLATE, 3RD & 4TH CLUTCH RING RETAINER
653 PLATE, 3RD & 4TH CLUTCH APPLY
(STEPPED)
654A PLATE ASSEMBLY, 3RD & 4TH CLUTCH (FIBER)
6548 PLATE, 3RD & 4TH CLUTCH (FLAT STEEL)
654C PLATE, 3RD & 4TH CLUTCH (STEEL)
655 PLATE, 3RD & 4TH CLUTCH BACKING (SELECTIVE)
656 RING, 3RD & 4TH CLUTCH BACKING
PLATE RETAINER
698 PLUG, ORIFICED CUP
LH0114-4L60
Figure 56 Input Clutch Assembly
!L"'!
7A-15B-27
Inspect
Figures 57 and 59
Turbine shaft 0-ring seal (618) for:

- Damage.
- Nicks or cuts.
Input housing check valve ball (620):
The ball must move freely.
- Leak check the ball with solvent.
II]
Important
If the 3-4 clutch plates are burned or worn and

a cause is not found during diagnosis or
disassembly, replacement of the retainer and
check ball assembly may be required (Figure
58).
621
687
636
A LUBE PASSAGE
SELECTIVE WASHER
620 RETAINER & CHECK BALL ASSEMBLY
687 SHAFT, OUTPUT
USED WITH
298mm CONVERTER
USED WITH
245mm CONVERTER
A SHAFT, TURBINE
618 SEAL, "O" RING (TURBINE SHAFT/
SELECTIVE WASHER)
LH0115-4L60
LHO 117 -4L60
Figure 57 Input Housing Check Valve Ball
Figure 59 Views of the Input Housing
!+-+!
Figure 60
!-++!
INSTALL
Tap out retainer and ball assembly.

Install or Connect
Figures 58 and 60
A
B
C
617
#4 EASY OUT
TURBINE SHAFT
9.5mm (3/8") METAL ROD
CHECK VALVE RETAINER & BALL ASSEMBLY
LH0116-4L60
Figure 58 Retainer and Ball Assembly- Replacement
Using same tools, tap in retainer and ball

assembly until shoulder is seated in housing.
7A-15B-28
1. Inner and outer 3-4 clutch lip seals (624) on the

3-4 clutch piston.
Seal lips must face away from the piston
hub.
Lubricate the seals with TRANSJEL
J 36850 or equivalent.
2. The 3-4 clutch piston (623) into the input
housing as shown.
Use care not to damage the seals.
620
621---...._
623
624
REMOVAL

623 PISTON, 3RD & 4TH CLUTCH
624 SEALS, 3RD & 4TH CL. (INNER & OUTER)
LH0119-4L60
Figure 61 Input Housing and 3-4 Piston
INSTALLATION
A
620
621
698
ROD STOCK/DRIFT, 5. 71 5mm ( 1 /4") DIA.

RETAINER & CHECK BALL ASSEMBLY
PLUG, ORIFICED CUP
LH0118-4L60
!L'I'!
Figures 62 and 63
Figure 60 Retainer and Checkball Removal/Installation
!L!
Inspect
Figure56
The 3-4 clutch piston (623) for damage or

porosity.
The 3-4 clutch apply ring (625) for:
- Bent tangs.
The 3-4 clutch spring assembly (626) for
damage or distortion.
The 3-4 clutch boost spring assemblies (600)
for damage or distortion.
!..!..! Assemble
Figure 61
Position the input housing and shaft assembly

on the bench with the turbine shaft through a bench
hole.
Inspect
!..!+-!
Forward clutch housing (628) for:

- Proper check ball operation.
- Damage or distortion.
- Burrs in seal areas.
- Cracks.
Forward clutch piston (630) and overrun clutch
piston (632) for:
- Apply leg damage.
Overrun spring assembly (634) for damage or
distortion.
Input housing to output shaft lip seal (636) for
damage or wear.
Assemble
Figures 62 and 63
1. Forward clutch housing to input clutch housing

0-ring seal (622) as shown.
equivalent.
621
622
623
625
626
628
629
630

SEAL, "O" RING INPUT TO FORWARD HSG.
PISTON, 3RD & 4TH CLUTCH
RING, 3RD & 4TH CLUTCH APPLY
SPRING ASSEMBLY, 3RD & 4TH CLUTCH
HOUSING, FORWARD CLUTCH
SEALS, FORWARD CLUTCH (INNER & OUTER)
PISTON, FORWARD CLUTCH
621
623
625
626
628
630
631
632

SEAL, OVERRUN CLUTCH (INNER & OUTER)
PISTON, OVERRUN CLUTCH
LH0120-4L60
LH0121-4L60
Figure 62 Forward Clutch and 3-4 Apply Ring Installed
2. Inner and outer seals (629) on forward clutch

piston.
Seal lips must face away from the piston
tangs as shown.
equivalent.
3. Forward clutch piston (630) into the forward
clutch housing.
Use care not to damage the outer lip seal.
4. The 3-4 clutch spring assembly (626) onto the
3-4 clutch apply ring.
5. Forward clutch assembly onto the 3-4 clutch
spring assembly.
The forward clutch piston apply legs m_ust
be indexed with the 3-4 clutch apply nng
legs.
6. J 29883 on the input housing as shown.
7. Apply ring and forward clutch assembly into
the input housing as shown.
A. Hold the assembly by the apply ring legs
B. Do not let the forward clutch piston
separate from the housing.
C. Firmly seat the assembly.
7A-15B-29
Figure 63 Overrun Piston - Installed
8. J 29882 on the input housing as shown.

9. Overrun clutch piston (632).
Hub facing upward as shown.
If all parts are properly seated to this point,
the overrun piston hub will be
approximately 4.7 mm (3/16 in.) below the
top of the snap ring groove in the input
housing hub.
!-+~+-!
Assemble
Figures 64 and 65
1. Overrun clutch spring assembly (634) onto the

overrun clutch piston.
Locate the springs on the piston tabs.
2. J 23456 and J 23327-1 with J 25018-A onto the
overrun spring assembly.
Compress springs (Do not over-compress).
3. Retainer snap ring (635) into the snap ring
groove.
4. Input housing to output shaft lip seal (636).
7A-15B-30
ll1t!
Inspect
Overrun clutch plates (645) for:

- Composition plate damaged tangs,
delamination, or excessive wear.
- Steel plate damaged tangs, wear, or heat
damage.
Input sun gear bearing assembly (637) for:

- Wear.
- Flatness.
- Damaged.
,..~+!
Assemble
Figures 66 and 67
621 INPUT HOUSING &

SHAFT ASSEMBLY
LHO 113-4L60
Figure 64 Overrun Clutch Retaining Ring - Installed
1. Overrun clutch plates (645) into the input

housing.
Overrun clutch plates are the smallest of
the three sets of plates in the input
housing.
Index the plates as shown starting with a
steel plate and alternate with composition.
2. Thrust bearing assembly (637) onto the input
clutch hub.
The inside race must face the input housing
hub.
equivalent.
3. Align the tangs on the two composition overrun
clutch plates.
OVERRUN
* ALIGN
WIDE NOTCHES TO CASE LUGS
OVERRUN CLUTCH
FLAT STEEL
MODEL
621
636
637
687

SEAL, INPUT HOUSING TO OUTPUT SHAFT
BEARING ASSEMBLY, INPUT SUN GEAR
SHAFT, OUTPUT
LH0123-4L60
ALL
MODELS
COMP. FACED
NO.
THICKNESS
NO.
THICKNESS
2.248mm - 2.400mm
(.089" - .094")
2.03mm
(.079")
Figure 65 Input Hsg. to Output Shaft Lip Seal

PH0158-4L60-E
Figure 66 Overrun Clutch Plate Chart
7A-158-31
Forward sprag outer race (644) for:

- Spline damage.
- Surface finish damage.
Plugged lubrication holes.
,vt~
637 638
639
643
644 641
THE NOTCHES ABOVE E A C H =

SPRAG MUST POINT UP AS
r==-----i
SHOWN WHEN ASSEMBLED
L___J
INTO THE OUTER RACE
CJ
637
638
639
641
642
643
644

658 GEAR, INPUT SUN
Figure 67 Input Sun Gear Thrust Bearing
Forward Clutch Sprag Assembly

Disassemble
Figure 68
1. Forward sprag outer race (644).

2. Overrun clutch hub retaining snap ring (638)
and clutch hub (639).
3. Forward clutch retainer and race assembly (641).
!L!
LH0126-4L60
Figure 68 Forward Clutch Sprag Assembly
LH0125-4L60
I+:+!

SNAP RING, OVERRUN CLUTCH HUB RET.
HUB, OVERRUN CLUTCH
RETAINER & RACE ASSEMBLY, SPRAG
FORWARD SPRAG ASSEMBLY
RETAINER RINGS, SPRAG ASSEMBLY
RACE, FORWARD CLUTCH OUTER
Inspect
Forward clutch sprag assembly (642) for:

- Wear or damage.
- Weak or broken springs.
- Damaged or missing retainer caps (brass).
Overrun clutch hub (639) for:
- Spline damage.
- Plugged lubrication holes.
- Damaged tangs.
- Cracks.
Forward clutch retainer and race assembly (641)
for:
- Spline damage.
- Loose retainer.
H+-!
Assemble
1. Forward clutch sprag assembly (642) into the

outer race.
To correctly install, the notches in the sprag
cage must face upward as shown.
2. One sprag retainer ring (643) onto the race and
retainer assembly.
The flange on the retainer ring must face
away from the retainer.
3. Race and retainer assembly into the sprag
assembly.
A. To assemble, hold the outer race in your
left hand with your fingers supporting the
sprag at the recessed side of the outer race.
B. Insert the race and retainer assembly by
pushing in and turning to the left.
4. The remaining retainer ring onto the sprag
assembly.
5. Overrun clutch hub (639).
6. Overrun clutch hub retaining snap ring (638)
into the snap ring groove of the race and retainer
assembly.
7. Test the assembly for proper operation as shown
(Figure 71).
[I]
Important
If the assembly operates backwards, you

have installed the sprag backwards.
Reassemble correctly.
7A-15B-32
l..~~I
Assemble
Forward clutch sprag assembly into the input

clutch housing.
Index the overrun clutch hub into the
overrun clutch plates.
ILI
Inspect
Figures 72 and 73
A
B
C
642
644
RECESSED FACE
NOTCHES POINT UPWARD AS SHOWN
LIPPED EDGE
RACE, FORWARD CLUTCH (OUTER)
LH0127-4L60
Figure 69 Sprag Assembly Procedure
541~~~~-f!ff;'-t"~
642--~~i,i\\
Forward (649) and 3-4 clutch plates (654) for:

- Composition plate damaged tangs,
delamination, or wear.
- Steel plate damaged tangs, wear, or heat
damage.
Forward (650) and 3-4 clutch backing plates
(655) for:
-- Flatness.
- Burrs or nicks.
Forward clutch apply plate (646) and spacer
plate (64 7) for:
- Flatness.
Burrs or nicks.
643
644
FORWARD CLUTCH PACK
A PUSH IN AND TURN COUNTERCLOCKWISE

TO INSTALL
641 RETAINER & RACE ASSEMBLY, SPRAG
642 FORWARD SPRAG ASSEMBLY
LH0128-4L60
Figure 70 Sprag Race and Retainer Assembly

Procedure
ALIGN WIDE NOTCHES

TO CASE LUGS
3-4 CLUTCH PACK
~600
LOCATE IN FIVE
PLACES AROUND
CLUTCH PACK
600
600
THE OVERRUN CLUTCH HUB MUST TURN

CLOCKWISE, BUT NOT COUNTERCLOCKWISE
600 SPRING ASM., BOOST 3-4 CLUTCH

LH0130-4L60
LH0129-4L60
Figure 71 Sprag Operation Check
600
Figure 72 Forward and 3-4 Clutch Plates - Installed
The 3-4 clutch apply plate (653) for:

- Flatness.
The 3-4 clutch ring retainer plate (652) for:
- Bent tangs.
- Flatness.
656
l+:+-1
655
7A-15B-33
Assemble
1. Forward clutch apply plate (646) into the input

clutch housing.
Index as shown.
2. Waved steel forward clutch plate (648) into the
input clutch housing.
Index as shown.
3. The remaining forward clutch plates (649) into
the input clutch housing.
Start with a steel plate and alternate with
composition.
4. Forward clutch selective backing plate (650).
5. Forward clutch retaining ring (651).
6548
654A
654C
653
Forward Clutch Piston Travel Check

652
F1gure 75
l~I
651
ILL.
NO.
600
621
646
648
649A
6498
650
651
652
653
654A
6548
654C
655
656
DESCRIPTION
SPRING ASSEMBLY, 3-4 CLUTCH BOOST (5)
PLATE, FORWARD CLUTCH BACKING (SELECTIVE)
RING, FORWARD CLUTCH BACKING PLATE RETAINER
PLATE, 3RD & 4TH CLUTCH RING RETAINER
PLATE, 3RD & 4TH CLUTCH APPLY (STEPPED)
PLATE ASSEMBLY, 3RD & 4TH CLUTCH (FIBER)
PLATE, 3RD & 4TH CLUTCH (STEEL)
PLATE, 3RD & 4TH CLUTCH BACKING (SELECTIVE)
RING. 3RD & 4TH CLUTCH BACKING PLATE RETAINER
Measure
1. With the overrun clutch and forward clutch fully

assembled in the Input Housing, check the end
clearance between the backing plate (650) and
the retaining ring (651) with two feeler gages.
2. Proper forward clutch backing plate travel
should be 0.75 to 1.60 mm (0.030 to 0.063
inch).
3. Select the proper backing plate from the chart
to obtain the correct clearance.
FORWARD CLUTCH INFORMATION CHART
PLATE TYPE
THICKNESS
QUANTITY REQUIRED
ALL MODELS
APPLY PLATE
4.30rnrn
(.169")
WAVED STEEL
CLUTCH PLATE
1. 79rnrn
(.070")
FLAT STEEL
CLUTCH PLATE
2.29rnrn
(.090")
COMPOSITION
FACED CLUTCH
PLATE
1. 78rnrn
(.070")
BACKING PLATE
SELEGTIVE
LH0131-4L60
Figure 73 Input Housing with Forward and

3-4 Clutch Plates
LH0132-4L60-R1
Figure 74 Forward Clutch Plate Chart
7A-15B-34
3-4 CLUTCH
INFORMATION CHART
FORWARD CLUTCH
BACKING PLATE SELECTION
QUANTITY REQUIRED
ALL MODELS
BACKING PLATE TRAVEL
PLATE TYPE
. 75mm 1.60mm
(.030" .063")
THICKNESS
STEPPED
APPLY PLATE
*A-MODELS
*B-MODELS
4.65mm
(.183")
PLATE THICKNESS
IDENTIFICATION
6.97mm 7.07mm
(.274" .278")
6.38mm 6.48mm
(.250" .255")
CLUTCH PLATES
1.78mm
(.070")
5. 79mm 5.89mm
(.227" - .232")
FLAT STEEL
CLUTCH PLATE
1.78mm
(.070")
5.20mm - 5.30mm
(.205" .208")
2.03mm
(0.79")
4.61mm - 4.71mm
(.180" 185")
COMPOSITION
FACED CLUTCH
PLATES
BACKING PLATE
SELECTIVE
t FLAT STEEL
*A-MODELS
SAM
*B-MODELS
ALL OTHERS
650
t SAME SPLINE CONFIGURATION AS APPLY PLATE
621
PH0134-4L60
Figure 76 3-4 Clutch Plate Chart

650 PLATE, FORWARD CLUTCH BACKING
651 RING, FORWARD CLUTCH BACKING PLATE RETAINER
LH0133-4L60
Figure 75 Forward Clutch Backing Plate Travel
3-4 Clutch Assembly
5. The 3-4 clutch backing plate (655) and retainer

ring (656).
Chamfered side up.
3-4 Clutch Piston Travel Check
Figure 77
!~!
Figures 76 and 80
lf-1
Assemble
1. The 3-4 ring retainer plate (652).

Index each leg into the apply ring legs.
2. The 3-4 clutch apply plate (653).
3. The 3-4 clutch plates (654).
Start with steel and alternate with
composition as shown in (Figure 80).
First steel plate has the same spline
configuration as apply plate.
4. The 3-4 boost springs (600).
Measure
Check the end clearance between the backing

plate (655) and the first composition plate with
a feeler gage.
Select the proper backing plate from the chart
to obtain the correct clearance for model you
are working on.
Clutch Air Check

Figure 78
Air check the 3-4, forward, and overrun clutches

by applying air pressure at the feed holes in the turbine
shaft. (When the overrun clutch is checked, the air
will blow by the forward clutch piston lip seals and
exit out the forward clutch feed hole in the turbine
shaft.)
7A-15B-35
3-4 BACKING PLATE SELECTION

*BACKING
PLATE
BACKING PLATE
TRAVEL
MODEL
Use Backing Plate

Which Gives
Correct Travel
2.42mm 1.61 mm
(.095" .063")
fBM, SAM
2.40mm 1.52mm
(.094" .060 ")
ALL OTHERS
DIM.
I.D.
6.5Bmm-6.38mm
(.259" .251 ")
5.75mm-5.55mm
(.226"-.218")
4.92mm4.72mm
(.194".186")
4.09mm-3.89mm
(.161 ".153")
--
655
1 CONVERTER RELEASE
2 OVERRUN CLUTCH
3 FORWARD CLUTCH
4 3-4 CLUTCH
5 LUBE
LH0136-4L60
Figure 78 Turbine Shaft Fluid Passages
J 36418-1
654 PLATE ASSEMBLY, 3RD & 4TH CLUTCH
655 PLATE, 3RD & 4TH CLUTCH BACKING
NH0135-4L60
Figure 77 3-4 Backing Plate Selection Chart
Turbine Shaft Seals

Figure 79
Tools Required:
J 36418-1 Seal Installer
J 36418-2A Seal Sizer
!..!+!
619 RING, OIL SEAL (TURBINE SHAFT)

LH0137-4L60
Assemble
1. Install four turbine shaft oil seal rings (619)

using J-36418-L
Adjust
Adjust screw to obtain proper height.

2. Use J 36418-2A to size the seals after
installation.
Figure 79 Turbine Shaft Oil Seal Rings
7A-15B-36
6458
, - - - - - - - - - -1
I
619
600
619
620
621
622
623
624
625
626
628
629
630
631
632
634
635
636
637
638
639
SPRING ASM., BOOST 3-4 CLUTCH

RING, OIL SEAL (TURBINE SHAFT)
RETAINER & CHECK BALL ASSEMBLY
SEAL, "O" RING INPUT TO FORWARD HSG.
SEAL, 3RD & 4TH CL. (INNER & OUTER)
SEAL, FORWARD CLUTCH (INNER & OUTER)
SEAL, OVERRUN CLUTCH (INNER & OUTER)
PISTON, OVERRUN CLUTCH
SPRING ASSEMBLY, OVERRUN CLUTCH
SNAP RING, OVERRUN CLUTCH SPRING RETAINER
SEAL, INPUT HOUSING TO OUTPUT SHAFT
SNAP RING, OVERRUN CL. HUB RETAINING
HUB, OVERRUN CLUTCH
641
642
643
644
645A
6458
646
648
649A
6498
650
651
652
653
654A
6548
654C
655
656
RETAINER & RACE ASSEMBLY, SPRAG

RETAINER RINGS, SPRAG ASSEMBLY
RACE, FORWARD CLUTCH (OUTER)
PLATE ASSEMBLY, OVERRUN CLUTCH (FIBER)
PLATE, OVERRUN CLUTCH (STEEL)
PLATE, FORWARD CLUTCH BACKING (SEL.)
RING, FORWARD CLUTCH BACKING PLATE RETAINER
PLATE, 3RD & 4TH CLUTCH RING RETAINER
PLATE, 3RD & 4TH CL. APPLY (STEPPED)
PLATE ASSEMBLY, 3RD & 4TH CLUTCH (FIBER)
PLATE, 3RD & 4TH CLUTCH BACKING (SELECTIVE)
RING, 3RD & 4TH CLUTCH BACKING PLATE RETAINER
LH0138-4L60
Figure 80 Input Clutch Assembly
Reverse Input Clutch Assembly

(611).
Tools Required:
Adaptor
141
Disassemble
Figures 81 and 82
1. Retaining ring (614)
housing.
2. Backing plate (613).

3. Clutch plates (612) and Belleville steel plate
from reverse input
4. Install J 23327-1 and J 25018-A.

Compress the spring assembly.
5. Spring assembly retainer ring (610) and spring
assembly (609).
6. Reverse input clutch piston (607).
Inner and outer lip seals (608).
7A-15B-37
J 25018-A
UNDER
J 23327-1
605
LH0140-4L60
Figure 82 Reverse Input Retainer Ring - Removal
ll'l'I
Inspect
Figures 81 and 83
ILL.
NO.
605
Backing plate (613) for:

Damage.
- Distortion or flatness.
- Burrs or surface finish damage.
Clutch Plates (612) for:
Composition plate tang damage,
delamination, or wear.
Steel plate tang damage, wear, or heat
damage.
Spring assembly (609) for distortion or damage.
Piston (607) for:
- Damage or porosity.
Housing and drum assembly (605) for:
Damaged or worn bushings (603 and 606).
Surface on the hub and outer housing.
Leak at the weld.
DESCRIPTION
HOUSING & DRUM ASSEMBLY, REVERSE

INPUT CLUTCH
607 PISTON ASM., REVERSE INPUT CLUTCH
608 SEALS, REVERSE INPUT CLUTCH (INNER & OUTER)
609 SPRING ASM., REVERSE INPUT CLUTCH
610 RING, REVERSE INPUT CLUTCH SPRING RETAINER
611 PLATE, REVERSE INPUT CL. (BELLEVILLE)
612A PLATE ASM., REVERSE INPUT CLUTCH (FIBER)
61 28 PLATE, REVERSE INPUT CLUTCH (STEEL)
613 PLATE, REVERSE INPUT CLUTCH BACKING
614 RING, REVERSE INPUT CL. RETAINING
LHO 139-4L60
Figure 81 Reverse Input Clutch Assembly
A CHECK FOR DISHING AT THIS POINT

INPUT CLUTCH
LH0141-4L60
Figure 83 Check Reverse Input Housing For Dishing
7A-15B-38
7. Backing plate (613).

Chamfered side up
1-+!+I Assemble
Figures 81, 82, 84, 85 and 86
1. Inner and outer seals (608) on the piston.

Lips must face away from the hub as
shown.
Lubricate with transmission fluid.
2. Piston (607) into the housing and drum
assembly.
Use an 8 mm feeler gage to position the lip
seals.
Use care not to damage the seals.
3. Spring assembly (609).
Large opening in the assembly goes
towards the piston.
4. Install J 23327-1 and J 25018-A.
A. Compress the spring assembly.
B. Install the retainer ring (610).
5. Belleville steel clutch plate (611 ).
6. Clutch plates (612). (4 steel and 4 composition
plates required).
Start with a steel and alternate with
composition.
Reverse Input Clutch Backing Plate Selection

l@I
Measure
1. With the reverse input clutch fully assembled,

apply an evenly distributed load to the clutch
pack in the direction shown in Figure 84.
Medium pressure (approximately 89 N or 20
lbs.) on the backing plate applied by hand on
five evenly distributed points will obtain the
backing plate travel for measurement.
NOTICE: Excessive pressure will distort the

Belleville plate resulting in an inaccurate
measurement.
2. Using a feeler gage, measure between the snap
ring and the backing plate. Backing plate travel
should be 1.02 to 1.94 mm (0.040 to 0.076
inch).
3. Select the proper backing plate to obtain the
specified travel.
CHECK FOR
REVERSE INPUT CLUTCH
(.040"-.075")
BACKING PLATE
TRAVEL
NO.
THICKNESS
BELLEVILLE
PLATE
2.311 mm (.091")
2.210mm (.087")
FLAT STEEL
CLUTCH PLATE
2.045mm (.081")
1.892mm (.075")
COMPOSITION
FACED CLUTCH
PLATE
1.880mm (.074")
1.730mm (.068")
BACKING PLATE
SELECTIVE
LH0143-4L60
Figure 85 Reverse Input Clutch Plate Chart
REVERSE INPUT CLUTCH

BACKING PLATE SELECTION
ALL MODELS
BACKING PLATE TRAVEL =
LH0142-4L60
Figure 84 Reverse Input Backing Plate Selection
1.02mm - 1.94mm
(0.40" - .076")
PLATE THICKNESS
IDENTIFICATION
7.60mm - 7.45mm
(.299" - .293")
6.94mm - 6. 79mm
(.273" - .267")
6.28mm - 6.13mm
(.24 7" - .241 ")
5.62mm - 5.47mm
(.221" - .215")
8
LH0144-4L60
Figure 86 Reverse Input Backing Plate Selection Chart
7A-15B-39
CORRECTLY
INSTALLED

INPUT CLUTCH
611 PLATE, REVERSE INPUT CL. (BELLEVILLE)
612A PLATE ASM., REVERSE INPUT CLUTCH (FIBER)
6128 PLATE, REVERSE INPUT CLUTCH (STEEL)
613 PLATE, REVERSE INPUT CLUTCH BACKING
605
LH0145-4L60
Figure 87 Reverse Input Clutch
--,--~---ILL.
NO.
DESCRIPTION
SELECTIVE WASHER
LH0146-4L60
Figure 88 Thrust Bearing and Selective Washer

Location
Reverse Input and Input Clutches

!-+!!
Assemble
Figures 88 and 89
1. Selective thrust washer (616) onto the input

housing.
2. Bearing assembly (615).
Inside (black race) goes toward the oil
pump.
3. Reverse input clutch assembly (605) onto the
input clutch assembly.
Index the reverse input clutch plates with
the input clutch hub.
Make certain all clutch plates are fully
engaged.

INPUT CLUTCH
SELECTIVE WASHER
LH0112-4L60
Figure 89 Reverse Input and Input Clutches
7A-158-40
l!..I Assemble
Figure 90
Reverse input and input clutch assembly into

the transmission case.
A. Index the 3-4 clutch plates with the input
internal gear.
B. Make sure all clutch plates are fully
engaged.
C. When properly assembled, the reverse input
clutch housing will be located just below
the case oil pump face.
602 BAND ASSEMBLY, 2-4
INPUT CLUTCH
LH01494L60
Figure 91 2-4 Band Assembly- Installed
Oil Pump Assembly

605------
Figures 92 and 94
621
1.
2.
3.
4.
5.
Thrust washer (601).

Pump cover to case gasket (9).
Pump to case oil seal (8).
Pump cover bolts (236).
Pump cover (217) from pump body (203).
Oil Pump Body

Figure94
l+tI
BAND ANCHOR PIN LOCATION

CASE, TRANSMISSION
PIN, BAND ANCHOR
INPUT CLUTCH
A
10
48
605
Disassemble
1. Pump slide spring (209).
LH0148-4L60
Figure 90 Installing Input Clutch
CAUTION: Spring is under very high

pressure. Place covering over spring to
prevent possible injury.
A. Compress with needle nose pliers.
B. Pull straight out.
2-4 Band Assembly

Figures 90 and 91
IL1tl
l!..I
7 OIL PUMP ASSEMBLY

601 THRUST WASHER
Inspect
2-4 band assembly (602) for damage or wear.

Assemble
Figures 90 and 91
1. Align the band anchor pin end with the case

pin hole.
2. Band anchor pin (48) into the case.
Index the pin into the 2-4 band.
LH0150-4L60
Figure 92 Oil Pump Thrust Washer Location
2. From the pump pocket:

Pump guide rings (212)
Pump vanes (215)
Pump rotor (214)
Pump guide (213)
Slide (206)
Slide seal (211)
Seal support (210)
Pivot slide pin (208) and spring (207)
Slide seal ring (204) and slide back up seal
(205)
3. Retainer (94), oil seal assembly (2).
Pry out with a screwdriver.
Oil Pump Cover
7A-15B-41
Pump cover (217) and pump body (203) for:

- Worn or damaged bushings (see Bushing
Replacement Procedure).
- Foreign material or debris.
- Porosity.
- Scored or irregular mating faces.
- Cross channel leaks.
Rotor (214) and slide (206) for cracks.
Oil seal assembly for damage or wear.
~ Clean
Wash and air dry all parts.
[I]
Important
Do not wipe dry with a cloth.
Tool Required:
One inch micrometer
l+!+I
Disassemble
Figures 94 and 97
1. Converter clutch apply valve train.

A. Compress converter clutch apply valve
spring (228) with a screwdriver.
B. Remove retaining ring (225).
C. Slowly release the spring tension.
D. Stop valve (226), converter clutch apply
valve (227) and two converter clutch valve
springs.
2. Pressure relief ball (231 ).
Ball is under strong spring pressure.
Cover the ball with a cloth when removed.
3. Pressure regulator assembly (218-224).
Follow the same procedure used to remove
the converter clutch valve.
ll""I
OIL PUMP ROTOR SELECTION CHART

THICKNESS (mm)
THICKNESS (In.)
17.948
17.961
17.974
17 .987
18.000
0.7066
0.7071
0.7076
0.7081
0.7086
17.961
17.974
17.987
18.000
18.013
- 0.7071
- 0.7076
- 0.7081
- 0.7086
- 0.7091
OIL PUMP SLIDE SELECTION CHART

THICKNESS (mm)
THICKNESS (in.)
17.948
17.961
17.974
17.987
18.000
0. 7066
0.7071
0.7076
0.7081
0.7086
17.961
17.974
17.987
18.000
18.013
0. 7071
0.7076
0.7081
0.7086
0.7091
Inspect
Figure 94
Pressure regulator valve assembly (218-224) and

converter clutch apply valve assembly (225229) for:
- Chips, burrs, distortion, plugged oil
passage, and free movement in bore.
- Remove burrs with lapping compound.
Pressure relief assembly (230-232) for damage
or distortion.
206 SLIDE, PUMP

214 ROTOR, OIL PUMP
LH0151-4L60
Figure 93 Oil Pump Rotor and Slide Selection
7A-15B-42
234
217
218
215 ~ ~ 2 1
m4
C)_:-D'
LJ-
o- .
219
~ 096
.tJ
e.
--u
-~-tJ
220
226
221
222
206
223
224
243
002
003
094
096
203
204
205
206
207
208
209
210
211
212
213
214
215
216
217
218
219
220
22J
222
223
224
225
226
227
228
229
230
231
232
233
234
235
236
237
238
239
240
242
243
244
245
SEAL ASSEMBLY, OIL

BUSHING, PUMP BODY
RETAINER, FRONT HELIX SEAL
BODY, PUMP
RING, OIL SEAL (SLIDE TO WEAR PLATE)
SEAL, 0-RING (SLIDE SEAL BACK-UP)
SLIDE, PUMP
SPRING, PIVOT PIN
PIN, PIVOT SLIDE
SPRING, PUMP SLIDE (OUTER)
SUPPORT, PUMP SLIDE SEAL
SEAL, PUMP SLIDE
RING, PUMP VANE
GUIDE, ROTOR
ROTOR, OIL PUMP
VANE, PUMP
SHAFT, STATOR
COVER, PUMP
SLEEVE, REVERSE BOOST VALVE
VALVE, TV BOOST
BUSHING, TV BOOST
RING, OIL PUMP REVERSE BOOST VALVE RETAINING
RING, OIL PUMP CONVERTER CLUTCH VALVE RETAINING
VALVE, STOP
VALVE, CONVERTER CLUTCH
SPRING, CONVERTER CLUTCH VALVE (OUTER)
SPRING, CONVERTER CLUTCH VALVE (INNER)
RIVET, PRESSURE RELIEF BOLT
BALL, PRESSURE RELIEF
SPRING, PRESSURE RELIEF
RING, OIL SEAL (STATOR SHAFT)
SEAL, OIL PUMP COVER SCREEN
SCREEN, OIL PUMP COVER
BOLT, M8 X 1.25 X 40 (COVER TO BODY)
PLUG, OIL PUMP AIR BLEED
PLUG, OIL PUMP COVER
PLUG, OIL PUMP COOLER FEED
PLUG, OIL PUMP CONVERTER CLUTCH SIGNAL
SCREW, STATOR SHAFT - M6 X 1 X 16.0
SPRING, PUMP SLIDE (INNER)
RETAINER AND BALL ASSEMBLY, (REVERSE CLUTCH)
RETAINER AND BALL ASSEMBLY, (OVERRUN CLUTCH!
203
094
LH0152-4L60-R1
Figure 94 Oil Pump Assembly
l~I
Measure
Figure93
[I]
Oil pump rotor (214) thickness.

Oil pump slide (206) thickness.
8.
9.
10.
11.
7A-15B-43
Vanes (215).
Vane guide ring (212).
Pump slide spring (209).
Oil seal assembly (2), retainer (94 ).
Use J 25016.
Important
Measurement of rotor/slide must be made on

undamaged surfaces. Select similar size
replacements. Lightly hone both sides of
replacement rotor or slide to remove any nicks
or burrs.
Oil Pump Body

Tool Required:
J 25016 Seal Installer
l~t+I
Assemble
1. 0-ring seal (205) and oil seal ring (204) into

the groove on the back side of the slide.
equivalent.
2. Pivot pin spring (207) and pivot pin (208) into
the pump body.
3. Slide (206).
Index the notch in the slide with the pivot
pin.
The oil seal ring must face downward into
the pump pocket.
4. Slide seal (211) and support (210).
5. Vane guide ring (212).
6. Rotor guide (213) onto the rotor.
equivalent.
7. Rotor (214).
With guide toward the pump pocket.
Figure 95 Oil Pump Seal
204 SLIDE BACK UP

205 SEAL AND RING
207 SPRING
208 PIVOT PIN

210 SUPPORT
211 SLIDE SEAL
LH0154-4L60
Figure 96 Slide Back Up and Slide Seal
Oil Pump Cover

Figure 94
l~H
Assemble
1. Pressure relief ball (231 ), spring (232) and rivet

(230).
2. Inner (229) and outer (228) converter clutch
valve springs into the converter clutch valve
bore.
3. Converter clutch valve (227).
4. Stop valve (226).
6. Pressure regulator valve (218) into the pressure
regulator bore.
7. Pressure regulator valve spring (219).
7A-15B-44
8. T.V. boost valve (222) onto the T.V. bushing.

Long land of the valve into the large hole
of the bushing.
equivalent.
9. Reverse boost valve (220) into the reverse boost
valve sleeve.
Small end of the valve first
equivalent.
10. Reverse boost valve sleeve (221) into the
pressure regulator bore.
11. T.V. boost valve sleeve (223) into the pressure
regulator bore.
219~
220~
Oil Pump Cover and Body
221~
Tools Required:
J 21368 Oil Pump Body and Cover
Alignment Band
J 25025-1 Alignment Pins
J 39855-2 Seal Sizer
1-+~3
222~
223~c
Assemble
~ lighten
Attaching bolts to 22 Nm (16 lb. ft.).

equivalent.
4. Install two oil seal rings (233) using J 38735-3

and J 39855-1.
5.
~225
224~
-====-
1. Oil pump cover (217) onto oil pump body.

Stator shaft through a bench hole
2. Pump cover bolts (236).
Leave finger tight.
3. Align pump cover and pump body with J 21368.
Place a screwdriver through a bolt hole
and into a hole in the bench.
~226
-=
ILL.
NO.
218
219
220
221
222
223
224
225
226
227
228
229
DESCRIPTION
VALVE, T. V. BOOST
BUSHING, T.V. BOOST
RING, OIL PUMP REVERSE BOOST VALVE
RETAINING
RING, OIL PUMP CONVERTER CLUTCH
VALVE RETAINING
VALVE, STOP
SPRING, CONVERTER CLUTCH VALVE
(OUTER)
SPRING, CONVERTER CLUTCH VALVE
(INNER)
.Adjust
Adjust screw to obtain proper height.
Use J 39855-2 to size seals after installation.

LH0155-4L60
Figure 97 Pressure Regulator and Converter Clutch

Apply Valve Trains
[I]
7A-15B-45
Important
Rotate the transmission to a horizontal position.

If the transmission is assembled properly the
turbine shaft should turn by hand. If not identify
and correct the misassembly now.
J 21368
A ALIGNMENT PINS
7 OIL PUMP ASSEMBLY
~\
LH0156-4L60
Figure 98 Oil Pump Alignment Band
J 39855-2
LH0159-4L60
Figure 101 Oil Pump and Case
Transmission End Play Check

Figures 102 through 106 and 109, 110 and 111
7 OIL PUMP ASSEMBLY
233 RING, OIL SEAL (STATOR SHAFT)
Tools Required:
J 24773-A End Play Checking Fixture
J 25022 End Play Checking Fixture Adaptor
(245 mm)
J 34725 End Play Checking Fixture Adaptor
(298 mm)
J 25025-7 A Post or 278 mm ( 11 inch) Bolt
and Nut
Dialdndicator
PH0211-4L60
Figure 99 Install and Size Oil Seal Rings
E3
Install or Connect
Figur~ 100 and 101
1. Thrust washer (601).

2. J 25025-1 into the case as shown.
3. Oil pump assembly into the case.
Align all holes properly.
4. Bolts and 0-rings (5 and 6).
I@!
~ Tighten
Measure
I.
Bolts to 22 Nm (16 lb. ft.).
7 OIL PUMP ASSEMBLY

601 THRUST WASHER
LH0150-4L60
Figure 100 Oil Pump Thrust Washer
Remove an oil pump to case bolt and install a

278 mm ( 11 inch) bolt and lock nut or J 250257A.
2. Install J 25022-A or J 34725 as shown.
3. Install J 24773-A as shown.
4. Install a dial indicator.
Set to zero.
5. Pull up on J 24773-A.
End play should be 0.13 to 0.92 mm (0.005
to 0.036 inch).
The selective washer which controls end play is
located between the input housing and the thrust
bearing on the oil pump hub. If more or less end play
is required, select the proper washer from the chart
and install. If dial indicator shows no end play, the
selective washer and thrust bearing have been
misassembled.
7A-15B-46
TRANSMISSION END PLAY

WASHER SELECTION CHART
WASHER THICKNESS
1 .87
2.04
2.21
2.38
2.55
2.72
2.89
3.06
1 .97
2.14
2.31
2.48
2.65
2.82
2.99
3.16
mm
mm
mm
mm
mm
mm
mm
mm
(.074" (.080" (.087" (.094" (.100" (.107" (.113" .(.120" -
1.0.
.078")
.084")
.091 ")
.098")
.104")
.111 ")
.118")
.124")
67
68
69
70
71
72
73
74
LH01624L60
Figure 104 End Play Chart
CORRECTLY
INSTALLED
A 298mm TURBINE SHAFT

B 245mm TURBINE SHAFT
LH0073-4L60
Figure 102 End Play Tool
A DIAL INDICATOR
B 278mm (11 ") BOLT
C LOCK NUT
ILL.
DESCRIPTION
NO.
SELECTIVE WASHER
LH007 4-4L60
Figure 103 J 25022-A Installed
LH0146-4L60
Figure 105 Selective Washer and Thrust Bearing

Properly Installed
l+t+-!
Assemble
Figure 106
64
0-ring seal (618) into the groove in the end of

the turbine shaft.
[I]
7A-158-47
Important
There should be clearance between the reverse

input clutch and the reaction sun gear shell.
This clearance can be observed at the point
shown in Figure 108. Do not try to shim the
internal parts because of this clearance (Figure
107).
USED WITH
298mm CONVERTER
64 THROTTLE LINK
65 LEVER AND BRACKET ASSEMBLY, THROTTLE
91 BALL, CARBON STEEL - T.V. EXHAUST
(LOCATED IN VALVE BODY)
USED WITH
245mm CONVERTER
LH0166-4L60
Figure 108 Throttle Lever and Bracket Assembly
A SHAFT, TURBINE
618 SEAL, "O" RING (TURBINE SHAFT/
SELECTIVE WASHER)
!L"'!
LH0117-4L60
Figure 106 Turbine Shaft 0-Ring Seal
670
LH0165-4L60
Figure 107 Clearance Between Reverse Input Clutch

and the Sun Gear Shell
Inspect
The 1-2 accumulator cover and pin assembly

(62) for:
- Scored piston wall.
- Plugged oil passage.
1-2 accumulator piston (61) and the 3-4
accumulator piston (52) for:
Porosity.
- Pin hole damage.
7A-15B-48
1-2 accumulator spring (59) and 3-4

accumulator spring (54) for distortion or
damage.
Spacer plate (56) and gaskets (88 and 89) for
damage.
Checkballs (55) for damage.
T. V. link (64) for damage.
Manual detent spring (709) for damage.
Oil filter (71) for:
- Cut or damaged filter seal (70).
- Cracks in the neck or body.
- Casting flash in the neck.
Solenoid assembly (50) for:
- Damage.
- Cut or pinched wires.
- Damaged connectors. / /
- Cut or damaged 0-ring (49).
88
52
53
54
56
59
60
61
62
63
77
88
89
Valve Body and Associated Parts

Figures 109 and 111
Tool Required:
J 25025-5 Guide Pins
NOTICE: The use of a honing stone, fine
sandpaper or crocus cloth is not recommended
for servicing stuck valves. All valve lands have
sharply machined comers that are necessary for
"cleaning" the bore. If these comers are rounded,
foreign material could wedge between the valve
and bore causing the valve to stick.
If it is found necessary to clean a valve, "micro

fine" lapping compound 900 grit or finer should
be used.
Too much "lapping" of a valve will cause
excessive clearances and increase the chance of a
valve not operating.
1993
MODELS
1-2 ACCUMULATOR
SPRING COLOR
3-4 ACCUMULATOR
SPRING COLOR
BAM
ORANGE, LT. GREEN,

WHITE OR PLAIN
VIOLET
SAM
YELLOW
RED
BFM
ORANGE, LT. GREEN,

WHITE OR PLAIN
ORANGE, LT. GREEN

WHITE OR PLAIN
BBM, BHM, BRM, FDM,

FFM, FMM, YAM, YDM
YELLOW
ORANGE, LT. GREEN,

WHITE OR PLAIN
BCM
DK. GREEN
ORANGE, LT. GREEN,

WHITE OR PLAIN

RING, OIL SEAL (3-4 ACCUMULATOR PISTON)
RING, OIL SEAL (1-2 ACCUM. PISTON)
COVER & PIN ASSEMBLY, 1-2 ACCUM.
PIN, ACCUMULATOR PISTON
LH0066-4L60
Figure 109 Accumulator Assembly
PH0168-4L60
Figure 110 1-2 and 3-4 Accumulator Spring Chart
!-++-!
2. Four checkballs (55) into the case as shown.

equivalent.
3. J 25025-5 into the case.
4. Spacer plate to case gasket (88).
Gasket identified by a "C".
5. Spacer plate (56).
6. Valve body to spacer plate gasket (89).
Gasket identified by a "V".
Install or Connect
Figure 109
1. The 3-4 accumulator pin (77) into the case.

2. The 3-4 accumulator piston seal (53) onto the
3-4 accumulator piston.
3. The 3-4 accumulator piston (52) onto the pin.
The end with three legs must face the valve
body.
4. The 3-4 accumulator piston spring (54).
E3
Control Valve Assembly
Install or Connect
Figure 111
1. Governor and converter clutch oil screens (47).
!~!
7A-158-49
'---'o-~o
j+-:+!
Clean
Control valve assembly (67) thoroughly in clean

solvent.
A. Move the valves with a pick or small
screwdriver to dislodge any dirt or debris
that may have accumulated.
B. Air dry.
Disassemble
Figure 112
Position as shown on a clean surface.

A. Valve trains beginning with the upper left
hand comer
[I)
Important
ILL.
NO.
4 7A
4 78
55E
55F
55G
55H
106
Some valves are under pressure - cover

the bores while removing the roll pins.
Valves, springs and bushings must be
laid out on a clean surface in the exact
sequence they are removed.
B. Blind hole roll pins with a modified drill
bit
C. Pressure switches
DESCRIPTION
GOVERNOR FILTER LOCATION
CONVERTER CLUTCH FILTER LOCATION
#4 CHECK BALL (3-4 CLUTCH/3-2 EX.)
#8 CHECK BALL (2ND/1-2)
#1 CHECK BALL (4TH ACCUMULATOR)
#3 CHECK BALL (PART THROTTLE/DRIVE 3)
RETAINER & BALL ASM. (DOUBLE ORIFICE)
~ Clean
LH0072-4L60
Figure 111 Case Checkballs and Oil Screens - Location
All valves, springs, bushings and control valve

body in clean solvent
Dry using compressed air.
7A-15B-50
341
/~
352
301 VALVE, T.V. MODULATOR DOWNSHIFT

302 SPRING, T.V. MODULATOR DOWNSHIFT VALVE
303 VALVE, T.V. MODULATOR UPSHIFT
304 SPRING, T.V. MODULATOR UPSHIFTVALVE
323 SLEEVE, THROTTLE VALVE PLUNGER
324 PLUNGER, THROTTLE VALVE
325 SPRING, THROTTLE VALVE
326 VALVE, THROTTLE
328 VALVE, 3-4 RELAY
329 VALVE, 4-3 SEQUENCE
330
331
332
333
334
335
336
337
338
339
340
341
342
343
344
345
346
347
348
349
350
351
352

VALVE, T.V. LIMIT
VALVE, LINE BIAS
SPRING, 3-2 CONTROL
VALVE, 3-2 CONTROL
VALVE, MANUAL
PIN, COILED SPRING
PIN, COILED SPRING
PLUG, VALVE BORE
PLUG, CUP (.33 DIA)
SWITCH ASM., PRESSURE (3RD CL.)
SWITCH ASM., PRESSURE (4-3 PULSE)
SWITCH ASM., PRESSURE (4TH CL.)
SWITCH ASM., PRESSURE (T.C.C. SIGNAL)
BODY, CONTROL VALVE
PLUG, T.V. LIMIT
PLUG. VALVE BORE (12.5 - 0.D.)
NH0170-4L60
Figure 112 Control Valve Assembly
7A-15B-51
ILr Inspect
EE
All valves and bushings for:

- Porosity.
- Scoring.
- Nicks.
- Scratches.
Springs for damaged or distorted coils.
Valve body casting for:
- Porosity.
- Cracks.
- Interconnected oil passages.
- Damaged machined surfaces.
Assemble
558
551
Figure 112
E3
Control valve assembly (67) exactly as shown.

- Notice the position of the valve lands and
bushing passages.
Install or Connect
Figures 113 and 115
l. Four checkballs (55A), (55C), (551) and (91)

1nto the valve body assembly. Checkball (91) is
the larger copper colored ball.
equivalent.
2. Valve body assembly (67).
Connect the manual valve link (705) to the
inside detent lever (703).
55A
558
55C
551
91
395
Tools Required:
#3 Screw Extractor
9.5 mm (3/8 inch) rod
~ Clean
Figure 114
Auxiliary valve assembly (377) thoroughly in

clean solvent
- Move the valves with a pick or small
screwdriver to dislodge any dirt or debris
that may have accumulated.
- Air dry.
#2 CHECKBALL (3RD CLUTCH ACCUM.)

#12 CHECKBALL (FORWARD CLUTCH)
#6 CHECKBALL (DRIVE 3)
#11 CHECKBALL (REVERSE)
#10 CHECKBALL (T.V. EXHAUST)
CUP PLUG - ORIFICE
LH0071-4L60-R1
Figure 113 Valve Body Checkball Locations
I+!+!
Disassemble
Figure 114
l. (3) Bolts (373).

2. Cover (371) and accumulator piston spring
(370).
Auxiliary Accumulator Valve Body Assembly

Figures 108, 109, 114, 117, 118 and 119
55A
[I]
Important
Cover (371) is under spring pressure.

3. Piston (367).
4. Piston oil seal ring (53).
I+!+!
Disassemble
Figure 114
Position the auxiliary accumulator valve body

on a clean surface. Remove valve trains beginning
with the lower left hand comer. NOTE: valves are
under pressure-cover bores while removing the roll
pin.
[jJ
Important
Valves and springs must be laid out on a clean

surface in the exact sequence as they are
removed.
7A-15B-52
365
55
359
360
361
362
363
364
365
366
367
369
370
371
#12 CHECKBALL
PLUG, CUP (ORIFICE)
VALVE, ABUSE
SPRING, ABUSE VALVE
STOP, ABUSE VALVE
PIN, SPRING
VALVE, LO OVERRUN CLUTCH
SPRING, LO OVERRUN CLUTCH VALVE
PIN, SPRING VALVE RETAINING
PISTON, ACCUMULATOR
RING, OIL SEAL ACCUMULATOR PISTON
SPRING, ACCUMULATOR PISTON
COVER, AUXILIARY ACCUMULATOR VALVE
373 BOLT, SPEC. HEX WASHER HEAD

(M6 X 1 X 24)
(M6 X 1 X 16)
375 BOLT, HEX HEAD (M6 X 1 X 401
377 AUXILIARY ACCUM. VALVE BODY ASM.
LH0173-4L60
Figure 114 Auxiliary Valve Body Assembly
~ Clean
ll1"1
All valves and springs in clean solvent

Airdry.
Inspect
Piston (367) for:

- Cracks.
- Porosity.
- Damage.
Valves for:
- Scoring.
- Nicks.
- Scratches.
Springs for damaged or distorted coils
Auxiliary valve body (377) for:
- Porosity.
- Damaged machined surfaces.
Orifice cup plug (359).
- Replace only if damaged.
I Remove or Disconnect
f~ ..
E3
!3
f..
Orifice cup plug (359). Use modified #3 screw

extractor.
Install or Connect
Orifice cup plug (359). Use 9.5 mm (3/8 in.)

rod.
- Seat flush.
Assemble
Figure 114
!3
f..
Auxiliary accumulator valve train exactly as

shown. Notice the valve lands.
Assemble
Figure 114
1. Piston oil seal ring (369) onto piston (367).

equivalent.
2. Piston (367).
3. Accumulator spring (370).
4. Cover (371) and (3) bolts (373).
340
703
705
709
VALVE, MANUAL
LEVER, DETENT (INNER)
LINK, MANUAL VALVE
SPRING ASSEMBLY, MANUAL DETENT
Figure 115 Manual Valve Link
7A-15B-53

69 BOLTS, CONTROL VALVE ASSEMBLY
LH0067-4L60
LH0068-4L60
Figure 116 T.V. Lever and Bracket
69
A
50
51
63
66
69
75
WASHER WIRE RETAINER

SOLENOID ASSEMBLY
BOLT, HEX WASHER HEAD (SOLENOID)
CLIP, ELECTRICAL WIRE
BOLT, VALVE BODY
BOLT, MANUAL DETENT SPRING
92 CONDUIT, SOLENOID WIRE

97 CLAMP, AUXILIARY TUBE
(M6 X 1 X 18)
MH0211-4L60
Figure 117 Valve Body Bolt Locations
7A-15B-54
l++-1
E3
Install or Connect
Install or Connect
1. Check ball (55B) into auxiliary accumulator

valve body (377) as shown in Figure 114.
Do not block orifice cup plug.
equivalent.
2. Auxiliary valve body (377).
3. Bolts (374) and (375) finger tight.
4. Auxiliary accumulator valve tube (96).
5. Bolt (376) with tube clamp (97) finger tight.
1. T. V. link (64) onto the T. V. lever and bracket as

shown.
2. T.V. lever and bracket assembly (65) onto the
valve body as shown.
Attach with two valve body to case bolts
(69).
3. Wire harness clips (66), manual spring assembly
(68), wire retaining washer, and all remaining
valve body to case bolts (69).
NOTICE: Torque valve body bolts in a spiral

pattern starting from the center. If bolts are torqued
at random, valve bores may be distorted and
inhibit valve operation.
l~.J
Tighten
Bolts to 11 Nm (98 lb. in.)
4. 0-ring seal (34) onto the electrical connector

(33).
equivalent.
5. Electrical connector (33) into the case.
6. 0-ring seal (49) on the solenoid assembly (50).
7. Solenoid assembly (50) into the case.
Attach with two solenoid bolts (51).
ILL.
NO.
A
33
96
97
374
375
376
377
710
715
l~I
DESCRIPTION
WASHER, WIRE RETAINING

BOLT, SPECIAL HEX HEAD (M6 X 1 X 16)
AUXILIARY ACCUM. VALVE BODY ASM.
Figure 118 Outside Electrical Connector
Inspect
Figure 108
Bolts (51) to 11 Nm (98 lb. in.)
To correctly route and hook up the wires, see

the wiring diagrams in the 700-R4 diagnosis section.
LH0069-4L60
ll"'I
Tighten
Throttle lever and bracket assembly (65) for:

- Sticking, binding or damage.
Make sure it operates freely.
Replace if necessary.
The wire connectors are color coded to

correspond to the information in the wiring diagram.
On switches which take two connectors, the terminals
are reversible. It will be necessary to identify and use
the wiring diagram chart which corresponds to the
model you are working on. (See the Diagnosis Section
for the wiring diagrams.)
E3
Install or Connect
1. Parking bracket (710).
~ Tighten
Bolt to 22 Nm (16 lb. ft.)
2. The 1-2 accumulator piston seal (60) onto the
1-2 accumulator piston (61).
3. The 1-2 accumulator piston (61) into the 1-2

accumulator cover and pin assembly (62).
The three legs on the piston must face up
toward the case when installed.
4. The 1-2 accumulator spring (59) onto the piston.
5. The 1-2 accumulator cover and pin assembly
(62) onto the case.
l~.J
2-4 Servo Assembly

Tools Required:
J 33037 Band Apply Pin Tool
Vernier calipers
Scale
J 22269-01 Piston Compressor
J 29714 Servo Cover Compressor
lighten
Torque to 11 Nm (98 lb. in.)
1-+.,I
I@!
Install or Connect
1. Install J 33037 as shown with apply pin (29).
1. Filter seal (70) onto the oil filter.
Lubricate with TRANSJEL J 368'50 or

equivalent.
Oil filter (71).
Oil pan gasket (72).
Chip magnet (93) onto oil pan (73).
Oil pan (73) and bolts (74).
l~J
Measure
Figure 120
Figure 119
2.
3.
4.
5.
7A-15B-55
lighten
2. Install servo cover retaining ring (13) to secure

tool.
3. Apply 11 Nm (98 lb. in.) torque.
4. If white line "A" appears in the gage slot "B",
pin length is correct.
5. Use pin selection chart to determine the correct
pin length if new pin is needed.
!L!
Torque to 16 Nm (12 lb. ft.)
Inspect
Pistons for:
73
72
71
10
J 33037
A WHITE LINE
B GAGE SLOT
10
70
71
72
73
74
93
CASE, TRANSMISSION
SEAL, FILTER
FILTER ASSEMBLY, TRANSMISSION OIL
GASKET, TRANSMISSION OIL PAN
PAN, TRANSMISSION OIL
SCREW, SPEC. HEX WASHER HEAD (PAN)
MAGNET, CHIP COLLECTOR
LH0064-4L60-R 1
Figure 119 Case, Pan and Filter Assembly
PIN IS PRESET AT FACTORY AND MUST NOT BE

READJUSTED
2-4 SERVO PIN SELECTION

PIN LENGTH
PIN 1.D.
MM
INCH
65.82-66.12
2.59-2.60
1 GROOVE
67 .23-67 .53
2.65-2.66
2 GROOVES
68.64-68.94
2.70-2.71
NO GROOVE
PH0102-4L60-E
Figure 120 Servo Pin Length
7A-158-56
Cover (15) for porosity or damage.

Seals for:
- Nicks or cuts.
- Freeness in the seal groove.
Springs for distortion.
Pin for wear or burrs.
[I]
14
Important
Check servo bore in the case for any wear which

may cut the servo seals.
!@!
Measure
Figure 121
1. Measure piston (25) dimension *A.

2. Measure housing (22) dimension **B.
3. Check model application.
2ND APPLY PISTON AND HOUSING APPLICATION
MODEL
PISTON
DIMENSION
HOUSING
DIMENSION
**B
*A
FFM, FMM, LHM,
YAM, YCM, YDM
44.64mm
(1.78")
45.54mm
(1.79")
AAM, ADM, BAM, BBM, BCM,

BFM, BHM, BRM, BWM, DOM, FDM
57.85mm
(2.28")
58.74mm
(2.31")
SAM
63.10mm
(2.48")
64.00mm
(2.52")
17
22 HOUSING, SERVO PISTON (INNER)

25 PISTON, 2ND APPLY
20
PHO 180-4L60
13
14
15
16
17
18
19
20
21
22
23
24
25
26
26A
27
28
29
31

COVER, 2-4 SERVO
PISTON, 4TH APPLY
RING, OIL SEAL (4TH APPLY PISTON - OUTER)
RING, RETAINER (APPLY PIN)
WASHER, SERVO APPLY PIN
SPRING, SERVO APPLY PIN
SEAL, "O" RING
HOUSING, SERVO PISTON (INNER)
RING, OIL SEAL (2ND APPLY PISTON - INNER)
RING, OIL SEAL (2ND APPLY PISTON - OUTER)
PISTON, 2ND APPLY
SPRING, SERVO CUSHION ASSIST (CORVETIE ONLY)
RING, RETAINER (2ND APPLY PISTON)
NH0059-4L60
Figure 121 2nd Apply Piston and Housing

Measurement
Figure 122 2-4 Servo Assembly
7A-15B-57
!-+!+-! Assemble
1. Cushion spring (26) into the 2nd apply piston

(25).
2. Cushion spring retainer (27) on the cushion
spring.
3. Install J 22269-01.
A. Compress the retainer past the snap ring
groove in the 2nd apply piston.
4. The 2nd apply piston (25) onto the apply pin
(29)
Retainer goes toward the shoulder of the
pin.
5. Servo apply pin spring (20) on the pin.
6. Servo apply pin washer (19) and retaining clip
(18).
7. Inner (23) and outer (24) seals on the 2nd apply
piston.
equivalent.
8. 0-ring seal (21) on servo piston housing.
9. Servo piston inner housing (22) on the 2nd apply
piston.
10. Seal ring (17) onto the 4th apply piston.
11. The 4th apply piston (16) onto the apply pin.
12. Return spring (31) on the pin.
13. Servo piston assembly into the servo bore.
14. 0-ring seal (14) on the servo cover.
Lubricate the seal with TRANSJEL
J 36850 or equivalent.
15. Servo cover (15) into the servo bore.
16. Install J 29714.
A. Compress the servo cover.
13
A
13
14
15
16
17
25 SECOND APPLY PISTON ASM.
LH0061-4L60
CASE SERVO BORE

COVER, 2-4 SERVO
PISTON, 4TH APPLY
RING, OIL SEAL (4TH APPLY PISTON)
(OUTER)
18-30 2ND APPLY PISTON ASSEMBLY
21 SEAL, "O" RING
24 RING, OIL SEAL (2ND APPLY PISTON)
(OUTER)
31 SPRING, SERVO RETURN
Figure 123 2nd Servo Piston -Assembly

LH0183-4L60
Figure 124 2-4 Servo Bore
7A-15B-58
1 5 2-4 SERVO COVER
LH0058-4L60
Figure 125 Servo Cover - Installed
!+!+I
Assemble
1. Install a new governor driven gear.

A. Support the governor or plates through the
exhaust slots.
B. Press gear (83) into the sleeve until seated.
C. Drill a new retaining pin hole in the sleeve
ninety degrees from the existing hole. Use
a 3.1 mm (1/8 inch) drill.
D. Install retainer pin (82) and stake.
2. Valve into the sleeve.
3. Weights, springs, and thrust cap onto the
governor assembly.
4. Retaining pins (84) into the thrust cap (85) and
governor assembly.
5. Stake the retaining pins (84).
6. Check for free operation of the valve and
weights.
Governor and Governor Cover

Figures 126 and 127
84
IL"'I
Inspect
Figure 126
l~+I
Valve for free operation.

Weights for free operation.
Springs - missing or distorted.
Sleeve for nicks, burrs, scores or delamination.
Driven gear for damage.
~111
108-~
85
Disassemble
109
DO NOT DISASSEMBLE EXCEPT FOR

CLEANING OR PART REPLACEMENT.
1.
2.
3.
4.
5.
~ Clean
GOVERNOR ASSEMBLY
Cut off one end of each governor weight pin.

Pins (84).
Weights.
Valve.
Driven gear (83).
A. Drive out the retainer pin (82) with a small
punch.
B. Support the governor assembly sleeve on
plates installed in the exhaust slots. Push
out the gear with an arbor press and a long
punch.
Wash all parts in solvent.

Air dry and blow out passages.
82
83
84
85
1 07
108
109
110
111
112
PIN, GOVERNOR GEAR RETAINER

GEAR, GOVERNOR DRIVEN
PIN, GOVERNOR WEIGHT
CAP, GOVERNOR THRUST
VALVE, GOVERNOR
WEIGHT, GOVERNOR SECONDARY
WEIGHT, GOVERNOR PRIMARY
SPRING, GOVERNOR WEIGHT PRIMARY
SPRING, GOVERNOR WEIGHT SECONDARY
SLEEVE & CARRIER ASSEMBLY
LH0185-4L60
Figure 126 Governor Assembly
!++!
Install or Connect
Figures 126 and 127
1.
2.
Governor assembly (45) into the governor bore.

Governor cover (46).
Apply sealant, such as Loctite cup plug
sealant #11 or equivalent, to cover flange
before installation.
7A-158-59
687
A APPLY SEALANT ON THIS FLANGE BEFORE

INSTALLATION
45 GOVERNOR, ASSEMBLY
46 COVER, GOVERNOR
A SPEEDO CLIP HOLE FOR CORVETTE ONLY

B SPEEDO CLIP HOLE FOR ALL OTHER VEHICLES
687 SHAF~ OUTPUT
LH0186-4L60
LH0187-4L60
Figure 127 Governor Cover
SpeedSensor/Speedometer and Case

Extension
Figure 128 Speedometer Clip Holes
-Torque Converter Assembly

Figure 136
Figures 128 and 133
Tools Required:
J 23J03 or J 25016 Seal Installer
'/'
\
'',
' '
~-;,..,
.
J 21'426 Seal In5taller
J 38417 Speed Sensor Remover and
Installer
'
E3
1.
2.
3.
4.
5.
Tool Required:
J 35138 Torque Converter End Play
Checking Tool
,. (
Install or Connect
Speedometer drive gear (689) and clip (688).

If the output shaft has two speedometer
locating holes, use the hole nearest the yoke
spline for Corvette vehicles only.
0-ring seal (691) on the output shaft sleeve.
Output shaft sleeve (690) on the output shaft.
UseJ 25016 or J 23103.
Do not push the sleeve past the machined
surface on the output shaft.
Seal ring (35) on the case extension.
Case extension (36) and bolts (37) or, stud (100)
and nut (98).
Position extension so the speedometer bore
is on the governor side of the case.
~ lighten
Torque to 35 Nm (26 lb. ft.).
6. Remove case extension oil seal (39).
A. Pry out with a screwdriver.
B. Install new seal with J 21426.
7. Speedometer driven gear (44) and assembly
(43), or speed sensor (99) with J 38417.
8. Retainer (40) bolt and washer{41).
9. Outside electrical
connector, manual lever and
',
nut.
IL1tl
Inspect
The torque converter assembly must be replaced

for any of the following conditions:
Evidence of damage to the pump assembly.
Metal particles are found after flushing the

cooler and cooler lines.
External leaks in hub weld area.
Converter pilot is broken, damaged or poor fit

into crankshaft.
Converter hub is scored or damaged.
Internal damage to stator.
Contamination from engine coolant.
Excess end play.
l@I
Measure
Figure 136
Install J 35138 and measure end play.

- 0 to 0.5 mm (0.000 to 0.020 inch) for
245 mm torque converters.
- 0 to 0.6 mm (0;000 to 0.024 inch) for
298 mm torque converters.
7A-15B-60
The Torque Converter should not be replaced If:
The fluid has an odor, discoloration or no

evidence of metal or clutch plate material.
A. Drain out as much fluid as possible.
B. Replace the oil filter and pan gasket.
C. Fill to proper level (Refer to Section 7 A).
The converter bolt hole threads are damaged.
- Correct with thread insert (Refer to Section
6A).
[[) Important
,1
Flushing the torque 't cbnverter is

recommended.
lHI
not
690 SLEEVE, OUTPUT SHAFT

691 SEAL, OUTPUT SHAFT
LH0189-4L60
Install or Connect
1. Torque converter.
2. J 21366 converter holding strap.
3. Remove transmission from holding fixture.
Figure 131 Output Shaft Sleeve and Seal
687 SHAF~ OUTPUT
688 CLIP, SPEEDO DRIVE GEAR

689 GEAR, SPEEDO DRIVE
LH0192-4L60
Figure 132 Output Shaft Sleeve - Installation

LH0188-4L60
Figure 129 Speedometer Gear
35 SEAL, CASE EXTENSION TO CASE

36 EXTENSION, CASE
37 BOLTS, CASE EXTENSION
LH0190-4L60
Figure 133 Case Extension and Seal
688 CLIP; SPEEDO DRIVE GEAR

LH0191-4L60
Figure 130 Speedometer Gear - Installation
7A-15B-61
LH0194-4L60
Figure 135 Case Extension Oil Seal Assembly
J 8001
ILL
NO.
DESCRIPTION
35
36
37
39
40
41
42
43
44
45
46
99
100
687
688
689
690
691
699
SEAL, CASE EXTENSION TO CASE

EXTENSION, CASE
BOLT, CASE EXTENSION TO CASE
RETAINER, SPEEDO DRIVEN GEAR FITTING
BOLT & WASHER ASSEMBLY
SEAL, 0-RING (SPEEDO FITTING TO
CASE EXTENSION)
FITTING ASSEMBLY, SPEEDO DRIVEN GEAR
GEAR, SPEEDO DRIVEN
GOVERNOR ASSEMBLY
COVER, GOVERNOR
SPEED SENSOR, INTERNAL TRANSMISSION
BOLT, SPEEDO SENSOR RETAINING
SHAFT, OUTPUT
CLIP, SPEEDO DRIVE GEAR
GEAR, SPEEDO DRIVE
SLEEVE, OUTPUT SHAFT NOT USED ON
SEAL, OUTPUT SHAFT
ALL MODELS
ROTOR, INTERNAL TRANSMISSION SPEED SENSOR
LH0063-4L60-R1
Figure 134 Case Extension and Associated Parts
Figure 136 Checking Torque Converter End Play
7A-15B-62
359
\Y
377
374
37~)'r97
96
~76
97
LHO 196-4L60
F",gure 137 Case and External Parts
ILL.
NO.
DESCRIPTION
1 CONVERTER ASSEMBLY
2 SEAL ASSEMBLY, OIL
3 BUSHING, OIL PUMP BODY
4 BUSHING, STATOR SHAFT (FRONT)
5 BOLT, PUMP TO CASE
6 0-RING, PUMP TO CASE BOLT
7 PUMP ASSEMBLY, OIL
8 SEAL, OIL (PUMP TO CASE)
9 GASKET, PUMP COVER TO CASE
11 VENT ASSEMBLY, TRANSMISSION
12 CONNECTOR, OIL COOLER PIPE
13 RING, SERVO COVER RETAINING
14 SEAL, "O" RING (2-4 SERVO COVER)
15 COVER, 2-4 SERVO
16 PISTON, 4TH APPLY
17 RING, OIL SEAL (4TH APPLY PISTON)
(OUTER)
18 RING, RETAINER (APPLY PIN)
19 WASHER, SERVO APPLY PIN
20 SPRING, SERVO APPLY PIN
21 SEAL, "O" RING
22 HOUSING, SERVO PISTON (INNER)
(INNER)
(OUTER)
25 PISTON, 2ND APPLY
26 SPRING, SERVO CUSHION
27 RETAINER, SERVO CUSHION SPRING
28 RING, RETAINER (2ND APPLY PISTON)
29 PIN, 2ND APPLY PISTON
31 SPRING, SERVO RETURN
32 PLUG, PRESSURE
33 CONNECTOR, ELECTRICAL
34 SEAL, "O" RING (ELECTRICAL CONNECTION)
35 SEAL, CASE EXTENSION TO CASE
36 EXTENSION, CASE
37 BOLT, CASE EXTENSION TO CASE
38 BUSHING, CASE EXTENSION
39 SEAL ASSEMBLY, CASE EXTENSION OIL
40 RETAINER, SPEEDO DRIVEN GEAR FITTING
41 BOLT & WASHER ASSEMBLY
42 SEAL, "O" RING (SPEEDO FITTING TO
CASE EXTENSION)
43 FITTING ASSEMBLY, SPEEDO DRIVEN GEAR
44 GEAR, SPEEDO DRIVEN
45 GOVERNOR ASSEMBLY
46 COVER, GOVERNOR
47 SCREEN, TRANSMISSION OIL PRESSURE
(CONVERTER & GOVERNOR)
48 PIN, BAND ANCHOR
49 SEAL, "O" RING (SOLENOID)
50 SOLENOID ASSEMBLY
51 BOLT, HEX WASHER HEAD (SOLENOID)
53 RING, OIL SEAL (3-4 ACCUMULATOR PISTON)
54 SPRING, 3-4 ACCUMULATOR
55 BALL, .25 DIAMETER
56 PLATE, VALVE BODY SPACER
7A-15B-63
ILL.
NO.
DESCRIPTION
59 SPRING, 1-2 ACCUMULATOR
60 RING, OIL SEAL (1-2 ACCUMULATOR
PISTON)
62 COVER & PIN ASSEMBLY, 1-2 ACCUM.
63 BOLT, ACCUMULATOR COVER
66 CLIP, ELECTRICAL WIRE
67 VALVE ASSEMBLY, CONTROL BODY
69 BOLT, VALVE BODY
70 SEAL, FILTER
71 FILTER ASSEMBLY, TRANSMISSION OIL
72 GASKET, TRANSMISSION OIL PAN
73 PAN, TRANSMISSION OIL
74 SCREW, SPEC. HEX WASHER HEAD (PAN)
75 BOLT, MANUAL DETENT SPRING
76 BUSHING, CASE
77 PIN, ACCUMULATOR PISTON
80 RETAINER & BALL ASSEMBLY, 3RD
ACCUMULATOR
81 PLUG, TRANSMISSION CASE
(ACCUMULATOR BLEED)
82 PIN, GOVERNOR GEAR RETAINER
83 GEAR, GOVERNOR DRIVEN
84 PIN, GOVERNOR WEIGHT
85 CAP, GOVERNOR THRUST
86 PLUG, CASE SERVO
88 GASKET, SPACER PLATE TO CASE
89 GASKET, SPACER PLATE TO VALVE BODY
90 BUSHING, STATOR SHAFT (REAR)
91 BALL, CARBON STEEL (T. V. EXHAUST)
92 CONDUIT, SOLENOID WIRE
93 MAGNET, CHIP COLLECTOR
94 RETAINER, FRONT HELIX SEAL
96 TUBE, AUXILIARY ACCUMULATOR VALVE
97 CLAMP, TUBE
99 SPEED SENSOR, INTERNAL TRANSMISSION
100 BOLT, SPEEDO SENSOR RETAINING
106 RETAINER & BALL ASM. (DOUBLE ORIFICE)
359 PLUG, CUP (ORIFICE)
372 SWITCH, TEMPERATURE (SOME MODELS)
374 BOLT, SPECIAL HEX HEAD (M6 X 1 X 16)
377 AUXILIARY ACCUMULATOR VALVE
BODY ASSEMBLY
709 SPRING ASSEMBLY, MANUAL DETENT
LH0197-4L60
Figure 138 Case and External Parts - Legend
7A-15B-64
602
613
605
614
6I
618
639
642
643
654C
6548
644
641
649A
648
646
6498 650
651
652 653
-&
661 662
655
663
664
669
665 666
l_
,~-~--~
I
682C
6820
6828 682A 683 684 685
686
687
/6991
: (Q) :
692
L__ ~
~ () (JQ
688 689 690 691
LH0198-4L60-R1
Figure 139 Transmission Internal Parts
ILL
NO.
600
601
602
603
605
ILL.
NO.
DESCRIPTION
SPRING ASM., 3-4 CLUTCH BOOST (5)

WASHER, THRUST (PUMP TO DRUM)
BAND ASSEMBLY, 2-4
BUSHING, REVERSE INPUT CL. (FRONT)
HOUSING AND DRUM Assr- '13LY, REVERSE INPUT
CLUTCH
606 BUSHING, REVERSE INPUT CLUTCH (REAR)
608 SEALS, REVERSE INPUT CLUTCH
(INNER AND OUTER)
611 PLATE, REVERSE INPUT CLUTCH (BELLEVILLE)
612A
PLATE ASM., REVERSE INPUT CLUTCH (FIBER)
6128
PLATE, REVERSE INPUT CLUTCH (STEEL)
613 PLATE, REVERSE INPUT CLUTCH BACKING (SELECTIVE)
615 BEARING ASSEMBLY, STATOR SHAFT/ SELECTIVE
WASHER
617 RETAINER AND BALL ASM., CHECK VALVE
618 SEAL, 0-RING (TURBINE SHAFT/ SELECTIVE WASHER)
619 RING, OIL SEAL (SOLID)
620 RETAINER AND CHECKBALL ASSEMBLY
621 HOUSING AND SHAFT ASSEMBLY, INPUT
622 SEAL, 0-RING INPUT TO FORWARD HSG.
623 PISTON, 3RD AND 4TH CLUTCH
624 SEAL, 3RD AND 4TH CL. (INNER AND OUTER)
625 RING, 3RD AND 4TH CLUTCH (APPLY)
626 SPRING ASSEMBLY, 3RD AND 4TH CLUTCH
627 RETAINER AND BALL ASSEMBLY, FORWARD CLUTCH
HOUSING
628 HOUSING, FORWARD CLUTCH
629 SEAL, FORWARD CLUTCH (INNER AND OUTER)
630 PISTON, FORWARD CLUTCH
631 SEAL, OVERRUN CLUTCH (INNER AND OUTER)
632 PISTON, OVERRUN CLUTCH
633 BALL, OVERRUN CLUTCH
634 SPRING ASSEMBLY, OVERRUN CLUTCH
635 SNAP RING, OVERRUN CLUTCH SPRING RETAINER
638 SNAP RING, OVERRUN CL. HUB RETAINING
641 RETAINER AND RACE ASSEMBLY, SPRAG
642 FORWARD-SPRAG ASSEMBLY
645A
PLATE ASSEMBLY, OVERRUN CLUTCH (FIBER)
6458
PLATE, OVERRUN CLUTCH (STEEL)
646 PLATE, FORWARD CLUTCH (APPLY)
648 PLATE, FORWARD CLUTCH (WAVED)
649A
6498
650 PLATE, FORWARD CLUTCH BACKING (SEU
651 RING, FORWARD CLUTCH BACKING PLATE RETAINER
652 PLATE, 3RD AND 4TH CLUTCH RING RETAINER
653 PLATE, 3RD AND 4TH CLUTCH APPLY (STEPPED)
7A-15B-65
DESCRIPTION
654A
PLATE ASSEMBLY, 3RD AND 4TH CLUTCH (FIBER)
6548
PLATE, 3RD AND 4TH CLUTCH (STEEL)
654C
PLATE, 3RD AND 4TH CLUTCH (STEEL)
655 PLATE, 3RD AND 4TH CLUTCH BACKING (SEL.)
656 RING, 3RD AND 4TH CLUTCH BACKING PLATE RETAINER
657 BUSHING, INPUT SUN GEAR (FRONT)
658 GEAR, INPUT SUN
659 BUSHING, INPUT SUN GEAR (REAR)
661 RET., OUTPUT SHAFT TO INPUT CARRIER
662 CARRIER ASSEMBLY, INPUT (COMPLETE)
663 BEARING ASSEMBLY, THRUST (INPUT CARRIER TO
REACTION SHAFT)
664 GEAR, INPUT INTERNAL
665 BUSHING, REACTION CARRIER SHAFT (FRONT)
667 BUSHING, REACTION CARRIER SHAFT (REAR)
668 RING, REACTION SHAFT/INTERNAL GEAR RETAINER
669 WASHER, THRUST (REACTION SHAFT/SHELL)
670 SHELL, REACTION SUN
671 RING, REACTION SUN GEAR RETAINER
672 BUSHING, REACTION SUN
675 RACE, LO AND REVERSE ROLLER CLUTCH
676 RING, LO AND REVERSE SUPPORT TO CASE RETAINER
677 RING, LO AND REVERSE RETAINER (ROLLER ASSEMBLY/
CAM)
678 CLUTCH ASSEMBLY, LO AND REVERSE ROLLER
679 SUPPORT ASM., LO AND REVERSE CLUTCH
680 SPRING, TRANSMISSION (LO AND REVERSE CLUTCH
SUPPORT RETAINER)
681 CARRIER ASSEMBLY, REACTION
682A
PLATE, LO AND REVERSE CLUTCH (WAVED)
6828
PLATE, SPACER LO AND REVERSE CLUTCH
(SELECTIVE)
682C
PLATE ASSEMBLY, LO AND REVERSE CLUTCH (FIBER)
6820
PLATE, LO AND REVERSE CLUTCH (STEEL)
683 BEARING ASSEMBLY, THRUST (REACTION CARRIER/
SUPPORT)
684 GEAR, INTERNAL REACTION
685 SUPPORT, INTERNAL REACTION GEAR
686 RING, REACTION GEAR/SUPPORT RETAINER
687 SHAFT, OUTPUT
688 CLIP, SPEEDO DRIVE GEAR
690 SLEEVE, OUTPUT SHAFT
692 BAG., REACTION GEAR SUPPORT TO CASE
693 RING, LO AND REVERSE CLUTCH RETAINER
694 SPRING ASSEMBLY, LO AND REVERSE CLUTCH
695 PISTON, LO AND REVERSE CLUTCH
696 SEAL, TRANSMISSION (LO AND REVERSE CLUTCH OUTER, CENTER, INNER)
697 DEFLECTOR, OIL (HIGH OUTPUT MODELS ONLY)
699 ROTOR, INTERNAL TRANSMISSION SPEED SENSOR
PH0199-4L60
Figure 140 Transmission Internal Parts - Legend
7A-15B-66
341
/~
-~341
"'309
1J
341,~
341i
301
302
303
304
309
310
311
312
313
314
315
316
317
318
319
322
323
324
325
326
328
329
VALVE, T.V. MODULATOR DOWNSHIFT

SPRING, T.V. MODULATOR DOWNSHIFT VALVE
VALVE, T.V. MODULATOR UPSHIFT
SPRING, T.V. MODULATOR UPSHIFTVALVE
SLEEVE, 3-4 THROTILE VALVE
SPRING, 3-4 THROTILE VALVE
VALVE, 3-4 THROTILE
VALVE, 3-4 SHIFT
VALVE, 2-3 THROTILE
VALVE, 2-3 SHIFT
VALVE, 1-2 THROTILE
VALVE, 1-2 SHIFT
SLEEVE, THROTILE VALVE PLUNGER
PLUNGER, THROTILE VALVE
SPRING, THROTILE VALVE
VALVE, THROTILE
VALVE, 3-4 RELAY
VALVE, 4-3 SEQUENCE
330
331
332
333
334
335
336
337
338
339
340
341
342
343
344
345
346
347
348
349
350
351
352

VALVE, T.V. LIMIT
VALVE, LINE BIAS
SPRING, 3-2 CONTROL
VALVE, 3-2 CONTROL
VALVE, MANUAL
PIN, COILED SPRING
PIN, COILED SPRING
PLUG, VALVE BORE
PLUG, CUP (.33 DIA)
SWITCH ASM., PRESSURE (3RD CL)
SWITCH ASM., PRESSURE (4-3 PULSE)
SWITCH ASM., PRESSURE (4TH CL)
SWITCH ASM., PRESSURE (T.C.C. SIGNAL)
BODY, CONTROL VALVE
PLUG, T.V. LIMIT
NH0170-4L60
PLUG, VALVE BORE (12.5 - 0.D.)
Figure 141 Control Valve Assembly
7A-15B-67
ILL.
234
217
,,!.,
244 - - 0
'
~~
8
'
--..;;;;;~~Tf~r--L:_-::r_J
J
. . . - 1&--"' 239
-~'t:_
245
229
218
228
~-
219
Iv'
-t::)
~.
-~
227
220
226
221
225
222
206
211
223
-~-
224
NO.
002
003
094
096
203
204
205
206
207
208
209
210
211
212
213
214
215
216
217
218
219
220
221
222
223
224
225
226
227
228
229
230
231
232
233
234
235
236
237
238
239
240
242
243
244
245
DESCRIPTION
SEAL ASSEMBLY, OIL
BUSHING, PUMP BODY
RETAINER, FRONT HELIX SEAL
BODY, PUMP
RING, OIL SEAL (SLIDE TO WEAR PLATE)
SEAL, "O" RING (SLIDE SEAL BACK-UP)
SLIDE, PUMP
SPRING, PIVOT PIN
PIN, PIVOT SLIDE
SPRING, PUMP SLIDE (OUTER)
SUPPORT, PUMP SLIDE SEAL
SEAL, PUMP SLIDE
RING, PUMP VANE
GUIDE, ROTOR
ROTOR, OIL PUMP
VANE, PUMP
SHAFT, STATOR
COVER, PUMP
VALVE, T.V. BOOST
BUSHING, T.V. BOOST
RING, OIL PUMP REVERSE BOOST VALVE RETAINING
RING, OIL PUMP CONVERTER CLUTCH VALVE
RETAINING
VALVE, STOP
SPRING, CONVERTER CLUTCH VALVE (OUTER)
SPRING, CONVERTER CLUTCH VALVE (INNER)
RIVET, PRESSURE RELIEF BOLT
BALL, PRESSURE RELIEF
SPRING, PRESSURE RELIEF
RING, OIL SEAL (STATOR SHAFT)
SEAL, OIL PUMP COVER SCREEN
SCREEN, OIL PUMP COVER
BOLT, MB x 1.25 x 40 (COVER TO BODY)
PLUG, OIL PUMP AIR BLEED
PLUG, OIL PUMP COVER
PLUG, OIL PUMP COOLER FEED
PLUG, OIL PUMP CONVERTER CLUTCH SIGNAL
SCREW, STATOR SHAFT (M6 x 1 x 16.0)
SPRING, PUMP SLIDE (INNER)
RETAINER & BALL ASSEMBLY, (REVERSE CLUTCH)
RETAINER & BALL ASSEMBLY, (OVERRUN CLUTCH)
243
203
~003
LH0152-4L60
Figure 142 Oil Pump Assembly
7A-15B-68
696
ILL.
ILL.
NO.
DESCRIPTION
601 WASHER, THRUST (PUMP TO DRUM)
608 SEALS, REVERSE INPUT CLUTCH
(INNER & OUTER)
SELECTIVE WASHER
622 SEAL, "O" RING INPUT TO FORWARD HSG.
624 SEAL, 3RD & 4TH CL. (INNER & OUTER)
629 SEAL, FORWARD CLUTCH (INNER & OUTER)
631 SEAL, OVERRUN CLUTCH (INNER & OUTER)
NO.
DESCRIPTION
663 BEARING ASSEMBLY, THRUST (INPUT
CARRIER TO REACTION SHAFT)
669 WASHER, THRUST (REACTION SHAFT/
SHELL)
683 BEARING ASSEMBLY, THRUST (REACTION
CARRIER/SUPPORT)
692 BRG., REACTION GEAR SUPPORT TO CASE
696 SEAL, TRANSMISSION (LO & REVERSE
CLUTCH - OUTER, CENTER, INNER)
LH0203-4L60
Figure 143 Seal and Bearing Locations
603
665
672
76
667
7A-15B-69
38
(])
3 BUSHING,
4- BUSHING,
38 BUSHING,
76 BUSHING,
90 BUSHING,
603 BUSHING,
606 BUSHING,
657
659
665
667
672
OIL PUMP BODY

STATOR SHAFT (FRONT)
CASE EXTENSION
CASE
STATOR SHAFT (REAR)
REVERSE INPUT CLUTCH (FRONT)
REVERSE INPUT CLUTCH (REAR)
BUSHING,
BUSHING,
BUSHING,
BUSHING,
BUSHING,
INPUT SUN GEAR (FRONT)

INPUT SUN GEAR (REAR)
REACTION SHAFT (FRONT)
REACTION SHAFT (REAR)
REACTION SUN GEAR
QTY.
SIZE
TORQUE
PARK BRAKE
BRACKET TO CASE
MB
1.25 X 20.0
31 Nm
(23 LB.-FT.)
11 Nm
(8 LB.-FT.)
PUMP COVER TO
BODY
MB
1.25 X 40.0
24 Nm
(18 LB.-FT.)
MB
1.25 x 20.0
24 Nm
(18 LB.-FT.)
PUMP ASSEMBLY
TO CASE
MB
1.25 X 60.0
24 Nm
(18 LB.-FT.)
15
M6
1.0 x 50.0
11 Nm
(8 LB.-FT.)
CASE EXTENSION
TO CASE
M10
1.50 X 30.0
35 Nm
(26 LB.-FT.)
M6
1.0 x 24.0
11 Nm
(8 LB.-FT.)
MANUAL SHAFT TO
INSIDE DETENT LEVER
M10
1.50 NUT
31 Nm
(23 LB.-FT.)
M6
1.0x 12.0
11 Nm
(8 LB.-FT.)
PRESSURE PLUGS
1-4
1/8 - 27
11 Nm
(8 LB.-FT.)
TRANSMISSION OIL
PAN TO CASE
16
MB
1.25 x 19.3
12 Nm
(9 LB.-FT.)
CONNECTOR COOLER
PIPE
1/4 - 18
38 Nm
(28 LB.-FT.)
PRESSURE SWITCHES
1-3
1/8 - 27
11 Nm
(8 LB.-FT.)
SPEED SENSOR
RETAINER
M6
1.0X21.7
11 Nm
(8 LB.-FT.)
AUXILIARY VALVE
BODY TO CASE
M6
1.0 x 19.0
11 Nm
(8 LB.-FT.)
AUXILIARY VALVE
BODY TO CASE
M6
1.0 x 35.0
11 Nm
(8 LB.-FT.)
AUXILIARY VALVE
BODY TO CASE
M6
1.0x47.4
11 Nm
(8 LB.-FT.)
QTY.
SIZE
TORQUE
ACCUMULATOR
COVER TO CASE
M6
1.0 x 35.0
11 Nm
(8 LB.-FT.)
ACCUMULATOR
COVER TO CASE
M6
1.0 x 65.0
DETENT SPRING TO
VALVE BODY
VALVE BODY TO
CASE
OIL PASSAGE COVER
TO AUX. VALVE BODY
LOCATION
SOLENOID ASSEMBLY
TO PUMP COVER
LOCATION
PH0204-4L60
Figure 144 Torque Specifications and Bushing Locations
7A-15B-70
BUSHING REPLACEMENT PROCEDURE

PROTECT PARTS WITH WOOD BLOCKS OR CLOTH AS NECESSARY
INSTALL AS SHOWN
REMOVE AS SHOWN
J 25019-14
4 BUSHING, STATOR SHAFT - FRONT

90 BUSHING, STATOR SHAFT - REAR
21 7 COVER, PUMP
4 BUSHING, STATOR SHAFT - FRONT

90 BUSHING, STATOR SHAFT - REAR
21 7 COVER, PUMP
203
203

203 BODY, PUMP

203 BODY, PUMP
603 BUSHING, REVERSE INPUT CLUTCH - FRONT

605 HOUSING & DRUM ASM., REVERSE INPUT CLUTCH
606 BUSHING, REVERSE INPUT CLUTCH - REAR
603 BUSHING, REVERSE INPUT CLUTCH - FRONT

605 HOUSING & DRUM ASM., REVERSE INPUT CLUTCH
606 BUSHING, REVERSE INPUT CLUTCH - REAR
LH0205-4L60
Figure 145 Bushing Replacement Procedure
7A-15B-71

INSTALL AS SHOWN
REMOVE AS SHOWN
J 8092
J 34196-6
J 34196-5
659
657 BUSHING, INPUT SUN GEAR - FRONT

658 GEAR, INPUT SUN
659 BUSHING, INPUT SUN GEAR - REAR
657 BUSHING, INPUT SUN GEAR - FRONT

658 GEAR, INPUT SUN
659 BUSHING, INPUT SUN GEAR - REAR
J 7004-1
~J8092--....
J 25019-14
J 34196-3
667
665
665 BUSHING, REACTION CARRIER SHAFT - FRONT

667 BUSHING, REACTION CARRIER SHAFT - REAR
665
667
665 BUSHING, REACTION CARRIER SHAFT - FRONT

667 BUSHING, REACTION CARRIER SHAFT - REAR
/J8092
J 8092
J 34196-1
J 34196-1
672


LH0206-4L60
7A-158-72

INSTALL AS SHOWN
REMOVE AS SHOWN
8092
J 23062-14
J 34196-4
38
38
36 EXTENSION, CASE
36 EXTENSION, CASE
J 34196-10
J 34196-6
76
76
76 BUSHING, CASE
76 BUSHING, CASE
LH0207-4L60
7A-15B-73
GOVERNOR BORE REPAIR PROCEDURE

FOLLOW STEPS 1-6 TO REPAIR THE GOVERNOR BORE
J 22976-9
B RATCHET & SOCKET
STEP 1 Install holding fixture J 8763 and mount in vise.
STEP 4 Ream the governor bore as follows:

Oil J 22976-9, J 22976-1 and the governor bore with
transmission fluid.
After each ten revolutions, remove the reamer and dip in
transmission fluid to clean.
After the reamer reaches the end of the bore and bottoms
on the governor support pin, rotate the reamer ten additional revolutions.
Remove the reamer. Be certain to rotate during removal to
prevent scoring the bore.
Remove the tools and thorougly clean the case.
STEP 2 Remove (file) any excess material from the governor

face.
C BUSHING
D SLOTS
22976-3
STEP 5 Align the slots in the bushing with the slots in the
governor bore.
J 22976-1
A PIN, GOVERNOR SUPPORT

STEP 3 Install J 22976-3 and J 22976-1. Torque bolts to
13 Nm (10 ft.-lbs.). Make sure J 22976-3 rotates
freely and then remove it.
C BUSHING
E BRASS HAMMER
STEP 6 Install the bushing until the slots in the bushing align
with the feed holes in the governor bore.
LH0208-4L60
Figure 148 Governor Bore Repair Procedure
7A-15B-74
SPECIAL TOOLS
Universal Remover
Rear Seal Installer
Dial Indicator Set
J 7004-1
Holding Fixture & Base
~MO
J 8001
Oil Pump Body & Cover Alignment
~~
J 21368
J 8763-02
Pump Oil Seal
End Play Checking

Fixture
J 21426
Clutch Spring
Compressor
Press
Piston Compressor
Bushing Remover
J 23456
Pump Remover & Installer
'"~
J 25022
J 25016
Clutch Spring
Compressor
Clutch Spring
Compresso@
Adapter
J 24773
J 25018
Bushing Remover
~
Adaptor
Bushing Remover
J 34725
J 39119
Turbine Shaft
Seal Sizer
Bushing & Universal Remover Set
J 25019-12
J 25019-9
BusMag R o m ~
JJD
J 38417
Bushing Remover
J 25019-16
Servo Cover Compressor
fi1I
J 25019-14
J 24036
Speedometer Gear Puller & Adapter
J 29714
Inner Forward Clutch Seal Protector
cr;:2,a-2
J 36418-1
Speed Sensor
Remover
J 25019-4
J 23907
J 37789
Bushing Installer
""""~
Universal Remover
End Play Fixture

Adaptor
J 23062-14
J 22269-01
Oil Pump Remover & End Play Checking
~ J ;,4~7-01 & J 8433

Inner Overrun Clutch Seal Protector
J 29883
Cooler Flusher
([JJ
J 29369-1
J 29369-2
Output Shaft Support Fixture
J 29882
Speed Sensor Rotor Installer
J 29837
2-4 Band Apply Pin Tools
J 36352
J 33037
Dial Indicator Stand & Guide Pin Set
WM---
IIWMm:::==::::i1mmoun
J 5590
Handle
1<11110, mw=:::mmi11111n
.fij@I
-==::JIIIIIIIDIIIIII
J 25025-B
J 35944
Bushing Set
Speedometer Gear Installer
J 8092
ro
al]
ffi)
O]j)
@)
OD)
cm])
J 34196
NH0209-4L60
MANUAL TRANSMISSION ON-VEHICLE SERVICE 78-1
SECTION 78
MANUAL TRANSMISSION
ON-VEHICLE SERVICE
RPO M28, M29, AND M49
when installing fasteners that require it. If the above conditions are not. followed, parts or system damage could
result.
CONTENTS
5-Speed Manual Transmission Assembly
(RPO M49) . . . . . . . . . . . . . . . . . . . . . . . . . .
6-Speed Manual Transmission Assemblies
(RPO M28 and M29) . . . . . . . . . . . . . . . . . . .
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking Manual Transmission Assembly
Fluid Level . . . . . . . . . . . . . . . . . . . . . . . . . . .
Transmission Support and Transmission
Mount Assembly . . . . . . . . . . . . . . . . . . . . . .
Manual Transmission Control Lever Boot
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Manual Transmission Control Assembly
(5-Speed) ............................
Manual Transmission Control Lever
Handle Assembly (6-Speed) .............
7B- l
7B- l
7B- l
7B-2
78-4
78-4
7B-4
7B-4
78-6
Manual Transmission Control Assembly

(6-Speed) ............................ 7B-8
Output Shaft Seal . . . . . . . . . . . . . . . . . . . . . . . . 7B-9
Backup Lamp Switch Assembly ............ 7B-9
Speed Sensor Assembly (5-Speed) . . . . . . . . . 7B- l l
Electronic Speed Sensor (6-Speed) . . . . . . . . . 7B- l 1
Reverse Lockout Solenoid (6-Speed) . . . . . . . 7B-11
Reverse Lockout Assembly (6-Speed) ...... 7B-14
(RPO M49) ......................... 7B-14
(RPO M28 and M29) . . . . . . . . . . . . . . . . . . 7B-15
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B-17
Fastener Tightening Specifications . . . . . . . . . 7B- l 7
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7B-18
7B-8
GENERAL DESCRIPTION
The 5-speed manual transmission assembly (RPO
M49) is the only manual transmission assembly available
for the 3.4L L32 V6 engine assembly. The 6-speed
manual transmission assemblies (RPO M28 and M29) are
available for the 5.7L LT! VS engine assembly. Manual
transmission assemblies are identified by the number of
forward gears and the measured distance between the
centerline of the output shaft and the counter gear.
5-SPEED MANUAL TRANSMISSION

ASSEMBLY (RPO M49)
The 5-speed 77 mm manual transmission assembly
is a fully synchronized unit with blocker ring synchronizers and a sliding mesh reverse gear. First and second
gears have three-piece synchronizer rings, consisting of
steel inner and outer cones and a tapered metal ring that is
lined on both sides with friction material similar to automatic transmission friction plates. The cones are independent of the gears and can be replaced separately. Third and
fourth gear blocker rings are more conventional in appearance, but are also lined with friction material. The fifth
gear blocker ring is brass.
NOTICE: No lubricant other than DEXRON-II

GM P/N 1051855 should be used in this manual
transmission assembly. Other lubricants or additives
may damage the blocker ring friction material or its
adhesive.
The mainshaft and countershaft are supported on
tapered roller bearings and must be shimmed for proper
end play. First through fourth speed mainshaft gears ride
on caged roller bearings. An aluminum transmission case
houses the various gears and bearings. The manual transmission control assembly is mounted on top of the extension housing. The manual transmission control assembly
cannot be adjusted and can be serviced independently of
the manual transmission assembly.

ASSEMBLIES (RPO M28 and M29)
The two 6-speed 85 mm manual transmission
assemblies are basically the same, with the only difference being the first and third gear ratios. Both transmission assemblies are fully synchronized units with
blocker ring synchronizers and sliding mesh reverse
gears.
78-2 MANUAL TRANSMISSION ON-VEHICLE SERVICE

NOTICE: No lubricant other than DEXRON-11
GM PIN 1051855 should be used in this manual
adhesive.
Both 6-speed manual transmission assemblies have
a reverse lockout solenoid, which operates a reverse
lockout assembly to prevent the operator from accidently
shifting into reverse when the vehicle is moving forward
at a speed of 5 km/h (3 mph) or more.
The 6-speed manual transmission assemblies also
utilize an electronic speed sensor.
roller bearings. An aluminum transmission case houses

the various gears and bearings.
Like the 5-speed manual transmission assembly,
the 6-speed manual transmission control assembly is
mounted on top of the extension housing, and can be
serviced independently of the manual transmission
assembly. The manual transmission control assembly
cannot be adjusted. Unlike the 5-speed manual transmission assembly, the manual transmission control lever
handle assembly on the 6-speed manual transmtssion
assembly can be removed from the manual transmtssion
control assembly. This allows for removal of the 6-speed
manual transmission assembly with the manual transmission control assembly intact.
Each forward gear synchronizer assembly is made

up of a splined hub with three synchronizer keys, a sleeve,
and two synchronizer springs. The reverse synchronizer
has a splined hub with three synchronizer keys, a sleeve,
two synchronizer springs, and a reverse synchronizer
retainer.
The mainshaft and countershaft are supported on
tapered roller bearings. All speed gears ride on caged
DIAGNOSIS
For diagnosis of the 5-speed 77 mm manual transmission assembly or the 6-speed 85 mm manual transmission assembly refer to the following diagnosis chart.
CONDITION
POSSIBLE CAUSE
CORRECTION
Transmission Assembly
Shifts Hard
I.
2.
I. Refer to SECTION 7C.

2. Check alignment as necessary.
3.
Incorrect clutch travel.

Misaligned clutch housing bore to
crankshaft pilot.
Binding shift rail.
4. Internal bind in transmission assembly caused by shift forks, selector

plates, or synchronizer assemblies.
5.
Incorrect lubricant.
Manual Transmission
1. No power to reverse lockout
Assembly Shifts Hard Into
solenoid.
Reverse or Does Not Shift
Into Reverse (6-Speed Manual 2. Damaged reverse lockout solenoid.
Transmission Assembly)
Worn or broken reverse lockout
mechansim.
3. Worn or broken shift linkage
components. Worn or damaged
synchronizer sleeve or hub.
3. 5-Speed Manual Transmission

Assembly - remove transmission
cover and check for mispositioned
selector arm roll pin, loose cover
bolts, worn shift rail bores, worn
shift rail, distorted oil seal, or extension housing not aligned with case.
Replace worn or damaged components as necessary.
6-Speed Manual Transmission
Assembly - remove, disassemble
and inspect transmission. Check for
worn shift bores, worn shift rail or
worn shift rail bushings. Replace
worn or damaged components as
necessary.
4. Remove, disassemble and inspect
5. Drain and refill manual transmission assembly.
1. Turn ignition switch to "RUN"
position and check for voltage
(12 volts) at the reverse lockout.
2. Remove and check function of
reverse lockout assembly. Replace
worn or damaged parts as necessary.
3. Remove, disassemble, and inspect

CONDITION
Gear Clash When Shifting
From One Gear to Another
POSSIBLE CAUSE
1. Incorrect clutch travel.
2. Low lubricant level or incorrect
lubricant.
3. Worn or damaged control or synchronizer assemblies.
Noisy Transmission
1. Low lubricant level or incorrect

lubricant.
2. Loose clutch housing-to-engine, or

transmission-to-clutch, housing
bolts.
3. Misaligned clutch housing bore to
crankshaft pilot.
4. Worn or damaged control assembly,
transmission gears, or bearing
components.
Jumps Out of Gear
1.
2.
3.
Will Not Shift Into One Gear
I.
2.
Locked In One Gear, Cannot

Be Shifted Out
I.
2.
CORRECTION
1. Refer to SECTION 7C.
2. Drain and refill manual transmission assembly. If lubricant level
was low, check for leaks and repair
as necessary.
1. Drain and refill manual transmission assembly. If lubricant level
was low, check for leaks and repair
as necessary.
2. Check for correct bolt torque and
torque as necessary.
3. Check alignment.

Worn offset lever plastic insert or
1. Remove control assembly and
loose lever.
check for loose offset lever or worn
insert. Replace worn or damaged
components as necessary.
Worn or damaged control assembly,
shift forks, selector plates, interlock
plate, selector arm, shift rail, springs
Replace worn or damaged compoor shift cover.
nents as necessary.
Worn or tapered gear teeth, worn or
damaged syncrhonizer assemblies,
excessive end play caused by worn
Replace worn or damaged compothrust washers or output shaft gears.
nents as necessary.
Worn, damaged, or incorrectly
assembled control assembly, selector
plates, interlock plate, or selector
Replace worn or damaged compoarm.
nents as necessary.
Damaged or worn synchronizer
sleeves or hubs.
Worn or broken shift rail(s). Bent or
damaged shift fork.
Worn control assembly. Incorrectly
assembled or broken shift mechamanual transmission assembly.
nism. Worn or damaged gear train
Replace worn or damaged parts or
components.
assemble correctly.
ON-VEHICLE SERVICE
3. Support manual transmission assembly ( I or 2) with

transmission stand.
CHECKING MANUAL TRANSMISSION

ASSEMBLY FLUID LEVEL
4. Transmission mount nut (16) and washer (17) from

transmission mount assembly (13 ).
Figure 1
5. Transmission support bolts/screws (15) from rail

assembly.

I. Raise and suitably support vehicle. Refer to SECTION OA.
lt:.WI Clean
All dirt and oil from around fill plug (IO or 11 ).
- Fill plug (11) is located on right side of
5-speed manual transmission assembly.
- Fill plug (10) is located on left side of
6-speed manual transmission assembly.
2. Fill plug (10 or 11).
3. Fluid level should be even with bottom of fill plug
hole.

NOTICE: No lubricant other than DEXRON-11
GM PIN 1051855, should be used in this manual
adhesive.
NOTICE: See "Notice" on page 7B- l of this
section.
1. Lubricant, if required.
2. Fill plug (10 or 11).
l~I Tighten
Fill plug ( 11) on 5-speed manual transmission
assembly to 27 Nm (20 lb. ft.).
Fill plug ( 10) on 6-speed manual transmission
assembly to 30 Nm (22 lb. ft.).
3. Lower vehicle.
TRANSMISSION SUPPORT AND

TRANSMISSION MOUNT ASSEMBLY
Figure 2
The transmission mount assembly for the 5-speed
manual transmission assembly is similar to the transmission mount assembly for the 6-speed manual transmission
assemblies. The difference between the two mount assemblies is the shape. The removal and installation procedure
for the two different mount assemblies will be the same.

6. Transmission support (14).

7. Transmission mount bolts/screws (18) from manual
transmission assembly (I or 2).
8. Transmission mount assembly (13).

section.
1. Transmission mount assembly (13) to manual
2. Transmission mount bolts/screws ( 18).
!~I Tighten
Transmission mount bolts/screws (18) to 54
Nm (40 lb. ft.).
3. Transmission support (14) to rail assemblies.
4. Transmission support bolts/screws ( 15).
!~I Tighten
Transmission support bolts/screws (15) to
58 Nm (43 lb. ft.).
5. Transmission mount washer ( 17) and nut ( 16).
l~I Tighten
Transmission mount nut (16) to 47 Nm
(35 lb. ft.).
6. Remove transmission stand supporting manual
7. Lower vehicle.
MANUAL TRANSMISSION CONTROL LEVER

BOOT ASSEMBLY
Figures 3 and 4

SECTION 8C.
2. Handle bolts/screws (27), for 6-speed manual
3. Handle assembly (26), for 6-speed manual transmission assembly.
12
10
A
A 6-SPEED MANUAL TRANSMISSION COMPONENT

LOCATIONS
B 5-SPEED MANUAL TRANSMISSION COMPONENT
LOCATIONS
1 TRANSMISSION ASSEMBLY, 6-SPEED MANUAL
3 SWITCH ASSEMBLY, BACKUP LAMP (6-SPEED)
4 SWITCH ASSEMBLY, BACKUP LAMP (5-SPEED)
5 PLUG, TRANSMISSION OIL DRAIN (6-SPEED)
6 PLUG, TRANSMISSION OIL DRAIN (5-SPEED)
7 SOLENOID, REVERSE LOCKOUT (6-SPEED)
8 LOCKOUT ASSEMBLY, REVERSE (6-SPEED)
9 SENSOR, ELECTRONIC SPEED (6-SPEED)
10 PLUG, TRANSMISSION OIL FILL (6-SPEED)
11 PLUG, TRANSMISSION OIL FILL (5-SPEED)
12 SENSOR ASSEMBLY, SPEED (5-SPEED)
PC0001-7B-F-RP
Figure 1 - Manual Transmission Assembly Component Locations
13
,,--?
r-----14
16
-15
1
2
13
14
15
TRANSMISSION ASSEMBLY, 6-SPEED MANUAL

MOUNT ASSEMBLY, TRANSMISSION
SUPPORT, TRANSMISSION
BOLT/SCREW, TRANSMISSION SUPPORT, 58 Nm
(43 LB. FT.)
16 NUT, TRANSMISSION MOUNT, 47 Nm (35 LB. FT.)
17 WASHER, TRANSMISSION MOUNT
18 BOLT/SCREW, TRANSMISSION MOUNT, 54 Nm
(40 LB. FT.)
PC0002-7B-F-RP
Figure 2 - Transmission Support and Transmission Mount Assembly (Typical)
4. Boot bolts/screws (22 or 23).

5. Boot assembly (24 or 25) from front compartment
floor pan assembly (44 or 51).
l~I
Handle bolts/screws (27) to 25 Nm (18 lb. ft.).

SECTION 8C.

section.
1. Boot assembly (24 or 25) to front compartment floor
pan assembly (44 or 51).
2. Boot bolts/screws (22 or 23).
l~I
Tighten
Boot bolts/screws (22 or 23) to I. 7 Nm

(15 lb. in.).
3. Handle assembly (26) to control assembly (20).
4. Handle bolts/screws (27).
Tighten
MANUAL TRANSMISSION CONTROL

ASSEMBLY (5-SPEED)
Figure 3

SECTION 8C.
2. Boot bolts/screws (23).
3. Boot assembly (24).
24
19
21

19 BOLT/SCREW, TRANSMISSION CONTROL, 17 Nm
(13 LB. FT.)
21 CONTROL ASSEMBLY, MANUAL TRANSMISSION
23 BOLT/SCREW, MANUAL TRANSMISSION CONTROL
LEVER BOOT, 1.7 Nm (15 LB. IN.)
24 BOOT ASSEMBLY, MANUAL TRANSMISSION
CONTROL LEVER
51 PAN ASSEMBLY, FRONT COMPARTMENT FLOOR
PC0003-7B-F-RP
Figure 3 - Manual Transmission Control Lever Boot Assembly (5-Speed)
4. Transmission control bolts/screws ( 19).

NOTICE: The upper and lower transmission control

levers are bonded together. Separation of the levers
will cause damage, requiring replacement of the
transmission control assembly.
l++I
Install or Connect

section.
lt:'I
Clean
Sealant from manual transmission extension

housing.
Sealant from control assembly (21 ), if reinstalling.
1. Apply a continuous 3 mm (1/8-inch) bead of RTV

Sealant GM P/N 12345739, or equivalent to manual
transmission extension housing-to-control assembly
sealing surface.
3. Transmission control bolts/screws (19).
l~I
Tighten
Transmission control bolts/screws ( 19) to

17 Nm (13 lb. ft.).
l~I
Tighten
Boot bolts/screws (23) to 1.7 Nm (15 lb. in.).

6. Front floor console trim plate assembly. Ref:'r to
SECTION SC.
f~I
Tighten
Control lever handle bolts/screws (27) to

25 Nm (18 lb. ft.).
SECTION 8C.
MANUAL TRANSMISSION CONTROL

ASSEMBLY (6-SPEED)
Figure4
l++f Remove or Disconnect
A REMOVAL OF 6-SPEED MANUAL TRANSMISSION

CONTROL LEVER BOOT ASSEMBLY
B REMOVAL OF 6-SPEED MANUAL TRANSMISSION
CONTROL LEVER HANDLE ASSEMBLY
20 CONTROL ASSEMBLY, MANUAL TRANSMISSION
(6-SPEED)_
LEVER BOOT, 1.7 Nm (15 LB. IN.)
25 BOOT ASSEMBLY, MANUAL TRANSMISSION
CONTROL LEVER
26 HANDLE ASSEMBLY, MANUAL TRANSMISSION
CONTROL LEVER
LEVER HANDLE, 25 Nm (18 LB. FT.)
44 PAN ASSEMBLY, FRONT COMPARTMENT FLOOR
52 BOLT/SCREW, TRANSMISSION CONTROL,
18 Nm (13 LB. FT.)
PC0004-7B-F-RP
Figure 4 - Manual Transmission Control, Handle, and Boot

Assemblies (6-Speed)
MANUAL TRANSMISSION CONTROL LEVER

HANDLE ASSEMBLY (6-SPEED)
Figure 4

SECTION 8C.
2. Control lever handle bolts/screws (27).
3. Control lever handle assembly (26).

section.
1. Control lever handle assembly (26).
2. Control lever handle bolts/screws (27).

SECTION 8C.
3. Handle assembly (26).

section.
lr:tl Clean
housing.
Sealant from control assembly (20), if reinstalling.
1. Apply a continuous 3 mm ( 1/8-inch) bead of RTV
Sealant GM PIN 12345739, or equivalent to manual
sealing surface.
3. Transmission control bolts/screws (52)_
f~I
Tighten
Transmission control bolts/screws (52) to

18 Nm (13 lb. ft.).
f~I
Tighten
Boot bolts/screws (22) to 1.7 Nm (15 lb. in.).

6. Handle assembly (26) to control assembly (20).
f~I Tighten
Handle bolts/screws (27) to 25 Nm (18 lb. ft.)
SECTION 8C.
OUTPUT SHAFT SEAL

The output shaft seal for the 5-speed manual transmission assembly is similar to the output shaft seal for the
6-speed manual transmission assemblies. Whi~e there ~re
differences in the design, the removal and mstallat1~n
procedures for the two differe~t output _shaft _seals is
essentially the same. The only difference 1s the mstallation tool used to install the different seals.
Figures 5 and 6
Tools Required:
J 23907 Slide Hammer
J 26941 Extension Housing Seal Remover
J 21426 Extension Housing Seal Installer,
J 39440 Extension Housing Seal Installer,
ll'l'I
Inspect
Manual transmission assembly fluid level. Refer to

"Checking Manual Transmission Assembly Fluid
Level" in this section.
BACKUP LAMP SWITCH ASSEMBLY

The backup lamp switch assembly is located on the
left-hand side of the 5-speed manual transmission assembly, while the backup lamp switch assembly on the
6-speed manual transmission assembly is located on the
right-hand side.
Figures 7 and 8

2. Output shaft seal (28 or 29) using J 26941 with

J 23907.

section.
1. Output shaft seal (28 or 29), using J 21426 for
5-speed manual transmission assembly, or J 39440
for 6-speed manual transmission assembly.
2. Lubricate inside diameter of output shaft seal (28 or

29) with transmission fluid.

3. Electrical connector from backup lamp switch
assembly (3 or 4).
4. Backup lamp switch assembly (3 or 4) from manual
transmission assembly ( 1 or 2).

section.
1. Apply thin coating of teflon sealant, GM PIN
1052080 or equivalent to threads of backup lamp
switch assembly (3 or 4).
J 39440
A
28
B
A REMOVAL OF OUTPUT SHAFT SEAL
B INSTALLATION OF OUTPUT SHAFT SEAL
C RUBBER MALLET
PC0005-78-F-RP
Figure 5 - Manual Transmission Output Shaft Seal (6-Speed)
A REMOVAL OF OUTPUT SHAFT SEAL

B INSTALLATION OF OUTPUT SHAFT SEAL
C RUBBER MALLET
29
PC0006 78-f-RP
Figure 6 - Manual Transmission Output Shaft Seal (5-Speed)
d!Efl/1~
p:~
4

4 SWITCH ASSEMBLY, BACKUP LAMP
12 SENSOR ASSEMBLY, SPEED

30 BOLT/SCREW, SPEED SENSOR RETAINING, 10 Nm
(89 LB. IN.)
31 DRIVEN GEAR, SPEEDOMETER
PC0007-7B-F-RP
Figure 7 - Manual Transmission Backup Lamp Switch and Speed Sensor Assemblies (5-Speed)
2. Backup lamp switch assembly (3 or 4) to manual

transmission assembly (1 or 2).
l~I
Tighten
Backup lamp switch assembly (4) 38 Nm

(28 lb. ft.) for 5-speed manual transmission
assembly.
Backup lamp switch assembly (3) to 20 Nm

(15 lb. ft.) for 6-speed manual transmission
assembly.
3. Electrical connector to backup lamp switch assembly (3 or 4).
4. Lower vehicle.
SPEED SENSOR ASSEMBLY (5-SPEED)
l++I
Figure 7
l++I
Install or Connect
section.
Install or Connect

1. Electronic speed sensor (9) to 6-speed manual

transmission assembly ( 1).
2. Electronic speed sensor retaining bolt/screw (32) to
6-speed manual transmission assembly (1).
l~I
I. Battery negative cable assembly.
Tighten
Electronic speed sensor retaining bolt/screw

(32) to 10 Nm (89 lb. in.).
3. Electrical connector from speed sensor assembly

(12).
3. Electrical connector to electronic speed sensor (9).
4. Speed sensor retaining bolt/screw (30) from 5-speed

manual transmission assembly (2).
4. Lower vehicle.
5. Speed sensor assembly (12) and speedometer driven

gear (31) from 5-speed manual transmission assembly (2).
l++I
Install or Connect
REVERSE LOCKOUT SOLENOID (6-SPEED)

Figures 8 and 9
l++I

section.
1. Speedometer driven gear (31) and speed sensor
assembly (12) to 5-speed manual transmission
assembly (2).
2. Speed sensor retaining bolt/screw (30) to 5-speed

manual transmission assembly (2).
!~I
Tighten
Speed sensor retammg bolt/screw (30) to

10 Nm (89 lb. in.).
3. Electrical connector to speed sensor assembly (12).
4. Lower vehicle.
3. Electrical connector from reverse lockout solenoid

(7).
4. Reverse lockout bolt/screw (40).
5. Reverse lockout assembly (8).
6. Reverse lockout solenoid (7) from reverse lockout
assembly (8).
l++I
Install or Connect
ELECTRONIC SPEED SENSOR (6-SPEED)

Figure 8
l++I

3. Electrical connector from electronic speed sensor

(9).
4. Electronic speed sensor retaining bolt/screw (32)
from 6-speed manual transmission assembly (1).
5. Electronic speed sensor (9) from 6-speed manual
transmission assembly (1 ).
section.
1. Reverse lockout solenoid (7) to reverse lockout
assembly (8).
l~I
Tighten
Reverse lockout solenoid (7) to 41 Nm

(30 lb. ft.).
2. Reverse lockout assembly (8) to 6-speed manual
3. Reverse lockout bolt/screw (40).
l~I
Tighten
Reverse lockout bolt/screw (40) to 18 Nm

(13 lb. ft.).
4. Electrical connector to reverse lockout solenoid (7).
5. Lower vehicle.
/~
32
_____-fl
39
A
B
1
3
7
8
9
32
33
34
35
36
37
38
39
40
LEFT-HAND SIDE
RIGHT-HAND SIDE
SWITCH ASSEMBLV, BACKUP LAMP
SOLENOID, REVERSE LOCKOUT
LOCKOUT ASSEMBLY, REVERSE
SENSOR, ELECTRONIC SPEED
BOLT/SCREW, ELECTRONIC SPEED SENSOR
RETAINING, 10 Nm (89 LB. IN.)
RING, REVERSE LOCKOUT SNAP
PLUNGER,REVERSELOCKOUT
SPRING, REVERSE LOCKOUT OUTER
SEAT,REVERSELOCKOUT
RETAINING RING, REVERSE LOCKOUT
SPRING, REVERSE LOCKOUT INNER
BODY,REVE~SELOCKOUT
BOLT/SCREW, REVERSE LOCKOUT, 18 Nm (13 LB. FT.)
PCOOOS-78-F-RP
Figure 8 - Manual Transmission Backup Lamp Switch, Electronic Speed Sensor, Reverse Lockout Solenoid, and Reverse
Lockout Assembly (6-Speed)
Apply 12 volts to reverse lockout solenoid.
Remove reverse lockout

solenoid assembly
Solenoid plunger retracted
Replace reverse lockout solenoid.
Solenoid plunger extended.
Check reverse lockout assembly.

Refer to SECTION 78-108
(Extension Housing).
Reverse lockout plunger can

be depressed easily with thumb.
Reverse lockout plunger

cannot be depressed easily
with thumb.
Reverse lockout solenoid

and reverse lockout
assembly ok
Remove reverse lockout

solenoid from reverse lockout
assembly.
Check reverse lockout

solenoid circuit. Refer to
SECTION SA
I
I
Reverse lockout plunger can

Replace reverse lockout solenoid.
I
I
Reverse lockout plunger cannot

Check reverse lockout assembly.

Refer to SECTION 78-108.
(Extension Housing)
PC0009-7B-F-RP
Figure 9 - Reverse Lockout Assembly Bench Check
REVERSE LOCKOUT ASSEMBLY (6-SPEED)

Figures 8 and 9
l+I

l. Battery negative cable assembly.
3. Electrical connector from reverse lockout solenoid
(7).
4. Reverse lockout bolt/screw (40) from 6-speed
manual transmission assembly (1 ).
5. Reverse lockout assembly (8) from 6-speed manual
transmission assembly ( l ).
ll'l"I
Inspect
Reverse lockout assembly. Refer to SECTION

7B-10B for inspection and disassembly procedures.
!++I
Install or Connect

section.
l. Reverse lockout assembly (8) to 6-speed manual
transmission assembly ( l ).
2. Reverse lockout bolt/screw (40) to 6-speed manual
transmission assembly (1 ).
l~I
Tighten
Reverse lockout bolt/screw ( 40) to 18 N m

(13 lb. ft.).
3. Electrical connector to reverse lockout solenoid (7).
4. Lower vehicle.
4. Drain fluid from 5-speed manual transmission

assembly (2).
6. Support rear axle assembly with jack stand.
30.
9. Wiring harness connector from backup lamp switch
assembly (4).
10. Wiring harness connector from speed sensor
assembly (12).
11. Support engine assembly with a jack stand.
12. Support 5-speed manual transmission assembly (2)
with jack stand.
13. Transmission support and transmission mount
assembly. Refer to "Transmission Support and
Transmission Mount Assembly" in this section.
14. Lower 5-speed manual transmission assembly (2),
enough to reach transmission control bolts/screws
( 19), with aid of helper.
NOTICE: Manual transmission control assembly
must be held when lowering manual transmission
assembly, as control assembly is not retained in
vehicle. If control assembly is not held it could drop
causing damage to the component.
16. Lower 5-speed manual transmission assembly (2).
17. Manual transmission control assembly (21 ).
18. Transmission bolts/screws (41 ).
19. 5-speed manual transmission assembly (2) with aid
of helper.
20. Place 5-speed manual transmission assembly (2) in
J 36842.
!++I

section.
li:-1 Clean

ASSEMBLY (RPO M49)
Figures 1,2,3, and 10
Tools Required:
J 36842 Transmission Holding Fixture
J 3289-20 Bench Mount Holding Fixture Base
l+I
l.
2.

SECTION 8C.
Install or Connect
3.
4.

housing.
Sealant from control assembly (21), if reinstalling.
Control assembly (21) to installed position on
vehicle.
5-speed manual transmission assembly (2) to flywheel housing assembly, with aid of helper.
Pilot splined input shaft assembly (53) into
clutch disc hub assembly and pilot bearing.
Support 5-speed manual transmission assembly (2)
with jack stand.
Transmission bolts/screws (41).
!~I
Tighten
Transmission bolts/screws (41) to 75 Nm

(55 lb. ft.).

11. Wiring harness connector to speed sensor assembly
(12).
12. Wiring harness connector to backup lamp switch
assembly (4).
13. Catalytic converter hanger assembly. Refer to
SECTION 6F.
30.
15. Remove support from rear axle assembly.
17. Check and fill manual transmission assembly with
fluid. Refer to "Checking Manual Transmission
Assembly Fluid Level" in this section.
18. Lower vehicle.
SECTION 8C.
45
41

ASSEMBLY (RPO M28 AND M29)
Figures 1,2,4, and 11
Tool Required:
J 39430 Transmission Holding Fixture

2
41
45
53

BOLT/SCREW, TRANSMISSION, 75 Nm (55 LB. FT.)
HOUSING ASSEMBLY, FLYWHEEL
SHAFT ASSEMBLY, INPUT
PC0010-7B-F-RP
Figure 1O- Manual Transmission Assembly to Engine

Assembly (5-Speed)
5. Apply a continuous 3 mm ( 1/8-inch) bead of RTV

Sealant GM P/N 12345739, or equivalent to manual
sealing surface.
6. Raise 5-speed manual transmission assembly (2) up
engaging manual transmission control assembly
(21).
l~I
Tighten
Transmission control bolts/screws (19) to 17

Nm (13 lb. ft.).
8. Raise 5-speed manual transmission assembly (2) to
installed position.
10. Remove jack stands from transmission and engine
assemblies.

SECTION 8C.
3. Manual transmission control lever handle bolts/
screws (27).
6. Drain fluid from 6-speed manual transmission
assembly (1 ).
7. Support rear axle assembly with jack stand.
9. Rear axle torque arm. Refer to SECTION 30.
SECTION 6F.
11. Wiring harness connector from reverse lockout
solenoid (7).
12. Wiring harness connector from backup lamp switch
assembly (3).
13. Actuator cylinder nuts (50).
NOTICE: Disconnect the clutch master cylinder
pushrod before removing the actuator cylinder
assembly. If not disconnected, permanent damage to
the actuator cylinder will occur if the clutch pedal is
depressed while the actuator is disconnected.
[I] Important
Do not let the actuator cylinder hang by
hydraulic line.
A
1
43
46
47
48
49
50
CYLINDER, CLUTCH ACTUATOR

BOLT/SCREW, TRANSMISSION, 35 Nm (26 LB. FT.)
SPACER, CLUTCH ACTUATOR
FORK ASSEMBLY, CLUTCH
ENGINE ASSEMBLY
NUT, CLUTCH ACTUATOR CYLINDER, 20 Nm
(15 LB. FT.)
54 SHAFT ASSEMBLY, INPUT
A
43
PC00117B-F-RP
Figure 11 - Manual Transmission Assembly to Engine Assembly (6-Speed)
14. C~utch actuator cylinder and retain with mechanic's

Wlfe.
15. Actuator spacer (46).

16. Pull clutch fork assembly (47) down to disengage
from release bearing.
17. Wiring harness connector from electronic speed
sensor (9).
18. Support engine assembly with jack stand.
with jack stand.
Pilot transm1ss10n input shaft through the

release bearing, the clutch driven plate splines
and into the clutch pilot bearing.
with jack stand.
3. Transmission bolts/screws (43).
l~I
4.
5.
NOTICE: The clutch fork assembly (47) must be

disengaged from the release bearing assembly to
prevent damage to the clutch system.
21. Transmission bolts/screws (43).
of helper.
23. Place 6-speed manual transmission assembly (1) in
J 39430.
l++l
tnstall or Connect

section.
of helper.
6.
7.
8.
9.
Tighten
Transmission bolts/screws (43) to 35 Nm

(26 lb. ft.).
Transmission support and transmission mount
Remove jack stands from transmission and engine
assemblies.
Push clutch fork assembly (47) up to engage release
bearing.
Actuator spacer (46).
Actuator cylinder.
Actuator cylinder nuts (50).
l~I
Tighten
Actuator cylinder nuts (50) to 20 Nm

(15 lb. ft.).
10. Wiring harness connector to electronic speed sensor
(9).
11. Wiring harness connector to backup lamp switch
assembly (3).

12. Wiring harness connector to reverse lockout solenoid (7).
SECTION 6F.
14. Rear axle torque arm. Refer to SECTION 3D.
16. Remove support from rear axle assembly.
17. Fill transmission assembly with fluid. Refer to
"Checking Manual Transmission Assembly Fluid
Level" in this section.
18. Lower vehicle.
19. Clutch master cylinder pushrod. Refer to SECTION

7C.
20. Manual transmission control lever handle assembly
(26).
21. Manual transmission control lever handle bolts/
screws (27).
l~I
Tighten
Manual transm1ss10n control lever handle

SECTION SC.
SPECIFICATIONS
Backup Lamp Switch Assembly (5-Speed) ............................... 38 Nm (28 lb. ft.)
Backup Lamp Switch Assembly (6-Speed) ............................... 20 Nm (15 lb. ft.)
Electronic Speed Sensor Retaining Bolt/Screw ............................ 10 Nm (89 lb. in.)
Manual Transmission Control Lever Boot Assembly Bolt/Screw (5-Speed) ..... 1.7 Nm (15 lb. in.)
Manual Transmission Control Lever Boot Assembly Bolt/Screw (6-Speed) ..... 1.7 Nm (15 lb. in.)
Manual Transmission Control Lever Handle Bolt/Screw ..................... 25 Nm (18 lb. ft.)
Reverse Lockout Bolt/Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 N m (13 lb. ft.)
Reverse Lockout Solenoid ............................................ 41 Nm (30 lb. ft.)
Speed Sensor Retaining Bolt/Screw ..................................... 10 Nm (89 lb. in.)
Transmission Bolt/Screw (5-Speed) ..................................... 75 Nm (55 lb. ft.)
Transmission Bolt/Screw (6-Speed) ..................................... 35 Nm (26 lb. ft.)
Transmission Control Bolt/Screw ....................................... 17 Nm (13 lb. ft.)
Transmission Mount Bolt/Screw ........................................ 54 Nm (40 lb. ft.)
Transmission Mount Nut .............................................. 47 Nm (35 lb. ft.)
Transmission Support Bolt/Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 N m (43 lb. ft.)
SPECIAL TOOLS
J 39430
2.
4.
6-SPEED MANUAL TRANSMISSION ASSSEMBLV
1.
2.
3.
4.
5.
BENCH MOUNT HOLDING FIXTURE BASE

TRANSMISSION HOLDING FIXTURE
SLIDE HAMMER
EXTENSION HOUSING SEAL INSTALLER
EXTENSION HOUSING SEAL REMOVER
PC0012-7B-F-RP
4.
J 21426
J 23907
2.
E3
Ui&Q~:,
<--. )"g~
J 36842
<=-=- >
5-SPEED MANUAL TRANSMISSION ASSEMBLV
1.
2.
3.
4.
5.
BENCH MOUNT HOLDING FIXTURE BASE

SLIDE HAMMER
EXTENSION HOUSING SEAL INSTALLER
EXTENSION HOUSING SEAL REMOVER
PC0013-7B-F-RP
BORG-WARNER (TS) UNIT REPAIR 78-68-1
SECTION 78-68
BORG-WARNER {T5) UNIT REPAIR

RPO M49
could result.
CONTENTS
Unit Disassembly ...................................... 7BTransmission Disassembly ......................... 7BMain shaft Disassembly ............................. 7BDrive Gear Disassembly ........................... 7BCleaning and Inspection ........................... 7BTransmission Case ................................ 7BBearing Rollers and Spacers ................... 7BGears ................................................ 7BFront and Rear Bearings ........................ 7BSynchronizer Blocker Rings .................... 7BThird/Fourth Blocker Rings ..................... 7BFirst/Second Blocker Rings ..................... 7B-
1
1
7
8
8
8
8
8
8
9
9
9
Synchronizer Keys and Springs .................. 7B- 9

Extension Housing Oil Seal ....................... 7B-10
Extension Housing Bushing ....................... 7B-10
Drive Gear Bearing Retainer Oil
Seal ................................................. 7B-10
Transmission Cover ................................. 7B-11
Front Countershaft Bearing ........................ 7B-12
Drive Gear Assembly .............................. 7B-12
Mainshaft Assembly ................................ 7B-13
Transmission Assembly ............................ 7B-14
Specifications ........................................... 7B-17
Special Tools ........................................... 7B-19
NOTICE: Do not attempt to remove the offset

lever while the extension housing is still bolted in
place. The lever has a positioning lug engaged in
the housing detent plate, which prevents moving
the lever far enough for removal.
UNIT DISASSEMBLV
TRANSMISSION DISASSEMBLY
~Clean
Exterior of the transmission assembly thoroughly

with appropriate solvent.
j+t+! Disassemble
Tools Required:
J 37359 Countershaft Bearing Remover

J 22912-01 Bearing and Gear Puller
Remove drain bolt on transmission case and
drain lubricant.
NOTICE: Removal of offset lever in position

other than neutral (centered) may result in driving
the roll pin into the detent plate without releasing
lever, making further disassembly extremely
difficult.
1.
Position offset lever in neutral gate (centered).

Roll pin attaching offset lever to shift rail (Figure
3).
2.
Extension housing-to-transmission case bolts.
3.
Housing and offset lever as an assembly (Figure

4).
4.
Detent ball and spring from offset lever (Figure

5).
5.
6.
Roll pin from extension housing or offset lever.

Oiling funnel from rear of countershaft (Figure
6).
7.
8.
9.
10.
11.
12.
Bolts attaching transmission cover and shift fork

assembly to case.
Two of the transmission cover attaching
bolts are alignment-type dowel bolts. Note
the location of these bolts for assembly
reference.
Cover (Figure 7 ).
Reverse lever spring clip, pivot bolt and shift
lever (Figure 8).
Backup lamp switch.
Fifth gear synchronizer snap ring and retainer
from rear of countershaft (Figure 9 ).
Unhook reverse lock spring from front of
transmission case (Figure 10).
-=~--
78-68-2 BORG -WARNER (TS) UNIT REPAIR
P0001-7B6B-F-RA
Figure
100~,sassembled
~~;i;;iVi;;--------~POI
v1ew
BORG-WARNER (T5) UNIT REPAIR 78-68-3
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.
35.
36.
37.
38.
39.
40.
41.
42.
43.
44.
45.
46.
49.
50.
51.
COVER, TRANSMISSION
BOLT, ALIGNMENT DOWEL
BOLT
SEAL. 0-RING
PLUG, SHIFT RAIL
RAIL, SHIFT
FORK, 3RD AND 4TH SHIFT
ARM, SELECTOR
PLATE, GEAR SELECT INTERLOCK
FORK, 1ST AND 2ND SHIFT
INSERT. SHIFT FORK
PLATE, SHIFT FORK
PIN, ROLL - SELECTOR ARM
SHAFT, MAIN WITH 1ST AND 2ND
SYNCHRONIZER HUB
SPRING, SYNCHRONIZER
GEAR, REVERSE SLIDING
CONE. INNER - 1ST AND 2ND SYNCHRONIZER
CONE. OUTER - lST AND 2ND SYNCHRONIZER
RING, BLOCKER - lST AND 2ND SYNCHRONIZER
SLEEVE, 1ST GEAR BEARING

BEARING, lST GEAR
GEAR, 1ST SPEED
BEARING, MAINSHAFT REAR
RACE. MAINSHAFT REAR BEARING
GEAR, 5TH SPEED DRIVEN
RING, SNAP
GEAR. SPEEDOMETER DRIVE
CLIP, SPEEDOMETER DRIVE GEAR
BEARING, MAIN DRIVEGEAR THRUST
RACE, MAIN DRIVE GEAR THRUST BEARING
RING, BLOCKER - 3RD AND 4TH
SYNCHRONIZER
HUB, 3RD AND 4TH SYNCHRONIZER
KEY, SYNCHRONIZER
SLEEVE, 3RD AND 4TH SYNCHRONIZER
GEAR, 3RD SPEED
BEARING, 3RD GEAR
SPACER, 3RD GEAR BEARING
RING, SNAP 2ND GEAR THRUST WASHER
WASHER, THRUST - 2ND GEAR
GEAR, 2ND SPEED
BEARING, 2ND GEAR
SPACER, 2ND GEAR BEARING
RING, SPIRAL RETAINING - 2ND SYNCHRONIZER
WASHER, THRUST - 2ND SYNCHRONIZER
KEY, 1ST-2ND SYNCHRONIZER
PIN, LOCATING - lST SPEED
BEARING SLEEVE
0-RING, BEARING RACE
RACE, FRONT COUNTERSHAFT BEARING
BEARING, COUNTERSHAFT
52. GEAR CLUSTER, COUNTERSHAFT

53. RACE, REAR COUNTERSHAFT
54.
55.
56.
57.
58.
59.
60.
61.
62.
63.
64.
65.
66.
67.
68.
69.
70.
71.
72.
SHIM, COUNTERSHAFT BEARING ADJUSTMENT

RETAINER, COUNTERSHAFT
BOLT, COUNTERSHAFT RETAINER
GEAR, STH SPEED DRIVE
RING, BLOCKER - 5TH SYNCHRONIZER
SPRING, STH SYNCHRONIZER
HUB, STH SYNCHRONIZER
KEY, 5TH SYNCHRONIZER
SLEEVE, STH SYNCHRONIZER
RETAINER, STH SYNCHRONIZER
RING, SNAP - 5TH
SYNCHRONIZER RETAINER
FUNNEL, TRANSMISSION OILING
PLUG, FILL AND DRAIN
CASE, TRANSMISSION
SPRING, REVERSE LOCK
0-RING, REVERSE IDLER
GEAR.REVERSE IDLER
PIN, ROLL - REVERSE IDLER
SHAFT, REVERSE IDLER
FORK, 5TH SHIFT
PIN, ROLL - SHIFT FORK
RAIL, 5TH AND REVERSE SHIFT
73.
74.
75.
76. CLIP, SPRING - 5TH AND REVERSE LEVER
77. LEVER, 5TH AND REVERSE SHIFT
78. BOLT, 5TH AND REVERSE
SHIFT LEVER PIVOT
79. SWITCH, REVERSE LAMP
80. CONTROL, TRANSMISSION SHIFT LEVER AND HOUSING

81. SLEEVE, SHIFT LEVER DAMPER
82. LEVER, OFFSET SHIFT
83 ..PIN, ROLL - OFFSET LEVER
84. SPRING, DETENT
85. BALL, DETENT
86.
87.
88.
89.
90.
91.
92.
93.
94.
95.
96.
0-RING, EXTENSION HOUSING VENT

VENT, EXTENSION HOUSING
SEAL, EXTENSION HOUSING REAR OIL
BUSHING, EXTENSION HOUSING
HOUSING, EXTENSION
BOLT, EXTENSION HOUSING
BOLT, DRIVE GEAR BEARING RETAINER
RETAINER, DRIVE GEAR BEARING
SEAL, DRIVE GEAR BEARING RETAINER OIL
SHIM, MAINSHAFT BEARING ADJUSTMENT
RACE. MAIN DRIVE GEAR FRONT BEARING

97. GEAR, MAIN DRIVE
98. BEARINGS, ROLLER - MAIN DRIVE GEAR PILOT

99. SPACER
MC0002-7B-F-RP
Figure 2 Disassembled View -
Legend
78-68-4 BORG-WARNER (T5) UNIT REPAIR
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
Fifth gear, synchronizer, shift fork and shift rail

as an assembly. If necessary, rotate rail to
disengage from reverse lever assembly (Figure
11 ).
Circlip, speedometer gear and retaining clip.
Snap ring from fifth speed driven gear (Figure
12).
Front bearing retainer bolts.
Front bearing retainer.
Front bearing race and end play shims from front
bearing retainer (Figure 13).
Rotate drive gear until flat surface faces
countershaft and remove drive gear from the
transmission case.
Be careful not to drop the 15 roller bearings,
thrust bearing, or race from the rear of drive
gear (Figure 14).
Fourth gear blocker ring from third/fourth
synchronizer.
Mainshaft rear bearing race.
If the race sticks, it is probably misaligned
in the case bore. To free the race, work the
shaft back and fourth in the case.
Tilt mainshaft upward and remove assembly
from transmission case (Figure 15).
Reverse fork assembly from transmission case.
Countershaft retainer and shims (Figure 16).
Roll pin from forward end of reverse idler shaft.
Remove reverse idler shaft, rubber 0-ring and
gear from the transmission case (Figure 17).
Rear countershaft bearing race.
Countershaft bearing using appropriate pullers
(Figure 18).
Move countershaft assembly rearward, tilt
countershaft upward and remove from case.
Rear countershaft bearing from shaft using J
37359 with J 22912-01.
KC0002-7B-F-RP
Figure 4
Extension Housing to Transmission Case
82.
84.
85. DETENT
BALL
KC0014-7B-F-RP
Figure 5
Detent and Offset Lever
82. OFFSET
LEVER
83. ROLL PIN
KCOOl 5-78-F-RP
KC0013-7B-F-RP
Figure 3
Offset Lever
Figure 6 Oiling Funnel
63. RETAINER
64. SNAP RING
KC001 B-76-F-RP
Figure 9
Fifth Gear Synchronizer Retainer
KC0016-7B-F-RP
Figure 7
Transmission Cover
68. SPRING
75. FIFTH/REVERSE
SHIFT RAIL
77. REVERSE LEVER
KC0019-7B-F-RP
Figure 10
76. SPRING CLIP

KC0017-7B-F-RP
Figure 8
Reverse Lever Spring Clip
Reverse Lock Spring
78-68-6 BORG-WARNER (TS) UNIT REPAIR
KC0020-7B-F-RP
Figure 11
Fifth Gear Synchronizer
KC0005-7B-F-RP
Figure 14
Drive Gear
Figure 15
Mainshaft
P0002-7868-F-RA
Figure 12
93. DRIVE GEAR

BEARING RETAINER
95. SHIM
96. FRONT BEARING
RACE
Figure 13
Fifth Gear Snap Ring
54. SHIM
55. COUNTERSHAFT
RETAINER
KC0021-7B-F-RP
Bearing Retainer and Shims
KC0022-7B-F-RP
Figure 16
Countershaft Retainer
9.
10.
First/second synchronizer spring and keys from

first-reverse sliding gear.
Sleeve from mainshaft hub.
NOTICE: Do not attempt to remove the firstsecond-reverse hub from mainshaft. The hub and
shaft are permanently assembled and machined as
a matched set.
11.
12.
13.
14.
15.
16.
Fifth gear, using J 22912-01 and press.

Mainshaft rear bearing assembly.
First gear.
Needle bearing and sleeve.
Locating pin.
Three-piece first gear blocker ring assembly.
71. ROLL PIN

KC0023-7B-F-RP
Figure 17
Removing Reverse Idler Shaft Roll Pin
J 22912-01
J 22912-01
KC0024- 78-F-RP
Figure 18
Removing Countershaft Bearing
MAINSHAFT DISASSEMBLY
!+!! Disassemble
KC0025-7B-F-RP
Figure 19
Removing Third-Fourth Synchronizer
Tool Required:
1.
2.
3.
4.
5.
6.
7.
8.
Thrust bearing and race from front end of

mains haft.
Scribe
reference
mark
on
third-fourth
synchronizer hub and sleeve for reassembly.
Third-fourth synchronizer, third blocker ring,
sleeve, hub and third gear as an assembly from
mainshaft, using J 22912-01 and press.
Needle bearing assembly and spacer.
Second gear snap ring and thrust washer.
Second gear, spacer and needle bearing.
Spiral snap ring.
Thrust washer.
Three-piece second gear blocker ring assembly.
Scribe
reference
mark
on
first-second
synchronizer hub and sleeve for reassembly.
14. MAINSHAFT
36. NEEDLE BEARING
37. SPACER
KC0026-7B-F-RP
Figure 20
Needle Bearing and Spacer
78-688 BORG-WARNER {T5) UNIT REPAIR
17. INNER CONE

18. OUTER CONE
19. BLOCKER RING
Figure 21
KC0029-7B-F-RP
KC0027-7B-F-RP
Three"Piece Blocker Ring
Figure 23
Removing Drive Gear Bearing
CLEANING AND INSPECTION

DRIVE GEAR DISASSEMBLY
Transmission Case
Figures 22 and 23
1-:-! Clean
I+!+! Disassemble
1.
2.
3.
4.
1.
Tool Required:
Bearing race.
Thrust bearing.
Roller bearings from cavity of drive gear.
Remove bearing from drive gear using J 22912-01
and a press.
,~, Clean
2.
!Lj 1nspect
Case for cracks.

Front and rear faces of the transmission case for
burrs, and if present, dress them off with a fine
mill file.
1.
2.
Bearing Rollers and Spacers
IL! inspect
Parts in appropriate solvent.
IL! inspect
Transmission case thoroughly inside and outside

with appropriate solvent.
Magnetic disk at the bottom of the transmission
case.
Gear teeth and shaft pilot for wear.
29. THRUST BEARING

30. THRUST RACE
98. ROLLER BEARINGS
Drive gear bearing rollers.

Reverse idler shaft.
Spacers.
Gears
IL! inspect
Drive gear bearing rollers for chips, cracks, or

excessive wear and replace if necessary.
Clutch sleeves to insure that they slide freely on
their hubs.
Front and Rear Bearings
Drive Gear Bearings
Front and rear bearings

appropriate solvent.
thoroughly with
NOTICE: Do not allow the bearings to spin.

Turn them slowly by hand. Spinning bearings may
damage the race and rollers.
KC0028-7B-F-RP
Figure 22
Clean
Blow out bearings with compressed air.

Lubricate bearings with transmission lubricant.
!L! 1nspect
Bearings for roughness by slowly turning race by

hand.
A. BLOCKER TEETH
B. FEELER GAGE
C. CLUTCH TEETH
Svnchronizer Blocker Rings

Figure 24
First/second synchronizer outer cone and third/
fourth blocker ring are lined with friction material and
cannot be checked visually for wear. Replacement is
necessary when gap between blocker teeth and adjacent
clutch teeth is significantly less than specified. Fifth
gear blocker ring is brass and can be checked visually
for wear and damage.
NOTICE: Make certain the blocker rings are
correctly identified before assembly. First/second
synchronizer blocker ring does not have friction
material. The third/fourth synchronizer blocker
ring has friction material. Assembling one in place
of the other will result in serious damage to the
transmission.
KC0030-7B-F-RP
Figure 24
SYNCHRONIZER KEYS AND SPRINGS

NOTICE: The synchronizer hubs and sliding
sleeves are a selected assembly and should be kept
together as originally assembled, but the keys and
springs may be replaced if worn or broken.
IL! inspect
Fifth gear blocker ring for wear and damage.
Third/Fourth Blocker Rings
!+.,.! Remove or Disconnect
Figure 24
!..;+! Assemble
1.
2.
Third gear blocker ring to third gear with

twisting motion to fully seat.
Fourth gear blocker ring to main drive gear with
twisting motion to fully seat.
!@! Measure
Gap between vertical faces of blocker teeth and

clutch teeth. Nominal gap is 0.88-1.50 mm (0.
035-0.059 inch) for new blocker rings (Figure 28).
Measuring Blocker Ring Wear
Keys and springs.

If relation of hub and sleeve are not already
marked, mark for assembly purposes.
Push the sliding sleeve from the hub. The
keys will fall free and the springs may be
easily removed.
!.. +! Install or Connect
Keys and springs.

Place a blocker ring on side of the hub and
sle~ve and install keys and retain with a
spnng.
Place a blocker ring on opposite side of the
hub and sleeve and install remaining spring.
First/Second Blocker Rings

Figure 24
!..!+! Assemble
l.
2.
3.
4.
Three-piece first gear blocker ring assembly,

using a twisting motion to fully seat.
Three-piece first gear blocker ring assembly, with
needle bearing and bearing sleeve, to first gear.
Three-piece second gear blocker ring assembly,
using a twisting motion to fully seat.
Three-piece second gear blocker ring assembly,
with thrust washer, to second gear.
!@! Measure
Gap between vertical faces of blocker teeth and

clutch teeth. Nominal gap is 0.81-1.40 mm (0.
032-0.055 inch) for new blocker ring assemblies
(Figure 28).
15. SPRING
31. BLOCKER RING
32. HUB
33. KEYS
34. SLEEVE
KC0031-7B-F-RP
Figure 25
Third-Fourth Synchronizer Assembly
B
EJ
~
[,2]
~
EJ
MAIN SHAFT WITH HUB

SPRING
REVERSE SLIDING GEAR
INNER CONE
[ [[_
OUTER CONE
BLOCKER RING
KEYS
MC0003-7B-F-RP
Figure 26
First-Second Synchronizer Assembly
EXTENSION HOUSING BUSHING

Figure28
j++j Remove or Disconnect
I.
2.
58. BLOCKER
RING
59. SPRING
60. HUB
61. KEYS
62. SLEEVE
63. RETAINER
j++j Install or Connect
KC0033-7B-F-RP
Figure 27
Fifth Gear Synchronizer Assembly
EXTENSION HOUSING OIL SEAL
j++I Remove or Disconnect
Oil seal out of extension housing, usmg a

screwdriver or small chisel.
1.
2.
Tool Required:
J 21426 Extension Housing Seal Installer
New oil seal into extension housing using J 21426.
Lubricate inside diameter of seal with
transmission lubricant.
Tools Required:
J 8092 Universal Driver Handle
J 23062-14 Extension Housing Bushing
Oil seal out of extension housing, using a
screwdriver or small chisel.
Bushing out of housing, usmg J 8092 with J
23062-14.
Tools Required:
J 23062-14 Extension Housing Bushing
J 21426 Extension Housing Seal Installer
Bushing in housing, using J 8092 with J 23062-14.
New oil seal into extension housing using J 21426.
DRIVE GEAR BEARING RETAINER OIL SEAL

Figure 29
j++j Remove or Disconnect
Oil seal, using a screwdriver or small chisel.
1.
Tool Required:
J 37375 Drive Gear Bearing Retainer Seal
Installer
New seal into retainer using J 37375 until it
bottoms in bore.
2.
3.
4.
Selector arm roll pin usmg a pin punch and

hammer (Figure 31).
Shift rail, shift forks, shift fork plates, selector
arm, interlock plate and roll pin.
Transmission cover to extension housing 0-ring
seal using a screwdriver.
Nylon inserts and shift fork plates from shift
forks.
Note position of inserts and plates for
assembly reference.
!+!+! Assemble
J 23062-14
1.
Nylon inserts and shift fork plates in shift forks.
If removed, coat edges of shift rail plug with

sealer GM p/n 1052624, or equivalent, before
installing.
Coat shift rail and rail bores with transmission
lubricant.
Shift rail in cover until flush with inside edge of
cover.
Place first-second shift fork in cover with fork
offset facing rear of cover and push shift rail
through fork.
The first-second shift fork is the larger of
the two forks.
Selector arm and C-shaped interlock plate in

cover and insert shift rail through arm.
Widest part of interlock plate must face
away from cover, and selector arm roll pin
hole must face downward and toward rear
of cover.
Third-fourth shift fork in cover with fork offset
facing rear of cover.
2.
3.
KC0034- 7 B-F-R P
Figure 28
4.
Installing Extension Housing Bushing
5.
6.
KC0054-7B-F-RP
Figure 29
Installing Bearing Retainer Oil Seal
7.
TRANSMISSION COVER
Figures 30 and 31
l+!+! Disassemble
Place selector arm plates and shift rail in neutral

position (centered).
Rotate shift rail until selector arm disengages
from selector arm plates and roll pin is accessible.
Third-fourth shift fork plate must be under

first-second shift fork plate.
Shift rail through third-fourth shift fork and into
front bore in cover.
Rotate shift rail until shift fork plate at forward
end of rail faces away from, but is parallel to
cover.
Align roll pin holes in selector arm and shift rail
and install roll pin.
Roll pin must be flush with surface of
selector arm to prevent pin from contacting
shift fork plates during shifts.
New transmission cover to extension housing 0ring seal.
Coat 0-ring seal with transmission lubricant.
FRONT COUNTERSHAFT BEARING
j+-+j Remove or Disconnect

Tools Required:
J 37358-1, -2 Bearing Race Receiver and
Case Support
J 37359 Countershaft Bearing Remover
NOTICE: Failure to support the case properly

will result in permanent distortion of the case
during bearing race removal.
1.
1. TRANSMISSION COVER
2. ALIGNMENT BOLT
8. SELECTOR ARM
9. INTERLOCK PLATE
10. 1 ST/2ND SHIFT FORK
11 INSERT
3. BOLT
4. 0-RING SEAL
5. SHIFT RAIL PLUG
12. SHIFT FORK PLATE
6. SHIFT RAIL
13. ROLL PIN
2.
7. 3RD/4TH SHIFT FORK

NC1002-7B-F-RP
Figure 30
Transmission Cover
13. ROLL PIN
Countershaft front bearing race and 0-ring from

the transmission case, using J 37358-1 with J
37358-2 and a press.
Remove the front countershaft bearing race
only if it is worn or damaged.
Countershaft
front
bearing
from
the
countershaft, using J 22912-01 with J 37359, J
8092 and a press.
1.
2.
3.
Tools Required:
J 37357 Countershaft Bearing and Race
Countershaft front bearing onto the countershaft,
using J 37357 with J 22912-01, J 8092 and a press.
New 0-ring onto the countershaft front bearing
race.
Lubricate the 0-ring.
Countershaft front bearing race into the
transmission case, using J 37357 with J 8092 and a
press.
Lightly tap the race into its bore until the 0ring is compressed.
Use a press to install the race until its
shoulder rests on the inside of the case.
DRIVE GEAR ASSEMBLY
j-+;+j Assemble
Tools Required:
J 6133-01 Installer
KC0036-7B-F-RP
Figure 31
Removing Selector Arm Roll Pin
1.
2.
3.
Bearing onto the drive gear, using J 22912-01

with J 6133-01 and a press.
Coat roller bearings and drive gear bearing
bore with lightweight grease.
Roller bearings into the bore of the drive gear.
Thrust bearing and race into the drive gear.
J 37357
J 37358-2
KC0037-7B-F-RP
Figure 32
KC0039,7B-F-RP
Removing Bearing Race from Case
Figure 35
Installing Bearing Race to Case
MAINSHAFT ASSEMBLY
j..;+-! Assemble
Tools Required:
J 25234 Front and Rear Bearing Installer
J 37360 Spiral Snap Ring Installer
J 37 372 Synchronizer and Gear Installer
J 37359
NOTICE: If replacing first/second or third/fourth

synchronizer blocker rings, soak new blocker ring
assemblies for 10 minutes in Dexron-IIE or
equivalent before assembly on mainshaft.
LC0001-7B-F-RP
Figure 33
Removing Bearing from Countershaft
1.
Coat mainshaft and gear bores with transmission

lubricant.
First-second synchronizer sleeve on mainshaft
hub aligning marks made at disassembly.
NOTICE: Use care in synchronizer spring
placement. If synchronizer is assembled with
improper spring replacement, hard shifting will
result.
2.
49. 0-RING
50. BEARING
RACE
67. TRANSMISSION
CASE
3.
4.
5.
6.
KC0038- 78-F-RP
Figure 34
Front Countershaft Bearing Assembly
7.
First-second synchronizer keys and springs.

Engage tang end of each spring in same
synchronizer key, but position open end of
springs opposite of each other.
Three-piece first gear blocker ring assembly.
Locating pin into mainshaft.
Sleeve and needle bearing onto mainshaft,
aligning notch in sleeve with locating pin.
First gear, aligning slots in first gear with tabs on
blocker ring assembly.
Rear mainshaft bearing with taper facing rear of
shaft.
Lubricate fifth gear splines with petroleum jelly.
NOTICE: Carefully align the mainshaft and gear

splines. If splines are improperly aligned, damage
could occur when the gear is pressed onto the
mainshaft.
8.
9.
10.
11.
12.
13.
14.
15.
16.
rn
Fifth gear onto mainshaft, using J 25234 and a

press.
Fifth gear snap ring.
Three-piece second gear blocker ring assembly
and thrust washer.
Spiral snap ring, using J 37360.
Second gear spacer, needle bearing and gear,
aligning slots in second gear with tabs on blocker
ring assembly.
Second gear thrust washer and snap ring.
Third gear spacer and needle bearing assembly.
Make sure the bearing spacer is not trapped
between the gear face and snap ring. The
spacer runs inside the gear bore.
Third-fourth synchronizer, third blocker ring,
sleeve, hub and third gear as an assembly, using
J 37372 and a press.
Thrust bearing and race to front end of
main shaft.
Figures 1 through 18 and 37 through 39
I~!+! Assemble
Tools Required:
J 37357 Countershaft Bearing and Race
J 37372 Synchronizer and Gear Installer
J 8001 Dial Indicator
1.
2.
3.
Front countershaft bearing onto countershaft

using J 37357 with J 8092 and a press.
Countershaft in case.
Rear countershaft bearing to countershaft using
J 37372 and a press (Figure 37).
NOTICE: Failure to properly support the

countershaft may result in permanent distortion of
the case during installation.
Support the countershaft with J 37357.
Important
51. REAR COUNTERSHAFT

BEARING
Before pressing components together, make sure

the synchronizer hub faces the short end of the
mainshaft. Hold third gear against the
synchronizer to maintain blocker ring alignment
with keys.
J 37372
Figure 37
4.
5.
15. SPRING
33. KEY
Figure 36
KC0040-7B-F-RP
Synchronizer Springs
6.
7.
Installing Rear Countershaft Bearing
Rear countershaft bearing race.

Rubber 0-ring and reverse idler gear in case with
shift lever groove facing rear of case.
Reverse idler shaft from rear of case.
Roll pin in idler shaft.
8.
Countershaft retainer
transmission housing.
(without
shims)
to
l~I Tighten
Countershaft retainer bolts to 20 N m (15

lb. ft.).
l~I Measure
15.
Countershaft end play using dial indicator

J 8001.
16.
17.
18.
19.
20.
Blocker ring and fifth gear synchronizer in fifth

gear shift fork.
Slide fork rail assembly and synchronizer into
position.
Fifth gear synchronizer retainer and snap ring
(Figure 9).
Oiling funnel into rear of countershaft (Figure
6 ).
Fifth/ reverse shift lever in case.
Lever return spring to front of case.
Make sure reverse shift fork pin and fifth
gear shift rail pin are engaged with shift
lever.
Fifth gear/reverse lever pivot bolts and retaining
clip.
Coat pivot bolt threads with pipe thread
sealant GM p/n 1052080.
!~I Tighten
Figure 38
J 8001
21.
K C0042-7 B-F-R P
22.
23.
Measuring Countershaft End Play
9.
10.
11.
12.
13.
14.
Remove retainer and install shim(s) as

necessary to provide proper end play. Zero
end play with no preload is ideal, but up to
0.10 mm (0.004 inch) end play is allowable.
Do not preload bearing with shim(s) larger
than original end play measurement. Refer
to "Specifications" in this section.
Reinstall retainer and bolts.
l~I Tighten
Bolts to 20 N m (15 lb. ft.).

Bend tabs over the four attaching bolts.
Reverse shift fork in case.
Assembled mainshaft in transmission case.
Rear mainshaft bearing race in case.
Drive gear in case (make sure rollers, thrust
bearing and washer are in place), and engage in
third-fourth synchronizer sleeve and blocker
rmg.
Front bearing race in front bearing retainer.
Do not install shims in front bearing
retainer at this time.
Temporarily install front bearing retainer.
Fifth gear on countershaft.
Slide shift rail/fifth gear shift fork assembly
into case. As shift rail enters case, align
reverse shift fork and slide rail through fork.
Position lever return spring in case with
long end of spring to rear, and slide rail
through spring (Figure 10).
24.
25.
26.
27.
Pivot bolt to 27 N m (20 lb. ft.).

Backup lamp switch.
Coat threads with pipe thread sealant
GM p/n 1052080.
Speedometer gear and retaining clip.
Circlip.
Apply 3 mm (1/8-inch) bead of RTV Sealant
GM p/n 12345739 to transmission cover assembly.
Make sure all synchronizers are in the neutral
position and that the shift forks in the cover are
in the neutral (center) position.
Lower cover onto case while aligning shift forks
and synchronizer sleeves.
Cover and install two dowel bolts.
Remaining cover bolts.
l~I Tighten
Cover bolts to 13 N m ( 115 lb. in.).

Apply 3 mm (1/8-inch) bead of RTV Sealant
GM p/n 12345739 to extension housing mating
surface.
Coat detent spring with petroleum jelly and insert
in offset lever.
Lubricate detent plate and install detent ball in
neutral position on plate.
Position offset lever in extension housing with
spring over detent ball. Slide lever and extension
into position as an assembly.
Extension housing vent.
Press downward on offset lever to compress
detent spring and push lever and housing into
position.
Extension housing bolts.
Apply pipe thread sealant GM p/n 1052080
to threads of bolts.
l~I Tighten
Extension housing bolts to 30 N m (22 lb. ft.).
28.
29.
Roll pin in offset lever and shift rail.

Damper sleeve in offset lever.
Turn transmission case on end, and mount a dial
indicator on extension housing with indicator on
the end of mainshaft (Figure 39).
!@! Measure
30.
31.
Mainshaft end play.

- Rotate mainshaft and zero dial
indicator. Pull upward on mainshaft
until end play is removed and record
reading.
- Ideal mainshaft end play is zero with
plus or minus 0.02 mm (0.001 inch)
allowable.
- To set preload, select a shim pack
equal to the dial indicator reading
recorded.
Remove front bearing retainer and front bearing
race.
32.
Apply pipe thread sealant GM p/n 1052080 to

the threads of the drain and fill plugs.
Drain plug.
!~! Tighten
33.
Drain plug to 27 N m (20 lb. ft.).

Fill the transmission to its proper level with
Dexron-IIE.
Fill plug.
l~I Tighten
Fill plug to 27 N m (20 lb. ft.).

J 8001
Install necessary shims and reinstall bearing race.

Refer to "Specifications" in this section.
Apply a 3 mm diameter ( I /8-inch) bead of
RTV Sealant GM p/n 12345739 on case mating
surface of front bearing retainer.
Bearing retainer.
Apply pipe thread sealant GM pin 1052080 to
the threads of the retainer bolts.
Retainer bolts.
!~! Tighten
Retainer bolts to 20 N m (15 lb. ft.).
KC0043-7B-F-AP
Figure 39
Measuring Mainshaft End Play
SPECIFICATIONS
Catalytic Converter-to-Transmission Nut ...................................................... 52 Nm (38 lb. ft.)
Transmission-to-Flywheel Housing Bolt ........................................................ 75 N m (55 lb. ft.)
Extension Housing Bolt .................................................................................. 30 N m (22 lb. ft.)
Transmission Cover-to-Case Bolt .................................................................. 13 N m (115 lb. in.)
Front Bearing Retainer Bolt .......................................................................... 20 N m (15 lb. ft.)
Countershaft Retainer Bolt ............................................................................ 20 N m (15 lb. ft.)
Reverse Pivot Bolt .......................................................................................... 27 N m (20 lb. ft.)
Fill Plug .......................................................................................................... 27 N m (20 lb. ft.)
Drain Plug ...................................................................................................... 27 N m (20 lb. ft.)
Support-to-Rail Bolt ........................................................................................ 54 N m (40 lb. ft.)
Transmission Mount-to-Transmission Bolt .................................................... 54 N m (40 lb. ft.)
Transmission Mount-to-Support Nut... ........................................................... 47 N m (35 lb. ft.)
Transmission Mount-to-Support Bolt ............................................................ 54 N m (40 lb. ft.)
Speed Sensor Retainer Bolt ............................................................................ 10 N m (89 lb. in)
Shift Control Assembly Boot Screw ................................................................ 6 N m (53 lb. in)
Shift Control Assembly Bolt .......................................................................... 17 N m ( 13 lb. ft.)
Vehicle Speed Sensor Retainer Bolt ................................................................ 10 Nm (89 lb. in.)
Torque Arm Outer Bracket Nut ...................................................................... 41 Nm (30 lb. ft.)
Torque Arm-to-Rear Axle Differential Nut .................................................... .133 Nm (98 lb. ft.)
LUBRICANT SPECIFICATIONS
Lubricant Capacity (approximate) ............................................................ 2.8 Liters (2.96 quarts)
Lubricant Recommended ........................................................................ Dexron-IIE

TIRE SIZE
P215/65R15
P235/55R16
P245/50ZR 16
P215/65R15
P245/50ZR 16
AXLE RATIO
3.08
3.42
TRANSMISSION
M39
MB1
MK6
DRIVE GEAR
COLOR
TEETH
DRIVEN GEAR
COLOR
TEETH
RED
GREY
22
PURPLE
WHITE
19
MC0004-7B-F-RP
7B-6Q18 BORG-WARNER (TS) UNIT REPAIR
SHIM SPECIFICATIONS
lnput/Mainshaft
Countershaft
Thickness
(inches)
GM P/N
0.012
0.014
0.016
0.018
0.020
0.022
0.023
0.024
0.025
0.026
0.027
0.028
0.029
0.030
0.031
0.032
0.033
0.034
0.035
0.036
0.037
0.038
0.039
0.040
0.041
0.042
0.043
0.044
14050783
14050780
14050781
14050782
14050784
14050786
14050787
14069868
14069869
14069870
14069871
14069872
14069873
14069874
14069875
14069876
14069877
14069878
14069879
14050785
14069880
14069881
14069882
14069883
14069884
14069885
14069886
14069887
Thickness
(inches)
GM P/N
0.1005
0.102
0.1035
0.105
0.1065
0.108
0.1095
0.111
0.1125
0.114
0.1155
0.117
0.1185
0.120
0.1215
0.123
0.1245
0.126
0.1275
0.129
0.1305
0.132
0.1335
0.135
0.1365
0.138
0.1395
0.141
0.1425
0.144
0.1455
0.147
0.1485
0.150
0.1515
0.1530
10117781
10117782
10117783
10117784
10117785
10117786
10117787
10117788
10117789
10117790
10117791
10117792
10117793
10117794
10117795
10117796
10117797
10117798
10117799
10117800
10117801
10117802
10117803
10117804
10117805
10117806
10117807
10117808
10117809
10117810
10117811
10117812
10117813
10117814
10117815
10117816
LC00027B-F-RP
SPECIAL TOOLS
J 8001
J6133-01
J 8092
J 37357
J 21426
J 37358-1
J 37358-2
J2291201
J 37359
J 23062-14
J 25234
J37360
J 37372
J 37375
0
0
0
0
0
0
0
0
J 34162-A
DIAL INDICATOR
UNIVERSAL DRIVER HANDLE
EXTENSION HOUSING SEAL INST ALLER
BEARING AND GEAR PULLER
EXTENSION HOUSING BUSHING REMOVER
AND INSTALLER
FRONT AND REAR BEARING INSTALLER
0
~
~
~
CG]
HOLDING FIXTURE
INSTALLER
COUNTERSHAFT BEARING AND RACE

REMOVER AND INSTALLER
BEARING RACE RECEIVER AND CASE SUPPORT
COUNTERSHAFT BEARING REMOVER
SPIRAL SNAP RING INSTALLER
SYNCHRONIZER AND GEAR INSTALLER
DRIVE GEAR BEARING RETAINER
SEAL INSTALLER
HEAVY DUTY PULLEY PULLER
NC1001 78 F RP
SECTION 78-108
BORG-WARNER (T56) UNIT REPAIR

RPO's M28 AND M29
could result.
CONTENTS
Unit Disassembly ................................ 7B-10B- 1
Shifter ........................................... 7B-10B- 1
Transmission Disassembled View .......... 7B-10B- 2
Extension Housing ............................ 7B-10B- 4
Speedometer Gear ............................ 7B-10B- 5
Reverse Speed Gear .......................... 7B-10B- 5
Reverse Shift Fork ............................ 7B-10B- 6
5th/6th Driven Gear .......................... 7B-10B- 6
Countershaft Extension Assembly ......... 7B-10B- 7
Guide Plate ..................................... 7B-10B- 7
Transmission Case ............................ 7B-10B- 8
Shift Rail Assemblies and Gear Clusters. 7B-10B- 9
Unit Subassembly Repair and Inspection ... 7B-10B- 9
Input Shaft ..................................... 7B-10B- 9
Mainshaft ....................................... 7B-10B-10
Countershaft .................................... 7B-10B-13
Countershaft Extension Assembly ......... 7B-10B-13
Synchronizers .................................. 7B-10B-16
Shift Rail and Fork Assemblies ............ 7B-10B-19
Transmission Adapter Plate ................. 7B-10B-21
Transmission Case ............................ 7B-10B-21
UNIT DISASSEMBLY
A complete disassembled view is shown on
page 2.
SHIFTER
Extension Housing ............................ 7B-10B-23

Unit Assembly ................................... 7B-10B-26
Shift Rail Assemblies and Gear Clusters. 7B-10B-26
Transmission Case ............................ 7B-10B-27
Guide Plate ..................................... 7B-10B-28
Countershaft Extension Assembly ......... 7B-1 OB-28
5th/6th Driven Gear .......................... 7B-10B-29
Reverse Shift Fork ............................ 7B-10B-29
Reverse Speed Gear .......................... 7B-10B-30
Speedometer Gear ............................ 7B-10B-30
Extension Housing ............................ 7B-10B-31
Shifter ........................................... 7B-10B-31
Shimming Procedures ........................... 7B-10B-32
Input Shaft/Mainshaft and Countershaft .. 7B-10B-32
Countershaft Extension ....................... 7B-10B-34
Specifications ..................................... 7B-10B-35
Fastener Tightening Specifications ......... 7B-10B-35
Shimming Specifications ..................... 7B-10B-35
Lubricant Specifications ..................... 7B-10B-35
Special Tools ..................................... 7B-10B-36
5.
6.
7.
Figures 3 and 4
Tools Required:
J 3289-20 Holding Fixture Bench Mount
J 39430 Transmission Support Fixture
E3
1. Vent tube (161).

2. Clutch housing bolts (163).
3. Clutch housing (162).
4. Clutch fork bolt (166).
Clutch fork (164) and T-handle (165).

Install transmission to J 39430 and J 3289-20.
8.
9.
10.
11.
Use bolts (163) to secure transmission to
J 39430.
Rotate transmission in horizontal position

shifter up.
'
Plug (101) and drain transmission fluid.
Put transmission in 3rd/4th neutral position.
Shifter bolts (97).
Shifter (96).
!L!
Inspect
Isolator cup (95) for wear. Replace rear

offset shift lever (93) if wear is excessive
or isolator cup (95) is loose.
30
,,~'fl
I
28
~7
26
~,
25~'
24
168
105
102
P0001-7810B-RA
Figure 1 Disassembled View
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
PLATE, TRANSMISSION ADAPTER

PLUG
PIN, DOWEL
PIN, DOWEL
BUSHING, SHIFT RAIL
SEAL, INPUT SHAFT
SHIM, INPUT SHAFT
RACE, INPUT SHAFT BEARING
BEARING, INPUT SHAFT TAPERED
SHAFT, INPUT
RING, 4TH GEAR BLOCKER
RING, SNAP
SYNCHRONIZER ASSEMBLY,
3RD/4TH
SPRING, 3RD/4TH SYNCHRONIZER
KEY, 3RD/4TH SYNCRONIZER
HUB, 3RD/4TH SYNCHRONIZER
SLEEVE, 3RD/4TH SYNCHRONIZER
RING, 3RD GEAR BLOCKER
GEAR, 3RD SPEED
BEARING, 3RD GEAR NEEDLE
BEARING, MAINSHAFT SMALL
TAPERED
MAINS HAFT
BEARING, 2ND GEAR NEEDLE
GEAR, 2ND SPEED
WASHER, THRUST
CONE, INNER
CONE, FRICTION
RING, 2ND GEAR BLOCKER
1ST/2ND
SPRING, 1ST/2ND SYNCHRONIZER
KEY, 1ST/2ND SYNCHRONIZER
HUB, 1ST/2ND SYNCHRONIZER
SLEEVE, 1ST/2ND SYNCHRONIZER
RING, 1ST GEAR BLOCKER
CONE, FRICTION
CONE, INNER
WASHER, THRUST
RING, SNAP
BEARING, 1ST GEAR NEEDLE
GEAR, 1ST SPEED
BEARING, MAINSHAFT LARGE
fAPERED
RACE, MAINSHAFT BEARING
CASE, TRANSMISSION
BOLT, SHIFT LEVER GUIDE
BOLT, SHIFT DETENT COVER
COVER, SHIFT DETENT
BUSHING, SHIFT RAIL
PIN, FRONT OFFSET LEVER ROLL
LEVER, FRONT OFFSET
SPRING, SHIFT DETENT
BALL, SHIFT DETENT
BOLT, SHIFT GUIDEPLATE
PLATE, SHIFT GUIDE
DETENT ASSEMBLY, SHIFT
MAGNET
PIN, DOWEL
SWITCH, BACK-UP LAMP
PLUG, FILL
GEAR, 5TH/6TH DRIVEN
REVERSE
SPRING, REVERSE
SYNCHRONIZER
KEY, REVERSE SYNCHRONIZER
HUB, REVERSE SYNCHRONIZER
66
67
68
69
70
71
72
73
74
75
76
77
78
79
80
81
82
83
84
85
86
87
88
89
90
91
92
93
94
95
96
97
98
99
100
101
102
103
104
105
106
107
108
109
110
111
112
113
114
115
116
117
118
119
120
121
122
123
124
SLEEVE.REVERSE
SYNCHRONIZER
RETAINER, REVERSE
SYNCHRONIZER KEY
WASHER, THRUST
RING, SNAP
RING, REVERSE GEAR BLOCKER
WASHER, WAVE
BEARING, REVERSE GEAR
NEEDLE
GEAR, REVERSE
WASHER, THRUST
RING, SNAP
SPACER
BEARING, REAR MAINSHAFT
SPACER
RING, SNAP
RING, SNAP
GEAR, SPEEDOMETER
(ELECTRONIC)
RING, SNAP
SPACER
RING, SNAP
HOUSING, TRANSMISSION
EXTENSION
SENSOR, ELECTRONIC SPEED
BOLT, SPEED SENSOR
BOLT, REVERSE LOCKOUT
ASSEMBLY
BODY ASSEMBLY, REVERSE
LOCKOUT
BUSHING, SHIFT RAIL
LEVER, REAR OFFSET SHIFT
PIN, REAR OFFSET SHIFT LEVER
ROLL
CUP, ISOLATOR
SHIFTER ASSEMBLY
BOLT, SHIFTER ASSEMBLY
BOOT, SHIFTER
SEAL AND BOOT, REAR OUTPUT
BOLT, TRANSMISSION
EXTENSION HOUSING
PLUG, DRAIN
SHIM, COUNTERSHAFT
RACE, COUNTERSHAFT BEARING
TAPERED
COUNTERS HAFT
TAPERED
WASHER, THRUST
GEAR, 6TH DRIVE
BEARING, 6TH GEAR NEEDLE
FORK, REVERSE SHIFT
PAD, REVERSE SHIFT FORK
RING, SNAP
SPACER
RING, SNAP
SYNCHRONIZER ASSEMBLY. 5TH/
6TH
SPRING, 5TH/6TH SYNCHRONIZER
KEY, 5TH/6TH SYNCHRONIZER
HUB, 5TH/6TH SYNCHRONIZER
SLEEVE, 5TH/6TH SYNCHRONIZER
FORK, 5TH/6TH SHIFT
PAD, 5TH/6TH SHIFT FORK
RING, SNAP
125
126
127
128
129
130
131
132
133
134
135
136
137
138
139
140
141
142
143
144
145
146
147
148
149
150
151
152
153
154
155
156
157
158
159
160
161
162
163
164
165
166
167
168
169
170
171
172
173
174
175
176
177
178
179
180

GEAR, 5TH DRIVE
EXTENSION, COUNTERSHAFT
EXTENSION TAPERED
RACE, COUNTERSHAFT
EXTENSION BEARING
SHIM, COUNTERSHAFT EXTENSION
FUNNEL, OIL
BOLT, REVERSE IDLER SHAFT
BRACKET
BRACKET, REVERSE IDLER SHAFT
WASHER, REVERSE IDLER GEAR
THRUST
GEAR,REVERSEIDLER
BEARING, REVERSE IDLER GEAR
ROLLER
SHAFT, REVERSE IDLER GEAR
WASHER, REVERSE IDLER GEAR
THRUST
RAIL ASSEMBLY, 5TH/6TH SHIFT
PIN, ROLL
COLLAR
RAIL, SHIFT
LEVER, 5TH/6TH SHIFT RAIL
PAD, 5TH/6TH SHIFT RAIL LEVER
BUSHING, 5TH/6TH SHIFT RAIL
LEVER
PIN, ROLL
LEVER, REVERSE SHIFT RAIL
RAIL ASSEMBLY, 1ST/2ND 3RD/4TH
SHIFT
FORK, 1ST/2ND SHIFT
PAD, 1ST/2ND SHIFT FORK
LINK, SHIFT
RAIL ASSEMBLY, 1ST/2ND 3RD/4TH
SHIFT
PIN, ROLL
PIN, SELECTOR
PLATE, INTERLOCK
LINK, SHIFT
FORK, 3RD/4TH SHIFT
PAD, 3RD/4TH SHIFT FORK
0-RING, REVERSE LOCKOUT
ASSEMBLY
TUBE, VENT
HOUSING, CLUTCH ADAPTER
BOLT, CLUTCH ADAPTER HOUSING
FORK, CLUTCH
T-HANDLE, CLUTCH FORK PIVOT
BOLT, CLUTCH FORK PIVOT
HOUSING, CLUTCH ACTUATOR
ADAPTER
BOLT, CLUTCH ACTUATOR
ADAPTER HOUSING
RING, SNAP
PLUNGER, REVERSE LOCKOUT
SPRING, REVERSE LOCKOUT
OUTER
COLLAR, REVERSE LOCKOUT
RING, SNAP
SPRING, REVERSE LOCKOUT INNER
BODY, REVERSE LOCKOUT
BODY, REVERSE LOCKOUT
BUMPER, TRANSMISSION
BOLT, TRANSMISSION ADAPTER
PLATE
SPACER
FITTING, VENT TUBE
P0002-7B10B-RA
Figure 2 Disassembled View - Legend
95
86
95
96
97
HOUSING,
TRANSMISSION
EXTENSION
CUP. ISOLATOR
SHIFTER ASSEMBLY
P0004-7BUB-RA 1
'
\ __WJ)
Figure 4 Shifter
EXTENSION HOUSING
Figure 5
E3
1.
II]
163
BOLT, CLUTCH HOUSING

P0003-7B10B-RA
Figure 3 Transmission Support Fixture
Rear offset shift lever roll pin (94).

Important
If isolator cup (95) is not fully retained in rear

offset lever with adhesive, replace rear offset
lever assembly (93).
2.
Rear offset shift lever (93) and isolator cup (95)

assembly.
Extension housing bolts (100).
Extension housing (86).
3.
4.
With transmission in horizontal position,

slide extension housing (86) off shift rails
(140 and 149).
23
44
86
140
149
23
73
81
CASE, TRANSMISSION
HOUSING, TRANSMISSION EXTENSION
RAIL ASSEMBLY, 5TH/6TH SHIFT
RAIL ASSEMBLY, 1ST/2ND 3RD/4TH SHIFT
MAINSHAFT
GEAR,REVERSE
GEAR, SPEEDOMETER (ELECTRONIC)
P0005-7B 108-RA
P0006-7B10B-RA
Figure 5 Extension Housing
SPEEDOMETER GEAR
Figure 6
Tools Required:
J 8433 Universal Bridge Puller
J 39431 Gear Remover
J 39431-1 Gear Remover Bolts
E31.
2.
3.
4.
5.
Rotate transmission in vertical position.
Sealing ring.
Speedometer gear snap ring (82).
Speedometer gear (81) using J 8433, J 39431
and J 39431-1.
A. Set J 8433 onto nose of main shaft (23).
B. Slide J 39431 under speedometer gear.
C. Install bolts J 39431-1 to J 39431.
D. Speedometer gear (81) using J 8433,
J 39431 and J 39431-1.
REVERSE SPEED GEAR

Figure 7
! +!
1. Roller bearing snap ring (79).

2. Spacer (78).
3. Roller bearing (77).
4. Spacer (76).
5. Snap ring (75).
7. Reverse speed gear (73).
8. Caged needle bearing (72).
9. Wave washer (71).
10. Blocker ring (70).
62
69
111
113
73
70
71
72
73
74
75
76
77
78
79

WASHER, WAVE
BEARING, REVERSE GEAR NEEDLE
GEAR,REVERSE
WASHER, THRUST
RING, SNAP
SPACER
BEARING, ROLLER
SPACER
RING, SNAP
5th/6th DRIVEN GEAR

Figure 9
Tools Required:
~70
J 8433 Universal Bridge Puller

J 39431 Gear Remover
J 39431-2 Gear Remover Bolts
P0007-7B10B-RA
REVERSE SHIFT FORK

Figure 8
1.
2.
3.
P0008-7B10B-RA
Figure 8 Reverse Shift Fork
Figure 7 Reverse Speed Gear
E3
SYNCHRONIZER ASSEMBLY, REVERSE

RING, SNAP
FORK, REVERSE SHIFT
RING,SNAP
Reverse synchronizer snap ring (69).

Reverse shift fork snap ring (113) and discard.
Reverse shift fork (111 ), synchronizer (62) and
thrust washer (68) at the same time.
!+ !
1.
5th/6th driven gear (61) using J 8433, J 39431

and J 39431-2.
A.
B.
C.
D.
Set J 8433 onto nose of main shaft (23).

Slide J 39431 under 5th/6th driven gear.
Install bolts J 39431-2 to J 39431.
5th/6th driven gear (61) using J 8433,
J 39431 and J 39431-2.
124
122
J 39431-2
128
116
108
109
110
114
115
116
117
122
124
126
128
129
WASHER, THRUST
GEAR, 6TH DRIVE
SPACER
RING, SNAP
SYNCHRONIZER
ASSEMBLY, 5TH/6TH
FORK, 5TH/6TH SHIFT
RING, SNAP
GEAR, 5TH DRIVE
EXTENSION TAPERED
P0010-7810B-RA
Figure 10 Countershaft Extension Assembly
GUIDE PLATE
Figure 11
61
E3
GEAR, 5th/6th DRIVEN

POOOS-78108-RA
Figure 9 5th/6th Driven Gear
COUNTERSHAFT EXTENSION ASSEMBLY

Figure 10
E3
1. 5th/6th shift fork snap ring (124).

2. Rotate transmission in horizontal position,
guide plate up.
3. Countershaft extension assembly with 5th/6th
shift fork (122).
1.
2.
3.
4.
5.
6.
Cover plate bolts (47).

Cover plate (48).
Shift detent assembly (56).
Front offset lever roll pin (50).
Shift guide plate bolts (54).
Guide plate (55) and front offset lever (51) at the
same time.
!+:+!
A.
B.
C.
D.
E.
Hold guide plate (55) and front offset

leyer (51) together while sliding off shift
rail (149) to prevent spring release of
detent ball (53) and spnng (52).
Rotate front offset lever (51) to clear case
while removing assembly.
Disassemble
Front offset lever (51).

Shift detent spring (52).
Shift detent ball (53).
Shift guide plate (55).
55
56
50
51
54
55
56

LEVER, FRONT OFFSET
BOLT, SHIFT GUIDE PLATE
PLATE, SHIFT GUIDE
ENHANCER, SHIFT
P0011-7810B-RA
Figure 11 Shift Detent Assembly
TRANSMISSION CASE
Figure 12
E3
1.
2.
3.
4.
5.
6.
8 of the 10 adapter plate to transmission case

bolts (178).
Rotate transmission into vertical position.
Last 2 adapter plate to transmission case bolts
(178).
Shift lever guide bolts (45 and 46).
Magnets (57).
Transmission case (44).
Slide transmission case (44) up off of gear

clusters and shift rail components.
Clean
Shift lever guide bolt threads (45 and 46).

Case (44) and magnets (57) with solvent and dry
with compressed air.
1
44
45
46

CASE, TRANSMISSION
P0012-7810B-RA
Figure 12 Transmission Case
SHIFT RAIL ASSEMBLIES AND GEAR

CLUSTERS
Figure 13
E3
1. Rotate 5th/6th and reverse shift rail levers (140)

2.
3.
4.
5.
6.
7.
off shift interlock plate (156).

5th/6th and reverse shift rail assembly (140).
Countershaft (105).
Lift up mainshaft (23) enough to remove
countershaft (105).
Mainshaft (23) and shift rail assembly (149).
Remove components as an assembly.
Shift rail assembly (149) from mainshaft (23).
4th gear blocker ring (12).
Input shaft (10).
UNIT SUBASSEMBLY REPAIR AND

INSPECTION
INPUT SHAFT
Figure 14
Tools Required:
J 5590 Press Tube
J 22912-01 Split Plate
J 28537-17 Race Installer
J 39594 Race Remover
Hydraulic Press
F:3
Disassemble
[I]
1.
2.
&!I
!L!
Important
Do not replace tapered bearing (9) or race
(11) unless inspection shows bearing or
race damage.
Input shaft tapered bearing (9) from input shaft
(10) using J 22912-01 ana hydraulic press.
lnput shaft bearing race (11) using J 23907 and
J 39594.
1
10

SHAFT, INPUT
23 MAINS HAFT
105 COUNTERSHAFT
140 RAIL ASSEMBLY, 5TH/6TH
AND REVERSE SHIFT
153 RAIL ASSEMBLY,
1ST/2ND 3RD/4TH SHIFT
156 PLATE, INTERLOCK
23
Clean
Input shaft components with solvent and dry
Inspect
Input shaft components.
Shaft (10) and spline for excessive wear or
cracks. Replace if these conditions exist.
Gear teeth for excessive wear, pitting,
scoring, spalling or fractures.
Bearing (9) for roughness of rotation,
burred or pitted conditions. Replace if
these conditions exist.
P0013-7B10B-RA
Figure 13 Shift Rail Assemblies and Gear Clusters
!+!+!
1.
2.
If scuffed, nicked, burred or scoring conditions

cannot be reconditioned by hand with a soft
stone or crocus cloth, replace the component.
When replacing bearing (9) also replace bearing
race (8).
When re_Elacing bearing race (11) also replace
bearing (22).
Assemble
7.
8.
9.
10.
11.
New bearing race (11) to input shaft (10) using

J 28537-17 hydraulic press.
New input shaft tapered bearing (9) to input
shaft (10) using J 5590 and hydraulic press.
[I]
Tools Required:
J 36183 Press Tube
J 36184 Press Tube Adapter
J 36513 Split Plate
J 39371 1st/2nd Synchronizer Installer
J 39428 Split Plate
J 39442 Press Adapter
J 39443 Split plate
J 39473 Bearing Installer/Press Adapter
Hydraulic Press
V-Blocks
Ft!
12.
Do not replace tapered bearing (22) unless

inspection shows bearing damage.
Mainshaft small tapered bearing (22) using
J 39442, J 39443 and hydraulic press.
Discard small tapered bearing (22).
&!)
Clean
1.
2.
3.
4.
5.
!L!
Important
Identify and mark blocker rings. DO NOT

MIX.
Main shaft large tapered bearing (42) and

0-ring.
1st speed gear (41).
1st speed gear caged needle bearing (40).
Snap ring (39).
1st speed gear blocker ring assembly.
A.
B.
C.
D.
6.
Disassemble
[I)
Thrust washer (38).

Inner cone (37).
Friction cone (36).
Blocker ring (35).
2nd speed gear (25) usrng J 36513 and

hydraulic press.
1st/2nd synchronizer assembly (30), 2nd

speed gear blocker ring (29), friction cone
(28), 2nd speed gear inner cone (27), and
thrust washer (2b ), will press off with 2nd
speed gear (25).
Important
MAINS HAFT
Figure 15
2nd speed gear caged needle bearing (24).

3rd/4th synchronizer snap ring (13).
3rd speed gear (20) using J 39473, V-blocks
and hydraulic press.
3rd/4th synchronizer assembly (14) and
3rd speed gear blocker ring (19) will press
off with 3rd speed gear (20).
Spacer (179).
3rd speed gear caged needle bearing (21 ).
1:1
Mainshaft components with solvent and drywith

compressed air.
Inspect
Mainshaft components.
Shaft (23) and spline for excessive wear or
cracks. Replace if these conditions exist.
Gear teeth (20, 25 and 41) for excessive
wear, pittrng, scoring, spalling or
fractures.
Bearings (22 and 42) for roughness of
rotation, burred or pitted conditions.
Replace if these conditions exist.
Synchronizers (14 and 30). Refer to
"Synchronizers" m this section.
When replacing bearings (22 or 42) also replace
bearing races (11 or 43).
Assemble
1. New mainshaft small tapered bearing (22) using

2.
3.
4.
5.
J 39473, V-blocks ancf hydraulic press.

3rd speed gear caged needle bearing (21 ).
Spacer (179).
3rd speed gear (20).
3rd speed gear blocker ring (19).
(I]
Important
When pressing the 3rd/4th synchronizer

assembly (14):
A. Start press operation. STOP before
keys engage blocker ring slots.
B. Lift and rotate 3rd speed gear (20) to
engage keys with blocker ring.
C. Continue to press until seated.
J 23907
J39594~
11
PRESS
10
J 28537-17
11
10
PRESS
J 5590
PRESS BED
A
B
BEARING REMOVAL
BEARING INSTALLATION
C
D
RACE REMOVAL
RACE INSTALLATION
9
10
11
BEARING, INPUT SHAFT TAPERED

SHAFT, INPUT
P0014-7810B-RA
Figure 14 Input Shaft
14
20
PRESS
BED
PRESS---
BED
21
PRESS
20
BED
~--19
F
-----14
~13
~'-----22
D
PRESS~
J39473
22
J36183
14
:_.............20
PRESS
/BED
A
B
c
D
E
F
13
14
19
20
21
2ND GEAR REMOVAL

3RD GEAR REMOVAL
BEARING REMOVAL
BEARING INSTALLATION
3RD/4TH SYNCHRONIZER INSTALLATION
1ST/2ND SYNCHRONIZER INSTALLATION
RING, SNAP
SYNCHRONIZER ASSEMBLY, 3RD/4TH
RING, 3RD GEAR BLOCKER
GEAR, 3RD SPEED
BEARING, 3RD GEAR NEEDLE
22
23
24
25
26
27
28
29
30
35
36
BEARING, MAINSHAFT SMALL TAPER

MAINS HAFT
BEARING, 2ND GEAR NEEDLE
GEAR, 2ND SPEED
WASHER, THRUST
CONE INNER
CONE, FRICTION
RING, 2ND GEAR BLOCKER
SYNCHRONIZER ASSEMBLY, 1ST/2ND
RING, 1ST GEAR BLOCKER
CONE, FRICTION
Figure 15 Mainshaft
37
38
39
40
41
42
CONE, INNER
WASHER, THRUST
RING, SNAP
BEARING, 1ST GEAR NEEDLE
GEAR, 1ST SPEED
BEARING, MAINSHAFT LARGE
TAPERED
179 SPACER
P0015-7810B-RA
6.
3rd/4th synchronizer assembly (14) usmg

Install 3rd/4th synchronizer so ID groove
on sleeve faces 3rd gear.
7. 3rd/4th synchronizer snap ring (13).
8. 2nd speed gear caged needle bearing (24).
9. 2nd speed gear (25).
11. 2nd speed gear inner cone (27).
12. Friction cone (28).
13. 2nd speed gear blocker ring (29).
[I]
Important
14.
15.
16.
17.
18.
19.
When pressing the 1st/2nd synchronizer

assemb1y (30):
B. Lift and rotate 2nd speed gear (25) to
1st/2nd synchronizer assembly (30) using
Install 1st/2nd synchronizer so ID groove
on sleeve faces 1st gear.
1st speed gear blocker ring assembly.
A. Blocker ring (35).
B. Friction cone (36).
C. Inner cone (37).
D. Thrust washer (38).
Snap ring (39).
1st speed gear caged needle bearing (40).
1st speed gear (41).
Mainshaft large tapered bearing (42) and
0-ring.
COUNTERSHAFT
1.
Small tapered bearing (104) using J 22912-01,

J 39473 and hydraulic press.
2.
Discard tapered bearing (104).

Large tapered bearing (106) using J 39511,
!2!
!l!
Disassemble
Countershaft with solvent and dry with

compressed air.
Inspect
Countershaft components.
Shaft (105) for excessive wear or cracks.
Gear teeth for excessive wear, pitting,
scoring, spalling or fractures.
Bearings (104 and 106) for roughness of
rotation, burred or pitted conditions.
When replacing bearings (104 or 106) also

replace bearing races (103 or 107).
!!!
1.
2.
Assemble
New large tapered bearing (106) using J 39438

New small tapered bearing (104) using J 5590

Figure 17
Tools Required:
Tools Required:
J 5590 Press Tube
J 22912-01 Split Plate
J 39438 Large Countershaft Bearing
Installer
J 39511 Split Plate
Hydraulic Press
V-Blocks
[I]
Clean
Figure 16
!t!
Discard tapered bearing (106).
Important
Do not replace tapered bearings (104 and

106) unless inspection shows bearing
damage.
J 5590 Press Tube

J 36513 Split Plate
J 39443 Split Plate
J 39473 Bearing Installer
Hydraulic Press
V-Blocks
!t3
Disassemble
1. 5th/6th shift fork (122).

3. 6th drive gear (109).
4. Caged needle bearing (110).
5. Spacer (115).
6. 6th drive gear blocker ring (114).
7.
5th/6th synchronizer snap nng (116) and

discard.
5th drive gear (126) using J 36513 and
hydraulic press.
8.
9.
Inspect
Countershaft extension components.

Shaft (128) and spline for excessive wear
or cracks. Replace if these conditions
exist.
Gear teeth (109 and 126) for excessive
wear, pitting, scoring, spalling or
fractures.
Bearing (129) for roughness of rotation,
burred or pitted conditions. Replace if
Synchronizer (117). Refer to
"Synchronizers" in this section.
5th/6th synchronizer assembly (117) and

5th drive gear blocker ring (i25) will
press off with 5th drive gear (126).
5th drive gear caged needle bearing (127).
(I]
Important
Do not replace small tapered bearing

(129) unless inspection shows bearing
damage.
Small tapered bearing (129) using J 39442,

10.
&!J
ILI
When replacing bearing (129) also replace

bearing race (130).
Clean
Countershaft extension components with solvent

and dry with compressed au.
104
J 39547
-----~~
~~~--"
PRESS BED
J 39511
J 22912-01
11
PRESS~
J 39438
106
SMALL TAPERED BEARING REMOVAL
~ESSBED
B SMALL TAPERED BEARING INSTALLATION

C LARGE TAPERED BEARING REMOVAL
D LARGE TAPERED BEARING INSTALLATION
104 BEARING, COUNTERSHAFT TAPERED
105 COUNTERSHAFT
106 BEARING, COUNTERSHAFT TAPERED
104
PRESS BED
Figure 16 Countershaft
P0016-7B10B-RA
PRESS BED
PRESS
B
PRESS BED
PRESS
126
5th GEAR REMOVAL
TAPERED BEARING
REMOVAL
J 39473
PRESS BED
C TAPERED BEARING
INSTALLATION
D 5th/6th SYNCHRONIZER
INSTALLATION
108
WASHER, THRUST
109
GEAR, 6th DRIVE
11D
BEARING, 6th GEAR

NEEDLE
114
RING, 6th GEAR

BLOCKER
115
SPACER
116
RING, SNAP
117
SYNCHRONIZER
ASSEMBLY, 5th/6th
125
RING, 5th GEAR

BLOCKER
126
GEAR, 5th DRIVE
127
BEARING, 5th
GEAR NEEDLE
128
EXTENSION,
COUNTERSHAFT
129
EXTENSION TAPERED
114
D
109
@m~~~
110
@ma~~
~108
PRESS BED
P0017-7810B-RA
Figure 17 Countershaft Extension
Assemble
1.
2.
3.
4.
New small tapered bearing (129) using

J 39473, V-blocks and hydraulic press.
5th drive gear (126).
5th drive gear blocker ring (125).
rn
l2f
Clean
Synchronizer components with solvent and dry

ILI
Inspect
Synchronizer components.
Teeth for wear, nicked, burred or broken
teeth. Replace hub and sleeve if excessive
wear exists.
Keys for wear or distortion. Replace if
Springs for distortion, cracks or wear.
Important
When pressing the 5th/6th synchronizer

assembly (117):
5.
6.
7.
8.
9.
10.
11.
12.

B. Lift and rotate 5th drive gear (126) to
5th/6th synchronizer assembly (117) usmg
Install 5th/6th synchronizer so ID groove
on sleeve faces 5th gear.
New 5th/6th synchronizer snap ring (116).
6th drive gear blocker ring (114).
6th drive gear spacer (115).
6th drive gear (109).
6th drive gear thrust washer (108).
5th/6th shift fork (122).
If scuffed, nicked or burred conditions cannot be

corrected by hand with a soft stone or crocus
cloth, replace the component.
31
SYNCHRONIZERS
1st/2nd, 3rd/4th, 5th/6th Synchronizers
rn
l+!+I
1.
2.
3.
4.
5.
Important
Synchronizer components are not

interchangeable. Keep synchronizer components
separate.
Synchronizer hubs and sleeves are a selected
assembly and should be kept together as
originally assembled.
Disassemble
Synchronizer spring (15), (31), (118) using a

small-bladed screwdriver.
Turn synchronizer assembly (14), (30), (117)
over.
Synchronizer spring (15), (31), (118) using a
Keys (16), (32), (119).
Synchronizer sleeve (18), (34), (121) from hub
(17), (33), (120).
31
SPRING, 1st/2nd SYNCHRONIZER
32
33
KEY, 1st/2nd SYNCHRONIZER

HUB, 1st/2nd SYNCHRONIZER
34
SLEEVE, 1st/2nd SYNCHRONIZER
P0018-7B10B-RA
Figure 18 1st/2nd Synchronizer
H!
Assemble
1. Synchronizer sleeve (18), (34), (121) to hub

(17), (33), (120).
118
Align key openings in hub (17), (33),

(120) with cuts in synchronizer sleeve
(18), (34), (121).
2. Keys (16), (32), (119) with slots facing hub

(17), (33), (120).
3. Synchronizer spring (15), (31), (118) using a
Locate spring tang to one of the key slots.
4. Turn synchronizer assembly (14), (30), (117)
over.
5. Synchronizer spring (15), (31), (118) using a
small-bladed screwariver.
~ocate SP.ring_ tang on same key but wind

m opposite duection.
118
119
120
SPRiNG, 5th/6th SYNCHRONIZER

KEY, 5th/6th SYNCHRONIZER
HUB, 5th/6th SYNCHRONIZER
121
SLEEVE, 5th/6th SYNCHRONIZER

P00207B10BRA
Figure 20 5th/6th Synchronizer
Reverse Synchronizer
Figure 21
Ft!
15
1.
2.
3.
15
16
17
SPRING, 3rd/4th SYNCHRONIZER

KEY, 3rd/4th SYNCHRONIZER
HUB, 3rd/4th SYNCHRONIZER
18
SLEEVE, 3rd/4th SYNCHRONIZER

P00197B10B-RA
Figure 19 3rd/4th Synchronizer
4.
5.
Disassemble
Synchronizer spring (63) using a small-bladed

screwdriver.
Synchronizer sleeve (66) from hub (65) by
pressing against inner hub (65).
Turn hub (65) over.
Keys (64) will slide out from hub (65).
Synchronizer key retainer (67) using a
small-bladed screwdriver through key slots of
hub (65) and discard retainer (67).
screwdriver.
!L!
!+!+!
Clean
Synchronizer components with solvent and dry

Inspect
Synchronizer components.
Teeth for wear, nicked, burred or broken
teeth. Replace hub and sleeve if excessive
wear exists.
Keys for wear or distortion. Replace if
Springs for distortion, cracks or wear.
Retainer for distortion. Replace if this
condition exists.
Assemble
1.
Synchronizer sleeve (66) to hub (65).

Align key openings in hub (65) with cuts
in synchromzer sleeve (66).
2.
3.
Keys (64) with slots facing hub (65).

screwdriver.
Locate spring tang to one of the key slots.
4.
5.
Turn synchronizer assembly (62) over.

screwdriver.
!-,ocate SJ?ring_ tang on same key but wind
m opposite duection.
6.
New synchronizer key retainer (67).

Locate key retainer tangs over
synchronizer keys (64).
If scuffed, nicked or burred conditions cannot be

corrected by hand with a soft stone or crocus
Synchronizer Blocker Ring Inspection

Figure 22
Inspect the gear cones, clutch teeth and blocker

rings for excessive wear.
Inspect the synchronizer sleeve and gear clutch
teeth for evidence of gear clash or cause of
hop-out.
Measure the gap between the blocker ring and
the speed gear. Make sure the correct blocker
ring 1s measured with the correct gear and the
blocker ring is fully seated on the gear.
Replace blocker rings for 1st, 2nd, 3rd, 4th, 5th
and 6th gears if the wear gap is less than 0.38
mm (0.015 in.).
Replace the reverse blocker ring if the wear gap
is less than 0.75 mm (0.030 in.), when measured
without the wave washer (71) in between the
blocker ring and reverse gear.
--s
A
A BLOCKER TEETH
B FEELER GAGE
C CLUTCH TEETH
63
64
65
66
67
SPRING, REVERSE SYNCHRONIZER

KEY, REVERSE SYNCHRONIZER
HUB, REVERSE SYNCHRONIZER
SLEEVE, REVERSE SYNCHRONIZER
RETAINER, REVERSE SYNCHRONIZER KEY
P0021-7B10B-RA
Figure 21 Reverse Synchronizer
P0033-7B10B-RA
Figure 22 Measuring Blocker Ring Wear
SHIFT RAIL AND FORK ASSEMBLIES
5th/6th, Reverse Shift Rail Assembly
1st/2nd, 3rd/4th Shift Rail Assembly
Figure 23
Tool Required:
Figure 23
!(3

J 36800 Bushing Remover
J 39437 Bushing Installer
Disassemble
1. Rotate selector pin (155) until opposite shift

links (152 and 157).
2. 3rd/4th shift fork (158) with shift link (157)
from rail (153).
3. 1st/2nd shift fork (150) with shift link (152)
from rail (153).
4. Interlock plate (156) from rail (153).
5. Selector pin roll pin (154).
6. Selector pin (155).
&!I
!L!
Clean
Shift rail and fork assembly components with

solvent and dry with compressed air.
Inspect
Shift rail and fork assembly components.

Rail (153) for excessive wear or burrs.
Shift forks (150 and 158) for excessive
wear, fracture or distortion. Replace if
Shift links (152 and 157) for excessive
wear, fracture or distortion. Replace if
Shift fork nylon inserts (151 and 159) for
excessive wear. Replace if this condition
exists.
!+!+!
Assemble
1. Selector pin (155).

2. Selector pin roll pin (154).
3. Interlock plate (156) to rail (153).
4. 1st/2nd shift fork (150) with shift link (152) to
rail (153).
5. 3rd/4th shift fork (158) with shift link (157) to
rail (153).
6. Align selector pin (155) with slots in shift links
(152 and 157).
Ft3
Disassemble
1. Collar roll pin (141).

2.
3.
Collar (142).
5th/6th shift rail lever (144) from rail (143).
[I]
4.
5.
6.
&!I
!L!
Important
Do not replace bushings (146) unless

inspection shows bushing damage.
5th/6th shift rail lever bushings (146) using

J 23907 and J 36800.
Reverse shift rail lever roll pin (147).
Reverse shift rail lever (148) from rail (143).
Clean
Shift rail assembly components with solvent and

dry with compressed air.
Inspect
Shift rail assembly components.

Rail (143) for excessive wear or burrs.
Shift rail levers (144 and 148) for
excessive wear, fracture or distortion.
Shift rail lever nylon insert for excessive
wear. Replace if this condition exists.
Shift rail lever bushings (146) for
excessive wear. Replace if this condition
exists.
141-;i
142
150
143
147~'
144
154
148
23
105
140
141
142
143
144
147
148

MAINS HAFT
COUNTERS HAFT
RAIL ASSEMBLY, 5TH/6TH AND REVERSE SHIFT
PIN, ROLL
COLLAR
RAIL, SHIFT
LEVER, 5TH/6TH SHIFT RAIL
PIN, ROLL
LEVER, REVERSE SHIFT RAIL
149
150
151
152
154
155
156
157
158
159
RAIL ASSEMBLY, 1ST/2ND 3RD/4TH SHIFT

FORK, 1ST/2ND SHIFT
PAD, 1ST/2ND SHIFT FORK
LINK, SHIFT
PIN, ROLL
PIN, SELECTOR
PLATE, INTERLOCK
LINK, SHIFT
FORK, 3RD/4TH SHIFT
PAD, 3RD/4TH SHIFT FORK
P0022-7B10B-RA
Figure 23 Shift Rail and Fork Assemblies
!+!+!
1.
Assemble
!+!+!
Reverse shift rail lever (148) to rail (143).

Locate reverse shift rail lever (148) to roll
pin ho!e at opposite end of rail (143) from
snap nng groove.
- Notched edge of reverse shift rail
lever should face towards other roll
pin hole.
3.
2. Reverse shift rail lever roll pin (147).

3. 5th/6th shift rail lever bushings (146) using
J 39437.
4. 5th/6th shift rail lever (144) to rail (143).
5. Collar (142).
6. Collar roll pin (141).
4.
5.
TRANSMISSION ADAPTER PLATE
1.
2.
Assemble
Dowel pins (3 and 4 ).

1st/2nd, 3rd/4th shift rail bushing (5) using
J 39437.
Input shaft seal (6) using J 39433.
[I]
Countershaft bearing race (103).

Input shaft bearing race (8).
Figure 25
Tools Required
J 8092 Drive Handle
J 36190 Drive Handle
J 39435 Mainshaft Bearing Race Installer
J 39436 Countershaft Bearing Race
Installer
J 39790 Mainshaft Bearing Race Remover
J 39791 Countershaft Bearing Race
Remover
Tools Required:
J 39433 Input Shaft Seal Installer
1.
2.
3.
4.
Disassemble
Input shaft bearing race (8) and shim (7).

Countershaft bearing race (103) and shim (102).
Adapter plate plug (2).
Input shaft seal (6).
[I] Important
po no.t replace
bus_hing (5) unless

mspect10n shows bushmg damage.
F:!
1.
2.
3.

J 23907 and J 36800.
6. Dowel pins (3 and 4).
IL!
Disassemble
Fill plug (60).

Backup lamp switch (59).
Dowel pins (58).
[I]
5.
Do not install shims (102 and 7) until after

performing "Shimming Procedures" later
m this section.
TRANSMISSION CASE
Figure 24
fE
Important
Clean
Adapter plate coml?onents with solvent and dry

4.
5.
Inspect
Adapter plate components.

Bearing races (8 and 103) and bores for
wear, scratches or grooves.
Bushing (5) for excessive wear or burrs.
Replace if this condition exists.
Case for cracks, sealing surfaces for nicks,
burrs or scratches. If case is cracked, it
must be replaced.
[f scratches, grooves or nicks cannot be removed
by hand with a soft stone or crocus cloth, replace
the components.
6.
Important
Do not replace bearing races (107 and 43)

unless inspection snows bearing race
damage.
Countershaft bearing race (107) using J 8092

and J 39791.
Mainshaft bearing race (43) using J 8092 and
J 39790.
J 36190 and J 39439.
Clean
Transmission case components with solvent and

dry with compressed air.
REMOVE
J 23907
INSTALL
,,,.,,~ ~t=J
J 39433
36800
L_
103
102
2
4
5
6
7
8
_PLUG
PIN, DOWEL
BUSHING, SHIFT RAIL
SEAL, INPUT SHAFT
SHIM, INPUT SHAFT
102
103
SHIM, COUNTERSHAFT
P0023-7810B-RA
Figure 24 Transmission Adapter Plate
ILI
Inspect
Transmission case components.

Bushing (49) for excessive wear. Replace
if this condition exists.
Case (44) for cracks, threaded openings for
damaged threads, sealing surfaces f9r
nicks burrs or scratches. If case is
crack;d, it must be replaced.
If scratches, groov~s or scoring cannot be
removed by hand with a soft stone or crocus
6.
7.
8.
9.
10.
11.
12.

Reverse idler shaft (138).
Countershaft extension bearing race (130).
Shim (131).
Funnel (132).
Plug (101).
Reverse lockout assembly bolt (90).
CAUTION: The reverse lockout assembly is under spring pressure. Exercise caution when removing snap ring
(173), as bodily injury may result.
13.
l!I
Assemble
1. 1st/2nd, 3rd/4th shift rail bushing (49) using
J 39437.
2. Mainshaft bearing race (43) using J 8092 and
J 39435.
3. Countershaft bearing race (107) using J 8092
and J 39436.
4. Dowel pins (58).
5. Backup lamp switch (59).
l~I
Tighten
Switch (59) to 27 Nm (20 lb. ft.)

6. Fill plug (60) with sealant GM p/n 1052080.
l~I
Tighten
14.
15.
16.
Fill plug (60) to 18 Nm (13 lb. ft.).
EXTENSION HOUSING
17.
[I]
Figure 26
Tools Required:
J 8092 Drive Handle
J 39439 Bushing Remover/Installer
J 39440 Rear Boot and Seal Installer
J 39546 Bearing Race Installer
J 39789 Bearing Race Remover
FtI
1.
2.
3.
4.
5.
Disassemble
Reverse idler shaft bracket bolts (133).

Reverse idler shaft bracket (134).
Reverse idler gear thrust washer (135).
Reverse idler gear (136).
Roller bearing (137).
Reverse lockout assembly (91).

A. Reverse lockout solenoid (89) from reverse
lockout body (175).
B. 0-ring (160) from body (175).
C. Snap ring (169) from body (175).
D. Reverse lockout inner spring (174).
E. Compress reverse lockout /lunger (170)
and collar (172) in vise an remove snap
ring (173).
F. Reverse lockout plunger (170).
G. Reverse lockout outer spring (171 ).
H. Reverse lockout collar (172).
Vehicle speed sensor bolt (88).
Vehicle speed sensor (87) and clamp.
0-ring seal from vehicle speed sensor
(87).
Rear seal and boot (99).
Pry out seal and boot (99) with suitable
tool.
Mainshaft bearing race snap ring (84).
Important
18.
[I]
Do not replace bearing race (85) unless

inspection shows bearing race damage.
J 39789.
Important
Do not replace bushing (92) unless inspection

shows bushing damage.
19. Shift rail bushing (92) using J 36190 and
J 39439.
Clean
Extension housing components with solvent and

dry with compressed au.
REMOVE
INSTALL
J 39439-1
J 39437
J 36190
~--mi~~
i. .
REMOVE
~j--3_9_4:r-5--IN..... EA'""'D....,L}
J 8092
rt \
107
J 39791
J 8092
44
J 39436
INSTALL
Bii 1
J 8092
REMOVE
43
44
CASE, TRANSMISSION
49
107
BUSHING, SHIFT RAIL

P0024-7811B-RA
!Lj
Inspect
!!+!
1.
2.
3.
4.
If scratches, grooves or nicks cannot be removed

by hand with a soft stone or crocus cloth, replace
the component.
Assemble
Shift rail bushing (92) usmg J 36190 and

J 39439.
J 39546.
Mainshaft bearing race snap ring (84).
Rear seal and boot (99) using J 39440.
5.
6.
Locate drain hole in rear seal and boot

(99) down.
0-ring seal to vehicle speed sensor (87).

Vehicle speed sensor (87) and clamp.
Vehicle speed sensor bolt (88).
!~!
Extension housing components.

Bushing (92) for excessive wear or burrs.
Replace if this condition exists.
Case (86) for cracks, sealing surfaces for
nicks, burrs or scratches. If case is
cracked, it must be replaced.
7.
Tighten
Bolt (88) to 10 Nm (84 lb. in.)
CAUTION: The reverse lockout assembly is under spring pressure. Exercise caution when installing snap ring
(173), as bodily injury may result.
8.
Assemble reverse lockout body assembly.

A.
B.
C.
D.
Reverse lockout plunger (170).

Reverse lockout outer spring (171).
Reverse lockout collar (172).
Compress reverse lockout plunger (170),
collar (172) and outer spring (171) in vise
and install snap ring (173).
E. Reverse lockout inner spring (174).
F. Install reverse lockout components in
lockout body (175) and install snap ring
(169).
G. Reverse lockout solenoid (89) to reverse
lockout body assembly (91).
!~!
Tighten
Solenoid (89) to 40 Nm (30 lb. ft.).
H. 0-ring (160) to body assembly (91).
160
91
90
89
J 39440
~~
REMOVE/INSTALL
J 39439
INSTALL
99
'
~
- ~
JS~~
J39789~
J 8092
84
85
RING, SNAP
~
86
HOUSING, TRANSMISSION
EXTENSION
88
BOLT, SPEED SENSOR
89
90

BOLT, REVERSE LOCKOUT ASSEMBLY
91
BODY ASSEMBLY, REVERSE

LOCKOUT
101
1.
92
BUSHING, SHIFT RAIL

SEAL AND BOOT, REAR OUTPUT
101
PLUG, DRAIN
130
RACE, COUNTERSHAFT EXTENSION BEARING
131
SHIM, COUNTERSHAFT
EXTENSION
132
FUNNEL, OIL
160
0-RING, REVERSE LOCKOUT

ASSEMBLY
99
INSTALL
J 39546
139
~
138
~
137
136
~~35
134
132
~31
130
~m
P0025-7B10B-RA
Figure 26 Transmission Extension Housing
10. Reverse lockout assembly.

11. Reverse lockout assembly bolt (90).
l~I
Tighten
Bolt (90) to 18 Nm (13 lb. ft.).

12. Plug (101) with sealant GM p/n 1052080.
l~I
Tighten
Plug (101) to 18 Nm (13 lb. ft.).
14.
[I]
Important
Do not install shim ( 131) until after

performing "Shimming Procedures" later
m this section.
UNIT ASSEMBLY
SHIFT RAIL ASSEMBLIES AND GEAR
CLUSTERS
Figure 27
Tool Required:
J 36850 Transmission Assembly Lube
f++!
1.
2.
3.
4.
5.
6.
7.
8.
Install or Connect
Lubricate all components as assembly

progresses. Use J 36850 Transmission
Assembly Lube or equivalent.
Selective shims (7 and 102). Refer to "Input
Shaft/Mainshaft and Countershaft" under
"Shimming Procedures" in this section.
Input shaft (10) and 4th gear blocker ring (12).
Shift rail assembly (149) to mainshaft assembly.
Mainshaft assembly with shift rail assembly
(149).
Countershaft assembly.
A. Lift up mainshaft assembly enough to
install countershaft assembly.
B. Countershaft assembly.
C. Lift mainshaft assembly enough to rotate
input shaft (10) to engage synchronizer
keys (16) with 4th gear blocker ring (12).
5th/6th and reverse shift rail (140).
Align slots of shift rail levers with
interlock plate (156).
1 PLATE, TRANSMISSION ADAPTER

10 SHAFT, INPUT
23 MAINS HAFT
105 COUNTERSHAFT
140 RAIL ASSEMBLY, 5TH/6TH
AND REVERSE SHIFT
153 RAIL ASSEMBLY,
1ST/2ND 3RD/4TH SHIFT
156 PLATE, INTERLOCK
P0013-7B10B-RA
Figure 27 Shift Rail Assemblies and Gear Clusters
TRANSMISSION CASE
Figure 28
Tool Required:
Install or Connect
E3 Lubricate
all components
as assembly
progresses. Use J 36850 Transmission
Assembly Lube.
1. Sealant GM p/n 12345739 at transmission case
to adapter plate mating surface.
2. Transmission case (44).
Slide transmission case (44) onto gear
clusters and shift rail components.
3. Shift lever guide bolts (45 and 46).

Atply anaerobic threadlocker GM I?ln
1 345382 to threads of shift lever gmde
bolts (45 and 46).
Pull u on 5th/6th and reverse shift rail
assem ly (140) enough to ali~n the slot of
the shift interlock plate (156 with guide
bolt hole.
Tighten
Bolts (45 and 46) to 27 Nm (20 lb. ft.) .
4. Adapter plate to transmission case bolts (178).
44
Tighten
Bolts (178) to 35 Nm (26 lb. ft.) .
1
44
45
46

CASE, TRANSMISSION
P0012-7B10B-RA
GUIDE PLATE
Figure 29
Tool Required:
ltI
Assemble
1. Shift detent ball (53) in neutral detent groove of

2.
3.
lI
1.
shift guide plate (55).

Shift detent spring (52) into front offset lever
(51).
Front offset lever (51) and spring (52) to shift
guide plate (55) and hall (53 ).
55
Install or Connect
56
Guide plate (55) and front offset lever (51) at the

same time.
A. Lubricate shift rail (153) using J 36850
Transmission Assembly Lube.
B. Compress guide plate (55) and front offset
lever (51) together while sliding onto shift
rail (149) to prevent spring release of inner
components.
2.
Figure 29 Shift Detent Assembly
l~I
lI
Tighten
Apply anaerobic threadlocker GM p/n

12345382 to threads of shift detent
assembly (56).
Shift detent assembly (56) to 34 Nm (25
lb. ft.).
Figure 30
1.

mating surface of cover plate (48).
Cover plate bolts (47).
l~I
Tighten
Bolts (47) to 20 Nm (15 lb. ft.).
Install or Connect
Countershaft extension assembly and 5th/6th

shift fork (122) with transmission in horizontal
position.
Cover plate (48).
6.
P0011-7B10S-RA
Tighten
Bolts (54) to 22 Nm (16 lb. ft.).

Shift detent assembly (56).
5.

LEVER, FRONT OFFSET
BOLT, SHIFT GUIDE PLATE
PLATE, SHIFT GUIDE
ENHANCER, SHIFT
Shift guide plate bolts (54).
l~I
3.
4.
50
51
54
55
56
2.
Ensure splines of countershaft extension

(128) engage splines of countershaft
(105).
5th/6th shift fork snap ring (124 ).
J 39441-1
--J
39441
124
122
128
116
108
109
110
114
115
116
117
122
124
126
128
129
WASHER. THRUST
GEAR, 6TH DRIVE
SPACER
RING, SNAP
SYNCHRONIZER
ASSEMBLY, 5TH/6TH
FORK, 5TH/6TH SHIFT
RING, SNAP
GEAR, 5TH DRIVE
EXTENSION TAPERED
61
P0010-7B10B-RA
Figure 30 Countershaft Extension Assembly
5th/6th DRIVEN GEAR

Figure 31
Tool Required:
61
J 39441 Gear Installer

J 39441-1 Gear Installer Bolts
!!
P0026-7B10B-RA
Figure 31 5th/6th Driven Gear
Install or Connect
5th/6th driven gear (61) using J 39441 and

J 39441-1.
Smaller OD gear down.
Engage splines of 5th/6th driven gear (61)
to shaft splines (23) before pressing gear
onto shaft.
GEAR, 5th/6th DRIVEN
REVERSE SHIFT FORK

Figure 32
El
1.
2.
3.
Install or Connect
Reverse shift fork (111), synchronizer (62) and

thrust washer (68) at the same time.
New reverse shift fork snap ring (113).
Reverse synchronizer snap ring (69).
62
69
111
SYNCHRONIZER ASSEMBLY, REVERSE

RING, SNAP
FORK, REVERSE SHIFT
113
RING.SNAP
P0008-7B10B-RA
Figure 32 Reverse Shift Fork
REVERSE SPEED GEAR

Figure 33
j++j
1.
2.
Install or Connect
Blocker ring (70).

Wave washer (71).
3.
4.
5.
6.
7.
8.
9.
10.
Install wave washer (71) so concave side

faces blocker ring (70).
Needle bearing (72).

Reverse speed gear (73).
Thrust washer (74).
Snap ring (75).
Spacer (76).
Spacer (78).
Roller bearing snap ring (79).
70
71
72
73
74
75
76
77
78
79

WASHER, WAVE
BEARING, REVERSE GEAR NEEDLE
GEAR, REVERSE
WASHER, THRUST
RING, SNAP
SPACER
BEARING, ROLLER
SPACER
RING, SNAP
P0007-7B10B-RA
Figure 33 Reverse Speed Gear
SPEEDOMETER GEAR
Figure 34
Tool Required:
J 39441 Gear Installer
J 39441-2 Gear Installer Bolts
j++j
1.
2.
3.
4.
Install or Connect

Speedometer gear (81) using J 39441 and
J 39441-2.
Sealing ring.
12.
Extension housing bolts (100) and transmission

bumper (177).
l~I
J 39441
13.
14.
Tighten
Apply sealant GM p/n 1052080 to threads

of bolts retaining transmission bumper.
Bolts (100) to 35 Nm (26 lb. ft.).
Rear offset shift lever (93) and isolator cup (95).

Rear offset shift lever roll pin (94).
86
\\
~~
~1-
~~
r
81
132--@J
GEAR, SPEEDOMETER (ELECTRONIC)
130---$
Figure 35
~135
- 134
Install or Connect
Funnel (132).
2. Selective shim (131). Refer to "Countershaft
5.
6.
7.
8.
9.
10.
~136
EXTENSION HOUSING
3.
4.
137
131~"(7
P0032-7B10B-RA
El1.
139
Extension" under "Shimming Procedures" in

this section.
Reverse idler shaft (138).
Reverse idler gear (136).
Reverse idler gear thrust washer (135).
Reverse idler shaft bracket (134).
Reverse idler shaft bracket bolts (133).
threads of bolts (133).
l~I
86
130
131
132
133
134
135
136
137
138
139
133
I
HOUSING, TRANSMISSION EXTENSION
RACE, COUNTERSHAFT EXTENSION BEARING
SHIM, COUNTERSHAFT EXTENSION
FUNNEL, OIL
BOLT, REVERSE IDLER SHAFT BRACKET
BRACKET, REVERSE IDLER SHAFT
WASHER, REVERSE IDLER GEAR THRUST
GEAR,REVERSEIDLER
BEARING, REVERSE IDLER GEAR ROLLER
SHAFT, REVERSE IDLER GEAR
WASHER, REVERSE IDLER GEAR THRUST
P0027-7B10B-RA
Figure 35 Extension Housing
SHIFTER
Tighten
Bolts (133) to 25 Nm (18 lb. ft.).

11. Extension housing (86).
extension housing to transmission case
mating surface.
Align 5th/6th and reverse shift rail (140)
with extension housing bore.
Figure 36
lI
1.
Install or Connect
Shifter (96).
extension housing to shifter mating
surface.
2.
,~,
3.
4.
5.
Remove transmission from J 39430 and

J 3289-20.
Clutch fork (164) and T-handle (165).
Clutch fork bolt (166).
Tighten

threads of clutch fork bolt (166).
Bolt (166) to 25 Nm (18 lb. ft.).
1.
2.
3.
4.
Install or Connect
Position transmission in vertical position.

Input shaft (10) to adapter plate (1).
Mainshaft (23) to input shaft (10).
Countershaft (105).
A. Lift up mainshaft (23) enough to install
countershaft (105).
B. Countershaft (105).
5.
6.

Adapter plate to transmission case bolts (178).
!~!
Clutch housing (162).

Clutch housing bolts (163).
!~!
8.
Tighten
Bolts (97) to 20 Nm (15 lb. ft.).
,~,
6.
7.
j++j
Bolts (97).
7.
Measure
A. Input shaft/mainshaft end play by moving

input shaft (10) up and down.
B. Select shim (6) to achieve 0.000 to 0.002
inch (0.00 to 0.05 mm) preload.
Bolts (163) to 35 Nm (26 lb. ft.).
Vent tube (161).

8.
9.
10.
Remove J 8001.
Place tip of J 8001 on end of countershaft
(105).
J 39444-1 through adapter plate plug hole.
!@!
86
95
Bolts (178) to 35 Nm (26 lb. ft.).
Place tip of J 8001 on end of mainshaft (23).
!@!
Tighten
Tighten
Measure
A. Countershaft end play using J 39444-1 to

move countershaft (105) up and down.
B. Select shim (102) to achieve 0.000 to
0.002 inch (0.00 to 0.05 mm) preload.
86
95
96
97
HOUSING,
TRANSMISSION
EXTENSION
CUP, ISOLATOR
SHIFTER ASSEMBLY
P0004-7B10B-RA
"'-
',_____Jl,IJ)
Figure 36 Shifter
11.
Remove J 39444-1 and J 8001.
E3
1.
2.
3.
A. Lift up mainshaft (23) enough to remove

countershaft (105).
B. Countershaft (105).
SHIMMING PROCEDURES
INPUT SHAFT/MAINSHAFT AND
COUNTERSHAFT
Figure 37
Tools Required:
J 39444-1 Countershaft End Play
Measuring Tool
Adapter plate to transmission case bolts (167).

Countershaft (105).
4.
5.
6.
7.
Mainshaft (23).
Input shaft (10) from adapter plate (1).
J 39444-1
J 39444-1
44
44
A
B
COUNTERSHAFT SHIMMING PROCEDURE

INPUT SHAFT/MAINSHAFT SHIMMING PROCEDURE
10
23
SHAFT, INPUT
MAINSHAFT
CASE, TRANSMISSION
COUNTERSHAFT
44
105
23--.....u..-...F=i
P0028-7B10B-RA
Figure 37 Input Shaft/Mainshaft and Countershaft
COUNTERSHAFT EXTENSION
Figure 38
Tools Required:
J 39444-2 Countershaft Extension End
Play Measuring Rod
l++f
Install or Connect
[I]
1.
2.
3.
4.
7.
This procedure cannot be performed

accurately until the "Countershaft
Shimming Procedure" has been
completed and the transmission has been
assembled to the point of installing the
countershaft extension.
Position transmission in horizontal position.

Countershaft extension (128) to countershaft
(105) making sure splines fufly engage.
l~I
5.
Important
Tighten
Bolts (100) to 35 Nm (26 lb. ft.).
J 39444-2 through adapter plate plug hole and

screw J 39444-2 into countershaft extension.
J 8001 so tip is on end of J 39444-2.
l@I
Measure
A. Position transmission in vertical position.

B. Countershaft extension end play using
J 39444-2 to move countershaft extension
(128) up and down.
C. Select shim (131) to achieve 0.002 to
0.005 inch (0.05 to 0.13 mm) axial play.
8.
9.
Remove J 8001 and J 39444-2.

Install adapter plate plug (2).
I~!
E3
1.
2.
3.
4.
Apply sealant GM p/n 1052080 to plug

threads (2).
J 8001
Tighten
Plug (2) to 17 Nm (13 lb. ft.).

Countershaft extension (128).
NOTE: COUNTERSHAFT SHIMMING

PROCEDURE MUST BE
PERFORMED FIRST. COUNTERSHAFT
AND CORRECT SHIM MUST BE IN
STALLED DURING THIS PROCEDURE
P0029-7B10B-RA
Figure 38 Countershaft Extension
SPECIFICATIONS
DESCRIPTION
NO.*
2
178
59
166
163
48
101
100
133
90
89
97
56
45,46
54
60
88
Adapter Plate Plug

Adapter Plate to Transmission Case Bolts
Backup Lamp Switch
Clutch Fork Bolt
Clutch Housing to Adapter Plate Bolt
Cover Plate Bolts
Extension Housing Plug
Extension Housing to Transmission Case Bolts
Reverse Idler Shaft Bracket Bolts
Reverse Lockout Assembly Bolt
Shifter Bolts
Shift Detent Assembly
Shift Lever Guide Bolts
Shift Guide Plate Bolts
Transmission Case Fill Plug
Vehicle Speed Sensor Bolt
TORQUE
17 Nm
35 Nm
27 Nm
25 Nm
35 Nm
20 Nm
18 Nm
35 Nm
25 Nm
18 Nm
40 Nm
20 Nm
34 Nm
27 Nm
22 Nm
18 Nm
10 Nm
(13 lb.
(26 lb.
(20 lb.
(18 lb.
(26 lb.
(15 lb.
(13 lb.
(26 lb.
(18 lb.
(13 lb.
(30 lb.
(15 lb.
(25 lb.
(20 lb.
(16 lb.
(13 lb.
(89 lb.
ft.)
ft.)
ft.)
ft.)
ft.)
ft.)
ft.)
ft.)
ft.)
ft.)
ft.)
ft.)
ft.)
ft.)
ft.)
ft.)
in.)
*Disassembled Parts Illustration, Figure 1
SHIMMING SPECIFICATIONS
SHIM NO.*
7
DESCRIPTION
Input Shaft/Mainshaft Shim
102
Countershaft Shim
131
Countershaft Extension Shim
SHIM TO ATTAIN
Preload of 0.0-0.002 inch
(0.0 to 0.05 mm)
Preload of 0.0-0.002 inch
(0.0 to 0.05 mm)
Axial Play of 0.002-0.005 inch
(0.05 to 0.13 mm)
*Disassembled Parts Illustration, Figure 1
LUBRICANT SPECIFICATIONS
Lube Capacity (Approximate) ............................................................................ 3.9 Liters (4.1 Quarts)
After refill, fluid level must be checked as outlined under On-Vehicle Service in Section 78.
Recommended Lube ......... , ........................................................................................... Dexron-IIE
SPECIAL TOOLS
HOLDING FIXTURE
BEARING RACE INSTALLER
PRESS TUBE
PRESS TUBE
GEAR REMOVER AND BOLTS
J36183
J5590
DIAL INDICATOR SET
J39431,-1,-2
SPLIT PLATE
PRESS TUBE ADAPTER
Q
J36184
J8001
UNIVERSAL DRIVE HANDLE
SEAL INSTALLER
DRIVE HANDLE
J36190
J8092
UNIVERSAL BRIDGE PULLER
SPLIT PLATE
J39433
SPLIT PLATE
J8433
J39428
tt
J39435
J36513
BUSHING REMOVER
~
J36800
J22912-01
SLIDE HAMMER
1ST/2ND SYNCHRONIZER INSTALLER
J39436
BUSHING INSTALLER
Q
J39437
J23907
J39371
P0030-7B10BRA
SPECIAL TOOLS (CONT.)

BEARING INSTALLER
COUNTERSHAFT END PLAY ROD
J39438
BUSHING REMOVER/INSTALLER
PRESS ADAPTER
J39444-1
COUNTERSHAFT EXTENSION END
PLAY ROD
J39547
BEARING RACE REMOVER
J39439-1
REAR SEAL
AND BOOT INSTALLER
J39594
STORAGE CASE
J39440
GEAR INSTALLER AND BOLTS
J39445
BEARING INSTALLER/ADAPTER
J39441,-1,-2
PRESS ADAPTER
J39473
SPLIT PLATE
J39790
J39511
J39442
SPLIT PLATE
J39789
J39791
J39443
J39546
P0031-7B10B-RA
CLUTCH 7C-1
SECTION 7C
CLUTCH
CAUTION: When servicing the clutch system, do not create dust by cleaning components
with compressed air. While not containing asbestos fibers, the clutch disc does contain
fiberglass fibers which could cause bodily harm if inhaled. Any residue should also be
washed from the skin as it could cause irritation.
result.
CONTENTS
Principle Components . . . . . . . . . . . . . . . . . . . .
Driving Members . . . . . . . . . . . . . . . . . . . . . .
Driven Member . . . . . . . . . . . . . . . . . . . . . . .
Hydraulic Clutch . . . . . . . . . . . . . . . . . . . . . .
Hydraulic Clutch Fluid .................
. Clu.tch Pilot Bearing . . . . . . . . . . . . . . . . . . . .
Diagnosis ................................
Preliminary Checks . . . . . . . . . . . . . . . . . . . . . .
Clutch System Diagnosis . . . . . . . . . . . . . . . . . .
Bleeding Hydraulic System . . . . . . . . . . . . . . . .
Clutch Master and Actuator Cylinder
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Clutch Pedal Assembly . . . . . . . . . . . . . . . . . . .
Clutch Anticipate Switch Assembly . . . . . . . . .
7C- l
7C- l
7C- l
7C- l
7C- l
7C-2
7C-2
7C-2
7C-2
7C-2
7C-4
7C-4
7C-7
7C-7
7C-7
GENERAL DESCRIPTION
PRINCIPLE COMPONENTS
The principal components of the clutch system are
the driving members, attached to the engine assembly and
turning with the engine assembly; the driven member,
attached to the transmission assembly and turning with
the transmission assembly; and the operating members.
The operating members include the clutch master cylinder
and actuator assembly, the clutch release bearing assembly, the clutch pedal assembly, and the clutch pilot
bearing.
Driving Members
The driving members of the clutch consist of two
flat surfaced iron plates machined to a smooth finish. One
of these surfaces is the rear face of the engine flywheel
assembly and the other is the clutch pressure plate assembly (with cover). The 3.4L L32 engine uses a push-type
clutch release system, while the 5. 7L LTl engine utilizes a
pull-type clutch release system.
Driven Member
The driven member is the clutch driven plate assembly. This clutch driven plate assembly has a splined hub
which meshes with the splines of the input shaft and
drives the input shaft.
Clutch Pedal Position Switch Assembly

(Clutch Start Switch Assembly) .......... 7C-8
Clutch Driven Plate Assembly (5-Speed) ..... 7C-8
Clutch Driven Plate Assembly (6-Speed) ..... 7C-9
Clutch Fork Assembly and Clutch Release
Bearing Assembly (5-Speed) . . . . . . . . . . . . 7C- l 2
Bearing Assembly (6-Speed) ............ 7C-12
3.4L L32 Engine Flywheel
Assembly .............. Refer to Section 6A2A
5.7L LTl Engine Flywheel
Assembly .............. Refer to Section 6A3A
Clutch Pilot Bearing . . . . . . . . . . . . . . . . . . . . . 7C- l 3
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7C- l 5
Fastener Tightening Specifications . . . . . . . . . 7C- l 5
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7C-15
The driving and driven members are held in contact

by spring pressure. This pressure is exerted by a diaphragm spring in the clutch pressure plate assembly (with
cover).
Hydraulic Clutch
A hydraulic clutch operating mechanism is used to
engage and disengage the clutch system. The mechanism
consists of a remote master cylinder reservoir, a clutch
master cylinder and a clutch actuator cylinder. The remote
master cylinder reservoir is mounted to the left-hand hood
strut bracket using a push-on retainer. The clutch master
cylinder is mounted on the front of dash with a U-bolt
fastener. The clutch actuator cylinder is mounted on the
flywheel housing assembly on the 3.4L L32 engine and to
the clutch actuator cylinder spacer on the flywheel housing assembly with the 5.7L LTl engine. The clutch master
cylinder is operated directly by the clutch pedal assembly.
When the clutch pedal assembly is pressed down,
hydraulic fluid under pressure from the clutch master
cylinder flows into the clutch actuator. On the 3.4L L32
engine the actuator piston engages the clutch fork
assembly, which moves the release bearing assembly,
pressing the diaphragm spring fingers to disengage the
clutch.
On the 5.7L LTl engine the actuator piston engages
the clutch fork assembly which moves the release bearing
7C-2 CLUTCH
assembly pulling the diaphragm spring fingers to disengage the clutch.
The hydraulic clutch system sets the clutch pedal
height and provides automatic clutch adjustment. No
adjustment of clutch or clutch pedal assembly position is
required.
Hydraulic Clutch Fluid

When adding fluid to or refilling the system after
service operations use GM Delco-Supreme 11 brake
fluid or an equivalent fluid that meets DOT 3
specifications.
NOTICE: Do not use silicon, mineral or paraffin
based oil in the clutch hydraulic system. These
fluids will damage the rubber parts in the cylinders.
Before removal of the clutch hydraulic system,

verify the malfunction by removing the flywheel housing
cover and measure the travel of the clutch actuator pushrod. With the clutch pedal pushed fully to the floor, the
clutch actuator pushrod should extend a minimum of
11 mm (0.43 inch) against the clutch fork assembly. Do
not replace the hydraulic system if pushrod travel exceeds
this distance.
If the clutch actuator pushrod does not meet the
travel requirements, check the clutch master cylinder
reservoir fluid level.
The clutch actuator cylinder must be in place

when checking the fluid level.
The proper level is indicated by a step on the
clutch master cylinder reservoir. Fill to specified level with GM Delco-Supreme 11 brake
fluid or an equivalent fluid that meets DOT 3
specifications.
Clutch Pilot Bearing

The clutch pilot bearing is an oil-impregnated
bearing pressed into the crankshaft. This bearing requires
attention when the clutch is removed from the vehicle.
The clutch pilot bearing should be cleaned and inspected
for excessive wear or damage and replaced if necessary.
Do not overfill. The upper portion of the clutch

master cylinder reservoir must accept fluid that
is displaced from the clutch actuator cylinder
as the clutch wears.
DIAGNOSIS
NOTICE: Carefully clean the top and sides of the

clutch master cylinder reservoir before opening to
prevent contamination of the system with dirt, water
or other foreign material. Remove the clutch master
cylinder reservoir diaphragm before adding fluid.
Carefully replace the diaphragm, cover gasket and
cover after filling.
PRELIMINARY CHECKS
Before attempting to repair the clutch, manual transmission assembly or related hydraulic components for any
reason other than an obvious failure, the problem and
probable cause should be identified. A large percentage of
clutch and manual transmission assembly problems show
up as shifting difficulties, such as high shift effort, gear
clash and grinding, or transmission assembly blackout.
When any of these conditions occur, a careful analysis of
these difficulties should be performed before removing
the clutch or manual transmission assembly for repairs.
Refer to "Clutch System Diagnosis" in this section for
conditions, causes and corrections.
If the clutch master cylinder reservoir requires any

fluid, check the clutch hydraulic system components for
leakage. Remove rubber boots from the clutch master cylinder and check for leakage past the pistons. A slight wetting of the surfaces is acceptable. Replace the clutch
hydraulic system if excessive leakage is evident.
CLUTCH SYSTEM DIAGNOSIS

For diagnosis of either the 5-speed manual transmission clutch system or the 6-speed manual transmission clutch system
refer to the following chart:
CONDITION
PROBABLE CAUSE
Fails to Release (Pedal

assembly pressed to floor,
shift lever does not move
freely in and out of reverse
gear)
1.
2.
Faulty clutch pilot bearing.

Faulty driven plate assembly.
3.
Fork assembly off of clutch fork ball

stud or ball stud loose on 5-speed
(called T-stud on 6-speed).
Driven plate assembly hub binding
on input shaft assembly splines.
4.
5.
Driven plate assembly warped or

bent.
6.
7.
Air in clutch hydraulic system.

Pedal assembly misaligned to the
cowl.
CORRECTION
1. Replace clutch pilot bearing.
2. Replace clutch driven plate
assembly.
3. Install properly and lightly lubricate
fingers at clutch release bearing and
clutch fork ball stud.
4. Repair or replace input shaft
assembly and/or driven plate
assembly.
5. Replace driven plate assembly.
Runout should not exceed 0.5 mm
(0.020 inch).
6. Bleed clutch hydraulic system.
7. Loosen pedal assembly mounting
bolts and realign pedal assembly.
CLUTCH 7C3
CONDITION
PROBABLE CAUSE
Slipping
1.
Oil-soaked driven plate assembly.
2. Worn facing or facing torn from

3.
4.
5.
6.
Grabbing (Chattering)
1.
2.
3.
4.
driven plate assembly.

Warped pressure plate assembly or
flywheel assembly.
Weak diaphragm spring.
Clutch driven plate assembly not
seated in.
Clutch driven plate assembly
overheated.
I. Release bearing binding on

transmission bearing retainer.
2. Fork assembly improperly installed.
Noisy
1. Worn release bearing.

2. Fork assembly off ball stud on
5-speed (called T-stud on 6-speed)
(heavy clicking).
3. Clutch pilot bearing loose in
crankshaft.
Excessive Pedal Pressure
Rapid Clutch Driven Plate

Assembly Wear
1.
1.
2.
3.
4.
5.
6.
Bind in release bearing assembly.
1.
2.
Clean, lubricate, check for burrs,

nicks, and other wear.
Install properly.
1.
Replace bearing assembly.
2. Install properly and lubricate fork

3.
1.
2. Master cylinder fell off pedal.
2.
Linkage needs lubrication.

2. Pressure plate assembly release
fingers binding.
3. Linkage misaligned.
4. Release bearing assembly sleeve
binding on transmission bearing
retainer.
5. Sticking linkage, master cylinder or
actuator cylinder.
1.
1.
1.
2.
3.
4.
5.
Install new clutch driven plate

assembly and correct leak at source.
Replace clutch driven plate
assembly.
Replace pressure plate assembly or
flywheel assembly.
Replace pressure plate assembly.
Make 30 to 40 normal starts. Do not
overheat.
Allow to cool.
Oil on clutch pressure plate assembly 1. Install new clutch driven plate
facing or burned or glazed facing.
assembly and correct leak at source.
Worn splines on input shaft
2. Replace input shaft assembly.
assembly.
Warped pressure plate assembly or
3. Replace pressure plate assembly or
flywheel assembly.
flywheel assembly.
Burned or smeared resin on flywheel 4. Sand off if superficial. Replace
or pressure plate assemblies.
burned or heat checked parts.
Release Bearing Assembly

Noise with Clutch Fully
Engaged
Clutch Pedal Assembly Stays

on Floor when Disengaged
CORRECTION
Scored flywheel assembly or

pressure plate assembly.
Driver rides the clutch (rests left foot
on clutch while driving).
Driver races engine and slips clutch
excessively during starting.
Driver holds vehicle on hill by
slipping clutch.
Weak pressure plate assembly
springs.
assembly fingers and bearing

assembly.
Replace clutch pilot bearing.
Lubricate and free-up release
bearing assembly.
Install correctly.
2.
Lubricate linkage.
Free and lubricate.
3.
4.
Align linkage.
Free and lubricate.
5.
Clean or replace as needed.
1.
Grind or replace.
2. Instruct driver.
3.
Instruct driver.
4.
Instruct driver.
5.
Rebuild or replace pressure plate

assembly.
7C-4 CLUTCH
ON-VEHICLE SERVICE
BLEEDING HYDRAULIC SYSTEM
Figures 1, 2, and 3
Bleeding is necessary whenever the level of fluid in
the reservoir has been allowed to fall so low that air has
been drawn into the master cylinder.
NOTICE: Never, under any circumstances, use
fluid which has been bled from a system to fill the
clutch master cylinder reservoir as it may be aerated,
have too much moisture content and possibly be
contaminated.
NOTICE: See "Notice" on page 7C-1 of this section.
1. Loosen clutch master cylinder nuts (23 and 24) to
end of threads on U-bolt (25).
2. Clean dirt and grease from the reservoir cap to
ensure no foreign substances will enter the system.
3. Remove the reservoir cap and diaphragm.

4. Wrap a piece of mechanics wire around left-hand
hood strut bracket (2 or 8) making sure wire is accessible from underside of vehicle.
6. Remove actuator cylinder nuts (5 or 10).
7. Remove actuator cylinder.

Retain actuator cylinder in engine compartment using mechanics wire previously
installed.
8. Lower vehicle.
9. Grasp actuator cylinder and depress hydraulic actuator cylinder pushrod approximately 20.0 mm (0.787
inch) into actuator cylinder bore and hold.
10. Install diaphragm and reservoir cap while holding in
actuator cylinder pushrod.
A
A
A
B
C
1
2
3
4
5
RESERVOIR, CLUTCH MASTER CYLINDER

MASTER CYLINDER, CLUTCH
ACTUATOR CYLINDER, CLUTCH
CYLINDER ASSEMBLY, CLUTCH MASTER AND
ACTUATOR
BRACKET, HOOD STRUT LEFT-HAND
RETAINER, CLUTCH MASTER CYLINDER RESERVOIR
HOSE CLIP, CLUTCH MASTER CYLINDER AND
ACTUATOR
NUT, CLUTCH ACTUATOR CYLINDER, 20 Nm (15 LB. FT.)
PC0001-7C-F-RP
Figure 1 - Clutch Hydraulic System (6-Speed)
CLUTCH 7C-5
!VIEWA
!VIEWC
A RESERVOIR, CLUTCH MASTER CYLINDER
B MASTER CYLINDER, CLUTCH
C ACTUATOR CYLINDER, CLUTCH
6 CYLINDER ASSEMBLY, CLUTCH MASTER AND
ACTUATOR
7 RETAINER, CLUTCH MASTER CYLINDER RESERVOIR
8 BRACKET, HOOD STRUT LEFT-HAND
9 HOSE CLIP, CLUTCH MASTER CYLINDER AND

ACTUATOR
10 NUT, CLUTCH ACTUATOR CYLINDER, 20 Nm (15 LB. FT.)
11 NUT, TRANSMISSION BRACE, 50 Nm (37 LB. FT.)
12 COVER, FLYWHEEL HOUSING
13 BRACE, TRANSMISSION
14 BOLT/SCREW, TRANSMISSION BRACE,
50 Nm (37 LB. FT.)
PC0002-7C-F-RP
Figure 2 - Clutch Hydraulic System (5-Speed)
11. Release actuator cylinder pushrod.

12. Hold actuator cylinder vertically with the pushrod
end facing down_
rn
Important
Actuator cylinder should be lower than the

master cylinder.
13_ Press pushrod into actuator cylinder bore with short
1o_o mm (0.390 inch) strokes_
!Ll 1nspect
Master cylinder reservoir for air bubbles.
14. Continue until air bubbles are no longer entering reservoir.
15. Raise and suitably support vehicle_ Refer to SECTION OA.
16_ Remove actuator cylinder from mechanics wire.
17. [nstall actuator cylinder.
18. Install actuator cylinder nuts (5 or 10).
l~I
Tighten
Clutch actuator cylinder nuts (5 or 10) to 20

Nm (15 lb. ft.).
19. Lower vehicle.
20. Remove mechanics wire from left-hand hood strut
bracket (2 or 8).
21. Install clutch master cylinder nuts (23 and 24).
l~I
Tighten
Clutch master cylinder nuts (23) to 27 Nm (20

lb. ft.).
ILl 1nspect
Fluid level in clutch master cylinder reservoir.
Fill clutch master cylinder reservoir with
Delco-Supreme 11 fluid or equivalent DOT 3
fluid.
7C-6 CLUTCH
18
15~
<
16
25
A PUSHROD, CLUTCH MASTER CYLINDER

B MASTER CYLINDER, CLUTCH
C CONNECTOR, CLUTCH ANTICIPATE SWITCH HARNESS
ELECTRICAL
D CONNECTOR, CLUTCH ANTICIPATE SWITCH HARNESS
ELECTRICAL
E CONNECTOR, CLUTCH PEDAL POSITION SWITCH
HARNESS ELECTRICAL
15 NUT, BRAKE PEDAL 25 Nm (18 LB. FT.)
17 NUT, BRAKE PEDAL PIVOT, 54 Nm (40 LB. FT.)
18 BUSHING, CLUTCH PEDAL PIVOT
19 PEDAL ASSEMBLY, CLUTCH
20 RETAINER, CLUTCH PEDAL LEVER PIN
22 BUMPER, CLUTCH PEDAL
23 NUT, CLUTCH MASTER CYLINDER, 27 Nm (20 LB. FT.)
24 NUT, CLUTCH MASTER CYLINDER (PUSH-ON)
25 U-BOLT, CLUTCH MASTER CYLINDER
26 SWITCH ASSEMBLY, CLUTCH ANTICIPATE (WITH 3.4L
L32 ENGINE)
27 SWITCH ASSEMBLY, CLUTCH ANTICIPATE (WITH 5.7L
LT1 ENGINE)
28 SWITCH ASSEMBLY, CLUTCH PEDAL POSITION (SWITCH
ASSEMBLY, CLUTCH START)
27
PC0003-7C-F-RP
Figure 3 - Clutch Pedal Assembly and Switches
CLUTCH 7C-7
CLUTCH MASTER AND ACTUATOR

CYLINDER ASSEMBLY
10. Instrument panel driver knee bolster assembly.

Figures 1, 2 and 3
!+I Remove or Disconnect

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.

Instrument panel driver knee bolster assembly.
Clutch master cylinder pushrod from clutch pedal
assembly (19).
Clutch master cylinder nuts (23 and 24) from dash
panel assembly.
Clutch master cylinder U-bolt (25) from dash panel
assembly.
Clutch master cylinder from dash panel assembly.
Clutch master cylinder reservoir retainer (3 or 7).
Clutch master cylinder reservoir from left-hand
hood strut bracket (2 or 8).
Clutch actuator cylinder nuts (5 or 10).
Clutch actuator cylinder from clutch housing.
Clutch master and actuator cylinder assembly ( 1 or
6) from vehicle.

1. Clutch actuator cylinder.
2. Clutch actuator cylinder nuts (5 or 10).
l~I
Tighten
Clutch actuator cylinder nuts (5 or 10) to 20

Nm (15 lb. ft.).
CLUTCH PEDAL ASSEMBLY

Figure 3
!+I Remove or Disconnect

1. Brake and accelerator and clutch pedal assembly
(with bracket). Refer to SECTION 5.
2. Brake pedal pivot nut (17) and bolt/screw (21).
3. Clutch pedal assembly (19) with pivot bushings
(18).

1. Clutch pedal assembly (19) with pivot bushings
(18).
2. Brake pedal pivot bolt/screw (21) and nut (17).
!~I Tighten
Brake pedal pivot nut (17) to 54 N m (40 lb.
ft.).
3. Brake and accelerator and clutch pedal assembly
(with bracket). Refer to SECTION 5.
CLUTCH ANTICIPATE SWITCH ASSEMBLY

Figure 3

1.
2.
3. Lower vehicle.
3.
4. Clutch master cylinder to dash panel assembly.

5. Clutch master cylinder U-bolt (25) to dash panel
assembly.
4.
6. Clutch master cylinder nuts (23 and 24).
l~I
Tighten
Clutch master cylinder nuts (23) to 27 Nm (20

lb. ft.).
7. Clutch master cylinder reservoir to left-hand hood
strut bracket (2 or 8).
8. Clutch master cylinder reservoir retainer (3 or 7).
9. Clutch master cylinder pushrod to clutch pedal
assembly (19).

Clutch anticipate switch harness electrical connector
from clutch anticipate switch assembly (26 or 27).
Clutch anticipate switch assembly (26 or 27) from
brake and accelerator and clutch pedal assembly
(with bracket) (16).

1. Clutch anticipate switch assembly (26 or 27) to
2. Clutch anticipate switch harness electrical connector
to clutch anticipate switch assembly (26 or 27).
7C-8 CLUTCH
CLUTCH PEDAL POSITION SWITCH

ASSEMBLY (CLUTCH START SWITCH
ASSEMBLY)
Figure 3
l++I

Refer to SECTION SC.
3. Clutch pedal position switch harness electrical connector from clutch pedal position switch assembly
(28).
4. Clutch pedal position switch assembly (28) from
l++I
Install or Connect
1. Clutch pedal position switch assembly (28) to brake

and accelerator and clutch pedal assembly (with
bracket) (16).
2. Clutch pedal position switch harness electrical connector to clutch pedal position switch assembly (28).
CLUTCH DRIVEN PLATE ASSEMBLY

(5-SPEED)
Tool Required:
J 33169 Clutch Alignment Arbor
l+I

3. Clutch master cylinder pushrod from clutch pedal
assembly (19).
5. 5-Speed manual transmission assembly. Refer to
SECTION7B.
6. Clutch actuator cylinder nuts (10).
NOTICE: Do not allow clutch actuator cylinder to
hang by hydraulic lines as this could cause damage
to clutch hydraulic lines.
7. C~utch actuator cylinder and retain with mechanics
Wlfe.
8.
9.
10.
11.
12.
13.
14.
15.
IL..,I
Transmission brace nut (11) and bolt/screw (14).

Transmission brace (13).
Flywheel housing cover bolts/screws (53).
Flywheel housing cover (12).
Flywheel housing bolts/screws (65).
Flywheel housing assembly (34).
Clutch pressure plate and cover bolts/screws (51).
Clutch pressure plate assembly (with cover) (30)
and clutch driven plate assembly (37).
Inspect
Clutch pressure plate assembly (with cover) (30) for

wear or damage. Repair or replace as necessary.
Clutch driven plate assembly (37) for wear or damage. Replace as necessary.
Engine flywheel assembly. Refer to SECTION
6A2A.
!++I
Install or Connect
NOTICE: See "Notice" on page 7C-l of this section.

l. Clutch driven plate assembly (37) to engine flywheel assembly (29).
2. Clutch pressure plate assembly (with cover) (30).
3. Clutch pressure plate and cover bolts/screws (51 ).
l~I
Tighten
Clutch pressure plate and cover bolts/screws

( 51) finger tight.
4. Align clutch driven plate assembly (37) with pilot
bearing assembly (38) and clutch pressure plate
assembly (with cover) (30) using J 33169.
l~I
Tighten

(51) to 20 Nm (15 lb. ft.) plus 30 degrees.
5. Flywheel housing assembly (34).
6. Flywheel housing bolts/screws (65).
I~!
Tighten
Flywheel housing bolts/screws (65) to 75 Nm

(55 lb. ft.).
[TI Important
Check for proper clutch fork assembly (36) to
clutch release bearing assembly (31) engagement.
7. Flywheel housing cover (12).
8. Flywheel housing cover bolts/screws (53).
l~I
Tighten
Flywheel housing cover bolts/screws (53) to

8.5 Nm (75 lb. in.).
9. Transmission brace (13).
CLUTCH 7C-9
33
34
29
38
A
A
29
30
31
32
33
34
35
36
37

FLYWHEEL ASSEMBLY, ENGINE
PLATE ASSEMBLY, CLUTCH PRESSURE (WITH COVER)
BEARING ASSEMBLY, CLUTCH RELEASE
STUD, CLUTCH FORK BALL
WASHER, CLUTCH FORK BALL STUD
BOOT, CLUTCH FORK
PLATE ASSEMBLY, CLUTCH DRIVEN
38 BEARING, CLUTCH PILOT
PC0004-7C-F-RP
Figure 4 - Clutch System Cross Section (5-Speed)
10. Transmission brace nut ( 11) and bolt/screw ( 14 ).
!~I
Tighten
Transmission brace nut ( 11) and bolt/screw

(14) to 50 Nm (37 lb. ft.).
!~I
Tighten
Clutch actuator cylinder nuts (10) to 20 Nm

(15 lb. ft.).
SECTION 7B.
14. Lower vehicle.
assembly (19).

CLUTCH DRIVEN PLATE ASSEMBLY

(6-SPEED)
Figures 3, 6, and 7
!++I
Tool Required:
assembly (19).
7C-10 CLUTCH
12
29
30
31
32
33
34
35
36
37
38
49
50
51
52
53
54
65
COVER, FLYWHEEL HOUSING

STUD, CLUTCH FORK BALL
WASHER, CLUTCH FORK BALL STUD
BOOT, CLUTCH FORK
PIN, FLYWHEEL HOUSING LOCATOR
BOLT/SCREW, FLYWHEEL, 83 Nm (61 LB. FT.)
BOLT/SCREW, CLUTCH PRESSURE PLATE AND COVER,
20 Nm (15 LB. FT.) PLUS 30 DEGREES
PIN, FLYWHEEL GROOVE
BOLT/SCREW, FLYWHEEL HOUSING COVER, 8.5 Nm
(75 LB. IN.)
TRANSMISSION ASSEMBLY, MANUAL (5-SPEED)
BOLT/SCREW, FLYWHEEL HOUSING, 75 Nm
(55 LB. FT.)
PC0005-7C-F-RP
Figure 5 - Clutch System (5-Speed)
CLUTCH 7C 11
42
41
43
44
A
39
40
41
42
43
44
45
46
47
48
46

T-STUD, CLUTCH FORK
SPACER, CLUTCH ACTUATOR CYLINDER
PC0006-7C-F-RP
Figure 6 - Clutch System Cross Section (6-Speed)

SECTION 7B.
7_ Flywheel housing bolts/screws (62).
9. Clutch pressure plate and cover bolts/screws (57).
10. Clutch pressure plate assembly (with cover) (39)
ILl
1nspect
Clutch pressure plate assembly (with cover) (39) for

wear or damage_ Repair or replace as necessary.
Clutch driven plate assembly (47) for wear or damage. Replace as necessary.
Engine flywheel assembly_ Refer to SECTION
6A3A.
l++I
Install or Connect

1. Clutch driven plate assembly (47) to engine fly-
wheel assembly (46).

2. Clutch pressure plate assembly (with cover) (39).
l~I
Tighten

(57) finger tight.
4_ Align clutch driven plate assembly (4 7) with clutch
pilot bearing (48) and clutch pressure plate assembly
(with cover) (39) using J 38836.
l~I
Tighten

(57) to 30 Nm (22 lb. ft.).
7C-12 CLUTCH
l~I
Tighten

(35 lb. ft.).
8. Flywheel housing cover bolts/screws (61 ).
l~I
9.
10.
11.
12.
Tighten

8.5 Nm (75 lb. in.).
6-Speed manual transmission assembly. Refer to
SECTION 7B.
Lower vehicle.
Clutch master cylinder pushrod to clutch pedal
assembly ( 19).
CLUTCH FORK ASSEMBLY AND CLUTCH

RELEASE BEARING ASSEMBLY (5-SPEED)
Figures 2, 4 and 5
l++I

assembly (19).
SECTION 7B.
5. Clutch actuator cylinder nuts ( 10).
6. C~utch actuator cylinder and retain with mechanics
Wlfe.
7.
8.
9.
10.
11.
12.
13.
14.
15.
ll'l'I
Transmission brace nut (11) and bolt/screw (14).

Transmission brace (13).
Flywheel housing cover bolts/screws (53).
Flywheel housing cover (12).
Flywheel housing bolts/screws (65).
Flywheel housing assembly (34).
Clutch release bearing assembly (31).
Clutch fork assembly (36).
Clutch fork ball stud (32) and washer (33).
Inspect
Clutch release bearing assembly, clutch fork assembly, and clutch fork ball stud for wear or damage.
Replace as necessary.
!++I
Install or Connect

1. Clutch fork ball stud (32) and washer (33).
2. Lubricate clutch ball stud (32) using wheel bearing
lubricant GM PIN 1051344, or equivalent.
3. Clutch fork assembly (36) onto clutch ball stud (32).
4. Lubricate recess on inside diameter of clutch release
bearing assembly (31) and the clutch fork groove
using wheel bearing lubricant GM PIN 1051344, or
equivalent.
5. Clutch release bearing assembly (31) to clutch fork
assembly ((36).
l~I
Tighten

(55 lb. ft.).
l~I
Tighten

8.5 Nm (75 lb. in.).
10. Transmission brace (13).
11. Transmission brace nut ( 11) and bolt/screw ( 14).
l~I
Tighten
Transmission brace nut ( 11) and bolt/screw

(14) to 50 Nm (37 lb. ft.).
l~I
Tighten
Clutch actuator cylinder nuts (10) to 20 Nm

(15 lb. ft.).
SECTION 7B.
15. Lower vehicle.
assembly (19).
CLUTCH FORK ASSEMBLY AND CLUTCH

RELEASE BEARING ASSEMBLY (6-SPEED)
Figures 3, 6, and 7
Tool Required:
CLUTCH 7C-13

1. Instrument panel driver knee bolster assembly. Refer to SECTION 8C.
assembly ( 19).
SECTION 7B.
10. Clutch pressure plate assembly (with cover) (39)
11. Clutch release bearing retainer (58).
12. Clutch release bearing assembly (40).
13. Clutch fork assembly (45) from 6-speed manual
14. Bolt/screw (63) and clutch fork T-stud (41) from
6-speed manual transmission assembly (42).
ll'l'! Inspect
Clutch release bearing assembly (40), clutch fork
assembly (45), and clutch fork T-stud (41) for wear
or damage. Replace as necessary.

1. Clutch fork T-stud (41) and bolt/screw (63).
l~I
2.
3.
4.
5.
6.
7.
8.
Tighten
Clutch fork T-stud bolt/screw (63) to 24 Nm

(18 lb. ft.).
Lubricate clutch fork T-stud (41) using wheel bearing lubricant GM P/N 1051344, or equivalent.
Clutch fork assembly (45) on clutch fork T-stud (41)
at first detent position.
Do not fully seat clutch fork assembly (45) on
clutch fork T-stud (41) until after installation of
6-speed manual transmission assembly (42). It
will fully seat itself when transmission assembly (42) is installed.
Clutch release bearing assembly (40) to clutch pressure plate assembly (with cover) (39).
Clutch release bearing retainer (58).
Clutch driven plate assembly (47) to engine flywheel assembly (46).
Clutch pressure plate assembly (with cover) (39).
Clutch pressure plate and cover bolts/screws (57).
l~I Tighten
(57) finger tight.
9. Align clutch driven plate assembly (47) with clutch
pilot bearing (48) and clutch pressure plate assembly
(with cover) (39) using J 38836.
l~l
Tighten

(57) to 30 Nm (22 lb. ft.).
11. Flywheel housing assembly bolts/screws (62).
l~I
Tighten

(35 lb. ft.).
l~I Tighten
8.5 Nm (75 lb. in.).
SECTION 7B.
15. Lower vehicle.
assembly ( 19).
CLUTCH PILOT BEARING

Figures 5 through 7
Tool Required:
J 23907 Clutch Pilot Bearing Remover

1. Clutch driven plate assembly. Refer to "Clutch
Driven Plate Assembly (5-Speed)" or "Clutch Driven Plate Assembly (6-Speed)" in this section.
2. Engine flywheel assembly. Refer to SECTION
6A2A or 6A3A.
3. Clutch pilot bearing (38 or 48) using J 23907.

1. Clutch pilot bearing (38 or 48).
2. Engine flywheel assembly. Refer to SECTION
6A2A or 6A3A.
3. Clutch driven plate assembly. Refer to "Clutch
Driven Plate Assembly (5-Speed)" or "Clutch Driven Plate Assembly (6-Speed)" in this section.
7C-14 CLUTCH
56
48
46
60
47
------ --------
39
44
45
39
40
41
42
43
44
45
46
47
48
55
56
1
43

T-STUD, CLUTCH FORK
SPACER, CLUTCH ACTUATOR CYLINDER
PIN, FLYWHEEL HOUSING LOCATOR
COVER, FLYWHEEL HOUSING
57 BOLT/SCREW, CLUTCH PRESSURE PLATE AND COVER

30 Nm (22 LB. FT.)
58 RETAINER, CLUTCH RELEASE BEARING
59 BOLT/SCREW, FLYWHEEL, 100 Nm (74 LB. FT.)
60 PIN, FLYWHEEL GROOVE
61 BOLT/SCREW, FLYWHEEL HOUSING COVER,
8.5 Nm (75 LB. IN.)
62 BOLT/SCREW, FLYWHEEL HOUSING, 47 Nm
(35 LB. FT.)
63 BOLT/SCREW, CLUTCH FORK T-STUD, 24 Nm
(18 LB. FT.)
PC0007-7C-f.RP
Figure 7 - Clutch System (6-Speed)
CLUTCH 7C-15
SPECIFICATIONS
Brake Pedal Nut .................................................... 25 Nm (18 lb. ft.)
Brake Pedal Pivot Nut ................................................ 54 Nm (40 lb. ft.)
Clutch Actuator Cylinder Nut .......................................... 20 Nm (15 lb. ft.)
Clutch Fork T-Stud Bolt/Screw ......................................... 24 Nm (18 lb. ft.)
Clutch Master Cylinder Nut ........................................... 27 Nm (20 lb. ft.)
Clutch Pressure Plate and Cover Bolt/Screw (6-Speed) ...................... 30 Nm (22 lb. ft.)
Clutch Pressure Plate and Cover Bolt/Screw (5-Speed) . . . . . . . . 20 Nm (15 lb. ft.) Plus 45 Degrees
Flywheel Bolt/Screw (5-Speed) ........................................ 83 Nm (61 lb. ft.)
Flywheel Bolt/Screw (6-Speed) ....................................... 100 Nm (74 lb. ft.)
Flywheel Housing Cover Bolt/Screw ................................... 8.5 Nm (75 lb. in.)
Flywheel Housing Bolt/Screw (5-Speed) ................................. 75 Nm (55 lb. ft.)
Flywheel Housing Bolt/Screw (6-Speed) ................................. 47 Nm (35 lb. ft.)
Transmission Brace Bolt/Screw ........................................ 50 Nm (37 lb. ft.)
Transmission Brace Nut .............................................. 50 Nm (37 lb. ft.)
Transmission Bolt/Screw ............................................. 35 Nm (26 lb. ft.)
SPECIAL TOOLS
1.
J>------""'I}
J 33169
2.
3.
1. CLUTCH ALIGNMENT ARBOR (3.4L L32 ENGINE)

2. CLUTCH ALIGNMENT ARBOR (5.7L LT1 ENGINE)
3. CLUTCH PILOT BEARING REMOVER
J 23907
PCOOOS-7C-F-RP
ELECTRICAL BODY AND CHASSIS 8-1
SECTION 8
ELECTRICAL
BODY AND CHASSIS
CONTENTS
Electrical Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lighting Systems and Horns .................................................
Instrument Panel, Gages and Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Windshield Wiper/Washer System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Section 8A
Section 8B
Section 8C
Section 8E
ELECTRICAL DIAGNOSIS SA - CONTENTS
SECTION SA
1993 FIREBIRD
CAUTION: This vehicle is equipped with Supplemental Inflatable Restraint (SIR) Refer to
CAUTIONS in Section 9J under "ON-VEHICLE SERVICE" and the SIR Component and
Wiring Location view in Section 9J before performing service on or around SIR components
or wiring. Failure to follow CAUTIONS could result in possible air bag deployment,
personal injury, or otherwise unneeded SIR system repairs.
SECTION
SECTION
2
3
4
5
9
10
11
14
15
20
21
30
31
32
33
34
40
41
44
47
50
60
61
63
64
Index
Introduction
Symbols
Trou bl eshooti ng Procedures
Repair Procedures
Vehicle Zoning
Power Distribution
Fuse Block Details
Ground Distribution
Retained Accessory Power (KP2)
Sequential Fuel Injection: VG VIN S
(3.4L L32)
Multiport Fuel Injection: VS VIN P
{5.7L LT1)
Starter and Charging
Coolant Fans
Engine Coolant Heater (KOS)
Cruise Control (K34)
Horns
Brake Warning System
Anti lock Brakes
Supplemental Inflatable Restraints (SIR)
Data Link Connector (DLC):
Pin Assignment
Heater (C41)
Defogger (C49)
HVAC Blower Control (CGO)
HVAC Compressor Control (C60)
65
76
81
89
91
100
102
104
110
112
114
117
120
130
132
133
135
138
140
141
147
150
200
201
202
203
HVAC Air Delivery and Temperature

Control (Refer to SECTION 1B)
Audible Warnings: Tone
Instrument Cluster: With Gages
Steering Wheel Controls: Radio (UK3)
(Refer to SA-150-2)
Wiper/Washer: Pulse
Headlights and Fog Lights: Without DRL
(TG 1)
Headlights and Fog Lights: Daytime
Running Lights (T61)
Headlight Doors
Exterior Lights
Backup Lights
Interior Lights
Interior Lights Dimming
Power Windows (A31)
Power Door Locks (AU3)
Keyless Entry (AUO)
Theft Deterrent System: PASS-Key II
Hatch Release (A90)
Brake Transmission Shift Interlock (BTSI)
Power Seat: Driver 6-Way (AC3)
Power Seats: Ultima (AQ9)
Power Mirrors (DG7)
Radio
Service Parts Information
Component Location Views
Harness Connector Faces
Harness Routing Views
8A -
1 - 0 ELECTRICAL DIAGNOSIS
INDEX
PAGE
PAGE
ABS Brake Pressure Valve Solenoids ......
ABS Motor Pack ....................
ABS Relay .......................
Air Conditioning
A/C Clutch Diode (V6 VIN S) ......... .
A/C Clutch Diode (V8 VIN P) ......... .
A/C Compressor Clutch ............. .
A/C Compressor Low Pressure Cut
Off Switch ......................
A/C Compressor Relay
.............. .

A/C Refrigerant Pressure Sensor .......
Air Pump Relay ..................... .
Ambient Light Sensor ................ .
Amplifier (part of UW2 Speaker Option)
Antenna .......................... .
Anti lock Brakes ....................
Arming Sensor, Dual Pole ............. .
Ashtray Lamp ...................... .
Audible Warnings ...................
AudioAlarm Module ................. .
Backup Lights ...................... .
Backup Lamps .................... .
Backup Light Switch ............... .
Blower Motor ...................... .
Blower Resistor ..................... .
Blower Switch (C41) .................. .
Blower Switch (C60) .................. .
Brake Combo Valve (ABS) ............. .
Brake Switch Assembly ............... .
Brake Transmission Shift Interlock ....... .
Brake Transmission Shift Interrupt Solenoid .
Brake Warning System ................ .
Camshaft Position Sensor (V6 VIN S) ..... .
Center High Mounted Stop Light (CHMSL) .
Cigar Lighter ......................
Circuit Breaker Details
# 12 DEFOG/Seats ................. .
#15 Windows .................... .
Clutch Anticipate/Cruise Release Switch ... .
Clutch Start Switch ..................
Component Location Views ............
44-0
44-1
44-1
Console Compartment Lamp ........... .

Convenience Center .................
Coolant Fan, Primary ..............
64-0
64-1
64-0,
64-1
Coolant Fan(s) (VG VIN S) ..............

Coolant Fan(s) (V8 VIN P) ............
Coolant Fan, Secondary ...............
Crankshaft Position Sensors (VG VIN S) ....
Cruise Control ....... ; .............
Cruise Control Module ..............
64-0,
64-1
64-0,
64-1
64-0,
64-1
64-0,
64-1
11-10
102-0
150-1
150-1,
150-3
44-0
47-1
117-1
76-0
76-0
112-0
112-0
112-0
63-0
63-0
60-0
63-0
44-0
110-1
138-0
138-0
41-0
20-4
110-1
114-0
11-6
11-8
20-7
30-0
201-0
Cruise Release Brake switch (all with K34)

Cruise Release Clutch Switch
(V8 Manual with K34, 2 pin) ........
Data Link Connector (DLC) ............. .
Daytime Running Lights (DRL) Module .... .
Defogger (C49) .....................
Diagnostic Energy Reserve Module (DERM)
Discriminating Sensor, Forward ......... .
Discriminating Sensor, Passenger
Compartment ....................
Distributor ......................... .
Dome Lamp ........................
Door Illumination Lamps .............. .
Door Jamb Switches .................. .
Door Lock Actuators ................. .
Electronic Brake Control Module (EBCM) .. .
Electronic Ignition Module (VG VIN S) .....
Engine Control Module (ECM) (VG VIN S)
Engine Control Module (ECM) (V8 VIN P)
Engine Controls (VG VIN S) ............ .
Engine Controls (V8 VIN P) ............ .
Engine Coolant Heater (KOS) ........... .
Engine Coolant Level Sensor (V8 VIN P) ... .
(V6 VIN S) .......................
(V8 VIN P) ....................... .
Engine Coolant Temperature Gage Sensor ..
Purge Solenoid Valve (VG VIN S) ...... .
Purge Solenoid Valve (V8 VIN P) ...... .
Exhaust Gas Recirculation (EGR) Solenoid
Valve (VG VIN S) .................. .
114-0
76-1
31-0,
31-1
31-0
31-1
31-1
20-4
34-0
34-0,
34-1
34-0
34-0
50-0
102-0,
102-1
61-0
47-0,
47-1
47-1
47-1
21-4
114-0
117-1
114-0
130-0
44-0,
44-1
20-4
20-0
21-0
20-0
21-0
32-0
81-3
20-0
21-0
81-1
20-1
21-1
20-1
ELECTRICAL DIAGNOSIS SA -
PAGE
Valve (V8 VIN P) .................. .
Express Down Module ................ .
Exterior Lights ...................... .
Fog Lights
Fog Lamps ....................... .
FogLamps(T61) .................. .
Fog Light Relay ................... .
Fog Light Relay (T61) ............... .
Fog Light Switch .................. .
Fog Light Switch (T61) .............. .
Forward/Back Motor (AC3 Power Seat)
Front Height Motor (AC3 Power Seat)
Fuel Gage Sender ................... .
Fuel Injectors (V6 VIN S) .............. .
Fuel Injectors (V8 VIN P) .............. .
Fuel Pump ......................... .
Fuel Pump Relay (V6 VIN S) ............ .
Fuel Pump Relay (V8 VIN P) ............ .
Fuse Block Details ................... .
#1 Air Bag ....................... .
#2 TURN B-U ..................... .
#3 HVAC ........................ .
#4 ECM BAT ..................... .
#5 ECM IGN ...................... .
#6 Stop/Hazard ................... .
#7 PWRACCY .................... .
#8 Courtesy ......................
#9 Gages ........................ .
#10TAILLTS ..................... .
#11 Cigar/Horn ................... .
#12 DEFOG/Seats Circuit Breaker ...... .
#13 1/P Dimmer ................... .
#14 Wiper/Wash .................. .
#15 Windows Circuit Breaker ........ .
#16 Crank ....................... .
#17Radio ....................... .
Fusible Link (BTSI) ................... .
Fusible Links ....................... .
Gages ............................ .
Coolant Temperature .............. .
Oil Pressure ...................... .
Speedometer .................... .
Tachometer ...................... .
Voltmeter ....................... .
Generator ......................... .
Ground Distribution ........ , ........ .
Harness Connector Faces .............. .
21-1
120-0
110-0
100-1
102-2
100-1
102-2
100-1
102-2
140-0
140-0
81-2
20-2
21-2
81-3
20-5
21-5
11-0
11-4
11-5
11-5
11-6
11-4
11-6
11-7
11-7
11-4
11-6
11-7
11-6
11-8
11-8
11-8
11-8
11-8
138-0
10-0
81-0
81-1
81-0
81-0
81-0
81-0
30-1
14-0
202-0
1-1
PAGE
Harness Routing Views ................
Hatch Release (A90) ..................
Hatch Release Actuator ............. .
Hatch Release Relay ................
Hatch Release Switch ............... .
Hazard Flasher ...................... .
Headlight Doors .................... .
Headlamp Door Motor Assembly ...... .
Headlight Doors Module ............ .
Headlight Doors Module ..............
Headlights
With (T61) Daytime Running Lights
Without(T61) Daytime Running Lights ...
Headlight Dimmer Switch (withoutT61)
Headlight Dimmer Switch (with T61) ...
Headlight Switch (without T61) ....... .
Headlight Switch (with T61) ..........
Heater ((41) ......................
Heater/Vent/Air Conditioning (HVAC)
Control Assembly .................. .
High Blower Relay ...................
Horns
Horn Relay .......................
Horn Switch ...................... .
Horn #1 (A note) .................. .
Horn #2 (F note) ..................
HVAC System
Air Delivery and Temperature Control
Blower Control ((60) ............... .
Compressor Control ((60)
Hydraulic Modulator Assembly
1/P Compartment Lamp ............... .
1/P Dimmer Switch ................... .
1/P Fuse Block ....................... .
Idle Air Control (IA() Motor (V6 VIN S)
Idle Air Control (IAC) Motor (V8 VIN P)
Ignition Coil Module (V8 VIN P) ........ .
Ignition Coil (V8 VIN P) ............... .
Ignition Key Lock Cylinder ............. .
Ignition Key Warning Switch ........... .
Ignition Switch ..................... .
Indicators
ABS INOP
Air Bag ......................... .
Brake ........................... .
Check Gages ..................... .
203-0
135-0
135-0
135-0
135-0
110-0
104-0
104-0
104-0
104-0
102-0
100-0
100-0
102-1
100-0
102-1
60-0
63-0
63-0
40-0
40-0
40-0
40-0
40-0
Sec 18
63-0
64-0
44-0,
44-1
114-0
117-0
11-0
20-1
21-1
21-4
21-4
133-1
76-0
10-2,
10-3
81-1
81-3
81-3
81-1
SA -
INDEX
PAGE
Fasten Seat Belts .................. .
High Beam ......................
Left Turn ........................ .
Low Coolant ..................... .
Low Oil ........................
LOW TRAC ....................... .
Right Turn .......................
Security ........................
Service Engine Soon ................
lnflator Module, Driver ...............
lnflator Module, Passenger ............ .
Instrument Cluster ................... .
(V6 VIN S) .......................
(V8 VIN P) ....................... .
Interior Lights ......................
Interior Lights Dimming ............... .
Introduction .....................
Isolation Diode (Low Coolant) ..........
Isolation Diode (RAP) ................. .
Keyless Entry .......................
Keyless Entry Receiver ................ .
Knock Sensor (V6 VIN S) ..............
Knock Sensor (V8 VIN P) ..............
License Lamp ....................... .
Lights (Exterior)
Backup ......................... .
Fog ............................ .
Front Marker .....................
Headlights ....................... .
License ......................... .
Park/Turn ....................... .
Rear Marker ..................... .
Tail/Stop/Turn .................... .
Lights (Interior)
Dome .......................... .
Door Illumination ................. .
1/P Compartment .................. .
Interior Lights Dimming ............. .
Low Coolant Relay ................... .
(V6 VIN 5) .......................
(V8 VIN P) ......................
81-3
81-3
81-3
81-3
81-1
81-3
81-3
81-2
81-3
47-1
47-1
81-0
PAGE
Marker Lamps, Front
.................
Marker Lamps, Rear .................. .

Mirror Motor Pack ................... .
Modules
Audio Alarm
Cruise Control
Daytime Running Lights .............
Diagnostic Energy Reserve ..........
....
20-0
21-0
114-0
117-0
2-0
81-3
15-0
132-0
132-0,
132-1
20-0
21-0
110-4
112-0
100-1
110-2
100-0
110-4
110-2,
110-3
110-4
110-1
114-0
117-1
114-0
114-0
81-3
20-0
21-0
Engine Control Module (VG)

Engine Control Module (V8)
Express Down .................... .
Headlight Doors .................. .
Ignition Coil ...................... .
Inflater ......................... .
PASS-KeyII Decoder ............... .
Power Seat Control ................ .
Retained Accessory Power ........... .
Windshield/Wiper Motor ............ .
Motors
Blower .......................... .
Headlamp Door ..................
Power Mirror (DG7) ...............
Power Seat (AC3) ..................
Starter .......................... .
Window ........................ .
Windshield Washer Pump ........... .
Windshield Wiper ................. .
Multi-Function Lever ................. .
Oil Level Sensor ..................... .
Oil Pressure Sensor ................... .
Outside Mirrors ..................... .
Oxygen Sensors (V6 VIN S) ............ .
Oxygen Sensors (V8 VIN P) ............ .
Park Brake Switch ................... .
Park/Turn Lamps .................... .
PASS-KeyII Decoder Module .......... .
Power Distribution .................. .
Power Door Locks (AU3) ............... .
Power Door Lock Switch, LH
Power Door Lock Switch, RH
110-2,
110-3
110-4
147-0
76-0
34-0,
34-1
102-0,
102-1
47-0,
47-1
44-0,
44-1
20-0
21-0
120-0
104-0
21-4
47-1
133-1
141-0
15-0
91-0
63-0
104-0
147-0
140-0
30-1
120-0
91-0
91-0
34-0
81-1
81-0
147-0
20-0
21-0
41-0
110-2,
110-3
133-1
10-0
130-0
130-0
130-0
ELECTRICAL DIAGNOSIS SA - 1 - 3
PAGE
Power Mirrors (DG7)
Power Mirror Switch
Power Seat (AC3)
Power Seat Actuator Assembly (AC3) ...
Power Seat Motor (AC3) ............
Power Seat Switch (AC3) ............
Rear Height Motor (AC3) ............
Power Seats (AQ9)
Power Seat Control Module
(AQ9 Power Seat) ...............
Power Seat Switch, Driver (AQ9) ......
Power Seat Switch, Passenger (AQ9)
Pump Assembly (AQ9) ..............
Solenoid Valve Assembly (AQ9) .......
Power Windows (A31) ................
Power Window Switch, LH .............
Power Window Switch, RH .............
PRNDL Illumination Lamp (Auto Trans)
Radio ............................
Rear Defogger ......................
Rear Defogger Switch ................
Rear Defogger Ti mer/Relay ............
Rear Dome Light Switch ...............
Rearview Mirror ....................
Relays
AJC Compressor ...................
147-0
147-0
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
ABS ............................ .
Air Pump ........................ .
Coolant Fan, Primary ............... .
Coolant Fan, Secondary ............. .
Fog Lights ....................... .
FogLights(T61) ................... .
Fuel Pump (V6 VIN S) .............. .
Fuel Pump (V8 VIN P) .............. .
Hatch Release .................... .
High Blower ..................... .
Horn ........................... .
Low Coolant ..................... .
Starter Enable .................... .
Repair Procedures ................... .
Retained Accessory Power (RAP) Module .. .
Reverse Lockout Solenoid (V8 VIN P Manual)
Seat Belt Switch ..................... .
Secondary Air Injection Pump Assembly
(V6 VIN S) ....................... .
140-0
140-0
140-0
140-0
141-0
141-0
141-1
141-0
141-0,
141-1
120-0
120-0
120-0
117-1
150-0
61-0
61-0
61-0
114-0
114-0
64-0,
64-1
44-1
11-10
31-0,
31-1
31-1
100-1
102-2
20-5
21-5
135-0
63-0
40-0
81-3
30-0
5-0
15-0
21-7
76-0
20-1
PAGE
Secondary Air Injection Pump Assembly
(V8 VIN P) ......................
Sensors
A/C Evaporator Temperature ......... .
A/C Refrigerant Pressure
Ambient Light .................... .
Arming, Dual Pole .................
Camshaft Position .................
Crankshaft Position ................ .
Discriminating Sensor, Forward ....... .
Discriminating Sensor, Passenger ...... .
Engine Coolant Temperature (V6 VIN S)
Engine Coolant Temperature (V8 VIN P)
Intake Air Temperature (V6 VIN S)
Intake Air Temperature (V8 VIN P)
Knock (V6 VIN S) .................. .
Knock (V8 VIN P) .................. .
Manifold Absolute Pressure (V6 VIN S)
Manifold Absolute Pressure (V8 VIN P)
Oil Level ........................ .
Oil Pressure ...................... .
Oxygen (V6 VIN S) ................ .
Oxygen (V8 VIN P) ................ .
Throttle Position Sensor (V6 VIN S) .... .
Throttle Position Sensor (V8 VIN P) .... .
Vehicle Speed .................... .
Wheel Speed ..................... .
Service Parts Information ............. .
SIR Coil Assembly ................... .
Solenoids
ABS Brake Pressure Valve ............ .
Brake Transmission Shift Interrupt (BTSI)
Canister Purge (V6 VIN S) ........... .
Canister Purge (V8 VIN P) ........... .
Reverse Lockout ................... .
Starter .......................... .
Torque Converter Clutch (V6 VIN S)
Torque Converter Clutch (V8 VIN P)
Speakers
Left Front (Base - UQO) .............. .
Left Front Midrange (with UW2 Speakers)
Left Front Tweeter (with UW2 Speakers)
Left Rear (Base - UQO) .............. .
Left Rear Subwoofer (with UW2 Speakers)
Left Rear (with UW2 Speakers) ........ .
Right Front (Base - UQO) ............. .
21-1
64-0,
64-1
64-0,
64-1
102-0
47-1
20-4
20-4
47-1
47-1
20-0
21-0
20-0
21-0
20-0
21-0
20-0
21-0
81-1
81-0
20-0
21-0
20-0
21-0
33-0
44-1
200-0
47-0
44-0
138-0
20-1
21-1
21-7
30-1
20-6
21-6
150-3
150-0
150-0
150-3
150-1
150-1
150-3
SA -
INDEX
PAGE
PAGE
Right Front Midrange (with UW2 Speakers)
Right Front Tweeter (with UW2 Speakers)
Right Rear (Base - UQO) ............. .
Right Rear Subwoofer (with UW2 Speakers)
Right Rear (with UW2 Speakers) ...... .
Starter and Charging ................. .
Starter Enable Relay ................. .
Starter Motor ...................... .
Starter Solenoid .................... .
Steering Wheel Controls, Radio (UK3)
Supplemental Inflatable Restraints ...... .
Switches
A/C Compressor ................... .
Backup Lights ....................
Blower (C41) ..................... .
Blower (C60) ..................... .
Brake .......................... .
Clutch Anticipate/Cruise Release ...... .
Clutch Start ...................... .
Cruise Release Brake ...............
Cruise Release Clutch ............... .
Door Jamb ....................... .
Hatch Release .................... .
Headlight ....................... .
Headlight Dimmer ................. .
Ignition .... ..................... .
Ignition Key Warning ..............
Park Brake .......................
Seat Belt ........................
Transmission Position (for Backup Lights)
Transmission Position (V6 VIN S) ......
Transmission Position (V8 VIN P) ......
Symbols ...........................
Tachometer Filter (V8 VIN P) ...........
Taillamps ..........................
Tail/Stop/Turn Lamps .................
.
.
.
.
.
.
.
.
.
Theft Deterrent System ............... .

Throttle Position (TP) Sensor (V6 VIN S)
Throttle Position (TP) Sensor (V8 VIN P) ....
150-0
150-0
150-3
150-1
150-1
30-0
30-1
30-1
30-1
150-2
47-0
64-0,
64-1
112-0
63-0
64-0
41-0
20-7
30-0
34-0
34-0
114-0
135-0
100-0
100-2
10-2,
10-3
76-0
41-0
76-0
112-0
20-6
21-6
3-0
21-4
110-4
110-1,
110-4
133-0
20-0
21-0
Torque Converter Clutch (TCC) Solenoid

(V6 VIN S) .......................
Torque Converter Clutch (TC() Solenoid
(V8 VIN P) ....................... .
Transmission Position Switch
(for Backup Lights) .................
Transmission Position Switch (V6 VIN S)
Transmission Position Switch (V8 VIN P)
Troubleshooting Procedures ...........
Turn Flasher ........................ .
Turn/Hazard Switch Assembly .......... .
Underhood Electrical Center Fuse Details
#1 ABS ......................... .
#2 FOG LP ....................... .
#3 R-HDLP DR ....................
#4 L-HDLP DR ....................
#5ABS IGN ......................
#6 FANS/ACTR ....................
#7 Air Pump .....................
#9 Injector (V6 VIN S) .............. .
#9 Injector (V8 VIN P) .............. .
#10 Injector (V6 VIN S) ............. .
# 10 Injector (V8 VIN P) ............. .
#11 Ignition ..................... .
# 12 A/C-CRU ISE ................... .
Underhood Electrical Center Relay Details
A/C Compressor ................... .
ABS ...................... ,
Air Pump ........................ .
Coolant Fan, Primary ............... .
Coolant Fan, Secondary ............. .
Fog Lights ....................... .
High Blower ..................... .
Low Coolant ..................... .
Vehicle Speed Sensor ................. .
Vehicle Zoning ...................... .
Wheel Speed Sensors ................. .
Window Motors ..................... .
Windshield Washer Pump Motor ........ .
Windshield Wiper Motor Module ........ .
Windshield Wiper/Washer Switch ....... .
Wiper/Washer ...................... .
20-6
21-6
112-0
20-6
21-6
4-0
110-0
110-0
11-9
11-9
11-9
11-9
11-10
11-11
11-10
11-13
11-12
11-13
11-12
11-14
11-14
11-14
11-10
11-10
11-11
11-11
11-9
63-0
11-14
33-0
9-0
44-1
120-0
91-0
91-0
91-0
91-0
BLANK
1-5
8A -
2 -0
INTRODUCTION
DIAGNOSTIC INFORMATION
The Electrical Diagnosis section contains the
following types of diagnostic information (the way in
which the information is arranged may vary from
system to system or vehicle to vehicle):
Electrical Schematics
Component Location Lists
Harness Connector Faces
Troubleshooting Hints
System Checks
System Diagnosis
Circuit Operation Descriptions
Harness Routing Views
Using these elements together will make electrical
troubleshooting faster and easier. Each element is
described below.
The Circuit Schematic shows the electrical current
paths when a circuit is operating properly. It is
essential to understand how a circuit should work
before trying to diagnose a failure.
The Component Location List helps to find where
the components of a system can be located. A brief
statement of the location is given and also a reference
to a drawing that shows the component and its
connecting wires. These Component Location Views
are in SECTION SA-201.
The Harness Connector Faces show the cavity or
terminal locations in all the 4 pin or larger connectors
shown in the schematic. Together with the wire colors
and terminals given in the schematic, they help locate
test points. The drawings show the connector faces as
seen after the harness connector has been disconnected
from a component or mating connector.
The Troubleshooting Hints offer short-cuts or
checks to help determine the cause of a complaint.
They are not intended to be a rigid procedure for
solving an electrical situation.
Rather,
Troubleshooting Hints represent a common-sense
approach, based on an understanding of the circuit.
The System Check gives a summary of how the
system should be operated and what should happen.
This is especially important when working on a new
system. The System Check will help identify
symptoms, lead to diagnosis and confirm normal
operation of the system after repair.
The System Diagnosis provides a procedure to

follow that will locate the condition in a circuit causing
a malfunction. If your own knowledge of the system
and the Troubleshooting Hints have not produced a
quick fix, follow the System Diagnosis. All procedures
are based on symptoms to assist in locating the
condition as fast as possible.
The Circuit Operation describes the components
and how the circuit works.
Harness Routing Views are found in SECTION
8A-203. These views show the routing of the major
wiring harnesses and the in-line connectors between
the major harnesses.
SECTION/PAGE NUMBER
Sections are organized by sub-systems with most
containing a circuit schematic and the associated text.
This makes the section easy to use, since the page
number will stay the same year after year. For
example, the Cruise Control schematic will always
begin on page SA-34-0. The other information for
Cruise Control follows and is paged SA-34-1, SA-34-2,
etc.
Some sections may have more than one circuit
schematic, such as Power Distribution, Interior Lights
and Air Conditioning. The circuit of interest can
either be located by using the Index or by a quick look
through the related section.
All the engine circuits for a particular engine VIN
type are in the same section. This makes that section
easy to use, since schematics for other engines are not
in your way. The Instrument Panel schematics are
organized similarly. If you are working on a vehicle
with a Digital Cluster, only the schematics that apply
to that vehicle's Digital Cluster will be in the section
you use. Information on the Indicators and Gages
Clusters will be in other sections.
2-1
HORN
-
1 ORN
-,FUSE
BLOCK
I
I
I
5212- -
SEE FUSE
. . . BLOCKDETAILS
PAGESA-11-1
l
I
~1!
I
: Q-------------------.:i~ ~ :
1 ORN
r- - - - - - - - - -
I
I
- - - - - - - - -
HORN
RELAY
.....
CONVENIENCE
I CENTER
I
~--~---------~t----~
1 DK GRN!29
.35 BLK!28
G
QQ!
GTC100
--------....
1 DK GRN
.8 BLK
28
29
~.139
29
HORN
BRUSH~
STEERING _ _ _ _.;,.-..,...__ __
WHEEL
-.;.p.-HORN
SWITCH
SEE GROUND
DISTRIBUTION
PAGE SA-14-1
Figure 1 - Typical Horn Schematic
SCHEMATICS
Schematics break the entire electrical system
down into individual circuits. Wiring which is not part
of the circuit of interest is referenced to another page,
where the circuit is shown complete.
rn
Important:
It is important to realize that no attempt is made
on the schematic to represent components and
wiring as they physically appear on the vehicle.
For example, a 4-foot length of wire is treated no
differently in a schematic from one which is only
a few inches long. The number of cavities for
each connector is listed in the Component
Location List. Similarly, switches and other
components are shown as simply as possible,
with regard to function only.
When diagnosing a Horn problem, the technician

would reference the Horn section. The schematic in
Figure 1 is a typical example of what would be found in
a Horn section of SECTION 8A, along with the
following text.
Voltage is applied to the Horn Relay at all times.
When the relay coil is grounded by closing the Horn
Switch, the relay contacts close. When the relay
contacts are closed, both the LH and RH Horns are
energized.
SA -
2 -2
INTRODUCTION
COMPONENT LOCATIONS
To locate the schematic components on the vehicle,
use the Component Location List, see Figure 2.
Listed in the left hand column are the components,
connectors, grounds and splices shown on the
schematic. To the right of the component is the
location, "Under RH side of I/P." Reference to LH and
RH is made as though the technician was sitting in the
driver's seat. On the same line, in the next two
columns, are page and figure references for
SECTION 8A-201, "Component Location Views." In
this case, you are directed to Figure 4 on page
8A-201-1.
Where connectors are listed, the number of
cavities is provided. This represents the total number
COMPONENT
LOCATION
of cavities in the connector, regardless of how many

are actually used. This information is provided to help
identify connectors on the vehicle. In the far right
column is a page reference where a view of the
connector face may be found. Connectors with 3
cavities or less are not included in SECTION SA-202,
"Harness Connector Faces."
Grounds are listed next in the table. The location
description for G 101 reads, "Behind LH Composite
Headlamp." You are directed to page SA-201-8,
Figure 14.
:\'early every component, connector, ground or
splice shown on a schematic can be pinpointed visually
by using the Component Location View figures.
201-PG
Convenience Center
C nder RH side of I/P ............................ .
Fuse Block . . . . . . . . . . . . . Behind I/P Compartment Door ................... .
FIG.
4
CONN
0 ....
Mounted to LH Hood Hinge ...................... .

Above Convenience Center, behind
I/P Compartment .............................. .
7 ..
11
202-0
18 . . .
23
202-2
Behind LH Composite Headlamp ................. .
8 ....
14
8
6
15
8
CONNECTORS
ClOO (34 cavities)
C210 (15 cavities)
GROUNDS
GlOl
SPLICES
8139 .................. . Forward Lamp Wiring Harn, behind
RH Composite Headlamp ...................... .
S212
I/P Wiring Harn, behind 1/P, above Steering Column
Figure 2 - Typical Entries in the Component Location List
ELECTRICAL DIAGNOSIS SA- 2 - 3
12059472
12064752
7-WAY F METRlPACK MIXED SERIES

BLK
6-WAY F METRlPACK 280 SERIES

BLK
C406
mreE reD~C ~
~B
G~
~J~K~L~M~
12065666
12034297
4-WA Y WEATHER PACK
BLK
12-WA Y PC EDGEBOARD
BLK
CRUISE CONTROL MODULE
Figure 3 - Typical Harness Connector Faces
HARNESS CONNECTOR FACES

The connectors, see Figure 3, are labeled with the
component they are connected to, or the connector
number. In addition the color of the connector is given
along with the family/series name.
If you need to backprobe a connector while it is on
the component (refer to page SA-4-3 for probing
procedures), the order of the terminals must be
mentally reversed. The wire color is a help in this
situation. If there is more than one wire of the same
color, you may need to locate a test point from its
terminal number. A useful trick is to imagine that you
are probing a terminal from behind the page you are
looking at. Then mentally locate that terminal with
respect to the keyway or other reference mark.
SA -
2 -4
INTRODUCTION
WINDSHIELD
HEADER
DASH PANEL
REAR SHELF
END PANEL
LH "A"
PILLAR
LH REAR
QUARTER PANEL
Figure 4 - Body Part Names
OTHER INFORMATION
BODY PART NAMES
Refer to Figure 4 for the correct body part names.

VIN REFERENCES
If schematics for more than one variation of an

engine type - V6, for example - are shown, then the
schematics will be labeled with VIN designation to
distinguish the variations.
SERVICE PARTS IDENTIFICATION LABEL
To aid service and parts personnel in identifying

options and parts originally installed, a Service Parts
Identification Label has been placed in the vehicle.
See SECTION OA for the location of the label and the
definition of the option codes.
ABBREVIATIONS
Air Conditioning
A/C
CCM
Central Control Module
Circuit
CKT
Connector
CONN
EBCM
ECM
Harness
HARN
Instrument Panel
1/P
Left Hand
LH
Right Hand
RH
TERM
Terminal
For a list of additional abbreviations, refer to

SECTION OA.
ELECTRICAL DIAGNOSIS SA-
w1nng to the first component in each circuit is

extremely helpful in locating short circuits which
cause fusible links and fuses to open.
Figure 5 is a sample Power Distribution
schematic. It shows how voltage is applied from the
positive battery terminal to the various circuits on the
vehicle. For example, battery voltage is applied to the
Starter Solenoid, Fusible Link D, Fuses 1 and 2 in the
Fuse Block and the Light Switch in the LH Pod. These
fuses are said to be Hot At All Times, since battery
voltage is always applied to them.
Notice that battery voltage is also applied to
Fusible Link F and Coolant Fan Relay.
POWER DISTRIBUTION
The Power Distribution schematic shows the

wiring from the Battery and Generator to the Starter
Solenoid, Fuse Block, Ignition Switch and Light
Switch. The first component after a Fusible Link is
also shown. In certain instances, the first component
after a Fuse Block fuse and Light Switch is also shown.
The Power Distribution schematic refers to Fuse
Block Details or the appropriate section schematics.
By using these schematics, power distribution wiring
can be followed from the Battery and Generator to the
first component after a Fusible Link, Fuse or Light
Switch. The ability to follow the power distribution
POWER DISTRIBUTION
FUSll!_L_E__LINK D
3 RED
V6 VIN L
L4 VIN U
V6 VIN L
2 RED
F!/2.IBLE LINK F
V6 VIN L
L4 VIN U
I I
/2R::J
1 RED I
1 BLK I
3 RED
.
G
I
I
I
V6 VINL
I"" -
I
I
...
- , COOLANT
FANRELAV
I PAGE
SA-31-0
I
II., -
.SGRN I
1 BLK :
P100 , - - - - - ,
V6 VIN L
L4 VIN U
32 BLK
19 BLK
:.61-----...
- , STARTER
SOLENOID
PAGE SA-31-1
I
I
.........__....
11..-..1
_,
3 RED
5206
3 RED
LHPODr :
I
I
I
I
C1
Dh-----;;_-;;..-;;_-;;..-l-~;~~~H:
_,' ,
_cl~ ----3,-Q-----------
I
I
HEADr .. _
PARK
OFF HEAD
OFF
PARK
1,.._
L- -
-----
1VEL
HEADLIGHT.- DIMMER SWITCH
PAGE 8A1000
I
I._
10
_..J
-,
I
_,I
SEE EXTERIOR
LIGHTS
PAGE SA-110-0
.SORN
240
HOT AT ALL TIMES
,...
I
J
"'IFUSE
BLOCK
I
I
I
I
I
FUSE 1
20AMP
._
2-5
____________ ...
~
SEE FUSE
BLOCK DETAILS
PAGE SA-11-1
Figure 5 Typical Power Distribution Schematic
BATIERV
SA -
INTRODUCTION
FUSE BLOCK DETAILS
FUSE 1 AND FUSE 2
r----------1
I
I
,-~
- - - - - - - - - - - - 1 BLOCK
F.\)_~
FUSE 2
20 AMP
FUSE 1
20AMP
L-
I
I
- - - .J
.8 ORN
340
q
H2
C205
.8 ORN
.8 ORN
240
.8 ORN
r- -
- -
340
340
.8 ORN
340
.8 ORN
340
.8 ORN
C233
340
,l,_fi__POD
A
C2
I PAGE SA-12-0
I I'"" - -,LIGHT
I I
I SWITQ! I
I I
I
I
I
I '- - .J
L-----.J
COURTESY LAMPS
PAGE 8A114-0
C1
I""' -
..,-
(
L. -
.J
ANTENNA
l!Il~-PAGE 8A-1510
Figure 6 - Typical Fuse Block Details Schematic
FUSE BLOCK DETAILS
The Fuse Block Details schematic, see Figure 6,

shows all of the wiring between a fuse and the
components connected to the fuse. The Fuse Block
Details schematic is extremely helpful in locating a
short circuit that causes a fuse to open.
--
GROUND DISTRIBUTION
FRONT LIGHTS GROUNDS G101 AND G102
LH FRONT
PARK/TURN
LAMP
-
LH
HIGH BEAM
HEADLIGHT
LH DUAL
BEAM
HEADLIGHT
-- - --
-'
.8 BLK
"
-"
'
150
-'"
.8 BLK
.8 BLK
150
150
RH FRONT
PARK/TURN
LAMP
RH
HIGH BEAM
HEADLIGHT
RH DUAL
BEAM
HEADLIGHT
-- - --.,-
-'"
.8 BLKWHT
-"
";-
'
.8 BLK WHT
151
.8 BLK,WHT
151
5105
5100~~,
. . . . . . . . . . . . . . . . . . .. .
.8 BLK
150
-------.8 BLK!WHT
Figure 7 - Typical Ground Distribution Schematic
GROUND DISTRIBUTION
Figure 7 is a sample Ground Distribution

schematic for the Headlamps. It shows exactly which
components share each ground. This information can
often be a time-saver when troubleshooting ground
circuits.
For example, if both Headlamps and the
Park/Turn Lamp on one side are out, suspect an open
in their common ground wire or the ground connection
itself. On the other hand, if one of the lamps work, the
ground and the wire up to the splice are good. You
have learned this just by inspecting the schematic and
knowing the vehicle's symptoms. No actual work on
the lighting system was needed.
151
151
2-7
8A -
SYMBOLS
ELECTROSTATIC DISCHARGE (ESD) AND SUPPLEMENTAL INFLATABLE RESTRAINT (SIR)
ELECTROSTATIC DISCHARGE (ESD) SENSITIVE
DEVICES
All ESD sensitive components are Solid State and
the following information applies to them.
The ESD symbol (Figure 1) is used on schematics
(Figure 2) to indicate which components are ESD
sensitive. When handling any electronic part, the
service technician should follow the guidelines below
to reduce any possible electrostatic charge build-up on
the service technician's body and inadvertent
discharge to the electronic part. If it is not known
whether or not a component is ESD sensitive, assume
it is susceptible.
HANDLING PROCEDURES
1.
2.
3.
4.
5.
Always touch a known good ground before

handling the part. This should be repeated while
handling the part and more frequently after
sliding across a seat, sitting down from a standing
position or walking a distance.
Avoid touching electrical terminals of the part,
unless so instructed by a written diagnostic
procedure.
When using a voltmeter, be sure to connect the
ground lead first.
Do not remove a part from its protective package
until it is time to install the part.
Before removing the part from its package, ground
the package to a known good ground on the
vehicle.
MEASURING PROCEDURES
The circuits shown within the boxes are greatly

simplified. Do not troubleshoot by measuring
resistance at any terminal of these devices unless so
Figure 1 - ESD Symbol
Figure 2 - Typical Schematic
instructed by a written diagnostic procedure. Due to

the simplification of the schematics, resistance
measurements could be misleading, or could lead to
electrostatic discharge.

(SIR) SYSTEM: IF EQUIPPED
The SIR symbol (Figure 3) is used on schematics to
alert the technician of the following important
caution:
CAUTION: This vehicle is equipped with

Supplemental Inflatable Restraint (SIR).
Refer to CAUTIONS in SECTION 9J under
"ON-VEHICLE SERVICE" and the SIR
Component and Wiring Location view in
SECTION 9J before performing service on
or around SIR components or wiring.
Failure to follow CAUTIONS could result
in possible air bag deployment, personal
injury, or otherwise unneeded SIR system
repairs.
Figure 3 - SIR Symbol
SYMBOLS
D
r---,
I
I
L. -
ENTIRE
COMPONENT
SHOWN
PART OF A
COMPONENT
SHOWN
2RED/YEL ...,_ _ _ _ WIRE INSULATION

Ill(
IS RED WITH A
YELLOW STRIPE.
79
,L
. 5 RED
.J
PARK
IIRAKE ~
SWITCH
CLOSED WITH
[ ] PARKING . . . .
BRAKE ON
WIRE GAGE AND INSULATION

COLOR ARE LABELED .
,.
12
NAME OF
COMPONENT
.5 RED
. _---
-~
I
SPLICES ARE SHOWN

AND NUMBERED.
5200
CIRCUIT NUMBER IS
SHOWN TO HELP IN
TRACING CIRCUITS.
DETAILS ABOUT
COMPONENT OR
ITS OPERATION
~ PASS THROUGH
l:lOO - - - -
COMPONENT CASE
IS DIRECTLY
AITACHEDTO
METAL PART
OF VEHICLE
{GROUNDED}.
WIRE IS A TI ACHED TO
METAL PART OF VEHICLE
{GROUNDED}.
GROUND IS NUMBERED
FOR REFERENCE ON
COMPONENT LOCATION LIST.
l~I
I
SEE GROUND
DISTRIBUTION
PAGE SA-14-0
.5 RED
1 RED
A WAVY LINE
__.,.,,,,. MEANS A WIRE IS
~
TO BE CONTINUED.
FUSIBLE
LINK - -
WIRE IS INDIRECTLY
WIRE MAY HAVE ONE OR
MORE SPLICES OR CONNECTORS
BEFORE IT IS GROUNDED.
----.-2101
TO GENERA TOR
PAGE SA-30-0
17"""""
C103
CONNECTOR REFERENCE
NUMBER FOR COMPONENT
LOCATION UST
LIST ALSO SHOWS TOTAL
NUMBER OF TERMINALS
POSSIBLE. C103 (6 CAVITIES}
1 DK GRN
GROMMET, NUMBERED
FOR REFERENCE.
19
FUSIBLE LINK SIZE AND

INSULATION COLOR
ARE LABELED.
CURRENT PA TH
IS CONTINUED
AS LABELED.
THE ARROW SHOWS
THE DIRECTION OF
CURRENT FLOW
AND IS REPEATED
WHERE CURRENT
PATH CONTINUES.
A WIRE WHICH
CONNECTS TO
ANOTHER CIRCUIT.
THE WIRE IS
SHOWN AGAIN
ON THAT CIRCUIT.
~'""""
TO INSTRUMENT CLUSTER
PAGE SA-81-3
CONNECTOR
AITACHEDTO
COMPONENT
CIRCUIT
BREAKER
SWITCH CONTACTS THAT

MOVE TOGETHER
CONNECTOR ON
COMPONENT
LEAD {PIGTAIL)
DASHED LINE SHOWS

A MECHANICAL
CONNECTION BETWEEN
SWITCH CONTACTS.
3-1
SA -
3-2
SYMBOLS
.5LTBLUt4
.8 YEL
---
INDICATES THIS CIRCUIT

CONTINUES WITHIN DEVICE;
I.E., OTHER BULBS
TWO TERMINALS
IN THE SAME
CONNECTOR
237
C216
r1~--,
DASHED LINE SHOWS

A PHYSICAL
CONNECTION
BETWEEN PARTS
(SAME CONNECTOR).
I
I
I
CD
AN INDICATOR
WHICH DISPLAYS
THE LIGHTED
WORD "BRAKE"
I
I
I
"BRAKE"
INDICATOR
(RED)
~l____ J
ECM CONNECTOR IDENTIFICATION

Cl
BLACK
C2 - BLACK
,
ENGINE
CONTROL
MODULE (ECM)
I
I
~
I~
_....
32WAY
24WAY
'
ELECTROSTATIC DISCHARGE
(ESD) SENSITIVE DEVICES
ARE IDENTIFIED. REFER TO
PAGE SA-3-0 FOR HANDLING
AND MEASURING PROCEDURES.
3 BLK
I;.
/--::::====::--
150
=--...iii
THE CIRCUITRY IS
NOT SHOWN IN
COMPLETE DETAIL
BUT IS COMPLETE ON
THE INDICATED PAGE
__A_J200
1 ORN140
_N_o_G_A_G_E_s~I
WIRE CHOICES
FOR OPTIONS
OR DIFFERENT
MODELS ARE
SHOWN AND
LABELED.
1 1
009
1 ORN
HEATACTUATED
CONTACT
HEATING
ELEMENT
SEE GROUND
DISTRIBUTION
PAGE SA-14-0
INDICATES THAT
40
009
.5 ORN
40
LABEL OF
FUSE BLOCK
CONNECTOR
CAVITY
UNLESS NOTED,
THE RELAY WILL
BE SHOWN INA
DE-ENERGIZED STATE
WITH NO CURRENT
FLOWING THROUGH
THE COIL.
INDICATES THAT
POWER IS
SUPPLIED WITH
IGNITION SWITCH
IN" ACCY" AND
"RUN" POSITIONS
-,FUSE
RADIO
~_USE 4(
10AMP
I ~QQ<_
I
__ _.
WHEN CURRENT FLOWS

THROUGH COIL, CONTACT
WILL TOGGLE.
DIODE
ALLOWS CURRENT
TO FLOW IN ONE
DIRECTION ONLY
0
I
...L..
iFUiSilBiLiEiLltNiK
I
I
V.a
FUSIBLE LINK
CONNECTS TO
SCREW TERMINAL.
SHOWN SEPARATED
V.JM Tv.D
C210
3 CONNECTORS ARE
SHOWN CONNECTED
TOGETHER AT A
JUNCTION BLOCK.
1
~g~~!~E~ :~~0MMDN
CONNECTION ON
BLOCK.
NUMBER FOR TOTAL
CONNECTOR
LETIERS FOR EACH
CONNECTOR TERMINAL
VACUUM JUNCTION
BLUE
3-3
EASY FLOW DIRECTION
B ~ HOSE COLOR
RED
- tzu4==
VA.CUUM
CHECK
IIA~Y!
NO FLOW DIRECTION
VACUUM SOURCE
VENT
MECHANICAL
VACUUM VALVE
t--
IN THE 'AT REST"

POSITION SHOWN,
THE VALVE DOES
THE FOLLOWING:
PORT A IS SEALED.
PORT BIS VENTED
TO THE ATMOSPHERE.
DOUBLE DIAPHRAGM MOTOR

NO VACUUM
---?
VACUUM SOURCE
VENT
SOLENOID
VACUUM
VALVE
WHEN THE VALVE IS

MOVED TO THE
"OPERATED" POSITION,
VACUUM FROM PORT A
IS CONNECTED TO
PORTS.
THE SOLENOID VACUUM
VALVE USES THE
SOLENOID TO MOVE
THE VALVE.
~
NO VACUUM
B
SERVO MOTOR
SINGLE DIAPHRAGM MOTOR
NO VACUUM
VACUUM
Vacuum Motors operate like electrical solenoids,

mechanically pushing or pulling a shaft between two
fixed positions. When vacuum is applied, the shaft is
pulled in. When no vacuum is applied, the shaft is
pushed all the way out by a spring.
Double Diaphragm Motors can be operated by

vacuum in two directions. When there is no vacuum,
the motor is in the center "at rest" position.
Some Vacuum Motors such as the Servo Motor in
the Cruise Control can position the actuating arm at
any position between fully extended and fully
retracted. The servo is operated by a control valve that
applies varying amounts of vacuum to the motor. The
higher the vacuum level, the greater the retraction of
the motor arm. Servo Motors work like the two
position motors; the only difference is in the way the
vacuum is applied. Servo Motors are generally larger
and provide a calibrated control.
SA.-
4- 0
TROUBLESHOOTING PROCEDURES
BASIC KNOWLEDGE REQUIRED
Without a basic knowledge of electricity, it will be
difficult to use the diagnostic procedures contained in
this section. You should understand the basic theory
of electricity and know the meaning of voltage, current
(amps) and resistance (ohms). You should understand
what happens in a circuit with an open or a shorted
wire. You should be able to read and understand a
wiring diagram.
The following four-step troubleshooting procedure
is recommended:
Step 2: Read the Electrical Schematic
Study the schematic. Read the Circuit Operation

text if you do not understand how the circuit should
work. Check circuits that share wiring with the
problem circuit. (Shared circuits are shown on Power
Distribution, Ground Distribution, Fuse Block Details
and Light Switch Details pages.) Try to operate the
shared circuits. If the shared circuits work, then the
shared wiring is OK. The cause must be within the
wiring used only by the problem circuit. If several
circuits fail at the same time, chances are the power
(fuse) or ground circuit is faulty.
Step 1: Check the Problem

Step 3: Find the fault and repair
Perform a System Check to determine a symptom.

Don't waste time fixing part of the problem! Do not
begin disassembly or testing until you have narrowed
down the possible causes.
HEADLIGHTS
Narrow down the possible causes.

Use the Troubleshooting Hints.
Make the necessary measurements or checks
as given in the System Diagnosis.
-------1-,,-
CIRCUIT BREAKER
HEAD
OFF
HEAD
~s.~
HEADLIGHT
SW!~
OFF
SEE PAGE 8A30

FOR MEASURING
AND HANDLING
PROCEDURES
,
RK
...,;RK
L
_ .!. r ~_____
4j; __ .J,
v;f
o
HEADLIGHT
DIMMER
~\!\(ITCH
.8LTGRN
1 TAN
11
r D- - - - - ,
12
I
I
HIGH BEAM
INDICATOR
INSTRUMENT
I CLUSTEll.
I J~
,.
I~
L ___ ::_.J
SEE GROUND
DISTRIBUTION
PAGE 8A-14-4
.ss~Klso
~--S205
3 BLK 1150
----2200
Figure 1 - Typical Headlights Schematic
Before replacing a component, check power,

signal and ground wires at the component
harness connector. If the checks and
connections are OK, the most probable cause is
component failure.
Step4: Test the Repair
Repeat the System Check to verify the fault has

been corrected and that no other faults were induced
during the repair.
Example:
A customer brings in a vehicle and says that the

HI beams do not work.
Step 1: Perform a System Check on the Headlight
Circuit. You may discover that both LO beams operate.
In "HI," you may notice that the HI Beam Indicator

comes on, but neither HI beam operates.
Step 2:
4-1
Step 3: Find the fault and repair it. Using the

Component Location List and the corresponding
figure, you can quickly find C 100 and the LT G RN
wire, locate the exact trouble point and make the
repair.
Step 4: Check the repair by performing a System
Check on the Headlights Circuit. This, of course,
means making sure that both HI beams, both LO

beams and the HI Beam Indicator are all working.
Now suppose that the symptoms were different.
You may have operated the Headlamps and found that
the LO beams were working, but neither the HI beams
nor the HI Beam Indicator were working. Looking at
the schematic, you might conclude that it is unlikely
that both HI beam filaments and the HI Beam
Indicator have all burned out at once. The cause is
probably the Headlight Dimmer Switch or its
connector.
Read the Headlights Electrical Schematic, see
Figure 1. This is the step that will save time and

labor. Remember, it is essential to understand how a
circuit should work, before trying to figure out why it
doesn't.
TROUBLESHOOTING TOOLS
Electrical troubleshooting requires the use of
common electrical test equipment.
TEST LIGHT/VOLTMETER
After you understand how the circuit should

operate, read the schematic again, this time keeping in
mind what you have learned by operating the circuit.
Since both LO beams work, you know that the
Headlight Switch, the YEL wire, the LO contacts of
the Headlight Dimmer Switch, terminal "lE" of C 100,
the TAN wires and grounds Gl05 and Gl09 are all
good.
Furthermore, since you saw that the HI Beam
Indicator came on when the Headlight Dimmer Switch
was moved to "HI," you know that the HI contacts of
the Headlight Dimmer Switch and the LT GRN wire
between the Headlight Dimmer Switch and ClOO are
good.
At this point, you could test for voltage at the RH
Headlamp with the Headlight Dimmer Switch in "HI."
However, it is extremely unlikely that the HI beam
filaments have burned out in both headlamps, or that
both headlamps connections are bad. The cause must
be a bad connection at C 100, or a break in the LT GRN
wire between ClOO and the RH Headlamp.
You have quickly narrowed the possible causes
down to one specific area, and have done absolutely no
work on the vehicle itself.
Use a test light to check for voltage. A Test Light

(J 34142-B) is made up of a 12 volt light bulb with a
pair of leads attached. After grounding one lead, touch

the other lead to various points along the circuit where
voltage should be present. When the bulb goes on,
there is voltage at the point being tested.
A voltmeter can be used instead of a test light.
While a test light shows whether or not voltage is
present, a voltmeter indicates how much voltage is
present.
An increasing number of circuits include solid
state control modules. One example is the Engine
Control Module (ECM). Voltages in these circuits
should be tested only with a IO-megohm or
higher impedance digital voltmeter or multimeter
(J 39200). Unless directed to within the diagnostics,
never use a test light on circuits that contain solid
state components, since damage to these components
may result.
BA - 4 - 2 ELECTRICAL DIAGNOSIS
When testing for voltage or continuity at the
connection, it is not necessary to separate the two
halves of the connector. Unless testing a Weather
Pack connector, always probe the connector from the
back. Always check both sides of the connector. An
accumulation of dirt and corrosion between contact
surfaces is sometimes a cause of electrical problems. A
terminal contact checking procedure can be found on
page SA-4-6.
CONNECTOR TEST ADAPTERS
Connector Test Adapter Kit (J 35616-A) is

available for making tests and measurements at
separated connectors. This kit contains an assortment
of probes which mate with many of the types of
terminals you will see. Avoid using paper clips and
other substitutes since they can damage terminals and
cause incorrect measurements.
Diodes and solid state components in a circuit can

cause an ohmmeter to give a false reading. To find out
if a component is affecting a measurement, take a
reading once, reverse the leads and take a second
reading. If the readings differ, the solid state
component is affecting the measurement.
FUSED JUMPER WIRE
A fused jumper (J 36169) is available with small

clamp connectors providing adaptation to most
connectors without damage. This fused jumper wire is
supplied with a 20 amp fuse which may not be suitable
for some circuits. Do not use a fuse with a higher
rating than the fuse that protects the circuit being
tested.
NOTICE: A fused jumper may not protect solid

state components from being damaged.
SELF-POWERED TEST LIGHT
SHORT FINDER
A self-powered test light (J 21008-A) can be used to

check for continuity. This tool is made up of a light
bulb, Battery and two leads. If the leads are touched
together, the bulb will go on.
A self-powered test light is used only on an
unpowered circuit. First remove the fuse which feeds
the circuit you're working on. Select two specific
points along the circuit through which there should be
continuity. Connect one lead of the self-powered test
light to each point. If there is continuity, the test light
circuit will be completed and the bulb will go on.
Never use a self-powered test light on circuits that
contain solid state components, since damage to these
components may result.
Short Finders (J 8681-A) are available to locate

hidden shorts to ground. The short finder creates a
pulsing magnetic field in the shorted circuit and shows
you the location of the short through body trim or
sheet metal.
A simple tester (J 34764) can detect a blown fuse.

To check a fuse, the tester is applied directly to the
fuse in the Fuse Block. Two probes contact the fuse,
either into the slots of a flat fuse or to the metal ends of
a glass fuse. With power on, a red LED in the tester
lights if the fuse is open. The handle of the tester is a
tool for removing either type of fuse.
OHMMETER
TROUBLESHOOTING TESTS
An ohmmeter can be used instead of a self-powered

test light. The ohmmeter shows how much resistance
there is between two points along a circuit. Low
resistance means good continuity.
Circuits which include any solid state control
modules, such as the Engine Control Module (ECM),
should be tested only with a 10-megohm or higher
impedance digital multimeter (J 39200).
When measuring resistance with a digital
multimeter, the vehicle Battery should be
disconnected. This will prevent incorrect readings.
Digital meters apply such a small voltage to measure
resistance that the presence of voltages can upset a
resistance reading.
Always check for aftermarket accessories (non

OEM) as the first step in diagnosing electrical
problems. If the vehicle is so equipped, disconnect the
system to verify that these add-on accessories are not
the cause of the problems.
Some possible causes of vehicle problems related to
aftermarket accessories include:
I. Power feeds connected to points other than the
Battery.
2. Antenna location.
3. Transceiver wiring located too close to vehicle
electronic modules or wiring.
4. Poor shielding or poor connectors on antenna
feedline.
FUSE TESTER
Refer to 1990/1991 model year bulletin entitled,

"Installation Guidelines for Aftermarket Accessories"
for specific information.
4 -3
After backprobing any connector, al ways check for

terminal damage. If terminal damage is suspected,
check for proper terminal contact, refer to "Checking
Terminal Contact," page 8A-4-6.
PROBING
After probing, when reconnecting connectors or

replacing terminals, always be sure to reinstall
Connector Position Assurance (CPA) and Terminal
Position Assurance (TPA).
TESTING FOR VOLTAGE (Figure 2)

1. Connect one lead of a test light to a known good
2.
Fron1probe
When frontprobing of connectors is required,

always use a mating terminal adapter from Connector
Test Adapter Kit (J 35616-A). The use of proper
adaptors will ensure that proper terminal contact
integrity is maintained. For a terminal contact
checking procedure, refer to page 8A-4-6.
Backprobe
Only backprobe connector terminals when

specifically called for in diagnostic procedures. Since
backprobing can be a source of damage to connector
terminals, extra care must be taken to a void
deforming the terminal, either by forcing the test
probe too far into the cavity or by using too large a test
probe.
3.
ground. When using a voltmeter, be sure the

voltmeter's negative lead is connected to ground.
Connect the other lead of the test light or
voltmeter to a selected test point (connector or
terminal).
If the test light illuminates, there is voltage
present. When using a voltmeter, note the voltage
reading.
TESTING FOR CONTINUITY (Figure 3)
1. Remove the fuse to the circuit involved.

2. Connect one lead of a self-powered test light or
ohmmeter to one end of the part of the circuit you
wish to test.
3. Connect the other lead to the other end of the
circuit.
4. If the self-powered test light glows, there is
continuity. When using an ohmmeter, low or no
resistance means good continuity.
HOT AT ALL TIMES

FUSE
BLOCK
.,,.-- ....
ON
SELF
POWERED
BLOWER
SWITCH
LIGHT
OHMMETER)
Figure 2 - Voltage Check
Figure 3 Continuity Check through a Switch
SA -
4 -4
HOT AT ALL TIMES

FUSE
BLOCK
RED
(+)
'-1.../
(-)
[ZJ~'""
Ur""
-
I:'"
[]'.'"'"
LOAD
DISCONNECTED
lBLU
[]'""'0"
Figure 5 - Testing for Short with Test Light

or Voltmeter
Figure 4 - Voltage Drop Test
TESTING FOR VOLTAGE DROP (Figure 4)
This test checks for voltage being lost along a wire,

or through a connection or switch.
1. Connect the positive lead of a voltmeter to the end
of the wire (or to one side of the connection or
switch) which is closer to the Battery.
2. Connect the negative lead to the other end of the
wire (or the other side of the connection or switch).
3. Operate the circuit.
4. The voltmeter will show the difference in voltage
between the two points.
TESTING FOR SHORT TO GROUND

With a Test Light or Voltmeter (Figure 5)
1.
2.
Remove the .blown fuse and .disconnect the load.

Connect a test light or voltmeter across the fuse
terminals (be sure that the fuse is powered).
3. Beginning near the Fuse Block, wiggle the harness
from side to side. Continue this at convenient
points (about 6 inches apart) while watching the
test light or voltmeter.
4. When the test light glows, or the voltmeter
registers, there is a short to ground in the wiring
near that point.
4- 5
With a Self-Powered Test Light or Ohmmeter

(Figure 6)
1.
2.
3.
4.
5.
Remove the blown fuse and disconnect the Battery

and load.
Connect one lead of a self-powered test light or
ohmmeter to the fuse terminal on the load side.
Connect the other lead to a known good ground.
Beginning near the Fuse Block, wiggle the harness
from side to side. Continue this at convenient
points (about 6 inches apart) while watching the
self-powered test light or ohmmeter.
When the self-powered test light glows, or the
ohmmeter registers, there is a short to ground in
the wiring near that point.
BATTERY DISCONNECTED
FUSE
BLOCK
(FUSE
REMOVED)
SELFPOWERED
[ZJ'w"'".
LIGHT
(OR
OHMMETER)
Fuses Powering Several Loads
1.
2.
3.
4.
Find the schematic in "Fuse Block Details," page

8A-11-0 for the fuse that has blown.
Open the first connector or switch leading from the
fuse to. each load.
Replace the fuse.
If the fuse blows, the short is in the wiring
leading to the first connector or switch. Use a
test light or meter as described on previous
page.
If fuse does not blow, refer to next step.
Close each connector or switch until the fuse blows
in order to find which circuit has the short.
Connect test lamp or meter at the connector to the
suspect circuit (disconnected) rather than at the
fuse terminals.
Figure 6 - Testing for Short with Self-Powered

Test Light or Ohmmeter
JUMi> STARTING PROCEDURE
Refer to SECTION 6D- l for jump starting

procedure.
INTERMITTENTS AND POOR CONNECTIONS

Most intermittents are caused by faulty electrical
connections or wiring, although occasionally a sticking
relay or solenoid can be a problem. Some items to
check are:
Poor mating of connector halves, or terminals
not fully seated in the connector body (backed
out).
Dirt or corrosion on the terminals. The
terminals must be clean and free of any foreign
material which could impede proper terminal
contact.
LU
LOAD
DISCONNECTED
Damaged connector body, exposing the

terminals to moisture and dirt, as well as not
maintaining proper terminal orientation with
the component or mating connector.
Improperly formed or damaged terminals. All
connector terminals in problem circuits should
be checked carefully to ensure good contact
tension. Use a corresponding mating terminal
to check for proper tension. Refer to "Checking
Terminal Contact" in this section for the
specific procedure.
The J 35616-A Connector Test Adapter Kit
must be used whenever a diagnostic procedure
requests checking or probing a terminal.
Using the adapter will ensure that no damage
to the terminal will occur, as well as giving an
idea of whether contact tension is sufficient. If
contact tension seems incorrect, refer to
"Checking Terminal Contact" in this section
for specifics.
8A -
4 -6
Poor terminal-to-wire connection. Some

conditions which fall under this description
are poor crimps, poor solder joints, crimping
over wire insulation rather than the wire
itself, corrosion in the wire-to-terminal contact
area, etc.
Wire insulation which is rubbed through,
causing an intermittent short as the bare area
touches other wiring or parts of the vehicle.
Wiring broken inside the insulation. This
condition could cause a continuity check to
show a good circuit, but if only 1 or 2 strands of
a multi-strand-type wire are intact, resistance
could be far too high.
To avoid any of the above problems when making
wiring or terminal repairs, always follow the
instructions for wiring and terminal repair outlined in
SECTION 8A-5.
CHECKING TERMINAL CONTACT

When diagnosing an electrical system that utilizes
Metri-Pack 150/280/480/630 series terminals (refer to
Terminal Repair Kit, J 38125-A, instruction manual,
J 38125-4 for terminal identification), it is important
to check terminal contact between a connector and
component, or between in-line connectors, before
replacing a suspect component.
Frequently, a diagnostic chart leads to a step that
reads: "Check for poor connection." Mating terminals
must be inspected to assure good terminal contact. A
poor connection between the male and female terminal
at a connector may be the result of contamination or
deformation.
Contamination is caused by the connector halves
being improperly connected, a missing or damaged
connector seal, or damage to the connector itself,
exposing the terminals to moisture and dirt.
Contamination, usually in underhood or underbody
connectors, leads to terminal corrosion, causing an
open circuit or intermittently open circuit.
Deformation is caused by probing the mating side
of a connector terminal without the proper adapter,
improperly joining the connector halves or repeatedly
separating and joining the connector halves.
Deformation, usually to the female terminal contact
tang, can result in poor terminal contact, see figure 7,
causing an open or intermittently open circuit.
Follow the procedure below to check terminal

contact.
1. Separate the connector halves. Refer to
Terminal Repair Kit, J 38125-A, instruction
manual, J 38125-4.
2. Inspect the connector halves for
contamination. Contamination will result in a
white or green build-up within the conrrector
body or between terminals, causing high
terminal resistance, intermittent contact or an
open circuit. An underhood or underbody
connector that shows signs of contamination
should be replaced in its entirety: terminals,
seals and connector body.
3. Using an equivalent male terminal from the
Terminal Repair Kit, J 38125-A, check the
retention force of the female terminal in
question by inserting and removing the male
terminal to the female terminal in the
connector body. Good terminal contact will
require a certain amount of force to separate
the terminals.
4. Using an equivalent female terminal from the
Terminal Repair Kit, J 38125-A, compare the
retention force of this terminal to the female
terminal in question by joining and separating
the male terminal to the good female terminal,
and then joining and separating the male
terminal to the female terminal in question. If
the retention force is significantly different
between the two female terminals, replace the
female terminal in question, refer to Terminal
Repair Kit, J 38125-A.
If a visual (physical) check does not reveal the
cause of the problem, the vehicle may be able to be
driven with a DVM connected to the suspected circuit.
An abnormal voltage reading when the problem occurs
indicates the problem may be in that circuit.
d ABOUT EQUAL TO 0, GOOD TERMINAL CONTACT
d MUCH GREATER THAN 0, POOR TERMINAL CONTACT
OJ TYPICAL METRI-PACK 150/280/480/630 SERIES FEMALE TERMINAL

(150 SERIES PUSH-TO-SEAT SHOWN)
[I]
CONTACT TANG
[I]
AMOUNT OF DEFORMATION
Figure 7 - Deformation of a Typical Metri-Pack 150/280/480/630 Series Female Terminal
SA -
4 -8
DETECTING ELECTRICAL INTERMITTENTS
Use the following procedure to detect intermittent
terminal contact or a broken wire with an intermittent
connection inside the insulation.
The J 39200 Digital Multimeter has the ability to
monitor current, resistance, or voltage while recording
the minimum (MIN) and maximum (MAX) values
measured. The meter can also be set to display the
average (AVG) value measured.
When diagnosing circuits that have voltage
applied, use the voltage setting to monitor a connector
(or length of a circuit) which is suspected of having an
intermittent connection but is currently operating
normally.
1. Connect the J 39200 Digital Multimeter to
both sides of a suspect connector (still
connected) or from one end of a suspect circuit
to the other. This will continuously monitor
the terminal contacts or length of wire being
checked. See "Meter Connections" for
examples of the various methods for
connecting the meter to the circuit.
2. Set the meter for voltage. Since the "MIN
MAX" mode does not use auto ranging,
manually select the voltage range necessary
before proceeding.
3. Press the "MIN MAX" button. The meter
should read "100 ms RECORD" (100
millisecond record) and emit a 1/4 second beep.
The meter is now ready to record and will
generate an audible tone for any change in
voltage. At this point, you may wish to press
the "PEAK MIN MAX" button, which will
record any voltage variations that occur for at
least 1 millisecond.
4. Try to simulate the condition that is
potentially causing an intermittent
connection, either by wiggling connections or
wiring, test driving or performing other
operations. If an open or resistance is created,
a voltage will be present and the meter will
emit a tone for as long as the open or resistance
exists. Any change in voltage will cause the
meter to emit a tone for no less than l/4 second.
(Listening for a tone while manipulating
wiring is very helpful for narrowing in on an
intermittent connection.)
rn
Use the MIN and MAX values when the meter

is out of sight or sound range, in noisy areas or
for test driving when it may not be possible to
monitor the meter.
To check the MIN and MAX recorded voltages
press "MIN MAX" once for MAX and twice for
MIN. A variation between :VUN and MAX
recorded voltages (unless nearly O volts)
suggests an intermittent open or resistance
exists and should be repaired as necessary.
Refer to SECTION SA-5 of any current GM
Service Manual for approved repair
procedures.
Important:
The "100 ms RECORD" (100 millisecond record)
mode is NOT the amount of time allowed to
perform a specific procedure. It is the amount of
time used to record each snapshot of information
used for calculating "A VG" when in the "MIN
MAX"mode.
METER CONNECTIONS
The previous diagnostic procedure was written to
detect intermittents using the meter set to voltage.
Whether using the current, voltage or resistance
setting to detect intermittents, it is necessary to
connect the meter to the circuit.
Following are examples of the various methods of
connecting the meter to the circuit to be checked:
Backprobe both ends of the connector and
either hold the leads in place while
manipulating the connector or tape the leads
to the harness for continuous monitoring while
performing other operations or test driving.
(Do not backprobe "Weather Pack" type
connectors.)
Disconnect the harness at both ends of the
suspect circuit where it connects either to a
component or to other harnesses.
Use Connector Test Adapter Kit J 35616-A to
connect the meter to the circuit.
If the system being diagnosed has a specified
pinout or breakout box, it may be used to
simplify connecting the meter to the circuit or
for checking multiple circuits quickly.
ELECTRICAL DIAGNOSIS 8A-4- 9
ADDITIONAL INFORMATION
NOTICE: Turn off power to the test circuit before
attempting in-circuit resistance measurements to
prevent false readings or damage to the meter. Do
not use the meter to measure resistance through a
solid state module.
Continuity tests that work well for detecting
intermittent shorts to ground can be performed by
setting the meter to ohms then pressing the "PEAK
MIN MAX" button. An audible tone will be heard
whenever the meter detects continuity for at least 1
millisecond.
The J 39200 Instruction Manual is a good source of
information and should be read thoroughly upon
receipt of the meter as well as kept on hand for
reference during new procedures.
SA - 5 - 0 ELECTRICAL DIAGNOSIS
REPAIR PROCEDURES
ELECTRICAL REPAIRS
CYCLING CIRCUIT BREAKER
This section provides instruction in the following

repairs:
Circuit Protection
Typical Electrical Repairs
Splicing Copper Wire
Splicing Twisted/Shielded Cable
Repairing Connectors (Except Weather Pack)
Repairing Weather Pack (Environmental)
Connectors
Terminal Repair
The cycling breaker will open due to heat

generated when excessive current passes through it for
a period of time. Once the circuit breaker cools, it will
close again after a few seconds. If the cause of the high
current is still present it will open again. It will
continue to cycle open and closed until the condition
causing the high current is removed.
After any electrical repair is made, always test the

circuit afterwards by operating the devices in the
circuit. This confirms not only that the repair is
correct, but also, that it was the cause of the complaint.
CIRCUIT PROTECTION
The purpose of circuit protection is to protect the
wiring assembly during normal and overload
conditions. An overload is defined as a current
requirement that is higher than normal. This
overload could be caused by a short circuit or system
malfunction. The short circuit could be the result of a
pinched or cut wire or an internal device short circuit,
such as an electronic module failure.
The circuit protection device is only applied to
protect the wiring assembly, and not the electrical load
at the end of the assembly. For example, if an
electronic component short circuits, the circuit
protection device will assure a minimal amount of
damage to the wiring assembly. However, it will not
necessarily prevent damage to the component.
CIRCUIT PROTECTION DEVICES

There are three basic types of circuit protection
devices: Circuit Breaker, Fuse and Fusible Link.
CIRCUIT BREAKERS
A circuit breaker is a protective device designed to
open the circuit when a current load is in excess of
rated breaker capacity. If there is a short or other type
of overload condition in the circuit, the excessive
current will open the circuit between the circuit
breaker terminals. There are two basic types of circuit
breakers used m GM vehicles:
cycling and
non-cycling.
NON-CYCLING CIRCUIT BREAKER
There are two types of non-cycling circuit

breakers. One type is mechanical and is nearly the
same as a cycling breaker. The difference is a small
heater wire within the non-cycling circuit breaker.
This wire provides enough heat to keep the bimetallic
element open until the current source is removed.
The other type is solid state, called out in this
section as Electronic Circuit Breaker (ECB). This
device has a Positive Temperature Coefficient. It
increases its resistance greatly when excessive current
passes through it. The excessive current heats the
ECB. As it heats, its resistance increases, therefore
having a Positive Temperature Coefficient.
Eventually the resistance gets so high that the circuit
is effectively open. The ECB will not reset until the
circuit is opened, removing voltage from its terminals.
Once voltage is removed, the circuit breaker will
re-close within a second or two.
FUSES
The most common method of automotive w1nng
circuit protection is the fuse (Figure 1). A fuse is a
device that, by the melting of its element, opens an
electrical circuit when the current exceeds a given
level for a sufficient time. The action is non-reversible
and the fuse must be replaced each time a circuit is
overloaded or after a malfunction is repaired.
Fuses are color coded. The standardized color
identification and ratings are shown in Figure 2. For
service replacement, non-color coded fuses of the same
respective current rating can be used.
Examine a suspect fuse for a break in the element.
If the element is broken or melted, replace the fuse
with one of equal current rating.
There are additional specific circuits with in-line
fuses. These fuses are located within the individual
wiring harness and will appear to be an open circuit if
blown.
AUTO FUSE
The Autofuse, normally referred to simply as

"Fuse," is the most common circuit protection device in
today's vehicle. The Autofuse is most often used to
protect the wiring assembly between the Fuse Block
and the system components.
MAXI FUSE
The Maxifuse was designed to replace the fusible

link and Pacific Fuse Elements. The Maxifuse is
designed to protect cables, normally between the
Battery and Fuse Block, from both direct short circuits
and resistive short circuits.
Compared to a fusible link or a Pacific Fuse
Element, the Maxifuse performs much more like an
Autofuse, although the average opening time is
slightly longer. This is because the Maxifuse was
designed to be a slower blowing fuse, with less chance
of nuisance blows.
AUTOFUSE
CURRENT RATING
COLOR
3
5
7.5
10
15
20
25
30
VIOLET
TAN
BROWN
RED
BLUE
YELLOW
NATURAL
GREEN
MAXI FUSE
CURRENT RATING
COLOR
20
30
40
50
60
70
80
YELLOW
~TOP
GREEN
AMBER
RED
BLUE
BROWN
NATURAL
MINIFUSE
CURRENT RATING
SIDE
Fuse Element
Maxifuse
5
7.5
10
15
20
25
30
COLOR
TAN
BROWN
RED
BLUE
YELLOW
WHITE
GREEN
PACIFIC FUSE ELEMENT
a
Autofuse
Minifuse
Figure 1 - Fuse Devices
CURRENT RATING
COLOR
30
40
50
60
PINK
GREEN
RED
YELLOW
Figure 2 - Fuse Rating and Color
5-1
SA -
REPAIR PROCEDURES
MINI FUSE
The Minifuse is a smaller version of the Autofuse

and has a similar performance. As with the Autofuse,
the Minifuse is usually used to protect the wiring
assembly between a Fuse Block and system
components. Since the Minifuse is a smaller device, it
allows for more system specific fusing to be
accomplished within the same amount of space as
Auto fuses.
PACIFIC FUSE ELEMENT/MAXI FUSE
The Pacific Fuse Element and Maxifuse were

developed to be a replacement for the fusible link.
Like a fusible link, the fuses are designed to protect
wiring from a direct short to ground. These elements
are easier to service and inspect than a fusible link and
will eventually replace fusible links in all future
vehicle applications.
FUSIBLE LINKS
In addition to circuit breakers and fuses, some

circuits use fusible links to protect the wiring. Like
fuses, fusible links are "one-time" protection devices
that will melt and create an open circuit (see Figure 3).
Not all fusible link open circuits can be detected by
observation. Always inspect that there is battery
voltage past the fusible link to verify continuity.
Fusible links are used instead of a fuse in wiring
circuits that are not normally fused, such as the
ignition circuit. For AWG sizes, each fusible link is
four wire gage sizes smaller than the wire it is
designed to protect. For example: to protect a 10 gage
wire use a 14 gage link or for metric, to protect a 5 mm~
wire use a 2 mm 2 link (see Figure 6). Links are
marked on the insulation with wire-gage size because
the heavy insulation makes the link appear to be a
heavier gage than it actually is. The same wire size
fusible link must be used when replacing a blown
fusible link.
Fusible links are available with three types of
insulation: Hypalon, Silicone/GXL (SIL/GXL) and
Expanded Duty. All future vehicles that use fusible
links will utilize the Expanded Duty type of fusible
link. When servicing fusible links, all fusible links
can be replaced with the Expanded Duty type.
SIL/GXI fusible links can be used to replace either
SIL/GXI or Hypalon fusible links. Hypalon fusible
links can only be used to replace Hypalon fusible
links.
Determining characteristics of the types of fusible

links:
Hypalon (limited use): only available in
.35 mm 2 or smaller and its insulation is one
color all the way through.
SIL/GXL (widely used): available in all sizes
and has a white inner core under the outer
color of insulation.
Expanded Duty: available in all sizes, has an
insulation that is one color all the way through
and has three dots following the writing on the
insulation.
Service fusible links are available in many
lengths. Choose the shortest length that is suitable. If
the fusible link is to be cut from a spool, it should be
cut 150-225 mm (approx 6-9 in.) long. NEVER make a
fusible link longer than 225 mm (approx 9 in.).
CAUTION: Fusible links cut longer than

225 mm (approx 9 in.) will not provide
sufficient overload protection.
CONNECTOR COVERING
FUSIBLE LINK BEFORE SHORT CIRCUIT
BROKEN CIRCUIT
INSIDE INSULATION
FUSIBLE LINK AFTER SHORT CIRCUIT
Figure 3 Good and Damaged Fusible links
To replace a damaged fusible link (Figure 4), cut it

off beyond the splice. Replace with a repair link.
When connecting the repair link, strip wire and use
staking-type pliers to crimp the splice securely in two
places. For more details on splicing procedures, see
"Splicing Copper Wire." Use Crimp and Seal splices
whenever possible. When using Splice Clips, refer to
page 8A-5-3; when using Crimp and Seal splice
sleeves, refer to page 8A-5-6.
To replace a damaged fusible link which feeds two
harness wires, cut them both off beyond the splice.
Use two repair links, one spliced to each harness wire
(see Figure 5).
TYPICAL ELECTRICAL REPAIRS

An open circuit is an incomplete circuit. Power
cannot reach the load or reach ground. If a circuit is
open, active components do not energize. A short
circuit is an unwanted connection between one part of
the circuit and either ground or another part of the
circuit. A short circuit causes a fuse to blow or a
circuit breaker to open.
SHORT CIRCUITS CAUSED BY DAMAGED WIRE

INSULATION
Locate the damaged wire.

Find and correct the cause of the wire insulation
damage.
For minor damage, tape over the wire. If damage
is more extensive, replace the faulty segment of
the wire (Refer to the splicing instructions for
copper or shielded cable for the correct splicing
procedure).
SPLICING COPPER WIRE USING SPLICE CLIPS

Splice Clips are included in the J 38125-A
Terminal Repair Kit. The Splice Clip is a general
purpose wire repair device. It may not be acceptable
for applications having special requirements such as
moisture sealing. Refer to the appropriate Service
Manual Section to determine if there are any special
requirements.
DAMAGED
FUSIBLE
LINK
CUT HERE
CUT HERE
TERMINAL
TERMINAL
REPAIR LINK
SPLICE
SPLICE
ONE HARNESS
WIRE (RED)
ONE HARNESS
WIRE (RED)
Figure 4 - Single Wire Feed Fusible Link
5-3
I
.~
HARNESS
WIRES (RED)
REPAIR LINKS
@::,
HARNESS
WIRES (RED)
Figure 5 Double Wire Feed Fusible Link
:.,
SA -
5-4
REPAIR PROCEDURES
Step 1: Open the Harness
If the harness is taped, remove the tape. To avoid

wire insulation damage, use a sewing "seam ripper" to
cut open the harness (available from sewing supply
stores). If the harness has a black plastic conduit,
simply pull out the desired wire.
Step 2: Cut the Wire
Begin by cutting as little wire off the harness as

possible. You may need the extra length of the wire
later if you decide to cut more wire off to change the
location of a splice. You may have to adjust splice
locations to make certain that each splice is at least
40 mm (1 t") away from other splices, harness branches
or connectors.
Step 3: Strip the Insulation
When replacing a wire, use a wire of the same size

as the original wire or larger. The schematics list wire
size in metric units. The following table (Figure 6)
shows the commercial (A WG) wire sizes that can be
used to replace each metric wire size. Each A WG size
is either equal to or larger than the equivalent metric
size.
To find the correct wire size either find the wire on
the schematic page and convert the metric size to the
A WG size, or use an A WG wire gage.
If you aren't sure of the wire size, start with the
largest opening in the wire stripper and work down
until a clean strip of the insulation is removed. Be
careful to avoid nicking or cutting any of the wires.
METRIC WIRE
SIZES (mm 2 )
.22
.35
.5
.8
1.0
2.0
3.0
5.0
8.0
13.0
19.0
32.0
AWG SIZES
24
22
20
18
16
14
12
10
8
6
4
2
Figure 6 Wire Size Conversion Table
Figure 7 Centering the Splice Clip
Step 4: Crimp the Wires
Select the proper clip to secure the splice. To

determine the proper clip size for the wire being
spliced, follow the directions included in the J 38125-A
Terminal Repair Kit. Select the correct anvil on the
crimper. On most crimpers your choice is limited to
either a small or large anvil. Overlap the stripped
wire ends and hold them between your thumb and
forefinger as shown in Figure 7. Then, center the
splice clip under the stripped wires and hold it in place.
Open the crimping tool to its full width and rest
one handle on a firm t1at surface.
Center the back of the splice clip on the proper
anvil and close the crimping tool to the point
where the former touches the wings of the clip.
Make sure that the clip and wires are still in the
correct position. Then, apply steady pressure until
the crimping tool closes (see Figure 8).
Before crimping the ends of the clip, be sure that:
The wires extend beyond the clip in each
direction.
No strands of wire are cut loose, and
No insulation is caught under the clip.
Crimp the splice again, once on each end. Do not
let the crimping tool extend beyond the edge of the clip
or you may damage or nick the wires (Figure 9).
existing wires. Do not flag the tape. Flagged tape may

not provide enough insulation, and the flagged ends
will tangle with the other wires in the harness (see
Figure 11).
If the wire does not belong in a conduit or other
harness covering, tape the wire again. Use a winding
motion to cover the first piece of tape (Figure 12).
Step 5: Solder
Apply 60/40 rosin core solder to the opening in the

back of the clip (see Figure 10). Follow the
manufacturer's instruction for the solder equipment
you are using.
SPLICE CLIP
Step 6: Tape the Splice
Center and roll the splicing tape. The tape should

cover the entire splice. Roll on enough tape to
duplicate the thickness of the insulation on the
ALIGN TOOL WITH EDGE OF CLIP

TO CRIMP ENDS OF SPLICE
WINGS OF CLIP
TOUCHING
FORMER
Figure 9 - Completing the Crimp
Figure 8 - Crimping the Splice Clip
5-5
Figure 10 - Applying the Solder
SA 5 6 ELECTRICAL DIAGNOSIS
REPAIR PROCEDURES
SPLICING COPPER WIRE USING CRIMP AND
SEAL SPLICE SLEEVES
Crimp and Seal splice sleeves may be used on all
types of insulation except tefzel and coaxial to form a
one to one splice. They are to be used where there are
special requirements such as moisture sealing. Refer
to the appropriate section of the Service Manual to
determine if the Crimp and Seal is necessary. Crimp
and Seal splice sleeves are included in the J 38125-A
Terminal Repair Kit.
GOOD (ROLLED)

wire insulation damage, use a sewing "seam ripper" to
cut open the harness (available from sewing supply
stores). The Crimp and Seal splice sleeves may be used
on all types of insulation except tefzel and coaxial and
may only be used to form a one to one splice.
Step 2: Cut the Wire

possible. Yoti may need the extra length of wire later
if you decide to cut more wire to change the location of
a splice. You may have to adjust splice locations to
make certain that each splice is at least 40 mm (1.5 in.)
away from other splices, harness branches or
connectors. This will help prevent moisture from
bridging adjacent splices and causing damage.
BAD (FLAGGED)
Figure 11 Proper First Taping
~ - - S--s.)= =
TAPE AGAIN IF NEEDED
Figure 12 Proper Second Taping
If it is necessary to add a length of wire to the

existing harness, be certain to use the same size as the
original wire (refer to Figure 6, "Wire Size Conversion
Table").
the schematic and convert the metric size to the
equivalent AWG size or use an AWG wire gage. If
unsure about the wire size, begin with the largest
opening in the wire stripper and work down until a
clean strip of the insulation is removed. Strip
approximately 7.5 mm (5/16 in.) of insulation from
each wire to be spliced. Be careful to avoid nicking or
cutting any of the wires. Check the stripped wire for
nicks or cut strands. If the wire is damaged, repeat
this procedure after removing the damaged section.
5-7
Step 4: Select and Position the Splice Sleeve

Select the proper splice sleeve according to wire
size. The splice sleeves and tool nests are color coded
(see following chart).
CRIMP AND SEAL SPLICE SLEEVE CHART

Color splice
sleeve
Crimp tool
nest color
Wire gage
AWG I (metric)
Salmon
(yellowish-pink)
Red
20, 18/
(0.5, 0.8)
Blue
Blue
16, 14/
(1.0, 2.0)
Yellow
Yellow
12, 10/
(3.0, 5.0)
'stop
a. Splice before crimping
b. Splice after crimping

hsealant==l
c. Splice after heating
RED FILL
BLUE FILL
YELLOW FILL
Figure 13 - Hand Crimp Tool
Using the J 38125-8 splice crimp tool (Figure 13),

position the splice sleeve in the proper color nest of the
hand crimp tool. Place the splice sleeve in the nest so
that the crimp falls midway between the end of the
barrel and the stop.
The sleeve has a stop in the middle of the barrel to
prevent the wire from going further (Figure 14). Close
the hand crimper handles slightly to hold the splice
sleeve firmly in the proper nest.
Figure 14- Seal Splice Sequence

Step 5: Insert Wires into Splice Sleeve and Crimp
Insert the wire into the splice sleeve until it hits
the barrel stop and close the handles of the J 38125-8
crimper tightly until the crimper handles open when
released. The crimper handles will not open until the
proper amount of pressure is applied to the splice
sleeve. Repeat steps 4 and 5 for opposite end of the
splice.
Step 6: Shrink the Insulation around the Splice
Using the Ultratorch J 38125-5 (follow
instructions that accompany Ultratorch), apply heat
where the barrel is crimped. Gradually move the heat
barrel to the open end of the tubing, shrinking the
tubing completely as the heat is moved along the
insulation. A small amount of sealant will come out of
the end of the tubing when sufficient shrinking is
achieved (Figure 14).
SPLICING TWISTED/SHIELDED CABLE

Twisted/shielded cable is sometimes used to
protect wiring from electrical noise (stray signals).
For example, two-conductor cable of this construction
is used between the ECM and the distributor. See
Figure 15 for a breakdown of twisted/shielded cable
construction.
SA -
5-8
REPAIR PROCEDURES
OUTER
JACKET
MYLAR TAPE
DRAIN WIRE
(UNINSULATED)
Figure 16 - The Untwisted Conductors
TWISTED
CONDUCTORS
Figure 15 - Twisted/Shielded Cable

DRAIN WIRE
Step 1: Remove Outer Jacket
Remove the outer jacket and discard it. Be careful

to avoid cutting into the drain wire or the mylar tape.
Step 2: Unwrap the Tape
Unwrap the aluminum/mylar tape, but do not

remove it. The tape will be used to rewrap the twisted
conductors after the splices have been made.
Figure 17 - The Re-assembled Cable
Step 3: Prepare the Splice
Untwist the conductors. Then, prepare the splice

by following the splicing instructions for copper wire
presented earlier. Remember to stagger splices to
avoid shorts (Figure 16).
Step 4: Re-assemble the Cable
After you have spliced and taped each wire, rewrap

the conductors with the mylar tape. Be careful to
avoid wrapping the drain wire in the tape.
Next, splice the drain wire following the splicing
instructions for copper wire. Then, wrap the drain
wire around the conductors and mylar tape
(Figure 17).
Figure 18 - Proper Taping
Step 5: Tape the Cable
Tape over the entire cable using a winding motion

(see Figure 18). This tape will replace the section of
the jacket you removed to make the repair.
REPAIRING CONNECTORS
The following general repair procedures can be
used to repair most types of connectors. The repair
procedures are divided into three general groups:
Push-to-Seat and Pull-to-Seat and Weather Pack.
See "Harness Connector Faces," page 8A-202-0 to

determine which type of connector is to be
serviced.
Use the proper Pick(s) or Tool(s) that apply to the
terminal.
The Terminal Repair Kit (J 38125-A) contains
further information.
TERMINAL
PICK RELEASING
LOCKING TANG
LOCKING
TANG
CONNECTOR
BODY
Figure 19 -Typical Push-to-Seat Connector and Terminal
PUSH-TO-SEAT AND PULL-TO-SEAT
Step 2:
Follow the steps below to repair Push-to-Seat

(Figure 19) or Pull-to-Seat (Figure 20) connectors. The
steps are illustrated with typical connectors. Your
connector may differ, but the repair steps are similar.
Some connectors do not require all the steps shown.
Skip those that don't apply.
Step 1:
Remove any CPA (Connector Position

Assurance) Locks. CPAs are designed to
retain connectors when mated.
PICK RELEASING
LOCKING TANG
Remove any TPA (Terminal Position

Assurance) Locks. TPAs are designed to
keep the terminal from backing out of the
connector.
NOTICE: The TPA must be removed prior

to terminal removal and must be replaced
when the terminal is repaired and reseated.
Step 3:
Open any secondary locks. A secondary lock

aids in terminal retention and is usually
molded to the connector.
LOCKING
TANG
Figure 20 - Typical Pull-to-Seat Connector and Terminal
SA
5 10 ELECTRICAL DIAGNOSIS
REPAIR PROCEDURES
Step 2:
Open secondary lock. A secondary lock aids

in terminal retention and is usually molded
to the connector.
Step 3:
Grasp the lead and push the terminal to the

forward most position. Hold the lead at this
position.
Locate the terminal lock tang rn the

connector canal.
Step 4:
Insert the proper size pick (refer to Terminal

Repair Kit J 38125-A) straight into the
connector canal at the mating end of the
connector.
Insert the Weather Pack terminal removal

tool into the front (mating end) of the
connector cavity until it rests on the cavity
shoulder.
Step 5:
Gently pull on the lead to remov the

terminal through the back of the connector.
Step 4:
Separate the connector halves and back out

seals.
Step 5:
Grasp the lead and push the terminal to the

forward most position. Hold the lead at this
position.
Step 6:
Step 7:
Step 8:
Depress the locking tang to unseat the

terminal.
Push-to-Seat - Gently pull on the lead to
remove the terminal
through the back of the
connector.
Pull-to-Seat-
Gently push on the lead to

remove the terminal
through the front of the
connector.
NOTICE:
Never use force to remove a

terminal from a connector.
Step 6:
Inspect the terminal and connector for

damage. Repair as necessary (see
"Terminal Repair," on the following page).
Step 7:
Reform the lock tang and reseat terminal in

connector body.
Step 8:
Close secondary locks and join connctor

halves.
NOTICE:
Never use force to remove a

terminal from a connector.
Step 9:
Inspect terminal and connector for damage.

Repair as necessary (see "Terminal Repair,"
page 8A-5-11).
Step 10:
Reform lock tang and reseat terminal in

connector body. Apply grease if connector
was originally equipped with grease.
Step 11:
Install any CPAs or TPAs, close any

secondary locks and join connector halves.
WEATHER PACK
CONNECTOR
BODY
WEATHER
PACK TERMINAL
REMOVAL TOOL
LOCKING
TANG
Follow the steps below to repair Weather Pack

connectors (Figure 21 ).
Step 1:
Separate the connector halves.
Figure 21 - Typical Weather Pack Connector

and Terminal
CORE WINGS
INSULATION
WINGS
1
~ "" '::0J /
MATING END
i_
-,
Step 5:
Position strip (and seal for Weather Pack)

in terminal.
Step 6:
Hand crimp core wings.
Step 7:
Hand crimp insulation wings (non-Weather

Pack). Hand crimp insulation wings
around seal and cable (Weather Pack).
Step 8:
Solder all hand crimped terminals.
CABLE
5 - 11
TYPICAL PUSH-TO-SEAT TERMINAL
CABLE
CORE
WINGS
,m~
SEAL
MATING END
WINGS
DIODE REPLACEMENT
Many vehicle electrical systems use a diode to
isolate circuits and protect the components from
voltage spikes. When installing a new diode, use the
following procedure:
If the diode is taped to the harness, remove all of

the tape.
Step 2: Remove Inoperative Diode
TYPICAL WEATHER PACKTERMINAL
Figure 22 -Terminal Repair
TERMINAL REPAIR
The following repair procedures can be used to
repair Push-to-Seat, Pull-to-Seat or Weather Pack
terminals (Figure 22). Some terminals do not require
all steps shown. Skip those that don't apply. The
Terminal Repair Kit (J 38125-A) contains further
information.
Step 1:
Cut off terminal between core and

insulation crimp (minimize wire loss) and
remove seal for Weather Pack terminals.
Step 2:
Apply correct seal per gauge size of wire and

slide back along wire to enable insulation
removal (Weather Pack terminals only).
Step 3:
Remove insulation.
Step 4:
Align seal with end of cable insulation

(Weather Pack terminals only).
Paying attention to current flow direction, remove

inoperative diode from the harness with a suitable
soldering tool. If the diode is located next to a
connector terminal, remove the terminal(s) from the
connector to prevent damage from the soldering tool.
Carefully strip a way a section of insulation next to

the old soldered portion of the wire(s). Do not remove
any more than is needed to attach the new diode.
Step 4: Install New Diode
Check current flow direction of the new diode,

being sure to install the diode with correct bias.
Reference the appropriate service manual wiring
schematic to obtain the correct diode installation
position. Reference Figure 23 for replacement diode
symbols and current flow explanations. Attach the
new diode to the wire(s) using 60/40 rosin core solder.
Use a heat sink (aluminum alligator clip) attached
across the diode wire ends to protect the diode from
excess heat. Follow the manufacturer's instructions
for the soldering equipment you are using.
SA
5 12
REPAIR PROCEDURES
~ CURRENT FLOW
SILVER BAND
CORRESPONDS WITH
ARROW IN DIODE
ELECTRICAL SYMBOL
DIODE IDENTIFICATION MARKINGS

1. INDUSTRY STANDARD
RATING NUMBER
2. TRADEMARK AND/OR
PART NUMBER
1 OR 2
I~
DIODE CURRENT FLOWS

ONLY IN DIRECTION
OF ARROW
Figure 23 - Diode Identification

Step 5: Install Terminal(s)
Install terminal(s) into the connector body if

previously removed in step 2.
Step 6: Tape Diode to Harness
Tape the diode to the harness or connector using

electrical tape. To prevent shorts to ground and water
intrusion, completely cover all exposed wire and diode
attachment points.
ACCEPTABLE DIODE REPLACEMENTS

Diode
Brand
Rating
Number
P/N
Comments
GMSPO
1N4001
8907496
1 amp, 50 PIV -All

applications except
A/C Compressor
Clutch. Will need
to remove diode
from connector
assembly.
GMSPO
1N4004
16039386
1 amp, 400 PIV A/C Compressor

Clutch application
In the event 1 amp, 50 PIV (Peak Inverse Rating)

diodes are unavailable, a universal diode with a 1 amp,
400 PIV rating can be used for the following
applications:
NC Compressor Clutch
ABS/4WAL (the ABS Diode on the Delco
Moraine is hidden inside of an electrical
connector under the carpet at the right panel)
Wiper
Charging System (hidden in wire harness)
Parking Brake (vehicle with ABS)
Relays
Solenoids
Diesel Glow Plug Circuit
5 - 13
REPAIR PROCEDURES
SPECIAL TOOLS
J 36169
Jumper Wire
J 35689-A
Micro-Pack Connector
Terminal Remover
J 34636
Solenoid, Relay and
Circuit Tester
J 35616-A
Connector Test Adapter Kit
J 28742-A
Weather Pack II Terminal Remover
J 34142-B
Unpowered Test Light
J 8681-A
Universal Short Checker
J 22727
Electrical Terminal Remover
J 21008-A
Self-Powered Test Light
J 33095
Terminal Remover: Micro-Pack,
Com-Pack III and ECM Edgeboard
Connectors
J 39200
Digital Multimeter
J 34764
Autofuse Tester
J 38125-A
Terminal Repair Kit
VEHICLE ZONING
100-199
300-399
CALLOUT NUMBERS
(For Splices, Connectors and Pass Thru Grommets)
ZONE DESCRIPTION
100-199
All forward of and including dash panel
200-299
Within Instrument Panel area
300-399
Passenger Compartment, forward of hatch
400-499
Hatch area, to rear of vehicle
500-599
To and within left door
600-699
To and within right door
Fora Harness Routing View, refer to SECTION 8A-203.
8A- 10- 0 ELECTRICAL DIAGNOSIS
POWER DISTRIBUTION
,----,
--------------_...__,_..._
_J
L __
BATIERY
JUNCTION
13 RED
-si:0~1<
F_lJSIBLE
1 RUST
8 RED
19 BLK
L!N_K !!,_
LINK
C:
FUS1_1!1_E_
2 GRY
u~
+
BATTERY
3 RED
-,STARTER
SOLENOID
PAGE SA-30-1
I
I
202
3 RED
402
5 RED
-, GENERATOR
I PAGE 8A-30-1
5 RED
... _.....
-~-'
TO IGNITION SWITCH
PAGE 8A-10-2
302
302
5 RED
3 RED
OPTIONAL
FORV8 VIN P
WITH (60
502
51_75 - - - - - - - - - -
5 RED
302
402
r-HI;
I
I
I
:
I
1
COOLANT
FANR_Ei:_~
PRIMARY
(DRIVER
SIDE)
BLOWER
RELAY
J4
(_001,_~N!
FAN RELAY,
SECONDARY
(PASSENGER
SIDE)
J2
~o
86
--
87
85
L- - J~I- Jl
5
SEE HVAC BLOWER

CONTROL
PAGE 8A-63-0
SEE COOLANT FANS

PAGES 8A-31-0, 1
SEE ANTILDCK BRAKES

PAGE SA-44-1
SEE FUSE
BLOCK DETAILS
PAGE 8A-11-9
SEE HEADLIGHT
DOORS
PAGE SA-104-0
--------------------------------------------------0
...........
1 RUST
2 GRY
FUSIBLE
LINK K
FUSIBLE
LINK_F_
2GRY
5 RED
5 RED
FUSIBLE
LINK
3 RED
1002
702
502
-------------------------------------------86
3 RED
3 RED
1002
------------
r----
3 RED
1002
702
---,!!!'.
FUSE
DEFOG/SEATS
CIRCUIT
1!REA1<E R 12
35AMP
TAIL LTS
FUSE 10
20AMP
I BLOCK
I
I
I
___ J
SEE FUSE BLOCK DETAILS

PAGE 8A-11-6
.8 ORN
r -
240
.8 ORN
g_
240
,DAYTIME
RUNNING
LIGHTS (DRL)
MODULE
PAGES 8A-102-0, 1
I
I
L-...1
I
I
OPTIONAL
r - - - -\-- - - - - - - - - - - , I HEADLIGHT
I
SWITCH
I
I
:
CIRCUIT BREAKER
------------HEAD1;..,""
"<AOTA1; ""
------~-----...I
L - - - cV
EV
WITH DAYTIME RUNNING LIGHTS (DRL) SEE PAGE 8A-102-1

WITHOUT DAYTIME RUNNING LIGHTS (DRL) SEE PAGE 8A-100-0
POWER DISTRIBUTION
13RED
r - - I
- - - - - - -....--0. - --1--- - ------ - - --- - -- - - - -- -L - - ..J
~ - -...
8RED
19BLK
BATTERY
JUNCTION
BLOCK
1 RUST
STARTER r"
SOLENOID
PAGE SA-30-1
- , GENERATOR
r"
-.
I
I
FUSIBLE
LINKE
I PAGE SA-30-1
s RED
................
102
5RED
. .- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 5 2 0 Q
102
5 RED
B
-,
IGNITIONr----SWITCH
TO ABS RELAY
PAGE 8A-10-0
102
C2
~-------~
I
I
I
I
e START
ACCY
LOCK..._
OFF
.., BULB TEST

RUN
L------------- -.J
C1
------------------------------------------------'~1:. .
3 RED
3 BRN
102
102
3REf02
3BRt
3 RED
3 BRN
102
C
Ac:cESSORY
POWER(RAP)
MODULE
PAGE SA-15-0
r- -
I
I
I
._
C2000
.----------, 4
E4r---_!2_r g~~~
RETAINED
C6
-1 WITHOUT RAP (KP2) I
WITH RAP (KP2)
3 RED
3RE~02
~1
E4
3BRX
E21 C200D
- - - - - C200C
B+
RESET
-.
________ _.
3 RED
102
3 BRN
3 BRN
HOT IN ACCV, RUN OR

DURING RAP
P:KY,o
Y,5
3 DK B:U
E12 J - - - - - E ~ + I
3 PN;.a;O
g~~~
3 DK BL~S
3 PNK
E6;JC200C
E12 , - - - - - - C200D
3 PNXO
3 DK BLU
75
-~I
70
l1Pr
FUSE
BLOCK
I
I
I
I
I
\
I
CIGAR/
HORN
FUSE 11
25AMP
BATT
(NOT USED)
PWR ACCV
FUSE 7
15 AMP
WINDOWS
CIRCUIT
BREAKER 15
35AMP
WIPER1WASH
FUSE 14
25AMP
L----SEE FUSE BLOCK DETAILS

PAGE 8A-11-7

PAGE8A-11-8
ACCY
(NOT USED)
\
\
\
I
-----.J
10 - 3
r---------------------------------------,
ACCY
ACCY
'\
ACCY
'
'\
LOCK,
I
I
I
I
I
LOCK.._
LOCK.._
AIQ
3 PNK
5 YEL
cs
B1
5 VEL
3
3 ORN
,----
300
-------,
I
I
I
5223
YELi 5 5 YE15
A- - c2
r-,
5
c1
- - ....
PAGES SA-11-12, 13
5 YEL
3 ORN
I
\
AIR BAG
FUSE 1
15AMP
\
I
L----
.. _____ ..
STARTER
ENABLE
RELAY
PAGE SA-133-0

PAGE SA-11-14
300
3 PNK
r----
UNDERHOOD
ELECTRICAL
CENTER
AIR PUMP
FUSE 7
20AMP
C200B
C200D
C200B
C200D
3 PNK
-------~-----------ECM IGN
FUSE 5
15AMP
_J
GAGES
FUSE 9
10AMP
IGN
(NOT USED)
TURN B-U
FUSE 2
20AMP
-------SEE FUSE BLOCK DETAILS

PAGE SA-11-4
3 ORN
---
300
HVAC
FUSE 3
25AMP
---,
CRANK
FUSE 16
3AMP
I
I
I
I
I
______ J

PAGE SA-11-5
SA -
11 - 0
FUSE BLOCK DETAILS

1/P FUSE BLOCK
12052685
BASE FUSE BLOCK PACK-CON III
BLK
,1: 15 :121: 20 :1 31: 25 :1 41: 10 :1

51: 15 :16(:: 20 :1 11: 15 :1 al: 15 :1
AIR BAG
TURN B-U
HVAC
ECM BAT
ECM IGN
STOP/HAZARD
PWR ACCY
COURTESY
8 15(eA
8 111: 15 :1
81{: 5:1141: 25 :1
IGN
IP DIMMER
WIPER/WASH
:1
@161:
(NOT USED)
3
CRANK
ACCY
AUTOFUSE
BATT
(NOT
USED)
BR~El
WINDOWS
RADIO
COLOR/RATINGS
COLOR
AMPS
PPL
TAN
RED
10
BLUE
15
YEL
20
WHT
25
FRONT VIEW
r,:---;i r , : - - - ; i r , : - - - ; i
1EJ
EJ11EJ EJ11 81
C:---~~---~~ --~
r,:---:;-i r , : - - - ; i r,:
a B_8
--;,
(240 CKT has 2 Wires with ORL)
r.---:_i r,:---~
::~ t_~43
r,.---:_i
i[J
EJ1
~---~
REAR VIEW
39
~ ~
1/P FUSE BLOCK

FUSE
NUMBER
FUSE
NAME
RATING
(AMPS)
AIRBAG
15
Diagnostic Energy Reserve Module, Dual Pole Arming Sensor
SA-11-4
TURN B-U
20
Backup Lights, Daytime Running Lights Module, Turn Flasher
SA-11-5
HVAC
25
HVAC Selector Switch, Rear Defogger
SA-11-5
ECM BAT
10
Engine Control Module, Instrument Cluster, PASS-KeyII Decoder

Module
SA-11-6
ECMIGN
15
Engine Control Module, PASS-KeyII Decoder Module, Fuel Pump

Relay
SA-11-4
STOP/HAZARD
20
Brake Light/Cruise Release Switch, Hazard Flasher
SA-11-6
PWRACCY
15
Power Door Locks, Power Mirrors, Hatch Release
SA-11-7
COURTESY
15
Amplifier, Audio Alarm Module, Lamps: Console Compartment, 1/P

Compartment, Dome Lamp, Keyless Entry Receiver, Rearview Mirror
and Radio
SA-11-7
GAGES AND
IGN TERMINAL
10
Audio Alarm Module, Daytime Running Lights Module, Dia3nostic

Energy Reserve Module, Instrument Cluster, Keyless Entry Mo ule
SA-11-4
10
TAILLTS
20
Exterior Lighting
RELATED CIRCUITRY
PAGE
With DRL (Z49)

SA-102-1,
Without DRL (249)
SA-100-0
11
CIGAR/HORN
AND BATT
TERMINAL
25
Cigar Lighter, Horn Relay
SA-11-7
12
(Circuit
Breaker)
DEFOG/SEATS
35
Power Seats, Rear Defogger
SA-11-6
13
1/PDIMMER
Interior Lights Dimming
SA-117-0
14
WIPER/WASHER
ANDACCY
TERMINAL
25
Windshield Wiper/Washer
SA-91-0
or
SA-11-8
15
(Circuit
Breaker)
WINDOWS
35
Power Windows
SA-120-0
or
SA-11-8
16
CRANK
SA-11-8
17
RADIO
15
Radio, Steering Wheel Controls (Radio)
SA-11-8
SA -
FUSE BLOCK DETAILS

12129351
12110396
COVER CONVENIENCE CENTER
ASSEMBLY CONVENIENCE CENTER
BLK (COVER)
BLK (BLOCK)
COOLANT FAN
RELAY, PRIMARY
(DRIVER SIDE)
AIR PUMP
RELAY
A/C COMPRESSOR
RELAY
ABS
RELAY
0.0
INJECTOR
0,0
INJECTOR
~
IGNITION
00
A/C-CRUISE
COOLANT FAN
LOW COOLANT
RELAY, SECONDARY
RELAY
(PASSENGER SIDE)
FOG LIGHTS
RELAY
HIGH BLOWER
RELAY
TOP VIEW
** (250 CKT has 2 Wires with V8
#78
84 G ~} H 004 J 84
sE] rfuEJ sE] r8J rn sG r8J EJ 5~ r8J G
2
#38
01
01
81
~1
4
4
4
4
E]
#48
~#8~
502
#5~
641
#2
[!]
VIN P)
....
~
58 ~B 5EJ ~
#18
D [!]
E ~
2
B 500 ~ (jsE] ~ ;
El
* (402 CKT has 2 Wires with 2 Coolant Fans)
BACK VIEW
#118
E]
#128
#108
#98
ELECTRICAL DIAGNOSIS 8A -
11 - 3
UNDERHOOD ELECTRICAL CENTER- FUSES

FUSE
NUMBER
FUSE
NAME
RATING
{AMPS)
ABS BAT
FOG LTS
RELATED CIRCUITRY
PAGE
SA-11-9
20
Fog Lights
SA-11-9
HEADLAMP
DOOR.RH
15
Headlight Doors Module
SA-11-9
HEADLAMP
DOOR,LH
15
Headlight Doors Module
BA-11-9
ABS IGN
Antilock Brake System
SA-11-10
FANS/ACTR
10
Coolant Fan Relays, EVAP Canister Purge Solenoid, Exhaust Gas

Recirculation, Reverse Lockout Solenoid
SA-11-11
AIR PUMP
20
Air Injection Pump Assembly, Air Pump Relay
SA-11-11
NOT USED
INJECTOR
7.5
Fuel Injectors
10
INJECTOR
7.5
Fuel Injectors
11
IGNITION
10
V6 VIN S: Camshaft Position Sensor, Crankshaft Position Sensor,

Electronic Ignition Module
VS VIN P: Ignition Coil, Ignition Coil Driver
SA-11-14
12
A/C-CRUISE
20
A/C Compressor Relay, Cruise Control Switches and Module, Low

Coolant Relay
SA-11-14
{V6 VIN S)
BA-11-13,
{VS VIN P)
SA-11-12
UNDERHOOD ELECTRICAL CENTER - RELAYS

RELAY
LOCATION
RELAY NAME
PAGE
A/C COMPRESSOR
SA-11-14
ABS
SA-11-10
COOLANT FAN, PRIMARY
AUTO FUSE
FUSE COLOR/RATINGS
COLOR
AMPS
SA-11-11
TAN
AIR PUMP
SA-11-10
BROWN
7.5
COOLANT FAN, SECONDARY
SA-11-11
RED
10
LOW COOLANT
SA-11-11
BLUE
FOG LIGHTS
8A-11a9
15
HIGH BLOWER
BA-11-10
YELLOW
20
FUSE BLOCK DETAILS

1/P FUSES 1, 5 AND 9
..
AIR BAG
FUSE 1
15AMP
____ _
.8 YEL
GAGES
FUSE 9
10AMP
IGN
(NOT USED)
_____ .
1139
.....................
5204
.8 YEL
1139
.8::L
.8 YEL
1139
1139
.5 PNK
AlO
r---,
r------,
L.-..1
L------..1
DIAGNOSTIC ENERGY
ARMING
SENSOR,
DUALPC>LE
PAGE BA-47-1
439
.8 PNK
39
RESERVE MODULE (DERM)

PAGE 8A-47-0 -
.................................
.5 PNK
5205
439
GI.,.C230
-v6-V-1N-s-,I
.-!
I V8 VIN PI
., . 1. . . ...,I. . .
x(GRN)
"X(BLU)
I"' -
.,
I"' -
I
IL.
I
I
_.
I
I
.8 PNK
A2
.,
.,
I
I
...
ENGINE
CONTROL
MODULE (ECM)
PAGE BA-20-3
439
(1
I"' -
I
I
L. -
ENGINE
CONTROL
MODULE (ECM)
PAGE BA-21-3
1 PNK
439
I"' -
.,
I
I
L-..1
L-..1
PASS-Kevn
DECODER
MODULE
PAGE BA-133-1
FUEL PUMP
RELAY
PAGE 8A-21-5 (V8 VIN P)
OR
PAGE BA-20-5 (V6 VIN S)
.35 PNK
39
.35 PNK
39
.35 PNK
-- ...
r- H
I"' -
.,
.35 PNK
19
E10
r----,
I
I
TCC'5HIFT
INTERRUPT
SWITCH
I
I
L. _ _ _..,
._
..I
AUDIO
ALARM
MODULE
PAGE 8A-76-0
____ ....
CONVENIENCE
CENTER
BRAKE SWITCH
ASSEMBLY
.
PAGE 8A-f1 -6 (V8 VIN Pl
OR
PAGE SA-20-6 (VG VIN S)
.35 PNK
D
(2000
C200C
39
.8 PNK
39
.35 PNK
39
.35 PNK
39
19
Q.
.,
A1
82
AS
r--,
C
C1
I
I
r------,
I
I
I
I
I
I
L-..1
L-..1
L.-----..1
L-..1
KEYLESS
ENTRY
RECEIVER
PAGE SA-132-1
DIAGNOSTIC
ENERGY
RESERVE
MODULE (DERM)
PAGE SA-47-0
INSTRUMENT
CLUSTER
PAGES BA-81-0, 2
DAYTIME
RUNNING
LIGHTS (DRL)
MODULE
PAGE !!A-102-0
I"' -
I
I
I
I
I"' -
I
I
.,
OPTIONAL
FUSE BLOCK DETAILS

1/P FUSES 2 AND 3
HOTIN RUN
r-----
I
I
I
I._
-----~w
-----------
___ _
HOTIN RUN
1~~
BLOCK
, --
TURN B-U
HVAC
FUSE 2
20AMP
FUSE 3
25AMP
-----~I
3 BRN
241
5248 - - - - - - - -
3 BRN
241
.35BRN1241
C
.. -
g-
,---,
1:C4
P:K
-;:-N;-
Q_-
r---,
r---,
I
I
I
I
I
I
-,II
I
I
I
I
I
I
I
I
L.-.J
.8 BRN
HVAC
SELECTOR
SWITCH
PAGES 8A-630,
8A-64-0, 1
141
REAR
DEFOGGER
TIMER,RELAV
PAGE 8A-61-0
REAR
DEFOGGER
SWITCH
PAGE 8A-61-0
~------------------~
HEATERNENT/
AIR CONDITIONING (HVAC)
CONTROL ASSEMBL V
...A-U-.T-O_M_A-TI_C_..,
TRANSMISSION
.8 BRN
5207 - - - - - - - - - - - - - -. . .
MANUAL
,l.
TRANSMISSION
.8BRN
141
.8 BRN
141
.8 BRN
141
141
c
r- - .,
r---,
r- - .,
I""--,
L. -
L. -
L. -
L.-.J
.J
TRANSMISSION
POSITION
SWITCH
PAGE 8A-112-0
.J
BACKUP
LIGHT
SWITCH
PAGE 8A-112-0
.J
TURN
FLASHER
PAGE 8A-1100
DAYTIME
RUNNING
LIGHTS (DRL).
MODULE
PAGEiA-102-0
OPTIONAL
11 - 5
FUSE BLOCK DETAILS

1/P FUSES 4, 6 AND DEFOG/SEATS CIRCUIT BREAKER
-,ltP
I FUSE
BLOCK
1~-
DEFOG,SEATS
CIRCUIT
BREAKER 12
35AMP
1
I
__ _.
I.
'-v-"'
5 ORN
SEE FUSE
BLOCK DETAILS
PAGE SA 11-7
1240
SEE PAGE 8A1021 (WITH DRL)

SEE PAGE SA-100-0 (WITHOUT DRL)
5252 - - - - - - -
5 ORN11240,
3 ORN
.-~----,
I
I
A
I
I
I
I
I
I
340
,---,
I
I
I
I
L. -
.....
REAR
DEFOGGER
TIMERIRELA y
PAGE SA-61-0
140
----,
~.
rK
I r--.,
I
I
I
I
I
I
I L. - ..I
I HAZARD
FLASHER
I PAGE SA-110-0
I
ORN~
.8 ORN
.8 ORN
1240
I
I
I
I
I
I
I
I
I
I
I
I
I
Q
..-----,
I
B
BRAKE LIGHT/
CRUISE
I RELEASE
SWITCH
I
I
L.----1
BRAKE SWITCH
ASSEMBLY
PAGE 8A1101
'-- ----..J
L.-----.J
H EATERNENT/
AIR CONDITIONING (HVAC)
CONTROL ASSEMBLY
CONVENIENCE
CENTER
A1010
....
, W-I-TH_A_C_3--,I
...
, W-IT-H-AQ-9--,
3 ORl,240
5320 - - - - - - - - - - - - .8 ORN
340
.8 ORN
340
2 ORN
1240
] ORN11240
3 ORN11240
3o~NT, ~:o
1o~N 1~:;s
r--1--------,
s_n_(J----..
8 ORN
6
14
340
.8 ORN
17
15
340
<;
!!
(GRN) (VS VIN P)

(BLK) (V6 VIN S)
r- - .;;.-.;;.-..;:.. - - - .,
L-------..11
ENGINE
CONTROL
MODULE(ECM)
PAGE 8A213 (VS VIN P)
OR
PAGE SA-203 (V6 VIN S)
3 ORN
,--.,
A13
I
I
L. -
I
I
.....
INSTRUMENT
CLUSTER
PAGESSA-811, 2
1240
3 ORN
1240
--,
A1
r- - .,
I
I
L. -
I
I
..I
PAS~Il
DECODER
MOD UL{
PAGE SA-1331
rF
I r--.,
I
I
I L. - .....
I POWER
SEAT SWITCH
I PAGE SA-1400
I
I
I
I
I
I
rF
r- - .,
r- - .,
I
I
I
I
J.. -
I
I
..I
POWER SEAT
SWITC_H, DRIVER
PAGE SA-1410
L. -
I
I
.....
POWER SEAT
(_QNTRQL
l,,1_0DULE
PAGE SA-1410
--,
I r- - .,
I I
I
I I
I
I L. - .....
SEAT
I POWER
SWITCI:!,
I ~ASSENGER
PAGE SA-1411
I
I
I
I
I
I
L----..1 ---------..IL----.J
SEAT ASSEMBLY,
DB!~I!
SEAT ASSEMBLY,
DRIVER
SEAT ASSEMBLY,
i>!ISSENGER
11 - 7
FUSE BLOCK DETAILS

1/P FUSES 7, 8 AND 11
HOT IN ACCY, RUN OR
RETAINED ACCESSORY
POWER(RAP)
----,1/P
I FUSE
BLOCK
11
I
PWRACCY
BATT
(NOT USED)
~
15AMP
----.J
.8 ORN
! IMPORTANT:
640
FUSE 1 SHOWN
WITH ALL OPTIONS.
1 ORN
540
.SORN
540
.5 ORN
.. -
640
--,
I" -
-,
I
I
I
I
L. -
...
.. ____
HORN RELAY
Pl>.GE SA-40-0
I
I
I
I
I
...I
r---,
I
I
I
I
L. -
r- - -,
I
I
I
I
PSOO
...
CIGAR
LIGHTER
PAGE SA-114-0
.8 ORN
CONVENIENCE
CENTER
L. -
640
1 ORN
40
...
HATCH
RELEASE
SWITCH
PAGE SA-135-0
ssoo.
.8 ORN
640
.8 ORN
.8 ORN
640
L. -
r---,
...
r---,
I
I
I
I
r- - -,
L. -
L. -
...
POWER
DOORLOCK
SWITCH, RH
PAGE SA-130-0
POWER
DOORLOCK
SWITCH,LH.
PAGE SA-130-0
640
...
POWER
MIRROR
SWITCH
PAGE SA-147-0
C200D
E3 TC200C
.8 ORN
40
. .- - - - S 2 6 5
1 ORN
40
.5 ORN
40
.5 ORN
640
.50:Nl40
.5 ORN
40
r---,
I
I
L. -
I
I
...
KEY LESS
-i-- -
.~.
10
;_!_
,---,
I< ) < )I I
I 7ouRmY;- I I
I READINGI L. - ...
LAMPS
E_NTRY
~ARV!~ RECEIVER
MIRROR
PAGE SA-132-1 PAGE SA-1140
..I
RADIO
PAGESSA-150-0, 3
;J_,
I - I
I < )I
L.. -
..J
DOME
LAMP
PAGESA-114-0
.8 ORN
.5 ORN
40
.-
r- - -,
I
I
L. -
1:p
I
I
..I
(QMfARTMENT
LAMP
PAGESA-114-0
40
.8 ORN
--,
I ~ - -,
I I
I
I I
I
I L- - _.
AUDIO
I ALARM
MODULE
I PAGE SA 76-0
.. ____ ...
CONVENIENCE
CENTER
40
1 ORN
40
Cl
r- - -,
I
I
I
I
I
I
L--..1
L--..1
CONSOLE
i::oiiilPARTMENT
LAMP
PAGESA-114-0
AMPLIFIER
I"' -
-,
I
I
SA-150-1
WITHUW2
,---,
...._ ...
HATCH
RELEASE
RELAY
PAGE SA-135-0
FUSE BLOCK DETAILS

1/P FUSES 14, 16, 17 AND WINDOWS CIRCUIT BREAKER
HOTIN START
SEE INTERIOR LIGHTS DIMMING
PAGE SA-117-0
r---{--------
1
I
I
HOT IN ACCY, RUN OR

DURING RETAINED
ACCESSORY POWER (RAP)
SEE STARTER & CHARGING

PAGE SA-30-0 FOR POWER FEED
-,1/P
pusE
1/PDIMMER
FUSE 13
5 AMP
FUSE 14
25 AMP
CRANK
FUSE 16
3AMP
ACCY
(NOT USED)
~----------------
1 YEL
WINDOWS
CIRCUIT
BREAl<ER 15
JS AMP
,r,,
L.. -
,-
-,
I
I
I
I
L.. -
.J
,8 PPL
806
Al -,
810
,---,
L.. -
..I
3 BRN
..I
L.. -
DIAGNOSTIC
ENERGY
RESERVE
MODULE (DERM)
PAGE 8A-47-0
341
WITH UK3
GOOD
C200C
3 BRN
341
L.. -
..I
POWER
WINDOW
SWITC~LH
PAGE 8A-120-0
~.!!Q
c
,--,
I
I
I
I
L.. -
..I
EXPRESS
DOWN
MODULE
PAGE 8A-120-0
..I
L.. -
STEERING
WHEEL
c;Q_NTROLS,
RADIO
PAGESA-150-2
PSOO
,---,
I
I
. .- - - - - - - - - - - - - - - - - - 5 2 0 8
341
"
,-
- -,
L.. -
..I
POWER
WINDOW
SWITCH, RH
PAGE 8A-120-0
Cl
,--~
I
I
I
I
,-
E11
3 BRN
-- ....I
'" if,,::.,,.:
3 BRN
BLOCK
,-
ASSEMBLY
WIPER,WASHER
SWITCH
ASSEMBLY
PAGE SA-:g-1-0
WIPER
MOTOR
~JE~BLY
PAGE SA-91-0
FUSE 17
15 AMP
143
C200D
C200B
SEE INTERIOR
LIGHTS DIMMING
PAGE SA-117-0
RADIO
..I
RADIO
PAGES8A-150-0, 3
FUSE BLOCK DETAILS

UNDERHOOD FUSES 1, 2, 3, 4 AND FOG LIGHTS RELAY
HOT AT ALL TIMES
r - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -,
HEADLAMP
DOOR, RH
FUSE 3
15AMP
FOG
LTS
FUSE 2
20AMP
ABS BAT
FUSE 1
SAMP
.8 ORN
HEADLAMP
DOOR, LH
FUSE 4
1SAMP
1340
HZ
H4
Ll;H~~[g
86] O
~-1!._E_LA~Y
__
WITH T96
OPTION
L---
87.
85
___________ :t ~1-
____ ...J
SEE HEADLIGHTS AND FOG LIGHTS:

WITHOUTT61
PAGE 8A-1001
OR
.5 ORN
440
... - -,
I
I
I.... _...I
810
ELECTRONIC
BRAKE CONTROL
MODULE (EBCM)
PAGE 8A-44-1
HEADLIGHTS ANO FOG LIGHTS:

DAYTIME RUNNING LIGHTS (T61)
PAGE 8A-102-2
1 ORN
740
1 ORN
______ _B
840
,--------,
....
______ ....
HEADLIGHT
DOORS MODULE
PAGE SA-1040
UNOERHOOO
ELECTRICAL
CENTER
SA -
FUSE BLOCK DETAILS

UNDERHOOD FUSE 5, ABS RELAY AND AIR PUMP RELAY
I
I
r-------------------HOTINRUN
.35 BRN
641
541
.8 BRN
- , UNDERHOOQ
ELECTRICAL
CENTER
AIR
PUMP
FUSE 7
20AMP
FANS/ACTR
FUSE 6
10AMP
.35
BRN
441
.5 BRN
cs
Cl
El
ABS
RELAY
5
C4
(2
811
641
C2
r- - -i
L.--1
ELECTRONIC
BRAKE CONTROL
MODULE (EBCMI
PAGE BA-44-1
ES
11 1
:~;~1z-----. 871 ~ .
-------_]J _] _~
SEE FUSE
BLOCK DETAILS
PAGEBA-11-11
.35 BRN
441
SEE
PAGE BA-20-1 (V6 VIN SI
PAGE BA-21-1 (VB VIN Pl
11 - 11
FUSE BLOCK DETAILS

UNDERHOOD FUSE 6, PRIMARY COOLANT FAN RELAY,
SECONDARY COOLANT FAN RELAY AND LOW COOLANT RELAY
HOT IN RUN
UNDER HOOD
ELECTRICAL
r - - - - - -----.-------- - - - -
CENTER
- - - - - - - - - - - - - - - - - ---.
FANSiACTR
FUSE 6
10AMP
.35 BRN
.35
BRN
20AMP
541
641
F4
05
01
.35
BRN
AIR PUMP
F2
COOLANT
641
SECONDARY
OPTIONAL
VS VIN P
WITH (C60)
_______ : I~1__ _
F1
- --~
1 l ---
SEE COOLANT FANS

PAGE SA-31-1
SEE COOLANT FANS

PAGES 8A31 0, 1
.35BRN
_____ _.
F5
-- -
"-v--1'
SEE FUSE
BLOCK DETAILS
PAGE 8A-1110
SEE
PAGE SA-20-1 (V6 VIN S)
PAGE SA211 (VS VIN P)
541
.....................
5190
.35 BRN
541
. 35 BRN141
F
~I~--,I
V6 VIN S
1~--,1
II
I ~PTIONAL 11
11
I
I
11--.J
I REVERSE
I
LOCKOUT
SOLENOID
LA~S.!;21_2 MANUAL
TRANSMISSION
(MN6)
I
-
_J
3:::8~1
5.41-----
.35 BRN
-----,
., ~J,
541
541
.--~~,
'--===:.._
......-----....""}
..........
.35 BRN
C100
.35 BRNf 4-1-
VB VIN P .
.35 BRN
541
.SBRN
r--;,
r- -
..,
r- -
I
I
L. -
.J
EVAPORATIVE
EMISSION (EVAP)
CANISTER PURGE
SOLENOID VALVE
PAGE SA-21-1
L. -
441
FANRELAY,
PRIMARY
'-
.8 BRN
COOLANT
FANRELAY,
.J
EXHAUST GAS
RECIRCULATION
(EGR) SOLENOID
VALVE
PAGE SA-21-1
L. -
....
I
I
r- -
541
..,
I
I
.J
EVAPORATIVE
EMISSION (EVAP)
CANISTER PURGE
SOLENOID VALVE
PAGE SA-20-1
EXHAUST GAS
IIECIRCULATION
(EGR) SOLENOID
VALVE___ _
PAGE SA-20-1
SA -
FUSE BLOCK DETAILS

UNDERHOOD FUSES 9 AND 10 (VS VIN P)
I
I
I
A/C-CRUISE
FUSE12
20 AMP
I
I
___ .J
~
SEE FUSE
BLOCK DETAILS
PAGE 8A11-14
.8 PNK
639
.8 PNK
- - - - - - - - _ - - - - - ___ - - - _____ - - _ - - - - - - _____K
.8 PNK
639
.5 PNK
639
.5 PNK
.5 PNK
r- - -,
639
.5 PNK
639
r- - ..,
r- - ..,
I
I
L . - ...
L. -
FUEL
INJECTOR 2
FUEL
INJECTOR 4
FUEL
INJECTQR 6
...
r- - ..,
.8 PNK
839
.SPNK
839
...
FUEL
INJECTOR 8
.5 PNK
.SPNK
,--.,
8
I
I
L. -
C100
639
I
I
L . - ...
839
L. -
I
I
....
FUEL
INJECTOR 1
SEE MUL TIPORT FUEL

INJECTION (VS VIN P)
PAGE SA-21-2
839
,--.,
8
I
I
839
I
I
- ....
.5 PNK
.,
,-I
I
I
I
,... B
I
I
839
..,
I
I
- ...
'FUEL
L. -
~\!!=le
'FUEL
INJECTOR 3
iNJE_CJQRj
INJECTOR 7
....
11 - 13
FUSE BLOCK DETAILS

UNDERHOOD FUSES 9 AND 10 {VG VIN S)
I
I
I
INJECTOR
FUSE 9
7.5 AMP
IGNITION
FUSE 11
10AMP
AC-CRUISE
FUSE~
UNDERHOOD
I ELECTRICAL
I
I
___ ....
20AMP
"--v----/
.8 PNK
.8 PNK
.5 PNK
.8 PNK
639
SEE FUSE
BLOCK DETAILS
PAGE 8A-11-14
839
--------------------------------------639
.8 PNK
839
---------------------------------------
.5 PNK
639
839
51031~--------------
5104 ' ~ - - - - - - - - - - - - - -. .
.S PNK
639
.5 PNK
.5 PNK
I"' -
I
I
I
I
I
I
L.-.J
FUEL
INJECTOR 1
L. -
.5 PNK
839
.,
I
I
....
FUEL
~JECTOR 3
.5 PNK
.5 PNK
639
r- - .,
639
I"' -
I
I
.,
I"' -
I
I
I"' -
I
I
L.-...1
L. -
....
FUEL
INJECTOR 2
FUEL
INJECTOR_~
SEE MULTIPORTFUEL
INJECTION (V6 VIN S)
PAGE 8A-20-2
.,
L. -
839
839
.,
I
I
....
FUEL
iNITTT_QR~
I"' -
I
I
L. -
.,
I
I
.J
FUEL
@ECTOR6
CENTER
.SA-11 -14 ELECTRICAL DIAGNOSIS
FUSE BLOCK DETAILS

UNDERHOOD FUSES 11, 12 AND A/C COMPRESSOR RELAY
UNOERHOOD
ELECTRICAL
CENTER
-------------------------------~
AiCCRUISE
IGNITION
FUSE 11
10AMP
INJECTOR
FUSE 10
7.5 AMP
INJECTOR
FUSE 9
7.5 AMP
G4
G2
81
20AMP
LOW
BS
*MPRESSOR
RELAY
COOLANT
RELAY
(LATCHING)
OPTIONAL
_G:_'( ~
84
..,
B2
"-v--"
SEE MULTIPORT FUEL
INJECTION
PAGE 8A202 (V6 VIN S)
OR
PAGE 8A-21 2 (VS VIN P)
.8 PNK
.8 PNK
SEE
INSTRUMENT
CLUSTER
PAGE SA-81-3
239
139
.8 PNK
.8 PNK
5165
139
"
.8 PNK
.Jru.1.39_ ___
SHOWN WITH ALL OPTIONS

--35DKGRN_IIII(,
.35 DK GRN
~9
.35 DK GRN
59
I :s
5105
DK GRN/
----~
DK GRNIWHT
459
459
WHT
59
.35 PNK
.35 DK GRAN!59
239
2
1
Ai(
CLUTCH
DIODE
PAGES
SA-64-0, 1
C (BLU)
C (GRN)
I! (BLK) (V6 VIN 5)

B (RED) (VS VIN P)
,----------.,
r--.,
I
I._
I
I
,..._ ...
239
.8 PNK
I
I
139
.... -
IGN
-,
I
I
,..._ ...
IGNITION
COIL MO-DULE
PAGE 8A21-4
AUTOMATIC
1846
.35PNK
I
I
,..._ ...
.8PNK
MANUAL
I
I
CRUISE
CONTROL
MODULE
PAGE SA-34-0
ENGINE CONTROL
MODULE
PAGE SA-21-5 (VS VIN P)
OR
A/C
COMPRESSOR
CLUTCH
PAGES
8A64-0, 1
_______ ..,
5107 - - - - - - - - - -
.8 PNK/BLK
139
DK GRN
,---,
I
I
.8 PNK
139
.....................,=-----------
! IMPORTANT:
~
.8 PNK
139
I
I
I
I
L
AVg_
IGNITION
~
PAGE 8A21-4
.35 PNK
(2
I
I
I
I
.J
AVg_
.8 PNK
239
r- - -,
I
I
I
I
"'}
239
,---,
I
I
I
I
r- - -,
CRANKSHAFT
POSITION
SENSOR
(HI RES)
PAGE BA-20-4
ELECTRONIC
IGNITION
MODULE
PAGE SA-204
r--.,
I
I
,..._ ... ,..._ ... ,..._ ...

CAMSHAFT
POSITION
SENSOR
PAGE SA-20-4
.8PN1139
. .:I:"
239
V6 VIN 5
I
I
..--,
B
I
I
(ALL V6 MANUALS
HAVE A 4 CAVITY
CONN, 2 UNUSED
WITHOUT K34)
PAGE BA-34-0
I
I
CRUISE
RELEASE!
BRAKE
SWITCH
!'AGE SA-34-0
,..._ ...
'-:===:"'\
I I I
CLUTCH
ANTICIPATE
CRUISE RELEASE
SWITCH___ _
C250
,..._ ...
VS VIN p
CRUISE RELEASE;
c:LUTCHswirru
(VS MANUALS
WITH K34 HAVE A
2 CAVITY CONN)
PAGE SA-34-0
~.-f..-1
I I
I I
I ,... - _.
CRUISE
I CQ_N_IRQL
SWITCHES
I iiAGE
s.il:j4.o
.... -
- - .....
MULTI-FUNCTION
LEVER
-~-
11 - 15
FUSE BLOCK DETAILS

COMPONENT
LOCATION
201-PG
FIG.
AJC Clutch Diode

(V6 VIN S) . . . . . . . . . . . . . Sealed in Harn, 10 cm from NC Compressor
Clutch Conn .................................... . 28 ... 45
NC Clutch Diode
(VS VIN P) ........... . Sealed in Harn, 6 cm from Generator breakout ...... . 14 ... 26
NC Compressor Clutch .. . RH side of Engine, below Generator ................ . 14,28 26,45
Amplifier (part of UW2
Speaker Option) ....... . Mounted behind Right Rear Armrest, on Rail ....... . 44
64
Arming Sensor, Dual Pole . :vlounted to Floor Tunnel Bracket, under console ..... . 21
38
Audio Alarm Module ..... Mounted into Convenience Center
Backup Light Switch (M49)
(V6 VINS) ............ . Middle of Transmission, left side ................... . 16
30
Backup Light Switch (MN6)
(V8 VIN P) ........... . Middle of Transmission, right side ................. . 20
37
Brake Switch Assembly .. . Mounted in lower hole of brake pedal bracket (2 conn
with Automatic), (1 conn with Manual)
same switch for both ............................. . 0 .... 1
(V6 VIN S) ............ . In front top of Engine Block, between Intake and
Water Pump .................................... . 13
24
Cigar Lighter ........... . Mounted on front of console ........................ . 21
38
Console Compartment Lamp Under Console Compartment Door ................. . 21
38
Convenience Center ..... . Left of Steering Column, mounted to bottom of
1/P Carrier ..................................... . 8 .... 15
Crankshaft Position Sensor,
HI Resolution (V6 VIN S) Lower front of Engine Block, pigtail comes out
LH side of crank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
20
Cruise Control Module . . . . Front LH side of vehicle, mounted to frame rail, forward
of wheelhouse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
36
Cruise Release Brake Switch
(all with K34) . . . . . . . . . . Mounted in upper hole of brake pedal bracket
(2 cavity conn) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
1
(VB Manual with K34) . . Mounted in clutch pedal bracket (2 cavity conn) . . . . . . O
1
Daytime Running Lights
(DRL) Module . . . . . . . . . . Mounted behind Radio and HV AC Controls, left of
1/P Compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
12
Diagnostic Energy Reserve
Module (DERM) . . . . . . . . Snapped in bracket, behind RH side ofl/P Compartment 8
15
Dome Lamp . . . . . . . . . . . . . On roof, near hatch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
6
Module (EBCM) . . . . . . . . Under 1/P, next to LH hinge pillar, just above
Pass Thru Grommet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
14
(V6 VINS) ............ . Left front of Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
44
(ECM) (V6 VIN S) ..... . In Engine Compartment, rearward of RH Shock Tower
19
35 ..
(ECM) (V8 VIN P) ..... In Engine Compartment, rearward of RH Shock Tower
19
35 ..
(EV AP) Canister Purge
Solenoid Valve (V6 VIN S) Left side of Engine, mounted to Intake Plenum . . . . . . . 26
43
(EVAP) Canister Purge
Solenoid Valve (V8 VIN P) Right center of Engine, mounted to Manifold . . . . . . . . . 13
24
(EGR) Solenoid Valve
(V6 VIN S) ............ . Right side of Engine, mounted to Manifold .......... . 12
23
(EGR) Solenoid Valve
(V8 VIN P) ........... . Left rear of Engine, mounted to Intake Plenum ...... . 24
41
Express Down Module ... . Mounted to center of dash mat, above floor tunnel .... . 9 .... 17 . .
Fuel Injectors (V6 VIN S)
'.\llounted on Intake :\fanifold, part of Fuel Rail
Fuel Injectors (V8 VIN P)
Mounted on Intake Manifold, part of Fuel Rail ....... . 24 ... 41
CONN
202-9
202-16
202-17
202-10
202-17
202-12
202-13
202-17
202-18
202-19
202-20
202-20
(CONTINUED ON NEXT PAGE)
SA -
FUSE BLOCK DETAILS

(CONTINUED FROM PREVIOUS PAGE)
COMPONENT
LOCATION
201-PG
FIG.
Ft.1e l Pump Relay . . . . . . . . . Forward of LH kick panel, mounted to foot rest bracket
under carpet .................................... . 7 .... 13
Hatch Release Switch . . . . Left of Steering Column, in knee bolster pad ........ . 38
57
Headlight Doors Module . . Forward of LH front wheelhouse, mounted to Air Intake 19
36
Heater/Vent/Air Conditioning
(HVAC) Control Assembly Center of 1/P ..................................... . 45
65
1/P Compartment Lamp . . . Inside top center of compartment
1/P Fuse Block . . . . . . . . . . . LH side of I/P Carrier, on the side .................. . 8 .... 15
Ignition Coil (VS VIN P) . Front LH side of Engine ........................... . 23
40
(VS VIN P) ........... . Front LH side of Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
40
Instrument Cluster ...... . LH side of 1/P ................................................... .
61
Keyless Entry Receiver .. . Behind RH side kick panel, in molded pocket . . . . . . . . . 42
Multi-Function Lever ... . Left Arm on Steering Column . . . . . . . . . . . . . . . . . . . . . . . 2
4
PASS-KeyII Decoder
Module ............... . In I/P, just right of Radio, attached to Air Bag Bracket . 8
15
Power Door Lock Switch, LH Mounted in left door armrest . . . . . . . . . . . . . . . . . . . . . . . 18
33 ..
Power Door Lock Switch, RH Mounted in right door armrest . . . . . . . . . . . . . . . . . . . . . . 18
33
Power Mirror Switch ..... Mounted in left door armrest . . . . . . . . . . . . . . . . . . . . . . . 18
33 ..
(AQ9 Power Seat) . . . . . . . Under Driver's Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
60
Power Seat Switch (AC3) . On left side of Driver's Seat . . . . . . . . . . . . . . . . . . . . . . . . . 37
56 ..
Power Seat Switch,
Passenger (AQ9) ....... . On right side of Passenger Seat . . . . . . . . . . . . . . . . . . . . . 41
60
Power Window Switch, LH
33
Mounted in left door armrest . . . . . . . . . . . . . . . . . . . . . . . 18
Power Window Switch, RH
Mounted in right door armrest . . . . . . . . . . . . . . . . . . . . . . 18
33
58
Radio .................. . Center of I/P Carrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Rearview Mirror ........ . Top center of windshield ......................................... .
(VS VIN P Manual) .... . Rear LH side of Transmission ...................... . 20 ... 37
SIR Coil Assembly ...... . Top of Steering Column ........................... . 3,34. 5,51
Steering Wheel Controls,
Radio (UK3) .......... . On Steering Wheel ............................... . 2 .... 3 ...
Transmission Position
Switch ................ . Under console, on base of shift control lever ......... . 37 ... 54
Turn Flasher ........... . Mounted to bracket, right of Steering Column,
above Data Link Conn ........................... . 8 .... 15
Underhood Electrical Center LH side of Engine Compartment, forward
of wheelhouse ................................... . 19
36
Wiper Motor Assembly
Rear of LH Shock Tower, mounted to dash panel below
LH Wiper Mount ................................ . 10
18
Wiper/Washer Switch
Assembly ............. . In left side of Steering Column, actuated by
Multi-Function Lever ........................... . 3 " .. 5
ClOO (10 cavities) ....... . Engine to Forward Lamp Harn, behind LH wheelhouse,
attached to ECM bracket ......................... . 15
28
C110 (10 cavities) (L32) .. Engine to Injector Harn, top center of Intake Manifold
12
22
C200B (18 cavities)
Part of Forward Lamp Harn, between LH kick panel
and Steering Column ............................ . 47
72
C200C (13 cavities)
Part of Cross Car Harn, between LH kick panel and
Steering Column ................................ . 47
72
C200D (48 cavities)
Part ofI/P Harn, between LH kick panel and
Steering Column ................................ . 47
72
C210 (4cavities) ........ . Under RH side ofI/P, behind RH kick panel ......... . 46
67
C215 (11 cavities) ....... . ~ ear base of Steering Column ..................... . 35
52
C217 (4cavities) ........ . Near base of Steering Column ..................... . 34
51
C230 (10 cavities) ....... . Cnder RH side ofI/P, behind kick panel ............. . 46
67
CONN
202-20
202-21
202-21
202-22
202-21
202-22
202-22
202-14
202-23
202-23
202-23
202-22
202-23
202-23
202-23
202-22
202-15
202-24
202-24
202-24
202-24
202-24
202-0
202-1
202-2
202-2
202-2
202-16
202-4
202-16
202-7
COMPONENT
LOCATION
C250 (2 cavities)
Forward Lamp Harn to Clutch Jumper Harn or Switch,

near brake/clutch pedal bracket . . . . . . . . . . . . . . . . . . . 0, 1 ..
Under Driver Seat Assembly . . . . . . . . . . . . . . . . . . . . . . . 41 .. .
Under Passenger Seat Assembly . . . . . . . . . . . . . . . . . . . . 40 .. .
Between rear mounting bolt of Driver Seat near #3 Rail 6 ... .
Left side in dash panel, Engine to Passenger
Compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Between LH door and "A" pillar . . . . . . . . . . . . . . . . . . . . . 32
Between RH door and "A" pillar . . . . . . . . . . . . . . . . . . . . . 32
Engine Harn, approx 11 cm from Injectors 2
and 4 breakout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
and 3 breakout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Injector Jumper Harn, approx 7 cm from LH
Branch breakout
Injector Jumper Harn, approx 9 cm from Injector 6
Engine Harn, approx 20 cm from main branch and
ECM breakout
ECM breakout
Engine Harn, approx 3 cm from clip near ECM and
main branch
ECM breakout
Engine Harn, approx 4 cm from Transmission breakout
Engine Harn, approx 10 cm from A/C Compressor
Clutch Conn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
14
Engine Harn, approx 6 cm from Generator breakout
Engine Harn, approx 7 cm from RH branch
Engine Harn, approx 8 cm from left clip, on Intake
Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Forward Lamp Harn, approx 7 cm from Electrical
Center breakout
Center breakout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 . . .
I/P Harn, approx 10 cm from Steering Column breakout
I/P Harn, approx 31 cm from Convenience Center
breakout
breakout
I/P Harn, approx 4 cm before DLC breakout
Cross Car Harn, approx 5 cm from Express Down
Module breakout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 . . .
I/P Harn, approx 24 cm from Convenience Center breakout
I/P Harn, in center console breakout, approx 10 cm from
Main Harn
I/P Harn, approx 4 cm before RR Defog breakout
I/P Harn, approx 22 cm from HVAC Control
Illumination Conn
Cross Car Harn, approx 20 cm from Rearview
Mirror breakout
Seat Jumper Harn, near rosebud under Driver Seat
Driver Seat Harn, approx 22 cm from Power Seat Switch Conn
Cross Car Harn, approx 6 cm from Speaker breakout . . 17 . . .
C300
C305
C310
PlOO
(6 cavities) (AQ9) .. .
(6 cavities) (AQ9) .. .
(2 cavities) ........ .
................... .
P500 ................... .
P600 ................... .
SlOl (LTl) ............. .
8102 (LTl)
Sl03 (L32)
Sl04 (L32)
Sl05 (L32)
8105 (LTl)
Sl06 (L32)
8106 (LTl)
Sl07 (L32)
Sl 14 (L32)
Sll4 (LTl)
S127 (L32)
Sl27 (LTl)
S165
S190
S204
S205
8205
S207
S20B
8209
S210
S211
S24B
S252
8265
S320
8330
S500
For a Service Part Cross Reference List and Information, refer to SECTION SA-200.
201-PG
11 - 17
FIG.
CONN
1, 2
60
59
202-16
202-16
11
36
49
49
43
41
45
26
41
53
49
31
SA -
GROUND DISTRIBUTION
VS VIN P
A/C
COMPRESSOR
CLUTCH
CRUISE
CONTROL
MODULE
r- - .,
r- - .,
L.-...,
E
. .:l
L. -
ENGINE
CONTROL
MODULE (ECM)
IGNITION
AJC
CLUTCH
DIODE
~
MODULE
...,
TACHOMETER
FILTER
r- - .,
r- - .,
r- - .,
L. -
L. -
L.-...,
.8 BLK
...,
22
...,
(RED)
450
5115-----'
.35 BLK
450
.8 BLK
.8 BLK
19 BLK
50
13 BLK
50
450
1650
rn
IMPORTANT:
.8 TAN/WHT
551
.8 BLK
550
SOME EARLY PRODUCTION

VEHICLES USED GROUND CKT 150
FOR CRUISE CONTROL MODULE.
REFER TO PAGE 8A14-6.
.8 BLK
1 BLK
450 (WITHOUT C60l

450 (WITH C60l
TOG101
PAGE 8A-14-4
BRAIDED GROUND STRAP

350
LEFT FRONT
FRAME RAIL
__L __ ___a2109
_ . _ _ _ . _ ______________ _ . _ __________ -----2102
14 - 1
AUTOMATIC
TRANSMISSION
PASS-Keyll
DECODER
MODULE
OIL
LEVEL
SENSOR
ENGINE
CONTROL
MOOULE (ECM)
,-----------, ,... - -,
,... --,
I
I
I
I
I
I
I
I
L----------...J
16
I:> (BRN) 6
- - - - (RED)
17
I
I
L..--1
A
DA fA LINK
CQNNECTOR (DLC)
L. BS
.....
TRANSMISSION
POSITION
SWITCH
,---,
.35 BLKIWHT
451
,...
- -,
MANUAL
TRANSMISSION
(NOT USED)
A
C270
.35
BLK/
WHT
.35 BLK WHT
FUEL
PUMP
RELAY
L. A
....
L. -
....
A1
INSTRUMENT
CLUSTER
,...
- -,
I
I
L. -
815
.8 BLK. WHT
451
.35 BLK,WHT
451
451
.35 BLK/WHT
. . . . . . . . . 35BLK,W~,~~5~1
.
. . . . . . . . . . . .. .
451
.35 BLK.WHT
451
....................................................
. 5 BLK,WHTfs::s
B
.5 BLK/
WHT
351
.8 BLK WHT
C210
451
.5 BLK!WHT
............... .............................
-
~109
.8 BLK WHT
451
__._ _ - - - - - - - - - -.- - - - - - - ___ _._.l_{Ll
.....
451
.8 BLK1WHT
I
I
451
451
8A -
GROUND DISTRIBUTION
V6 VIN S
A/C
CRUISE
CONTROL
MODULE
COMPRESSOR
CLUTCH
.- --,
,---,
._ _.
OIL
LEVEL
SENSOR
ELECTRONIC
IGNITION
MODULE
A/C
CLUTCH
DIODE
,---,
r- - -,
._ _
.... A
'iil-.. .
.35 BLK
.J
.J
450
.8 BLK
450
5115. _ _ ___,
WITH AIR
CONDITIONING
'
.8 BLK
.8 BLK
19 BLK
50
13 BLK
50
450
1650
rn
.35 BLK/WHT
451
IMPORTANT:
SOME EARLY PRODUCTION
VEHICLES USED GROUND CKT 150
FOR CRUISE CONTROL MODULE.
REFER TO PAGE SA-14-6.
.8 BLK
1 BLK
TOG101
PAGE 8A-14-4
450 (WITHOUT C60)

450 (WITH C60)
.5 BLK/WHT
.5 BLKIWHT
451
451
.5 BLK/WHT
451
.8 BLK/WHT
451

350
LEFT FRONT
FRAME RAIL
ENGINE
BLOCK
-!----------------!-------------------~
ELECTRICAL DIAGNOSIS BA -
14 - 3
MANUAL
TRANSMISSION
CLUTCH
ANTlCIPATE;
CRUISE
PASS-KeyII RELEASE
SWITCH
DECODER
MODULE
,---,
DATA LINK
CONNECTOR (DLC)
A
I
I
I.. -
I
I
...
,... - .,
1...- ...
D
85
AUTOMATIC
TRANSMISSION
TRANSMISSION
POSITION
SWITCH
,... I
I
I
I
I.. A
.35 BLK.'
.35 8LK/WHT
.35 8LK/
451
.,
...
INSTRUMENT
CLUSTER
FUEL
PUMP
RELAV
,... -
.,
I
I
I.. -
A1
I
I
,---,
I
I
I
I
L. -
815
...
ENGINE
CONTROL
MODULE (ECMt
r---------------- .,
1
I
I
I
_.
L.---16
20
32
23
(! (8LK)
17
~ (8LU)
...
451
.35 8LK,WHT
WHT
.35 8LK,
451
451
451
.35 8LK,WHT
451
WHT
WHT
.5 8LK/WHT
451
.5 8LK,
351
.5 TAN
WHT
WHT
.5 8LK1
WHT
.5 8LK/WHT
451
.5 BLK,
WHT
351
551
.5 TAN/
551
WHT
451
~--...
.8 BLK,WHT
351
r--------------------------------------------------------------!----------
!G104
2 STUDS WITH
2 TERMINALS ON EACH
(INTERCHANGEABLE)
SA- 14- 4 ELECTRICAL DIAGNOSIS
GROUND DISTRIBUTION
ANTILOCK BRAKE SYSTEM (ABS) AND SUPPLEMENTAL INFLATABLE RESTRAINT (SIR)
HYDRAULIC
MODULATOR
ASSEMBLY
r-----------------,
I
I
I
I
r- - .., ABS
r- - ..,
I
I BRAKE
PRESSURE
I
I VALVE
I
I
SOLENOID,
em-
...I
Q FRONT
L., B
L-
L., B
-----
.8 BLKWHT
.8 BLK/WHT
ABS
I BRAKE
PRESSURE
I VALVE
SOLENOID,
-
...I RIGHT
Q FRONT
.... -
I I
I I
I~- - II E
...I
~
I
-,
I
I
r- - .., BRAKE
I <;_OMB_Q
VALVE
I.. B
-----
5 BLK,WHT
.8 BLK.WHT
....
<;_!
DISCRIMINATING
SENSOR,
E!)RWARD
.... -
-,
I
I
I
I
';,?-'
DISCRIMINATING
SENSOR,
PASSENGER
COMPARTMENT
.... I
I
-,
DIAGNOSTIC
ENERGY
RESERVE
MODULE (DERM)
r-------,
I
I
'2? ....
'-,7----I
A12' ,
A1
___ J
651
651
ELECTRONIC
BRAKE
CONTROL
i;fODULE (EBCM)
651
.8 BLK WHT
651
.8 BLK/WHT
17 51
1751
.8 BLK/WHT
.8 BLKWHT
1751
1751
..................
"II
01
-"'
~ (2000
C200B
.8 BLK:WHT
5 BLKWHT
651
8 BLK WHT
651
FROM BATTERY
(V8 VIN P) PAGE 8A-140
(V6 VIN S) PAGE 8A-14-l
13 BLK
50
_ . _ ____________ _ . _ _______________________ ~ 0 1
17 51
GROUND DISTRIBUTION
COOLANT LEVEL SENSOR, FORWARD LAMP AND HIGH BLOWER RELAY
UNDERHOOD
ELECTRICAL
CENTER
(V~l;;O:LY7" -
I ,... - -, LOW
r- - -, HIGH I
I I
I COOLANT I
I BLOW~ I
RELAY
RELAY
I I
I (LATCHING) I
1 - I
I t,,-...1
L.-...1
I
L_: '----)-, ___ J

.35BLK
250
FOG
LAMP,
RIGHT
FRONT
--
-B'
ENGINE
COOLANT
PARKfTURN
LAMP,
RIGHT
FRONT
~
SENSOR
r- - -,
I
I
I
I
~.,..1
MARKER
LAMP,
RIGHT
FRONT
-- )
.35 BLK
.5 BLK
250
1 BLK
.5 BLK
250
.8 BLK
250
250
HEADLAMP
DOOR
ASSEMBLY, RH
r---,
I HEADLAMP,
RIGHT
1--I(
)
I ~ 7'
I
I
I
I
L -
1 BLK
250
1 BLK
250
250
L
-----------------"~....____________________.....
~
3 BLK
250
14 - 5
8A -
GROUND DISTRIBUTION
AIR PUMP, COOLANT FAN, HEADLIGHT DOOR MODULE, FORWARD LAMP,
WINDSHIELD WIPER AND WASHER
WIPER
MOTOR
WASHER
PUMP
-ASSEMBLY MOTOR
HEADLAMP DOOR
ASSEMBLY, LH
"I PARKffURN
HEADLAMP
LAMP
LEFT
LEFTFRONT
r - - -
FOG
LAMP,
LEFT
FRONT
- -
.... - ., .... - ., I
I
II
l(---1-II
111
11(
I(
c
,
,
,-;
B -
G' L.
..... L.
B , - ; ..... I - - I
A
.. - .
1 BLK
'
.I
MARKER
LAMP,
LEFT
FRONT
COOLANT
COOLANT
EM!
EM!
PRIMARY
SECONDARY
-.,
....
- .,
L.
...
...
...
r- - ., ....
I I
)
I I
L.
A1-;
.....
HEADLIGHT
DOOR
MODULE
A,-,
D'-;g
SECONDARY
AIR
INJECTION
1 BLK
150
........
c ,-;
L.I-~~u
I
BLK
150
,,
150
.... .,
ASSEMBLY
r- - .,
I
I
I
I
c l ,c160
CRUISE
CONTROL
MODULE
1 BLK
3 BLK
150
150
.SBLK
EARLY
PRODUCTION
VEHICLES
,. .
OTHER
VEHICLES
150
BLK
.SBLK
150
.SBLK
150
.5BLK
150
3 BLK
150
3 BLK
150
.35 BLK
150
.8 BLK
1650
,r
~
3 BLK
,5113
150
SEE PAGE SA-14. .

(VS VIN P)
"PAGE SA-14-2
(V6 VIN S)

350
__._ _____ ----AJ109
14 - 7
GROUND DISTRIBUTION
BLOWER MOTOR, POWER DOORS, LOCKS, MIRRORS ANO WINDOWS
RETAINED
ACCESSORY
POWER(RAP)
MODULE
r- - .,
I
I
I
I
L . - ...
E
DOOR
ILLUMINATION
LAMP, LEFT
HAND
(
B
POWER
WINDOW
SWITCH,
LEFT HAND
POWER
MIRROR
SWITCH
,---,
r- - .,
I
I
_...
....
A
I
I
.__ ...
A
REARVIEW
MIRROR
r------,
I ,I I
I I
I
L-
-, COURTESY/
READING
LAMPS
KEYLESS
ENTRY
RECEIVER
,--.,
I
I
I
I
DOOR
ILLUMINATION
LAMP, RIGHT
HAND
~-(
1..J..1____ J
L. E
...
g_
POWER DOOR
LOCK SWITCH,
RIGHT HAND
r-----,
L-----.1
B
E
.35 BLK
.35 BLK
750
750
.35 BLK
.5 BLK
.8 BLK
.35 BLK
750
3 BLK
750
.8 BLK
750
750 (WITHOUT POWER
ACCESSORIES)
.35 BLK
750
rn
750
IMPORTANT:
5220 SHOWN WITH ALL
OPTIONS COMBINED.
FROM 5216
PAGE 8A-148
3 BLK
650
750
3 BLK
.8 BLK
750
750 (WITHOUT POWER
ACCESSORIES)
_ . _ ____________________ ----.J200
.8 BLK
750
SA -
GROUND DISTRIBUTION
AUDIO ALARM MODULE, HATCH RELEASE, LIGHT SWITCHES, POWER SEATS
AND REAR DEFOGGER
HEATERNENT AIR
CONDITIONING (HVAC)
CONTROL ASSEMBLY
CONVENIENCE
CENTER
r------1
I ,... - ., AUDIO
I I
I ALARM
I I
I MODULE
I ~ ,-; _.
L-
I
I
I
I
____ J
HEADLIGHT
INSTRUMENT
CLUSTER
... - .,
,---,
L,.
.....
D''
L,.
.....
BJ''
swrfC_I:!
I
I
I
I
1/P
DIMMER
SWITCH
r -;E;; - - ;;A~ - ,
FOG
LIGHT
SWITCH
,--.,
,... - .,
I
I
I
I
L,. B\
I
I
'
.....
L,. G \
I
I
'
.....
I DEFOGGER DEFOGGER I
~ V SWITCH
I ,--., r---, I
I I
I I
I I
I I
I I
I I
I L-1 _. L--..1 I
I
L-
~~J
D ' ~
.5 BLK
.5 BLK
650
.35 BLK
650
1 BLK
.35 BLK
650
.35 BLK
650
6 50
650
,,
s',
3BLK
650
3 BLK
650
TO G200
PAGE 8A-14-7
ELECTRICAL DIAGNOSI.S SA -
14 - 9
GROUND DISTRIBUTION
DIAGNOSTIC ENERGY RESERVE MODULE (DERM}, DAYTIME RUNNING LIGHTS (DRL}
MODULE, RADIO, INSTRUMENT PANEL AND CONSOLE AREA
SEAT BELT
SWITCH
RADIO
r- - -, Ir"'
I
I
-,
I
I I
L . - ...
5' :,, g_
CONSOLE
COMPARTMENT
LA~ - -
I (
L . I ...
MANUAL
TRANSMISSION
ASHT~LAMP
PRNDL
ILLUMINATION
LAMP
~--
A,- ,I
AUTOMATIC
TRANSMISSION
B'.,
B -' .,
DAYTIME
RUNNING
LIGHTS (DRL)
MODULE
CIGAR
LIGHTER
L.
- ...
BI ~
Bl Ii:
AMPLIFIER
I
I
I
I
I
I
I
I
.... -
r- ---,
r- -..,
L.
-,
I
I
...
r--,
I
I
L.
.4'~
A 1J C1
11'_
COMPARTMENT
LAMP
STEERING
WHrn::-t;QNTROLS,
RADIO
OPTIONAL
I
I
...
I
I
L.
D~
1 BLK
A ' ,I
- ~~
--
650
SIR COIL
ASS
~LY
p_
.5 BLK
,,
650
(217
HEATER/\/ENT!AIR
CONDITIONING (HVAC)
CONTROL ASSEMBLY
.35 BLK
1 BLK
650
.5 BLK
650
.8 BLK
.8 BLK
650
.5 BLK
650
.35 BLK
650
650
.8BLK
650
650
-,
r - -HVAC
--
--
I
I
I(
I 1
I
L.
B:
ILLUMINATIO N
LAMPS
...
---
I
) I
I
I
_.J
~Q
DIAGNOST IC
ENERGY
RESERVE
MODULE( DERM)
.5 BLK
..
, ..
650
.---,
I
I
I
I
~.? ...
"-v--"
, ,,
.8 BLK
.5 BLK
650
5217
7...
'
3 BLK
650
"
rn
IMPORTANT:
5217 SHOWN WITH ALL
OPTIONS COMBINED.
650
GROUND DISTRIBUTION
FUEL PUMP/SENDER, POWER SEATS, REAR DEFOGGER, CHMSL
WITH AO
BLOWER
MOTOR
,---,
I
I
I
I
....
.....
FUEL
TANK
UNIT
,-
I
I
....
WITHAQ9
SEAT ASSEMBLY,
DRIVER - - -
- -, r-----,
I
I
.....
J~~
I r- - -, POWER
I SEAT
I I
SWITCH
I I
IL- _ _.
,-
LC
SEAT ASSEMBLY,
DRIVE_'!
REAR
DEFOGGER
GRID
r - - - - - - - - , ,-
I
I
I
I
___ .J
C405B
2 BLK
1450
I
I r- - - - -, POWER
I SEAT
I
I
....
CONTROL
I ._
_.I MODULE A
I
I
I
I 3 BLK 1450
I
I 5335.
I 3 BLK 1450
______ J
L-
___
CENTER HIGH MOUNTED

STOP LIGHT (CHM SL)
- -,
r--------,
CD CD
.....
1::J-~
BLK
1150
BLK
T
B
C420
1450
1150
.5 BLK
1150
5420
BLK
1450 (WITH AC3)
,2 "}""
1w,rn '"''
850
1 BLK
1050
3 BLK
010
1450
_ . _ _____________ __._G305
1150
P410
3 BLK
3 BLK
....J
5450
Io.
3 BLK
---
L..
1 BLK
.5 BLK
11 SO (WITH C491
1150 (WITHOUT C49)
ELECTRICAL DIAGNOSIS SA - 14- 11
GROUND DISTRIBUTION
REAR LIGHTS
TAIL/STOP/
niRiiiLAMp.
MARKER
LAMP,
LEFT REAR
TAIL!STQP1
TURf>!LAMP,
LH
INBOARD
BACKUP
LAMP_,
BACKUP
LAMP,
TAILJSTQP/
TURN
LAMP, RH
INBOARD
TAIL/STQPI
TURNL.AMP,
MARKER
LAMP,
RIGHT
REAR
- - -- -- - - -., -- -- - - - -- -- - - - -- -- - -
LH
OUTBOARD
G,,
.8BLK
.5 BLK
~1-1
1 .,
1250
G 1 .I
1250
G1
.8 BLK
.8 BLK
LICENSE
LAMP
1:1.1-1
B 1 .,
.I
RH
OUTBOARD
G 1 ,I
G,
1:1.1-1
G,
.8BLK
.5 BLK
1250
1250
.8BLK
.8 BLK
1250
1250
.S BLK
'
. 5BLK
~,
'~~10
.5 BLK
1250
))
C430
.5 BLK
1250
.5 BLK
1250
15430
P400
1250
.5 BLK
1250
HATCH
RELEASE
ACTUATOR
REAR DOME
LIGHT
SWITCH
.... -.,
.... - .,
I
I
I
I
I
I
1250
I
I
L. - ... L.1..1
,~l~ ;r,~
____._ ___ - - - - ___________ _ . _ G400
1250
1250
.5 BLK
TAILLAMP,
1250
SA-14-12 ELECTRICAL DIAGNOSIS
GROUND DISTRIBUTION
COMPONENT
NC Clutch Diode
LOCATION
201-PG
FIG.
CONN
(V6 VIN S) . . . . . . . . . . . . . Sealed in Harn, 10 cm from NC Compressor

Clutch Conn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
45
NC Clutch Diode
(VS VIN P) ........... . Sealed in Harn, 6 cm from Generator breakout . . . . . . . 14
26
NC Compressor Clutch .. . RH side of Engine, below Generator . . . . . . . . . . . . . . . . . 14, 28 26,45
ABS Brake Pressure Valve
53
Solenoid, LF ........... . Part of Hydraulic Modulator Assembly . . . . . . . . . . . . . . 36
53
Solenoid, RF .......... . Part of Hydraulic Modulator Assembly . . . . . . . . . . . . . . 36
Amplifier (part of UW2
64
Speaker Option) ....... . Mounted behind Right Rear Armrest, on Rail . . . . . . . . 44
202-9
Ashtray Lamp (Auto Trans) Lighting Tube from PRNDL Lamp
Ashtray Lamp
(Manual Trans) ........ . Rearward of shifter, in ashtray . . . . . . . . . . . . . . . . . . . . . . 22
39
Backup Lamp, LH ....... . Mounted in Taillamp Assembly . . . . . . . . . . . . . . . . . . . . . 33
50
Backup Lamp, RH ....... . Mounted in Taillamp Assembly . . . . . . . . . . . . . . . . . . . . . 33
50
Battery ................ . RH front of Engine Compartment . . . . . . . . . . . . . . . . . . . 19
35
46
67
Blower Motor ........... . Under lower RH side of 1/P, mounted in HV AC Module
Brake Combo Valve (ABS)
Part of Hydraulic Modulator Assembly, inward side
36
53
Center High Mounted Stop
Light (CHMSL) ........ . Rear center of Spoiler
Cigar Lighter ........... . Mounted on front of console . . . . . . . . . . . . . . . . . . . . . . . . . 21 . . . 38
Clutch Anticipate/
Cruise Release Switch
(all V6 Manual) ........ . Mounted in clutch pedal bracket (4 cavity conn) . . . . . . 0 . . . . 1 ... 202-17
Console Compartment Lamp Under Console Compartment Door . . . . . . . . . . . . . . . . . . 21 . . . 38
Convenience Center ..... . Left of Steering Column, mounted to bottom of
1/P Carrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 . . . . 15
202-17
Coolant Fan, Primary ... . Behind radiator, Driver side
Coolant Fan, Secondary .. . Behind radiator, Passenger side
Cruise Control Module
Front LH side of vehicle, mounted to frame rail, forward
of wheelhouse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 . . . 36 .. 202-10
Data Link Conn (DLC)
Mounted to 1/P Tie Bar, below and right of
Steering Column ............................................... . 202-11
(DRL) Module . . . . . . . . . . Mounted behind Radio and HVAC Controls, left of
1/P Compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
12
202-17
Module (DERM) . . . . . . . . Snapped in bracket, behind RH side ofl/P Compartment 8
15
202-12
Discriminating Sensor,
Forward . . . . . . . . . . . . . . . Mounted to center offront end Tie Bar, near hood latch 19 . . . 36
Mounted to upper dash,just right of Steering Column
Passenger Compartment
68
Support Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
31
Door Illumination Lamp, LH Behinddoortrimpanel ............................. 17
31
Door Illumination Lamp, RH Behind door trim panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Module (EBCM) ....... . Under I/P, next to LH hinge pillar, just above
Pass Thru Grommet .............................. 8 . . . . 14
202-13
(V6 VIN S) . . . . . . . . . . . . . Left front of Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
44
202-17
19
(ECM) (V6 VIN S) . . . . . . In Engine Compartment, rearward of RH Shock Tower
35
202-18
COMPONENT
(ECM) (VS VIN P) .....
Engine Coolant Level Sensor
(VS VIN P) ........... .
Fog Lamp, Left Front .... .
Fog Lamp, Right Front .. .
Fog Light Switch ........ .
Fuel Pump Relay ........ .
LOCATION
In Engine Compartment, rearward of RH Shock Tower
14 - 13
201-PG
FIG.
CONN
19
35
202-19
Mounted on upper right side of radiator . . . . . . . . . . . . . . 19

35
Lower LH side offront Fascia
Lower RH side of front Fascia
Lower LH side ofl/P .............................. . 38 ... 57
Forward of LH kick panel, mounted to foot rest bracket
under carpet .................................... . 7 .... 13
Fuel Tank Unit . . . . . . . . . . Under rear of vehicle
47
Hatch Release Actuator . . . Center of end panel, in Cargo Compartment ......... . 30
Headlamp, Left . . . . . . . . . . LH front of vehicle .............. : ................. . 43
63
Headlamp, Right . . . . . . . . . RH front of vehicle
Headlight Doors Module . . Forward of LH front wheelhouse, mounted to Air Intake 19
36
Headlight Switch . . . . . . . . LH side ofl/P .................................... . 38
57
HeaterNent/Air Conditioning
(HV AC) Control Assembly Center ofl/P ..................................... . 45
65
Hydraulic Modulator
Assembly ............. . Front left of Engine Compartment ................. . 36
53
1/P Compartment Lamp .. . Inside top center of compartment
1/P Dimmer Switch ...... . Lower LH side of 1/P .............................. . 38
57
(VS VIN P) ........... . Front LH side of Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
40
61
Keyless Entry Receiver .. . Behind RH side kick panel, in molded pocket . . . . . . . . . 42
48
License Lamp ........... . Center ofrear Fascia, above license plate . . . . . . . . . . . . 31
Marker Lamp, Left Front . Exterior, left front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
32
48
Marker Lamp, Left Rear .. Exterior, left rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Marker Lamp, Right Front Exterior, right front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
32
Marker Lamp, Right Rear . Exterior, right rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
48
Oil Level Sensor ........ . Lower left side of Engine, in oil pan . . . . . . . . . . . . . . . . . . 11, 24 20, 41
Park/Turn Lamp, Left Front Exterior, left front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
32
Park/Turn Lamp,
Right Front . . . . . . . . . . . . Exterior, right front ................... , .......... . 17
32
PASS-KeyII Decoder
Module . . . . . . . . . . . . . . . . In 1/P,just right of Radio, attached to Air Bag Bracket . 8 .... 15
Power Door Lock Switch, RH Mounted in right door armrest ..................... . 18
33
Power Mirror Switch . . . . . Mounted in left door armrest ...................... . 18
33
Power Seat Switch,
Driver (AQ9) .......... . On left side of Driver's Seat ........................ . 41
60
Mounted in left door armrest ...................... . 18
33
PRNDL Illumination Lamp
38
(Auto Trans) .......... . Under console, left of Shifter . . . . . . . . . . . . . . . . . . . . . . . . 21
Radio .................. . Center ofl/P Carrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
58
Rear Defogger Grid ...... . Mounted on rear windshield . . . . . . . . . . . . . . . . . . . . . . . . 4 . . . . 7
Rear Defogger Timer/Relay Part of HV AC Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 . . . 65
Rear Dome Light Switch .. Center of end panel, in Cargo Compartment . . . . . . . . . . 30 . . . 47
Rearview Mirror ........ . Top center of windshield ......................................... .
(RAP) Module ......... . In molded pocket of dash mat, center above floor tunnel 9 . . . . 17
38
Seat Belt Switch ........ . Part of Driver's Seat Buckle Assembly . . . . . . . . . . . . . . . 21
Secondary Air Injection
21
Pump Assembly . . . . . . . . Front LH Frame Rail, in Engine Compartment . . . . . . . 11
202-20
202-20
202-21
202-14
202-21
202-22
202-21
202-22
202-22
202-14
202-23
202-23
202-23
202-23
202-15
202-24
202-24
SA -
14 - 14
GROUND DISTRIBUTION
COMPONENT
LOCATION
SIR Coil Assembly ...... .

Tachometer Filter
(VS VIN P) ........... .
Taillamp, LH ........... .
Taillamp, RH ........... .
Tail/Stoptrurn Lamp,
LH Inboard ........... .
LH Outboard .......... .
TaiVStoptrurn Lamp,
RH Inboard ........... .
RH Outboard .......... .
Switch . . . . . . . . . . . . . . . . .
Top of Steering Column . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3, 34 . 5, 51
Washer Pump Motor . . . . .

Wiper Motor Assembly . . .
C160 (3 cavities) . . . . . . . . .
C165 (3 cavities) . . . . . . . . .
C200B (18 cavities)
C200D (48 cavities)
C210 (4 cavities) . . . . . . . . .
C217 (4 cavities) . . . . . . . . .
C270 (2 cavities) . . . . . . . . .
C300 (6 cavities) (AQ9) . . .
C310 (2 cavities) . . . . . . . . .
C405A (4 cavities) . . . . . . .
C405B (10 cavities) . . . . . .
C430 (2 cavities) . . . . . . . . .
0100 (L32) . . . . . . . . . . . . . .
0100 (LTl) . . . . . . . . . . . . . .
0101 . . . . . . . . . . . . . . . . . . . .
0102 (LTl) . . . . . . . . . . . . . .
0103 (LTl) . . . . . . . . . . . . . .
0104 (L32) . . . . . . . . . . . . . .
0105 . . . . . . . . . . . . . . . . . . . .
0106 . . . . . . . . . . . . . . . . . . . .
0108 (L32) . . . . . . . . . . . . . .
0109 . . . . . . . . . . . . . . . . . . . .
201-PG
FIG.
CONN
Tapped to Harn, left front side of Engine . . . . . . . . . . . . . 23

Exterior, left rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Exterior, right rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
40
50
50
50
50
50
50
Under console, on base of shift control lever . . . . . . . . . .

LH side of Engine Compartment, forward
of wheelhouse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Front of vehicle, below Engine Hood Latch . . . . . . . . . . .
Rear of LH Shock Tower, mounted to dash panel below
LH Wiper Mount . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LH Headlight to Forward Lamp Harn Jumper, behind
Headlight Door Bracket . . . . . . . . . . . . . . . . . . . . . . . . . .
RH Headlight to Forward Lamp Harn Jumper, behind
Headlight Door Bracket . . . . . . . . . . . . . . . . . . . . . . . . . .
and Steering Column . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Part ofl/P Harn, between LH kick panel and
Steering Column .................................
Under RH side ofl/P, behind RH kick panel . . . . . . . . . .
Near base of Steering Column . . . . . . . . . . . . . . . . . . . . . .
1/P Harn to Clutch Jumper Harn, near brake/clutch
pedal bracket ................................... .
Under Driver Seat Assembly ...................... .
Between rear mounting bolt of Driver Seat near #3 Rail
Part of Pass Thru Conn, forward ofrear axle, to
Fuel Tank Unit ................................. .
Pass Thru Panel ................................ .
Between Rear Fascia and rear end panel, on LH side ..
Bolted to Belt Tension Bracket Bolt, lower RH front
of Engine (1 ring, 1 wire) ......................... .
Bolted to RH side of Engine Block, same bolt used for
NC Compressor if equipped (1 ring, 1 wire) ........ .
Top of RH Shock Tower(3 rings, 5 wires) ............ .
LH front of Engine Block,just below head
(4 rings, 3 wires and braided strap) ................ .
RH side of Engine Block,just above Starter
(2 rings, 2 wires) ................................ .
2 studs, 2 rings on each, interchangeable. Top RH side
of Engine, 1 stud in head, 1 stud in Intake Manifold ..
Near top RH side ofradiator, in top ofT-Bar ......... .
Near top LH side ofradiator, in top ofT-Bar ......... .
Braided ground strap, bolted to forward left side
of Engine Block ................................. .
Braided ground strap, bolted to left front frame rail
(some vehicles will have 1 ring terminal in addition
to ground strap) ................................. .
37
54
202-24
19
47
36
69
202-24
10
18
202-24
43
63
43
63
47
72
202-2
47
46
34
72
67
51
202-2
202-16
202-16
1 .... 2
41 ... 60
6
11
202-16
202-8
5
33
9
50
202-8
13
25
42
10
62
19
23
40
25
42
29
19
19
46
36
35
11
20
11 ...
21
COMPONENT
LOCATION
201-PG
G200 ................... . Near base ofLH "A" pillar, bolted to 1/P Mounting Stud
behind kick panel (2 rings, 2 wires) ............... . 9
G201
Near base of RH "A" pillar, bolted to I/P Mounting Stud
behind kick panel (1 ring, 1 wire) ................. . 9
Bolted to Floor Pan Bar #2, under Driver's Seat
G305
(2 rings, 2 wires, with AC3/AQ9), (1 ring, 1 wire
without AC3/AQ9) .............................. . 6
Bolted to roof, left of Dome Lamp (1 ring, 1 wire) ..... . 4
G310
Bolted to Hatch Release Bracket in Rear Compartment
G400
(2 rings, 3 wires) ................................ . 30
PlOO
Compartment ................................... . 19
PllO
Right side in dash panel, Engine to Passenger
Compartment ................................... . 19
P300 ................... . In rear center of roof, near Dome Lamp ............. . 4 ....
P400 ................... . Left rear in end gate panel ......................... . 30
P410 ................... . In left side spoiler
P500 ................... . Between LH door and "A" pillar .................... . 32
P600 ................... . Between RH door and "A" pillar .................... . 32
8108 (L32) ............. . Engine Harn, approx 4 cm from Cl 10 breakout ...... . 12
8108 (LTl) ............. . Engine Harn, approx 4 cm from Injectors 2
and 4 breakout .................................. . 26
8109 (LTl)
ECM breakout
SllO (L32)
ECM breakout
Slll
Forward Lamp Harn, approx 3 cm from Windshield
Wiper Motor Module breakout
Sl12
Forward Lamp Harn, approx 10 cm from G 106 breakout
Sl13
Center breakout
Sl 15 (L32)
Engine Harn, approx 10 cm from AIC Compressor
Clutch Conn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Sl15 (LTl) ............. . Engine Harn, approx 6 cm from Generator breakout . . 14
8131 (L32) ............. . Engine Harn, approx 13 cm from RH branch
8215 ................... . I/P Harn, approx 30 cm before DLC breakout
S216 ................... . 1/P Harn, approx 5 cm from Convenience Center breakout
8217 ................... . 1/P Harn, approx 23 cm before DLC breakout
S220 ................... . Cross Car Harn, approx 7 cm from Rearview
Mirror breakout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 . . .
S335
Driver Seat Harn, approx 12 cm from Power Seat
Control Module Conn
8410
Rear Body Harn, approx 7 cm from Left Backup
Lamp breakout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
8415
Lamp breakout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
S420
Hatch Harn, approx 7 cm from P300 . . . . . . . . . . . . . . . . . 4 . . . .
8430
Rear Fascia Harn, approx 5 cm from License
Lamp breakout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 . . .
8450
CHMSL ,Jumper Harn, approx 15 cm from bulbs
For a Service Part Cross Reference List and Information, refer to SECTION 8A-200.
FIG.
16
16
11
6
47
36
35
7
47
49
49
22
43
45
26
49
50
50
7
48
14 - 15
CONN
8A -
15- 0
RETAINED ACCESSORY POWER {RAP): KP2
FUSIBLE
l,!__NK E
2 GRY
5 RED
~ - - - - - ~ T O ABS RELAY
. ._ _ _ _ _...~PAGE8A-44-1
102
5 RED
2
BAQ
102
r----r-------,IGNITION
SWITCH
SEE POWER DISTRIBUTION
,-PAGE 8A-10-2
: ::01102
I
I
C200B
C200D
Cl
I
I
3 RED
102
3 RED
ACCY
LOCK-., _
OFF
START
I
I
,, BULB TEST
RUN
rn
102
IMPORTANT:
BOTH RELA VS WILL
REMAIN ENERGIZED FOR
10 MINUTES IF DOORS ARE
NOT OPENED.
3 BRN
4
3
:;Dr,02 --------------------------------
BATTERY
INPUT
SEE GROUND
SOLID
STATE
3 BLK
3 OK BLU
75
650
l -
.35 BLK
750
.5220
3 BLK
--------....._
750
_c200
DOOR
OPEN
INPUT
GRY/B~Ki
RAP 1
CONTROL
45
.5 GRYtBLK
~I ------------
I ISOLATION
JS266
-
IODE (RAP}
.5 GRY/BLK
A
~~~~~~
SEE INTERIOR
LIGHTS
~P_A_G_E_B_A_-1_1_4--0~
RAP 1 RELAY
ALWAYS ENERGIZED
WITH A DOOR OPEN.
REMAINS ENERGIZED
FOR 35 SECONDS
AFTER BOTH
DOORS ARE
CLOSED.
IGNITION
INPUT, RESET
RAP 2
CONTROL GROUND
l...
RETAINED
ACCESSORY
POWER(RAP}
MODULE
AA
RAP 2 RELAY
OE-ENERGIZES
IMMEDIATELY
WHEN A DOOR
IS OPENED.
DISTRIBUTION
PAGE 8A-l 4 - 7
C200D
C200C
E2
3 B~N
745
745
TO IGNITION
~ KEY WARNING
3 PNK
.5 TAN
A
159
PAGE 8A-76-0
A
~~~~~~~HB
ET 2
[ ]
CLOSED WITH
DOOR OPEN
~~~~~~~:
WINDOWS
CIRCUIT
BREAKER 15
35AMP-
C200C
C2000
CLOSED WITH
DOOR OPEN
3 PNK
RADIO
FUSE 17
15AMP
70
SWITCH
70
---,
PWRACCY
FUSE 7
15AMP
I
I
I
---------------------------- ---~
~
SEE FUSE
BLOCK DETAILS
PAGEBA-11-8
SEE FUSE
BLOCK DETAILS
PAGE SA-11-7
ELECTRICAL DIAGNOSIS 8A - 15 - 1
1/P HARNESS TO FORWARD

LAMP/CROSS CAR HARNESS
C200D
13
E
DDDDDDDD DODD D
1
E
: :__: : :~ ~u:
:
:
:::
c::::dJ
86 -,-11
11 1
1 11
1-1-1
ADDDDDDDDDDDDDDDDDA
81
11
12077822
M - CONNECTOR
F-TERMINAL
48-WAY M METRI-PACK MIXED SERIES
BLK
C200A
FORWARD LAMP HARNESS TO

1/P HARNESS
JA DDDDDDDDDDDDDDDDDA
11
12047842
17-WAY F METRI-PACK 150 SERIES
BLK

1/P HARNESS
C200B
81
C1
01
I
I
I
II
II
II
11
11
11
t::::i 2:1
11
11
II
11
11
11
1
I C6
106
86
12084183
18-WAY F METRI-PACK MIXED SERIES
BLK
CROSS CAR HARNESS TO

1/P HARNESS
C200C
IADDDDDD DODD DDDAul

1
\
7
12047840

GRY
SA -
RETAINED ACCESSORY POWER (RAP): KP2
12052854
12010966
5-WAY F 56 SERIES
BLU

BLK
IGNITION SWITCH (C2)
RETAINED ACCESSORY POWER (RAP) MODULE
COMPONENT
Door Jamb Switch, LH
Door Jamb Switch, RH
I/P Fuse Block .......... .
Ignition Switch ......... .
Isolation Diode (RAP) ... .
LOCATION
201-PG
Near base of LH "A" pillar . . . . . . . . . . . . . . . . . . . . . . . . . . 32 .. .
Near base of RH "A" pillar . . . . . . . . . . . . . . . . . . . . . . . . . . 32 .. .
LH side ofl/P Carrier, on the side . . . . . . . . . . . . . . . . . . . 8 ... .
Part of Steering Column . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Sealed in Harn, approx 9 cm right of Rearview
Mirror breakout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

(RAP) Module ......... . In molded pocket of dash mat, center above floor tunnel
C200B (18 cavities)
and Steering Column ............................ .
C200C (13 cavities)
Steering Column ................................ .
C200D (48 cavities)
Steering Column ................................ .
0200
Near base of LH "A" pillar, bolted to 1/P Mounting Stud
behind kick panel (2 rings, 2 wires) ............... .
PlOO
Compartment ................................... .
8200
Forward Lamp Harn, approx 8 cm from EBCM
breakout ....................................... .
8220
Mirror breakout ................................ .
8266
Mirror breakout ................................ .
FIG.
49
49
15 ..
51 ..
CONN
202-19
202-22
49
9 .... 17 . .
202-24
41
65 ..
202-2
47
72 ..
202-2
47
72 ..
202-2
9 .... 16
19 ... 36
8 .... 14
32
49
32
49
TROUBLESHOOTING HINTS
(Perform before beginning

Diagnosis)
System
1. Check Fusible Link E for open.

2. Check Window Circuit Breaker 15, Radio Fuse 17
and PWR ACCY Fuse 7 for an open. If open,
replace fuse or circuit breaker. Iffuse blows again
or circuit breaker reopens, use schematics and
DVM to check suspect power circuits for a short to
ground potential, either through a faulty
component or wiring.
3. Check for poor connections at C200 terminals
"Cl", "E2", "E4", "E6" and "E12".
4. Check that 0200 is clean and tight.
Check for a broken (or partially broken) wire
inside of the insulation which could cause system
failure but prove "GOOD" in a continuity/voltage
check. Use Test Light J 34142 whenever possible.

Test lights require more current than a high
impedance DVM and are more useful for detecting
abnormally high resistive circuits. Some test
lights have high impedances and will not be as
useful in detecting resistive circuits (see
"Troubleshooting Procedures," page 8A-4-0).
Check for proper installation of aftermarket
electronic equipment which may affect the
integrity of other systems (see "Troubleshooting
Procedures," page SA-4-0).
Refer to System Diagnosis.
SYSTEM DIAGNOSIS
Perform the System Check and refer to the
Symptom Table for the appropriate diagnostic
procedures.
SYSTEM CHECK
NORMAL RESULTS
ACTION
[ 1I
Ignition "OFF."
Open either LH or RH door .
[2]
Close doors.
[3]
Ignition Switch to "ACCY" or "RUN."
[4]
Power Door Locks, Hatch Release and Power

Mirrors all operate for approximately 10 minutes.
Radio and Power Windows operate for
approximately 10 minutes.
Ignition Switch to "RUN."

Ignition Switch to "OFF."
Open either LH or RH door.

Mirrors all operate as long as a door is open.
Radio and Power Windows are disabled
immediately when a door is opened.
Close doors.
rn

Mirrors all operate as long as the Ignition Switch is
in "ACCY" or "RUN."
Radio and Power Windows operate as long as the
Ignition Switch is in "ACCY" or "RUN."
[6]

Mirrors all continue to operate for approximately
35 seconds.
Radio and Power Windows do not operate .
[SI

Mirrors all operate as long as a door is open.

Mirrors all continue to operate for approximately
35 seconds.
Important:
If aftermarket equipment is installed on any circuit(s) for the Retained Accessory Power (RAP) System and
a problem exists with the Retained Accessory Power System operation, disconnect the aftermarket
equipment and retest.
These diagnostic procedures assume related fuse(s) or circuit breaker(s) and the circuitry to their related
components are all good.
SYMPTOM TABLE
SYMPTOM
PROCEDURE
PAGE NUMBER
Components on PWR ACCY Fuse 7, Radio Fuse 17 and

Windows Circuit Breaker 15 totally inoperative.
Chart #1
8A-15-5
Retained Accessory Power (RAP) Feature inoperative,

components on PWR ACCY Fuse 7, Radio Fuse 17 and
Windows Circuit Breaker 15 operate with Ignition
Switch in "RUN" or "ACCY" only.
Chart #2
8A-15-5
SA -
15 - 4

SYMPTOM TABLE
SYMPTOM
PROCEDURE
PAGE NUMBER
Components on Windows Circuit Breaker 15 and

Radio Fuse 17 totally inoperative, components on
PWR ACCY Fuse 7 operate normally.
Chart #3
SA-15-6
Components on Windows Circuit Breaker 15 and Replace Retained Accessory Power (RAP) Module.
Radio Fuse 17 do not operate during Retained
Accessory Power (RAP), operation is normal with
Ignition Switch in "ACCY" or "RUN" (components on
PWR ACCY Fuse 7 operate normally during RAP).
Chart #4
Components on PWR ACCY Fuse 7 totally inoperative,

components on Windows Circuit Breaker 15 and Radio
Fuse 17 operate normally.
SA-15-6
Components on PWR ACCY Fuse 7 do not operate Replace Retained Accessory Power (RAP) Module.
during Retained Accessory Power (RAP), operation is
normal with Ignition Switch in "ACCY" or "RUN"
(components on Circuit Breaker 15 and Radio Fuse 17
operate normally during RAP).
Retained Accessory Power (RAP) deactivates when
another vehicle system is used (otherwise RAP times
out normally).
Retained Accessory Power (RAP) deactivates before

specified time has elapsed (deactivation not caused by
the use of other vehicle systems).
If use of Interior Lights causes deactivation of

Retained Accessory Power (RAP), check Isolation
Diode (RAP).
Narrow in on system causing deactivation and
shield or filter power and grounds to component,
then retest system.
If unable to correct complaint, contact technical
assistance.
Refer to System Check to make sure the RAP
System is not operating properly.
Check for technical service bulletins.
If above checks do not correct symptom, replace
Retained Accessory Power (RAP) Module.
PWR ACCY Fuse 7 receives voltage continuously (past

the approximately 10 minute period) with doors
closed and Ignition Switch in "OFF."
Check for short to B + in CKT 70.

Check for short to ground through CKT 745,
including a bad Door Jamb Switch.
Check for poor connections at RAP Module
Connector.
If OK, replace Retained Accessory Power (RAP)
Module.
Radio Fuse 17 and Windows Circuit Breaker 15 receive

voltage continuously (past the approximately 10
minute period) with doors open and Ignition Switch in
"OFF."
Check for short to B + in CKT 75.

Module.
Check for bad Door Jamb Switch on side of entry.

Check for open in CKT 745.
Check for poor connection at RAP Module.
Module.
Power Door Locks do not operate when one or

both doors are opened.
Power Door Locks only operate with Ignition
"ON," or for 1O minutes after Ignition is turned
"OFF." (Opening the door does not disable the 10
minute timer or enable "PWR ACCY" Fuse 7.)
15 - 5
CHART #1
rn
COMPONENTS ON PWR ACCY FUSE 7, RADIO FUSE 17

AND WINDOWS CIRCUIT BREAKER 15 TOTALLY INOPERATIVE
IMPORTANT:
THIS CHART ASSUMES RELATED FUSE{S) OR CIRCUIT BREAKER{S) AND THE CIRCUITRY TO THEIR RELATED
COMPONENTS ARE ALL GOOD, AND INSTALLED AFTERMARKET EQUIPMENT IS NOT A PROBLEM.
IGNITION SWITCH TO "RUN."

WITH A TEST LIGHT TO GROUND, BACKPROBE RETAINED ACCESSORY POWER {RAP) MODULE CONN TERM "D".
IS TEST LIGHT "ON"?
WITH A TEST LIGHT TO GROUND, BACKPROBE IGNITION SWITCH CONN C2 TERM "B".
IS TEST LIGHT "ON"?
WITH A TEST LIGHT TO GROUND, BACKPROBE

IGNITION SWITCH CONN C2 TERM "E".
IS TEST LIGHT "ON"?
GJ
CHECK FOR POOR CONNECTION AT C200
TERM "C6" AND TERM "E2".
IF OK, REPAIR OPEN IN CKT 4 BETWEEN
IGNITION SWITCH AND RETAINED
ACCESSORY POWER {RAP) MODULE.
CHECK FOR:
POOR CONNECTIONS AT
RETAINED ACCESSORY POWER
{RAP) MODULE CONNECTOR.
POOR CONNECTIONS AT C200
TERM "E6" AND TERM "E12".
WIRING DAMAGE THAT MAY
CAUSE AN OPEN IN CKT 70
ANDCKT75.
IF ABOVE CHECKS ARE OK,
REPLACE RETAINED
ACCESSORY POWER {RAP)
MODULE.
CHECK FOR OPEN IN FUSIBLE LINK "E".

IGNITION SWITCH AND FUSIBLE LINK.
CHECK FOR POOR CONNECTION

A TIGNITION SWITCH.
IF OK, REPLACE IGNITION SWITCH.
CHART#2
rn
RETAINED ACCESSORY POWER (RAP) FEATURE INOPERATIVE, COMPONENTS ON

PWR ACCY FUSE 7, RADIO FUSE 17 AND WINDOWS CIRCUIT BREAKER 15
OPERATE WITH IGNITION SWITCH IN "RUN" OR "ACCY" ONLY
IMPORTANT:
THIS CHART ASSUMES RELATED FUSE(S) OR CIRCUIT BREAKER(S) AND THE CIRCUITRY TO THEIR RELATED
COMPONENTS ARE ALL GOOD, AND INSTALLED AFTERMARKET EQUIPMENT IS NOT A PROBLEM.
WITH A TEST LIGHT TO GROUND, BACKPROBE RETAINED ACCESSORY POWER (RAP) MODULE CONN TERM "C".
IS TEST LIGHT "ON"?
El
DISCONNECT RETAINED ACCESSORY POWER (RAP)MODULE CONNECTOR.
A TEST LIGHT BETWEEN TERMINALS "C" AND "E" OF THE RAP

CONNECT
MODULE CONNECTOR.
El
IS TEST LIGHT "ON"?
CHECK FOR POOR CONNECTIONS AT RETAINED ACCESSORY POWER

(RAP) MODULE CONNECTOR.
IF OK, REPLACE RETAINED ACCESSORY POWER MODULE. (IF POWER
ACCY FUSE RECEIVES VOLTAGE CONTINUOUSLY WITH DOORS CLOSED
AND IGNITION SWITCH "OFF," CHECK FOR A SHORT TO GROUND
THROUGH CKT 745, INCLUDING A BAD RAP ISOLATION DIODE OR
DOOR JAMB SWITCH.)

TERM "C1" AND TERM "E4".
RETAINED ACCESSORY POWER (RAP)
MODULE CONNECTOR AND 5200.
EJ
CHECK FOR POOR CONNECTIONS AT RAP MODULE

CONNECTOR.
IF OK, CHECK FOR OPEN IN CKT 750 BETWEEN RAP
MODULE AND G200.
15 - 6
SA -

CHART #3
COMPONENTS ON WINDOWS CIRCUIT BREAKER 15 AND RADIO FUSE 17
TOTALLY INOPERATIVE, COMPONENTS ON PWR ACCY FUSE 7 OPERATE NORMALLY
rn
IMPORTANT:
THIS CHART ASSUMES RELATED FUSE(S) OR CIRCUIT BREAKER(S) AND THE
CIRCUITRY TO THEIR RELATED COMPONENTS ARE ALL GOOD, AND
INSTALLED AFTERMARKET EQUIPMENT IS NOT A PROBLEM.

WITH A TEST LIGHT TO GROUND, FRONTPROBE RADIO FUSE 17.
IS TEST LIGHT "ON"?
WITH A TEST LIGHT TO GROUND, BACKPROBE RAP MODULE CONN TERM "B".
IS TEST LIGHT "ON"?
r-
--------------------------,
CHECK 1/P FUSE BLOCK FOR POOR WIRE

:
CONNECTIONS OR POSSIBLE DAMAGE.
1
IF OK, REFER TO "RADIO," PAGE SA-150-0.:
L----------------------------~
CHECK FOR POOR CONNECTION AT RAP MODULE CONN TERM "B".

IF OK, REPLACE RAP MODULE.

TERM "E6''.
IF OK, REPAIR OPEN IN CKT 75 BETWEEN RAP
MODULE CONNECTOR AND 1/P FUSE BLOCK.
CHART #4
COMPONENTS ON PWR ACCY FUSE 7 TOTALLY INOPERATIVE, COMPONENTS ON
WINDOWS CIRCUIT BREAKER 15 AND RADIO FUSE 17 OPERATE NORMALLY
rn
IMPORTANT:
THIS CHART ASSUMES RELATED FUSE(S) OR CIRCUIT BREAKER(S) AND THE
CIRCUITRY TO THEIR RELATED COMPONENTS ARE ALL GOOD, AND
INSTALLED AFTERMARKET EQUIPMENT IS NOT A PROBLEM.

WITH A TEST LIGHT TO GROUND, FRONTPROBE PWR ACCY FUSE 7.
IS TEST LIGHT "ON"?

RAP MODULE CONN TERM "A".
IS TEST LIGHT "ON"?
CHECK FOR POOR CONNECTION A TRAP MODULE CONN TERM "A".

IF OK, REPLACE RAP MODULE.
r-
------------------------------------,
CHECK 1/P FUSE BLOCK FOR POOR WIRE CONNECTIONS

:
OR POSSIBLE DAMAGE.
1
IF OK, REFER TO "POWER DOOR LOCKS," PAGE SA-130-0. :
L--------------------------------------J
CHECK FOR POOR CONNECTION AT C200 TERM "E12".

IF OK, REPAIR OPEN IN CKT 70 BETWEEN RAP MODULE
CONNECTOR AND 1/P FUSE BLOCK.
ELECTRICAL DIAGNOSIS SA - 15- 7
CIRCUIT OPERATION
The Retained Accessory Power (RAP) System is
designed to increase convenience and provide
increased security. Some Vehicle Systems will remain
operational for approximately 10 minutes after the
Ignition Switch is turned to "OFF" or until a door is
opened. Other systems will also be operational with
Ignition Switch "OFF" whenever a door is open or for
approximately 35 seconds after both doors are closed.
PWR ACCY FUSE 7 OPERATION
The Retained Accessory Power (RAP) Module will

enable the Power Door Locks, Hatch Release and
Power Mirrors to operate with the Ignition Switch in
"OFF" whenever either door is open or for 35 seconds
after both doors are closed. All components on this
circuit will be enabled as long as the Ignition Switch is
in "ACCY" or "RUN." After the Ignition Switch is
turned to "OFF" and both doors remain closed, the
components on this circuit will be enabled for
approximately 10 minutes. If either door opens, the 10
minute timer cancels, and the components remain
enabled as long as a door is opened.
RADIO FUSE 17 AND WINDOWS CIRCUIT BREAKER
OPERATION
The Retained Accessory Power (RAP) Module will

enable the Radio and Power Windows to operate
whenever the Ignition Switch is in "ACCY" or "RUN."
After the Ignition Switch is turned to "OFF" and both
doors remain closed, the Radio and Power Windows
will be enabled for approximately 10 minutes. If
either door opens, these components will be disabled
immediately.
SEQUENTIAL FUEL INJECTION: V6 VIN S

ENGINE DATA SENSORS
.5GRY
.SGRY
INTAKE AIR
TEMPERATURE
{IAT) SENSOR
I'
TEMP
1
/
416
MANIFOLD
ABSOLUTE
PRESSURE
(MAP) SENSOR
5V
REF
REF
LO
416
A/C EVAPORATOR
TEMPERATURE
A' ~
B
.5 BLK
.5 GRY
A/C
REFRIGERANT
PRESSURE
SENSOR
5V
REF
B; '
ill1
416
SENSOR - - - - - - - -
808
808
472
.STAN
ENGINE
CONTROL
MODULE
(ECM)
,,.
4:fA
r
I
I
I
I
.5LTGRN
432
.5 BLK
808
.5 REDIBLK
380
.5 DK BLU
732
.5 GRY
-r-__ -I ~-.:-.: -.:-.: ,_ . ;-:. :. :.: .-_,r~-:.-:.-:.-:.1!'~'_____

29,
, ;
(BLU)
29;
IAT
SENSOR
INPUT
MAP
SENSOR
INPUT
SENSOR
GROUND
REF
A/C
REFRIGERANT
PRESSURE
SENSOR
INPUT
-=-
:, If-------------------l------sv
A/C
EVAPORATOR
TEMPERATURE
SENSOR
INPUT
-=-
416
'.!. _ '!'~
SV
REF
f
\
5V
hs, ,cr
""''
om"
""O>,O"
~
I
L--~--------~~--- -------~~---~~--~~--J
~J:i~R
,a
SENSOR
GROUND
30
.5 DK BLU
17
.5 BLK
417
31
470
.5 YEL
INPUT
SENSOR
A
- (CLR)
20
.5 DK BLU
410
SENSOR
C
- (BLU)
496
21
.5 PPL'WHT
SENSOR
22
1665
.5 PPL
I!.
(BLKI
1666
.5 BLK
---- - - - - . 5122
470
.5 BLK
470
- - - -... ENGINE
COOLANT
TEMPERATURE
(ECD SENSOR
KNOCK
SENSOR ..__,.,..._
.SGRY
416
.5 PNK/BLK
470
_.
OXYGEN
~LH
OXYGEN
SENSOR.RH

CONTROLLED DEVICES
UNDERHOOD
. ELECTRICAL
------------------,
r-----SEE POWER
<:.E.N..rrn 1 01sTR1BuT10N
I
I
I
I
I
I
I
I
SEE COOLANTFANS
PAGE SA-31-0
......... ...........
.35 BRN
AIR _"""_ _ _ _ _'"""'"'I
541
PUMP
RELAY
~:.-.,;;:.-:.:es,; - - -- --
_35 BRN
541
F ,ii. C100
'i'-
EVAPORATIVE~
EM:~~f~
CANl5TER
PURGE
SOLENOID
VALVE
SECONDARY
1
INJ ECTl~ :
PUMP
11
21.8
EXHAUST
RECIRCULA~
(EGR)
SOLENOID
VALVE
~-
_ _J
:!.
.8RED
B
. .- - - - - - - - - - - - - - - - . 5127
.35 BRBN 1541
. 35 BORN s41
335
-?:1--
.35 BRN
436
.5 BRN
436
78
.35BRN 1541
.5 DK GRN
I
I
I
I
I
I
I
I
I
PAGE SA-10-3
---'"""--T""--.
M
ASSEMBLY
SIOILENOID-
SIIOLENOID-
SIOILENOID-
C\'1
--------
,
_
=-:r
_
_
_
_
:
:f~
.
.
1~"'
.
1,
_
_
_
:~~~~--~
~~1i
_
.
.
""'
r-r:0:A:F: -z-E:P:N:E:- RELAY CONTROL
PURGE SOLENOID
CONTROL
-=l_
-=l_
-lS:E:D~ SOLENOID tOLENOID CONTROL

CONTROL
CONTROL
-=l_
-=l_
-=l_
All SOLID STATE
r:~RM;- ,
RELAY
CONTROL
-=l_
NO RELAYS OR SWITCHES
\
\
COIL"A"
COIL"A"
COIL"B"
COIL"B"
I
I
I
I
I
I
I
~;j;~~~fi:::.,;;~:-------------..~"::J"'.~, -.~";; I"~. -..:.:X:

:.:.E;f
1"~.
1, [l
A - CLEAR (CLR)
B - BLACK (BLK)
C - BLUE (BLU)
32 WAY
32 WAY
. 32 WAY
WHT
D
WH~
B
IDLE AIR
CONTROL (IAC)
~OTOR
COIL B
STEPPER
MOTOR
SEE PAGE SA-3-0

FOR MEASURING
AND HANDLING
PROCEDURES
SA -
20 - 2

INJECTORS
HOT IN RUN, BULB TEST OR START
UNOERHOOD r" ELECTRICAL
CENTER
--,
-,
SEE POWER
DISTRIBUTION
PAGE 8A-103
INJECTOR
rusf9
I
I
______ _.
7.5 AMP
L
.8 PNK
639
.8PNK
.8 P:K1739 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
8 PN:1:~t
.--
.5 PNK B:Kt:39 - - - - - - - - - - - - - - - - - - - - - - - - - - - - .5 PNK;B:,8:~lO
.5 PNK/
BLK
639
..............
1
1
~103
5104
~639
.5 PNK/
BLK
639
FUEL
INJECTORS
.5 PNK.
8LK
.5 PNK/
BLK
~
PNK.'
5839
BLK
839
839
ffiJ@J ffiJ ~J ffiJ f iJ~;

.~ , ~:~~:L_,_~-~I~ ________::~ ~ : t~~~:~:, ~_~:,;I:,.
.5 PNK:BLK
.5 BLK
14
.S LT BLU,BLK
1746
1744
.5 BLK,WHT
845
.SL T GRN!BLK
13
16
------12
844
1745
.5 VEL.'BLK
32
------15
846
<:; (BLU)
ENGINEr--1---z---1--------7-----1----1-----~
CONTROL
MODULE (ECM)
I
I
~I
I
\
-'
-:_.__
INJECTOR #1
CONTROL
-=-l
INJECTOR #3
CONTROL
-=-l
INJECTOR #5
CONTROL
ALL 50LIO STATE
~~l~~~~;soR
1
INJECTOR #2
CONTROL
=l
INJECTOR #4
CONTROL
1
INJECTOR #6
CONTROL
I
/
L------------------------------------J
L32
ECM CONNECTOR IOENTIFICATIOI'!

ALL CONNECTOR BODIES ARE GRAV
WITH COLORED TPAs.
A CLEAR (CLR)
B BLACK (BLK)
C BLUE (BLU)
SEE PAGE 8A-3-0

FOR MEASURING
ANO HANDLING
PROCEDURES
32 WAY
- 32 WAY
- 32 WAY
20- 3

DATA LINK, GROUND AND POWER
--------------,~
SEE POWER
DISTRIBUTION
PAGE BA-10-3
FUSE
I BLOCK
I
I
I
GAGES
FUSE9
IGN
(NOT USED)
lOAMP
_____ J
.5 PNK
439
f-- -
5209-
SEE FUSE
BLOCK DETAILS
PAGE BA-11-6
.8 PNK
39
-5206
DATA LINK
CONNECTOR (OLC)
"""" ,...--H-----,
""1"
+I @
l
-J
BLOCK DETAILS
PAGE8A 11-4
J;
~INSTRUMENT
CLUSTER
AS
-BORN
I SEE
I INSTRUMENT
CLUSTER
I PAGE 8A-81-0
340
C210
5205
----,::.:r,00
I
I
I
(Mil)
"SERVICE
ENGINE
SOON"
I
I
INDICATOR
L..----
522~~
.]STAN
800
I
I
SEE DATA LINK

CONNECTOR
c200D
____ ......
A4
.35
80
TAN~
.SORN
340
.S PNK
.35 BRNIWHT
439
419
.35 WHTiBLK
.35 TAN
448
5270
800
.JS TAN
':::~i'" ""}"
-E--"'- --14
r - - -
El
____ .!_5
(BLK)
<:: (BLU)
7;;'N,Tio;' - - - - - -
_J
-l
7
INPUT
BATTERY
INPUTS
<:: (BLU)
GPOROWUENRDS
LH OXYGEN
~N~R~~
16
2
- : :L:.:l~T
.S BLK-WHT
45~ - -
0r-
RH OXYGEN
_lE~O~N~ -
ENGINE SOON"
INDICATOR
~CONTROL
SEE GROUND
....._
DISTRIBUTION
PAGES 8A-14-2. 3
,...- -
~
1 BLKWHTI 451
351
':!,01~!.~
- - - - "7v - - , I
DIAGNOSTIC
SERIAL
ENABLE
DATA
LINE
- - - - - - - - - - -:,_ - <:: (BLU)
3:1(BLK)
.5 TAN,WHT
551
.5 TANiWHT
551
5131
Cl Q_Q
B_ (BLK)
I
I
I
,'
REDUNDANT
-
451
.5 BLK.WHT
j_
17
:L~ ~:T
19
'iM1u
- - - - [sv"SERVICE
INPUTS
a.. -
-=-
GROUND
0
I!_ (BLK)
800
BLK,WHT 351
_._.8 ___
_.__ _____________ -----=- G104
2 STUDS WITH
2 TERMINALS ON EACH
(INTERCHANGEABLE)
8A -
20 - 4

IGNITION
r"" -
I
I
SEE POWER
DISTRIBUTION
PAGE 8A-10-3
.8 PNK
ELECTRICAL
--
L-----
-, UNDERHOOD
I CENTER
IGNITION
FUSE 11
10 AMP
I
---...I
239
GYC100
.35 PNK
.35PNK.23~~tlfl/l. . . . . . . . . . . . . . . . . . . . . .23
. . . . . . . . . . . . .~~~~~~~A~""~P"'-----.
S107
.35 PNK
r--------------,r-,
A "'
OPTICAL SENSOR
r"' -
CRANKSHAFT
POSITION
SENSOR,
HIRESOLUllON
(INDUCTIVE
PICKUP)
239
CAMSHAFT
POSITIONSENSOR
-, INSTRUMENT
I
I CLUSTER
I TACH I
INPUT
B';;
I-..,
.8WHT
.5 WHT
.8 PNK
121
239
C230
121
.5 TAN/BLK
424
.SWHT
ELECTRONIC
30
27
28
423
.5 LT BLU!
BLK
31
647
.S RED!BLK
453
r---...,.~~-------...;.~;;.;;;..._____________...;,i~---~-----,.,~-----,,~....,--,
IGNITION
MODULE
COIL
PACKS
mL
CYLINDER #5
#2
#3
#6
TO SPARK
PLUG WIRES
FIRING ORDER
1-2-3-4-5-6
#4
#1
SEE HVAC
COMPRESSOR
CONTROLS
PAGE 8A64-0
SEE GROUND
DISTRIBUTION
PAGE 8A-14-2
.8 BLK
450

FUEL PUMP, HVAC AND PASS-KeyII INPUT
r - - ,
PASS-KeyII
DECODER
I MODULE
---"'11/P
,I FUSE
BLOCK
L -
.35 OK BLU
SEE HVAC COMPRESSOR CONTROLS

PAGE 8A-64-0
..I
A3
..
229
.5 DK GRN
___ _
59
1
I
-
.5 PNK
SEE FUSE
BLOCK DETAILS
PAGE8A-11-4
.... -
.a
439
S205
L32 ECM CONNECTOR IDENTIFICATION

.5 OK BLU
23
,..- -
229
!'.; (BLU)
FUEL
ENABLE
INPUT
.5 DK GRN1
WHT
762
2
-
.5 DK GRN1
WHT
(CLR)
A.C
REQUEST
INPUT
A CLEAR (CLR)
B BLACK (BLK)
C BLUE (BLU)
~
6
-
ALL CONNECTOR BODIES ARE GRAV

WITH COLORED TPAs.
459
(BLK)
A,C
COMPRESSOR
CLUTCH
RELAY
CONTROL
32 WAV
32 WAV
32 WAV
!'.; (BLU)
A/C
STATUS
. , ENGINE
CONTROL
MODULE
(ECM)
I
I
I
,~
'
~---------~~-----~~---~
\
I
I
FUEL PUMP
.5 GRV
120
1T
.5 GRV
F
SEE INSTRUMENT
CLUSTER
PAGE 8A-81-2
.8 GRV
439
A (CLR)
~
.5 DK GRN/WHT
.5 GRV
5128.
1 PNK
I
I
FUEL PUMP
6T___________
ii-------(:11(----.
P110
120
465
C220
465
-------..--FUEL
PUMP
RELAY
120
C220
FUEL PUMP
PRIME CONNECTOR
120
1 GRV
s215e
.35 PPLtO
120
.8 GRV120
~:~~!
1
A2
---------~ __
F _ _.,__ _ _ _ _ _ _,.___._""'FUEL
TANK
UNIT
90Q
FUEL
PUMP
e
oQ
A1J:
.8 BLK/WHT
451
5215----,
210
sac,,w
,~,,,
~. WITH AC3 OR AQ9
see GROUND
DISTRIBUTION
PAGE BA-14-10
.8 BLK,WHT
3 BLK
1450
.5BLK/WHT1451
451
_..iilllllll
l
SEE GROUND
DISTRIBUTION
""f")
iw,A
L1:::--...1
.-Jl:..
G104
SEE PAGE 8A3-0

FOR MEASURING
AND HANDLING
PROCEDURES
SA -
20 - 6

AUTOMATIC TRANSMISSION CONTROLS (MOS) AND VSS
HOT IN RUN OR START
r------------,!Lf
I
I
I
I
SEE POWER
DISTRIBUTION
PAGE 8A-10-3
GAGES
FUSE 9
10AMP
IGN
(NOT USED)
L--------
__ ...
.8 PNK
SEE FUSE
BLOCK DETAILS
PAGE 8A-11-4
I
I
I
I
SEE PAGE SA-3-0

FOR MEASURING
AND HANDLING
PROCEDURES
FUSE
BLOCK
39
.---5206
.35 PNK 139
BAg
rn
.---------------..--------------...-----------~BRAKE
BRAKE LIGHT
BRAKE
SWITCH
TCCiSHIFT
DEPRESSED
CRUISE RELEASE
ASSEMBLY
INTERRUPT
SWITCH
~
SWITCH
(NORMALLY
(NORMALLY
OPEN)
CLOSED)
IMPORTANT:
==
1
TRANSMISSION MUST BE IN
4TH GEAR FOR THE
TEMPERATURE SWITCH TO
ENGAGE TORQUE
CONVERTER CLUTCH (TCC)
TO COOL TRANSMISSION.
CLOSES AT 136.5'C :!: 3.5'C
(277 .5'F :!: 6.5'F)
PAGE 8A-34-1
.35LTBLU/B~Kr,::
.35 LT BLU/BLK
---------35LTBLU/BLK_ _ _ _ _ _ _ ___
583
OPENS AT 126'C:!: 5'C

(259'F :!: 9'F)
$~38
m,~,.t:="
.SLT BLU/BLK
583
rn
. .583
- - - - - - - - - - - - - 5124
.35 LT BLU/B!~5;NORMALLY
OPEN,
CLOSED IN
4TH
...
4TH
GEAR
SWITCH
- :..
SWITCH
....,.
-.AUTOMATIC
TRANSMISSION
(MD8)
I
I
I
TCC
SOLENOID
Bl
.SLTBLU
446
________
C(~
USED)
FUSIBLE LINK WIRE IS

LOOPED OUTSIDE OF
TAPED BUNDLE.
APPROXIMATELY 12.5 CM
IN LENGTH.
B
TRANSMissioN
BRAKE[Q]
SHIFT INTERRUPT
(BTSI) SOLENOID
DATA LINK
CONNECTOR (DLC)
STARTER r"' SOLENOID
..!
- - - j;_ - - - - - - -
CASE
GND
18
IMPORTANT:
-----'4
1
.35TA~/~22
BL~
.35 TAN/BLK
SEE HATCH RELEASE

PAGE 8A-135-0
5118
422
.5 TAN/BLK 1422
3 PPL
I
I
5v
4000 PULSE
-=.f
-=-
PARK/NEUTRAL
~~~~~~~~~~~---~~---~
1
.5 ::Lr:0~ -
]Or.::K
~::):~tLK)
.5 YE,00
WHl
SEE VEHICLE SPEED SENSOR

PAGE 8A-33-0
P110
.5 ORN/~L K

ALL CONNECTOR BODIES ARE GRAY
WITH COLORED TPAs.
32 WAY
32 WAY
32 WAY
1 DK GRN
575
.35 ORN/BLKf:-
,----- ------- --,I

B
\ R
4:4(BLU)
I
I
e. , N @ D , : .2 ' I
.___ _ ........... .,r
L---- ------ ----~
TRANSMISSION
Av
POSITION
BLK/ 1451
SWITCH
WHT
s DK GRN I
575 .5 RUST
$245. ~ .
L32
A CLEAR (CLR)
B - BLACK (BLK)
C - BLUE (BLU)
__________ _!5..AA (CLR)
I
I
.35 TAN/Bf 2 2 . - - - - - - - - - ,
.8 ORN/BL~34
4
ENGINErf----f-----z----,
CONTROL
TORQUE
.35 ORN/BLK
C
MODULE
TCC
4TH
CONVERTER
. .- - - - - - - $ 2 3 4
(ECM)
BRAKE
. GEAR
CLUTCH (TCC)
434
.6.
INPUT
INPUT
CONTROL
~ I
~I-=-
-,
5 DK :~NJt:
.------SEE GROUND
DISTRIBUTION
PAGES8A-14-2,3
P110
_Jt..F104
r"' -
I
I
L. -
-,STARTER
I ENABLE
RELAY
I
...
""5257
FUSIBLE
LINK
(BTSI)
20 - 7

MANUAL TRANSMISSION CONTROLS (MM5) AND VSS
ENGINEr---------------,
I
I
~I
~
I
CONTROL
MODULE
(ECM}
L32

WITH COLORED TPAs.
L _vs1,!-o__ ~s ~ _
4000 PULSE
CLUTCH
PER MILE
ANTICIPATE
~T~T _ _ ..!N~ _ _
29
.5 PPL
28
.S DK GRN1
WHT
401
I!
(BLK)
817
A - CLEAR (CLR)
B - BLACK (BLK}
C - BLUE (BLU}
- 32 WAY
32 WAY
32 WAY
~ (CLR}
22
.35 GRY
48
I"" -
-,
STARTER
I SOLENOID

PAGE 8A-330
rn
.35 GRY
48
.35 GRY
48
IMPORTANT:
CKTS FROM C270 TO
SWITCH ARE CONTAINED
IN A CLUTCH JUMPER
HARNESS.
CLUTCH
ANTICIPATE!
CRUISE RELEASE
SWITCH
c
B"'
-----~-------r-----,
5 DK GRN
575
BRAKE
DEPRESSED
A2
CLUTCH
~NTICIPATE _
SWITCH
CRUISE
RELEASE
SWITCH
I"" -
-, STARTER
,-
I ENABL~
RELAY
L. -
..I
.35 BLKW:TIS1
AC270
.3S BLK.WHT.451
----S215
mw+
SEE GROUND
DISTRIBUTION
PAGES 8A-14-2, 3
SEE CRUISE
CONTROL
PAGE 8A-34-0
....... _
,...- -
.8 BLK,WHT
L---,
P110
451
_:_u104
SEE PAGE 8A-3-0

FOR MEASURING
AND HANDLING
PROCEDURES
20 - 8
SA -
@@@@@@@@@@@@@@@@
,@@@@@@@@@@@@@@@@16
12129025 {BODY)
32-WA Y F MICRO-PACK
GRY
12129022
TPA MICRO-PACK 100W
CLR
ENGINE CONTROL MODULE

**CAVITIES NOT LISTED ARE NOT USED
CAVITY
WIRE COLOR
CKT
DESCRIPTION
BLK
808
SENSOR GROUND FOR MAP, IAT, A/C REFRIGERANT PRESSURE SENSOR AND
DTC(s) 22, 23, 33, 71
DKGRN/WHT
762
A/C REQUEST
SECC10
DKBLU
732
A/C EVAPORATOR TEMPERATURE SIGNAL
DTC(s)71, 73
RED/BLK
380
A/C REFRIGERANT PRESSURE SIGNAL
DTC(s) 66, 70
GRY
120
FUEL PUMP SIGNAL
DTC54
DKGRN/WHT
465
FUEL PUMP ENABLE
DTC54
15
TAN/BLK
422
TORQUE CONVERTER CLUTCH ENABLE
SECC8
17
BLK
470
SENSOR GROUND FOR ECT AND TP SENSORS
DTC(s) 15,21,22
18
LT BLU/BLK
583
TCC/BRAKE SWITCH INPUT
DTC81
22
22
LTBLU
GRY
446
48
4th GEAR SWITCH (AIT)

CLUTCH ANTICIPATE SWITCH (MIT)
SECC8
29
LTGRN
432
MAP SENSOR SIGNAL
DTc(s) 33, 34, 44
30
DKBLU
417
TP SENSOR SIGNAL
DTC(s) 21, 22
31
YEL
410
ECT SENSOR SIGNAL
DTC(s) 14, 15
6E3 REFERENCE
B
17
@@@@@@@@@@@@@@@@
1@@@@@@@@@@@@@@@@16
12129025 (BODY)
32-WAY F MICRO-PACK
GRY
12129021
TPA MICRO-PACK 100W
BLK

DESCRIPTION
CAVITY
WIRE COLOR
CKT
DKGRN
335
COOLANT FAN RELAY CONTROL
SECC12
BRN
436
SECONDARY AIR INJECTION SYSTEM AIR BYPASS SOLENOID
SECC6
DKGRN/WHT
428
EVAP CANISTER PURGE
SECC3
DKGRN/WHT
459
A/C COMPRESSOR CLUTCH RELAY CONTROL
DTC68
BRN/WHT
419
MIL (SERVICE ENGINE SOON)
CHART A-1
11
LTBLU
697
EGR #1 CONTROL
DTC75
12
BRN
698
EGR #2 CONTROL
DTC76
13
RED
699
EGR #3 CONTROL
DTC77
14
ORN
340
BATTERY (KEEP ALIVE MEMORY)
CHART A-3
15
ORN
340
BATTERY (KEEP ALIVE MEMORY)
CHART A-3
16
BLK/WHT
451
ECMGROUND
CHART A-1
19
TAN
800
SERIAL DATA
CHART A-1
20
BLK/WHT
351
LEFT 025 GROUND
DTC(s) 13, 44, 45
21
PPL/WHT
1665
LEFT 025 SIGNAL
DTC(s) 13, 44, 45
22
PPL
1666
RIGHT 025 SIGNAL
DTC(s) 63, 64, 65
23
BLK/WHT
351
RIGHT 025 GROUND
DTC(s) 63, 64, 65
24
LTGRN/WHT
1749
IAC COIL "B" HIGH
DTC35
25
LTGRN/BLK
444
IAC COIL "B" LOW
DTC35
6E3 REFERENCE

CAVITY
WIRE COLOR
CKT
26
LT BLU/BLK
1748
IAC COIL "A" LOW
DTC35
27
LTBLU/WHT
1747
IACCOIL "A" HIGH
DTC35
28
DKGRN/WHT
817
BUFFERED SPEED OUTPUT(4000 PULSES/MILE)
OTC80
29
PPL
401
VSS INPUT LOW
OTC(s) 79, 80
30
YEL
400
VSS INPUT HIGH
DTC(s) 79, 80
31
GRY
416
5 VOLT REFERENCE, MAP, TP AND A/C PRESSURE SENSORS
DTC(s)22,34,66,67, 70, 71,73
32
BLK/WHT
451
ECMGROUND
FIG A-1
DESCRIPTION
6E3 REFERENCE
c
17
@@@@@@@@@@@@@@@@
1@@@@@@@@@@@@@@@@16
12129025 (BODY)
32-WAY F MICRO-PACK
GRY
12129023
TPA MICRO-PACK 100W
BLU
CAVITY
WIRE COLOR
CKT
TAN/WHT
551
ECMGROUND
FIG A-1
DKGRN
59
A/CSTATUS
DTC(s) 68, 69
PNK
439
IGNITION FEED
DTC82
WHT/BLK
448
DIAGNOSTIC ENABLE
080 SYSTEM CHECK
11
ORN/BLK
434
PARK/NEUTRAL POSITION SWITCH INPUT
SECC1
12
PNK/BLK
1746
INJECTOR DRIVER CYLINDER #3
SECC2
13
LTGRN/BLK
1745
SECC2
14
BLK
1744
SECC2
15
YEUBLK
846
SECC2
16
BLK/WHT
845
SECC2
DESCRIPTION
6E3 REFERENCE
20 - 11

DESCRIPTION
CAVITY
WIRE COLOR
CKT
17
TAN/WHT
551
ECMGROUND
FIG A-1
18
PNK/BLK
632
REFERENCE LOW CAMSHAFT AND CRANKSHAFT SENSORS
SECC4
20
DKBLU
496
KNOCK SENSOR SIGNAL
DTC43
21
LTBLU/WHT
1800
24X REFERENCE SIGNAL
DTC36
23
DKBLU
229
VEHICLE ANTI-THEFT SYSTEM INPUT
DTC46
25
BRN/WHT
633
CAMSHAFT SENSOR SIGNAL
OTC 17
27
WHT
423
IGNITION CONTROL
DTC42
28
TAN/BLK
424
IGNITION CONTROL BYPASS
DTC42
29
TAN
472
IAT SENSOR SIGNAL
DTC(s) 23, 25
30
LTBLU/BLK
647
3X REFERENCE HIGH
DTC82
31
RED/BLK
453
3X REFERENCE LOW
SECC4
32
LTBLU/BLK
844
SECC2
COMPONENT
NC Evaporator
Temperature Sensor
LOCATION
Mounted in Evaporator Core
6E3 REFERENCE
201-PG
46 ...
FIG.
CONN
67
NC Refrigerant Pressure
Sensor ................ . Above RH Shock Tower, forward of NC Compressor
Low Pressure Cut Off Switch ..................... . 18 ... 34
Brake Switch Assembly ... Mounted in lower hole of brake pedal bracket (2 conn
same switch for both ............................. . 0 .... 1
Interrupt (BTSI) Solenoid In console, under PRNDL Display .................. . 37
54
In front top of Engine Block, between Intake and
Water Pump .................................... . 13
24
Clutch Anticipate/
(all V6 Manual) ........ . Mounted in clutch pedal bracket (4 cavity conn)
0
1
Clutch Start Switch ..... . Mounted to clutch pedal bracket, behind
Convenience Center ............................. . 0
1
HI Resolution ......... . Lower front of Engine Block, pigtail comes out
LH side of crank ................................ . 11
20
LO Resolution ......... . Lower RH side of Engine Block, has no pigtail ....... . 28
45
Data Link Conn (DLC) ... . Mounted to I/P Tie Bar, below and right of
Steering Column ............................................... .
Left front of Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
44
(ECM) . . . . . . . . . . . . . . . . . In Engine Compartment, rearward of RH Shock Tower
19
35
(ECT) Sensor . . . . . . . . . . . Mounted in front top of Engine, under plenum
Solenoid Valve . . . . . . . . . Left side of Engine, mounted to Intake Plenum ....... 26 ... 43
202-17
202-11
202-17
202-18
SA-
20- 12 ELECTRICAL DIAGNOSIS

COMPONENT
(EGR) Solenoid Valve . . .
Fuel Injectors . . . . . . . . . . . .
Fuel Pump Prime Conn . . .
Fuel Pump Relay . . . . . . . . .
Fuel Tank Unit . . . . . . . . . .
Fusible Link (ETSI) . . . . . .
1/P Fuse Block . . . . . . . . . . .
Idle Air Control (IAC) Motor
Instrument Cluster . . . . . . .
(IAT) Sensor . . . . . . . . . . .
Knock Sensor . . . . . . . . . . . .
(MAP) Sensor . . . . . . . . . .
Oxygen Sensor, LH . . . . . . .
Oxygen Sensor, RH . . . . . . .
PASS- KeyII Decoder
Module . . . . . . . . . . . . . . . .
Pump Assembly . . . . . . . .
Starter Enable Relay . . . . .
Starter Solenoid . . . . . . . . .
Torque Converter Clutch
(TCC) Solenoid . . . . . . . . .
Switch ................ .
U nderhood Electrical Center
ClOO (10 cavities)
CllO (10 cavities) ....... .
C200A (17 cavities)
C200B (18 cavities)
C200D (48 cavities)
C210
C220
C230
C270
(4 cavities) ........ .
(10 cavities) ....... .
(10 cavities) ....... .
(2 cavities) ........ .
C405A (4 cavities) ...... .

C405B (10 cavities) ..... .
Gl04 ................... .
LOCATION
201-PG
FIG.
Left rear of Engine, mounted to Intake Plenum

24
41
Mounted on Intake Manifold, part of Fuel Rail
Top rear of RH Shock Tower, 1 way conn out of Harn . . 15
28
Forward of LH kick panel, mounted to foot rest bracket
under carpet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 . . . . 13
Under rear of vehicle
Under front part of console, approx 2 cm rearward of
Cigar Lighter breakout . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 . . . 38
LH side ofl/P Carrier, on the side . . . . . . . . . . . . . . . . . . . 8 . . . . 15
Right front on Throttle Body . . . . . . . . . . . . . . . . . . . . . . . . 29 . . . 46
LH side of 1/P ................................................... .
CONN
202.20
202-22
202-21
202.22
Mounted on air duct, in front oflntake Manifold ..... . 29 ... 46

In bottom RH side of Engine Block ................. . 25,28 42,45
Mounted to RH side oflntake Manifold ............. . 12,26
Mounted in left Exhaust Manifold .................. . 13,24
Mounted in right Exhaust Manifold ................ . 12,25
23,43
24,41
23,42
In 1/P,just right of Radio, attached to Air Bag Bracket . 8 .... 15

Front LH Frame Rail, in Engine Compartment ...... .
Mounted to right side of SIR Bracket, behind 1/P ..... .
Bottom of RH side of Engine, above Starter Motor .... .
Mounted to right front side'of intake ................ .
11
45
25
14,29
21
66
42
27,46
202-14
202-20
Part of Transmission .............................. . 16
29
202-17
Under console, on base of shift control lever ......... .

LH side of Engine Compartment, forward
of wheelhouse ................................... .
Engine to Forward Lamp Harn, behind LH wheelhouse,
attached to ECM bracket ......................... .
Engine to Injector Harn, top center oflntake Manifold
Part of 1/P Harn, between LH kick panel and
Steering Column ................................ .
Under RH side of I/P, behind RH kick panel ......... .
Under RH side ofl/P, behind kick panel ............. .
Under RH side of 1/P, behind kick panel ............. .
1/P Harn to Clutch Jumper Harn, near brake/clutch
pedal bracket ................................... .
Fuel Tank Unit ................................. .
Part of Pass Thru Conn, forward of rear axle, to
Pass Thru Panel ................................ .
of Engine, 1 stud in head, 1 stud in Intake Manifold ..
37
54
202-24
19
36
202-24
15
12
28
22
202-0
202-1
47
72
202-2
47
72
202-2
47
46
46
46
72
67
67
67
202-2
202-16
202-6
202-7
202-8
202-8
29 ... 46
COMPONENT
LOCATION
0106 ................... .
0305 ................... .
Neartop LH side ofradiator, in top ofT-Bar . . . . . . . . . . 19 . . .

without AC3/AQ9) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 . . . .
Compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 . . .
Injector Jumper Harn, approx 7 cm from LH
Branch breakout
Injector Jumper Harn, approx 9 cm from Injector 6
ECM breakout
Engine Harn, approx 4 cm from Transmission breakout
and 4 breakout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 . . .
ECM breakout
Center breakout
ECM breakout

ECM breakout
Engine Harn, approx 4 cm from Transmission breakout 11
Engine Harn, approx 4 cm from MAP Sensor breakout
12
Engine Harn, approx 1 cm from clip near ECM and
main branch
12 . . .
Engine Harn, approx 36 cm inboard of Pl 10
Center breakout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 . . .
breakout
breakout
1/P Harn, approx 4 cm from 0201 breakout
I/P Harn, approx 7 cm from 0200 breakout . . . . . . . . . . . 7 . . . .
I/P Harn, approx 20 cm from DERM Module breakout
I/P Harn, approx 2 cm rearward of Cigar
Lighter breakout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Forward Lamp Harn, approx 7 cm from breakout
inboardofPlOO .................................. 8 ....
P110
8103
8104
8106
8107
8108
8110
8113
8117
8118 (Automatic) ....... .
8119
8122
8124
8125
8127
8128
8131
8190
8205
8206
8209
8215
8225
8234
8235
8238
8245
(Automatic) ....... .
................... .
8257 (Automatic)
8270 ................... .
201-PG
FIG.
35
11
35
43
20
23
23
53
13
38
38
14
20 - 13
CONN
MULTIPORT FUEL INJECTION: V8 VIN P

ENGINE DATA SENSORS
.35 GRY
.35 GRY
416
..___s_J,.._.,.
416
B4 '
INTAKE AIR
TEMPERATURE
(IAT) SENSOR
TEMPT
/1
-~
REF
LO
B
.35 BLK
808
. . :~ 'L
GRY
5416
~ 43
A/C
REFRIGERANT
PRESSURE
SENSOR
A/C EVAPORATOR
TEMPERATURE
SENSOR.___......_.............___.
'r~
.,rn, """
808
5119
------------------.35 TAN
472
.35 LT GRN
.35 BLK
432
808
.35 REDiBLK
22
ENGINE I" CONTROL
MODULE (ECM)
- - - ..t.
~
I
I
r'
~-:,;-;;_-;;_-:..') : ~'.!.. - - '- J
IAT
SENSOR
INPUT
~ I
I
I
I
KNOCK
SENSOR
l!!:U,!_ 8
-=-
SV
L. -
~O.!,_ SENSOR
GROUND
REF
MAP
SENSOR
INPUT
c;:
RH OXYGEN
SENSOR
-l~U~ - -
~U,!_ - ~ (BRN) 3
22
(GRN)
AIC
REFRIGERANT
PRESSURE
SENSOR
!:NSOR
--------le;:
.35GRY
.35
DK BLU
TEMPERATURE
SENSOR
INPUT
(GRN)
- _!F_ - 18
~ (RED)
.35 BLK
13111
496
(GRV)
15
15V
(NOTUSED)
r--B--r-...... ENGINE
COOLANT
TEMPERATURE
(ECT) SENSOR
1666
B ~
.35 BLK
470
...:135B~K470
5122
l T1
A
B
C
D
SEE PAGE 8A-3-0
FOR MEASURING
AND HANDLING
PROCEDURES
Ve;:
STEERING
PRESSURE
SWITCH
470
.35 PPL
OIL
TEMP
410
SENSOR
.35 DK BLU
'
POWER
OXYGEN
SENSOR,
i!.!i~
- - - -l~T- ~Ul., _.
.35VEL
_ _ _A__,_ _ THROTTLE
1665
ECT
INPUT
POSITION
.35 PPLJWHT
SV
474
417
'.!.';I
REF
SENSOR
GROUND
_!E:_ -
416
:C
:C:.;:.;;;;:;;;::.;: SV
A/C EVAPORATOR
SV
sv
- -
.35 GRV
INPUT
-=-
-_ -
732
-1;-,:,;-:,;-; ;: -'l~
INPUT
LH OXYGEN
SENSOR
.35 DK BLU
380
GRAV (GRY)
RED
GREEN (GRN)
BROWN (BRN)
22 WAY
22WAV
22 WAY
22 WAY
MULTIPORT FUEL INJECTION: VS VIN P

CONTROLLED DEVICES
---------------------,
I
I
I
I
FANS/ACTR
FUSE 6
10AMP
.35 BRN
541
I
I
I
I
AIRl"""""""""-----,~'""I
PUMP
RELAY
_ _ ...J
BLOCK DETAILS
PAGESA-11-11
.35 BRN
436
.35BRNt41
F
C100
.35 DK BLU
.35 BRN
473
541
.35 BRN
5127
.35 DK GRN
.35 BR Nj541
335
8
EVAPORATIVE~
EMISSION (EVAP)
--C-ANISTER
PURGE
SOLENOID
VALVE
21.8 Q
11
541
- - - - - - - SECONDARY
.35 BARNj541
--~
INJECTION
~ RECIRCULATION
EXHAUST GAS
11
31.8
(EGR)
SOLENOID
VALVE
ASSEMBLY------~_.
SEE GROUND
DISTRIBUTION
PAGE SA-14-6
3 BLK
r-
.35 DK GR~/x28
-~};? --
-41::~1-:_;0z_
.35 G:Yr35
COOLANTFAN
RELAY(S) CONTROL
150
_u!\l
LNs~6,
~:r:1.. ~
SOLENOID VALVE
CONTROL
RELAY
CONTROL
~---------------------=,~~~r ~~rI
W~lT ~-A~~A~~;;~=-~1~G~--.,:-:,:-:,:-:,:-:,:-:,:~~=:_-;;.:=:_-=:_-=.-=--=--z8
PURGE SOLENOID
VALVE CONTROL
'
11
\
436
C'Ii(
.35 BRN
......._ 8 BLK 1150
,,..- ~
ALL SOLID STATE

NO RELAYS OR SWITCHES
COIL "A"
HI
WHT
1 1I
COIL "A"
LO
COIL "B"
HI
I
I
COIL "B"
LO
7:: ~5 1:_:L:~:r17:: :L~:fJ:4
(GR~)
WHT
r-~------~----~------r---.
A
IDLE AIR
CONTROL (IA()
~OTOR
COIL B
STEPPER
MOTOR

INJECTORS
-.
UNDERHOOD
ELECTRICAL
CENTER
I"'" -
.8 PNK
----------,
INJECTOR
FUSE 9
7.5 AMP
.8 PNK
.8 DK BLU
.8 PNK
639
.8 PNK
639
.8 PNK
.8 DK GRN
468
839
.8 DK GRN
467
467
.8 DK BLU
.8 DK BLU
.8 DK GRN
467
467
468
.8 DK BLU
DISTRIBUTION
PAGE 8A-10-3
_________ _.,
839
839
.8 DK BLU
INJECTOR
FUSE 10
7.5 AMP
I
I
.8 PNK
...-~~~~~~~~~~~~~~~~~~~~~---49-~~~SEEPOWER
.8 DK GRN
467
639
468
.8 DK GRN
468
468
(BLOCKED CONNECTOR
TERMINALS NOT USED)
11
ENGINEr CONTROL
MODULE (ECM)
_____ '.!'__
~1-------~~~------- ----,
I
I
~I
~I
I
I
I
LEFT SIDE INJECTORS

SOLID STATE
_..._ GROUND CONTROL
- T
RIGHT SIDE INJECTORS

SOLID STATE
_...__ GROUND CONTROL
\
\
I
I
L---------------~--------------------J
LT1
4%~
SEE PAGE 8A-3-0
FOR MEASURING
AND HANDLING
PROCEDURES
A
B
C
D

-
GRAY (GRY)
RED
GREEN (GRN)
BROWN (BRN)
22 WAY
22WAY
22 WAY
22 WAY
21 - 3

DATA LINK, GROUND AND POWER
--------------,~
FUSE
SEE POWER
DISTRIBUTION
PAGE 8A-10-3
GAGES
FUSE 9
10AMP
IGN
(NOT USED)
_____ J
52~-
.5 PNK
.8 PNK
439
39
f----5206
DATA LINK
CONNECTOR (DLC)
SEE FUSE
BLOCK DETAILS
PAGE 8A-11-6
.8 ORN
I BLOCK
I
I
I
SEE FUSE
BLOCK DETAILS
PAGE SA-11-4
+r;EE--
340
.35 PNK139
AS
----,~:.}"
:3----~
J..
I
INSTRUMEN;-I CLUSTER
I PAGE SA-81-3
I
"'
J., .... INSTRUMENT

~
CLUSTER
CD
(MIL) "SERVICE
ENGIN_E_ _
SOON"
INDICATOR
5225~
I
I
.35TAN
~--- _l_ -- __J
800
SEE DATA LINK

CONNECTOR
c200D
A4
.35TAN
.8 ORN
340
.S PNK
.35 BRNIWHT
439
.35 TAN
419
.35 WHT/BLK
448
5270
-
.35 TAN
5 1 0 6 - - -. . .
.SORN140
340
____
!7
_____ ~2
<:: (GRN)
--;;;-N1Tio;' INPUT
(GRY)
-Ii20
-l-::-sE-;1;;- - ENGINE SOON"

INDICATOR
J:ONTROL
-
BATIE RY
INPUTS
6
-
'
______
800
(NOT
USED)
____ ..!_ ~ [)_ (BRN)
sv
800
DIClOO
-c:2-- -6
r- - -
.SORN
8~0
.
DIAGNOSTIC
ENABLE
"7v- - -,I
SERIAL
DATA
LINE
I
I
I
L____ J___'I_~[ _:r:________ ~:~; :_ _______ -~ __ J

\
REDUNDANT
12v-----;
2
(NOT
USED)
~---~
SEEGROUND
DISTRIBUTION
PAGE SA-14-0
-----
.8 TAN/
------
:s BLK.
WHT
POWER
- - - -17 l~(RED)
451
!~~
..:...2102
-1:~
16
[J_(BRN)
SEE GROUND
DISTRIBUTION
PAGESA-14-1
:r
451
551
WHT
T
L--,
POWER
.5 BLK/
351
WHT
WHT
_.._ __________________ __A.2103

IGNITION
I SEE POWER
DISTRIBUTION
I PAGE 8A-103
HEI COIL WIRE
.... ____ _
IGNITION
<;Q!!,
.8 PNK
G
TACH
LB11;1Pu.::..
INSTRUMENT
Q.USTER
,
I
--, UNDERHOOD
ELECTRICAL
CENTER
,I
IGNITION
FUSE 11
10AMP
____ '
.......I
239
IGNITION
COIL MODULE
239
A
.8 PNKBLK
IGNITION
INPUT
PRIMARY
COIL
DRIVER
1846
I~
y<;,~f!(!
.8 PNK
r - - ,
SEC
COIL
.J
11
.8 WHT,BLK
IGNITION
CONTROL (IC)
GROUND
1847
.8WHT
121
8 BLK
.8WHT
423
450
12
.8WHT
PJJ.Q
1848
TACHOMETER,-~"''----,,~-,
FILTER
(TAPED IN
ENGINE
HARNESS)
c
.8 BLK (WITHOUT C60)
.8BLK
1 BLK (WITH C60)
A (GRY)
r----------------~-,
.8WfDT
1~21.Q
....---I ...
~~H C60 ONLY)
.35 BLKr50
LOW
HIGH
CAM
RESOLUTION
SIGNAL
RESOLUTION
SIGNAL
SENSOR
IGNITION
- ~s~I~T=
0_I
= ,~~IP
UT - "=' - '="~~IoL
~~~ _9
-=-
_-=-- -=-4~~PG~
USED)
.35 RED/BLK
A
.35 BLK/RED
.35 LT BLU,
BLK
453
_____B_
647
.35 RED
_ ___ C
453
---~
.35 YEL
.35 PPL'
WHT
647
.35 PNK
BLK
631
632
C140
631
.35 BLK.'
PNK
632
A "''---~'I':"'----,,,~---,,,:---------.
D15.IRI_BQTQ~ ........_..__ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _~
OPTICAL SENSOR GENERATES

BOTH HI AND LOW RESOLUTION
SIGNALS BY SENSING A ROTATING
NOTCHED WHEEL DRIVEN BY THE
CAMSHAFT.
LOW RES
SIGNAL
HI RES
SIGNAL
IGN
VOLTAGE
REF
LOW
SOLID STATE
CYLINDER #4
SPARK
PLUG WIRES
(PASSENGER
SIDE)
#6
/tS CYLINDER
FIRING ORDER
184 36572
#3
#8
#7
#2
#1
GROUND
USED)
450
SIGNAL
REFERENCE LOW
DISTRIBUTOR
I
I
I
~~
SEE GROUND
DISTRIBUTION
PAGE 8A-140
-----
IGNITION
CONTROL (IC)
SPARK
PLUG WIRES
(DRIVER
SIDE)
21 - 5

FUEL PUMP, HVAC AND MISCELLANEOUS
I" -
PASS-Key II
DECODER
---,1/P
,~
I FUSE
I MODULE
L -
BLOCK
.J
.. ___ _
SEE HVAC COMPRESSOR CONTROLS

PAGE SA-64-1
A3
'-~~~~~~~~~~~
-35 DK BLU
229
.5 PNK
.5 DK GRN
.35 DK GRN
WHT
229
.35 DK GRN'
WHT
________ 3_2
,- -
FUEL
ENABLE
INPUT
459
A
B
C
D
762
,\ (GRY)
A1C
REQUEST
INPUT
5
-
(RED)
-. A.C
ENABLE
<;_
5205
GRAY (GRY)
RED
GREEN (GRN)
BROWN (BRN)
22
22
22
22
WAY
WAY
WAY
WAY
ENGINE
CONTROL
I MODULE
:.
,~
(ECM)
(GRN)
A1C
STATUS
\
\
I
I
BLOCK DETAILS
PAGE 8A-11-4
LT1
19
439
59
SEE FUSE
.35 DK BLU
___ .I
FUEL PUMP
FUEL PUMP
I
I
1 PNK
439
~---------~~-------~~~~
V_'-F_"V
16
_'-'A (RED)
17
-
(NOT USED)
20
.5 GRY
<;_
(GRN)
14V- - - - 7
(NOT
USED)
Q (BRN)
120
P110
51281
. . . . . . .1.20............
A.;(.
120
FT
SEE INSTRUMENT
CLUSTER
PAGE 8A-81 2
.8 GRY
FUEL PUMP
PRIME CONNECTOR
1 GRY
A2
:::1
A1
- - - - - - - - - -
"'. ~;.J.
r---,...-----.,.,...-FUEL
PUMP
RELAY
(220
120
5
.35 PPtO
465
(2
5 GRY
.5 GRY
.35 DK GRN!WHT
120
120
C40SB
C405A
. ,~l:-3'
5215----,
I
I
.s BLK1WHT 1451
B J,.C210
.5 BLK/W
FUEL
PUMP
Oil
-1-
P110
5109. WITH AC3 OR AQ9

SEE GROUND
DISTRIBUTION
PAGE 8A-14-10
.8 BLK/WHT
C40SA
<;_4_058
_-"'1111111
1
SEE GROUND
DISTRIBUTION
PAGE 8A-14-1
451
.5 BLKWHT
351
3 BLK
1450
SEE PAGE SA-3-0

FOR MEASURING
AND HANDLING
PROCEDURES

AUTOMATIC TRANSMISSION CONTROLS (MOS) AND VSS
rSE;;.0-:E:- -
FUSE
I DISTRIBUTION
I PAGE 8A-10-3
I BLOCK
I
I
I
IGN
(NOT USED)
I
I
___ J
L--------
.8 PNK
SEE FUSE
BLOCK DETAILS
PAGE 8A-11-4
SEE PAGE 811-3-0

FOR MEASURING
ANO HANDLING
PROCEDURES
-------,1/P
39
. . . --5206
.35 PNK
139
B;o\g
.-------------------~"'"----------------------------"""----------------,BRAKE
BRAKE
SWITCH
TCC/SHIFT
BRAKE LIGHT
DEPRESSED
ASSEMBLY
iNTEiiRui>T
CRUISE RELEASE
SWITCH
SWITCH
(NORMALLY
(NORMALLY
CLOSED)
OPEN)
.....__
--------------
! IMPORTANT:
TRANSMISSION MUST BE IN 4TH
GEAR FOR THE TEMPERATURE
SWITCH TO ENGAGE TORQUE
CONVERTER CLUTCH (TCC) TO
COOL TRANSMISSION.
.35 LT BLU/BLK
583
.35LT BLU/BLK
583
[I] IMPORTANT:
CLOSES AT 136.5'C t 3.5'C

(277.5'F t 6.5'F)
OPENS AT 126'C t 5'C
(259'F t 9'F)
2ND
...... -.....
WHT
232
(MOS)
.35 LTBLU
~5~~)::2 -
I"
BL~
5118
446
C'
K
.35 TAN/BLK
.35 TAN/BLK
1111
MODULE
(ECM)
.._
I
I
I
~ I
,-
-l.., ---,
I:-.:;_-.:;_-.:;_f---;..,;-;..,;-f---
20
"""' I""
CONTROL
19
14
ZNO
3RO
TH
_
SV
5V
5V
4000 PULSE
TORQUE
CONVERTER
CLUTCH (TCC)
'CONTROL
-=-
__._
PARK/NEUTRAL
L.::r~::-;:r~~::~;i:::-;;-.:.~:~ .:.;;.35 YEL
400
c230
.35 TANl422 422

BLK
2
B (RED)
I
I
I
I
I
.J
STARTER r"' SOLENOID
cCONNECTOR
LT1
A
B
C
0

GRAY (GRY)
RED
GREEN (GRN)
BROWN (BRN)
22 WAY
22WAY
22 WAY
22 WAY
-,
A
DATA LINK
422
(DLC)
SEE HATCH RELEASE

PAGE 8A-1350
.35 ORN/BLK
.8 ORNiBLK
1 OK GRN
575
434
-44 - - - - - - - . 5234
3
.35 ORN/BLK 434
B~
r - - - - :
- - - - - - -
'-:.
@ )
- - ,
'-:.@ ):
,....--r
,....--r
L---- Y -----------J
y
TRANSMISSION
A
POSITION
BLK/ 1451

PAGE 8A-33-0
TRANSMISSION
BRAKE[QJ
SHIFT INTERRUPT
(BTSI) SOLENOID
I
I
I
NORMALLY~
OPEN,
CLOSED IN
.,!!H Bf
.35 WHT
I TRANSMISSION
...... -.....
~:I- =: :~143~ -
NORMALLYJ_ NORMALLY
CLOSED,
CLOSED,
OPEN IN
OPEN IN
~:~E
1 AUTOMATIC
TEMP
SWITCH
....... -,
L-
FUSIBLE LINK (BTSI) IS

LOOPED OUTSIDE OF
TAPED BUNDLE,
IN LENGTH.
5 DK GRN
I :75
.5 RUST
:~"" ~~I . . ,,.::.:~:k .t

DISTRIBUTION
PAGE 8A-14-1
' - - - - - - - ' ~G103
ENABLE
RELAY
--1
LINK (BTSI)
5257

MANUAL TRANSMISSION CONTROLS (MN6) AND VSS
L-----
--..J
.35 BRN
541
S190----l
r- - -, STARTER
.35BRN141
_ BRN
35
I SOLENOID
ClOO
SEE FUSE
BLOCK DETAILS
PAGE BA-11-11
541
s121e _ _ _ _
5 PPL
.35BRN141
r - I
I
I
I
- - - ,
B
[gJ
AI
A I C210
5 PPL
[ZJ
1652
8 (RED}
LV~LI;_ -V~H'..,_ P~~E~T,!'.!!T,J
.35 PPL
401
.35 VEL
.35 DK GRN,
400
5 DK GRN
575
A2
r- - -, STARTER
(BRN)
,-
I ENABLE
817
RELAY
WHT
L T1 ECM CONNECTOR IDENTIFICATION

PAGE BA-33-0
CLUTCH START
SWITCH
(CLOSED WITH
CLUTCH PEDAL
DEPRESSED}
r - - - - ..;. - - - - , ENGINE
CONTRO~
I
I MODULE
I
l(ECMI
I
4000 PULSE
I J.
1l--12l ____alo
___ .JI
IL - -
.35 LTGRN
MANUAL
I TRANSMISSION
11_!:VERSE
(MN6}
LOCKOUT
I
SOLENOio
-~I
I
A
B
C
D
GRAV (GRV}
RED
GREEN (GRN}
BROWN (BRN}
22 WAV
22WAV
22 WAV
22 WAV
L. -
..I
21 - 7
SA -
va
MULTIPORT FUEL INJECTION:
VIN p
~7
~ ~
~12~
~10~
~ ~
~16~
12065885
22-WAY F MICRO-PACK
GRY

VOLTAGE
CAVITY
WIRE COLOR
CKT
DESCRIPTION
6E3 REFERENCE
KEYON
ENG RUN
DKGRN/WHT
428
B+
B + (1)
SECTION C3
GRY
435
EGR SOLENOID VALVE CONTROL
B+
B + (1)
SECTION C7
LTBLU/WHT
1747
IACCOIL "A" HIGH
(3)
(3)
SECTION C2
LTGRN/BLK
444
IAC COIL "B" LOW
(3)
(3)
SECTION C2
BRN/WHT
419
MIL (SERVICE ENGINE SOON) CONTROL
O*
B+
CHARTS A-1, A-2
BRN
436
10
LT BLU/BLK
1748
IACCOIL "A" LOW
(3)
(3)
SECTION C2
11
LTGRN/WHT
1749
IAC COIL "B" HIGH
(3)
(3)
SECTION C2
12
WHT
423
IGNITION CONTROL
0 ..
1.1 (3)
SECTION C4
13
YEL
410
ECTSIGNAL
1.8 (4)
1.7 (4)
DTC(s)14, 15
19
DKBLU
229
FUEL ENABLE SIGNAL
2.5
2.5
21
ORN/BLK
434
PNPSIGNAL
0 * (5)
0 * (5)
22
DKGRN/WHT
762
A/C REQUEST
SECTION C6
CHART C-1A
SECTION C10
(1)
(2)
(3)
(4)
(5)
LESS THAN .5 VOLT WHEN SYSTEM ENABLED.

12 VOL TS FOR FIRST TWO SECONDS WITH
IGNITION "ON."
VARIES.
BATTERY VOLTAGE WHEN IN GEAR.
LESS THAN .5 VOLT.
21 - 9
12065886
RED

VOLTAGE
CAVITY
WIRE COLOR
DESCRIPTION
CKT
6E3 REFERENCE
KEYON
ENG RUN
LTGRN
1652
REVERSE LOCKOUT SOLENOID CONTROL
TAN/BLK
422
TCC
B+
B + (1)
BLK
808
MAP, IAT, & A/C REFRIGERANT SENSOR GROUND
O*
O*
DKGRN
335
PRIMARY COOLING FAN
B+
B + (1)
SECTIONC12
DKGRN/WHT
459
A/C CLUTCH CONTROL
B+
B + (1)
SECTION C10
BLK/WHT
451
ECMGROUND
O*
O*
10
DKBLU
473
SECONDARY COOLING FAN (WITH (60)
B+
B + (1)
SECTION C12
14
LTBLU
446
4th GEAR SIGNAL
B+
B+ (1)
SECTION
17
BLK/WHT
451
ECMGROUND
O*
O*
SECTION B
18
BLK
470
TP SENSOR, ECT GROUND
O*
O*
DTC(s) AFFECTED
19
DKGRN/WHT
438
3rd GEAR SIGNAL
O*
O*
DTC 72/SECTION
20
WHT
232
2nd GEAR SIGNAL
O*
O*
ca
DTC 72/SECTION ca
22
TAN/WHT
551
ECMGROUND
O*
O*
SECTION B
SECTION C8
(1)
SECTION C8
DTC(s) AFFECTED
SECTION B
ca
LESS THAN .5 VOLT WHEN SYSTEM IS ENABLED.

LESS THAN .5 VOLT.
SA-
21 - 10
12065887
22-WAY F MICRO-PACK
GRN

VOLTAGE
CAVITY
WIRE COLOR
CKT
DESCRIPTION
6E3 REFERENCE
KEYON
ENG RUN
A/CSTATUS
0 (3)
DKGRN
59
GRY
474
DKBLU
417
TP SENSOR SIGNAL
.62
.62
RED/BLK
453
LOW RESOLUTION
1.0 OR 5.0
1.0 (4)
ORN
340
BATTERY FEED
B+
B+
GRY
416
DKBLU
496
KNOCK SENSOR SIGNAL
2.5
2.5
PNK/BLK
632
REFERENCE LOW
SECTION C4
11
RED/BLK
380
A/C REFRIGERANT PRESSURE SENSOR SIGNAL
1.0
.6-1.0(5)
DTC(s) 66, 67
12
PNK
439
IGNITION FEED
B+
B+
14
LTBLU/BLK
647
HIGH RESOLUTION
O*
2.5 (4)
16
DKBLU
732
A/C TEMPERATURE SENSOR SIGNAL
17
ORN
340
BATTERY FEED
B+
B+
CHART A-1
18
RED
631
SYSTEM IGNITION FEED
B+
B+
SECTION C4
20
GRY
120
FUEL PUMP SIGNAL
O* (6}
B+
21
LTGRN
432
MAP SIGNAL
4.8 (1}
1.2 (1}
DTC(s) 33, 34
22
TAN
472
IATSIGNAL
2.0(2)
3.0 (2}
DTC(s} 23, 25
{1}
(2}
(3}
(4)
(5}
(6}
SECTION C10
DTC(s) AFFECTED
DTC(s) 21, 22
OTC 16
CHART A-1
DTC(s) AFFECTED
OTC 43, SECTION
cs
CHART A-1
DTC36
VARIES WITH ALTITUDE.

B + WHEN SYSTEM IS ENABLED.
VARIES.
WITH A/C "OFF."
B + WHEN FUEL PUMP IS ENABLED
LESS THAN .5 VOLT.
ELECTRICAL DIAGNOSIS SA - 21
- 11
12065888
22-WAV F MICRO-PACK
BRN

VOLTAGE
CAVITY
WIRE COLOR
DESCRIPTION
CKT
6E3 REFERENCE
KEYON
ENG RUN
PPL
401
VSSGROUND
O*
O*
DTC24
TAN
800
SERIAL DATA
(1)
(1)
CHART A-2
PPUWHT
1665
.38 (1)
.1-.9 (1)
DKGRN/WHT
465
FUEL PUMP RELAY DRIVER
0 (2)
B+
CHART A-5
DKGRN/WHT
817
VSS OUTPUT (4KPPM)
(3)
(3)
DTC24
10
DKGRN
468
INJECTOR DRIVER
B+
B+
CHART A-3
11
DKBLU
467
INJECTOR DRIVER
B+
B+
CHART A-3
12
YEL
400
VSS SIGNAL
(3)
(3)
DTC24
16
BLK/WHT
351
02SGROUND
0*
O*
DTC(s) 13, 63
20
BLK/WHT
448
DIAGNOSTIC "TEST" TERMINAL
22
PPL
1666
.36
.1-.9 (1)
(1)
(2)
(3)
*
DTC(s) 13, 44
CHART A-2
DTC(s) 63, 64
VARIES.
B + FOR TWO SECONDS WITH IGNITION "ON."
VARIES DEPENDING ON POSITION OF DRIVE WHEELS.
LESS THAN .5 VOLT.
SA- 21 -12 ELECTRICAL DIAGNOSIS

COMPONENT
LOCATION
201-PG
FIG.
CONN
A/C Evaporator
Temperature Sensor
Mounted in Evaporator Core . . . . . . . . . . . . . . . . . . . . . . . . 46
67
Sensor . . . . . . . . . . . . . . . . . Above RH Shock Tower, forward of A/C Compressor
34
Low Pressure Cut Off Switch . . . . . . . . . . . . . . . . . . . . . . 18
Brake Switch Assembly . . . Mounted in lower hole of brake pedal bracket (2 conn
.
same switch for both . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 . . . . 1
Interrupt (BTSI) Solenoid In console, under PRNDL Display . . . . . . . . . . . . . . . . . . . 37 . . . 54
Clutch Start Switch . . . . . . Mounted to clutch pedal bracket, behind
Convenience Center . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 . . . . 1
Data Link Conn (DLC) . . . . Mounted to I/P Tie Bar, below and right of
Steering Column . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202-11
Distributor . . . . . . . . . . . . . . In front center of Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
55
202-17
19
35
202-19
(ECM) . . . . . . . . . . . . . . . . . In Engine Compartment, rearward of RH Shock Tower
(ECT) Sensor . . . . . . . . . . . Front of Engine, mounted in water pump . . . . . . . . . . . . 23
40
Solenoid Valve . . . . . . . . . Right center of Engine, mounted to Manifold . . . . . . . . . 13
24
(EGR) Solenoid Valve . . . Left rear of Engine, mounted to Intake Plenum . . . . . . . 24
41
Fuel Injectors . . . . . . . . . . . . Mounted on Intake Manifold, part of Fuel Rail . . . . . . . . 24
41
Fuel Pump Prime Conn . . . Top rear of RH Shock Tower, 1 way conn out of Harn . . 15
28
Fuel Pump Relay . . . . . . . . . Forward ofLH kick panel, mounted to foot rest bracket
under carpet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 . . . . 13
202-20
Fusible Link (BTSI) . . . . . . Under front part of console, approx 2 cm rearward of
202-22
1/P Fuse Block . . . . . . . . . . . LH side ofl/P Carrier, on the side . . . . . . . . . . . . . . . . . . . 8 . . . . 15
Idle Air Control (IAC) Motor Right front on Throttle Body . . . . . . . . . . . . . . . . . . . . . . . . 14
27
202-21
Ignition Coil . . . . . . . . . . . . . Front LH side of Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 . . . 40
Ignition Coil Module . . . . . Front LH side of Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 . . . 40
202-21
Instrument Cluster . . . . . . . LH side ofl/P . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202-22
(IAT) Sensor . . . . . . . . . . . Mounted on air duct, in front oflntake Manifold ..... . 29 ... 46
Knock Sensor . . . . . . . . . . . . In bottom RH side of Engine Block ................. . 25,28 42,45
(MAP) Sensor . . . . . . . . . . Mounted to RH side oflntake Manifold ............. . 12,26 23,43
Oxygen Sensor, LH . . . . . . . Mounted in left Exhaust Manifold .................. . 13,24 24,41
Oxygen Sensor, RH . . . . . . . Mounted in right Exhaust Manifold ................ . 12,25 23,42
PASS-KeyII Decoder
Module . . . . . . . . . . . . . . . . In 1/P,just right of Radio, attached to Air Bag Bracket . 8 .... 15
202-14
37
(Manual) . . . . . . . . . . . . . . . Rear LH side of Transmission ...................... . 20
Pump Assembly . . . . . . . . Front LH Frame Rail, in Engine Compartment ...... . 11
21
Starter Enable Relay . . . . . Mounted to right side of SIR Bracket, behind I/P . . . . . . 45
202-20
66
Starter Solenoid . . . . . . . . . Bottom of RH side of Engine, above Starter Motor .... . 25
42
Tachometer Filter . . . . . . . . Tapped to Harn, left front side of Engine ............ . 23
40
Throttle Position (TP) Sensor Mounted to right front side of intake ................ . 14,29 27,46
(TCC) Solenoid . . . . . . . . . Part of Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
29
202-17
Switch . . . . . . . . . . . . . . . . . Under console, on base of shift control lever . . . . . . . . . . 37
54
202-24
lJ nderhood Electrical Center LH side of Engine Compartment, forward
of wheelhouse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
202-24
36
ClOO (10 cavities) . . . . . . . . Engine to Forward Lamp Harn, behind LH wheelhouse,
attached to ECM bracket . . . . . . . . . . . . . . . . . . . . . . . . . . 15
28
202-0
C200A (17 cavities)
and Steering Column . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
72
202-2
C200B (18 cavities)
72
202-2
COMPONENT
LOCATION
C200D (48 cavities)

Steering Column . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
72
Under RH side ofl/P, behind RH kick panel . . . . . . . . . . 46
67
Under RH side ofl/P, behind kick panel . . . . . . . . . . . . . . 46
67
Under RH side of 1/P, behind kick panel . . . . . . . . . . . . . . 46
67
I/P Harn to Clutch Jumper Harn, near brake/clutch
pedal bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2
Fuel Tank Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
9
9
Pass Thru Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
LH front of Engine Block,just below head
(4 rings, 3 wires and braided strap) . . . . . . . . . . . . . . . . . 23
40
RH side of Engine Block, just above Starter
(2 rings, 2 wires) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
42
NeartopLHsideofradiator,intopofT-Bar .......... 19
35
(2 rings, 2 wires, with AC3/AQ9); (1 ring, 1 wire
without AC3/ AQ9) . . . . .. . .. . . . . . . .. .. . . .. . .. .. . .. 6 .. .. 11
Compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
35
and 4 breakout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
43
and 3 breakout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
41
ECM breakout
and 4 breakout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 . . . 43
ECM breakout
Forward Lamp Harn, approx 13 cm from Electrical Center breakout
Engine Harn, approx 2 cm from clip near ECM
and main branch
Engine Harn, approx 3 cm from clip near ECM and main branch
ECM breakout
Engine Harn, approx 14 cm from Injectors 1 and 3
breakout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
41
Engine Harn, approx 8 cm from Injectors 6 and 8
breakout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
43
Engine Harn, approx 25 cm from main branch and ECM
breakout
Engine Harn, approx 8 cm from left clip, on Intake
Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
41
Engine Harn, approx 26 cm inboard of Pl10
Center breakout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
53
I/P Harn, approx 4 cm from G201 breakout
I/P Harn, approx 7 cm from G200 breakout . . . . . . . . . . . 7 . . . . 13
38
38
inboard of PlOO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 . . . . 14
C210
C220
C230
C270
(4 cavities) ........ .
(10 cavities) ....... .
(10 cavities) ....... .
(2 cavities) ........ .
C405A (4 cavities) ...... .

C405B (10 cavities) ..... .
G102
G103
G106
G305
P110
SlOl
S102
S106
S108
S109
S113
S117
Sl 18 (Automatic) ....... .
S119 ................... .
S120
S121
S122
S127
S128
S190
S205
S206
S209
S215
S225
S234
S235
S238
S245
................... .
,................... .
................... .
................... .
................... .
................... .
S257 (Automatic)
S270 ................... .
201-PG
FIG.
21 -13
CONN
202-2
202-16
202-6
202-7
202-8
202-8
SA -
30 - 0
STARTER AND CHARGING
---------------------~
rsETi.o-;;E;;- -
1i -
,11P
I BLOCK
I
I
' t CRANK
IGN
(NOTUSEDl
I
I
L-------- ----
.8 PNK
FUSE 16
3AMP
5 YEL
. . . . --5206
5200
806
r. - - -
,-~~~~~~-,""~~~~~~~~...;;~~~~~BRAKE
BRAKE
DEPRESSED
---------
SEE CRUISE CONTROL

PAGE SA-34-1
TO AUTOMATIC
TRANSMISSION
111111111
I
I
II
SWITCH
ASSEMBLY
SEE POWER
DISTRIBUTION
PAGE SA-10-3
_i.;;;;:_ --,
B
C2
IGNITION
SWITCH
I -I
ACCY
START
" ~ II
LOCK -. ...... - .. ,, fl BULB

OFF
RUN TEST
L--------
5y:1LC2
.35 LT BLUiBLK
q.................
583
.35 LT BLUIB:K
C200B
. .----5YEL---C5.:J'
. . C200D
5223
S238
l'J.
5 YEL
583
5 YEL
[l]:J ::;r,
C2
Cl
TR
ANSM~[Q]
SHIFT
INTERRUPT
(BTSll SOLENOID
1 DK GRN
rn
SEE POWER
DISTRIBUTION
PAGE SA-10-2
.35 LT BLUiB:Kr: :
....
PAGE SA-20-6 (V6 VIN SI

PAGE SA-21-6 (VS VIN Pl
TCC/SHIFT
INTERRUPT
SWITCH
(NORMALLY
CLOSED)
....
102
5RED1102
TO DIAGNOSTIC ENERGY
RESERVE MODULE (DERMl
PAGE SA-47-0
----lljp~
5RED
,,
.8 PPL
39
.35PNK139
BRAKE LIGHT
CRUISE RELEASE
SWITCH
(NORMALLY
OPEN)
FUSIBLE
LINKE
FUSE
I OISTRIBUTION
I PAGE SA-10-3
SEE FUSE
BLOCK DETAILS
PAGE SA-11-4
2 GRY
~~~-5_o_K-::N~7:
575
AUTOMATIC
Il
. ._ _ _. . . . . . . . . . . . . ..
MANUAL
IMPORTANT:
LOOPED OUTSIDE OF
TAPED BUNDLE,
IN LENGTH.
5DKGRf75
.5 RUST
i-
5257.
.8 YEUBLK
5245
FUSIBLE LINK (BT51l
S DK GRN
575
TRANSMISSION
POSITION
SWITCH
r- - - - - - -
--,
I
'._R
A4
CLUTCH
START
SWITCH
(CLOSED WITH
CLUTCH PEDAL
DEPRESSED)
,.I
____..
2/
,N@D)(
L--
____ J
"1
625
,---,
START
I ENABLE I
I
I
L..- ....
PASS-Kevn
DECODER
MODULE
,:1
3 PPL (V6 VIN SI

S PPL (VS VIN P)
P110
30 - 1
- --- -,~
~E;;O;E;- I DISTRIBUTION
I PAGE SA-10-1
FUSE
I BLOCK
IGN
-{NOT USED)I
GAGES
FUSE 9
10AMP
I
_.J
.SORN
340
SEE FUSE
BLOCK DETAILS
PAGE SA-11-6
SEE FUSE
BLOCK DETAILS
+
19 BLK
50
13 BLK
50
39
.8 PNK
PAGESA-11-4
5206
.JSPANS1l~
L-es209
.8 ORN 1340
C14A
f" - I
- - - - - - - - - - -
CID
BATTERY
SOLID
STATE
I
I
19BLK
SRED
PAGE SA-81-1
"CHECK
GAGES"
INDICATOR
~,;- -- -,,;:f,,--- -- - - - - - - ~
.8RtA
C:::10
{NOT USED)
"
DC VOLTAGE
SENSING
INPUT
GENERATOR
_"\/\1\A,----<--~TURN ON INPUT
{POWER UP FOR
REGULATOR)
AC VOLTAGE
BATT
_,___.,.____........, SENSING
\
INPUT
....rL...rL.r1. -
CLOSES WITH LOW {11.2V) OR

HIGH VOLTAGE {16.SV) OR
STOPPED GENERATOR
REGULATOR
(SOLID STATE)
3 PPL {V6 VIN S)

5 PPL {VS VIN P)
STARTER
SOLENOID
"
RECTIFIER
BRIDGE
s7e l~T;;;-M;;;T,
~=
INDICATOR
REQUEST
"""_
470
,---"""'If-------.....----.
HOLD-IN
COIL
SEE PAGE 8A-3-0

FOR MEASURING
AND HANDLING
PROCEDURES
SA-
30- 2

COMPONENT
LOCATION
201-PG
FIG.
Battery ................ . RH front of Engine Compartment . . . . . . . . . . . . . . . . . . . 19

35
Battery ,Junction Block
Top of RH Shock Tower . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 . . . 19
Brake Switch Assembly ... Mounted in lower hole of brake pedal bracket (2 conn
Interrupt (BTSI) Solenoid In console, under PRNDL Display . . . . . . . . . . . . . . . . . . . 37 . . . 54
Clutch Start Switch
Mounted to clutch pedal bracket, behind
Fusible Link (BTSI)
Under front part of console, approx 2 cm rearward of
Fusible Links ........... . Above RH Shock Tower . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 . . . 19
Generator .............. . RH front of Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14, 29 26, 46
I/P Fuse Block .......... . LH side ofl/P Carrier, on the side . . . . . . . . . . . . . . . . . . . 8 . . . . 15 ..
PASS-Key@II Decoder
Module ............... . In 1/P,just right of Radio, attached to Air Bag Bracket . 8 .... 15 ..
Starter Enable Relay .... . Mounted to right side of SIR Bracket, behind 1/P ..... . 45 ... 66 ..
Starter Motor ........... . Bottom of RH side of Engine ....................... . 25,28 42,45
Starter Solenoid ........ . Bottom of RH side of Engine, above Starter Motor .... . 25
42
Switch ................ . Under console, on base of shift control lever ......... . 37
54
C200B (18 cavities)
72
C200D (48 cavities)
72
Steering Column ................................ . 47
C210 (4cavities) ........ . Under RH side ofl/P, behind RH kick panel ......... . 46
67
C220 (10 cavities) ....... . Under RH side ofl/P, behind kick panel ............. . 46
67
GlOO (L32) ............. . Bolted to Belt Tension Bracket Bolt, lower RH front
25
of Engine (1 ring, 1 wire) ......................... . 13
GlOO (LTl)
Bolted to RH side of Engine Block, same bolt used for
NC Compressor if equipped (1 ring, 1 wire) ........ . 42
62
Top of RH Shock Tower (3 rings, 5 wires) ............ . 10
GlOl
19
PlOO
Compartment ................................... . 19
36
PllO
Compartment ................................... . 19
35
S200
Forward Lamp Harn, approx 8 cm from EBCM
breakout ....................................... . 8 .... 14
S206
breakout
S209 ................... . 1/P Harn, approx 24 cm from Convenience Center breakout
S223 ................... . 1/P Harn, approx 4 cm before DLC breakout
S238 (Automatic) ....... . I/P Harn, approx 20 cm from DERM Module breakout
S245 (Automatic) ....... . I/P Harn, approx 2 cm rearward of Cigar
38
S257 (Automatic)
1/P Harn, approx 2 cm rearward of Cigar
38
CONN
202-20
202-22
202-22
202-14
202-20
202-24
202-2
202-2
202-16
202-6
{Perform before beginning
Diagnosis)
STARTER
System
1. Visually inspect the hydrometer (built into

Battery).
Green eye - Battery is charged.
Dark eye - Charge and load test Battery, refer
to SECTION 601. If Battery passes load test,
refer to System Diagnosis, page SA-30-3.
Clear or light yellow eye - Battery electrolyte
is low. Replace Battery.
2. Always note condition of"SECURITY" Indicator if
Engine does not crank. If the indicator stays "ON"
or flashes continuously, refer to "Theft Deterrent
System," page SA-133-0.
3. Check that Starter Solenoid terminals "S" and "B"
and Battery connections are clean and tight.
4. Check that Fusible Link E is undamaged. If
Fusible Link E is open, check for a short to ground
through CKT 102 or CKT 5.
5. Check that GlOO and GlOl are clean and tight.
"Troubleshooting Procedures," page SA-4-0).
2.
3.
Check Gages Fuse 9 for open.

Check that the Generator connector and Generator
"BAT" terminal are both clean and tight.
4. Check that the Battery connections are clean and
tight.
5. Check Generator belt.
check. Use Test Light ,J 34142 whenever possible.
impedance DV:\11 and are more useful for detecting
useful in detecting resistive circuits ( see
SYSTEM DIAGNOSIS
Important:
The following tests are designed for engines and

batteries at normal operating temperatures and
assumes that there are no engine symptoms
which would cause a no-start symptom. The
Battery must be in a charged state before doing
diagnosis. To use the tests under other
conditions could result in misdiagnosis.
Important:
CHARGING SYSTEM
l. Visually inspect the hydrometer (built into
Battery).
Green eye - Battery is charged.
Dark eye - Charge and load test Battery, refer
to SECTION 601. If Battery passes load test,
refer to System Diagnosis, page SA-30-3.
Clear or light yellow eye - Battery electrolyte
is low. Replace Battery.
30 - 3
Perform the Diagnostic Circuit Check described

in SECTION 6E to be certain no trouble codes
are stored in ECM memory which may lead to
misdiagnosis, specifically Code 46, indicating a
problem in the PASS-KeyII Fuel Enable
circuit.
Always note condition of "SECURITY" Indicator
if Engine will not crank. If the indicator stays
"ON" or flashes continuously, refer to "Theft
Deterrent System," page SA-133-0.
BA - 30- 4 ELECTRICAL D.IAGNOSIS

SYMPTOM TABLE
SYMPTOM
PROCEDURE
PAGE NUMBER
Engine does not crank, Starter Solenoid does not click.
Chart #1
8A-30-4
Starter Solenoid clicks, but Engine cranks slowly or not

at all.
Chart #2
8A-30-6
Battery is undercharged or overcharged.
Chart #3
8A-30-7
"CHECK GAGES" Indicator on at all times.
Refer to page 8A-81-1.
"CHECK GAGES" Indicator inoperative.
Refer to page 8A-81-1.
Slower or no crank only after extended periods of

vehicle non-use.
See Parasitic Load Test. Refer to SECTION GD 1.
CHART #1
rn
ENGINE DOES NOT CRANK, STARTER SOLENOID DOES NOT CLICK

IMPORTANT:
BATTERY MUST BE IN A CHARGED STA TE TO AVOID MISDIAGNOSIS. FOR BATTERY CHARGING OR
TESTING, REFER TO SECTION 601.
IF "SECURITY" INDICATOR STAYS "ON" OR FLASHERS CONTINUOUSLY, REFER TO "THEFT
DETERRENT SYSTEM," PAGE SA-133-0 (NORMAL BULB CHECK IS APPROXIMATELY 5 SECONDS.
TO AVOID MISDIAGNOSIS, CHECK FOR DIAGNOSTIC TROUBLE CODES. SEE SECTION 6E3.
DISCONNECT STARTER ENABLE RELAY.

ATTACH A TEST LIGHT BETWEEN STARTER ENABLE RELAY CONN TERM "A1" AND B +.
WHILE OBSERVING TEST LIGHT, TURN IGNITION SWITCH TO "START."
CONNECT A TEST LIGHT BETWEEN STARTER ENABLE RELAY CONN

TERM "C2" AND GROUND.

! IMPORTANT:
DO NOT ALLOW STARTER TO CRANK LONGER THAN 15 SECONDS
OR DAMAGE TO THE STARTER MAY OCCUR.
ATTACH A 30 AMP FUSED JUMPER BETWEEN STARTER ENABLE
RELAY CONN TERM "C1" AND TERM" A2".
TRANSMISSION IN "PARK" OR "NEUTRAL" (AUTO TRANS) OR
WITH CLUTCH PEDAL DEPRESSED (MANUAL TRANS}.
IGNITION SWITCH TO "START."
DOES ENGINE CRANK?
{CONTINUED ON NEXT PAGE)
r-------------------------------,
: REFER TO "THEFT DETERRENT SYSTEM PASS-KeyII", :
I SECTION SA-133, CHART #1.
1
L----------------------------------J
CHECK FOR OPEN IN CKT 5 OR OPEN IN POWER FEED

THROUGH AND INCLUDING IGNITION SWITCH.
CHECK FOR OPEN IN CKT 5 BETWEEN STARTER ENABLE

RELAY CONN TERM "C1" AND 5223.
{CONTINUED FROM PREVIOUS PAGE)
CHECK FOR POOR

CONNECTION TO RELAY.
IF OK, REPLACE STARTER
ENABLE RELAY.
ALSO CHECK CKT 6 TO THE
STARTER SOLENOID FOR A
POSSIBLE SHORT. A SHORT
MAY HAVE CAUSED THE
RELAY TO FAIL.
FUSED JUMPER STILL CONNECTED.

INSTALL A TEST LIGHT FROM STARTER SOLENOID
TERM "S" TO GROUND.
TRANSMISSION IN "PARK" OR "NEUTRAL" {AUTO
TRANS) OR WITH CLUTCH PEDAL DEPRESSED
{MANUAL TRANS).
r- ------ ---------,
WITH A TEST LIGHT TO GROUND, BACKPROBE C210

TERM "A".
TRANSMISSION IN "PARK" OR "NEUTRAL" {AUTO
TRANS) OR WITH CLUTCH PEDAL DEPRESSED
{MANUAL TRANS).
:
I
:
:
I
CHECK FOR POOR

:
CONNECTION AT STARTER I
SOLENOID TERM "S".
:
IF OK, REPLACE STARTER :
SOLENOID.
REFER TO SECTION 6D2.
1
L------------------~

AT C210 TERM" A".
IF OK, REPAIR OPEN IN CKT 6
BETWEEN C210 AND STARTER
SOLENOID.
CHECK FOR OPEN IN CKT 575

FROM STARTER ENABLE
RELAY TERM "A2" TO
TRANSMISSION POSITION
SWITCH TERM "F".
CHECK FOR POOR
CONNECTIONS AT OR FOR AN
OPEN IN THE TRANSMISSION
POSITION SWITCH.
FROM TRANSMISSION
POSITION SWITCH TERM "E"
TO C210 TERM" A".
MANUAL TRANSMISSION
CHECK FOR OPEN IN CKT 575 FROM

STARTER ENABLE RELAY TERM "A2" TO
CLUTCH START SWITCH TERM" A".
CHECK FOR POOR CONNECTIONS AT OR
FOR AN OPEN IN THE CLUTCH START
SWITCH.
CLUTCH START SWITCH TERM "8" TO
C210 TERM "A".
30 - 6
SA -

CHART #2
STARTER SOLENOID CLICKS BUT ENGINE CRANKS SLOWLY
OR NOT AT ALL
rn
IMPORTANT:
THE FOLLOWING TESTS ARE DESIGNED FOR ENGINES AND BATTERIES AT
NORMAL OPERATING TEMPERATURES AND ASSUME THAT THERE ARE NO
ENGINE SYMPTOMS WHICH WOULD CAUSE A NO-START SYMPTOM. TO USE
THE TESTS UNDER OTHER CONDITIONS COULD RESULT IN MISDIAGNOSIS.
BATTERY MUST BE IN A CHARGED STA TE TO AVOID MISDIAGNOSIS. FOR
BATTERY CHARGING OR TESTING, REFER TO SECTION 601.
BATTERY IS FULLY CHARGED.

IGNITION SWITCH IN "START."
MEASURE THE VOLTAGE AT THE BATTERY WHILE CRANKING THE ENGINE.
CRANK ENGINE AND READ VOLTAGE AFTER 15 SECONDS, THEN REMOVE LOAD.
LESS THAN 9.5 VOL TS
GREATER THAN 9.5 VOLTS
MEASURE VOLTAGE BETWEEN NEGATIVE BATTERY

TERMINAL AND THE ENGINE BLOCK WHILE
CRANKING.
r-
---------------,
: t
LOAD TEST BATTERY.

:
REFER TO SECTION 601. 1
I t
L-
BATTERY OK
GREATER THAN
0.5 VOLTS
MEASURE THE VOLTAGE BETWEEN

THE POSITIVE BATTERY TERMINAL
AND THE STARTER SOLENOID,
TERM "B" WHILE CRANKING.
REPLACE NEGATIVE BATTERY

CABLE.
GREATER THAN
0.5 VOLTS
r- ---------------,
:
I
:
1
REMOVE STARTER
:
MOTOR ASSEMBLY
I
FOR REPAIR.
:
L-----------------J
REPLACE POSITIVE BATTERY

TERMINAL.
---------------J
BATTERY NOT OK
:,~- ---------------,
,.
I
I
REMOVE STARTER
I
ASSEMBLY FOR REPAIR. :
REPLACE BATTERY.
CHART #3
BATTERY UNDERCHARGED OR OVERCHARGED
DISCONNECT GENERATOR CONNECTOR.

ENGINE "OFF."
CONNECT VOLTMETER (SET AT DC SCALE) BETWEEN GENERATOR
CONNECTOR TERM "L" AND GROUND.
BATTERY VOLTAGE
MOVE VOLTMETER LEAD FROM TERM "L" TO

"BATT" TERM ON GENERATOR (RED WIRE).
CHECK FOR OPEN OR POOR CONNECTIONS IN

CKT 225 BETWEEN GENERATOR TERM "L" AND
INSTRUMENT CLUSTER TERM "C12".
CHECK FOR OPEN FUSE 9 OR OPEN IN CKT 39 TO
INSTRUMENT CLUSTER (IF FUSE 9 OR CKT 39 ARE
OPEN, THE INSTRUMENT CLUSTER WILL NOT BE
OPERA TING CORRECTLY).
IF OK, SERVICE INSTRUMENT CLUSTER.
BATTERY VOLTAGE
CHECK FOR OPEN IN CKT 1 BETWEEN GENERATOR

"BA TT" TERMINAL ANO BATTERY.
RECONNECT GENERA TOR CONN ECTOR.

ENGINE RUNNING AT FAST IDLE.
ALL ACCESSORIES TURNED "OFF."
CONNECT VOLTMETER (DC SCALE) ACROSS BATTERY
TERMINALS AND NOTE VOLTAGE.
UNDER 13.5 VOL TS

OR OVER 15.5 VOL TS
BETWEEN 13.5-15.5 VOLTS
----------------------------------, r-
:
:
1
---------------------,
PERFORMGENERATORLOADTEST. REFERTO
: : REPAIRORREPLACEGENERATOR. :
SECTION 603.
: 1 REFER TO SECTION 603.
1
IFGENERATORISOK,PERFORMBATTERYLOADTEST. 1 L.-----------------------..J
30 - 7
SA -
30 - 8

CIRCUIT OPERATION
BATTERY

CHARGING (ALSO REFERENCE SECTION 603)
The Generator provides voltage to operate the

vehicle's electrical system and to charge its Battery. A
magnetic field is created when current flows through
the Rotor. This field rotates as the Rotor is driven by
the Engine, creating an AC voltage in the Stator
windings. The AC voltage is converted to DC by the
Rectifier Bridge and is supplied to the electrical
system at the Battery terminal.
The Generat<?r's Regulator uses digital techniques
to supply the Rotor current and thereby control the
output voltage. The Rotor current is proportional to
the width of the electrical pulses supplied by the
Regulator. When the Ignition Switch is placed in
"RUN," voltage is supplied to terminal ''L", turning on
the Regulator. Narrow width pulses are supplied to
the Rotor, creating a weak magnetic field. When the
Engine is started, the Regulator senses Generator
rotation by detecting AC voltage at the Stator through
an internal wire. Once the Engine is running, the
Regulator varies the field current by controlling the
pulse width. This regulates the Generator output
voltage for proper Battery Charging and Electrical
System Operation.
The Digital Regulator controls the Charge
Indicator light with a Solid State lamp driver. The
lamp driver turns "ON" the light whenever an
undervoltage, overvoltage or stopped Generator is
detected.
STARTER (ALSO REFERENCE SECTION 602)
When the Ignition Switch is moved to the

"START" position, voltage is supplied to the Starter
Solenoid through the Starter Enable Relay contacts
and, either the Transmission Position Switch
(Automatic Transmission) when in "PARK" or
"NEUTRAL," or the Clutch Start Switch (Manual
Transmission). The PASS-KeyII Decoder Module
energizes the Starter Enable Relay by grounding one
side of the Relay Coil only when the Theft Deterrent
System has not been activated (See "Theft Deterrent
System," page SA-133-0).
When the Starter Enable Relay is energized, the

normally open contacts close, completing the circuit to
the Starter Solenoid. When the Starter Solenoid
circuit is completed, both the Hold-In and Pull-In
Windings are energized. The circuit through the PullIn Winding is completed to ground through the Starter
Motor. The windings work together magnetically to
pull in and hold in the Plunger. The Plunger moves
the Shift Lever. This action causes the Drive
Assembly to rotate as it engages the Flywheel ring
gear on the Engine. At the same time, the Plunger
also closes the solenoid switch contacts in the Starter
Solenoid. Full battery voltage is then applied directly
to the Starter Motor and it cranks the Engine.
As soon as the Solenoid Switch contacts close,
voltage is no longer applied to the Pull-In Winding
since battery voltage is applied to both ends of the
windings. The Hold-In Winding remains energized
and its magnetic field is strong enough to hold the
Plunger, the Shift Lever and the Drive Assembly
Solenoid Switch contacts in place to continue cranking
the Engine.
When the Ignition Switch is released from the
"START" position, battery voltage is removed from the
PPL wire and the junction of the two windings.
Voltage is applied through the motor contacts to both
windings to ground at the end of the Hold-In
Windings. However, the direction of current flow
through the Pull-In Winding is now opposite the
direction of the current flow when the winding was
first energized. The magnetic fields of the Pull-In and
Hold-In Windings now oppose one another. This
action of the windings, with the help of the Return
Spring, causes the Drive Assembly to disengage and
the Solenoid Switch contacts to open simultaneously.
As soon as the contacts open, the starter circuit is
turned "OFF."
BLANK
30 - 9
8A - 31 - 0 ELECTRICAL DIAGNOSIS
COOLANT FANS
V6 VIN S
1 RUST
FUSIBLE
LINK C
---
.5 BRN
3LT BLU
.35 BRN
409
541
---
541
. ._ _ _ 5190
B
.35 DK GRN
-1111111.....
SEE FUSE
BLOCK DETAILS
PAGE8A-11-11
......,........
---,
335
COOLANT~
FAN,
PRIMARY
5117
.5G:j416
, "'
AJ
3 BLK
SEE GROUND
DISTRIBUTION
PAGE 8A-14-6
5V
REF
-..
~--5113
.5 GRY
.5 DK GRN
416
PRESS
'I/
CI
335
_c106
IMPORTANT:
r" -
REFER TO SECTION 6E3 AND

CHECK FOR DTCs BEFORE
DIAGNOSING COOLANT FAN
SYSTEM OR REPLACING ECM.
- - -
I
I
.5 RED/BLK
-z--3
____ - - ~
,1/
B (BLK)
:t
;;_1- -s;s;; 5
.5 BLK
808
..!
- - -
""'
GROUND
GROUND
REFERENCE
-=-
f-":'-":'-":'-~ly
REFERENCE
7;
INPUT
VSS
;;C;) -
VSS
;;! - - - ~ ___
29
- - - - 30
I!
.5YE'A410
.5 BLK
470
TO THROTTLE
.35 BLK
POSITION SENSOR .......- - - - . 5122
PAGE 8A20-0
470
.5 BLK
470
K
.5 YEL/BLK
B
_ .....,.....--, ENGINE
COOLANT
TEMPERATURE
(ECTl SENSOR
(110
5 PNKiBLK
470
C110
410
.5 YEL
,~~~~REOL
MODULE
(ECM)
...
I
I
I~
I~
I
:I
h5V
ECT
SEE ENGINE
CONTROL,
PAGE SA-10-0
(CLR)
-f
SEE PAGE 8A-3-0

FOR MEASURING
AND HANDLING
PROCEDURES
.l
Ia
5119 -
-5;;--- REF
PRESSURE
SENSOR
INPUT
COOLANT
FAN
CONTROL
REF
LO
.5 Bl~~08
380
400
I
I
PRESSURE
SENSOR
--
150
3BLK,150
rn
AIC
(BLK)
.J
31 - 1
COOLANT FANS
va VIN p
1 RUSl
FUSIBLE
LINK C
r----------------
SEE POWER
DISTRIBUTION
PAGE SA-10-3
1
3 RED
HOTINRUN
-
,~
- , UNDERHOOD
~LECTRICAL
CENTER
FANS1ACTR
~
10AMP
I
I
I
I
3 RED
F2
COOLANT
~~~LANT
RELAY,
PRIMAR_y
RELAY,
SECONDARY
-F:t
F1
I- -
.5 SRN
.35 DK
BLU
541
rn
OPTIONAL FOR
~T~l~:o
IMPORTANT:
CHECK FOR ores BEFORE
DIAGNOSING COOLANT FAN
SYSTEM OR REPLACING ECM.
473
541
.35 BRN
Hy<:::1!:)Q
..................................
~1~
.35 DK GRN
HT BLU
335
409
5_1__1_l
.........................
35G:YJt6
SEE FUSE
BLOCK DETAILS
PAGE 8A11-11
A/C
PRESSURE
SENSOR
SV
REF
3 BRN
--,
504
(2J [2J ;p;~~1~~ft

B
::~Ji
.35 GRY
(DRIVER
M
M
SIDE)
S I D E ) Ir-- - - - - ,
OPTIONAL
.:1L;.,,,,
. +.
SEEGROUND
DISTRIBUTION
PAGE 8A-14-6
....________.
.I
3 BLK
.35 DK BLU
35 REOIBLK
4
______ !_0
8_ (RED)
_____
380
<;
_! 1
Bt/(1os
SEE ENGINE
35
5 1 1 9 - ~ CONTROLS
PAGE SA-21-0
.35 BLK 808
(GRN)
8_ (RED)
rl----2--------1-----~ENGINE
PRIMARY
SECONDARY SV AiC
SENSOR
CONTROL
COOLANT
COOLANT
REF PRESSURE
GROUND
MODULE
FAN
FAN
SENSOR
REFERENCE
(ECM)
I
I
=-rONTROL
:.roN ~ROL
INPUT
I+
~-=~~----------~
SENSOR
GROUND
----2106
ECT
INPUT
18
35 B
LKf :0 (RED)
vss
.JSPPL
.35YEL
.35 BLK
470
COOLANT
TEMPERATURE
.35 BLK
(ECT) SENSOR-
470
-~--~
12
401
vss
d............. 5_11_2_
POSITION SENSOR ....

PAGE SA-21-0
"11111111
!...,
150
TO THROTTLE
cl
416
473
REF
LO
PRESS
I
I
I
SEE VEHICLE
SPEED SENSOR
PAGE 8A-J3-0
Q IBRN)
400
COOLANT FANS
COMPONENT
LOCATION
201-PG
NC Refrigerant Pressure
Sensor . . . . . . . . . . . . . . . . . Above RH Shock Tower, forward of NC Compressor
Low Pressure Cut Off Switch . . . . . . . . . . . . . . . . . . . . . . 18 . . .
Coolant Fan, Primary . . . . Behind radiator, Driver side
Coolant Fan, Secondary . . . Behind radiator, Passenger side
19
(ECM) (VS VIN P) . . . . . In Engine Compartment, rearward of RH Shock Tower
19
(ECT) Sensor (V6 VIN S) Mounted in front top of Engine, under plenum
(ECT) Sensor (VS VIN P) Front of Engine, mounted in water pump . . . . . . . . . . . . 23
Fusible Links . . . . . . . . . . . . Above RH Shock Tower . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
U nderhood Electrical Center LH side of Engine Compartment, forward
of wheelhouse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Cl 10 (10 cavities) (L32) . . Engine to Injector Harn, top center oflntake Manifold
12
G106 . . . . . . . . . . . . . . . . . . . . Near top LH side ofradiator, in top of T-Bar . . . . . . . . . . 19
Sl 13 . . . . . . . . . . . . . . . . . . . . Forward Lamp Harn, approx 13 cm from Electrical
Center breakout
8117 (L32)
ECM breakout
8117 (LTl)
Engine Harn, approx 2 cm from clip near ECM
and main branch
8119 (L32)
Engine Harn, approx 4 cm from Transmission breakout 11 . . .
8119 (LTl)
ECM breakout
8122 (L32)
12 ...
8122 (LTl)
Engine Harn, approx 25 cm from main branch and ECM
breakout
8190 . . . . . . . . . . . . . . . . . . . . Forward Lamp Harn, approx 8 cm from Electrical
Center breakout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 . . .
SYSTEM DIAGNOSIS
For Diagnosis, refer to SECTION 6E3.
FIG.
CONN
34
35
202-18
35
202-19
40
19
36
202-24
28
22
35
202-0
202-1
20
23
53
BLANK
'
'
31 - 3
SA
32 0 ELECTRICAL DIAGNOSIS
ENGINE COOLANT HEATER: (KOS)
ENGINE COOLANT
HEATER CORD
(18/3 TYPE HPN)
BLACK
ENGINE
BLOCK
r - - - - - - - - -- ~. - - ~ - - - - ,
ENGINE COOLANT
HEATER
ORANGE
CONNECTOR
(HEATING ELEMENT)
L-----------------J
COMPONENT
(V6 VIN S) . . . . . . . . . . . . .
(V8 VIN P) . . . . . . . . . . . .
Cord (V6 VIN S) . . . . . . .
LOCATION
RH side, middle bottom of Engine, in block
201-PG
FIG.
28 ... 45
LH side of Engine Block, near Oil Level Sensor

Routed from RH side of Engine to positive Battery cable,
strapped on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 . . . 35

Cord (VS VIN P) . . . . . . . Routed from rear of Engine Compartment, strapped to
hood release cable, near Under hood Electrical Center
CIRCUIT OPERATION
The Engine Coolant Heater is inserted into the
Engine Block where there would normally be a Freeze
Plug. The Engine Coolant Heater is not connected to
the vehicle's 12 volt electrical system. For on-vehicle
Service, refer to SECTION 9E.
19 . . . 36
32 - 1
CONN
8A - 33 - 0 ELECTRICAL D,IAGNOSIS
r- - - - -
r- - - - - -, INSTRUMENT
-,CRUISE
I ksv
I ~OoN:ia~
I
1-K34
I
VEHICLE I ~
SPEED
I
INPUT _.
....I
:'GkNITION
I ..
I
__
.35 DK GRN,WHT
: cu,.ER
VEHICLE
SPEED
INPUT
....
----..J
B12
817
.35 DK GRN,WHT
817
A1 IC200A
C2000
.35 DK GRN,WHT
8.17_ _ _ _ _ _ _ _ _ __
(V6 VIN S) .5 DK GRN,WHT

(VB VIN P) .35 DK GRN,WHT
817
28
8
B (BLK) (V6 VIN S)

(BRN) (V8 VIN P)
r - - - D_.. - - - - - - - ,
4000 PULSES
ENGINE
CONTROL
I PER MILE, SPEED OUTPUT

I MODULE
I
~
I
~
VEHICLE SPEED
VEHICLE SPEED I
I
L - - - _!N':!f.T ~ - - l~U!_!!I _ ...J
29
(V6 VIN S) .5 PPL

(VB VIN P) .35 PPL
------
30
12
B (WHD (V6 VIN S)

Q_ (BRN)(V8 VIN P)
401
(V6 VIN S) .S VEL

(V8 VIN P) .35 VEL
400
VEHICLE
SPEED
SENSOR
PERMANENT
MAGNET
GENERATOR
SEE PAGE 8A-3-0

FOR MEASURING
ANO HANDLING
PROCEDURES
II ~
12065425
10-WAV F METRI-PACK 150 SERIES
BLK
B
17
@@@@@@@@@@@@@@@@
,@@@@@@@@@@@@@@@@16
12129025 (BODY)
32-WA V F MICRO-PACK
GRY
12129021(TPA}
TPA MICRO-PACK 100W
BLK
ENGINE CONTROL MODULE (ECM) - V6 VIN S
12065888
12065803
22-WA VF MICRO-PACK
BRN
34-WAV F MICRO-PACK 100 SERIES

BLK
ENGINE CONTROL MODULE (ECM) - V8 VIN P
INSTRUMENT CLUSTER
33 - 1
8A -

COMPONENT
Cruise Control Module
(ECM) (V6 VIN S) . . . . . .
(ECM) (V8 VIN P)
Instrument Cluster ...... .
(MD8 Automatic) ...... .
(M49 or MN6 Manual) ...
C200A (17 cavities)
LOCATION
201-PG
Front LH side of vehicle, mounted to frame rail, forward
of wheelhouse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
FIG.
CONN
36
202-10
35
202-18
19

19
35
LH side of I/P ................................................... .
Rear LH side of Transmission
202-19
202-22
16 . . . 29
Rear LH side of Transmission . . . . . . . . . . . . . . . . . . . . . . . 16, 20

C200D (48 cavities)
Steering Column . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
C220 (10 cavities) ....... . Under RH side ofl/P, behind kick panel . . . . . . . . . . . . . . 46
PlOO ................... . Left side in dash panel, Engine to Passenger
Compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
PllO
Compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
S242
30,37
72
202-2
72
67
202-2
202-6
36
35
(Perform before
Diagnosis)
beginning
System


Procedures," page 8A-4-0).
Refer to System Diagnosis
SYMPTOM TABLE
SYMPTOM
PROCEDURE
Refer to SECTION 6E3.
Speedometer inoperative. Code 24 set.

Speedometer and Cruise Control inoperative; Code 24
not set.
Speedometer inoperative.
Control operates.
Code 24 not set.
PAGE NUMBER
Chart #1
8A-33-3
Cruise Check for open, short to ground or short to B + in

CKT 817 between 5242 and Instrument Cluster
Connector. Also check for poor connection at
terminal "B 12". If OK, service Instrument Cluster.
ELECTRICAL DIAGNOSIS SA
CHART #1
SPEEDOMETER AND CRUISE CONTROL INOPERATIVE; CODE 24 NOT SET
DISCONNECT ECM CONN B (V6 VIN S) OR

CONN D (VS VIN P).
CONNECT SIGNAL GENERATOR 1/P TESTER
J 33431-B TO ECM CONN B (V6 VIN S)
TERM "28" OR CONN D (VS VIN P) TERM "8".
CONNECT J 33431-B GROUND TERMINAL TO
A GOOD CHASSIS GROUND.
SET SIGNAL GENERATOR 1/P TESTER J 33431-B
TO 54mph.
DOES SPEEDOMETER READ 54 mph?
CHECK FOR OPEN, SHORT TO GROUND OR

SHORTTO VOLTAGE ON CKT817.
INSTRUMENT CLUSTER CONN TERM "812".
IF OK, SERVICE INSTRUMENT CLUSTER.
CIRCUIT OPERATION
The Vehicle Speed Sensor is a gear-driven
Permanent Magnet Generator housed in the vehicle's
Transaxle. This sensor generates a sine wave output
with a frequency proportional to vehicle speed. The
ECM converts this signal to an output that is switched
to ground at a frequency of 4000 pulses per mile at the
DK GRN/WHT wire (GKT 817), which feeds the
Instrument Cluster and Cruise Control Module.

AT ECM CONN B (V6 VIN S) OR
CONN D (VS VIN P).
IF OK, REPLACE ECM.
33 3
SA -
34 - 0
CRUISE CONTROL (K34)
AIC
CRUISE
FUSE 12
20AMP
1 UNDERHOOD
'7E;;O;.;RDISTRIBUTION
PAGE SA-103
I ELECTRICAL
CENTER
I
I
_______ J
...---.8 PNK
139
~S165. . . . . . . . . . . . . . . .a.PNK. . . . . . . . . . . . . . . . .1191~M

. . . . . . . . . . . . . . . ..
139
.8PNK
139
-
SEE FUSE
BLOCK DETAILS
PAGESA-11-14
rn
IMPORTANT:
OFF
ON
-ON
RIA
V6 VIN S
CLUTCH ANTICIPATE/
CRUISE RELEASE SWITCH
(4 CAVITY DUAL SWITCH)
(OPEN WITH
CLUTCH PEDAL
DEPRESSED)
PAGE 8A207
I
r
139
-1- I
B
I
I _
VS VIN P
1 CRUISE
RELEASE/
I CLUTCH
SWITCH
I (2 CAVITY)
AI
.35 BRN/WBHT
-------K
(OPEN WITH
CLUTCH PEDAL
.35 GRY
397
.35 GRY/BLK
DEPRESSED)
379
C250
B
CRUISE RELEASE/[]
BRAKE SWITCH
(OPEN WITH
BRAKE DEPRESSED)
.35 B~"86
A..
[ ] CRUISE RELEASE/
BRAKE SWITCH
(OPEN WITH
BRAKE DEPRESSED)
.35 DK BLU
A J C250
c250
.35 BR:..:6
.35 BRN
86
'
------------------~:~ ------------BRAKE
INPUT
,-
1MULTIFUNCTION
LEVER
1
I
I
I
I
l-.35 PNK
139
RIA
I
I
I
I
ALL MANUAL TRANS

VEHICLES USE A CLUTCH
JUMPER HARNESS.
.8PNK
I CRUISE
I SWITCH
'
84
87
.8 ORN
34 - 1
TO HAZARD
FLASHER
PAGE SA-1100
140
I" -
., ENGINE
CONTROL
4000 PULSES
PER MILE,
SPEED
OUTPUT
c
.8 YEL
.8LTBLU
I MODULE
I (ECM)
A
I . ,.
L----.J~
9.
28
8
TO AUTO TRANS
PAGE SA-206 (V6 VIN SJ
SA-216 (VS VIN P)
NOT USED WITH
MANUAL TRANS
(V6 VIN S) .5 DK GRN/WHT
(VS VIN P) .35 DK GRN/WHT
820
20
(BLK) (V6 VIN S)

VIN P)
Q (BRN) (VS
817
TO TURN/HAZARD
SWITCH ASSEMBLY
PAGES8A1100, 1
TO CENTER
5243
rn
HIGH MOUNTED
P~ STOPLIGHT(CHMSL)
YEiiL_......
11111
820
..---------------
PAGE8A1101
IMPORTANT:
BRAKE SIGNAL INPUT MUST BE
PULLED LOW THRU CENTER HIGH
MOUNTED STOPLAMP BULB OR
CRUISE CONTROL WILL NOT WORK
.8 YEL
820
.35 DK GRN!WHT
----1111.-
817
TO ELECTRONIC
BRAKE CONTROL
VEHICLE SPEED
SENSOR INPUT
BRAKE
INPUT
STEPPERQ
MOTOR
12V
5V
I
EARL V PRODUCTION
VEHICLES
ALL OTHER
VEHICLES
I
I
I
.35BLf 50
SEE GROUND
DISTRIBUTION
PAGE 8A146
IIJii,,- -
3 BLK
MECHANICAL
LINK (CABLE)
TO THROTTLE BODY
S113
I ,so
__.tt2106
SEE PAGE SA-30

FOR MEASURING
ANO HANDLING
PROCEDURES
SA -
CRUISE CONTROL (K34)
12065425
BLK

CAVITY
WIRE COLOR
CKT
GRY
397
CRUISE CONTROL SWITCH - ON
8A-34-0
DKBLU
84
CRUISE CONTROL SWITCH - SET/COAST
8A-34-0
GRY/BLK
87
CRUISE CONTROL SWITCH - RESUME/ACCEL
8A-34-0
BRN
86
CRUISE RELEASE/BRAKE SWITCH OUTPUT
8A-34-0
BLK
150
1650
GROUND (EARLY PRODUCTION VEHICLES)

GROUND (ALL OTHER VEHICLES)
8A-14-6
8A-14-6
PNK
139
POWER FEED FROM A/CCRUISE FUSE #12
8A-34-0
YEL
820
BRAKE DEPRESSED INPUT
8A-34-1
DKGRN/WHT
817
VEHICLE SPEED SIGNAL
8A-34-1
PAGE
DESCRIPTION
B
17
@@@@@@@@@@@@@@@@
1@@@@@@@@@@@@@@@@16
12129025 (BODY)
GRY
12129021(TPA)
TPA MICRO-PACK 1OOW
BLK
ENGINE CONTROL MODULE (V6 VIN S)
12065888
22-WAY F MICRO-PACK
BRN
ENGINE CONTROL MODULE (VS VIN P)
34 - 3
C215
fr
~P
INIMIL IK I J 0 IH IG IF IE
FORWARD LAMP
l PJ ~~~~~SJ ~~iJ~~~ING
0
06294509
11-WAY FPACK-CON I
BLK
COMPONENT
Brake Switch Assembly
201-PG FIG.
LOCATION
Mounted in lower hole of brake pedal bracket (2 conn
Clutch Anticipate/
(all V6 Manual) . . . . . . . . . Mounted in clutch pedal bracket (4 cavity conn) . . . . . . 0 . . . .
of wheelhouse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 . . .
(2 cavity conn) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
(VS Manual with K34) . . Mounted in clutch pedal bracket (2 cavity conn) . . . . . . 0
19
(ECM) (VS VIN P) .... . In Engine Compartment, rearward of RH Shock Tower
19
1/P Fuse Block .......... . LH side ofl/P Carrier, on the side .................. . 8
Multi-Function Lever ... . Left Arm on Steering Column ...................... . 2 ....
of wheelhouse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
C200A (17 cavities)
and Steering Column ............................. 47
C200D (48 cavities)
Steering Column . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
C215 (11 cavities) ....... . Near base of Steering Column . . . . . . . . . . . . . . . . . . . . . . 35
C250 (2 cavities) ........ . Forward Lamp Harn to Clutch Jumper Harn or Switch,
G106 ................... . Near top LH side ofradiator, in top ofT-Bar . . . . . . . . . . 19
G109 ................... . Braided ground strap, bolted to left front frame rail (some
vehicles will have 1 ring terminal in addition to
ground strap) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 . . .
8113
Center breakout
8165
Center breakout
1/P Harn, approx 30 cm from Convenience Center breakout
8242
1/P Harn, approx 1 cm from Fuel Pump Relay breakout 7
8243
Forward of Lamp Harn, approx 13 cm from breakout
8271
inboard of PlOO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
SYSTEM DIAGNOSIS
For Diagnosis, refer to SECTION 9B.
CONN
1 ...
202-17
36 . .
202-10
1
1
35
202-18
35
15
4
202-19
202-22
36
202-24
72
202-2
72
52
67
202-2
202-4
202-6
1, 2
35
21
13
14
HORNS
-------,~
FUSE
I BLOCK
BATT
(NOT USED)
L----------
J
.8 ORN
540
1 ORN
r- -
540
-,CIGAR
LIGHTER
PAGE 8A114-0
I
I
L. -
r-
....
- - - - - - - - - - - - - - - ,
Ill
I
i ~-------------------~ :
II
~-~
1 DK GRN
rn
II CENTER
HORN
RELAY
CONVENIENCE
__________ :f __ J
29
.35 BL12~
C216
IMPORTANT:
WHEN REPLACING HORNS, BE SURE
TO REPLACE WITH THE SAME
SOUNDING HORN. THERE ISONE "A"
NOTE (450 Hz) AND ONE "F" NOTE
(360 Hz). HORNS ARE MARKED WITH
EITHER AN "A" OR "F" NEAR THE
HORN OPENING.
r-----
- - - - - - - - 1 STEERING
COLUMN
BLK
-------5158
1 DK GRN
29
1 DK GRN
rr-r1 ,.,. '""'

IJ-lJ
HORN #1
29
SPRING
HORN #2
(BOTH HORNS ON RIGHT FRONT SIDE OF VEHICLE)
SEE PAGE BA-3-0

FOR PROPER
HANDLING
PROCEDURES
r - - - I
RED
I
I
1
I
- - - - ,
RED
r-.
HORN SWITCH
(INCLUDES 2 SWITCHES
&WIRING)
STEERING
I WHEEL
i;ti.-.
I
I
1
I
L---- -----'
L--------------J
BLK
CAUTION: This vehicle is equipped with Supplemental Inflatable Restraint

(SIR). Refer to CAUTIONS in Section 9J under "ON-VEHICLE SERVICE" and
the SIR Component and Wiring Location view in Section 9J before
performing service on or around SIR components or wiring. Failure to
follow CAUTIONS could result in possible air bag deployment, personal
40 - 1
C216
F-CONN
M-TERM
12004147
11-WAY F PACK-CON I
BLK
1/P HARNESS TO STEERING COLUMN HARNESS
COMPONENT
201-PG
LOCATION
Cigar Lighter ........... . Mounted on front of console . . . . . . . . . . . . . . . . . . . . . . . . . 21 . . .
Convenience Center
Left of Steering Colum:n, mounted to bottom of
1/P Carrier ..................................... . 8 . ...
Horn #1 ("A" Note)
RH side, front of vehicle directly below Headlamps ... . 19 ...
Horn #2 ("F" Note)
RH side, front of vehicle directly below Headlamps ... . 19 ...
1/P Fuse Block .......... . LH side ofl/P Carrier, on the side .................. . 8 ....
C200A (17 cavities)
C200D (48 cavities)
Steering Column . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
C216 (11 cavities) ....... . Attached to base of Steering Column . . . . . . . . . . . . . . . . 34
PlOO ................... . Left side in dash panel, Engine to Passenger
Compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
S158
on horn branch
FIG.
38
CONN
15
35
35
15
202-17
202-22
72
202-2
72
51 ..
202-2
202-5
36

Diagnosis)
System
Check Fuse 7. An accessory plugged into the Cigar

Lighter may have caused an overload.

SYSTEM DIAGNOSIS
Refer to the Symptom Table for the appropriate
diagnostic procedure(s).
SA -
40 - 2
HORNS
SYMPTOM TABLE
SYMPTOM
Horns inoperative from both switches.
PROCEDURE
PAGE NUMBER
Chart #1
8A-40-2
Horns inoperative from one switch only.
Check for open in BLK or RED wire leading to

inoperative switch. If OK, replace Horn Switch as
necessary.
One Horn inoperative.
Remove connector from inoperative Horn. Attach one

end of a fused jumperto B +. Momentarily touch the
other end to the Horn. If the Horn sounds, repair
open in CKT 29. If the Horn does not sound, check the
Horn for a clean and tight ground at its case. If OK,
replace Horn.
Horns "ON" at all times.
Chart #2
8A-40-3
CHART #1
HORNS INOPERATIVE FROM BOTH SWITCHES
CHECKFUSE7.
IS FUSE 7 OPEN?
REMOVE HORN RELAY.

CONNECT A TEST LIGHT FROM CONVENIENCE
CENTER TERM "L" TO GROUND.
DID TEST LIGHT COME "ON"?
CHECK FOR A SHORT TO GROUND THROUGH CKT 540 OR CKT 29, REPAIR
AS NECESSARY. ITIS POSSIBLE THAT AN ACCESSORY PLUGGED INTO
THE CIGAR LIGHTER MAY HAVE CAUSED THE OVERLOAD.
REPLACE FUSE 7.
CONNECT A TEST LIGHT FROM THE

CONVENIENCE CENTER TERM "L" TO TERM "M".
PRESS EITHER HORN SWITCH.
REPAIR OPEN IN CKT 540 OR POWER FEED TO FUSE 7.
RECONNECT HORN RELAY.

BACKPROBE CONVENIENCE CENTER TERM "N"
DISCONNECTC216.
CONNECT A TEST LIGHT FROM CONVENIENCE CENTER TERM "L"
TO C216 TERM "G" (STEERING COLUMN SIDE).

BETWEEN C216 AND
HORN RELAY.
CHECK FOR OPEN IN BLK WIRES ATTACHED

TO HORN BRUSH SLIP RING AND FOR
CONTACT AT THE SLIP RING, OR CHECK FOR
CLEAN AND TIGHT GROUND AT CASE OF
HORN SWITCHES.
IF OK, REPLACE HORN SWITCHES AS
NECESSARY.
CHART #1 (continued)
CHART #2
HORNS INOPERATIVE FROM BOTH SWITCHES
HORNS "ON" AT ALL TIMES
REMOVE HORN RELAY.

ARE HORNS "ON"?
DISCONNECT EITHER HORN

CONNECTOR.
CONNECT A TEST LIGHT FROM
CONN TERM "B" TO GROUND.
DOES TEST LIGHT COME "ON"?
CHECK FOR POOR

CONNECTION AT
TERM "N".
IF OK, REPLACE
HORN RELAY.
CONNECT A TEST
LIGHT FROM
CONVENIENCE
CENTER TERM "L"
TO TERM "M".
IS TEST LIGHT "ON"?
CHECK HORNS FOR GOOD

GROUNDS AND GOOD
CONNECTIONS.
IF OK, REPLACE HORNS AS
NECESSARY (HORNS
INOPERATIVE COMPLAINTS
MAY NOT ARISE UNLESS
BOTH HORNS FAIL).
CHECK FOR POOR

CONNECTION AT
TERM"N".
IF OK, REPAIR
OPEN IN CKT 29.
CHECKFORSHORTTO
GROUND IN CKT 28.
IF OK, REPAIR OR
REPLACE HORN
SWITCHES AS
NECESSARY.
CIRCUIT OPERATION
Battery voltage is applied at all times to the Horn
Relay at terminal "L". When a Horn Switch is pressed,
it provides a ground to the Horn Relay Coil. The Horn
Relay contacts close, applying battery voltage to the
horns. The horns continue to sound until the Horn
Switch is released.
BRAKE WARNING SYSTEM
------,~
r----I
I
FUSE
sEE POWER
DISTRIBUTION
PAGE 8A-103
GAGES
FUSE 9
10AMP
I
I
IGN
(NOT USED)
I
_..J
L---------.8 PNK
SEE FUSE
BLOCK DETAILS
PAGE8A-11-4
I BLOCK
I
I
39
~--5206
.3SPNK139
AS
r;;.,D~A~R;-~ GAGES
I
I
I
~ BRAKE.
\JV
INDiCATOR
INST~UMENT
I CLUS ER
I ,.,J...&.
I~
TO HATCH
RELEASE RELAY
PAGE 8A-135-0
:. . ____ r___ J
MANUAL
TRANSMISSION
A10
.35TAN/WHT
.3STAN/WHT
33
.3STAN/WHT
33
33
WITH
DAYTIME
RUNNING
LIGHTS (DRL)
'. .~,J.
....
WITHOUT
DAYTIME
RUNNING
LIGHTS (DRL)
"l""'"
In
yc200A
.1s TANIWHT
,. ..
'
5273 - - - - - - - - -. .
. 35
,.--Jl
D
DAYTIMEr"' RUNNING
LIGHTS (DRL)
MODULEj
p
BRAKE
IN PUT
L..-
.35TAN/WHT
33
.35 TAN/WHT
33
I
I
1134
BRAKE
COMBO
VALVE
(ABS)
A, \
PARK BRAKE
SWITCH
CLOSED WITH
PARK BRAKE ON
PARK B R A K E [ ]
SWITCH
CLOSED WITH
PARK BRAKE ON
-
._
"'________
~-1 .
c
IGNITION r" SWITCH
I ACCY
I._
OFF
NORMALLY
OPEN.
CLOSED WITH
UNEQUAL
BRAKE PRESSURE.
I
I
I
I
._
C2
BRAKE
INDICATOR
CONTROL
-=-1._
-:::;-
651
..
mum,
I
START
SEE GROUND
DISTRIBUTION
PAGE 8A-14-4
ELECTRONIC
BRAKE
I CONTROL
I MODULI
I (EBCM)
____ ....
9.
~-
RUN
84
__ _ ____ ....
.8 BLK/WHT
SEE PAGE 8A-3-0

FOR MEASURING
AND HANDLING
PROCEDURES
33
r-z----.
HYDRAULIC
MODULATOR
ASSEMBLY
....
'f
.3SLT B~U
.35 TAN,WHT
9_
41 - 1
FRONT VIEW
A1
B16
B1
A17
12110113
32-WA Y F MICRO-PACK 100 SERIES
12065803
34-WAY F MICRO-PACK 100 SERIES
DK RED
BLK
ELECTRONIC BRAKE CONTROL MODULE (EBCM)
INSTRUMENT CLUSTER
COMPONENT
LOCATION
201-PG FIG.
CONN

Part of Hydraulic Modulator Assembly, inward side . . 36 . . . 53
I/PCompartment ................................ 7 .... 12 . . 202-17
Module (EBCM) ....... . Under I/P, next to LH hinge pillar,just above
Pass Thru Grommet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 . . . . 14 .. 202-13
I/P Fuse Block .......... . LH side ofI/P Carrier, on the side . . . . . . . . . . . . . . . . . . . 8 . . . . 15 .. 202-22
Ignition Switch ......... . PartofSteeringColumn ........................... 34 ... 51 .. 202-22
Instrument Cluster ...... . LH side ofI/P ............. ...................................... . 202-22
Park Brake Switch ...... . In console, at base of Park Brake Lever . . . . . . . . . . . . . . 22
39
C200A (17 cavities)
72 .. 202-2
C200D (48 cavities)
Part ofI/P Harn, between LH kick panel and
Steering Column . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
72 .. 202-2
GlOl
Top of RH Shock Tower (3 rings, 5 wires) . . . . . . . . . . . . . 10
19
PlOO
Compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
36
Slll
8206
breakout
8228
8273
inboard of PlOO .................................. 8 . . . . 14
8A - 41
- 2 ELECTRICAL DIAGNOSIS

(Perform before
Diagnosis)
beginning
System


SYSTEM DIAGNOSIS
procedures.
SYSTEM CHECK
NORMAL RESULTS
ACTION
[1]
Park Brake released .

Turn Ignition Switch slowly past "RUN" position .
"BRAKE" Indicator lights.
Release Ignition Switch to "RUN" position .
"BRAKE" Indicator does not light.
Ignition Switch in "RUN."

Apply Park Brake .
"BRAKE" Indicator lights.
Release Park Brake .
"BRAKE" Indicator does not light.
[2]
[3]
[4]
SYMPTOM TABLE
SYMPTOM
PROCEDURE
PAGE NUMBER
"BRAKE" Indicator remains on with Ignition Switch in

"RUN" and Park Brake released.
Chart #1
8A-41-3
"BRAKE" Indicator does not turn on under any

condition.
Chart #2
8A-41-4
"BRAKE" Indicator does not turn on for only one

condition.
Chart #3
8A-41-5
CHART #1
"BRAKE" INDICATOR REMAINS ON WITH IGNITION SWITCH IN "RUN"
AND PARK BRAKE RELEASED

DISCONNECT BRAKE COMBO VALVE CONNECTOR.
DID "BRAKE" INDICATOR GO OUT?
DISCONNECT PARK BRAKE SWITCH.

,-
----------------------------,
REFER TO SECTION 5.
REPAIR OR REPLACE MECHANICAL PARTS OR
BRAKE COMBO VALVE AS NECESSARY.
:
I
~------------------------------~
DISCONNECT ELECTRONIC BRAKE

CONTROL MODULE (EBCM) CONN C2.
IS VEHICLE EQUIPPED WITH DAYTIME

RUNNING LIGHTS (DRL)?
r- - - - - - - - - - - - - - - - - - - - - - - - - - - - - ,
: REFER TO SECTION 5E1 (CODES A086, A087 AND:
I A088 PERTAIN TO "BRAKE" INDICATOR).
1
L------------------------------J
CHECK FOR MECHANICAL INTERFERENCE.

IF OK, REPAIR OR REPLACE PARK BRAKE
DISCONNECT DRL MODULE CONN C1.

DISCONNECT IGNITION SWITCH

CONNC1 ONLY.
CHECK FOR SHORT TO GROUND

THROUGH CKT 33, INCLUDING HATCH
RELEASE RELAY IF EQUIPPED WITH A
MANUAL TRANSMISSION.
CONNECT A JUMPER WIRE AT DRL

MODULE CONN C1 FROM TERM "D" TO
TERM "E".
IF LIGHT COMES ON, REPAIR SHORT TO
GROUND IN CKT 1134.
IF LIGHT STAYS OFF, CHECK FOR
SHORTED TERMINALS IN CONNECTOR.
IF OK, REPLACE DRL MODULE.
CHECK CONN FORA SHORTED TERM.

IF OK, REPLACE IGNITION SWITCH.
-3
8A - 41
-4

CHART #2
"BRAKE" INDICATOR DOES NOT TURN ON UNDER ANY CONDITION
DISCONNECT INSTRUMENT CLUSTER.

CONNECT A TEST LIGHT FROM HARNESS
CONN TERM" AS" TO TERM" A 1O".
SET PARK BRAKE.
IS TEST LIGHT "ON"?

HARNESS CONN TERM" AS"
TO GROUND.
IS TEST LIGHT "ON"?

INSTRUMENT CLUSTER CONNECTORS
OR OPEN IN PRINTED CIRCUIT.
IF OK, REPLACE INDICATOR LAMP.
REPAIR OPEN IN CKT 39, POWER

FEED TO CLUSTER (FUEL GAGE
AND AT LEAST 3 OTHER
INDICATORS SHOULD ALSO
HAVE BEEN INOPERATIVE).

TERM "A10".
BETWEEN CLUSTER AND 5228.
IMPORTANT:
THIS CHART ASSUMES THAT THE

INDICATOR WOULD NOT TURN ON
DURING ANY OPERATION.
41 - 5
CHART #3
"BRAKE" INDICATOR DOES NOT TURN ON FOR ONLY ONE CONDITION
WHICH COMPONENT DOES NOT TURN "BRAKE" INDICATOR ON?
PARK BRAKE SWITCH
IGNITION SWITCH
EBCM
BRAKE COMBO VALVE
,- -------,
DOES VEHICLE
HAVE DRL?

BACKPROBE IGNITION SWITCH
CONN C1 TERM "C" WITH
MULTIMETER SET TO DC VOL TS.
- IF NO VOLTAGE, REPAIR
OPEN IN CKT 33 BETWEEN
SWITCH AND 5228 OR POOR
CONNECTION AT IGNITION
SWITCH CONNECTOR.
- IF BATTERY VOLTAGE,
CHECK FOR POOR
CONNECTION TO SWITCH AT
CONNC1 TERM"C".
IF OK, REPLACE IGNITION
SWITCH.

DISCONNECT BRAKE COMBO VALVE
(ABS CONN C4).
CHECK FOR BATTERY VOLTAGE AT
CONN C4 TERM "A".
IS BATTERY VOLTAGE PRESENT?
REPAIR OPEN IN
CKT 33 BETWEEN
BRAKE COMBO
VALVE AND 5228.
: REFERTO
:
: SECTION 5E1 :
1 (CODE A087). 1
L..--------..J
CONNECT A FUSED JUMPER

ACROSS HARNESS CONN FROM
TERM" A" TO TERM "B".
IS "BRAKE" INDICATOR ON?
IGNITION SWITCH TO
'RUN."
CHECK FOR BATTERY
VOLT AGE AT PARK
BRAKE SWITCH
CONNECTOR.
- IF NO VOLTAGE,
REPAIR OPEN IN
CKT 33 BETWEEN
SWITCH AND 5228.
- IFBATTERYVOLTAGE,
CHECK FOR POOR
CONNECTION AT
SWITCH OR FOR
MECHANICAL
INTERFERENCE.
IF OK, REPLACE
SWITCH.

CHECK FOR BATTERY VOLTAGE AT PARK BRAKE SWITCH.
IS BATTERY VOLTAGE PRESENT?
DISCONNECT DRL MODULE

CONN C1. CHECK FOR
BATTERY VOLTAGE AT
TERM "D" ON HARNESS
CONNECTOR.
IS BATTERY VOLTAGE
PRESENT?

BETWEEN DRL
MODULE AND 5228.
CIRCUIT OPERATION
When the Ignition Switch is turned to "RUN,"
"BCLB TEST" or "START," voltage is applied to the
Instrument Cluster through CKT 39 from Gages
Fuse 9. The Brake Indicator receives a ground through
CKT 33 by any one of four components: the Ignition
Switch, Park Brake Switch, Brake Combo Valve (ABS)
or the Electronic Brake Control Module !EBCM).
CHECK FOR POOR

CONNECTION AT
PARK BRAKE SWITCH,
OR FOR MECHANICAL
INTERFERENCE.
IF OK, REPLACE
SWITCH.
CHECK FOR OPEN IN

CKT 1134, OR FOR
POOR CONNECTION
TO DRL MODULE.
IF OK, REPLACE DRL
MODULE.
CHECK FOR POOR

CONNECTION TO
BRAKE COMBO
VALVE.
IF OK, REPLACE
BRAKE COMBO
VALVE.
When the Ignition Switch is turned to "BULB

TEST" or "START," CKT 33 is grounded through the
Ignition Switch. When the Park Brake is set, the Park
Brake Switch closes, grounding CKT 33 thro_ugh the
Park Brake Switch. For a better understanding of
when the Brake Combo Valve or Electronic Brake
Control Module (EBCM) will ground CKT 33, refer to
SECTION 5El.
ANTILOCK BRAKES
HOT AT ALL TIMES
------------------------------,~
rsE;;O;;,R- -
SEE POWER
DISTRIBUTION
PAGE8A-101
I DISTRIBUTION
PAGE 8A-103
I
I
FUSE
I BLOCK
-1
1
______ J
.8 PNK
SEE FUSE
BLOCK DETAILS
PAGE 8A-11-4
.SORN
39
liJii.- - -
5206
.35PN139
J.,. -6. INSTRUMENT

~
CLUSTER
TCC/SHIFT
INTERRUPT
SWITCH
(NORMALLY
CLOSED)
G~RU::~----1--------~---,
CID
CID
CID
AS
I PAGES
CLUSTER
SA-81-1, 3
I
"BRAKE"
INDICATOR
"LOW
TRAC"
INDICATOR
SOLID
STATE
!.. - - - _,4 ___ - _r_ ___

A 10
A 16
.35 DK BLU
.35 TAN/WHT
33
817
1537
"ABS INOP"
INDICATOR
II
I
.8 Y~L~~;
IS
.35LT GRN
5243
867
t..-- 111111111_. ., ~
.8 YEL
A4
Al
C200D
- - - - - - - 1 c200A
.8YEL
8 YEL
820
820
C200D
C200A
820
.8 YEL
....
TD CENTER HIGH
MOUNTED STOP LIGHT
PAGE8A110-1
....
TO CRUISE
S271 - - - - - - CONTROL MODULE
867
------------------------~j
BS
- - - lSLTG:~
~: 820
PAGE8A-341
ELECTRON1cr-A-BS__________....;;...;;...__________________________________~BR~A~K~E--------------------------""I
BRAKE
CONTROL
ABS
FAIL
ACTIVE
MODULE
(EBCM)
SV
SWITCH
SERIAL
DATA
LINE
r-S228
INPUT
SOLID STATE
TO BRAKE
WARNING
PAGE 8A-41-0
.35 TAN/
WHT
33
"BRAKE"'
INDICATOR
CONTROL AND
MONITOR
GROUND
AST~
All
C2000
.35 TAN
LEFT FRONT
SOLENOID
CONTROL
RIGHT FRONT
SOLENOID
CONTROL
.3STAN/W:TF3 - - - - - - - - - - Bl
800
.35TAN,WHT
- - - - - - - es2n
-----es210
.35TAN
.----t-'---S-.OO
SEE DATA LINK
CONNECTOR
PAGE 8A-500
Al
5 BLK/WHT
NORMALLY
OPEN
CLDSEDWITH
UNEQUAL
BRAKE
PRESSURE
651
.STAN
I,
- - - - - - - 5225
800
rn rn
A
BRAKE
COMBO
VALVE
C200A
C2000
21
.35TAN 800
..
.35 TAN1800
.8 BLK,WHT
651
.8BLK,WHT
.8 BLK,WHT
.35T:N~800
SEE PAGE SA-3-0

FOR MEASURING
AND HANDLING
PROCEDURES
DATA
LINK
CONNECTOR
(DLC)
SEE GROUND
DISTRIBUTION
PAGE 8A-14-4
ABS
BRAKE
PRESSURE
VALVE
SOLENOID,
651
651
ABS
BRAKE
PRESSURE
VALVE
SOLENOID,
~
44 - 1
WHEEL SPEED
SENSOR,
RIGHTFRQNT
HOTINRUN
SEE POWER
DISTRIBUTION
PAGE 8A-10-2
-----,
rsE7P~E;;- -
I DISTRIBUTION
PAGE8A100
I
I
I
I
I
I
I
I
I
.5WHT
I
I
I
ABS IGN
FUSE 5
SAMP
1 RUST
5 RED
641
86
CS
UNDERHOOD
ELECTRICAL
CENTER
87
C4~
-
.5 BLK
302
2 --------
s11s - - ' - - - 5 RED~02
30
M~Ta----~\
L----
FUSIBLE
l,INK B
5RED
102
5RED
.35 BRN
FUSIBLE
LINKE
.SWHT
C130
.35 DK
GRN
.35 TAN
.5 BLK
872
833
1:I
J
;;ED,=3-
s 1 8 0 - - -. .
.SORN
440
.35 PNK
.35 BRN
3 RED
1632
641
5 RED
WHEEL SPEED
SENSOR,
LEFTFRONT
1633
1633
5272----
5 RED 11633
gDA~
810
BATTERY
INPUT
IGNITION
RUN
INPUT
ABS
ENABLE
~ '-v--t'
LO
SWITCHED
BATTERY
LEFTFRONT
WHEEL SPEED
INPUT
SOLID STATE
RIGHT FRONT
WHEEL SPEED
INPUT
REAR
WHEEL SPEED INPUT
, - ~ ~....~~~~~...~~~~....~~~~.....ii,...~~~....,,...~~~~......._~~~~-.HYDRAULIC
MODULATOR
ASSEMBLY
LEFT FRONT
MOTOR
RIGHTFRONT
MOTOR
rn
REAR
MOTOR
IMPORTANT:
1811
TO PROTECT AGAINST INTERFERENCE.
SENSOR WIRES ARE TWISTED
APPROXIMATELY 9 TIMES PER FOOT.
.SWHT
1810
HI
ANTILOCK BRAKES
C1
C2
E::j\
12110626
12110113
8-WA Y F METRI-PACK 280 FLX LK
LTGRY
DK RED
ELECTRONIC BRAKE CONTROL MODULE {EBCM)
rn
IMPORTANT:
TPA'S WILL HAVE A CAVITY REFERENCE Of C
AND D, CONNECTOR BODY REFERS TO A AND B,
"*CAVITIES NOT LISTED ARE NOT USED

CAVITY
WIRE COLOR
CKT
Al
TAN
833
RIGHT FRONT WHEEL SPEED SENSOR RETURN
SA-44-1
A4
DKGRN
872
RIGHT FRONT WHEEL SPEED SENSOR SIGNAL
BA-44-1
AS
BRN
1811
REAR WHEEL SPEED SENSOR RETURN
SA-44-1
A6
WHT
1810
REAR WHEEL SPEED SENSOR SIGNAL
SA-44-1
A7
YEL
873
LEFT FRONT WHEEL SPEED SENSOR RETURN
SA-44-1
AS
LTBLU
830
LEFT FRONT WHEEL SPEED SENSOR SIGNAL
SA-44-1
A9
LTBLU
1289
RIGHT FRONT SOLENOID FEED
BA-44-0
A11
TAN
800
SERIAL DATA SIGNAL
SA-50-0
81
DKGRN
1288
LEFT FRONT SOLENOID FEED
8A-50-0
82
LTGRN
867
ABS FAILURE INPUT TO INSTRUMENT CLUSTER (SOLID STATE)
8A-44-0
83
PNK
1632
ABS ENABLE FEED TO RELAY
8Aa44-1
84
TAN/WHT
33
"BRAKE" INDICATOR LAMP (SWITCHED GROUND)
8A-44-0
BS
DKBLU
1537
"LOW TRAC" INDICATOR LAMP CONTROL
8A-44-1
810
ORN
440
POWER FEED FROM ABS BAT FUSE #1
8A-44-1
811
BRN
641
POWER FEED FROM ABS IGN FUSE #5
8A-44-1
812
YEL
820
8A-44-0
DESCRIPTION
PAGE
COMPONENT
Solenoid, LF ........... .
Solenoid, RF .......... .
ABS Motor Pack ........ .
Brake Switch Assembly ...
LOCATION
201-PG
FIG.
Part of Hydraulic Modulator Assembly . . . . . . . . . . . . . . 36
53
Part of Hydraulic Modulator Assembly . . . . . . . . . . . . . .

Part of Hydraulic Modulator Assembly . . . . . . . . . . . . . .
Part of Hydraulic Modulator Assembly, inward side
same switch for both . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
53
53
53
36
36
36
0
1
Module (EBCM) ....... . Under I/P, next to LH hinge pillar,just above
14
Fusible Links ........... . Above RH Shock Tower . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
19
Hydraulic Modulator
53
Assembly ............. . Front left of Engine Compartment . . . . . . . . . . . . . . . . . . 36
I/P Fuse Block .......... . LH side ofl/P Carrier, on the side . . . . . . . . . . . . . . . . . . . 8 . . . . 15
Instrument Cluster ...... . LH side of I/P ................................................... .
of wheelhouse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
36
Wheel Speed Sensor,
Left Front ............. . Middle ofleft front steering knuckle . . . . . . . . . . . . . . . . . 47
70
Wheel Speed Sensor, Rear . Top of Rear Differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
68
Wheel Speed Sensor,
Right Front ........... . Middle ofright front steering knuckle . . . . . . . . . . . . . . . 47
70
Cl20 (2 cavities) ........ . LH Wheel Speed Sensor Pigtail, mounted to LH Frame Rail
Cl30 (2 cavities) ........ . RH Wheel Speed Sensor Pigtail, mounted to RH Frame Rail
C200A (17 ca vi ties)
72
C200D (48 cavities)
Steering Column . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
72
C405B (10 cavities)
Pass Thru Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 . . . . 9 ...
C405C (4 cavities) ...... . Part of Pass Thru Conn, forward of rear axle, to
Speed Sensor (ABS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 . . . . 9 ...
19
GlOl
PlOO
Compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 . . . 36
Slll
8175
Center breakout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
53
8180
Center breakout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
53
8206
1/P Harn, approx 18 cm from Convenience Center
breakout
8225
8228
8243
I/P Harn, approx 1 cm from Fuel Pump Relay breakout 7
13
8270
inboard of PlOO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
14
8271
inboard of PlOO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
14
8272
inboardofPlOO .................................. 8
14
8273
inboard of PlOO .................................. 8
14
SYSTEM DIAGNOSIS
Refer to SECTIO~ 5El for Diagnosis.
CONN
202-16
202-13
202-22
202-22
202-24
202-2
202-2
202-8
202-8
SUPPLEMENTAL INFLATABLE RESTRAINTS (SIR)
---------------~w
SEE POWER
DISTRIBUTION
PAGE 8A-10-3
AIRBAG
FUSE 1
15 AMP
IGN
(NOT USED)
.8 PPL
39
.8 PNK
~~~~----~------~
806
39
5206
SEE FUSE
BLOCK DETAILS
PAGE 8A-11-4
f
I
- ___.
L.35 PNK
FUSE
BLOCK
,--
GAGES
FUSE9
10AMP
::139
.8 VEL
.-------------,
5204
.8 VEL
.8 VEL
1139
1139
1139
810
82
D I A G N O S T I C - - - - - - - - - - - - - - - - - -......- - - - - - - - - - - - - - - - ENERGY RESERVE
CRANK
REDUNDANT
MODULE (DERM)
INPUT
INDICATOR
IGN1
i,t,,4
SERIAL
DATA
SIR INDICATOR
"LOW" (MONITOR
AND CONTROL)
SOLID STATE
"" l
REDUNDANT
INDICATOR
GROUND
811
81
AS
- - - ,
INSTRUMENT
CLUSTER
A
I ~"AIRBAG" I ~
I \ViNDicATOR I ~
I y
I
L~---..J
A7
.8BRN
358
SHORTING
BAR
rn
IMPORTANT:
WHEN DERM
CONNECTOR IS
DISCONNECTED, A
SHORTING BAR IS
CLOSED SHORTING
TERMINAL "A1"
TO TERMINAL "81
ILLUMINATING
THE INDICATOR.
SEE DATA
LINK CONNECTOR
PAGE 8A-S0-0
.8B::~so
6
.8TAN
SEE GROUND
DISTRIBUTION
800
..... _
,,..- -
PAGE BA-14-9
. . . . es225
.35 TAN
----.
800
.8 PPL
3 BLK
5217
650
326 ,-SEE GROUND

DISTRIBUTION
PAGE 8A14-8
11
......._
,..-- -
5216
------K
DATA LINK
CONNECTOR (DLC)
3 BLK
650
SEE GROUND
DISTRIBUTION
PAGE BA-14-7
SEE PAGE 8A-3-0

FOR PROPER
HANDLING
PROCEDURES
iw.~
SEE PAGE SA-3-0
FOR MEASURING
AND HANDLING
PROCEDURES

47 - 1
.8 YEL
1139
.8 PNK
1401
.8 YEL BLK
. - - - - - - , . . - - - - - -.....- - - - - - - . . , . . ; . . . - - - - -.. ARMING

SENSOR,
DUALPOLE
CLOSED WITH
RAPID LOW
LEVEL VELOCITY
CHANGES
2490
10200
236
.8WHT
347
.8WHT.
BLK
1403
.8 LT GRN/WHT
1837
A3
PASSENGER
36VLR
(36 VLR) 36 VOLT

LOOP RESERVE
DRIVER
SOURCE
SENSE
DRIVER
36 VLR
PASSENGER
SOURCE
SENSE
SOLID STATE
PASSENGER
SIDE
"HIGH"
,-~
A7Y...
.8BLK/
WHT
.8 WHT1BLK . : : . _
1751
.8 DK GRN
348
SHORTING
BAR
.8 WHT
INFLATOR
.8 BLK/
MODULE.
DRIVER
1751
WHT
347
.6.
SIR COIL ASSEMBLY
J;~.
GORTING
SHORTIN~
BAJ
TO PREVENT ACCIOENTAL
DEPLOYMENT, SHORTING BARS CLOSE
TO SHORT CONNECTORS WHEN
CONNECTORS ARE SEPARATED .
.8 DK GRN
348
.8 OK
348
GRN
.8 DK GRN
.8BLK1
WHT
348
1751
.8 BLK/
WHT
1751
- - - - - - - - DISCRIMINATING
SENSOR, PASSENGER
{OMPARTMENT
CLOSED WITH
DEPLOYMENT
LEVEL VELOCITY
CHANGES
,-----r---"I DISCRIMINATING
8450
SENSOR, FORWARO
CLOSED WITH
DEPLOYMENT
LEVEL VELOCITY
CHANGES
SEE GROUND
DISTRIBUTION
PAGE SA-14-4
SUPPLEMENTAL INFLATABLE RESTRAINTS (SIR)
12092689
YEL
DIAGNOSTIC ENERGY RESERVE MODULE (DERM)

CAVITY
WIRE COLOR
CKT
At
BLK/WHT
1751
GROUND
SA-14-4
A2
BLK
650
GROUND
SA-14-8, 9
A3
PNK
1401
DUAL ARMING SENSOR FEED-PASSENGER-36 VOLT
SA-47-1
A4
YEUBLK
236
DUAL ARMING SENSOR FEED- DRIVER - 36 VOLT
SA-47-1
AS
LTGRN
1400
DUAL ARMING SENSOR SIGNAL- DRIVER
SA-47-1
A6
LTGRN!WHT
1837
DUAL ARMING SENSOR SIGNAL- PASSENGER
SA-47-1
A7
WHT/BLK
1403
INFLATOR FEED- PASSENGER
SA-47-1
AS
PPL
326
DIAGNOSTIC ENABLE SIGNAL
SA-47-0
A9
YEL
1139
POWER FEED FROM AIR BAG FUSE #1
SA-47-0, 1
A10
YEL
1139
SA-47-0, 1
A12
BLK/WHT
1751
GROUND
SA-14-4
81
BRN
358
AIR BAG INDICATOR LAMP FEED
SA-47-0
82
PNK
39
POWER FEED FROM GAGES FUSE #9
SA-11-4
87
DKGRN
348
SIR INFLATOR OUTPUT
SA-47-1
BS
DKGRN
348
SIR INFLATOR OUTPUT
SA-47-1
89
WHT
347
INFLATOR FEED - DRIVER
SA-47-1
810
PPL
806
POWER FEED FROM CRANK FUSE #17
SA-11-8
811
TAN
800
SERIAL DATA SIGNAL
SA-50-0
DESCRIPTION
PAGE
47 - 3
12092761
7-WA VF METRI-PACK 280 SERIES
YEL
ARMING SENSOR, DUAL POLE
COMPONENT
Arming Sensor, Dual Pole
CONN
201-PG FIG.
LOCATION
Mounted to Floor Tunnel Bracket, under console . . . . . . 21 . . . 38 . . 202-16
Mounted to 1/P Tie Bar, below and right of
Steering Column . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202-11
Diagnostic Energy
Snapped in bracket, behind RH side ofl/P Compartment 8 . . . . 15
Reserve Module (DERM)
202-12
Forward . . . . . . . . . . . . . . . Mounted to center of front end Tie Bar, near hood latch 19 . . . 36
Mounted to upper dash, just right of Steering Column
Support Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 . . . 68
202-22
I/P Fuse Block .......... . LH side of 1/P Carrier, on the side . . . . . . . . . . . . . . . . . . . 8
15
Inflator Module, Driver .. . Mounted on Steering Wheel . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . . 3
Inflator Module, Passenger Mounted on right side ofl/P
Instrument Cluster ...... . LH side ofI/P ................................................... . 202-22
SIR Coil Assembly ...... . Top of Steering Column . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3, 34 . 5, 51
C200B (18 cavities)
202-2
72
C200D (48 cavities)
202-2
Steering Column . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
72
19
GlOl
Near base of LH "A" pillar, bolted to I/P Mounting Stud
G200
behind kick panel (2 rings, 2 wires) . . . . . . . . . . . . . . . . 9 . . . . 16
Left
side in dash panel, Engine to Passenger
PlOO
Compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 . . . 36
I/P Harn, approx 10 cm from Steering Column breakout
8204
8206
breakout
8216
8217
8225
SYSTEM DIAGNOSIS
Refer to SECTION 9J-A for diagnosis.
SA -
DATA LINK CONNECTOR (DLC): PIN ASSIGNMENT
WITHM080NLY
DATA
LINK
CONNECTOR
(OLC)
----------------- ------
""~(.rS -------------.~~::.: ~----=:~: ..,~- - ~:, "'

5215----,
S BLKIWHT
A8
I DIAGNOSTIC
REQUEST
INPUT
--------
G103 (VS VIN P)

G104 (V6 V I N ~
D,(
T
I
__
I
I
I._
422
422
.35TAN
(V6 VIN S) .STAN

(VS VIN P) .35 TAN
ENGINE
CON.
TROL
MODULE
(ECM)
C2000
C200A
A (CLR)
B(RED)
DIAGNOSTIC
ENABLE
800
5270
~ (BLK)
19
4
Q_ (BRN)
TRANSAXLE
CONVERTER
CLUTCH
.35 TAN
SV
.3S TAN
800
-=.rONTROL
-=-
5V
SERIAL
DATA
LINE
L-------------~-----J
l T1
A
B
C
D

-
L32
GRAY (GRY)
RED
GREEN (GRN)
BROWN (BRN)
22
22
22
22
WAY
WAY
WAY
WAY

WITH COLORED TPAs.
SEE PAGE 8A-3-0
FOR PROPER
HANDLING
PROCEDURES
800
800
800
1-----z----- ------
r
I
15
2
SEE PAGE 8A-3-0

FOR MEASURING
AND HANDLING
PROCEDURES
s225
800
448
448
(BLU)
Q_ (BRN)
__-__ ...J
A12
<;
__ _.
KEYLESS
ENTRY
RECEIVER
II
I
(V6 VIN S) .S TAN/BLK

(VS VIN P) .35 TAN/BLK
(V6 VIN S) 9
(V8 VIN P) 20
C1
PROGRAl.1
.35 TAN
(V6 VIN S) .S WHT/BLK

(VS VIN P) .35 WHT/BLK
1455
,.I - ....--.,I
s 1 1 y .STAN
-----------
AUTOMATIC
TRANSMISSION
I
__.I
.35 BLKI
WHT
I
I~
SERIAL I
""
.____......_..DATA I
~
LINE
----I j._f-4
II
I
L
r-T~-,
I
I
FIC240
DIAGNOSTIC
ENERGY
RESERVE
MODULE
(OERM)
sv
I
I
422
I
I
I
I
I
II
422
.35 TANIBLK
5109 (V8 VIN P)

__...... SEE GROUND DISTRIBUTION
5110 (V6 VIN 5) - - . . . . . PAGES 8A-14-1 (V8 VIN P)
SA-14-2, 3 (V6 VIN S)
451
P110
.35 TAN/BLK
1
.8 BLK/WHT
WHT
r- - - - - - I
I
I
I
I
451
. .:.. "":' '"'
A - CLEAR (CLR)
B - BLACK (BLK)
C - BLUE (BLU)
- 32 WAY
- 32 WAY
- 32 WAY
A11
ELECTRONICr
BRAKE
CONTROL
MODULE
(EBCM)
I
I
-----,
C2
5V
I
I
I
SERIAL I
J.I
DATA
~I
LINE:
I
I
I
I
L_-____ ...J
50 - 1
12020043
Ci5l Cii:11;~ ctjJ [i5l CiiJ Q

---....r-- ~ clli OJ & CQ [Qi -,__,..,.
12-WAY F METRI-PACK 280 SERI ES

BLK
DATA LINK CONNECTOR (DLC)

CAVITY
WIRE COLOR
CKT
BLK/WHT
451
GROUND
8A-14-1,2,3
WHT/BLK
448
DIAGNOSTIC REQUEST, ECM
8A-20-3,
8A-21-3
TAN/BLK
422
TORQUE CONVERTER CLUTCH (TCC) CONTROL SIGNAL
8A-20-6,
8A-21-6
BLK/WHT
1455
PROGRAM INPUT, KEYLESS ENTRY MODULE
8A-132-0
PPL
326
DIAGNOSTIC REQUEST, DIAGNOSTIC ENERGY RESERVE MODULE (DERM)
8A-47-0
TAN
800
SERIAL DATA LINE, DIAGNOSTIC ENERGY RESERVE MODULE (DERM),

ELECTRONIC BRAKE CONTROL MODULE (EBCM) AND ECM
8A-500
COMPONENT
DESCRIPTION
LOCATION
PAGE
201-PG
FIG.
Mounted to 1/P-Tie Bar, below and right of

Steering Column ............................................... .

Module (DERM) ....... . Snapped in bracket, behind RH side ofl/P Compartment 8
Module (EBCM) ....... . Under 1/P, next to LH hinge pillar,just above
(ECM) (V6 VIN S) ..... . In Engine Compartment, rearward of RH Shock Tower
19
19
Key less Entry Receiver .. . Behind RH side kick panel, in molded pocket . . . . . . . . . 42
(TCC) Solenoid ........ . Part of Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
ClOO (10 cavities) ....... . Engine to Forward Lamp Harn, behind LH wheelhouse,
C200A (17 ca vi ties)
and Steering Column . . . . . . . . . . . . . . . . . . . . . . . . .
47
C200D (48 cavities)
Steering Column . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
C210 (4 cavities) ........ . Under RH side of 1/P, behind RH kick panel . . . . . . . . . . 46
Gl03 (LTl) ............. . RH side of Engine Block,just above Starter
(2 rings, 2 wires) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Gl04 (L32) ............. . 2 studs, 2 rings on each, interchangeable. Top RH side
of Engine, 1 stud in head, 1 stud in Intake Manifold . . 29
PlOO
Compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
PllO
Compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
8109 (LTl)
ECM breakout
SllO (L32)
ECM breakout
8118 (L32 Automatic)
ECM breakout
8118 (LTl Automatic)
Engine Harn, approx 3 cm from clip near ECM and main branch
8270 ................... . Forward Lamp Harn, approx 7 cm from breakout
inboard of PlOO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 . . . .
CONN
202-11
15
202-12
14
202-13
35
202-18
35
61
202-19
202-22
29
202-17
28
202-0
72
202-2
72
67
67
202-2
202-16
202-7
42
46
36
35
14
HEATER (C41)
HOTIN RUN
r-
I
I
I
HVAC
FUSE 3
25AMP
HOT AT ALL TIMES
-,1/P
FUSE
BLOCK
I
I
I
FUSIBLE
LINK A
1 RUST
- ___,
....
1-
3 BRN
241
TO HVAC CONTROL
.35 BRN
....
- . . . . . . . . . . . . 5248
ASSEMBLY C4
PAGE SA-61~
"'11111
241
3 BRN
*BLOWER SWITCH HAS MAKE

BEFORE BREAK CONTACTS.
241
C2
r-~------~:----------- ~----:;~~
L,,
-.... ', ...

*:!v~;~R~
VENT
OFF~TCH
OEF
3 RED
202
__i _______:--=-=-l-::~ ___ J_____ J
-.~:1:---------,
3LTGRN
.35 ORN
52
66
1 LTBLU
THERMAL
LIMITERS (NOT
REPLACEABLE)
72
---,
.61!2
\ t-wv.,...~....., ........
BLOWER
RESISTOR
.35 BLK
SEE GROUND
DISTRIBUTION
PAGE SA-14-5
Iii>- -
250
-5112
3 BLK 1250
.....-J105
84
3 PPL
C200B
C200D
65
3 PPL
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5229
65
3
[ii::-g~::
~~1t
3B~Kfso
.....9.2201
COMPONENT
LOCATION
201-PG
FIG.
Blower Motor . . . . . . . . . . . . Under lower RH side ofl/P, mounted in HVAC Module

46 . . . 67
Blower Resistor . . . . . . . . . . In HV AC Module, forward and left of Temperature
Control Cable Attachment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
19
Fusible Links . . . . . . . . . . . . Above RH Shock Tower . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
(HY AC) Control Assembly Center of I/P ..................................... . 45
65
1/P Fuse Block . . . . . . . . . . . LH side ofl/P Carrier, on the side .................. . 8 .... 15
36
of wheelhouse ................................... . 19
C200A (17 cavities)
72
C200B (18 cavities)
72
a.nd Steering Column ............................ . 47
Part of I/P Harn, between LH kick panel and
C200D (48 cavities)
72
Steering Column ................................ . 47
Near top RH side ofradiator, in top ofT-Bar ......... . 19
36
Gl05
Near
base
of
RH
"A"
pillar,
bolted
to
I/P
Mounting
Stud
G201
behind kick panel (1 ring, 1 wire) ................. . 9 .... 16
PlOO
Compartment ................................... . 19 ... 36
Forward
Lamp Harn, approx 10 cm from G 106 breakout
8112
l/P Harn, approx 4 cm from center console breakout
S229
S248
SYSTEM DIAGNOSIS
For Diagnosis, refer to "HVAC Blower Controls

(C60)," page SA-63-0.
60 - 1
CONN
202-17
202-21
202-22
202-24
202-2
202-2
202-2
BA- 61 - 0 ELECTRICAL DIAGNOSIS
DEFOGGER
HOTINRUN
I
-
-,1/P
,____
I FUSE
BLOCK
... ___ _
...1
5 ORN
1240
3 BRN
241
TO DRIVER
3
POWERSEAT .....
- . . .0RN-s 252
SWITCH~....
1240
PAGE 8A-140-0
.35 BRN
5 ORN
241
1240
TOHVAC
SELECTOR SWITCH
PAGES 8A-63-0,
8A-64-0, 1
A
C4
C
C4
HVAcr------------f~------------4- ~---------,
CONTROL
ORN 1240
PNK
ASSEMBLY
PNK 241
REAR DEFOGGER
241
4A----V\~
g
SWITC~
REAR
DEFOGGER
TIMER/
GRY 292
RELAY
IGN
ON/OFF
ON
INPUT
INDICATOR
---
SOLID STATE
GROUND
DEFOG
ENABLE
BLK 650
l . - - - - - - - - - - , ~ - - - - - ___ _:~ - - - - - - - -:.~(:- - __ .J
2
SEE GROUND
DISTRIBUTION
5315.
3 PPL
A
3 PPL
-S216
PAGESSA-14-7,8
293
C410
I
IE
.... _
......- -
3 BLK
650
3BLK
750
' 200
293
REAR,-~--,..,..~~~~~~~~~~~~~~~~~~~~-.
DEFOGGER
GRID
3 BLK
5420
.S BLK
..............................
~
,--~~~~~~~~--\_~~~>
1150
3BLKI 1150 1150
~~@
_e_J310
SEE GROUND
DISTRIBUTION
PAGE SA-14-10
HVAC CONTROL ASSEMBLY

CONNECTOR DESCRIPTIONS
61 - 1
PAGE
C1
Blower Switch
5-Way Connector
BA-63-0
C2
Selector Switch
3-Way Connector
BA-63-0, BA-64-0
C3
Illumination Lamps Jumper
2-Way Connector
BA-117-1
C4
HVAC Control Assembly to 1/P Harness
4-Way Connector
BA-61-0
cs
Rear Defogger Switch
Four 1-Way Connectors
BA-61-0
CG
Rear Defogger Timer/Relay
4-Way Connector
BA-61-0
C4
12015664
4-WA Y F METRlPACK 630 SERIES
BLK
COMPONENT
201-PG
LOCATION
(HY AC) Control Assembly Center of 1/P ..................................... . 45 ...
1/P Fuse Block . . . . . . . . . . . LH side ofl/P Carrier, on the side .................. . 8
Rear Defogger Grid ...... . Mounted on rear windshield ....................... . 4
C410 (3 cavities) ........ . Hatch to 1/P Harn, center ofroof near dome lamp .... . 4
G200 ................... . Near base of LH "A" pillar, bolted to 1/P Mounting Stud
behind kick panel (2 rings, 2 wires) ............... . 9
G310
Bolted to roof, left of Dome Lamp (1 ring, 1 wire) ..... . 4
In rear center ofroof, near Dome Lamp ............. . 4
P300
8217
1/P Harn, approx 23 cm before DLC breakout
8248
1/P Harn, approx 4 cm before RR Defog breakout
8252
1/P Harn, approx 22 cm from HV AC Control
Illumination Conn
S315
1/P Harn, approx 19 cm from conn C410
Hatch Harn, approx 7 cm from P300 . . . . . . . . . . . . . . . . . 4 . . . .
8420
FIG.
CONN
65
15
7
6
202-21
202-22
16
6
7
SA -
61 - 2
DEFOGGER

Diagnosis)
System
1.
Check Rear WDO Defogger Grid for opens, refer to

SECTION 10-2.
2. Check that G200 and G310 are clean and tight.
3. Check for an open HV AC Fuse #3.

Procedures," page 8A-4-0):
SYSTEM DIAGNOSIS
procedures.
SYSTEM CHECK
ACTION
NORMAL RESULTS
[1]
Engine running .
Press Rear Defogger Switch once and release .
Switch returns to "REST" position. Rear Defogger

Indicator is "ON" and Rear Defogger Grid becomes
warm. Indicator and Rear Defogger Grid turn "OFF"
in approximately 10 minutes.
Press Rear Defogger Switch once and release.
Switch returns to "REST" position. Indicator and Rear

Defogger Grid remain "ON" for 5 minutes and then
turn "OFF."
[2]
[3]
Press Rear Defogger Switch once and release .

Indicator and Rear Defogger Grid remain "ON" until
Press Rear Defogger Switch a second time and the Rear Defogger Switch is pressed a second time.
release.
SYMPTOM TABLE
SYMPTOM
PROCEDURE
PAGE NUMBER
Rear Defogger Grid and Indicator inoperative.
Chart #1
8A-61-3
Rear Defogger Grid inoperative but Indicator operates

normally.
Chart #2
8A-61-4
Indicator inoperative but Rear Defogger Grid operates

normally.
Chart #3
8A-61-5
Rear Defogger Grid and Indicator operative, but will Replace Rear Defogger Timer/Relay.
not cycle "ON/OFF" for 10 minutes or 5 minutes.
Rear Defogger Switch does not return to "REST" Replace Rear Defogger Switch.
position.
CHART #1
REAR DEFOGGER GRID AND INDICATOR INOPERATIVE
BACKPROBE ORANGE WIRE CONNECTION AT

REAR DEFOGGER TIMER/RELAY WITH A TEST
LIGHT TO GROUND.
TEST LIGHT "ON"?
l<iNITION SWITCH TO "RUN."

BACKPROBE CONN C6 TERM "4"
TO GROUND.
TEST LIGHT "ON"?
---------------------------------------------,
CHECK FOR OPEN IN CKT 1240 OR POOR CONNECTION AT CONN C4

TERMINAL "A".
CHECK CIRCUIT BREAKER.
IF OK, CHECK FOR SHORT TO GROUND THROUGH CKT 1240 CAUSING
BREAKER TO REMAIN OPEN.
CHECK POWER FEED TO CIRCUIT BREAKER 12 (REFER TO "POWER
DISTRIBUTION," PAGE SA-10-1).
'1F NO SHORT FOUND AND POWER FEED OK, REPLACE CIRCUIT BREAKER.
:
:
:
I
:
:
1
L-----------------------------------------------J
BACKPROBE FROM ORANGE

WIRE CONNECTION (CKT 1240)
TO CONN C6 TERM "1".
TEST LIGHT "ON"?
BACKPROBE CONN C6 TERM "3" WITH A

TEST LIGHT TO GROUND WHILE PRESSING
AND HOLDING REAR DEFOGGER SWITCH.
TEST LIGHT "ON"?
REPAIR OPEN IN CKT 650 BETWEEN REAR

DEFOGGER TIMER/RELAY AND GROUND.

CONN C4 TERM "C".
IF OK, REPAIR OPEN IN CKT241 TO
REAR DEFOGGER TIMER/RELAY.
-3
SA-
61 - 4
DEFOGGER
CHART #1 (continued)
REAR DEFOGGER GRID AND INDICATOR INOPERATIVE
CHECK FOR POOR CONNECTIONS AT REAR

DEFOGGER TIMER/RELAY.
IF OK, REPLACE REAR DEFOGGER RELAY.
CHECK FOR POOR CONNECTION AT REAR

DEFOGGER SWITCH CONN CS GRY WIRE
CONNECTION.
CHECK FOR OPEN IN GRY WIRE.
IF OK, REPLACE REAR DEFOGGER SWITCH.
CHECK FOR OPEN IN CKT 241 BETWEEN
CONNECTORS C4 & CS.
CHART #2
REAR DEFOGGER GRID INOPERATIVE BUT INDICATOR OPERATES NORMALLY
DISCONNECT REAR DEFOGGER GRID.

PRESS REAR DEFOG SWITCH ONCE.
CONNECT A TEST LIGHT FROM REAR WOO DEFOGGER
GRID CONNECTOR, CKT 293 SIDE (PPL WIRE) TO GROUND.
TEST LIGHT "ON"?

FROM REAR DEFOGGER
GRID CKT 293 SIDE TO
CKT 1150 SIDE.
TEST LIGHT "ON"?
BACKPROBE REAR DEFOGGER TIMER/RELAY

(CKT 293 PPL WIRE) CONNECTION TO GROUND.
IS TEST LIGHT ON?
CHECK FOR POOR CONNECTIONS OR

OPENS IN CKT 293 BETWEEN REAR
DEFOGGER TIMER/RELAY AND REAR
DEFOGGER GRID.

AT REAR DEFOGGER GRID
CONNECTOR OR OPEN IN REAR
DEFOGGER GRID.
CHECK FOR OPEN OR

POOR CONNECTION IN
CKT 1150.
REPLACE REAR
DEFOGGER
TIMER/RELAY.
61 - 5
CHART #3
INDICATOR INOPERATIVE BUT REAR DEFOGGER GRID OPERATES NORMALLY

PRESS REAR DEFOGGER SWITCH ONCE.
BACKPROBE CONN C6 TERM "2" WITH TEST LIGHT TO GROUND.
TEST LIGHT "ON"?
BACKPROBE CONN CS
{BRN WIRE) TO CONN CS
{BLK WIRE).
TEST LIGHT "ON"?
CHECK FOR POOR

CONNECTIONS AT CONN CS
{BLK) AND CONN CS {BRN).
IF OK, REPLACE REAR
DEFOGGER SWITCH.
REPAIR OPEN IN BRN WIRE

{CKT 293) OR BLK WIRE
{CKT6SO).
CIRCUIT OPERATION
When the Ignition Switch is turned to "RUN,"
voltage is applied through the HV AC Fuse to the Rear
Defogger Switch and the Rear Defogger Timer/Relay.
When the Rear Defogger Switch is pressed, voltage is
momentarily applied to the Rear Defogger
Timer/Relay through CKT 292. When voltage is
applied to the Rear Defogger Timer/Relay, the Rear
Defogger Timer/Relay will close the internal contacts.
The internal contacts remain closed until the defog
cycle is complete or Rear Defogger Switch is pressed a
second time.
CHECK FOR POOR

CONNECTION AT CONN C6
TERM "2".
IF OK, REPLACE REAR
DEFOGGER TIMER/RELAY.
When the internal contacts of the Rear Defogger

Timer/Relay are closed, voltage is applied to the Rear
Defogger Grid and Indicator.
The Rear Defogger Timer/Relay contains an
internal timer to control the time the internal contacts
are closed. When the Ignition Switch is turned to
"RUN" and the Rear Defogger Switch pressed for the
first time, the defog cycle lasts 10 minutes and further
operation will result in 5 minutes defog cycles. The
defog cycle is reset to 10 minutes when the Ignition
Switch is turned to "OFF" and back to "RUN."
HVAC BLOWER CONTROL (C60)
r-
I
I
I
3BRN
HOTIN RUN
-
HVAC
FUSE 3
25AMP
__
HOT AT ALL TIMES
-,1/P
FUSE
BLOCK
I
I
__.I
FUSIBLE
LINK A
1 RUST
241
TO
HVAC CONTROL....
.
. ._.35
ASSEMBLYC4
_.
_BRN
_ __
PAGE SA-61-0
241
*BLOWER SWITCH HAS MAKE

BEFORE BREAK CONTACTS.
d=-.i___ _
OFF
3 RED
DEF
202
-------.J
1 ORN
1 YEL
52
60
3LTGRN
66
1LTBLU
THERMAL
~
LIMITERS (NOT
REPLACEABLE)
.61
72
---,
\ +-vwv-:.~..D)I_
...
BLOWER
RESISTOR
.35 BLK
SEE GROUND
DISTRIBUTION
PAGE 8A-14-S
IJJii.- - -
250
es112
3 BLK 1250
--9..2105
B4T
3 PPL
. ._
(200B
C200D
65
3 PPL
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5229
65
:~lt
~~g~
3B~Kf5o
.....-.2201
ELECTRICAL DIAGNOSIS 8A - 63
HVAC CONTROL ASSEMBLY

CONNECTOR DESCRIPTIONS
PAGE
Cl
Blower Switch
5-Way Connector
SA-63-0
C2
Selector Switch
3-Way Connector
SA-63-0, SA-64-0
C3
Illumination Lamps Jumper
2-Way Connector
SA-117-1
C4
HVAC Control Assembly to 1/P Harness
4-Way Connector
SA-61-0
cs
Rear Defogger Switch
Four 1-Way Connectors
SA-61-0
CG
Rear Defogger Timer/Relay
4-Way Connector
SA-61-0
C1
12020813
12064752
BLK
BLK
HVAC BLOWER SWITCH (C1)
BLOWER RESISTOR
-1
SA -
63 - 2

LOCATION
201-PG FIG.
COMPONENT
CONN
46 . . . 67
Blower Motor ........... . Under lower RH side of 1/P, mounted in HV AC Module
Blower Resistor
In HVAC ~Iodule, forward and left of Temperature
Control Cable Attachment ...................................... . 202-17
19
Fusible Links ........... . Above RH Shock Tower . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
(HVAC) Control Assembly Center of 1/P ..................................... . 45
202-21
65
I/P Fuse Block . . . . . . . . . . . LH side ofl/P Carrier, on the side .................. . 8 .... 15
202-22
of wheelhouse ................................... . 19
36
202-24
C200A (17 cavities)
72
202-2
C200B (18 cavities)
72
202-2
C200D (48 cavities)
Steering Column ................................ . 47
72
202-2
Gl05
36
Near base of RH "A" pillar, bolted to 1/P Mounting Stud
G201
behind kick panel (1 ring, 1 wire) ................. . 9 .... 16
PlOO
Compartment ................................... . 19 ... 36
8112
8229
I/P Harn, approx 4 cm from center console breakout
S248
1/P Harn, approx 4 cm before RR Defog breakout
{Perform before
Diagnosis)
beginning
System
Check HV AC Fuse 3 for open. If open, check for

short to ground through CKT 241.
2. Check Fusible Link A.
3. Check that G201 and G105 are clean and tight.
1.
Check for proper installation of afterrnarket

SYSTEM DIAGNOSIS
procedures.
63 - 3
SYSTEM CHECK
NORMAL RESULTS
ACTION
[1]

Blower Switch in "LO."
Selector Switch in "VENT."
Blower Motor runs at low speed .
[2]
Blower Switch in "M 1" .
[3]
Blower Switch in "M2" .
[4]
Blower Switch in "HI."
[5]
Selector Switch in "VENT," "Bl-LEV," "HEAT,"
Put
"DEFOG" and "DEF."
Blower Motor runs faster than in low speed.

Blower Motor runs faster than "M1" speed.
Blower Motor runs at high speed.
Blower continues to run at high speed .
[6]
Put Selector Switch in "OFF."
Blower Motor stops .
SYMPTOM TABLE
SYMPTOM
PROCEDURE
PAGE NUMBER
Blower Motor does not operate in "HI," but does

operate in "LO," "M1" or "M2".
Chart #1
8A-63-4
Blower Motor does not operate at all.
Chart#2
8A-63-5
Blower Motor will only operate in "HI."
Chart #3
8A-63-6
One Blower speed inoperative, other than "HI."
Chart #4
8A-63-6
Blower Motor operates in "HI" continuously with

Ignition Switch "OFF."
Disconnect High Blower Relay.

If Blower Motor stops, replace High Blower Relay.
If Blower Motor continues to run, repair short to
B + in CKT65.
SA-

CHART#1
BLOWER MOTOR DOES NOT OPERATE IN "HI,"
BUT DOES OPERATE IN "LO," "M1" OR "M2"
DISCONNECT HIGH BLOWER RELAY FROM CONVENIENCE CENTER.

CONNECT A TEST LIGHT BETWEEN TERM" J4" AND GROUND.
IS TEST LIGHT "ON"?
CONNECT A TEST LIGHT BETWEEN TERM" J4" AND TERM" JS".

IS TEST LIGHT "ON"?
REPAIR OPEN IN CKT 202.
IGNITION SWITCH IN "RUN."

SELECTOR SWITCH IN "VENT."
BLOWER SWITCH IN "HI."
CONNECT TEST LIGHT BETWEEN TERM" J2" AND GROUND.
IS TEST LIGHT "ON"?
REPLACE THE HIGH BLOWER RELAY.
CHECK CKT 52 FOR AN OPEN OR FOR A POOR

CONNECTION AT BLOWER SWITCH C1 TERM "B".
IF OK, REPLACE THE BLOWER SWITCH.
CHART #2
BLOWER MOTOR DOES NOT OPERATE AT All

WITH A TEST LIGHT, BACKPROBE BLOWER SWITCH BETWEEN
CONN C1 TERM "E" AND GROUND.
IS TEST LIGHT "ON"?

BLOWER SWITCH IN "LO."
BACKPROBE WITH TEST LIGHT BETWEEN CONN C1
TERM "A" AND GROUND.
IS TEST LIGHT "ON"?
BACKPROBE SELECTOR SWITCH CONN C2 TERM "C".

IS TEST LIGHT "ON"?
BACKPROBE WITH TEST LIGHT

BLOWER MOTOR CONN TERM "B"
TO TERM "A".
IS TEST LIGHT "ON"?
CHECK FOR POOR

CONNECTION AT
CONN C1 TERM ''E''
AND TERM "A".
IF OK, REPLACE THE
BLOWER SWITCH.
CHECK CKT 66 FOR AN OPEN OR FOR A

POOR CONNECTION AT SELECTOR
SWITCH C2 TERM "B" AND TERM "C".
IF OK, REPLACE THE SELECTOR SWITCH.
DISCONNECT BLOWER MOTOR

CONNECTOR.
TERM "B" AND GROUND.
IS TEST LIGHT "ON"?
CHECK FOR POOR

CONNECTION AT
BLOWER MOTOR.
IF OK, REPLACE
BLOWER MOTOR.

BLOWER MOTOR AND 5229.
63 - 5

CHART #3
CHART #4
BLOWER MOTOR WILL ONLY OPERATE IN "HI"
ONE BLOWER SPEED INOPERATIVE,

OTHER THAN "HI"

BLOWER SWITCH IN "LO."
BACKPROBE WITH TEST LIGHT BETWEEN BLOWER RESISTOR
CONN TERM "B" AND GROUND.
IS TEST LIGHT "ON"?

BLOWER SWITCH IN "LO".
BACKPROBE BETWEEN BLOWER
RESISTOR CONN TERM "C" AND
GROUND.
IS TEST LIGHT "ON"?
CHECK FOR POOR

CONNECTION AT
BLOWER SWITCH
CONN C1 TERM "A".
IF OK, REPLACE THE
BLOWER SWITCH.
DISCONNECT BLOWER RESISTOR CONN.

BLOWER SWITCH IN SUSPECT POSITION.
CONNECT TEST LIGHT FROM SUSPECT TERMINAL (LO= B,
M1 = A, M2 = D) TO GROUND (HARNESS SIDE OF
CONNECTOR).
IS TEST LIGHT "ON"?
BACKPROBE WITH A TEST

LIGHT BETWEEN CONN C1
OF THE SUSPECT TERMINAL
(LO =A, Ml =C,M2= D)AND
GROUND.
IS TEST LIGHT "ON"?
CHECK FOR POOR

CONNECTION AT
SUSPECT TERMINAL
OF BLOWER
RESISTOR CONN.
IF OK, REPLACE THE
BLOWER RESISTOR.
REPAIR OPEN IN SUSPECT CIRCUIT

(LO = 60, M1 = 63, M2 = 72).
CHECK FOR POOR

CONNECTION AT
SUSPECT
TERMINAL.
IF OK, REPLACE
BLOWER SWITCH.

BLOWER RESISTOR AND S229.
CIRCUIT OPERATION
With the Ignition Switch in "RUN," battery
voltage is applied to the Selector Switch. The Selector
Switch applies power to the Blower Switch in all
modes but "OFF." With the Blower Switch set to "LO,"
battery voltage is applied to the Blower Motor through
the Blower Resistor. The Blower Motor runs at low
speed. When the Blower Switch is in the "Ml" or "M2"
positions, the operation is similar to the operation in
"LO" except the resistance through the Blower
Resistor is decreased, causing the Blower Motor to run
faster in "Ml" and even faster in "M2". When "HI"
blower speed is selected, the Blower Switch applies
voltage to the High Blower Relay coil. The High
Blower Relay is energized, applying voltage from
CKT 202 through the relay directly to the Blower
Motor. The Blower Motor then runs at high speed.
BLANK
64 - 0
SA -
HVAC COMPRESSOR CONTROL

V6 VIN S
- - mPciweii -
- - - - - ,
DISTRIBUTION
PAGE 8A-10-3
S165:i1,....
~~:NK
..8P::A39
UNDERHOOD
ELECTRICAL
CENTER
PAGE8A-11-14
82~
3 BRN
59
- - - - - - _!
.5 DK GRN/
WHT
.5 DKGRN
mo
Ll.J
459
Cl OO
r---~
SEE PAGE 8,0.-3-0

FOR MEASURING
AND HANDLING
PROCEDURES
,I FUSE
BLOCK
HVAC
FUSE 3
25AMP
_ _ .....
241
l!t,,
.35 BRN
TOHVAC
CONTROL ASSEMBLV C4
PAGE 8A-61-0
-
~-------,HVAC
I
C2
TO 2ND SET OF CONTACTS
DIAGNOSTIC TROUBLE
CODES (DTCs) RELATED TO
HVAC WILL NOT ALLOW
THE ECM TO ENABLE THE
A/C COMPRESSOR RELAY.

DIAGNOSING HVAC
SYSTEM. [HVAC CODES
WILL NOT ILLUMINATE
SERVICE ENGINE SOON
(MIL) LIGHn.
59
I
-,1/P
PAGE 8A-63-0
I
1-----~----~~~~.--.
IMPORTANT:
459
-1
~-----------~
.35 DK WGRHNT/
5248. - - - - - -......
241
3 BRN 241
:11-------g ,~. . ~ :
l_::* ___:l:______ J
.5 DKGRN
HOTINRUN
I
I
IL..
I
I
I
I
I
AIC CRUISE
FUSE 12
20 AMP
SEE FUSE
, .8PNK 139 , .... - - - - - - - - ~ BLOCK DETAILS
I...
VENT
I
I
I
I
I
-- ..
CONTROL
IASSEMBLY
I
I
I
I
I
HEATER
HEAT/DEF
. .,
SELECTOR
SWITCH
\ DEF
(1 OF 2 SETS
OFCONTACTS)
L---- --------.J
AlC2
.35 DK GRN/WHT
762
F
C230
SH'~?
1
L32
A - CLEAR (CLR)
8 - BLACK (BLK)
C BLUE (BLU)
P110

WITH COLORED TPAs.
32WAY
32 WAY
32WAY
A (CLR)
r - A/C- COMPRESSOR
- - - CLUTCH
- - RELAY
- - - - - - - - - -AIC REQUEST
- - - - - - - - - - - ,I CONTROL
ENGINE
s 1 0 5 - -. .
: 1~~~'"G<AA:1 !
.5DKG:159
sw1TcH
STATE
SV
REF
.5 DK GRN
.5 BLK
59
h"~1~; ::!..
MODULE
A/CREFRIGERANT
PRESSURE
SENSOR
SENSOR
GROUND
INPUT
REF
...................
.5 :Kr603
GRN
ATURE
SENSOR
INPUT
-;J~;L;;;- -
808
----.------5119
A/C
CLUTCH
DIODE
A/C
STATUS
INPUT
L-6 -;-(~)- - 2 ~ (~)-37-; (;K)- 5 - - - - -1f- -
CUTOFF -
27 ps,,
+OR-3 psi)
COMPRESS~[]
LOW
PRESSURE
:::::~ ~J
ALL SOLID
CONTROL (BRIEFLY ENABLES
5114
.5 RED/
BLK
.5DKi;;;;GRN
A
AIC COMPRESSOR
CLUTCH
[E
B
.5 BLK
6035 BLK
450
450
450
.8 BLK
450,- -
1
;
---.:_ G104
-----
c
PRESS
l!t,, TO ELECTRONIC
450
1 BLK
-----------
IGNITION MODULE
PAGE 8A-20-4
SEE GROUND
DISTRIBUTION
PAGE8A-14-2
2 STUDS WITH 2 TERMINALS

ON EACH (INTERCHANGEABLE)
1
I
808
.5 DK BLU
~
SEE MULTIPORT
FUEL INJECTION
PAGE 8A-20-0
- ~~~UTCH--
THE A/C CLUTCH DIODE, SEALED IN EPOXY,

APPROX 16mm UP FROM THE A/C COMPRESSOR
CLUTCH CONNECTOR, PREVENTS THE
PRODUCTION OF ELECTRICAL SPIKES WHEN THE
AiC CLUTCH IS TURNED OFF .
Sl 15
5108
.5 BLK
416
HARNESS
.5 DK GRN
l-
.5 BLK
.5 GRY
---
380
A1C
REFRIGERANT
PRESSURE
SENSOR
732
.35 BLK
808
PROBE
(INSERTED IN
64 - 1

VS VIN P
I
-
- - - SEE POWER
DISTRIBUTION
PAGE 8A-10-3
A/C - CRUISE
FUSE 12
20AMP
, .8PNK 139 ........
,.,.
.8 PNK
5165
139
.8 PNK 139
e1
e2
UNOERHOOO
ELECTRICAL
--
SEE FUSE
BLOCK DETAILS
PAGE8A-11-14
,l
r----
.S DK GRN
59
S105---
uJ
6psi
CLOSES A!
27 ps,,
+ OR-3 psi)
- -
A/C COMPRESSOR CLUTCH RELAY

CONTROL (BRIEFLY ENABLES
I
I
-=-
I
I
I
I
______..
L-
._
BT
.S DK
603
GRN
----
I!
(RED)
.35 DK GRN!WH~
F J;.C230
""""'~
LT1
A
B
C
D
P110
- -
SV
REF
GRAY (GRY)
RED
GREEN (GRN)
BROWN (BRN)
- -
I~
hsv
A/C REFRIGERANT
PRESSURE
SENSOR
SENSOR
GROUND
INPUT
REF
~ (GRN)
.5 DK GRN
ENGINE
I CONTROL
MODULE
----------------11
22WAY
22WAY
- 22WAY
- 22WAY
~ (GRY)
A/C REQUEST
INPUT
15V
.35 BLK
(RED)
16r
i~1~~- I:CE1~
TEMPERATURE
SENSOR
INPUT
---J
~ (GRN)
808
..--- -----..
59
5119
5114
.35 RED/
BLK
.5DKi~
GRN
I
I
380
A
A/C
CLUTCH
DIODE
I
I
I
I
L---- y1~:---------.J
STATE
A/C
STATUS
VENT '
- - .. ,HEATER
.. HEAT/DEF
SELECTOR
,
OFF~WITCH
_D_EF_ _ __,
(1 OF 2 SETS
OF CONTACTS)
ALL SOLID
: 1'''~J"""AA':P:K)
-=-
.5DKG:N159
COMPRESS~~
LOW
PRESSURE
CUTOFF
SWITCH
(OPENS AT
- -
C2
~-------,HVAC
TO 2ND SET OF CONTACTS
CONTROL
PAGE 8A-63-0
ASSEMBLY
Bl-LEVEL
NORM ,.
MAX
22
r -
________,......,
.....______.....
.--

DIAGNOSING HVAC
SYSTEM. [HVAC CODES
WILL NOT ILLUMINATE
SERVICE ENGINE SOON
(MIL) LIGHn.
459
,ruse
I BLOCK
-1
DIAGNOSTIC TROUBLE
CODES (DTCs) RELATED TO
HVAC WILL NOT ALLOW
THE ECM TO ENABLE THE
A/C COMPRESSOR RELAY.
SEE PAGE 8A-3-0

FOR MEASURING
AND HANDLING
PROCEDURES
-,1/P
TOHVAC
.35 BRN
_ _ _ _ _ _ _ _. . . CONTROL ASSEMBLY C4
...
241
PAGE 8A-61-0
241
3 BRN
,:~RTANT:
~_-__3~-D-K --~R_:efc5910-o
HVAC
FUSE 3
25AMP
5248
:11-------g ,=mo
~.;::* ~I -rn- .
.35 DK GRN/
WHT
1
I
I
I CENTER
--------+
I
I
HOTINRUN
r-
A/C COMPRESSOR
CLUTCH
-[ ] .5DKGRN
'(
603; :LK
5
.5 BLK 1450
.5 BLK
5115
450
.8 BLK
5108
BLK
1
?-
.35 GRY
.35 BLK
416
HARNESS
~---~~~~~~~~~~--..
~~~UTCH-
THE A/C CLUTCH DIODE, SEALED IN EPOXY,

APPROX 16mm UP FROM THE A/C COMPRESSOR
CLUTCH CONNECTOR. PREVENTS THE
PRODUCTION OF ELECTRICAL SPIKES WHEN THE
A/C CLUTCH IS TURNED OFF .
732
.35 BLK
SEE MULTIPORT
FUEL INJECTION
PAGE 8A-21-0
tI
c
PRESS
h, TO IGNITION
1111" COIL DRIVER
,..450 _..PAGE8A-214
0
SEE GROUND
DISTRIBUTION
PAGE 8A-14-0
808
.35 DK BLU
SVREF
A/C
REFRIGERANT
PRESSURE
SENSOR
I
I
I
A/C EVAPORATOR
TEMPERATURE
SENSOR
I
...............................
.35 GRY
_.___102
5117
416
808
SA -

COMPONENT
LOCATION
201-PG
A/C Clutch Diode
(V6 VIN S) . . . . . . . . . . . . . Sealed in Harn, 10 cm from A/C Compressor
Clutch Conn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
A/C Clutch Diode
(VS VIN P) . . . . . . . . . . . . Sealed in Harn, 6 cm from Generator breakout . . . . . . . 14
A/C Compressor Clutch . . . RH side of Engine, below Generator . . . . . . . . . . . . . . . . . 14, 28
A/C Compressor Low
Pressure Cut Off Switch
Above RH Shock Tower, rear of A/C Refrigerant
Pressure Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
A/C Evaporator
Temperature Sensor
Mounted in Evaporator Core . . . . . . . . . . . . . . . . . . . . . . . . 46
Sensor . . . . . . . . . . . . . . . . . Above RH Shock Tower, forward of A/C Compressor
Low Pressure Cut Off Switch . . . . . . . . . . . . . . . . . . . . . . 18
(ECM) (V6 VIN S) . . . . . . In Engine Compartment, rearward of RH Shock Tower 19
(ECM) (VS VIN P) . , . . . In Engine Compartment, rearward of RH Shock Tower 19
(HVAC) Control Assembly Center ofl/P ..................................... . 45
1/P Fuse Block . . . . . . . . . . . LH side ofl/P Carrier, on the side .................. . 8 ....
of wheelhouse ................................... . 19
attached to ECM bracket ......................... . 15
C230 (10 cavities) . . . . . . . . Under RH side ofl/P, behind kick panel ............. . 46
Gl02 (LTl) . . . . . . . . . . . . . . LH front of Engine Block,just below head
(4 rings, 3 wires and braided strap) ................ . 23
Gl04 (L32) . . . . . . . . . . . . . . 2 studs, 2 rings on each, interchangeable. Top RH side
of Engine, 1 stud in head, 1 stud in Intake Manifold .. 29
Pl 10 . . . . . . . . . . . . . . . . . . . . Right side in dash panel, Engine to Passenger
Compartment ................................... . 19
8105 (L32) . . . . . . . . . . . . . . Engine Harn, approx 20 cm from main branch and
ECM breakout
8105 (LTl)
ECM breakout
S108 (L32) . . . . . . . . . . . . . . Engine Harn, approx 4 cm from Cl 10 breakout ....... 12
8108 (LTl) .............. Engine Harn, approx 4 cm from Injectors 2
and 4 breakout ................................... 26
8114 (L32) .............. Engine Harn, approx 10 cm from A/C Compressor
Clutch Conn ..................................... 28
S114 (LTl) . . . . . . . . . . . . . . Engine Harn, approx 6 cm from Generator breakout .. 14
S115 (L32) .............. Engine Harn, approx 10 cm from A/C Compressor
Clutch Conn ..................................... 28
S115 (LTl) . . . . . . . . . . . . . . Engine Harn, approx 6 cm from Generator breakout .. 14
8117 (L32) .............. Engine Harn, approx 13 cm from main branch and
ECM breakout
S117 (LTl) .............. Engine Harn, approx 2 cm from clip near ECM
and main branch
FIG.
CONN
45
26
26, 45
34
67
34
35
202-18
35
202-19
65
15
202-21
202-22
36
202-24
28
67
202-0
202-7
40
46
35
22
43
45
26
45
26
COMPONENT
201-PG FIG.
LOCATION
S 119 (L32) . . . . . . . . . . . . . . Engine Harn, approx 4 cm from Transmission breakout 11 . . . 20
Sl 19 (LTl) . . . . . . . . . . . . . . Engine Harn, approx 18 cm from main branch and
ECM breakout
8165
Center breakout
8248
SYSTEM DIAGNOSIS
With Diagnostic Trouble Codes (DTCs) present,
refer to SECTION 6E3.
Without Diagnostic Trouble Codes (DTCs) present,
refer to SECTION lBl.
64 - 3
CONN
8A - 76 - 0 ELECTRICAL O.IAGNOSIS
AUDIBLE WARNINGS: TONE
HOT AT ALL TIMES
r---I
SEE POWER
DISTRIBUTION
PAGE SA-10-1
COURTESY
FUSES
15AMP
,-
1/PFUSE
BLOCK
HEADLIGHT
SWITCH
I
I
1 ORN
\ - -.
OFF
I
I
I
I
I
I
I
I
____ ....
___ J
L----
r"" -
I
I HEAD
I
PA:=IKI.._
~;: ., . +-,=1:"'
40
SEE POWER
DISTRIBUTION
PAGE SA-103
I
I
5210 - - 40- - - - -. .
SEE FUSE
BLOCK DETAILS
PAGESA-11-7
L---------
CONVENIENCE
CENTER
SEE FUSE
...
:'.~~','.'!"
,11f>FUSE
.8 PNK
LIGHTS ON
INPUT
POWER
INPUT
I
I
I
I
I
I BLOCK
I
I
I
.I
39
5206
-..:1
39---
--------~ ----------: ------,
r--;-
'
GAGES
FUSE9
IGN
10 AMP (NOT USED)
.SB:NY9
SEE EXTERIOR
.SORN
AUDIO
ALARM
MODULE
IGNITION SWITCH
INPUT
SV
FASTEN
BELTS
OUTPUT
GROUND
I
I
I
SEAT BELT
INPUT
--------r----'
.35 LTGRNl 80
.S BLK
.35 YEL
650
237
.35 BLK/WHT
238
C216
A
SEATBELT _ _ _,.
SWITCH
(OPEN WITH LH
FRONT SEATBELT
BUCKLED)
r-
I
1
I
-i- ---
IGNITION _....,_,.
KEV
WARNING
SWITCH
(CLOSED WITH
KEY IN IGNITION)
A12
~FASTEN
BELTS
INDICATOR
,INSTRUMENT
CLUSTER
I- I
~
I
,!t
B
E IC216
.35 BLK
650
~--r ____
J
111m1-----------
3 BLK
B3f7
1 BLK
650
650
..---------,
l
5216
3 BLK
650
SEE GROUND
DISTRIBUTION
PAGES 8A-14-7, 8, 9
3 BLK
750
SEE PAGE 8A30
FOR MEASURING
ANO HANDLING
PROCEDURES
I
I
I
.]STAN
ES
5217
.5 TAN
II
~J
159
C2000
C200C
159
rz ,
A
DOOR JAMB
SWITCH, LH
(CLOSED WITH
DOOR OPEN)
I
I -
I
I
L1i
BUZZER
Ll][I]IJJG]
mmmm
0
GJG]
IT]
HORN
m0
HZ/F
12015999
BLK
CONVENIENCE CENTER

CAVITY
WIRE COLOR
CKT
DESCRIPTION
PAGE
LTGRN
80
KEY-IN-IGNITION SIGNAL
SA-76-0
ORN
40
POWER FEED FROM COURTESY FUSE #8
SA-11-7
BRN
PARK LIGHT ON FEED
SA-76-0
BLK/WHT
238
SEATBELT SWITCH SIGNAL
SA-76-0
BLK
650
GROUND
SA-14-8
YEL
237
SEATBELT INDICATOR LAMP CONTROL
SA-76-0
PNK
39
SA-11-4
BRN
27
HAZARD FLASHER OUTPUT
SA-110-4
ORN
140
POWER FEED FROM STOP/HAZARD FUSE #6
SA-11-6
ORN
540
POWER FEED.FROM CIGAR/HORN FUSE #7
SA-11-7
BLK
28
HORN RELAY CONTROL
SA-40-0
DKGRN
29
HORN FEED
8A-40-0

201-PG FIG.
LOCATION
Left of Steering Column, mounted to bottom of
I/P Carrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 . . . . 15
DoorJambSwitch, LH ... . Near base of LH "A" pillar . . . . . . . . . . . . . . . . . . . . . . . . . . 32 . . . 49
Headlight Switch ....... . LH side ofl/P . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 . . . 57
15
I/P Fuse Block .......... . LH side ofl/P Carrier, on the side . . . . . . . . . . . . . . . . . . . 8
Ignition Key Warning
Switch ................ . Part of Steering Column .. .. .. .. .. .. .. .. .. .. .. .. .. . 3
5
Seat Belt Switch ........ . Part of Driver's Seat Buckle Assembly . . . . . . . . . . . . . . . 21
38
C200C (13 cavities)
Steering Column . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
72
C200D (48 cavities)
Steering Column . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
72
51
0200 ................... . Near base of LH "A" pillar, bolted to I/P Mounting Stud
8206
breakout
8210
8216
8217
8226
Under RH side of I/P, behind kick panel
COMPONENT
Convenience Center
CONN
202-17
202-14
202-22
202-22
202-2
202-2
202-5

Diagnosis)
System
Check that G200 is clean and tight.

If Ignition Key warning is inoperative check the
LH Door Jamb Switch or for open in CKT 159.

If all warning chimes are inoperative, check
Courtesy Fuse 8 for open.
SYSTEM DIAGNOSIS
proced ure(s).
SYSTEM CHECK
ACTION
NORMAL RESULTS
[1]
LIGHTS "ON" WARNING

Remove Ignition Key from Ignition Switch .
Headlamp Switch to "PARK" or "HEAD."
Headlamp Switch to "OFF."
Lights "ON" Warning sounds as long as the Headlight

Switch isin "HEAD" orin "PARK."
IGNITION KEY WARNING

Ignition Key in Ignition Switch .
Open LH door.
Close LH door.
Ignition Key Warning Tone sounds as long as the LH

door is open.
[2]
ELECTRICAL DIAGNOSIS 8A-
76- 3
SYSTEM CHECK
NORMAL RESULTS
ACTION
[3]

Driver's seat belt latched .
Open LH door .
Close LH door .
No tone sounds.
SEAT BELT WARNING

Close LH door.
Driver's seat belt unlatched .
Seat Belt Warning Tone sounds for 5 to 8 seconds.

Fasten Belts Indicator stays "ON."
SEAT BELT WARNING

Close LH door.
Latch driver's seat belt .
Ignition Switch to "OFF" and back to "RUN."
Seat Belt Warning Tone does not sound and does not
illuminate .
(4]
[SJ
SYMPTOM TABLE
PROCEDURE
PAGE NUMBER
All warnings inoperative.
Chart #1
BA-76-4
Ignition Key Warning inoperative.
Chart #2
BA-76-4
Seat Belt Warning inoperative.
Chart #3
BA-76-5
Fasten Belts Indicator "ON" continuously.
Chart #4
BA-76-5
Fasten Belts Indicator inoperative.
Chart #5
BA-76-5
SYMPTOM
Lights "ON" Warning inoperative.
Check for poor connection at Convenience Center

terminal "D" or open in CKT 9 to the Audio Alarm
Module. If OK, replace Audio Alarm Module.
Lights "ON" Warning sounds continuously with Check for poor connection at Convenience Center
terminal "H" or open in CKT 39 to the Audio Alarm
Module. If OK, replace Audio Alarm Module.
Ignition Key Warning sounds when LH front door is Check for short to ground in CKT 80. If OK, replace
Ignition Key Warning Switch.
open and key is not in Ignition Switch.
Ignition Key Warning continues to sound when LH Check for poor connection at Convenience Center
front door is closed and Ignition Switch is in "RUN."
terminal "H" or open in CKT 39 to the Audio Alarm
Module.
Seat Belt Warning sounds continuously.
Check for short to ground in CKT 238 or for Seat Belt

Switch stuck closed.
If OK, replace Audio Alarm Module.

CHART #1
ALL WARNINGS INOPERATIVE
DISCONNECT AUDIO ALARM MODULE.

CONNECT A TEST LIGHT TO CONVENIENCE
CENTER FROM TERM "C" TO TERM "F".
TEST LIGHT "ON"?
CONNECT A TEST LIGHT TO CONVENIENCE

CENTER FROM TERM "C" TO GROUND.
TEST LIGHT "ON"?

CONVENIENCE CENTER TERMINALS "C" AND "F"
OR OPEN IN CKT 650 FROM CONVENIENCE
CENTER TO 6200.

TO AUDIO ALARM MODULE.
CHART #2
IGNITION KEY WARNING INOPERATIVE
REMOVE KEY FROM IGNITION SWITCH .

USING A DVM, BACKPROBE C216 FROM TERM "F"
TO GROUND.
KEY IN IGNITION SWITCH .

IGNITION SWITCH IN "OFF."
CLOSE LH FRONT DOOR .
USING A DVM, BACKPROBE C216
FROM TERM "E" TO GROUND.
I
OVOLT

CONVENIENCE CENTER TERM "8" OR
OPEN IN CKT 80 FROM CONVENIENCE
CENTER TO C216.
IF OK, REPLACE AUDIO ALARM MODULE.
CHECK FOR POOR CONNECTIONS AT C216.

C216 AND LH DOOR JAMB SWITCH.
TERM "ES."
IF OK, REPLACE LH DOOR JAMB SWITCH.
O VOLT

AT C216 TERMINALS "E" AND "F".
IF OK, REPLACE IGNITION KEY
WARNING SWITCH.
CHART #3
SEATBELT WARNING INOPERATIVE
SEAT BELT NOT BUCKLED.

DISCONNECT AUDIO ALARM MODULE.
WITH TEST LIGHT, BACKPROBE CONVENIENCE CENTER FROM TERM "C" TO TERM "E".
IS TEST LIGHT "ON"?
BACKPROBE FROM CONVENIENCE CENTER

TERM "G" TO SEATBELT SWITCH CONN TERM "A".
IS TEST LIGHT "ON"?
BACKPROBE FROM CONVENIENCE CENTER

TERM "G" TO SEAT BELT SWITCH CONN TERM "B".
IS TEST LIGHT "ON"?
CHECK FOR POOR CONNECTION AT TERM ''E''.

IF OK, REPLACE AUDIO ALARM MODULE.
CHECK SEAT BELT SWITCH CONNECTION.

IF OK, REPLACE SEATBELT SWITCH.
CHART #4
CHART #5
FASTEN BELTS INDICATOR "ON" CONTINUOUSLY
FASTEN BELTS INDICATOR INOPERATIVE
REMOVE AUDIO ALARM MODULE.

FASTEN BELTS INDICATOR "ON"?
CHECK FOR SHORT TO VOLTAGE

TOCKT237.
IF OK, REPLACE INSTRUMENT
CLUSTER PRINTED CIRCUIT.
REMOVE AUDIO ALARM MODULE.

CONNECT A FUSED JUMPER FROM B + TO
THE CONVENIENCE CENTER TERM "G".
FASTEN BELTS INDICATOR "ON"?
FUSED JUMPER STILL

CONNECTED.
TO INSTRUMENT CLUSTER
CONN FROM TERM "A12'"
TO GROUND.
TEST LIGHT "ON"?
ALARM MODULE.

BETWEEN CONVENIENCE
CENTER AND
INSTRUMENT CLUSTER.
CHECK FOR POOR

CONNECTION AT
AUDIO ALARM
MODULE.
IF OK, REPLACE AUDIO
ALARM MODULE.
CHECK FOR POOR

CONNECTION AT
INSTRUMENT CLUSTER
CONNECTOR.
CHECK FASTEN BEL TS
INDICATOR LAMP.
If OK, REPLACE
INSTRUMENT CLUSTER
PRINTED CIRCUIT.
76 - 5
SA -
76 - 6

CIRCUIT OPERATION
The Audio Alarm Module generates a single tone
for: Lights "ON" Warning, Ignition Key Warning and
Fasten Belts Warning.
LIGHTS "ON" WARNING
When the Headlamp Switch is m "PARK" or

"HEAD," voltage is applied to the Lights "ON" Input
of the Audio Alarm Module. When the Ignition Switch
is turned out of the "RUN" position, voltage is removed
from the Ignition Switch Input of the Audio Alarm
Module. When voltage is present at the Lights "ON"
Input and no voltage applied to the Ignition Switch
Input, the Audio Alarm Module will sound the Lights
"ON" Warning.
The Audio Alarm Module applies voltage at all

times to the Ignition Key Warning Switch. When the
Ignition Key is placed into the Ignition Switch, the
Ignition Key Warning Switch is closed. When the LH
front door is open, the LH Front Door ,Jamb Switch
closes the circuit to ground. The Audio Alarm Module
senses a voltage drop at the Ignition Key Input and
will sound the Ignition Key Warning.
FASTEN BELTS WARNING
The Audio Alarm Module applies voltage to the

Seat Belt Switch at all times. The Audio Alarm
Module senses a voltage drop at the Seat Belt Input
through the closed contacts of the Seat Belt Switch
when the driver's seat belt is unlatched. When the
driver's seat belt is latched, the Seat Belt Switch is
opened and the Audio Alarm Module senses voltage at
the Seat Belt Input. When the Ignition Switch is
turned to "RUN," voltage is applied to the Audio
Alarm Module Ignition Switch Input. When voltage is
present at the Ignition Switch Input and zero volt at
the Seat Belt Input; the Audio Alarm Module will
sound the Fasten Belts Warning for 5 to 8 seconds. If
voltage is present at the Ignition Switch Input and the
Seat Belt Input, the Audio Alarm Module will disable
the Fasten Belts Warning.
When the Ignition Switch is turned to "RUN," the

Audio Alarm Module senses voltage at the Ignition
Switch Input. When voltage is applied to the Ignition
Switch Input, the Audio Alarm Module applies voltage
to the Fasten Belts Indicator for 5 to 8 seconds
independent of the Seat Belt Switch and Fasten Belts
Warning.
BLANK
76 - 7
SA- 81 - 0 ELECTRICAL DIAGNOSIS
INSTRUMENT CLUSTER: WITH GAGES
rs'; POWffi
-----,~
I DISTRIBUTION
PAGE 8A-10-3
FUSE
I BLOCK
GAGES
FUSE 9
I
I
IGN
l OAMP (NOTUSED)
L-------.8 PNK
I -I
_J
39
-------------J H >S:J
.35 PNK
r- - - - - - - - - - - - - -
INSTRUMENT
C~USTERI
5206
~ I
I
I
I
I
I
--.llrri......
...............
SEE FUSE
BLOCK DETAILS
PAGE 8A-114
----------.
~~ TO INDICATORS
~O=D=O=M=E=T=ER==-+-~~~~~~~~~~~....
,-
VOLTMETER
SPEEDOMETER
TACHOMETER
..............
I
I
'-.........
-.~"~l,~ ----------
"""'~::r17 ------ -.:~:r,,--_....illllll
5242 .35 DK GRN/WHTJ:17

G
(V6 VIN S) .5 DK
GRNIWHT
(V8 VIN P) .35 DK
GRN/WHT
f
I
~I
I....
SEE VEHICLE
SPEED SENSOR
PAGE 8A-33-0
C220
5215
D
C230
.5 WHT
.8 WHT
WITH V6 VIN S
B (BLK) V6 VIN S
VS VIN P
D (BRN)
-:l_
____
-=-
451
.5 BLKIWHT
451
S109 (V8 VIN P)

5110 (V6 VIN S)
817
4000
PULSES
PERMILE
.5 BLK/WHT
f
I
I
_.I
WITH
vs
VIN p
TO ELECTRONIC
IGNITION
MODULE
PAGE SA-20-4
121 (V6 VIN S)

121 (V8 VIN P)
817
-1----.
28
8
ENGINErCONTROL
MODULE
--"'1111111
I
I
.,
1
_..ollllllll
SEE GROUND
DISTRIBUTION
PAGES 8A-14-1 (V8 VIN P)
SA-14-2, 3 (V6 VIN S)
T
.8 BLKIWHT
451
I
I
I
I
___ ...
TO TACHOMETER
FILTER
PAGE SA-21-4
G103 (VS VIN P)
G104 (V6 VIN S)_.__
.35 TAN
31
rn
OIL
PRESSURE
SENSOR
(APPROX 90 OHM, AT
HIGH PRESSURE
APPROX 10 OHMS AT
LOW PRESSURE)
-,11P
FUSE
ECM BAT BLOCK
,~FUSE4
rsEePo-;;E;;- -
I DISTRIBUTION
I PAGE SA-10-1
__ J
L---.SORN
340
IMPORTANT:
--.llli...,.
THE COOLANT TEMPERATURE

GAGE DOES NOT HAVE
EQUAL DIVISIONS FOR
TEMPERATURE. THE CENTER
OF THE GAGE IS EQUAL TO
BElWEEN 210F TO 220F
(FOR Z49: 1
TO 1
ooc
S209
osq.
SEE FUSE
BLOCK DETAILS
PAGESA-11-6
_,.......
.8 ORN
340
~-----------------------------------------,
A13
10AMP
rn
-1
COOLANT
TEMPEiiATu RE
GAGE
COOLANT
TEMP
MONITOR
PRESSURE
MONITOR
SOLID STATE
IGNITION
BATTERV
SENSES
GENERATOR
Oil TURN ON
470
INDICATOR
CONTROL
ABS
OUTPUTS
FAIL~
LOW
Oil
INPUT
GND
"ABS
INOP"
@@
INOICATOR
SYMBOL
FORZ49:
"LOW
OIL"
INDICATOR
"CHECK
GAUGES"
INDICATOR
@ II
I
I
I
I
fQ."'\I
\v:::;JJ
J
.35 LTGRN
867
A
.35LT GRN
. 35 DK GRN
135
.8 RED
[E
TEMPEiiATU RE
GAGE SENSOR
1365 OHMS AT 100F
55 OHMS A T260F
,-----i-.
I TURN ON INPUT
(POWER UP FOR
I REGULA TOR)
CLOSES WITH
I11.2V
OR
T-
_L
I LOWER
OR
WITH 16.SV OR
I HIGHER OR
WITH STOPPED
I GENERATOR
GENERATOR
PAGESA-30-1 I. -
I
I
.35 BRN
B
II
I
-
867
225
ENGINE
COOLANT
C2000
C200A
1174
82
LEVEL
~OIL
SENSOR
(NORM ALL y
C2
r- - -, ELECTRONIC
ABS
I BRAKE
I FAIL
CONTROL
I
I MODULE
L. _
CLOSED, OPEN
WITH LOW OIL)
_. PAGE SA-44-0
Af
.35 BLK
WHT
451
..I
5109 (VS VINP)- 5110 (V6 VINS)
.8 BLK1WHT
451
..,
....
SEE GROUND
DISTRIBUTION
SA-14-2 (V6 VIN S)
__ y
4V~
SEE PAGE SA-3-0
FOR MEASURING
AND HANDLING
PROCEDURES
SEE INTERIOR LIGHTS

DIMMING PAGESA-117-1
--------------,~
FUSE
IGN
(NOT USED)
L----
- _ .J
.SORN
SEE FUSE
BLOCK DETAILS
PAGE SA-11-6
........__
........-- -
I
I
I
I
I
39
.5 GRY
SEE INTERIOR
.35 PNK
5209
5224
- - - - - - - - es206
39
340
A13
.35 GRY
LIGHTS DIMMING
PAGESA-117-1
SEE FUSE
BLOCK DETAILS
PAGE SA-11-4
-1------
--
.8 PNK
340
.8 ORN
INSTRUMENTr CLUSTER
I BLOCK
I
I
1/P
DIMMER
FUSE 13
SAMP
B2
AS
-------------,.
ILLUMINATION
LAMPS
"SECURITY"
INDICATOR
\J;,J
l___ l_ _______ _
Bl
Al
-------------'
TO 5235
.35 GRY
"'~ s:vt
PAGEBA-20-S (V6 VIN S)

SA-21-5 (VS VIN P)
728
lO _______
A2
1 BLK
650
_....olllllll SEE GROUND

5216 - - . . . . . . DISTRIBUTION
PAGE SA-14-8
1~
AS
PASS-KeyII
DECODER
MODULE
PAGE SA-133-1
r- - -,
I
I
FUEL
TANK
UNIT
90Q
.... ....
on
APPROXIMATE
FUEL LEVEL
88!!
FULL
60 il
3/4
43 il
1/2
26 il
114
1.0!l
EMPTY
650
3 BLK
FUEL
PUMP
FUEL GAGE SENDER

RESISTANCE
3 BLK
750
. I=~
C405B
1 BLK
1050
WITH AO OR AQ9
3 BLK
1450
~05
SEE GROUND
DISTRIBUTION
PAGE 8A-14-10
~
j.i~
SEE PAGE 8A-3-0
FOR MEASURING
AND HANDLING
PROCEDURES
TO AUDIO
ALARM MODULE
PAGE SA-76-0
TO HEADLIGHT
DIMMER SWITCH
PAGE 8A-100-0 (WITHOUTT61)
8A-1021 (WITH T61)
UNDERHOOD
ELECTRICAL
CENTER
-------,
r-----
I
I
SEE FUSE
BLOCK DETAILS
PAGE SA-11-14
HIGH
BLOWER
RELAY
5165
.35 YEL
11
.5 LT BLU
.5 LT BLU1WHT
237
.8 PNK
14
1414 (T61)
r- - -,
-,
139
.8 PNK
L _____
_
1 LTGRN
-3
L...-..1
139
JS
GS
C3
.8 LT GRN
r __ - -
C200B
C200D
'l
\l
15
1415 (T61)
11
,---""""l-..;.;..;..,,.~..,
87A
L-----
_A!!.,r -
.5 DK BLU
.5 DK BLUI
WHT
LOW
COOLANT
RELAY
(LATCHING)
(VS VIN P)
B,!!f -
.35LTGRN
~Sr ---
-A12f "FASTEN
SEATBELT"
~INDICATOR
LEFT
TURN~
RIGHT
~TURN
I
I
!.~~~VICE
~ENGIN.~
\VSOON
~"AIRBAG" ~ " L O W
\_VINDICATOR \_VTRAC"
"BRAKE"~
INDICATOR~
INDICATOR
OR Z49:
c23 0
B
(V6 VIN S) .5
.8 BRN
358
.35 DK BLU
1537
A9I~~~~~
r- - -W
rz-,=t' ,.---,
.35 DK BLU
81
L... -
.J
ENGINE
CONTROL
MODULE
PAGES SA-20-3,
SA-21-3
J.
I
I
I
I
I
L - .=. J
DIAGNOSTIC
ENERGY
RESERVE
MODULE (DERM)
PAGE SA-47-0
BS
537
5228
CKTS 68A AND 688
PRESENT BUT
NOT USED
WITH V6 VIN S
.5 YELi
ELECTRONIC
BRAKE
CONTROL
MODULE (EBCM)
PAGE 8A-44-0
.35 TAN/WHT
33
f--- c7_ - - - - - I
I
68A
BLK
C2
L--.J
1478
SEE BRAKE
WARNING
PAGE 8A-41-0
I ABS
I
ACTIVE
I
I OUTPUT
.35 LT
GRN
(VS VINPONLY)
+r - -
BRN/WHT
(VS VIN P)
P110
B (BLK) V6 VIN S
A (GRY) VS VIN P
~ I
\J;;.) I
SYMBOL
FOR Z49:
419
.35 BRN/WHT
"LOWCOOLANT"
INDICATOR
250
~ro ,..,..~ ~+ .!,. :

\ l
l
l
l
l :
y~:::T~l--- I '<0><0>1
l:
~ ---., -----.:A2::r3-----.~E2: :
. ::.:r,:---;;
HIGH
~BEAM
.35 BLK
1478
ACCY
'
LOCK ....... - .. ....
START ACCY
BULB TEST
-1
'
LOCK ....
.5 LTGRN
~ gJB ~~1;NT
_g _ - -
I
I
START
- ,..
~ --~F~ :N-'----------------------IGNITION
SWITCH
--J
SEE GROUND
............
DISTRIBUTION
PAGE SA-14-5
1478
SENSOR
(CLOSED
WITH LOW
J~i~~~:Y)
.5 BLK
250
-----
3 BLK
250
----.J10S
SA - 81
-4
12065803
34-WAV F MICRO-PACK 100SERIES
BLK
INSTRUMENT CLUSTER
CAVITY
WIRE COLOR
CKT
DESCRIPTION
A1
PNK
39
POWER FEED FROM GAGES FUSE 9
8A-11-4
A2
PPL
30
FUEL GAGE SIGNAL
8A-81-2
A3
GRY
728
SECURITY INDICATOR LAMP CONTROL
8A-81-2
A4
BRN/WHT
419
SERVICE ENGINE SOON INDICATOR LAMP CONTROL
8A-81-3
AS
PNK
39
POWER FEED FROM GAGES FUSE 9
8A-11-4
A6
YEL/BLK
68
LOW COOLANT LEVEL INDICATOR CONTROL
8A-81-3
A7
BRN
358
AIR BAG INDICATOR CONTROL
BA-81-3
A10
TAN/WHT
33
BRAKE WARNING INDICATOR LAMP CONTROL
BA-81-3
A11
LTGRN
11
HIGH BEAM HEADLIGHTS ON
8A-81-3
A12
YEL
237
SEATBELT INDICATOR LAMP CONTROL
BA-81-3
A13
ORN
340
POWER FE ED FROM ECM BAT FUSE 4
BA-11-6
A14
RED
225
GENERATOR OUTPUT INDICATOR CONTROL
BA-81-1
A15
BRN
1174
OIL LEVEL SENSOR SIGNAL
BA-81-1
A16
DKBLU
1537
ABS ACTIVE OUTPUT
BA-81-3
A17
DKGRN
135
COOLANT TEMPERATURE SENSOR SIGNAL
BA-81-1
82
GRY
1/P ILLUMINATION LAMPS FEED
SA-81-2
83
BLK
650
GROUND
8A-14-8
BS
BS
DKBLU
DK BLU/WHT
15
1415
(DOMESTIC) RIGHT TURN SIGNAL SWITCH OUTPUT

(WITH T61) RIGHT TURN SIGNAL SWITCH OUTPUT
8A-81-3
8A-81-3
812
YEL
817
VEHICLE SPEED SIGNAL -4000 PULSES PER MILE
SA-81-0
813
ORN
121
TACHOMETER SIGNAL
SA-81-0
814
814
LTBLU
LTBLU/WHT
14
1414
(DOMESTIC) LEFT TURN SIGNAL SWITCH OUTPUT

(WITH T61) LEFT TURN SIGNAL SWITCH OUTPUT
SA-81-3
8A-81-3
815
BLK/WHT
451
GROUND
8A-14-1,2,3
816
TAN
31
OIL PRESSURE INDICATOR CONTROL
8A-81-0
817
LTGRN
867
ABS FAIL SIGNAL
8A-81-1
PAGE
I FOR CONNECTOR CHART, SEE SECTION SA-202. I

C200D
El DDDDDDDDDDDD D El
I 11 11 1LJ, LJI II 1-,-1
"I II II In
@ nl II II '"
3
86
1 11
11
~1
11..=:=:::i
II
II
81
ADDDDDDDDDDDD DODD DA
11
12077822
M-CONNECTOR
F-TERMINAL
48-WAY M METRI-PACK MIXED SERIES
BLK
C200A

1/P HARNESS
c1 Al DD DD DODD DODD DD DD D All

7
c::::7
12047842
BLK

1/PHARNESS
C2008
81
(1
01
I
I
I
II
II
II
II
II
11
Dc:::1
II__II
II__11
II__H
86
I
!06
C6
12084183
BLK

1/P HARNESS
C200C
12047840
13-WAV F METRI-PACK 280 SERIES
GRY
SA - 81
-6
FOR CONNECTOR CHART, SEE SECTION SA-202.
(220
ENGINE HARNESS
TO 1/P HARNESS
ltrl ~ [,5] 't? f&

[~llfl dJ 1:2:J CQ
12064769

WHT
FOR CONNECTOR CHART, SEE SECTION SA-202.
(230
'tjl ~ 'i5J 't? Ci:jl
ENGINE HARNESS TO
1/P HARNESS
&icadJ &&
12064871
BLU
81 - 7
I FOR CONNECTOR CHART, SEE SECTION 8A-202.

C4058
1/P HARNESS TO FUEL
TANK UNIT PIGTAIL/
REAR WHEEL SPEED
SENSOR JUMPER HARNESS
12092789
10-WAY M METRI-PACK 150, 280 SERIES
BLK
C405A
C405C
FUEL TANK UNIT
PIGTAIL TO
1/P HARNESS
REAR WHEEL
SPEED SENSOR
JUMPER HARNESS
TO 1/P HARNESS
12110481
12092800
5-WAY F METRI-PACK 150, 280 SERIES

RED
BLK
8A -
81 - 8
(1
06294641
4-WA Y F MIXED SERIES
BLK
IGNITION SWITCH
(2
12010966
5-WAY F 56 SERIES
BLU
IGNITION SWITCH
~o
FORZ49:
FORZ49:
AIR
BAG
BJ,~E
FORZ49:
RPM
XIOOO
la
G~J~~S Lg;f
d':~"C,,
\.
100
..
~
o
ea
220~
210 2so'
.. .
~ <T')'jl
8
18
,E
F.
INSTRUMENT CLUSTER - FRONT VIEW
0 0
0
12
7
INSTRUMENT CLUSTER REAR VIEW
LAMP LOCATION LEGEND
1
"AIR BAG" Indicator Lamp
"LOW COOLANT" Indicator Lamp
"ABS INOP" Indicator Lamp
10
"LOW OIL" Indicator Lamp
"BRAKE" Indicator Lamp
11
"LOW TRAC" Indicator Lamp
"CHECK GAUGES" Indicator Lamp
12
Right Turn Indicator Lamp
"FASTEN SEAT BELT" Indicator Lamp
13
"SECURITY" Indicator Lamp
"HIGH BEAM" Indicator Lamp
14
"SERVICE ENGINE SOON" Indicator Lamp
Illumination Lamp
15
NOT USED
Left Turn Indicator Lamp
16
NOT USED
-9
SA- 81
- 10 ELECTRICAL DIAGNOSIS

COMPONENT
LOCATION
201-PG
FIG.

Module (DERM) . . . . . . . . Snapped in bracket, behind RH side ofI/P Compartment 8 . . . . 15 . .
Module (EBCM) . . . . . . . . Under I/P, next to LH hinge pillar, just above
Pass Thru Grommet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 . . . . 14
44
(V6 VIN S) . . . . . . . . . . . . . Left front of Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
19
35 . .
19
(ECM) (VS VIN P) . . . . . In Engine Compartment, rearward of RH Shock Tower
35 . .
Engine Coolant Level Sensor
(VS VIN P) . . . . . . . . . . . . Mounted on upper right side ofradiator . . . . . . . . . . . . . . 19
35
Gage Sensor (V6 VIN S)
Left front of Engine, mounted in Head . . . . . . . . . . . . . . . 27
44
Gage Sensor (V8 VIN P)
Mounted in LH Head, between 1 and 3 Cylinders
23
40
Fuel Gage Sender . . . . . . . . Part of Fuel Tank Unit
Generator . . . . . . . . . . . . . . . RH front of Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14, 29 26, 46
I/P Fuse Block . . . . . . . . . . . LH side ofI/P Carrier, on the side . . . . . . . . . . . . . . . . . . . 8 . . . . 15 . .
Ignition Switch . . . . . . . . . . Part of Steering Column . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 . . . 51 . .
Instrument Cluster . . . . . . . LH side of l/P . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Isolation Diode
(Low Coolant) . . . . . . . . . . Sealed in Harn, approx 2 cm from Air Pump breakout
Low Coolant Relay . . . . . . . Mounted in U nderhood Electrical Center
Oil Level Sensor . . . . . . . . . Lower left side of Engine, in oil pan ................. . 11, 24 20,41
Oil Pressure Sensor . . . . . . Lower left side of Engine, above oil filter ............ . 11,24 20,41
PASS-KeyII Decoder
Module . . . . . . . . . . . . . . . . In 1/P, just right of Radio, attached to Air Bag Bracket . 8 .... 15 ..
Tachometer Filter
(VS VIN P) . . . . . . . . . . . . Tapped to Harn, left front side of Engine ............ . 23
40
C200A (17 cavities)
72
C200B (18 cavities)
72
C200C (13 cavities)
Steering Column ................................ . 47
72
C200D (48 cavities)
Steering Column ................................ . 47
72
C210 (4 cavities) . . . . . . . . . Under RH side ofI/P, behind RH kick panel ......... . 46
67
C220 (10 cavities) . . . . . . . . U_nder RH side ofI/P, behind kick panel ............. . 46
67
C230 (10 cavities) . . . . . . . . Under RH side ofI/P, behind kick panel ............. . 46
67
C405A (4 cavities) . . . . . . . Part of PassThru Conn, forward ofrear axle, to
Fuel Tank unit ................................. . 5
9
C405B (10 cavities) . . . . . . Part of Pass Thru Conn, forward ofrear axle, to
Pass Thru Panel ................................ . 5
9
Gl03 (LTl) . . . . . . . . . . . . . . RH side of Engine Block,just above Starter
(2 rings, 2 wires) ................................ . 25 ... 42
CONN
202-12
202-13
202-17
202-18
202-19
202-20
202-22
202-22
202-22
202-22
202-14
202-2
202-2
202-2
202-2
202-16
202-6
202-7
202-8
202-8
COMPONENT
201-PG
LOCATION
G104 (L32) ............. . 2 studs, 2 rings on each, interchangeable. Top RH side

Near top RH side ofradiator, in top ofT-Bar . . . . . . . . . . 19
G105
G200
Near base ofLH "A" pillar, bolted to 1/P Mounting Stud
behind kick panel (2 rings, 2 wires) . . . . . . . . . . . . . . . . 9 . . . .
G305
without AC3/AQ9) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 . . . .
PlOO
Compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
P110
Compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
5109 (LTl)
ECM breakout
S110 (L32)
ECM breakout
S112
Forward Lamp Harn, approx 10 cm from G106 breakout
5165
Center breakout
S195
Forward Lamp Harn, approx 2 cm from Secondary
Air Pump breakout
5206
breakout
5209
5215
S216
5224
1/P Harn, approx 4 cm from Instrument Cluster breakout
S242
FIG.
- 11
CONN
46
36
16
11
36
35
(Perform before beg i n n i n g
Diagnosis)
System
For Instrument Cluster removal and replacement,

refer to SECTION SC.
1. It is possible to have an open circuit to an indicator
within the Cluster, though unlikely. Check
circuits from suspect socket to connector terminals
before replacing Cluster for an indicator problem.
2. If more than one gage or indicator are inoperative,
check the appropriate fuse and ground before
continuing.

SYSTEM DIAGNOSIS

procedures.

SYSTEM CHECK (for Indicators}
NORMAL RESULTS
ACTION
[1]
Turn Ignition Switch from "OFF" to "RUN."
- "AIR BAG" Indicator will flash 7 to 9 times, then go

out.
- "ABS INOP" Indicator is "ON" for approximately
3 seconds.
- "CHECK GAUGES" Indicator is "ON" continuou5ly.
- "LOW OIL" Indicator is "ON" for approximately
1 second.
- "SECURITY" Indicator is "ON" for approximately
4 seconds.
- "FASTEN SEAT BELT" Indicator "ON" if not buckled.
[2]
Turn Ignition Switch slowly through "BULB TEST" - "BRAKE" Indicator "ON" until switch is released.
to "START."
- "LOW COOLANT" Indicator "ON" until switch is
released.
- "LOW TRAC" Indicator flashes "ON" briefly.
- (MIL) "SERVICE ENGINE SOON" Indicator "ON"
momentarily at "START."
SYMPTOM TABLE
PROCEDURE
SYMPTOM
PAGE NUMBER
Instrument Cluster Illumination Lamps are inoperative See "Interior Lights Dimming," page SA-117-0.
or do not dim properly.
GAGES
Coolant Temperature Gage always indicates Cold.
Chart #1
SA-81-14
Coolant Temperature Gage always indicates Hot.
Chart #2
SA-81-14
Coolant Temperature Gage appears inaccurate.
Chart#3
SA-81-14
Fuel Gage always indicates Empty.
Chart #4
SA-81-15
Fuel Gage always indicates Full.
Chart #5
SA-81-15
Fuel Gage appears inaccurate.
Chart #6
SA-81-16
Oil Pressure Gage always indicates High Pressure.
Chart #7
SA-81-17
Oil Pressure Gage always indicates Low Pressure.
Chart #8
SA-81-17
Oil Pressure Gage appears inaccurate.
Chart #9
SA-81-17
Speedometer fluctuates with the operation of wipers

or hazard flashers.
Speedometer inoperative or inaccurate.
Change ground circuit for Cruise Control Module

to reflect grounding through CKT 1650 on page
SA-14-6. Use a new connector terminal and ring
terminal with .8 wire routed through harness from
Cruise Control Module to G 109 ground strap.
If unable to correct compliant, contact technical
assistance.
See "Vehicle Speed Sensor," page SA-33-0.
Tachometer inoperative or inaccurate.
Chart #10
Voltmeter inoperative or inaccurate.
Chart#11
SA-81-18
SA-81-18
81 - 13
SYMPTOM TABLE
SYMPTOM
PROCEDURE
PAGE NUMBER
INDICATORS
"ABS INOP" Indicator problem.
See SECTION SE 1.
"AIRBAG" Indicator problem.
See SECTION 9JA.
"BRAKE" Indicator problem.
See "Brake Warning," page BA-41-0.
"CHECK GAUGES" Indicator always "ON."
Chart #12
BA-81-19
"CHECK GAUGES" Indicator does not turn "ON."
Chart #13
BA-81-19
"FASTEN SEAT BELT" Indicator problem.
See "Audible Warnings," page BA-76-0.
High Beam Indicator problem.
See "Headlights and Fog Lights," page 8A-100-0

(without DRL), page 8A-102-0 (with DRL).
"LOW COOLANT" Indicator does not turn "ON."
Chart #14
BA-81-20
"LOW COOLANT" Indicator always "ON" (coolant

level OK).
Chart #15
BA-81-21
"LOW COOLANT" Indicator turns "ON" and "OFF"

intermittently while driving.
Chart #16
BA-81-22
"LOW OIL" Indicator does not turn "ON" when oil

level is low.
Chart #17
8A-81-23
"LOW OIL" Indicator stays "ON" when oil level is OK.
Chart #18
8A-81-23
"LOW TRAC" Indicator problem.
See SECTION SE 1.
"
"SECURITY" Indicator problem.
See SECTION 9D.
(MIL) "SERVICE ENGINE SOON" Indicator problem.
See SECTION 6E3.
Turn Indicator problem, Left or Right.
See "Exterior Lights," page 8A-110-0.
POWER AND GROUNDS

More than 1 gage or indicator inoperative.
Disconnect Instrument Cluster and connect a Test

Light across the appropriate power and ground
terminals.
Test Light "ON"? - Check connector for poor
connection to Clu.ster. If OK, replace Instrument
Cluster.
Test Light "OFF"? - Repair open in power or ground
circuit to Cluster.
SA-
81 - 14
CHART #1
CHART #2
COOLANT TEMPERATURE GAGE ALWAYS

INDICATES COLD
COOLANT TEMPERATURE GAGE ALWAYS

INDICATES HOT
IGNITION "ON" - ENGINE "OFF."

DISCONNECT ENGINE COOLANT TEMPERATURE
GAGE SENSOR CONNECTOR.
CONNECT A JUMPER BETWEEN TERM" A" OF
COOLANT TEMP GAGE SHOULD MOVE ALL THE
WAY TO THE RIGHT (HOT).
DOES IT?

DISCONNECT ENGINE COOLANT TEMPERATURE
GAGE SENSOR CONNECTOR.
DOES THE GAGE MOVE BACK TO THE LEFT (COLD)?
REPLACE THE ENGINE

COOLANT TEMPERATURE
GAGE SENSOR.
CHECK FOR POOR

CONNECTION.
IF OK, REPLACE THE
ENGINE COOLANT
TEMPERATURE GAGE
SENSOR.
CHECK CKT 135 FOR A POOR

CONNECTION OR AN OPEN.
IF OK, REPAIR/REPLACE
INSTRUMENT CLUSTER.
CHECK FOR A SHORT TO

GROUND IN CKT 135.
IF OK, REPAIR/REPLACE THE
INSTRUMENT CLUSTER.
CHART #3
COOLANT TEMPERATURE GAGE APPEARS INACCURATE

DISCONNECT ENGINE COOLANT TEMPERATURE GAGE SENSOR CONNECTOR.
USING 1/P TESTER J 33431 OR EQUIVALENT, CONNECT ONE RED CLIP LEAD FROM THE
TESTER TO THE SENSOR CONNECTOR TERM "A". CONNECT THE OTHER RED CLIP
LEAD TO GROUND.
ADJUST THE RESISTANCE DIALS OF THE TESTER TO 1400 OHMS AND THEN 55 OHMS.
THE COOLANT TEMP GAGE SHOULD REGISTER COLD AND THEN HOT.
DOES IT?
REPLACE THE ENGINE

COOLANT TEMPERATURE
GAGE SENSOR.
CHECK FOR A POOR CONNECTION

OR HIGH RESISTANCE IN CKT 135.
INSTRUMENT CLUSTER.
ELECTRICAL DIAGNOSIS SA- 81
- 15
CHART #4
FUEL GAGE ALWAYS INDICATES EMPTY
ASSUMES OTHER GAGES ARE OPERATING NORMALLY.

DISCONNECT FUEL TANK UNIT CONN C405A.
DOES FUEL GAGE INDICATE FULL?
IGNITION "OFF."
DISCONNECT INSTRUMENT CLUSTER CONN.
IGNITION "ON" - ENGINE "Off."
CONNECT A TEST LIGHT FROM TERM "AS" TO TERM "A2".
IS TEST LIGHT "ON"?
:
:
1
-------------------,
REPLACE FUEL GAGE SENDER, :

PART OF FUEL TANK UNIT.
:
REFER TO SECTION 6C.
1
~---------------------J
REPAIR SHORT TO
GROUND IN CKT 30.
INSTRUMENT CLUSTER.
CHART #5
FUEL GAGE ALWAYS INDICATES FULL
(VERIFY THAT FUEL TANK IS NOT ACTUALLY FULL)

CONNECT A FUSED JUMPER TO C405B TERM" A2"
(10-WAY CONN MOUNTED TO PANEL) TO GROUND.
DOES FUEL GAGE INDICATOR MOVE TO EMPTY?
IGNITION "OFF."
CONNECT FUSED JUMPER FROM C405B TERM" A2" TO
TERM" A3" (10-WAY CONN MOUNTED TO PANEL).
DOES FUEL GAGE INDICATOR STAY ON EMPTY?
r-
--------------------------------------------,
:
:
IGNITION "OFF."
CHECK FOR OPEN IN CKT 1050 OR CKT30 TO FUEL TANK UNIT, OR FOR
POOR CONNECTION AT (405.
If OK, REPLACE FUEL GAGE SENDER, PART OF FUEL TANK UNIT.
REFER TO SECTION 6C (A SHORT TO B + ON CKT 30 COULD CAUSE AN
ALWA VS FULL INDICATOR CONDITION, THOUGH UNLIKELY).
:
:
I
:
:
1
:
:
1
L----------------------------------------------~
CHECK FOR OPEN IN CKT 30 BETWEEN C405B AND

INSTRUMENT CLUSTER, OR FOR BAD CONNECTION AT
CLUSTER CONN TERM "A2".
If OK, REPAIR/REPLACE INSTRUMENT CLUSTER (A
SHORT TO B + ON CKT 30 COULD CAUSE AN ALWAYS
FULL INDICATOR CONDITION, THOUGH UNLIKELY).
REPAIR OPEN IN CKT 1050 BETWEEN 6305

AND (405, OR POOR GROUND AT G305.
SA - 81
- 16

CHART #6
FUEL GAGE APPEARS INACCURATE

USING 1/P TESTERJ 33431, CONNECT ONE RED CLIP LEAD FROM THE TESTER TO
C405B TERM" Al" (10-WAY CONN MOUNTED TO PANEL). CONNECT THE
OTHER RED CLIP LEAD TO GROUND.
SET TESTER TO "O" OHMS.
IGNITION "ON" -ENGINE "OFF."
DOES FUEL GAGE INDICATE EMPTY?
rn
r-
'
I
I
:
'
I
I
:
:
I
IMPORTANT:
IF A J 3343115 UNAVAILABLE, RESISTORS OF EQUAL VALUE MAY BE USED.
SET RESISTANCE TO "90" OHMS FOR 1

MINUTE OR UNTIL GAGE READS FULL, THEN
SLOWLY REDUCE RESISTANCE TO "O" OHMS
OVER 1 MINUTE'S TIME.
AS RESISTANCE VALUES CHANGE, DOES
GAGE INDICATOR CHANGE VALUES EQUAL
TO THE TABLE BELOW?
-------------------------------------,
CHECK FOR INTERMITTENT OPEN IN CKT 1050 OR FOR POOR

GROUND CONNECTION.
CHECK FUEL TANK UNIT WIRES FOR DAMAGE.
CHECK FOR MECHANICAL CLEARANCE BETWEEN FLOAT
AND TANK INTERIOR.
IF THE CONNECTIONS ARE LOOSE OR CORRODED, OR
WIRES SHORTED, REPAIR AS REQUIRED.
IF OK, REPLACE FUEL GAGE SENDER {REFER TO SECTION 6C).
CHECK CKT 30 AND CONNECTORS TO CLUSTER

AND FUEL TANK UNIT FOR A RESISTIVE OPEN
OR POOR CONNECTION. {A TOTALLY OPEN
CKT 30 WOULD CAUSE GAGE TO READ FULL, A
SHORT TO GROUND WOULD READ EMPTY.)
IF OK, REPAIR/REPLACE INSTRUMENT CLUSTER.
CHECK CKT 30 AND CONNECTORS TO CLUSTER

AND FUEL TANK UNIT FOR A RESISTIVE OPEN
OR POOR CONNECTION. {A TOTALLY OPEN
CKT 30 WOULD CAUSE GAGE TO READ FULL, A
SHORT TO GROUND WOULD READ EMPTY.)
L---------------------------------------~
FUEL GAGE SENDER
RESISTANCE
APPROXIMATE FUEL LEVEL
88Q
FULL
60Q
3/4
43Q
1/2
26Q
1/4
1.0 Q
EMPTY
rn
CHART #7
CHART #8
Oil PRESSURE GAGE ALWAYS INDICATES

HIGH PRESSURE
OIL PRESSURE GAGE ALWAYS INDICATES

LOW PRESSURE
rn
IMPORTANT:
CHECK FOR PROPER OIL LEVEL, THEN CHECK OIL

PRESSURE WITH A MECHANICAL GAGE BEFORE
PROCEEDING. IF NOT OK, REFER TO SECTION 6A.

DISCONNECT OIL PRESSURE SENSOR CONNECTOR.
CONNECT A JUMPER BETWEEN TERM" A" OF
DOES GAGE MOVE BACK TO THE LEFT (LO PRESSURE)?
CHECK FOR POOR

CONNECTION.
IF OK, REPLACE OIL
PRESSURE SENSOR.
IMPORTANT:

DOES OIL PRESSURE GAGE MOVE All THE WAY TO THE
RIGHT (HIGH PRESSURE)?
CHECK FOR A POOR

CONNECTION OR OPEN IN
CKT31.
INSTRUMENT CLUSTER.
CHART #9
rn
OIL PRESSURE GAGE APPEARS INACCURATE

IMPORTANT:

USING 1/P TESTER J 33431 OR EQUIVALENT, CONNECT ONE RED
CLIP LEAD TO THE SENSOR CONNECTOR TERM "A" AND CONNECT
THE OTHER RED CONNECTOR TO GROUND.
SET THE RESISTANCE DIALS ON THE TESTER TOO OHMS,40 OHMS
AND 100 OHMS.
THE OIL PRESSURE GAGE SHOULD GO FROM LO PRESSURE TO
APPROXIMATELY 30 psi, AND THEN TO HIGH PRESSURE.
DOES IT?
- 17
CHECK CKT 31 FOR POOR OR

CORRODED CONNECTIONS.
INSTRUMENT CLUSTER.
CHECK FOR SHORT TO GROUND

IN CKT 31.
IF OK, REPAIR/REPLACE THE
INSTRUMENT CLUSTER.

CHART #10
TACHOMETER INOPERATIVE OR INACCURATE
(ASSUMES ENGINE RUNS NORMALLY)
(V6 VIN S) DISCONNECT ELECTRONIC IGNITION MODULE CONN C1 (6-WAY).

(VS VIN P) DISCONNECT THE BLK2-WAY CONN AT THE IGNITION COIL.
USE 1/P TESTERJ33431 WITH J33431-10 HARNESS OR EQUIVALENT.
(V6 VIN S) CONNECT THE TESTER TO CONN C1 TERM "C" AND GROUND.
(VS VIN P) CONNECT THE TESTER TO TERM" A" OF BLK CONN AND GROUND.
SET THE TESTER TO 54 mph (60 Hz).
DOES THE TACHOMETER INDICATE APPROXIMATELY 1200 rpm FOR (V6 VIN S)
OR 900 rpm FOR (VS VIN P)?
r- --------------------------------------,
(V6 VIN S) REPLACE HIGH ENERGY IGNITION

MODULE OR ELECTRONIC IGNITION
MODULE AS NECESSARY.
(VS VIN P) CHECK FOR POOR CONNECTION
TO TACHOMETER FILTER.
IF OK, REPLACE IGNITION COIL.
: (V6 VIN S)
1
CHECKFORANOPEN,SHORTTOGROUNDORB+ INCKT121.
:
: (VS VIN P)
: CHECK FOR AN OPEN, SHORTTO GROUND ORB+ IN CKT 121
:
OR CKT 1848.
1
CHECK FOR A CORRECTLY OPERATING TACH FILTER(REFER
:
TO SECTION 6E3).
I
L----------------------------------------~
CHART #11
VOLTMETER INOPERATIVE OR INACCURATE

CONNECT A DVM SET TO DC SCALE TO THE POSITIVE AND NEGATIVE
TERMINALS OF THE BATTERY.
DOES THE VOLTMETER AT THE INSTRUMENT CLUSTER CLOSELY MATCH
THE VOLTAGE READING ON THE DVM?
START ENGINE AND AGAIN MEASURE THE VOLTAGE

ACROSS THE BATTERY TERMINALS.
DOES THE VOLTMETER IN THE INSTRUMENT
CLUSTER STILL CLOSELY MATCH THE DVM?
REPAIR/REPLACE
INSTRUMENT CLUSTER.
INSTRUMENT CLUSTER.
- 19
CHART #12
"CHECK GAUGES" INDICATOR ALWAYS "ON"
ENGINE RUNNING AT IDLE.

MEASURE SYSTEM VOLTAGE ACROSS BATTERY.
IS VOLTAGE MORE THAN 16.5 VOLTS OR LESS THAN 11.2 VOLTS?
----------------------------------------------,:
L_
CHECK FOR ECM CODES RELATIVE TO CHARGING SYSTEM, OIL PRESSURE

OR TEMPERATURE.
REFER TO SECTION 6E.
VERIFY COOLANT TEMPERATURE IS BELOW APPROXIMATELY 252F FOR
V6 VIN S OR BELOW 244F FOR VS VIN P.
VERIFY OIL PRESSURE IS ABOVE 8.3 psi (MINIMUM FOR PUMP). ANYTHING
BELOW 3 TO 5 psi SHOULD CAUSE CHECK GAGES LIGHT TO TURN "ON."
ARE ALL OK?
:
:
r:
1
------------------,
REPAIR CHARGING SYSTEM. :
1
L--------------------J
:
:
1
----------------------------------------------~
FOR THE SPECIFIC SYSTEM INDICATING

A PROBLEM CONDITION, REPAIR
MECHANICAL OR ELECTRICAL FAILURE.
SEE GAGES CHARTS IN THIS SECTION.
CHECK FOR OPEN OR POOR CONNECTION IN

CKT 225. (IF CIRCUIT IS OPEN, GENERATOR Will
NOT GENERATE VOLTAGE AND VEHICLE MAY BE
RUNNING ONLY ON BATTERY POWER.)
IF OK, REPLACE INSTRUMENT CLUSTER.
CHART #13
"CHECK GAUGES" INDICATOR DOES NOT TURN "ON"
START ENGINE WHILE MONITORING "CHECK GAUGES" INDICATOR (SEE VIEW OF CLUSTER FOR LOCATION).
DID "CHECK GAUGES" INDICATOR TURN "ON" FOR APPROXIMATELY 1 SECOND? ("CHECK GAUGES" INDICATOR
Will STAY ON CONTINUOUSLY IF ENGINE IS NOT STARTED.)
IS THERE AN INDICATION OF A PROBLEM

WITH ONE OF THE FOLLOWING SYSTEMS?
- CHARGING SYSTEM
- COOLANT TEMPERATURE
- OIL PRESSURE
FOR GAGE FAILURE INDICATIONS, SEE SYMPTOM

I
I
TABLE TO REFERENCE SPECIFIC CHARTS.
I
I
FOR SYSTEM FAILURES:
I
- CHARGING SYSTEM, REFER TO SECTION 6D3
I
I
- COOLANT TEMPERATURE, REFER TO SECTION 6E3
I
- OIL PRESSURE, REFER TO SECTION 6A2A (V6 VIN S) 1
SECTION 6A3A (VS VIN P). :
REPLACE "CHECK GAUGES" INDICATOR LAMP.

CYCLE IGNITION FROM "OFF" TO "ON" AGAIN.
IF INDICATOR DOES NOT TURN ON,
REPAIR/REPLACE INSTRUMENT CLUSTER.
SYSTEM OPERATING NORMALLY.

NO TROUBLE FOUND.
SA - 81
- 20

CHART #14
"LOW COOLANT" INDICATOR DOES NOT TURN "ON"
(ASSUMES OTHER INDICATORS OPERA TE NORMALL V)
DISCONNECT ENGINE COOLANT LEVEL SENSOR.

CONNECT A FUSED JUMPER FROM CONN TERM "B" TO GROUND.
DOES INDICATOR TURN "ON"?
IGNITION .. OFF."
DISCONNECT C200A ONLY (ONE OF THE
TWO FORWARD LAMPS TO 1/P HARNESS
CONNECTORS).
CONNECT THE FUSED JUMPER FROM C200D
TERM .. A 1
TO GROUND.
DOES INDICATOR TURN "ON"?
CHECK FORAN OPEN IN GROUNDCKT250

TO TERM "C" OF CONNECTOR OR FOR A
POOR CONNECTION.
IF OK, REPLACE ENGINE COOLANT LEVEL
SENSOR.
CHECK FOR OPEN IN CKT 68 BETWEEN C200 AND

INSTRUMENT CLUSTER CONN TERM .. A6 .. OR FOR
POOR CONNECTION TO CLUSTER.
IF OK, REPLACE INDICATOR LAMP. (IT IS POSSIBLE TO
HAVE AN OPEN CIRCUIT TO THE INDICATOR WITHIN
THE CLUSTER, THOUGH UNLIKELY. CHECK CIRCUITS
FROM SOCKET TO CONNECTOR TERMINALS BEFORE
REPLACING CLUSTER.)
CHECK FOR POOR CONNECTION AT CONN C200

TERM" A 17" OR OPEN IN CKT 68 OR CKT 1478
BETWEEN C200 AND COOLANT LEVEL SENSOR.
IF OK, REPLACE ISOLATION DIODE.
CHART #15
"LOW COOLANT" INDICATOR ALWAYS "ON"
(COOLANT LEVEL OK)

IS INDICATOR "ON"?
REMOVE LOW COOLANT RELAY FROM

UNDERHOOD ELECTRICAL CENTER.
IS INDICATOR "ON"?
DISCONNECT IGNITION SWITCH

CONN C1 ONLY.
IS INDICATOR "ON"?
DISCONNECT C200A FROM C200D

LEAVING C200B AND C200C CONNECTED.
IS INDICATOR "ON .. ?
REPAIR SHORT TO GROUND IN CKT 68 BETWEEN C200

AND CLUSTER CONN TERM" A6".
If NO SHORT FOUND, REPLACE INSTRUMENT CLUSTER.

IN CKT 1478 OR CKT 68
BETWEEN C200 AND 5195.
- 21
SA - 81
- 22

CHART #16
LOW COOLANT INDICATOR TURNS "ON" AND "OFF" INTERMITTENTLY WHILE DRIVING
[INDICATOR SHOULD STAY "ON" (LATCHED) FOR ENTIRE IGNITION CYCLE AFTER THE
ENGINE COOLANT LEVEL SENSOR DETECTS AN INTERMITTENT LOW]
REMOVE LOW COOLANT RELAY FROM

CONNECT A TEST LIGHT FROM ELECTRICAL
CENTER TERM "G1" TO TERM "GS".
IS TEST LIGHT "ON"?
IGNITION "OFF."
CONNECT A FUSED JUMPER FROM SENSOR
CONN TERM "B", HARNESS SIDE, TO GROUND.
CONNECT A TEST LIGHT FROM B + TO
UNDERHOOD ELECTRICAL CENTER TERM "G2"
THEN TERM "G4".
IS TEST LIGHT "ON" AT BOTH TERMINALS?
CHECK FOR INTERMITTENT OPEN IN CKT 68

BETWEEN INSTRUMENT CLUSTER AND 5195, OR
FOR POOR CONNECTION AT CLUSTER TERM" A6"0R
AT RELAY CONNECTIONS.
IF OK, REPLACE LOW COOLANT RELAY.
CONNECT TEST LIGHT FROM TERM "GS" TO GROUND.

IS TEST LIGHT "ON"?
REPAIR OPEN OR POOR

CONNECTION IN CKT 250
BETWEEN LOW COOLANT
RELAY TERM "G1" AND 5112.
REPAIR POWER FEED TO

TERM "GS", OPEN IN CKT 139 OR
SHORT TO GROUND IN CKT 139
CAUSING" A/C- CRUISE" FUSE 12
TO BLOW.

5195 AND TERMINAL THAT DID NOT
LIGHT THE TEST LIGHT.
CHART #17
"LOW OIL" INDICATOR DOES NOT TURN "ON" WHEN OIL LEVEL IS LOW
[I] IMPORTANT:
DUE TO THE PROGRAMMING OF THE CLUSTER, THE "LOW OIL" INDICATOR WILL NOT
TURN "ON" IF A LOW OIL CONDITION HAS OCCURRED WHILE ENGINE IS RUNNING. LET
ENGINE COOL SEVERAL HOURS THEN KEY "ON" BEFORE PERFORMING DIAGNOSTICS.
TURN IGNITION FROM "OFF" TO "ON" WHILE MONITORING "LOW OIL"

INDICATOR (SEE VIEW OF CLUSTER FOR LOCATION).
DID "LOW OIL" INDICATOR TURN "ON" FOR APPROXIMATELY 1 SECOND?
IGNITION "OFF," WAIT A MINIMUM OF 35 MINUTES FOR

CLUSTER'S COLD OIL DRAIN BACK CALCULATION TO CLEAR.
DISCONNECT OIL LEVEL SENSOR CONNECTOR.
DOES "LOW OIL" INDICATOR COME "ON" AND STAY "ON"?
REPLACE "LOW OIL" INDICATOR LAMP.

CYCLING IGNITION FROM "OFF" TO "ON" AGAIN.
IF INDICATOR DOES NOT TURN ON,
REPAIR/REPLACE INSTRUMENT CLUSTER.
VERIFY THERE IS A LOW OIL CONDITION.

IF LOW OIL, REPLACE OIL LEVEL SENSOR.
CHECK FOR A SHORT TO GROUND IN CKT 1174.

CHART #18
"LOW OIL" INDICATOR STAYS "ON" WHEN OIL LEVEL IS OK
IGNITION "OFF," WAIT A MINIMUM OF 35 MINUTES FOR CLUSTER'S

COLD OIL DRAINBACK CAL CU LA TION TO CLEAR.
DISCONNECT OIL LEVEL SENSOR CONNECTOR.
JUMPER THE HARNESS CONNECTOR FROM TERM" A" TO TERM "B".
DOES INDICATOR TURN "ON" FOR APPROXIMATELY 1 SECOND
THEN GO "OFF"?
IGNITION "OFF."
JUMPER STILL CONNECTED AT SENSOR CONN.
CONNECT A TEST LIGHT FROM TERM" A 15" TO B +.
IS TEST LIGHT "ON"?
VERIFY OIL LEVEL TO BE CORRECT.

IF OIL LEVEL IS OK, REPLACE OIL
LEVEL SENSOR.
CHECK FOR POOR CONNECTION TO

CLUSTER AT TERM "A15".
- 23
8A -

CIRCUIT OPERATION
The Instrument Cluster contains Analog Gages
and Indicators. Some Gages and Indicators are
controlled by solid state controls within the Cluster;
some are controlled by direct circuits into the Cluster
from other components. These operations are
described here briefly.
approximately 1365 ohms at 100F). The varying

sensor resistance causes the current through the coils
to fluctuate. The magnetic fields of the coils move the
pointer.
"FASTEN SEATBELT" INDICATOR
See "Audible Warnings," page 8A-76-0.
f~BS~
"ABS INOP" INDICATOR, FOR 249: \ ~ }
See SECTION 5El.

"AIR BAG" INDICATOR
See SECTION 9J.

\\
"BRAKE" INDICATOR, FOR 249: ((j))
II
<G>
See "Brake Warning," page 8A-41-5.
FUEL GAGE
The Fuel Gage contains internal coils that create

magnetic fields when current flows through them. The
current through the coils varies depending on the Fuel
Gage Sender resistance (see Fuel Level/Resistance
Chart). The varying sender resistance causes the
current through the coils to fluctuate. The magnetic
fields of the coils move the pointer.
"CHECK GAUGES" INDICATOR
HIGH BEAM INDICATOR
The Instrument Cluster's internal circuitry

monitors three inputs for determining when to
illuminate the "CHECK GAUGES" Indicator.
The "CHECK GAUGES" Indicator is provided a
ground for illumination when:
1. The Coolant Temperature Sensor indicates
above normal temperature (252F for
V6 VIN Sor 244F for V8 VIN P).
2. The Instrument Cluster senses the Generator
turn on input is at ground potential. The
Generator pulls CKT 225 low with system
voltage at or below ll.2v or with 16.5v or
higher, also pulled low if Generator is stopped.
3. The Oil Pressure Sensor indicates below
normal pressure. The minimum rating for the
pump is 8.3 psi, though the sensor will be
approximately 3 to 5 psi at 10 ohms which wiII
cause the "CHECK GAUGES" Indicator to
illuminate (maximum pressure should be
about 90 ohms at the sensor).
4. The Instrument Cluster performs a bulb check
function for approximately one second after
Ignition "ON."
The High Beam Indicator has system voltage

applied to it whenever the Headlights are "ON" and
the Headlight Dimmer Switch is on "HIGH." The
Indicator has a constant ground and will illuminate
whenever system voltage is applied.
COOLANT TEMPERATURE GAGE
The Coolant Temperature Gage contains internal

coils that create magnetic fields when current flows
though them. The current through the coils varies
depending on the Coolant Temperature Sensor
resistance (approximately 55 ohms at 260F (hot) and
"LOW COOLANT" INDICATOR (VS VIN P)
The "LOW COOLANT" Indicator has system

voltage applied in "RUN," "BULB TEST" or "START."
The Indicator requires a ground for illumination.
There are two ways the Indicator receives a ground:
1. During "BULB TEST" through the Ignition
Switch.
2. Whenever the Engine Coolant Level Sensor
detects a low coolant condition.
When a low coolant condition occurs, a ground
path is supplied through the Engine Coolant Level
Sensor, and the Isolation Diode to the Indicator. At
the same time, ground is supplied through the Engine
Coolant Level Sensor to the Low Coolant Relay. The
Low Coolant Relay is designed to provide a continuous
ground path to the Indicator for the remainder of the
Ignition cycle in which a momentary low coolant
condition occurred. (The relay provides its own ground
to its coil and to the Indicator until the Ignition is
turned "OFF." This is called latching.) The purpose of
the Isolation Diode is to prevent the ground path
through the Ignition Switch during "BULB TEST"
from latching the Low Coolant Relay.
- 25
"LOW OIL" INDICATOR
VOLTMETER
The Instrument Cluster's internal circuitry will

only check the Oil Level Sensor at Ignition "ON" if
Drainback Times are met (35 minutes after Ignition
"OFF" if the Engine was still cold, or 4 minutes after
Ignition "OFF" if the Engine was hot. Hot is defined
as running for at least 17 minutes). Drainback Timer
sets at Ignition "OFF." The sensor has normally closed
contacts that are open under a low oil condition. After
determining a low oil condition exists, the "LOW OIL"
Indicator is provided a ground for illumination. The
Indicator also receives a ground for approximately one
second during the Cluster's bulb check function right
afterlgnition "ON."
The Voltmeter measures the vehicle's electrical

system voltage during run or stopped conditions. The
Voltmeter has two coils internally that create
magnetic fields. These .coils are made of a different
amount of windings and are in series with a calibrated
resistance. Any voltage between 8 to 18 volts will
create a magnetic field that will move the pointer to
the appropriate voltage indication.
"LOW TRAC" INDICATOR
See SECTION 5El.

OIL PRESSURE GAGE
The Oil Pressure Gage contains internal coils that

create magnetic fields when current flows through
them. The current through the coils varies depending
on the Oil Pressure Sensor resistance. (Low pressure
resistance is approximately 10 ohms, high pressure
resistance is approximately 90 ohms.) The varying
sensor resistance causes the current through the coils
to fluctuate. The magnetic fields of the coils move the
pointer.
"SECURITY" INDICATOR
See SECTION 90.

(MIL) "SERVICE ENGINE SOON"
INDICATOR,FORZ49: ' : ~
See SECTION 6E3.~

SPEEDOMETER
See "Vehicle Speed Sensor," page 8A-33-0.

TACHOMETER
The Tachometer displays Engine speed in

Revolutions Per Minute (RPM). Voltage pulses from
the Ignition system are interpreted by solid state logic
circuits within the Cluster. The solid state circuits
process the pulses and put out a signal that drives the
pointer of the meter. The pointer is moved with
magnetic fields created from coils within the
Tachometer.
8A -
WIPER/WASHER: PULSE
,-
-WI/P
FUSE
BLOCK
ACCY
(NOT USED)
... _______ _
__
1
I
_.
1 YEL
1 YEL
143
WIPERIWASHER
SWITCH ASSEMBLY
WASHER
SWITCH
MIST
HI
MIST
'
OFF
e e e
LO
PULSE
PULSE
6
8
0
24dl
.8 PNK
94
WIPER/
WASHER
REQUEST
INPUT
WIPERS
DELAY
INPUT
WIPER
INTERLOCK
INPUT
ISOLA-f
TION
DIODE
(WIPERS)
WIPERS
ENABLE
SOLID
STATE
.8 RED
PARK
POSITION
INPUT
1------------'
1------------,
(PT()
.--+---+---+-~LOW
SPEED
RELAY
,,.,
t--------,
END OF
SWEEP
SWITCH
(OPEN AT
END OF
"SWEEP"
AND
"PARK"
POSITION)
T2
T1
t-------t------,
PARK
SWITCH
(CLOSED
UNTIL WIPERS
IN "PARK")
228
GROUND
PARK
WIPERS
CONTROL
1-----WIPER MOTOR
ASSEMBLY
1 B~KrSO
8 BLK
5113
ISO
3 BLK
--~
_
1,so
~106
......
SEE GROUND
DISTRIBUTION
PAGE 8A-146
C215
91 - 1

STEERING COLUMN HARNESS
12129126
06294509
11 WAY F PACK-CON I
BLK

BLK
WINDSHIELD WIPER MOTOR MODULE
COMPONENT
1/P Fuse Block .......... .
Isolation Diode (Wipers) ..
Washer Pump Motor .....
Wiper Motor Assembly
201-PG FIG.
LOCATION
Approx 20 cm from C215
Front of vehicle, below Engine Hood Latch . . . . . . . . . . . 47
69
Rear ofLHShock Tower, mounted to dash panel below
LH Wiper Mount . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
18
Wiper/Washer Switch
Assembly ............. . In left side of Steering Column, actuated by
Multi-Function Lever ........................... .
C200B (18 cavities)
C200D (48 cavities)
Steering Column ................................ .
C215 (11 cavities) ....... . Near base of Steering Column ..................... .
G106 ................... . Near top LH side of Radiator, in topofT-Bar ........ .
PlOO
Compartment ................................... .
8113
Center breakout
SYSTEM DIAGNOSIS
Refer to SECTION SE for Diagnosis.
CONN
202-22
202-24
3 . ... 5
47
72 . .
202-2
47
35
19
72 . .
52 ..
35
202-2
202-4
19
36
SA -
HEADLIGHTS AND FOG LIGHTS

WITHOUT DRL (T61)
HOT AT ALL TIMES

-
1 RUST
FUSIBLE
LINK Z
-,1/P
FUSE
BLOCK
,'
1,--------,
3 RED
702
.S GRY
..I
SEE INTERIOR
LIGHTS DIMMING
PAGESA-117-1
5224. _ _ _
.8 ORN
,SGf
240
-""'11:0-------..,..~""'llr---------------r-----------"'----,
_J..
:~
HEADLIGHT
SWITCH
SWITCH
ILLUMINATION
LAMP
HEAD
HEAD
AV 3Y:Lr0
.8 BRN
8~5 (2008
C200D
4-1
TO HEADLIGHT ....
DOOR MODULE .......
PAGE SA-104-0
YEL_ _ _ _ _
1 YEL
10
10
B
HEADLIGHT
DIMMER
_SW_IT_C_H
,,.
C
.35 BLK
650
A
1 LTGRN
11
C3T
.8 LTGRN
C200B
C200D
11
1 LTGRN
11
5152----------
53
1 ~: .12
1LTGRl11
B
------A
(160
1TAN
HEADLAMP
DOOR
r- - -
12
1LTGRN
----
11
I HEADLAMP~
Lb!:!_____
1 BLK
1 LTGRN
11
INSTRUMENT
CLUSTER
'~+
250
r-~
1 BLK 12so
5113--i..
---.Ji 106
1 BLK
C YC165
1 BLK 1150
J L---ct------1!!:!J
150
r-----i----,
~H}/ I
C YC160
SEE PAGE SA-3-0

FOR MEASURING
AND HANDLING
PROCEDURES
12
"""'~: 1 ..5l ___~:

A
1 TAN
!~?,~;:.~{, ' "'' , ,,,

___-J.105
HEADLAMP
ASSEMB~
I SEE INSTRUMENT
WITH ~
I CLUSTER:
GAGES
l!~E~A-!!_-2.:,! -
r--:
HI
BEAM
INDICATOR
-o
=
=
--
I
I
I
1 a::i5o
SEE GROUND
DISTRIBUTION
PAGESSA-14-7,8
..... 3 BLK
,,.
750
16.55:16_ _ _ _. .
'e
GlOO
100 - 1
.35GRY
...----------..
I
8
5226
.5 BRN
---~----------~-------"'I
B
SEE EXTERIOR LIGHTS

PAGE SA-110-4
OFF
ON
..:i,,
A16
C200D
C200A
.8BRN
1 LTGRN
rsEEPOWER- DISTRIBUTION
PAGE SA-100
I
I
I
I
I
I
I
I
I
I
I
317
----,
WITHT96
ONLY
INDICATOR
LAMP
(FOG LIGHTS ON)
. .:f~
ml~
5216. -
P100
.5 YEL
SWITCH
~ATION
LAMP
FOG LIGHT
1 PPL
-..ill
34
SEE GROUND
DISTRIBUTION
PAGES SA-14-7, 8
3 BLK
750
-~200
83
.SORN
C200D
C200B
1340
FOG
LIGHTS
RELAY
WITH T96
ONLY
1 PPL
L-----------
1t
1 PPL
34
..:1,,
5160 - - - - - - - - - - - - - - - - - -
"f
~ FOG LAMP,
FOG LAMP,~
LEFT FRONT
\J;)
~ RIGHT FRONT
8
1 BL:yso
1 BL KJ250
-....1111111
5113- 3~K
1W
_u106
SEE GROUND
DISTRIBUTION
PAGESSA-14-5,6
......_
-~
3~K
2W
_c105
34
8A -
100 - 2

WITHOUT DRL (T61)
12129077
BLK
HEADLIGHT SWITCH
CAVITY
WIRE COLOR
CKT
BRN
BLK
650
YEL
DESCRIPTION
PAGE
PARK LAMP FEED
SA-100-0
GROUND
SA-14-8
10
HEADLIGHTS ON
SA-100-0
GRY
POWER FEED FROM 1/P DIMMER FUSE #13
SA-100-0
ORN
240
POWER FEED FROM TAIL LTS FUSE #10
SA-100-0
RED
702
POWER FEED FROM FUSIBLE LINK Z
SA-100-0
I I I I I
I I I I I
A
12045688
8-WAY M METRI-PACK 150 SERIES
BLK
FOG LIGHT SWITCH
COMPONENT
LOCATION
201-PG
FIG.
Fog Lamp, Left Front

Lower LH side of front Fascia
Fog Lamp, Right Front . . . Lower RH side of front Fascia
Fog Light Switch . . . . . . . . . Lower LH side ofl/P . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
57
Headlamp Door Motor, LH
LH front of vehicle
Headlamp Door Motor, RH
RH front of vehicle ................................. 43
63
Headlight Dimmer Switch
Part of Steering Column, activated by
Multi-Function Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3, 35 . 5, 52
Headlight Switch . . . . . . . . LH side ofl/P . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 . . . 57 . .
Instrument Cluster . . . . . . . LH side ofl/P . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
I/P Fuse Block . . . . . . . . . . . LH side ofI/P Carrier, on the side . . . . . . . . . . . . . . . . . . . 8 . . . . 15
of wheelhouse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 . . . 36
CONN
202-20
202-14
202-22
202-22
202-24
COMPONENT
C160 (3 cavities)
C165 (3 cavities)
C200A (17 cavities)
C200B (18 cavities)
C200D (48 cavities)
G105
G106
G200
PlOO
8112
8113
8152
8153
8160
8216
8224
8226
LOCATION
201-PG
LH Headlight to Forward Lamp Harn Jumper, behind
Headlight Door Bracket ......................... . 43
RH Headlight to Forward Lamp Harn Jumper, behind
Steering Column ................................ . 47
Near top LH side ofradiator, in top ofT-Bar ......... . 19
behind kick panel (2 rings, 2 wires) ............... . 9 ....
Compartment ................................... . 19 ...
Forward Lamp Harn, approx 10 cm from G106 breakout
Center breakout
Center breakout
Forward Lamp Harn, at Air Pump breakout
Forward Lamp Harn, approx 4 cm from Cruise Control
Module breakout
I/P Harn, approx 4 cm from Instrument Cluster breakout
Under RH side ofl/P, behind kick panel
FIG.
100 - 3
CONN
63
63
72
202-2
72
202-2
72
36
35
202-2
16
36
(Perform before beginning System
Diagnosis)
1. Always suspect an open lamp filament before
proceeding with diagnostics.
2. Make sure Lamp Connectors are free from
corrosion.
3. Check that grounds G200, G106 and 0105 are
clean and tight.
4. Check Fusible Link Z for open.
5. Check TAIL LTS Fuse 10 and 1/P Dimmer Fuse 13
for open. If fuse(s) are open, refer to Chart #9 in
this section.
6. If Headlamp door(s) do not open and Headlamps do
not illuminate, repair Headlamp door(s) failure
first. See "Headlight Doors,"page 8A-104-0.

SYSTEM DIAGNOSIS
diagnostic procedures.
SA -
100 - 4

WITHOUT DRL (T61)
SYMPTOM TABLE
PROCEDURE
PAGE NUMBER
LO Beam and HI Beam Headlights are inoperative.
Chart #1
8A-100-4
LO Beam Headlights inoperative, HI Beam Headlights

operate normally.
Chart #2
8A-100-5
HI Beam Headlights inoperative, LO Beam Headlights

operate normally.
Chart #3
8A-100-5
HI Beam Indicator inoperative, HI Beam Headlights

operate normally.
Chart #4
8A-100-5
One LO Beam or one HI Beam Headlamp inoperative.
Chart #5
8A-l00-6
LO Beams or HI Beams do not turn "OFF."
Chart #6
8A-100-6
SYMPTOM
HI Beam Headlights and LO Beam Headlights "ON" at Check for short to B + in CKTs 11 and 12.
replace Headlamp Dimmer Switch.
the same time.
Fog Lights do not turn "ON" but Park Lights operate
normally.
Chart #7
8A-100-7
Fog Lights do not turn "OFF."
Chart #8
8A-100-8
One Fog Lamp inoperative.
Chart #9
8A-100-8
If OK,
Fog Lights "ON" Indicator Lamp on; Fog Light Switch Check for:
Poor connection at C200 terminal "83".
inoperative but Fog Lights operate normally.
Open in CKT 34 between S160 and Fog Light Switch.
Open in CKT 650 to ground.
Poor connections at Fog Light Switch.
If OK, replace Fog Light Switch.
Chart #10
Fuse(s) blows when replaced or when attempting to

use lighting system.
8A-100-9
CHART #1
LO BEAM AND HI BEAM HEADLIGHTS ARE INOPERATIVE
HEADLIGHT SWITCH TO "HEAD."

CONNECT A TEST LIGHT FROM HEADLIGHT DIMMER SWITCH CONN TERM "8" TO GROUND.
IS TEST LIGHT "ON"?
CONNECT A TEST LIGHT FROM HEADLIGHT

SWITCH CONN TERM "E" TO GROUND.
IS TEST LIGHT "ON"?
CHECK FOR POOR CONNECTION AT HEADLIGHT

DIMMER SWITCH OR POOR CONNECTION AT C101.
IF OK, REPLACE HEADLIGHT DIMMER SWITCH.
CHECK FOR AN OPEN IN CKT 702, AN OPEN IN FUSIBLE

LINK ZORA POOR CONNECTION AT C200.
CHECK FOR POOR CONNECTION AT HEADLIGHT SWITCH.
IF OK, REPLACE HEADLIGHT SWITCH.
CHECK FOR POOR CONNECTION AT C200 TERM "85".

IF OK, REPAIR OPEN IN CKT 10 BETWEEN HEADLIGHT
SWITCH AND HEADLIGHT DIMMER SWITCH.
100 - 5
CHART #2
CHART #3
LO BEAM HEADLIGHTS INOPERATIVE,

HI BEAM HEADLIGHTS OPERATE NORMALLY
HI BEAM HEADLIGHTS INOPERATIVE,

LO BEAM HEADLIGHTS OPERATE NORMALLY

HEADLIGHT DIMMER SWITCH "LO."
BACKPROBE HEADLIGHT DIMMER
SWITCH CONN TERM "C" WITH A TEST
LIGHT TO GROUND.
IS TEST LIGHT "ON"?
CHECK FOR POOR

CONNECTION AT HEADLIGHT
DIMMER SWITCH.
If OK, REPLACE HEADLIGHT
DIMMER SWITCH.
CHECK FOR OPEN IN

CKT 12 BETWEEN THE
HEADLIGHT DIMMER
SWITCH TERM "C" AND
S153.

HEADLIGHT DIMMER SWITCH TO "HI".
IS HI BEAM INDICATOR "ON"?
CHECK FOR POOR

CONNECTION AT HEADLIGHT
DIMMER SWITCH.
IF OK, REPLACE HEADLIGHT
DIMMER SWITCH.
CHECK FOR OPEN IN

CKT 11 BETWEEN
HEADLIGHT DIMMER
SWITCH TERM "A"
ANDS152.
CHART #4
HI BEAM INDICATOR INOPERATIVE,
HI BEAM HEADLIGHTS OPERATE NORMALLY
REMOVE INSTRUMENT CLUSTER .

HEADLIGHT DIMMER SWITCH TO "HI."
PROBE INSTRUMENT CLUSTER CONN TERM" A 11"
WITH A DIGITAL MULTIMETER TO GROUND.
MEASURE VOLTAGE .
O VOLTS
CHECK FOR POOR CONNECTION AT C200 OR

OPEN IN CKT 11 BETWEEN HEADLIGHT
DIMMER SWITCH CONN AND INSTRUMENT
CLUSTER CONN.
CHECK FOR POOR CONNECTION AT INSTRUMENT

CLUSTER CONNECTOR TERM" A 11 ".
CHECK FOR MISSING OR DAMAGED HI BEAM
INDICATOR LAMP OR POOR CONNECTION AT THE
INSTRUMENT CLUSTER PRINTED CIRCUIT.
CHECK PRINTED CIRCUIT FOR DAMAGE OR
FLAWS.
REPLACE OR REPAIR AS NECESSARY.
SA -
100 - 6

WITHOUT DRL (T61)
CHART #5
ONE LO BEAM OR ONE HI BEAM HEADLAMP INOPERATIVE
DISCONNECT INOPERATIVE HEADLAMP CONN.

HEADLIGHT DIMMER SWITCH TO "LO" IF LO BEAM IS INOPERATIVE OR TO
"HI" IF HI BEAM IS INOPERATIVE.
CONNECT A TEST LIGHT FROM HEADLAMP CONN TERM "B" (LO BEAM) OR
TERM" A" (HI BEAM) TO GROUND.
IS TEST LIGHT "ON"?

HEADLAMP CONN.
(LH) CHECK FOR OPEN IN GROUNDCKT 150.
(RH) CHECK FOR OPEN IN GROUND CKT 250.
IF OK, REPLACE HEADLAMP.
(HI BEAM) REPAIR OPEN IN CKT 11 BETWEEN

5152 AND INOPERATIVE HEADLAMP CONN.
(LO BEAM) REPAIR OPEN IN CKT 12 BETWEEN

5153 AND INOPERATIVE HEADLAMP CONN.
CHART #6
LO BEAMS OR HI BEAMS DO NOT TURN "OFF"
DISCONNECT HEADLIGHT SWITCH CONNECTOR FROM

HEADLIGHT SWITCH.
DO HEADLIGHTS TURN "OFF"?
DISCONNECT CONNECTOR FROM

HEADLIGHT DIMMER SWITCH.
(LO BEAMS) REPAIR SHORT TO B + IN CKT 12.
(HI BEAMS) REPAIR SHORT TO B + IN CKT 11.
100 - 7
CHART #7
FOG LIGHTS DO NOT TURN "ON" BUT PARK LIGHTS OPERATE NORMALLY
HEADLIGHT SWITCH TO "PARK."

FOG LIGHT SWITCH CONN TERM "D".
IS TEST LIGHT "ON"?

FOG LIGHT SWITCH TO "ON."
FOG LIGHT SWITCH CONN TERM" A".
IS TEST LIGHT "ON"?
CHECK FOR POOR CONNECTION AT FOG LIGHT

SWITCH CONN TERM "D".
IF OK, REPAIR OPEN IN CKT 9 BETWEEN FOG
LIGHT SWITCH AND 5226.

FOG LIGHT SWITCH TO "ON."
REMOVE FOG LIGHTS RELAY FROM UNDERHOOD ELECTRICAL
CENTER.
WITH A TEST LIGHT TO GROUND, PROBE FOG LIGHTS RELAY
CAVITY wH2" IN THE UNDERHOOD ELECTRICAL CENTER.
IS TEST LIGHT "ON"?
CHECK FOR POOR CONNECTIONS AT FOG LIGHT

SWITCH CONN TERM "A" AND TERM "D".
IF OK, REPLACE FOG LIGHT SWITCH.
WITH A TEST LIGHT TO GROUND, PROBE FOG LIGHTS RELAY

CAVITY "H4" IN THE UNDERHOOD ELECTRICAL CENTER.
IS TEST LIGHT "ON"?
CHECK FOR POOR CONNECTION AT C200 TERM "A 16."

IF OK, REPAIR OPEN IN CKT 317 BETWEEN FOG LIGHT
SWITCH AND FOG LIGHTS RELAY LOCATED IN
CONNECT A FUSED JUMPER FROM FOG LIGHTS RELAY

CAVITIES "H4" TO "H1" IN UNDERHOOD ELECTRICAL CENTER.
DO FOG LIGHTS TURN "ON"?
CHECK FOG LIGHTS FUSE 2 LOCATED IN UNDERHOOD

ELECTRICAL CENTER FOR OPEN.
IF OPEN, CHECK FOR OPEN OR SHORT TO GROUND
THROUGH CKTS 1340 AND 34 INCLUDING FAUL TV RELAY.
IF FUSE CONTINUES TO BLOW, REFER TO CHART #10 IN
THIS SECTION.
WITH A TEST LIGHT TO B +, PROBE FOG LIGHTS RELAY

CAVITY "HS" IN UNDERHOOD ELECTRICAL CENTER.
IS TEST LIGHT "ON"?
CHECK FOR POOR CONNECTIONS AT FOG LIGHTS RELAY

IF OK, REPLACE FOG LIGHTS RELAY.
IF FOG LIGHT SWITCH "ON" INDICATOR LIGHT

ILLUMINATES WITH FUSED JUMPER INSTALLED, CHECK FOR
POOR CONNECTIONS AT FOG LAMP BULBS.
IF OK, CHECK FOR MULTIPLE BULB FAILURE.
IF FOG LIGHT SWITCH "ON"' INDICATOR LIGHT DOES NOT
ILLUMINATE WITH FUSED JUMPER INSTALLED, CHECK FOR
OPEN IN CKT 34 BETWEEN FOG LIGHTS RELAY AND S160.

FOG LIGHTS RELAY AND S152.
SA -
100 - 8

WITHOUT DRL(T61)
CHART #8
FOG LIGHTS DO NOT TURN "OFF"
FOG LIGHT SWITCH "OFF."

DISCONNECT FOG LIGHTS RELAY LOCATED IN UNDERHOOD
ELECTRICAL CENTER.
DO FOG LIGHTS REMAIN "ON" WITH RELAY REMOVED?
WITH A TEST LIGHT TO GROUND, PROBE FOG LIGHTS

RELAY CAVITY "H2" IN UNDERHOOD .ELECTRICAL CENTER.
IS TEST LIGHT "ON"?
DISCONNECT CONNECTOR FROM FOG LIGHT SWITCH.

WITH A TEST LIGHT TO GROUND, PROBE FOG LIGHTS
RELAY CAVITY "H2" IN UNDERHOOD ELECTRICAL CENTER.
IS TEST LIGHT "ON"?
REPAIR SHORT TO B + IN CKT 34

BETWEEN FOG LIGHTS AND FOG
LIGHTS RELAY.
REPAIR SHORT TO B + IN CKT 317 BETWEEN

FOG LIGHT SWITCH AND FOG LIGHTS RELAY.
CHART #9
ONE FOG LAMP INOPERATIVE
DISCONNECT CONNECTOR FROM FOG LAMP THAT DOES

NOT ILLUMINATE AND CONNECT A TEST LIGHT BETWEEN
TERMINALS" A" AND "B" OF THAT FOG LAMP CONNECTOR.
TURN PARK LIGHTS AND FOG LIGHTS "ON."
IS TEST LIGHT "ON"?

GROUND, PROBE THE SAME
FOG LAMP CONN TERM "A".
IS TEST LIGHT" ON"?
REPAIR OPEN IN GROUND CIRCUIT TO FOG LAMP

CONNECTOR (LH) CKT 150 OR (RH) CKT 250.
CHECK FOR POOR CONNECTIONS

AND FOG LAMP CONN
TERMINALS "A" AND "B".
IF OK, REPLACE FOG LAMP.

BETWEEN 5160 AND
INOPERATIVE FOG LAMP.
100 - 9
CHART #10
FUSE(S) BLOWS WHEN REPLACED OR WHEN ATTEMPTING TO USE LIGHTING SYSTEM
REPLACE BLOWN FUSE(S).

DOES FUSE BLOW BEFORE
ATTEMPTING TO OPERATE SYSTEM?
TEST SYSTEM ONE FUNCTION AT A

TIME, UNTIL FUSE BLOWS.
WHEN FUSE BLOWS, USE SCHEMATIC
TO DETERMINE WHAT CIRCUITS OR
COMPONENTS COULD BE FAILING.
USE A TEST LIGHT OR DVM TO
NARROW IN ON SHORT TO GROUND
POTENTIAL (DISCONNECTING
COMPONENTS IS HELPFUL WHEN
TRYING TO CHECK CIRCUITS THAT
SHOULDNOTBEATAGROUND
POTENTIAL).
USE SCHEMATICS AND DVM TO CHECK SUSPECT

POWER CIRCUITS FOR A SHORT TO GROUND
POTENTIAL, EITHER THROUGH A FAUL TY
COMPONENT OR IN WIRING.
CONNECT A DVM SET TO VOLTAGE ACROSS
FUSE TERMINALS. START BY DISCONNECTING
ONE COMPONENT AT A TIME.
IF ALL RELATED COMPONENTS ARE
DISCONNECTED AND SHORT IS STILL PRESENT,
LOCATE AND REPAIR SHORT IN WIRING.
CIRCUIT OPERATION
FOG LIGHTS
HEADLIGHTS
With the Headlight Switch in "HEAD" or "PARK,"

voltage is applied to one side of the Fog Light Switch.
When the Fog Light Switch is closed, voltage is applied
to one side of the Fog Lights Relay Coil, energizing the
relay (the other side of the coil is grounded through the
HI Beam Filament of the Headlamps).
When energized, the normally open contacts of the
Fog Lights Relay close, allowing voltage to be applied
to the Fog Lights.
When the HI Beams are activated, ground is
removed to one side of the Fog Lights Relay Coil, deenergizing the relay and turning off the Fog Lights.
Voltage is applied to the Headlight Switch at all

times from Fusible Link Z. When the Headlight
Switch is in "HEAD," voltage is applied to the HI and
LO Beam Circuits through the Headlight Dimmer
Switch.
At the same time, this voltage is applied to the
Headlamp Door Motor Assemblies, which allows the
doors to open.
When the HeadHght Switch is moved to "HEAD"
and the Headlight Dimmer Switch is placed in "LO,"
voltage is applied through the closed contacts of the
Headlight Dimmer Switch to the LO Beam Circuit of
the Headlights. When the Headlight Dimmer Switch
is placed in "HI," battery voltage is applied to the HI
Beam circuit of the Headlights, and the HI Beam
Indicator. The LH Headlamp, RH Headlamp, and the
HI Beam Indicator are permanently grounded so that
when battery voltage is applied, the lamps operate.
HEADLIGHTS AND FOG LIGHTS: DAYTIME RUNNING LIGHTS (T61)
I I
r1-----------
AMBIENT
LIGHTSENSOR
HOTIN RUN
Cd)
SEE BRAKE
WARNING SYSTEM
PAGE 8A-410
I
I
I
.5
YELi
.SLT GRN/ BLK
----------- G
------- I..
GAGES
FUSE 9
10AMP
~~:;~:~:ioN
PAGE 8A-103
IGN
(NOT USED}
.8 BRN
SEE FUSE
BLOCK DETAILS
PAGE8A-11-5
1137
-- - -- - - - - - - -- -
141
---J
.8 PNK
SEE FUSE
BLOCK DETAILS
PAGESA-11-4
5207
f,111
.... -
~r---------------
1138
BLK
.35 TANr33
WHT
TURN B-U
FUSE 2
20AMP
39
,I
5206
.8 BR;,.:41- - - - - - - - - - - - - - - - - - - - - - - - - - _.35 p:~3~
~IGNITION
LIGHT SENSOR
INPUT
LEFT
TURN
PARK
LEFT
RELAY
BRAKE
TURN
CONTROL INPUT GROUND INPUT
DRL CONTROL
LOGIC
SOLID STATE
RIGHT
TURN
INPUT
IGNITION
PARK
RIGHT
HEADLIGHT LIGHT
HEAD TURN
RELAY
RELAY
ON
RELAY
CONTROL
CONTROL INPUT CONTROL
EfA
.35LTB~U
1134
.SLTBLU/WHT
1414
BRAKE
PARK[}]
SWITCH
1415
.SLTBLU
.35 BLK
.5 DK BLU
14
TO INSTRUMENT
CLUSTER
LEFT TURN
INDICATOR
PAGE 8A-81-3
650
r-5217
Li----iJ
t.
~~!T~~~~~gN
PAGES 8A-14-8, 9
3 BLK
TO INSTRUMENT
CLUSTER
RIGHT TURN
INDICATOR
PAGE 8A-81-3
TURN/HAZARD
SWITCH ASSEMBLY
YEL
.8 YEL
18
DK GRN
--------N
.8 DK GRN
18
19
C216
19
SEE EXTERIOR LIGHTS

PAGE8A-110-1
650
15
.8 BRN
~-----------------------------Df,-~;~~~g__,l
6
- 5 2 1 6 D f . ' - - - - - - - - - - - - - - - - - - - -.
-.
..
.8LTBLU
3BLK
650
14 - - - - - - - - - --~S~;N-- -
I
BA
-----J;. -------~
'"'
5150.
I
L
PARK/TURN
LAMP, LEFT
FRONT
.8BLK
150
.8 BLK (WITHOUT PWR ACCESSORIES}
BLK
ACCESSORIES}
A
..ollllll_ _ 3_
_(WITH
_ _PWR
__
_ _ _ _.,.."111111.1
~
200
750
SEE
GROUND
DISTRIBUTION
PAGESA-14-7
~R~---- - - - - - - -
9
TOFRONT
MARKER LAMPS
AND
---......... HEADLIGHT
....,......DOORS
MODULE
PAGESA-110-3
~ ~; BLU
i
@
BA
15 PlOO
A
PARK/TURN
LAMP, RIGHT
FRONT
l._._____.,l
---------(
.8 BLK
250
102 - 1
HOT AT ALL TIMES
FUSIBLE
LINK Z
1 RUST
DRL MODULE
3 RED
C1 = BLUE CONNECTOR
C2 = BLACK CONNECTOR
702
.BORN
240
3 RED,WHT
.35 GRY
1372
,-------~----------------.....------------------""'I DAYTIME
RUNNING
---+-------+--
LIGHTS (DRL)
MODULE
SOLID STATE
DO NOT
MEASURE
RESISTANCE
HEADLIGHT
RELAY
--
OFF
OFF
HEAD
SWITCH
ILLUMINATION
LAMP
PARK
10
3 YEL
85
.8 BRN
10
10
C200D
C200B
G;SJ
1 YEL
10
.S BRN
HEADLIGHT
DIMMER
SWITCH
--
LO
.....
__
SWITCH
PAGE BA-102-2
1 LTGRN
1LTGRN
___
11..., _ _ _ _ _ _ _ _ _ _ _ _
1LTGRN
~ii
,
5153.
1 TANl:2
1 LTGR~11
1 TANl.2
1 LTGRN
HEADLAMP
DOOR ASSEMBLY,
..u
-
..Cf
-
..._ _
,...--
.:.r::60
'
:5::L:K::::::::::.8:B:LK::::::~::::::::::::::~1
3 BLK
~
150
~106
WITHT960NLY
1 T:Ni2---1~;~~1~
~,): :
c"i- - -
:1:::::::::~;
165
0
1 BLKl50
RELAY
TOFOGLIGHTS
PAGE 8A102-2
r - - - - - - - - ,I r - - - - - - - - ,
Lh!!-
SEE GROUND
DISTRIBUTION
PAGE SA-14-6
11
11
16
1T:N~;--~:T-G~i1~
.88RN
B>
11
1 T
WITHT960NLY
TO 1/P CLUSTER
PAGE SA-81-3
HI
TO FOG LIGHT
,,,,,.
SEE INTERIOR LIGHTS DIMMING

PAGE SA-117-1
TO HEADLIGHT
DOOR MODULE
PAGE SA-104-0
SEE EXTERIOR
LIGHTS
PAGE SA-110-4
_J L - - -
~
,,,,~..
c'j~ - - - - l
!!!!.J
1 BLK,50
1 B:Kr:~65
~~!T;~~~:N
PAGE BA-14-5
?.!1l. 3 BLK
250
----2105
HEADLAMP
DOOR ASSEMBLY,
FROM S226
PAGE SA-102-1
-,l/P
,FUSE
I BLOCK
1!'
DIMMER
FUSE 13
SAMP
--..J
.5 GRY
.5 BRN
SEE INTERIOR
S 2 2 4 - - ~ LIGHTS DIMMING
PAGESA-117-1
'"71
OFF
FOG LIGHT
CD
ON
CD
SWITCH
iiJ:uMINATION
LAMP
INDICATOR
~
(FOG LIGHTS ON)
WITHT96
ONLY
1 PPL
83
.35B: '1:50
,~
S216. -
.5 YEL
3 BLK
317
-
rS;P~=DISTRIBUTION
PAGE SA-10-0
I
I
I
I
I
I
I
I
I
I
UNOERHOOD
ELECTRICAL
CENTER
C2000
C200B
SEEGROUNO
- . . . . . DISTRIBUTION
PAGES SA-14-7, 8
.s
650
34
3 BLK
~~:200. . . . .1
.......
1340
1 PPL
.,.._...._._._,._.... FOG
LIGHTS
iiliAY"
WITHT96
ONLY
I
Ht HSI
L----------t----~I
1 PPL
34
1 LTGRN
11
c:Q
FROM S152
PAGE 8A-102-1
----------------------------------------~
Sf60.!III. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . .
1 p:134
1 p : f34
FOG LAMP,~
LEFTFRONT~
~ F O G LAMP,
RIGHTFRONT
8
1 BL:Jso
S113- 3 BLK
150
.....A..J106
1 BL KJ250
- ~ SEE GROUND
.......__
~ DISTRIBUTION
,.,.-- PAGES SA-14-5, 6
-5112
3 BLK
250
____aj105
34
102 - 3
12129077
BLK
HEADLIGHT SWITCH

CAVITY
WIRE COLOR
CKT
BRN
BLK
650
YEL
DESCRIPTION
PAGE
PARK LAMP FEED
SA-102-1
GROUND
SA-14-8
10
HEADLIGHTS ON
SA-102-1
GRY
SA-102-1
RED/WHT
1372
POWER FEED TO DRL MODULE - HEADLIGHT RELAY
SA-102-1
ORN
240
SA-102-1
RED
702
SA-102-1
~lt?ct?ct?
[~:U:~] rlJ cb
12064766
12064998
BLU
BLK
DAYTIME RUNNING LIGHTS (DRL) MODULE C1
DAYTIME RUNNING LIGHTS (DRL) MODULE C2
SA -
102 - 4
12004147
12064762
11-WAV F PACK-CON I
BLK
6-WA V F METRI-PACK 150 SERIES
FOG LIGHT SWITCH
COMPONENT
LOCATION
GRY
201-PG FIG.
Ambient Light Sensor

Mounted in top ofl/P, near Defrost Grill
45 ... 66
I/P Compartment ............................... . 7 .... 12 ..
Fog Lamp, Left Front .... . Lower LH side offront Fascia
Fog Lamp, Right Front .. . Lower RH side of front Fascia
Fog Light Switch ........ . Lower LH side ofl/P . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
57 ..
Headlamp, Left ......... . LH front of vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
63
Headlamp, Right ........ . RH front of vehicle
Multi-Function Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3, 35 . 5, 52
Headlight Switch . . . . . .. . LH side ofl/P . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . 38 . . . 57 . .
I/P Fuse Block . . . . . . . . . . . LH side ofl/P Carrier, on the side . . . . . . . . . . . . . . . . . . . 8 . . . . 15 . .
Park Brake Switch . . . . . . . In console, at base of Park Brake Lever . . . . . . . . . . . . . . 22
39
Park/Turn Lamp, Left Front Exterior, left front ................................ . 17
32
Park/Turn Lamp,
Right Front . . . . . . . . . . . . Exterior, right front .............................. . 17
32
Turn/Hazard Switch
Assembly . . . . . . . . . . . . . . Part of Steering Column .......................... . 3 .... 5
of wheelhouse ................................... . 19
36 ..
C160 (3 cavities) . . . . . . . . . LH Headlight to Forward Lamp Harn Jumper, behind
63
C165 (3 cavities) . . . . . . . . . RH Headlight to Forward Lamp Harn Jumper, behind
63
C200A (17 cavities)
72 ..
C200B (18 cavities)
72 ..
C200D (48 ca vi ties)
Steering Column ................................ . 47
72 ..
CONN
202-17
202-20
202-14
202-22
202-22
202-24
202-2
202-2
202-2
COMPONENT
C216 (11 cavities) ....... .
G105 ................... .
G106 ................... .
G200 ................... .
PlOO
Sll2
8113
8150
8152
8153
8160
8206
8207
8216
8217
8226
S227
201-PG
LOCATION
Attached to base of Steering Column . . . . . . . . . . . . . . . . 34
Near top RH side ofradiator, in top ofT-Bar . . . . . . . . . . 19
Near top LH side ofradiator, in top ofT-Bar . . . . . . . . . . 19
Compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Center breakout
Forward Lamp Harn, approx 7 cm forward of Electrical
Center breakout, on lighting branch
Center breakout
Forward Lamp Harn, at Air Pump breakout
Forward Lamp Harn, approx 4 cm from Cruise Control
Module breakout
breakout
Under RH side of 1/P, behind kick panel
FIG.
51
36
35
102 - 5
CONN
202-5
16
36

Diagnosis)
System
1. Make sure Headlights and Park Lights operate

normally when using the Light Switch before
proceeding with Daytime Running Lamp (DRL)
diagnosis.
2. Make sure the Brake Warning System is
functioning properly. DRL will not turn "ON" if
Park Brake is "ON."
3. Check Fusible Link Z for open.
4. Check Turn B-U Fuse 2, Gages Fuse 9 and TAIL
LTS Fuse 10 for open. Iffuse(s) are blown, replace
fuse(s). If fuse(s) re-blows, check for short to
ground through the suspected circuit(s).

SYSTEM DIAGNOSIS
SA.:
102 - 6

SYMPTOM TABLE
SYMPTOM
PROCEDURE
PAGE NUMBER
DRLwill not turn "ON."
Chart #1
8A-102-6
DRL operates normally in daytime, but Park Lights and

Headlights will not turn "ON" automatically at dark.
Chart #2
8A-102-8
Park Lights will not turn "ON" automatically at dark

(Headlights turn "ON" OK).
Chart #3
8A-102-8
Headlights will not turn "ON" automatically at dark

(Park Lights turn "ON" OK).
Chart #4
8A-102-8
Park Lights always stay "ON" during daylight hours

(Headlights remain "OFF").
Chart #5
8A-102-9
Headlights always stay "ON" during daylight hours

(Park Lights remain "OFF").
Chart #6
8A-102-9
Park Lights and Headlights remain "ON" during

daylight hours.
Chart #5
Chart #6
8A-102-9
8A-102-9
LH Front Turn Signal inoperative.
Chart #7
8A-102-9
RH Front Turn Signal inoperative.
Chart #8
SA-102-10
Fog Lights entire system inoperative or individual For diagnosis, refer to "Headlights," page 8A-100-0.
lamp inoperative.
CHART #1
DRL WILL NOT TURN "ON"
DISCONNECT DRL MODULE CONN C1 (BLUE).

CONNECT A TEST LIGHT BETWEEN TERM "C" OF CONNECTOR AND GROUND.
IS TEST LIGHT "ON"?
AT SAME CONNECTOR, CONNECT THE TEST

LIGHT BETWEEN TERM "F" AND GROUND.
IS TEST LIGHT "ON"?
CHECK GAGES FUSE FOR OPEN.

IF OPEN, CHECK FOR SHORT TO GROUND THROUGH CKT 39.
CHECK FOR OPEN IN CKT 39 TO DRL MODULE.

LIGHT BETWEEN TERMINALS "A" AND "F".
IS TEST LIGHT "ON"?
CHECK TURN B-U FUSE FOR OPEN.

IF OPEN.CHECK FOR SHORT TO GROUND THROUGH CKT 141.
CHECK FOR OPEN IN CKT 141 TO DRL MODULE.
102 - 7

LIGHT BETWEEN TERMINALS "E" & ''f''.
PARK BRAKE "OFF."
DOES TEST LIGHT STAY "OFF"?
REPAIR AN OPEN OR SHORT TO B + IN GROUND

CKT 650 BETWEEN DRL MODULE AND G200.
USING A DVM SET TO OHMS SCALE, CONNECT THE RED &

SLACK METER LEADS ACROSS TERMINALS "G" & "H" OF
CONN C1.
WHILE OBSERVING THE DVM, SHINE A BRIGHT LIGHT AT THE
DRLAMBIENT LIGHT SENSOR AT THE TOP OF THE
INSTRUMENT PANEL AND THEN COVER THE LIGHT SENSOR
WITH HEAVY MATERIAL.
DID THE RESISTANCE CHANGE SIGNIFICANTLY?
CHECK FOR PROPER ADJUSTMENT OF PARK BRAKE SWITCH.

CHECK FOR SHORT TO GROUND IN CKT 1134 BETWEEN
PARK BRAKE SWITCH AND DRL MODULE.
IF OK, REPLACE PARK BRAKE SWITCH.
SACKPROBE DRL MODULE CONN C2 (BLACK) WITH THE TEST

LIGHT BETWEEN TERM "F" AND GROUND.
HEADLIGHTS TURNED "OFF" AT LIGHT SWITCH.
DOES TEST LIGHT STAY "OFF"?
CHECK FOR AN OPEN OR SHORT TO GROUND

(ORB+) IN CKT 1137 OR CKT 1138.
IF OK, REPLACE AMB.IENT LIGHT SENSOR.
CHECK FOR SHORT TO B + IN CKT 10.

IF NOT SHORTED, REPLACE HEADLIGHT SWITCH.
DOT.HE FRONT TURN SIGNAL BULBS ILLUMINATE NORMALLY

WHEN USING TURN SIGNAL LEVER?
PERFORM CHART #7, "LH FRONT TURN SIGNAL INOPERATIVE,"

PAGE SA-102-9 AND/OR CHART #8, "RH FRONT TURN SIGNAL
INOPERATIVE," PAGE 8A-102-10.
102 - 8
SA -
rn
CHART #2
CHART #3
DRL OPERATES NORMALLY IN DAYTIME,

BUT PARK LIGHTS AND HEADLIGHTS DO NOT
TURN "ON" AUTOMATICALLY AT DARK
PARK LIGHTS WILL NOT TURN "ON"

AUTO MA Tl CALLY AT DARK
(HEADLIGHTS TURN "ON" OK)
rn
IMPORTANT:
MAKE SURE PARK LIGHTS AND HEADLIGHTS OPERATE

PROPERLY FROM HEADLIGHT SWITCH BEFORE
PROCEEDING. IF NOT, REFER TO "EXTERIOR LIGHTS,"
PAGE SA-110-0 FOR PARK LIGHT DIAGNOSIS AND/OR
"HEADLIGHTS," PAGE SA-100-0 FOR HEADLIGHT
DIAGNOSIS.
DISCONNECT DRL MODULE CONN C1 (BLUE).

USING A DVM SET TO THE OHMS SCALE, CONNECT THE RED
& BLACK METER LEADS ACROSS TERMINALS "G" & "H" OF (1.
WHILE OBSERVING THE RESISTANCE ON THE DVM, SHINE A
BRIGHT LIGHT INTO THE DRL AMBIENT LIGHT SENSOR (AT THE
TOP OF THE INSTRUMENT PANEL), THEN COVER THE LIGHT
SENSOR WITH A PIECE OF HEAVY MATERIAL.
DID THE RESISTANCE MEASUREMENTS CHANGE
SIGNIFICANTLY?
CHECK FOR POOR

CONNECTION AT
THE DRL MODULE.
IF OK, REPLACE THE
DRLMODULE.
CHECK FOR AN OPEN, SHORT TO

GROUND, OR SHORT TO B + IN
CKT 1137 OR CKT 1138.
IF OK, REPLACE DRL AMBIENT
LIGHT SENSOR.
MAKE SURE PARK LIGHTS OPERA TE NORMALLY

FROM HEADLIGHT SWITCH BEFORE PROCEEDING. IF
NOT OPERATING NORMALLY, REFER TO "EXTERIOR
LIGHTS," PAGE SA-110-0 FOR DIAGNOSIS.
DISCONNECT DRL MODULE CONN C2 (BLACK).

CONNECT A TEST LIGHT BETWEEN TERM "A" OF
IS TEST LIGHT "ON"?
RECONNECT CONN (2.

COVER DRL AMBIENT LIGHT
SENSOR WITH HEAVY
MATERIAL.
BACKPROBE CONN C2 WITH
THE TEST LIGHT BETWEEN
TERM "H" AND GROUND.
IS TEST LIGHT "ON"?
IMPORTANT:
CHECK FOR OPEN

TAILLTSFUSE.
IF OPEN, CHECK FOR
SHORT TO GROUND
THROUGH CKT 240.
CHECK FOR OPEN IN
CKT 240 BETWEEN 1/P
FUSE BLOCK AND
DRLMODULE.
DRL MODULE AND 5226.
CHART #4
rn
HEADLIGHTS WILL NOT TURN "ON" AUTOMATICALLY AT DARK

(PARK LIGHTS TURN "ON" OK)
IMPORTANT:
MAKE SURE HEADLIGHTS OPERA TE NORMALLY FROM HEADLIGHT SWITCH BEFORE
PROCEEDING. IF NOT, REFER TO "HEADLIGHTS," PAGE SA-100-0 FOR DIAGNOSIS.

CONNECT A TEST LIGHT BETWEEN TERM "D" OF CONNECTOR AND GROUND.
IS TEST LIGHT "ON"?
CONNECT A FUSED JUMPER BETWEEN TERM "F"

AND TERM "D" OF DRL MODULE CONN C2.
DO HEADLIGHTS TURN "ON"?

AT DRL MODULE CONN C2.

DRL MODULE AND 5227.
CHECK FOR AN OPEN IN CKT 1372 BETWEEN

HEADLIGHT SWITCH AND DRL MODULE.
IF OK, REPLACE LIGHT SWITCH.
CHART #5
CHART #6
PARK LIGHTS ALWAYS STAY "ON"

DURING DAYLIGHT HOURS
(HEADLIGHTS REMAIN "OFF")
HEADLIGHTS ALWA VS STAY "ON"

DURING DAYLIGHT HOURS
(PARK LIGHTS REMAIN "OFF")

DO PARK LIGHTS TURN "OFF"?
r-
----------------,
REPAIR SHORT TO B + IN :
CKT9.
1
I
FOR A COMPLETE
I
CIRCUITSCHEMATIC
:
REFER TO "EXTERIOR
I
I
LIGHTS," PAGE BA-110-0. 1
I
I
:
I
I
DISCONNECT DRL CONN C2 (BLACK).

----------------,
:
:
CHECK FOR SHORT TO

:
B + IN CKT 10.
1
REFER TO "HEADLIGHTS," :
PAGE SA-100-0 FOR
:
FURTHER DIAGNOSIS.
1
~------------------~
I
L------------------J
CHART #7
LH FRONT TURN SIGNAL INOPERATIVE
rn
102 - 9
IMPORTANT:
MAKE SURE THE DRL SYSTEM OPERATES NORMALLY (FRONT
TURN SIGNAL BULBS ILLUMINATE DURING DAYLIGHT HOURS)
BEFORE PROCEEDING. IF NOT OPERATING CORRECTLY, PERFORM
CHART #1, "DRL WILL NOT TURN 'ON."'

WITH A TEST LIGHT TO GROUND, BACKPROBE DRL
MODULE CONN C2 TERM "E".
DOES TEST LIGHT ILLUMINATE (OR FLASH ON & OFF)
WHEN TURN SIGNAL LEVER IS MOVED TO THE "LEFT
TURN" POSITION?
BACKPROBE SAME CONNECTOR

WITH THE TEST LIGHT BETWEEN
TERM "B" AND GROUND.
DOES TEST LIGHT ILLUMINATE WHEN
THE TURN SIGNAL LEVER IS MOVED
TO THE "LEFT TURN" POSITION?
----------------------------------,
CHECK FOR POOR CONNECTION AT DRL MODULE.

:
CHECK FOR AN OPEN IN CKT 1414 BETWEEN
I
TURN/HAZARD SWITCH ASSEMBLY AND DRL MODULE. :
IF OK, REFER TO "EXTERIOR LIGHTS," PAGE BA-110-0
FOR FURTHER DIAGNOSIS.
1
L------------------------------------~
CHECK FOR POOR CONNECTIONS AT DRL

MODULE CONN C2 TERMINALS "E" AND "B".
SA -
102 - 10

CHART #8
RH FRONT TURN SIGNAL INOPERATIVE
rn
IMPORTANT:
MAKE SURE THE DRL SYSTEM OPERA TES NORMALLY (FRONT TURN SIGNAL BULBS ILLUMINATE DURING
DAYLIGHT HOURS) BEFORE PROCEEDING.
IF NOT OPERATING CORRECTLY, PERFORM CHART #1, "DRL WILL NOT TURN 'ON."'

WITH A TEST LIGHT TO GROUND, BACKPROBE DRL MODULE CONN C2 TERM "G".
DOES TEST LIGHT ILLUMINATE (OR FLASH ON & OFF) WHEN TURN SIGNAL LEVER IS
MOVED TO THE "RIGHT TURN" POSITION?
BACKPROBE SAME CONNECTOR WITH THE TEST LIGHT

BETWEEN TERM "C" AND GROUND.
DOES TEST LIGHT ILLUMINATE WHEN THE TURN SIGNAL
LEVER IS MOVED TO THE "RIGHT TURN" POSITION?
r- -------------------------------------,
1
::
:
1
~~:~~ ~~: :~~Rp~~~:~~~ ~4~: ;~T~:~~~~~/HAZARD i
SWITCH ASSEMBLY AND DRL MODULE.

IF OK, REFER TO "EXTERIOR LIGHTS," PAGE SA-110-0 FOR
FURTHER DIAGNOSIS.
:
I
L----------- ---------------------------j
CIRCUtT OPERATION
The Daytime Running Lamp (DRL) system
consists of a Control Module and an Ambient Light
Sensor.
During daylight hours, the DRL Module turns
"ON" the Front Turn Signal Lights if 1.) Ignition is
"ON," 2.)The Headlights are "OFF" and 3.) If the Park
Brake is "OFF." As darkness approaches, the DRL
Module will turn "OFF" the Front Turn Signal Lights
and turn "ON" the Park Lights and Headlights.
The DRL Module determines daylight or
nighttime hours by receiving voltage from the
Ambient Light Sensor. As darkness approaches the
Ambient Light Sensor will change resistance and thus
change the voltage received by the DRL Module.
The Control Logic within the DRL Module receives
its voltage from the Turn B-lJ Fuse 2 and the Gages
Fuse 9. The Gag~s Fuse also supplies voltage to the
CHECK FOR POOR CONNECTION AT DRL MODULE

CONN C2 TERMINALS "C" AND "G".
relays within the DRL Module and supplies voltage to

the Front Turn Signal bulbs during DRL operation
through the Left and Right DRL Relays within the
DRL Module. The Headlight Switch supplies voltage
for the Headlights, through the Headlight Relay
contacts within the DRL Module, during nighttime
hours. The Tail Fuse supplies voltage to the Park
Lights during nighttime hours.
During DRL operation, the Turn Signals and
Hazard Flasher will operate normally. The Park
Lights and/or the Headlights may be operated
manually at any time by using the Light Switch.
The DRL Module will not operate if the system
voltage is less than 9 volts or greater than 18 volts.
When the Park Lights/Headlights are turned
"OFF," and the Ambient Light Sensor indicates a
night condition, the Park Lights will illuminate when
Ignition Switch is moved to "CRANK" position.
BLANK
102 - 11
SA -
HEADLIGHT DOORS
HOT AT ALL TIMES
HOT AT ALL TIMES
f --,
r - - - - - - - - - - - - - - - -
: ~--~.~;---------------~~1- ,,.,
~~-r
-~K
r""
HEADLIGHT
L-----~---------- --~
E
.5 BRN
'
:r
WITHOUTT61
1 ORN
840
10RN
HT
740
'\
3YEL
10
3YEL
r- - - - - -
I
I
PARK
LIGHTS
ON
~N~T -
~T~T ..I MODULE
Fy-----;\.'c2
H
L-
DAYTIME
RUNNING
LIGHTS
(DRL)
I HEADLIGHTS
I ON
5227
rnf, ",
'"I
r--.:.,,:1-
.SBRN
- - - - - 5226
"''"'""'
LIGHTS
PAGESSA-1102, 3, 4
'Y
'f""
C200D
PlOO
.SBRN
L..----5150
------------------~-~-~--' "~~- --------------------__ "j~
HEADLIGHTS
ON INPUT
BATTERY
RIGHT BAT
REFERENCE
HEADLIGHT
DOORS
MODULE
PARK LIGHTS
ON INPUT
SOLID STATE
OUTPUT
OUTPUT
_.n..n.r,...
LEFT BAT
REFERENCE
.COAST
DRIVr
SENSE
INPUT
OPEN/CLOSE
RELAY
CONTROL
OUTPUTS RAPIDLY SWITCH

BETWEEN DRIVE ANO COAST
- MOTORS ARE POWERED IN DRIVE
VOLTAGE FROM TURNING MOTOR
IS SENSED IN COAST
LOW COAST VOLTAGE INDICATES
ACTUATOR IS AT END OF TRAVEL,
STUCK OR DISCONNECTED. OUTPUT
STAYS IN COAST WHEN LOW COAST
VOLTAGE IS SENSED. OR AFTER 6
SECONDS. MOTOR STOPS.
..r"\M.r"L
. . .r f "SENSE
INPUT
-=-
GROUND
RELAY
COIL
OPEN
c
1 LTGRN
~
~
SEE PAGE 8A-3-0
FOR PROPER
HANDLING
PROCEDURES
':. ~~~-- ------__. . L----"'~"---------
OPEN
D
576
1 DK GRN
CLOSE
-------------------
8
DTC1
577
1 LTBLU
578
1 DK BLU
579
3 BLK
150
3BLK
150
r-~
l
B
GRY/BLK
HEADLAMP
DOOR MOTOR, LH
A
DK GRN,WHT
B
GRY/BLK
SEE GROUND
DISTRIBUTION
PAGE BA-14-6
HEADLAMPP'"~l'-~~~~~~~__.l'-'""'1
DOOR MOTOR, RH
15300030
15300029
BLK
BLK
HEADLIGHT DOORS MODULE ((1)
HEADLIGHT DOORS MODULE (C2)
COMPONENT
LOCATION
201-PG

1/P Compartment
Headlamp Door Motor, LH
LH front of vehicle
Headlamp Door Motor, RH
RH front of vehicle
Multi-Function Lever ........................... .
Headlight Doors Module . . Forward of LH front wheelhouse, mounted to Air Intake
Headlight Switch . . . . . . . . LH side of 1/P .................................... .
of wheelhouse ................................... .
C200B (18 cavities)
C2000 (48 cavities)
Steering Column ................................ .
G106
Near top LH side ofradiator, in top ofT-Bar ......... .
PlOO
Compartment ................................... .
S113
Center breakout
S150
S226
S227
FIG.
7 .... 12
104 - 1
CONN
202-17
43 ... 63
3, 35 . 5,52
19
36
38
57
202-21
202-14
19
36 ..
202-24
47
72
202-2
47
19
72
35
202-2
19
36
SA -
104 - 2
HEADLIGHT DOORS
(Perform before
Diagnosis)
1.
2.
3.
4.
5.
beginning
System
Before doing Electrical Diagnosis, check the

mechanical linkages attached to the Headlamp
Doors for binding, breakage, etc.
Check for corrosion at the Headlamp Door Motor
connector terminals.
If Headlamp Doors open slowly, check that G106 is
clean and tight and also that the battery is good
and fully charged.
If Headlamp Doors open only partially and no
problems were found with mechanical linkages on
Headlamp Doors, perform Chart #1.
If Headlamp Doors pop up without requesting
Headlights, check for bulletins to determine if a
correction is necessary.

useful in detecting re sis ti ve circuits (see
SYSTEM DIAGNOSIS
SYMPTOM TABLE
PROCEDURE
PAGE NUMBER
Both Headlamp Doors remain open or closed.
Chart #1
8A-104-3
LH Headlamp Door stays open or closed.
Chart #2
8A-104-3
RH Headlamp Door stays open or closed.
Chart #3
8A-104-4
SYMPTOM
104 - 3
CHART #1
BOTH HEADLAMP DOORS REMAIN OPEN OR CLOSED
rn
IMPORTANT:
IF HEADLIGHTS STAY ON All THE TIME OR DO NOT TURN ON AT ALL,
REFER TO "HEADLIGHTS," PAGE SA-100-0.
DISCONNECT CONN C1 AT HEADLIGHT DOORS MODULE.

CONNECT A TEST LIGHT BETWEEN TERMINALS "O" & "E" OF
CONNECTOR ANO THEN BETWEEN TERMINALS "O" & "B".
TEST LIGHT SHOULD ILLUMINATE BOTH TIMES. DOES IT?
CONNECT THE TEST LIGHT BETWEEN

TERMINALS "A" & "O" OF C1.
DOES THE TEST LIGHT ILLUMINATE
WHEN HEADLIGHTS ARE TURNED "ON"?
CHECK FOR OPEN IN GROUND CKT 150 FROM

HEADLIGHTS DOOR MODULE TO G106.
CHECK LH AND RH HEADLAMP DOOR FUSES FOR OPEN
ALSO CHECK FOR OPEN IN CKT 740 ANO CKT 840.
IF FUSE(S) ARE BLOWN CHECK FOR SHORT TO GROUND
THROUGH CKT 740 AND/OR CKT 840.

HEADLIGHT SWITCH AND HEADLIGHT
DOORS MODULE.

HEADLIGHT DOORS MODULE.
IF OK, REFER TO CHARTS 2 & 3 FOR
INDIVIDUAL HEADLAMP DOOR
DIAGNOSIS.
IF OK, REPLACE HEADLIGHT DOORS
MODULE.
CHART #2
LH HEADLAMP DOOR STAYS OPEN OR CLOSED
DISCONNECT LH HEADLAMP DOOR MOTOR 2-WAY CONNECTOR.

CONNECT A FUSED JUMPER FROM THE BATTERY POSITIVE
TERMINAL TO TERM "A" OF DOOR MOTOR2-WAY CONNECTOR.
CONNECT A JUMPER FROM TERM "B" OF CONNECTOR TO GROUND.
IF DOOR WAS OPEN, IT SHOULD NOW CLOSE. DOES IT?
REVERSE THE WIRES TO TERMINALS" A" & "B"

(GROUND TO TERM" A").
IF DOOR WAS CLOSED, IT SHOULD NOW OPEN. DOES IT?
CHECK FOR A SHORT TO GROUND, SHORT TO

B + OR AN OPEN IN THE TWO WIRES FROM THE
HEADLIGHT DOORS MODULE TO THE HEADLAMP
DOOR MOTOR CONNECTOR (CKTS 576 & 577).
IF WIRES ARE OK, REPLACE THE HEADLIGHT
DOORS MODULE.
DOOR MOTOR ASSEMBLY.
8A -
104 - 4
HEADLIGHT DOORS
CHART #3
RH HEADLAMP DOOR STA VS OPEN OR CLOSED
DISCONNECT RH HEADLAMP DOOR MOTOR 2-WAY CONNECTOR.

CONNECT A FUSED JUMPER FROM THE BATTERY POSITIVE TERMINAL TO
TERM" A" OF DOOR MOTOR 2-WAY CONNECTOR.
CONNECT A JUMPER FROM TERM "B" OF CONNECTOR TO GROUND.
IF DOOR WAS OPEN, IT SHOULD NOW CLOSE. DOES IT?
REVERSE THE WIRES TO TERMINALS "A" & "B" {GROUND

TO TERM" A").
IF DOOR WAS CLOSED, IT SHOULD NOW OPEN. DOES IT?
CHECK FOR A SHORT TO GROUND, SHORT

TO B + OR AN OPEN IN THE TWO WIRES
FROM THE HEADLIGHT DOORS MODULE TO
THE HEADLAMP DOOR MOTOR
CONNECTOR (CKTS 578 & 579).
IF WIRES ARE OK, REPLACE THE HEADLIGHT
DOORS MODULE.
REPLACE THE RH HEADLAMP

DOOR MOTOR ASSEMBLY.
CIRCUIT OPERATION
Voltage to open the Headlamp Doors and to power
the solid state circuitry is applied to the Headlight
Doors Module at all times at terminals "B" and "E" of
Cl. When the Headlights are turned "ON", voltage is
applied to terminal "A" of Cl as a request for the
Headlamp Doors to open.
When the Headlights are turned "ON", ground is
applied to the relay coil within the Headlight Doors
Module. The relay contacts close and voltage is
applied to the Headlamp Door Motor Assemblies.
Ground is provided for the motors through the solid
state circuitry until the Headlamp Doors are open.
The ground circuit for each Headlamp Door Motor is
rapidly switched within the Headlight Doors Module
between a ground potential and a high impedance
sense input. This input monitors for a fully open
Headlamp Door and will allow ground to be provided
until open or up to 6 seconds. A difficult to open or
obstructed door will be sensed as fully open and ground
will be removed by the module.
When the Headlights are turned "OFF", the
ground to the relay coil within the module is removed.
The contacts then return to the normally closed
position which switches power and ground to the
Headlamp Door Motors. The Headlamp Door Motors
run in the opposite direction to close the Headlamp
Doors. The ground circuit operation within the
module is the same during the closing sequence as
during the opening sequence.
104 - 5
8A -
110 - 0
EXTERIOR LIGHTS
TURN/HAZARD/STOP/PARK/FRONT MARKER
I~
I
I
SEE FUSE
BLOCK DETAILS
PAGE SA-11 5
HOTINRUN
.8BRN
HOTATALLTIMES
--------- ---~w
SEE POWER
DISTRIBUTION
PAGE SA-10-1
TURN/BU
FUSE 2
20 AMP
STOP/HAZARD
FUSE 6
20 AMP
I FUSE
BLOCK
I
141
.SORN
.---5207
.8 BRN""141
A [ 5 ] ;~::HER
rn:
-i
~itHRE~ : CENTER
I. :, '~- ----_:~:-1~~~~
PPL
I
I
16
I
I
BRN
r-------
140
CONVENIENCE
111
y!I-C - - - - - - - - ~ 8
0LTBLU - - - - - - - r 1 1
2 16
WHT
27
20
1TURN/HAZARD
HAZARD SWITCH
SWITCH
I ASSEMBLY
- I
I
I
I
TURN
LEFT
LTBLU
TURN
RIGHT
DK BLU
____________ J
L-----
DKGRN
19
YEL
18
H
.5 LTBLU
.5 LT BLUIWHT
.5 DK BLU
.5 DK BLU,WHT
14 (WITHOUTT61)
1414 (WITH T61)
15 (WITHOUTT61)
1415 (WITH T61)
814
.SLTBLU
.5 LT BLUIWHT
14 (WITHOUTT61)
1414 (WITH T61)
-r -----
BS
r - ,f:" -
- - - - - LH
RH
~TURN
INDICATOR
TURN~
INDICA"rORW
t ...
I \it,)
I
I
L-
IN~C~O~ -
,::,f~
I (_LUSI_~f!
I
~
~ ....
V
-
1 INSTRUMENT
...
-
SEE 11P
CLUSTER
..:A!! ~8:.:!
I
I
J
5216-----,
3BLKl650
L_
G
200
3 BLK
750
1111111
SEE GROUND
DISTRIBUTION
PAGESSA-14-7,8
SEE PAGE BA-1102 FOR VEHICLE WITHOUT DAYTIME RUNNING LIGHTS (T61)
SEE PAGE 8A-1103 FOR VEHICLE WITH DAYTIME RUNNING LIGHTS (T61)
.5 DK BLU
.5 DK BLUIWHT
15 (WITHOUTT61)
1415 (WITH T611
l
l
.8 VEL
820
.SORN
110 - 1
140
Q ~
.8LTBLU
P410
TO AUTO TRANS
PAGE 8A-20-6 (VG VIN S)
8A-21-6 (V8 VIN P)
20
(NOT USED WITH MANUAL TRANS)
...------
5460
VEL
5243
.8 VEL
820
VEL
820
820
CD
"'f'
TO 5271
PAGE 8A-34 1
BLK
CD
1150
T,
BLK
CENTER HIGH
MOUNTED
STOPLIGHT
(CHMSL)
1150.
5450
DKGRN
1'"' "---------~~'1-'" t ""m, """*,'.;,w,rnoom'I
~,-----::L-----19-----M;i
(216
TO~l::RC49
DEFOGGER
PAGESA-61-0
5:410
BTc
420
mo
SEE PAGE
8A-110-4
18 _________s:9'.'
3 BLK
...
t Al
.8 VEL
.8 BRN
- - - - - - - - - . 5401
.8B:N
G
8 BLK
'""
18
TAILtSTOP/
TURN LAMP,
LH OUTBOARD
5402
.sv;f1s
Q
B
TAIL/STOP/
TURN LAMP,
LH INBOARD
---------.
1250
8 B~Kf 250
.5 BLK
.5 BLK
1250
P400
~~:119
1250
19
TAIL/STOP/
TURN LAMP,
RH INBOARD
Al
.1______..
.8 B~Kr:250
5410
'-- _
.8 DK GRN
1150 IWITH C49)

P300
-
G
.8 BLK
_c310
TAIL/STOP/
TURN LAMP,
RH OUTBOARD
1250
5415
SEE GROUND
DISTRIBUTION
PAGE SA-14-11
SEE PAGE 8A-3-0

FOR PROPER
HANDLING
PROCEDURES
SEE PAGE 8A-3-0

FOR MEASURING
AND HANDLING
PROCEDURES
SA -
EXTERIOR LIGHTS
WITHOUT DAYTIME RUNNING LIGHTS (T61)
FROM PAGE8A-1100
I-,
HOT AT ALL TIMES
Ir - -
:-i-
I
I
.5 LT BLU
14
I HEADLIGHT
SWITCH
HEAD
PARK
L--
SEE EXTERIOR
LIGHTS
PAGE 8A 110-4
,u:J
I
I
--.I
.5 DK BLU
15
.8 DK
15
~--5226
.8 BRN
.8 BRN
9
.8 LT BLU
OFF
14
.5 BRN
.5 BRN
.5 BRN
c,
I"" -
BLU
,Q
-, HEADLIGHT
,-I DOORS
MODULE
PARK/TURNQ
LAMP,
LEFT FRONT
MARKER L A M P , ~
LEFT FRONT\V
~
\J:.)
.5 BLK
150
~..oillllll
5113. -
150
PARK1TURN
LAMP,
RIGHT FRONT
250
.8 BLK
150
_........ SEE GROUND

~. -
~ DISTRIBUTION
PAGE 8A145
3 BLK
PAGE 8A-146
3 BLK
Bl ,
MARKER LAMP,
RIGHT FRONT
SEEGROUND
~ DISTRIBUTION
..I
.5 BLK
.8 BLK
L. -
Al ,
Al ,
Bl ,
250
250
110 - 3
EXTERIOR LIGHTS
WITH DAYTIME RUNNING LIGHTS (T61)
FROM PAGE 8A-110-0
HOT AT All TIMES
.8LTBLU
14
.8 DK
BLU
.5 BRN
.5 BRN
.5 BRN
MARKER L A M P . ~
LEFT FRONT\V
~MARKER LAMP,
WRIGHT FRONT
.5 BLK
.8BLK
150
.5 BLK
5113. -
PAGE 8A-14-6
3 BLK
150
,-~
I DOORS
L. -
.J
PARKITURNQ
LAMP,
RIGHT FRONT
G
250
.8 BLK
150
~~
SEEGROUND
~ DISTRIBUTION
-, HEADLIGHT
C1
MODULE
PARK/TURNQ
LAMP,
LEFT FRONT
r"' -
15
~ -
3 BLK
250
SEEGROUND
DISTRIBUTION
PAGE 8A-14-5
250
SEE PAGE 8A-3-0

FOR PROPER
HANDLING
PROCEDURES
AW~
SEE PAGE 8A-3-0
FOR MEASURING
ANO HANDLING
PROCEDURES
SA -
110 - 4
EXTERIOR LIGHTS
REAR MARKER/LICENSE/TAIL
--,~
FUSE
I BLOCK
I
I
_ _ ...J
L---.8oRN
RADIOr"" -
WITHT96
r- -
-,
L . - ...
6
g_
.5 BRN
240
.,1/P
DIMMER
SWITCH
I
I
I
I
.5 BRN
I RUNNING
LIGHTS
I (DRL)
I
L. -
L . - ....
..I MODULE
r- - -, DA'fTIME
.5 BRN
WITHT61
....
.5 BRN
I
r- -
I
I
L. D
-,FOG
LIGHT
SWITCH
.8 BRN
TO
C200D
.8BRN
WITH
T61 CAVITY 04~
..._._ _ _
_ __ ,
PAGE 8A110-3
WITHOUTT61
PAGE SA-110-2
.5 BRN
.5 BRN
9
SEE PAGE
8A-110-1
SEE PAGE
8A-110-1
.8 BRN
.8 BRN
.8 BRN
S40d
.8 YEL
B
A
.8 YEL
\..Vht!
B
.58RN
M1!~E:.
OUTBOARD
~
\V
.5BLK
~
\V
1250
.8 BLK
1250
.5 BLK
1250
))
.5 BLK
1250
~A~:.ER
RIGHT REAR
TAlliSTOP/Q
TURN
LAMP, RH
OlJTBOARD
G
.5 BLK
1250
.8BLK
1250
.8 BLK
1250 .5 BLK
5430
.....................................................
C430
.5 BLK
1250
.5 BLK
1250
SEE PAGE 8A-3-0

FOR PROPER
HANDLING
PROCEDURES
TAILLAMP,
~
1250 B
.5 BLK
.8 BLK
Brc_ .
G)
TAIL!STOPQ
TURN LAMP,
RH INBOARD
LEFT REAR
19
.8DKl19
GRN
A
G
TAIL/STOP/
TURN
LAMP, LH
.8 DK GRN
TAIL1STOP1
TURN LAMP,
LHINBOARD
~TAILLAMP,
S40218
18
A~
18
9. DKt .8 BRN
8
9
GRN
d..- -1111B111LKllllllll,I.
8
......BLK--,b~ TO BACKUP LAMP ....
1111"'
PAGE8A-112-0
...
1250
_....olllllll SEE GROUND

,,,,.. . _ - . . . . . . DISTRIBUTION
'---PAGE8A-14-11
----.9-400
~---~
1250
5415
1250
110 - 5
EXTERIOR LIGHTS
C216
12004147
11-WAY F PACK-CON I
BLK
201-PG FIG.
COMPONENT
LOCATION
Audio Alarm Module

Brake Switch Assembly . . .
Mounted into Convenience Center

with Automatic), (1 conn with Manual) . . . . . . . . . . . . . 0 . . . . 1
Center High Mounted Stop

Light (CHMSL) . . . . . . . . . Rear center of Spoiler
Convenience Center . . . . . . Left of Steering Column, mounted to bottom of
I/P Carrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 . . . . 15 . .
I/P Compartment ............................... . 7 " " 12
Fog Light Switch ........ . Lower LH side ofl/P .............................. . 38
57
Headlight Doors Module .. Forward ofLH front wheelhouse, mounted to Air Intake 19
36
Headlight Switch ....... . LH side of I/P .................................... . 38
57
I/P Dimmer Switch ...... . Lower LH side of 1/P .............................. . 38
57
I/P Fuse Block .......... . LH side ofl/P Carrier, on the side . . . . . . . . . . . . . . . . . . . 8 . . . . 15
Instrument Cluster ...... . LH side ofl/P . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
License Lamp ........... . Center of rear Fascia, above license plate . . . . . . . . . . . . 31
48
Marker Lamp, Left Front . Exterior, left front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
32
Marker Lamp, Left Rear .. Exterior, left rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
48
Marker Lamp, Right Front
Exterior, right front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
32
Marker Lamp, Right Rear . Exterior, right rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
48
Park/Turn Lamp, Left Front Exterior, left front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
32
Park/Turn Lamp,
32
Right Front ........... . Exterior, right front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Radio .................. . Center of I/P Carrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
58
Taillamp, LH ........... . Exterior, left rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
50
Taillamp, RH ........... . Exterior, right rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
50
Tail/Stop/Turn Lamp,
LH Inboard ........... . Exterior, left rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
50
LH Outboard .......... . Exterior, left rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
50
RH Inboard . . . . . . . . . . . . Exterior, right rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
50
RH Outboard . . . . . . . . . . . Exterior, right rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
50
Turn/Hazard Switch
Assembly . . . . . . . . . . . . . . Part of Steering Column . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 . . . . 5
CONN
202-17
202-17
202-20
202-21
202-14
202-22
202-22
202-22
202-15
8A -
EXTERIOR LIGHTS
COMPONENT
LOCATION
201-PG
Turn Flasher ........... . Mounted to bracket, right of Steering Column,

above Data Link Conn . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 ....
C200B (18 cavities)
C200D (48 cavities)
Steering Column . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
C400 (6 cavities) ........ . LH Rear Cargo Compartment, between rear end
panel and carpet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
C410 (3 cavities) ........ . Hatch to 1/P Harn, center ofroof near dome lamp . . . . . 4 ... .
C420 (2 cavities) ........ . LH side of Hatch, between Hatch Frame and plastic panel4 ... .
C430 (2 cavities) ........ . Between Rear Fascia and rear end panel, on LH side . . 33
G105 ................... . Near top RH side ofradiator, in topofT-Bar . . . . . . . . . . 19
G106 ................... . Near top LH side ofradiator, in top ofT-Bar . . . . . . . . . . 19
G200 ................... . Near base of LH "A" pillar, bolted to I/P Mounting Stud
behind kick panel (2 rings, 2 wires) . . . . . . . . . . . . . . . . 9
Bolted to roof, left of Dome Lamp (1 ring, 1 wire) . . . . . . 4
G310
G400
(2 rings, 3 wires) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
PlOO
Compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
P300
In rear center of roof, near Dome Lamp . . . . . . . . . . . . . . 4 ... .
P400
Left rear in end gate panel . . . . . . . . . . . . . . . . . . . . . . . . . . 30 .. .
P410
In left side spoiler
S112
S113
Center breakout
S150
S207
S216
8226
8243
1/P Harn, approx 1 cm from Fuel Pump Relay breakout 7
8400
Rear Body Harn, approx 13 cm from Left Backup Lamp
breakout ....................................... . 33
S401
Rear Body Harn, approx 16 cm forward of P400 ...... . 30
S402
Rear Body Harn, approx 13 cm forward of P400 ...... . 30
8410
Lamp breakout ................................. . 33
S415
Lamp breakout ................................. . 33
8420
Hatch Harn, approx 7 cm from P300 ................ . 4 ....
S430
Lamp breakout ................................. . 31
8440
Lamp breakout ................................. . 31
S450
CHMSL Jumper Harn, approx 15 cm from bulbs
S460
CHMSL Jumper Harn, approx 15 cm from bulbs
FIG.
CONN
15
72
202-2
72
51
202-2
202-5
47
6
7
50
36
35
202-16
16
6
47
36
7
47
13
50
47
47
50
50
7
48
48

Diagnosis)

Make sure all lamps are operational before
replacing flashers.
System

110 - 7
SYSTEM DIAGNOSIS

For Daytime Running Lights (DRL) related
failures, refer to "Headlights and Fog Lights:
Daytime Running Lights (T61)," page SA-102-0.
SYMPTOM TABLE
SYMPTOM
PROCEDURE
PAGE NUMBER

Chart #1
SA-110-7
Entire lighting system inoperative.
Use schematics and DVM or test light to check suspect

power circuits and ground circuits for opens or poor
connections.
Individual lamp inoperative.
Determine if lamp is defective.

Check for corrosion or poor connection at socket .
If OK, use schematic and DVM or test light to
check suspect circuits.
CHART #1

DOES FUSE BLOW BEFORE ATTEMPTING TO OPERA TE SYSTEM?
TEST SYSTEM ONE FUNCTION AT A TIME,

UNTIL FUSE BLOWS.
WHEN FUSE BLOWS, USE SCHEMATIC TO
DETERMINE WHAT CIRCUITS OR
COMPONENTS COULD BE FAILING. USE A
TEST LIGHT OR DVM TO NARROW IN ON
SHORT TO GROUND POTENTIAL
(DISCONNECTING COMPONENTS IS
HELPFUL WHEN TRYING TO CHECK
CIRCUITS THAT SHOULD NOT BE AT A
GROUND POTENTIAL).
USE SCHEMATICS AND DVM TO CHECK

SUSPECT POWER CIRCUITS FOR A SHORT TO
GROUND POTENTIAL, EITHER THROUGH A
FAUL TY COMPONENT OR IN WIRING.
BACKUP LIGHTS
I
--,~
HOTINRUN
FUSE
TURN/B-U
FUSE2
20AMP
I
1
__ .J
L
.8 BRN
141
5207. -
.8 BRN
MANUAL TRANSMISSION
I BLOCK
-I
..........
.....,,....
SEEFUSE
BLOCK DETAILS
PAGE8A-11-5
141
.8 BRN
r-7-
.8 BRN
141
141
I
I
LIGHT ... MANUAL

I TRANSMISSION
IN REVERSE)
I
BACKUP
SWITCH (CLOSED
... .:,1 ____ _.
.8LTGRX.4
TP110
JT.c230
1 LTGR~24
(MANUAL) 1 LTGRl4
(AUTOMATIC) .8 LT GR;J:.4
F i'C400
.8 LTGRN 124
."#--------_:~- ----_:'.'CD_'*""
G)
BACKUP
LAMP,
BACKUP
LAMP,
h!:!
I!!!
.5e~/i~250
.SBLK
.SB~KY,2so
5410.
-
5415
',
_5 BLK
...
1250 ,.._
1250
SEEGROUND
DISTRIBUTION
PAGE 8A14-11
T
L---..1
__JL_G400
.-
..I
~I
112 - 1
lo
12015307
BLK
COMPONENT
LOCATION
Backup Lamp, LH ....... .

Backup Lamp, RH ....... .
Backup Light Switch (M49)
(V6 VIN S) ............ .
Backup Light Switch (MN6)
(VB VIN P) . . . . . . . . . . . .
1/P Fuse Block . . . . . . . . . . .
Switch ................ .
C230 (10 cavities) ....... .
C400 (6 cavities) ........ .
Mounted in Taillamp Assembly ..................... 33

Mounted in Taillamp Assembly
33
50
50
Middle of Transmission, left side . . . . . . . . . . . . . . . . . . . . 16
30
Middle of Transmission, right side . . . . . . . . . . . . . . . . . . 20
37
G400
PllO
P400
8207
8405
8410
8415
201-PG
FIG.
CONN
202-22
37
46
54
67
202-24
202-7
30
47
202-16
30
47
19
30
35
47
30
47
33
50
33
50
Under console, on base of shift control lever . . . . . . . . . .

Under RH side of I/P, behind kick panel . . . . . . . . . . . . . .
LH Rear Cargo Compartment, between rear end
panel and carpet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
(2 rings, 3 wires) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Left rear in end gate panel . . . . . . . . . . . . . . . . . . . . . . . . . .
Rear Body Harn, approx 9 cm forward of P400 . . . . . . . .
Lamp breakout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lamp breakout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SA
112 2
BACKUP LIGHTS

Diagnosis)

System

"Troubleshooting Procedures," page 8A-4-0l.
SYSTEM DIAGNOSIS

SYMPTOM TABLE
SYMPTOM
PROCEDURE
PAGE NUMBER

Chart #1
SA-112-2

connections. Repair or replace as necessary.
Both lights inoperative.

Check for corrosion or poor connection at socket.
CHART #1
FUSE{S) BLOWS WHEN REPLACED OR WHEN ATTEMPTING TO USE LIGHTING SYSTEM

DOES FUSE BLOW BEFORE ATTEMPTING TO OPERATE SYSTEM?

UNTIL FUSE BLOWS.
GROUND POTENTIAL).

BLANK
112 - 3
INTERIOR LIGHTS
HOT AT All TIMES
r---------------------------I
sEE POWER
DISTRIBUTION
PAGE 8A-102
SEE POWER
DISTRIBUTION
PAGE SA-10-1
CIGAR/HORN
FUSE 11
25AMP
-,rip
FUSE
I BLOCK
I
I
I
BATT
(NOT USED)
L------------
----.J
1 ORN
'-'-lORN-~ TO HORN RELAY

540
PAGE 8A-400
40
SEE FUSE
BLOCK DETAILS
PAGE8A-117
.5 ORN
40
B
DOME
LAMP
.8 ORN
540
.8 ORN
40
.8 ORN
B
.---,"''--,11P
COMPARTMENT
LAMP
I
I
- - - - - -.. REAR
DOME
LIGHT
SWITCH
40
CONSOLE
COMPARTMENT
LAMP
_.
1
(D
OPEN
CLOSED
CLOSED
C200C
El JC200D
B
.8 ORN
40
A
.SORN
-:---:I..
T
5265.
.8 BLK
650
.8 BLK
6SO
-,'-~
.8 BLK
650
40
5217----------------
40
SEE GROUND
DISTRIBUTION
PAGE 8A-14-9
lr=;;===;:_-------------~C.;;~REARVIEW
FROM EXTERIOR
LIGHTS S226
PAGE SA-110-4
,,:I
.SORN
TO KEYLESS
ENTRY RECEIVER
PAGE 8A-132-1
MIRROR
.5 WHT
156
.SWHT
E1
(D
156
C200D
C200C
ON
(D
COURTESY/
READING
LAMPS
ON
\
\1
5 WH
5262
.SWHT
- - - - -- _ _ _ _ _ _ _ _ _ _ _1.SOLATIONDIOD-E
156
.5 BLK
.8 BLK
TO 1/P DIMMER FUSE
PAGE 8A-117-0
SEE GROUND
......__
DISTRIBUTION
PAGE 8A-148
,...- -
SEE GROUND
DISTRIBUTION
PAGE8A-14-7
5216
3 BLK
3 BLK
-. . . . . . . . . . . .. .
650
3 BLK (WITH POWER ACCESSORIES)
.8 BLK (WITHOUT POWER ACCESSORIES)
(RAP)
.35 WHT
156
.....
TO KEYLESS
ENTRY MODULE
PAGE8A-1321
WITH KP
TO RETAINED
.5 GRYiBLK ... ACCESSORY POWER
................
.
52661745
(RAP) MODULE
PAGE8A-15-0
.SGRY1
BLK
745
~TOIGNITION
KEY WARNING
159
SWITCH
PAGE 8A-76-0
TI
sw)H~~~[ZJ ~ - - - - iiH.LH
CLOSED
CLOSED
5220
WITH DOOR
OPEN
~--,so------------.
650
750
750 (WITHOUT
POWER
ACCESSORIES)
1 56
,
WITH AUO
.5 GRY/BLK
A
745
.5 TAN
A
WITH DOOR
OPEN
COMPONENT
Cigar Lighter . . . . . . . . . . . .
Console Compartment Lamp
Dome Lamp . . . . . . . . . . . . .
DoorJambSwitch,LH ....
DoorJambSwitch,RH ....
I/P Compartment Lamp . . .
I/P Dimmer Switch . . . . . . .
I/PFuse Block . . . . . . . . . . .
Isolation Diode (RAP) . . . .
Rear Dome Light Switch . .
Rearview Mirror . . . . . . . . .
C200C (13 cavities)
C200D (48 cavities)
G2DO . . . . . . . . . . . . . . . . . . . .
G4DO . . . . . . . . . . . . . . . . . . . .
8210
8216
8217
8220
8262
8265
8266
....................
. ...................
....................
....................
201-PG FIG.
LOCATION
Mounted on front of console . . . . . . . . . . . . . . . . . . . . . . . . . 21
38
Under Console Compartment Door . . . . . . . . . . . . . . . . . . 21 . . . 38
On roof, near hatch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 . . . . 6
NearbaseofLH"A"pillar .......................... 32
49
NearbaseofRH"A"pillar .......................... 32
49
Inside top center of compartment
Lower LH side ofl/P . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
57
Sealed in Harn, approx 9 cm right of Rearview
Mirror breakout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
49
Center of end panel, in Cargo Compartment . . . . . . . . . . 30
47
Top center of windshield ............. ; . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Steering Column . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
72
Steering Column . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
72
(2 rings, 3 wires) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
47
Mirror breakout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
49
Cross Car Harn, approx 9 cm from Rearview Mirror
49
breakout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Mirror breakout
Mirror breakout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 . . . 49
114 - 1
CONN
202-22
202-22
202-24
202-2
202-2
Diagnosis)
System


SYSTEM DIAGNOSIS
8A -
114 - 2
INTERIOR LIGHTS
SYMPTOM TABLE
SYMPTOM
PROCEDURE
PAGE NUMBER

Chart #1
8A-114-2


Check for corrosion or poor connection at socket.
CHART #1


UNTIL FUSE BLOWS.
WHEN FUSE BLOWS, USE SCHEMA TIC TO
GROUND POTENTIAL).

FAULTY COMPONENT OR IN WIRING.
BLANK
114 - 3
INTERIOR LIGHTS DIMMING
---,11P
SEE POWER
DISTRIBUTION
PAGE 8A-10-3
1/P DIMMER
FUSE 13
5AMP
I FUSE
BLOCK
f
- __ ..J
L--------
.5GRY
.8 PNK
39
.35 GRY
SEE FUSE
BLOCK DETAILS
PAGE 8A-11-4
..........- -
.35 PNK
5206
.8 ORN
240
.8 ORN
240
39
0
.5 OK GRN
SEE INTERIOR LIGHTS

PAGE 8A-1140
.5WHT
.5 BRN
44
156
_ _....,.._ _ _ _ _ _, __ _ _ 1/P
DIMMER
SWITCH
LO
.35 BLK
.5 BLK
650
650
rn
117 - 1
IMPORTANT:
SOME 93 MODELS MAY CONTAIN 94
STYLE DOOR ILLUMINATION LAMPS
AND LIGHT PIPES. THESE LAMPS
AND WIRES WILL BE INTRODUCED
DURING THE 93 MODEL VEAR.
l
l
.SGRV
.35 GRV
8
.35 GRV
E7
.35 GRV
))
-.I
C200C
C200D
5260
.35GRV
P6004
.3SG:V18
.SGRV
.35GRV
.35 GRV
.35 GRY
.5 GRV
INSTRUMENT
CLUSTER
r1--. -~
B2
I~
I \Jt)
6LAMPS
IN PARALLEL
MANUAL
TRANSMISSION
DOOR
ILLUMINATION
LAMP, RH
AUTOMATIC
TRANSMISSION
B
DOOR
iillJMINATION
LAMP, LH
I
I
ASHTRAY PRNDL
LAMP
iiiuMfNATION
LAMP
(USES A LIGHT
B
TUBE TO
ILLUMINATE
ASHTRAY)
~J__ !_J
SIR COIL
ASSEMBLY
8 (AUTOMATIC)
8 (MANUAL)
B3
;F1 ,
F
"'"
I CClNTROLS,
I R~_A_D_10_~ I
\V
.35 GRV
8
SEE GROUND
DISTRIBUTION
STEERING
WHEEL
I
I
:
.3SGRY
f .,
i@i
q;iJ
FOG
I LIGHT
SWITCH
11-
~ 1 1~1THUK311
~ 1
f
l
A ~_]_
PAGE SA-14-7
C1
r"'
~RADIO
l~I
1w1
WITHT96
~rJ
II
L..
II
...I
-,HVAC
CONTROL
ASSEMBLY
:@@:
.35 BLK
650
__ _!
I
~ ~ I
.5 BLK
650
SIR COIL
ASSEMBLY
.35 BLK
.5 ILK
650
1 BLK
650
1 BLK
650
650
.35 BLK
650
.5 BLK
3 BLK
650
650
SEE GROUND
DISTRIBUTION
PAGE SA-14-9
SEE GROUND
DISTRIBUTION
PAGE SA-14-8
3 BLK (WITH POWER ACCESSORIES)
.8 BLK (WITHOUT POWER ACCESSORIES)
750
BA -
117 - 2
INTERIOR LIGHTS DIMMING
12034060
NAT(WHT)
1/P DIMMER SWITCH
COMPONENT
LOCATION
201-PG
FIG.
Ashtray Lamp (Auto Trans) Lighting Tube from PRNDL Lamp

Ashtray Lamp
(Manual Trans) . . . . . . . . . Rearward of shifter, in ashtray . . . . . . . . . . . . . . . . . . . . . . 22 . . . 39
I/P Compartment ............................... . 7 .... 12
Door Illumination Lamp, LH Behind door trim panel ............................ . 17
31
Door Illumination Lamp, RH Behind door trim panel ............................ . 17
31
Fog Light Switch . . . . . . . . . Lower LH side of 1/P .............................. . 38
57
Headlight Switch . . . . . . . . LH side of 1/P .................................... . 38
57
(HVAC) Control Assembly Center ofl/P . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
65
I/P Dimmer Switch . . . . . . . Lower LH side ofl/P . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
57
I/P Fuse Block . . . . . . . . . . . LH side ofl/P Carrier, on the side . . . . . . . . . . . . . . . . . . . 8 . . . . 15
PRNDL Illumination Lamp
(Auto Trans) . . . . . . . . . . . Under console, left of Shifter ....................... . 21 ... 38
Radio . . . . . . . . . . . . . . . . . . . Center ofl/P Carrier .............................. . 39 ... 58
SIR Coil Assembly . . . . . . . Top of Steering Column ........................... . 3,34. 5,51
Radio (UK3) .......... . On Steering Wheel ............................... . 2 .... 3 . ..
C200C (13 cavities)
Steering Column . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
72 ..
C200D (48 cavities)
Steering Column . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
72 ..
C217 (4 cavities) ........ . Near base of Steering Column . . . . . . . . . . . . . . . . . . . . . . 34
51 ..
G200 ................... . Near base of LH "A" pillar, bolted to I/P Mounting Stud
behind kick panel (2 rings, 2 wires) . . . . . . . . . . . . . . . . 9 .... 16
P500
49
P600
49
8206
8216
8217
8220
Mirror breakout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 . . . 49
8224
1/P Harn, approx 4 cm from Instrument Cluster breakout
8226
8260
Mirror breakout
CONN
202-17
202-20
202-14
202-21
202-22
202-22
202-22
202-15
202-24
202-2
202-2
202-16

With DRL suspect failures, for a better
understanding of the DRL System, refer to the
Circuit Operation and Circuit Mechanization in
SECTION SA-102.

Diagnosis)

useful in detecting re sis ti ve circuits (see
117 - 3
SYSTEM DIAGNOSIS

SYMPTOM TABLE
SYMPTOM
PROCEDURE
PAGE NUMBER
Fuse blows when replaced or when attempting to use

lighting system.
Chart #1
8A-117-3


Check for corrosion or poor connection at socket .
CHART #1
FUSE BLOWS WHEN REPLACED OR WHEN ATTEMPTING TO USE LIGHTING SYSTEM


UNTIL FUSE BLOWS.
GROUND POTENTIAL).

IFALLRELATEDCOMPONENTSARE
POWER WINDOWS (A31)
HOT IN ACCV, RUN OR

I
I
~P;W;;DISTRIBUTION
PAGE SA-10-2
WINDOWS
CIRCUIT
BREAKER 15
35AMP
11/PFUSE
BLOCK
,--
I
I
l----
3 BRN
341
3 BRN
3 BLK
341
750
3TAN
167
3LTBLU
,-s220
166
I
I
.o5Q
3 BLK
I!!!
750
_ _..__ _ _..__ _ _ _ _ _ . . i , - - i - - - ~ -.. EXPRESS
see GROUND
DISTRIBUTION
PAGESA-14-7
WINDOW
DOWN REQ
3 DK BLU
IGNITION
ON INPUT
164
SOLID STA TE
UPREQ
MONITOR
3 BLK
POWER
WINDOW
SWITCH,
WINDOW
STOPPED
INPUT
,- ,
DOWN
RELAY
EXPRESS
UP
DOWN
CONTROL
650
EXPRESS
DOWN
MODULE
3 BRN
3 DK BLU
3 BRN
rn
667
666
165
IMPORTANT:
EACH MOTOR CONTAINS

AN ELECTRONIC CIRCUIT
BREAKER (ECB).
ECB RESISTANCE INCREASES

IF MOTOR IS OVERLOADED.
RESISTANCE RETURNS TO
NORMAL AFTER VOLTAGE
IS REMOVED FROM MOTOR
TERMINALS.
~"''-----,r--, WINDOW
MQTOIU.H
WITH
ECB
WINDOW
MOTO!tRH
WITH
ECB
201-PG
LOCATION
Mounted to center of dash mat, above floor tunnel
9 ....
LH side of I/P Carrier, on the side .................. . 8 . . . .
Mounted in left door armrest ...................... . 18
Mounted in right door armrest ..................... . 18
Inside LH door ................................... . 17
Inside RH door ................................... . 17
Steering Column . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
C200D (48 cavities)
Steering Column .. -. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
G200 ................... . Near base of LH "A" pillar, bolted to 1/P Mounting Stud
behind kick panel (2 rings, 2 wires) ............... . 9 ....
P500
Between LH door and "A" pillar .................... . 32
P600
Between RH door and "A" pillar .................... . 32
8208
Cross Car Harn, approx 5 cm from Express Down
Module breakout ................................ . 32
8220
Mirror breakout ................................ . 32
8263
Cross Car Harn, approx 17 cm from C200 breakout ... . 32
COMPONENT
Express Down Module
1/P Fuse Block .......... .
Power Window Switch, RH
Window Motor, LH ...... .
Window Motor, RH ...... .
C200C (13 cavities)
FIG.
17
15
33
33
31
31
120- 1
CONN
202-20
202-22
202-23
202-22
72
202-2
72
202-2
16
49
49
49
49
49

Diagnosis)
Sys t e m
If both windows are inoperative, check windows

Circuit Breaker 15 for open. If open check for short
to ground through CKT 341 Check for poor connection at C200 terminal "El 1".
2. If windows move slowly, check that:
- Windows free of mechanical binding and pivot
joints and tracks are properly lubed.
- Battery is fully charged.
- Ground G200 is clean and tight.
3. If the Express Down Feature does not work, but
window moves down with each switch depression,
check for poor connection at Express Down Module
terminal "A" or open in CKT 164 from Express
Down Module to 8263.

lights have high impedancel'J and will not be as
SYSTEM DIAGNOSIS
procedure(s).
SYSTEM CHECK
ACTION
NORMAL RESULTS
[1]
Operate each window "UP" and "DOWN" from Each window operates quietly and smoothly, with no
the Master Power Window Switch Assembly.
sticking. LH Front Window rolls down all the way
without the switch being held (Express Down
Feature).
[2]
Operate each window from its individual Window Each window operates quietly and smoothly, with no
Switch.
sticking.
SA-
120- 2
POWER WINDOWS (A31)
rn
IMPORTANT:
FOR A BETTER UNDERSTANDING OF THE RETAINED ACCESSORY POWER {RAP)
OPERATION, REFER TO CIRCUIT OPERATION AT THE END OF THIS SECTION.
SYMPTOM TABLE
SYMPTOM
PROCEDURE
PAGE NUMBER
Both Power Windows inoperative from both switches.
Chart #1
8A-120-2
Power Windows inoperative from the LH Switch, RH

Switch operates RH Window normally.
Chart #2
8A-120-3
RH Window inoperative from both switches, LH

Window operates normally.
Chart #3
8A-120-4
RH Power Window inoperative from LH Power Check for poor connection at LH Power Window
Window Switch with normal operation from RH Switch. If OK, replace LH Power Window Switch.
Power Window Switch.
Express Down Feature inoperative. Window does Check for poor connections at Express Down Module
operate up and down while switch is held in the terminal "A" and terminal "C". Check for open in
desired position.
CKT 164 from 5263 to terminal "A" of Express Down
Module and in CKT 341 from 5208 to terminal "C of
Express Down Module If OK, replace Express Down
Important:
Express Down Feature is for the LH Window Module.
rn
only.
RH Power Window Switch inoperative, LH Power Check for poor connection or open in CKT 341 from
RH Power Window Switch terminal "A" to 5208.
Window Switch operates normally.
CHART #1
BOTH POWER WINDOWS INOPERATIVE FROM BOTH SWITCHES
IGNITION SWITCH IN THE "RUN" POSITION.

WITH A TEST LIGHT, BACKPROBE LH POWER WINDOW
SWITCH ASSEMBLY FROM TERM "F" TO GROUND.
IS TEST LIGHT "ON"?
WITH A TEST LIGHT, BACKPROBE

THE LH POWER WINDOW
SWITCH ASSEMBLY BETWEEN
TERM"F" ANDTERM"A".
IS TEST LIGHT "ON"?
CHECK FOR POOR CONNECTION AT C200 TERM "E11 ".

IF OK, REPAIR OPEN IN CKT 341 BETWEEN WINDOWS
CIRCUIT BREAKER 15 AND LH POWER WINDOW
SWITCH ASSEMBLY CONN TERM "F".
CHECK LH POWER WINDOW

SWITCH ASSEMBLY CONNECTOR
FOR POOR CONNECTION.
IF OK, REPLACE SWITCH.
CHECK FOR POOR CONNECTION AT G200.

LH POWER WINDOW SWITCH ASSEMBLY
CONN TERM" A" AND G200.
CHART #2
POWER WINDOWS INOPERATIVE FROM THE LH SWITCH,
RH SWITCH OPERA TES RH WINDOW NORMALL V
IGNITION SWITCH IN THE "RUN" POSITION.

WITH A TEST LIGHT, BACKPROBE LH POWER WINDOW SWITCH ASSEMBLY FROM TERM "F" TO GROUND.
IS TEST LIGHT "ON"?
WITH A TEST LIGHT, BACKPROBE THE LH POWER WINDOW

SWITCH ASSEMBLY FROM TERM "D" TO TERM "E".
PRESS THE LEFT WINDOW "UP" AND WINDOW "DOWN"
SWITCH AT THE LH POWER WINDOW SWITCH.
IS TEST LIGHT "ON" IN BOTH CASES?
REPAIR OPEN IN CKT 341 BETWEEN 5208

AND TERM "F" OF THE LH POWER WINDOW
SWITCH ASSEMBLY.
WITH A TEST LIGHT, BACKPROBE EXPRESS DOWN MODULE CONN

FROM TERM "A" TO TERM ''E''.
PRESS THE LEFT WINDOW "UP" AND WINDOW "DOWN" SWITCH.
IS TEST LIGHT "ON"?

LH POWER WINDOW SWITCH CONN.
WITH A TEST LIGHT, BACKPROBE EXPRESS DOWN

MODULE CONN FROM TERM" A" TO TERM "D".
PRESS THE LEFT WINDOW "UP" AND WINDOW
"DOWN" SWITCH AT THE LH POWER WINDOW SWITCH.
IS TEST LIGHT "ON"?
CHECK FOR OPEN IN CKT 1136 BETWEEN LH

POWER WINDOW SWITCH TERM "E" AND
EXPRESS DOWN MODULE TERM "E".
CHECK FOR OPEN IN CKT 164 FROM LH POWER
WINDOW SWITCH TERM "D" TO 5263 AND FROM
5263 TO EXPRESS DOWN MODULE TERM "A".
:
:
1
DISCONNECT LH WINDOW MOTOR CONNECTOR.

CONNECT A TEST LIGHT BETWEEN TERMINALS" A" AND "B" OF
THE LH WINDOW MOTOR CONNECTOR.
PRESS THE LEFT WINDOW "UP" AND WINDOW "DOWN" SWITCH.
IS TEST LIGHT "ON"?
CHECK FOR POWER CONNECTIONS AT

EXPRESS DOWN MODULE.
IF OK, REPLACE EXPRESS DOWN MODULE.
C~ECKFORPOORCONNECTIONSATLHWINDOWMOTOR.:
IF OK, REPLACE LH WINDOW MOTOR.
:
REFER TO SECTION 10-6 FOR REPLACEMENT PROCEDURES. 1

EXPRESS DOWN MODULE TERM "D" AND
LH WINDOW MOTOR TERM" A." ALSO
EXPRESS DOWN MODULE TERM" A" TO
5263 AND FROM 5263 TO LH WINDOW
MOTOR TERM "B."
L---------------------------------------~
SA -
120 - 4
POWER WINDOWS (A31)

CHART #3
RH WINDOW INOPERATIVE FROM BOTH SWITCHES,
LH WINDOW OPERATES NORMALLY

WITH A TEST LIGHT, BACKPROBE THE RH POWER WINDOW MOTOR CONN FROM TERM" A" TO TERM "B."
WHILE OBSERVING THE TEST LIGHT, PRESS THE RH WINDOW "UP" AND WINDOW "DOWN" SWITCH.
IS THE TEST LIGHT "ON" IN BOTH CASES?
WITH A TEST LIGHT, BACKPROBE THE RH POWER

WINDOW SWITCH FROM CONN TERM "D" TO
TERM"C."
WHILE OBSERVING THE TEST LIGHT, PRESS THE RH
WINDOW "UP" AND WINDOW "DOWN" SWITCH.
------------------------------------,
CHECK POWER WINDOW MOTOR CONNECTOR FOR POOR :

CONNECTION.
1
IF OK, REPLACE INOPERATIVE POWER WINDOW MOTOR. :
REFER TO SECTION 10-6 FOR REPLACEMENT
PROCEDURES.
1
L--------------------------------------~
WITH A TEST LIGHT, BACKPROBE RH POWER

WINDOW SWITCH CONN TERM "B" TO TERM "E."
WHILE OBSERVING THE TEST LIGHT AND USING
THE LH WINDOW SWITCH, PRESS THE RH
CHECK FOR OPEN IN CKT 666 OR CKT 667 BETWEEN RH

POWER WINDOW SWITCH AND RH WINDOW MOTOR.
WITH A TEST LIGHT, BACKPROBE LH POWER

WINDOW SWITCH CONN TERM "B" TO TERM "C."
WHILE OBSERVING THE TEST LIGHT AND USING
THE LH WINDOW SWITCH, PRESS THE RH
CHECK FOR POOR CONNECTIONS AT RH POWER

WINDOW SWITCH CONN.
IF OK, REPLACE RH POWER WINDOW SWITCH.
CHECK FOR POOR CONNECTIONS AT LH

POWER WINDOW SWITCH.
IF OK, CHECK FOR OPEN IN CKT 166 AND
CKT 167 BETWEEN LH POWER WINDOW
SWITCH AND RH POWER WINDOW SWITCH.
CHECK FOR POOR CONNECTIONS AT LH

POWER WINDOW SWITCH.
IF OK, REPLACE LH POWER WINDOW SWITCH.
CIRCUIT OPERATION
[I] Important:
The Power Windows System has voltage applied

from the Windows Circuit Breaker 15 which is
controlled by the Retained Accessory Power
(RAP) Module. Voltage is applied to the PWR
ACCY Fuse for up to 10 minutes after Ignition is
turned off or for 35 seconds after exiting the
vehicle and closing the doors or whenever a door
is open. For a complete understanding of
Retained Accessory Power (RAP) operation,
refer to SECTION 8A-15.
When the Ignition Switch is in the ''RUN,"

"ACCY," or RAP voltage is applied from windows
Circuit Breaker 15 to the LH Power Window Switch
and the RH Window Switch through CKT 341. The
Window Motors and Switches receive ground through
the LH Power Window Switch Assembly, which is
grounded at G200. The RH Window can be operated
from the LH and RH Power Window Switch
. Assemblies. The LH Front Window is operated
directly from the LH Power Window Switch.
The Power Windows are driven by reversible,
permanent magnet motors. Each motor is controlled
by a set of two switches, which are normally closed to
ground. When any Window Switch is moved to the
"UP" position, the "UP" switch will provide battery
voltage to the Window Motor through the DK BLU
wire. The Window Motor will receive ground through
the BRN wire, the "DN" switch, and the LH Power
Window Switch Assembly and drive the window up.
When the switch is released, the switch contacts will
return to their normal grounded position.
To lower the window, the "DN" switch will connect
the BRN wire to battery voltage. Ground will be
provided to the DK BLU wire through the "UP" switch
and the LH Power Window Switch Assembly. The
polarity across the motor will be reversed, causing the
motor to rotate in the opposite direction and lower the
window.
The Power Windows System also includes an

Express Down Feature for the LH Front Window. This
allows the LH Front Window to open fully when the
LH Front Window Switch is pressed momentarily. All
of the solid state circuitry controlling this feature is
contained within the Express Down Module.
Each motor is protected by an Electronic Circuit
Breaker (ECB). If a Window Switch is held in the
"UP" or "DN" position too long with the window
obstructed, or after the window is fully up or down, the
ECB will increase its resistance. By increasing its
resistance, the ECB will prevent the Window Motor
from overloading. The ECB will reset to normal
resistance when voltage to the Window Motor is
interrupted.
SA -
130 - 0
POWER DOOR LOCKS (AU3)
'7EE7o..;R -
---,~
I DISTRIBUTION
I PAGE SA-10-2
SEE PAGE SA-3-0

FOR PROPER
HANDLING
PROCEDURES
FUSE
I BLOCK
I
I
PWR ACCV
FUSE 7
15 AMP
L----
SEE PAGE SA-3-0

FOR MEASURING
AND HANDLING
PROCEDURES
--..J
.8 ORN
640
..-----5211
.l
.SORN
640
SEE FUSE
BLOCK DETAILS
PAGE SA-11-7
L--~
.8 ORAN
POWER
DOOR
LOCK
SWITCH, LH
(lfl
640
~---iJU-Psoo--~
640
:
POWER , - - - - - - A " T - - - - - - - .
~
I
DOOR
I
LOCK
UNLOCK
LOCK
:SWITCH.RH
----..
----..
LOCK
UNLOCK
.SORN
I
I
I
I
I
I
I
I
I
rn
IMPORTANT:
I
I
EACH MOTOR CONTAINS

BREAKER (ECB).

TERMINALS.
.8GRY
295
.8 TAN
5504
SS03
P500
P600
.8 GRY
294
295
.STAN
.8 GRY
294
29S
ECB
ECB
DOOR LOCK ACTUATOR, RH
---11!.---..
r---J
5220
I
I
I
I
DOOR LOCK ACTUATOR, LH
244
294
.STAN
.8 LT BLU
SEE GROUND
DISTRIBUTION
PAGES SA-14-7
3 BLK
II,
3 BLK
650
750
130 - 1
12004680
5-WAY F PIN GRIP SERIES
BLKJWHT
POWER DOOR LOCK SWITCH, LH AND RH
201-PG
COMPONENT
LOCATION
Door Lock Actuator, LH

Door Lock Actuator, RH
I/P Fuse Block . . . . . . . . . . .
C200C (13 cavities)
Inside rear ofleft door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Inside rear ofright door . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LH side ofI/P Carrier, on the side . . . . . . . . . . . . . . . . . . .
Mounted in left door armrest . . . . . . . . . . . . . . . . . . . . . . .
Mounted in right door armrest . . . . . . . . . . . . . . . . . . . . . .
Steering Column . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Steering Column . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Near base of LH "A" pillar, bolted to 1/P Mounting Stud
behind kick panel (2 rings, 2 wires) . . . . . . . . . . . . . . . .
Between LH door and "A" pillar . . . . . . . . . . . . . . . . . . . . .
Between RH door and "A" pillar . . . . . . . . . . . . . . . . . . . . .
1/P Harn, in center console breakout, approx 10 cm from
Main Harn
Mirror breakout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cross Car Harn, approx 6 cm from Speaker breakout . .
Cross Car Harn, approx 3 cm from LH Power
Mirror breakout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cross Car Harn, approx 11 cm from Left Front
Speaker breakout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
C200D (48 cavities)

G200
P500
P600
8211
8220
8500
8503
8504
FIG.
CONN
17 . . .
17 . . .
8 ....
18
18
31
31
15
33
33
202-22
202-23
202-23
47
72
202-2
47
72
202-2
9 . . . . 16
32
49
32 . . . 49
32
17
49
31
17
31
17
31
SA -
130 - 2


Diagnosis)
System
Check PWR ACCY Fuse 7 in I/P Fuse Block. If

open, refer to Diagnostic Chart #4.
2. Check for poor connection at G200.
1.

SYSTEM DIAGNOSIS

[I) Important:
For a better understanding of Retained Accessory Power (RAP) operation,

refer to Circuit Operation at the end of this section.
SYMPTOM TABLE
SYMPTOM
PROCEDURE
PAGE NUMBER
Power Door Locks wi II not operate from both Power

Door Switches.
Chart #1
Chart #2
Chart #3
SA-130-3
SA-130-4
SA-130-5
RH Door Lock Switch operates normally. LH Door Lock Check for B + at terminal "A" of LH Door Lock
Connector.
Switch does not "LOCK" or "UN LOCK."
- If not present, repair open in CKT 640.
- If present, replace LH Door Lock Switch.
LH Door Lock Switch operates normally. RH Door Lock
Switch does not.
Chart #1
SA-130-3
One Door Lock Switch "UNLOCKS" but does not Check for poor connection at suspect Door Lock
Switch. If OK, replace suspect Door Lock Switch.
"LOCK." Other switch OK.
One Door Lock Switch "LOCKS" but does not Check for poor connection at suspect Door Lock
Switch. If OK, replace suspect Door Lock Switch.
"UNLOCK." Other switch OK.
Power Door Locks either "LOCK" only or "UNLOCK"
only from both Door LockSwitches.
Chart #1
Chart #2
SA-130-3
SA-130-4
One door does not "LOCK" or "UNLOCK."
Chart #3
SA-130-5
PWR ACCY Fuse 7 repeatedly blows whenever Ignition

is "ON" or when attempting to use Power Door Locks.
Chart #4
SA-130-5
Power Door Locks do not operate when one or Refer to "Retained Accessory Power (RAP),"
page SA-15-0.
both doors are opened.
Power Door Locks only operate with Ignition
"ON," or for 10 minutes after Ignition is turned
"OFF" and exiting the vehicle and closing the
door{s).
130 - 3
CHART #1
rn
RH DOOR LOCK SWITCH TEST

IMPORTANT:
IF PWR ACCY FUSE CONTINUALLY BLOWS, REFER TO CHART #4.
BACKPROBE RH DOOR LOCK SWITCH CONNECTOR WITH

A TEST LIGHT BETWEEN TERM "A" AND GROUND.
IS TEST LIGHT "ON"?
BACKPROBE SAME CONNECTOR WITH THE

TEST LIGHT BETWEEN TERMINALS "A" & "C".
IS TEST LIGHT "ON"?
CHECK FOR OPEN IN CKT 640 BETWEEN RH DOOR

LOCK SWITCH AND PWR ACCY FUSE.
IF OK, REPAIR POWER FEED TO PWR ACCY FUSE.
BACKPROBE SAME CONNECTOR WITH THE

TEST LIGHT BETWEEN TERMINALS "A" & "D".
IS TEST LIGHT "ON"?
CHECK FOR OPEN IN GROUND CKT 750 (G200)

TO TERM "E" OF CONNECTOR OR POOR
CONNECTION TO SWITCH.
IF OK, REPLACE RH DOOR LOCK SWITCH.
BACKPROBE SAME CONNECTOR WITH THE TEST LIGHT BETWEEN

TERMINALS "C" & "E".
MOVE THE RH DOOR LOCK SWITCH TO THE "LOCK" POSITION
WHILE OBSERVING THE TEST LIGHT.
IS TEST LIGHT "ON"?
CHECK FOR OPEN IN GROUND CKT 750

(G200) TO RH DOOR LOCK SWITCH
CONNECTOR TERM "B" OR POOR
CONNECTION TO SWITCH.
BACKPROBE SAME CONNECTOR WITH THE TEST LIGHT

BETWEEN TERMINALS "D" & "E".
MOVE THE RH DOOR LOCK SWITCH TO THE "UNLOCK"
POSITION WHILE OBSERVING THE TEST LIGHT.
IS TEST LIGHT "ON"?
CHECK FOR POOR CONNECTION AT SWITCH.

CHECK CONTINUITY FROM TERM "C" OF RH DOOR LOCK SWITCH

CONNECTOR TO TERM ''E'' OF LH DOOR LOCK SWITCH CONNECTOR.
IS THERE CONTINUITY (NEARLY O OHMS)?
CHECK FOR POOR CONNECTION AT SWITCH.

CHECK CONTINUITY FROM TERM "D" OF RH DOOR LOCK SWITCH

CONNECTOR TO TERM "B" OF LH DOOR LOCK SWITCH CONNECTOR.
IS THERE CONTINUITY (NEARLY O OHMS)?
NO TROUBLE FOUND WITH THE RH DOOR LOCK SWITCH.

IF LH DOOR LOCK SWITCH IS INOPERATIVE, REFER TO CHART #2,
"LH DOOR LOCK SWITCH TEST," PAGE SA-130-4.
SA -
130 - 4

CHART #2
LH DOOR LOCK SWITCH TEST
rn
IMPORTANT:
CHART #1, "RH DOOR LOCK SWITCH TEST," PAGE SA-130-3 MUST BE
PERFORMED BEFORE PROCEEDING.
BACKPROBE LH DOOR LOCK SWITCH

CONNECTOR WITH A TEST LIGHT
BETWEEN TERM" A" AND GROUND.
IS TEST LIGHT "ON"?
BACKPROBE SAME CONNECTOR

WITH THE TEST LIGHT BETWEEN
TERMINALS" A" & "C".
IS TEST LIGHT oN"?

S500 AND LH POWER DOOR LOCK
SWITCH AT TERM "A".
BACKPROBE SAME CONNECTOR WITH THE TEST

LIGHT BETWEEN TERMINALS "A" & "D".
IS TEST LIGHT "ON"?
CHECK FOR POOR CONNECTION A TLH SWITCH.

IF OK, REPLACE LH DOOR LOCK SWITCH.
BACKPROBE THE SAME CONNECTOR WITH THE

TEST LIGHT BETWEEN TERMINALS "C" & "E".
MOVE LH DOOR LOCK SWITCH TO "LOCK"
POSITION WHILE OBSERVING TEST LIGHT.
IS TEST LIGHT "ON"?
CHECK FOR OPEN IN CKT 245.

CHECK FOR POOR CONNECTION AT LH
SWITCH.
BACKPROBE SAME CONNECTOR WITH THE TEST

LIGHT BETWEEN TERMINALS "D" & "E".
MOVE LH DOOR LOCK SWITCH TO THE "UNLOCK"
IS TEST LIGHT "ON"?
CHECK FOR POOR CONNECTION AT LH SWITCH.

NO TROUBLE FOUND WITH LH DOOR

LOCK SWITCH.
REFER TO CHART #3, "DOOR LOCK
ACTUATOR TEST," PAGE SA-130-5.
CHECK FOR POOR CONNECTION AT LH SWITCH.

130 - 5
CHART #3
DOOR LOCK ACTUATORS TEST
rn
IMPORTANT:
IF BOTH DOOR LOCK ACTUATORS DO NOT OPERATE, PERFORM CHART #1,
"RH DOOR LOCK SWITCH TEST," PAGE SA-130-3 AND CHART #2,
"LH DOOR LOCK SWITCH TEST," PAGE SA-1304 BEFORE PROCEEDING.
DISCONNECT SUSPECT DOOR LOCK ACTUATOR CONNECTOR.

CONNECT A TEST LIGHT BETWEEN TERM "B" OF CONNECTOR
ANDB+.
IS TEST LIGHT "ON"?
CONNECT THE TEST LIGHT BETWEEN

TERM" A" OF SUSPECT DOOR LOCK
MOTOR CONNECTOR AND B +.
IS TEST LIGHT "ON"?
CHECK FOR POOR CONNECTION AT DOOR LOCK

ACTUATOR.
IF OK, REPLACE DOOR LOCK ACTUATOR.
CHART #4
PWR ACCY FUSE 7 REPEATEDLY BLOWS WHENEVER IGNITION IS "ON"
OR WHEN ATTEMPTING TO OPERATE POWER DOOR LOCKS
REPLACE BLOWN FUSE.

DOES FUSE BLOW BEFORE A TT EMPTING TO
OPERATE POWER DOOR LOCKS?
TEST POWER DOOR LOCK SWITCH ONE FUNCTION AT A

TIME UNTIL FUSE BLOWS.
WHEN THE FUSE BLOWS, USE SCHEMATICS TO
DETERMINE WHAT CIRCUITS OR COMPONENTS COULD
BE FAILING. USE A TEST LIGHT OR DVM TO NARROW IN
ON SHORT TO GROUND POTENTIAL.
DISCONNECTING COMPONENTS IS HELPFUL WHEN
TRYING TO CHECK CIRCUITS THAT SHOULD NOT BE AT
A GROUND POTENTIAL.
USE SCHEMATICS AND DVM TO CHECK SUSPECT POWER

CIRCUITS FOR A SHORT TO GROUND POTENTIAL, EITHER
THROUGH A FAUL TY COMPONENT OR IN WIRING.
CONNECT A DVM SET TO VOLTAGE ACROSS FUSE
TERMINALS. START BY DISCONNECTING ONE COMPONENT
AT A TIME.
IF ALL RELATED COMPONENTS ARE DISCONNECTED AND
SHORT IS STILL PRESENT, LOCATE AND REPAIR SHORT IN
WIRING.
SA -
130 - 6

CIRCUIT OPERATION
rn
Important:
The Power Door Lock System has voltage
applied from the PWR ACCY Fuse which is
controlled by the Retained Accessory Power
(RAP) Module. Voltage is applied to the PWR
ACCY Fuse for up to 10 minutes after Ignition is
turned off or for 35 seconds after exiting the
vehicle and closing the doors. Voltage is also
applied whenever a door is open. For a complete
understanding of Retained Accessory Power
(RAP) operation, refer to "Retained Accessory
Power (RAP): KP2," page SA-15-0.
When a Door Lock Switch is activated in the Power

Door Lock system, both doors will lock or unlock in
unison. Each lock can also be operated manually. The
locks are operated by reversible Actuators. The Door
Lock Switches operate the Actuators by applying a
voltage to one of the terminals and a ground to the
other terminal.
Battery voltage is applied to both Door Lock
Switches at terminal "A". When the LH Door Lock
Switch is moved to "LOCK," battery voltage is applied
to both Door Lock Actuators from the GRY (295) wires.
Both Actuators are grounded through the TAN (294)
wires, the contacts of the LH Door Lock Switch, the
DK BLU (245) wire, the contacts of the RH Door Lock
Switch and the BLK (750) wires to ground G200.
When the LH Door Lock Switch is moved to
"UNLOCK," battery voltage is applied to both Door
Lock Actuators in the opposite direction from the TAN
(294) wires. Both Actuators are grounded through the
GRY (295) wires, the contacts of the LH Door Lock
Switch, the LT BLU (244) wire, the contacts of the RH
Door Lock Switch and the BLK (750) wires to ground
G200.
When the RH Door Lock Switch is moved to
"LOCK," battery voltage is applied from the LT BLU
(244) wires, the contacts of the LH Door Lock Switch
and the GRY (295) wires to both Door Lock Actuators.
When the RH Door Lock Switch is moved to
"UNLOCK," battery voltage is applied from the DK
BLU (245) wire, the contacts of the LH Door Lock
Switch, and the TAN (294) wires to both Door Lock
Actuators in the opposite direction. During RH Door
Lock Switch operation, the Door Lock Actuators are
grounded similarly to the way they are grounded
during LH Door Lock Switch operation.
BLANK
130 - 7
SA -
KEYLESS ENTRY: AUO

HOT IS ACCY, RUN OR DURING
--------------------- ----,
rsETPo-;E;- DISTRIBUTION
PAGE 8A-102
I
I
I
\
L----
------------------------~
. - - - - - -.....- - - - - -.. POWER

DOORLOCK
SWITCH, RH
. - - - - - -....,....------.POWER
DOORLOCK
SWITCH.LH
.8 DK BLU
245
3 BLK
.8 BLK
750
,..,
,..,
RELAY
#1
---
LOCK
All
,..,
,..,
--
KEYLES5
ENTRY
RECEIVER
GROUND
/fl_
lllUM
INATION
OUTPUT
LOW
ILLUM
INATION
UNLOCK
All
UNLOCK
DRIVER
RELAY
BATTERY
UNLOCK
ALL
OUTPUT
LOW
.8 GRY
.8 TAN
295
294
.8GRY
rn
DOOR LOCK
ACTUATOR. LH
l"'""""..,.___
IMPORTANT:
EACH MOTOR CONTAINS

BREAKER (ECB).

TERMINALS.
"":-,DOORLOCK
ACTUATOR, RH
UNLOCK
DRIVER
OUTPUT
LOW
LOCK
All
OUTPUT
LOW
650
~E;-;O~R- DISTRIBUTION
\ PAGE SA-10-3
132 - 1
I
I
IGN
(NOTUSEDl
__ J
L.SORN
640
.8 PNK
39
1 ORN
40
.SORN
r -
5206-.,
.35PNK
39
...
,----=~--,
SEE FUSE
BLOCK DETAILS
PAGE SA-11-4
5210
SEE FUSE
BLOCK DETAILS
PAGE SA-11-7
40
E3
C2000
2
39 - - - - - - - - - - - - - - - - - . 8 0 R J : : 00C
.5 ORN
SEE INTERIOR
LIGHTS
PAGE SA-114-0
40
tI
f-
TO REARVIEW ....
.5 ORN tN
MIRROR
PAGESA-114-0
40
.5 ORN
5265
40
----
rl-,
SOLID STATE
LOGIC
8.SV
HATCH
RELEASE
OUTPUT
LOW
~~-+--,,..,
--
.35 WHT
---->g
IGNITION
ON INPUT
156
s262
.5 WHT
156
E1
RELAY
!t1
B
HATCH
RELEASE
SWITCH
HATCH
RELEASE
Af---------------.;B~f(<,I
1455
EB
FIC240
.35 BLK,W:T
1455
A ciooc
I
I
ON
1/P
DIMMER
I SWITCH
I
:t.i
.5 BLK
.5B:Ki50
S216-~
~6
.5 BLK
1576
C200C
ii' C2000
3 BLK
650
3 BLK
650
DATA LINK
HATCH
RELEASE
ACTUATOR
CONNECTOR (DLC}
..____lc
( A~
~B
.SBLK,WHT
.8 ORN/BLK 1434 (AUTOMATIC)

.35 TAN;WHT 33 (MANUAL)
GROUND PATH THROUGH
OR PARK BRAKE SWITCH
PAGE SA-135-0_L
56
_
SEE GROUND
DISTRIBUTION
PAGESA-14-11
156
156
.5BLK.1576
5244-----
15 16
.SrBc_L2K"l~P_ _ _ _ _ _ _:--.,
II
.5WHT
C2000
.5 WHT
.35 BLKIWHT
DOME
LAMP
.8 ORN
.35::K
el
40
SEE GROUND
DISTRIBUTION
PAGE SA-14-8
1550
SA -
KEYLESS ENTRY: AUO
~ lti1 [j:jlctjl
rbcaca~
12064766
12064998
BLU
BLK
KEYLESS ENTRY RECEIVER (C1)
12004680
5-WA Y F PIN GRIP SERIES
BLK/WHT
201-PG FIG.
COMPONENT
LOCATION
Mounted to I/P Tie Bar, below and right of

Steering Column . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202-11
On roof, near hatch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 . . . . 6
Inside rear of left door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
31
lnsiderearofrightdoor ............................ 17
31
47
Mounted to right side of SIR Bracket, behind I/P . . . . . . 45
66
202-20
Left of Steering Column, in knee bolster pad . . . . . . . . . 38
57
Lower LH side ofl/P . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
57
202-22
202-22
Behind RH side kick panel, in molded pocket . . . . . . . . . 42
61
202-22
33
202-23
Mounted in right door armrest . . . . . . . . . . . . . . . . . . . . . . 18
33
202-23
47
Steering Column . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
72
202-2
Steering Column . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
72 . . 202-2
Under RH side of I/P, behind kick panel . . . . . . . . . . . . . . 46
67 . . 202-16
Dome Lamp . . . . . . . . . . . . .
Door Lock Actuator, LH . .
DoorLockActuator,RH ..
Hatch Release Actuator . . .
Hatch Release Relay . . . . .
Hatch Release Switch . . . .
I/P Dimmer Switch . . . . . . .
I/P Fuse Block . . . . . . . . . . .
Key less Entry Receiver . . .
Rear Dome Light Switch . .
C200C (13 cavities)
C200D (48 cavities)
C240 (6 cavities) . . . . . . . . .
CONN
COMPONENT
LOCATION
0200

(2 rings, 3 wires) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
breakout
I/P Harn, in center console bteakout, approx 10 cm from
Main Harn
breakout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 . . .
Mirror breakout
Cross Car Harn, approx 6 cm from Speaker breakout
17
Speaker breakout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
0400
P500
P600
8206
8210
8211
8244
8262
8265
8500
8504
SYSTEM DIAGNOSIS
For Diagnosis, refer to SECTION 9K.
201-PG
FIG.
16
47
49
49
49
31
31
132 - 3
CONN
THEFT DETERRENT SYSTEM: PASS-KeyII

(PERSONALIZED AUTOMOTIVE SECURITY SYSTEM)
-r---
r- - I
1
I
HOT AT ALL TIMES
1 IGNITION
SWITCH
ACCY
START , - -
/ ~ II
LOCK-.. .. _ _. ..... BuLB

OFF
RUN TEST
L-------
5Y~fs9-
..__...................1.
c5Te200B
(2000
.................
5.YE.L. . . . . . . . . . . . ...;:..SYEL
r1
I
I
5
-
CRANK
FUSE17
-,1/P
FUSE
BLOCK
,--
5 YEL
__ ...,
3AMP
5223
5 YEL
C2
~~-----------------------:~1:~~f
TO DIAGNOSTIC
ENERGY RESERVE
MODULE
PAGE SA-47-0
A:l
5 DK GRN
MANUAL I
___I:::-;;;:;;=::::.
____,,
I.
5 DK GARN
Air
575
AUTOMATIC
5 DK GR:l';75
, ,
.5 RUST
575
5245 . . . . . . . . .. .
5 DK GRt
C
LUTCH[]
START
SWITCH
(CLOSED WITH
CLUTCH PEDAL
_
DEPRESSED)
TRANSMISSION
POSITION
SWITCH
FUSIBLE
LINK (BTSI)
575
1 DK GRN
\R
I
1 I
2, I
,N@D)(
6
575
ro,
Ll.J
--__
_~..
_ _ JI
IMPORTANT:
FUSIBLE LINK (BTSI) 15
LOOPED OUTSIDE OF TAPED
BUNDLE, APPROXIMATELY
12.S CM IN LENGTH.
r- - - - - - ,
B
5 PPL
.8 YEUBLK
.)
. . . . . . . . . . . . . . . . . . . ..,,
625
TO BRAKE
TRANSMISSION
SHIFT INTERRUPT
(BTSll SOLENOID
PAGES SA-20-6,
SA-21-6
SP:
,______________ ~ - - - - - w /
3 PPL (V6 VIN Sl

5 PPL (VS VIN Pl
I"'
S - , STARTER
I SOLENOID
I
I
J
SEE PAGE SA-3-0

FOR PROPER
HANDLING
PROCEDURES

ii~
--,'!!'.
SEE PAGE BA-3-0

FOR MEASURING
AND HANDLING
PROCEDURES
FUSE
I BLOCK
I
I
ECM BAT
FUSE 4
10AMP
-----------
L---.5 PNK
SEE FUSE
BLOCK DETAILS
PAGE SA-11-4
..... _
.,,,,- -
.8 ORN
5205
1-----,
1 --,,~:'l" ---.~... "'
INSTRUMENT
CLUSTER
AlUl
r
I
~I
., ~ '"
I
340
r==--- =--,
439
__ _J
.8 VEUBLK
625
"SECURITY"
INDICATOR
AS
A2
I
I
I
I
r ;' - - I
I
I
SEE FUSE
BLOCK DETAILS
PAGESA-11-6
ENGINE CONTROL
.~(ECM)
FUEL
ENABLE
I
I
_ 1!,_G~L..J
~ (BLU) (V6 VIN S)

~ (GRV) (VB VIN P)
23
19
(V6 VIN S) .5 DK BLU

(VS VIN P) .35 DK BLU
229
Al
r-~~~...,.''""~~~~~--:~~~~~~~~~~~~~~--::~~~~~~~~~~~~~~~~~~~-.PASSKeyII
DECODER
MODULE
I
I
I
I
I
I
IGNITION
INDICATOR CONTROL
L_
START
ENABLE
BA TTERV
SOLID STATE
DETECTOR
AND TIMER
SVREF
PWM
FUEL ENABLE
SIGNAL
L" _______________ .as .,,,,.:J.,..i
.,sw,n:,
.35 WHT
BSf
.35 BLK,WHT
451
ii:.:_A
IGNITION KEV
LOCK CYLINDER
5215----,
.35 WHT
.s BLK!WHT
rn
....ri...r,_
GROUND
SIGNAL
--
J:s1
I
I
210
fk T
___ .
c
IMPORTANT:
ANY NEW PASS-KeyII
DECODER MODULE WILL
AUTOMATICALLY PROGRAM
TO THE RESISTANCE OF THE
KEV (OR INTERROGATOR
SETTING) BEING USED AT THE
FIRST IGNITION "ON" CYCLE.
THIS CAN ONL V BE DONE
ONCE FOR THE LIFE OF THE
MODULE.
P110
.5 BLK/W
5109 (VIN Pl
5110 (VIN S). -
.8 BLK/WHT
RESISTOR
SENSING
CONTACTS
--..111111111
-......
451
__G103 (VINP)
G104 (VIN 5)
0
IGNITION
KEV
-=-
SEE GROUND
DISTRIBUTION
PAGESBA-14-1,2,3
SA -
133 - 2
THEFT DETERRENT SYSTEM: PASS-KeyII
12110259
GRN
PASS-KeyII DECODER MODULE

DESCRIPTION
CAVITY
WIRE COLOR
CKT
A1
ORN
340
POWER FEED FROM ECM BATFUSE #4
8A-11-6
A2
PNK
439
POWER FEED FROM ECM IGN FUSE #5
8A-11-4
A3
DKBLU
229
FUEL ENABLE SIGNAL
8A-133-1
A4
YEUBLK
625
STARTER ENABLE RELAY CONTROL
8A-133-0, 1
AS
GRY
728
"SECURITY" INDICATOR LAMP CONTROL
8A-133-1
BS
BLK,WHT
451
GROUND
8A-14-1, 2, 3
87
PPUWHT
1074
IGNITION KEY RESISTOR RETURN
8A-133-1
88
WHT/BLK
1073
IGNITION KEY RESISTOR FEED
8A-133-1
PAGE
201-PG
COMPONENT
LOCATION
Clutch Start Switch

Convenience Center . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 . . . . l

(ECM) (V6 VIN S) ..... .
(ECM) (VS VIN P) .... .
1/P Fuse Block .......... .
[gnition Key Lock Cylinder
[nstrument Cluster ...... .
PASS-KeyII Decoder
Module ............... .
Starter Enable Relay .... .
Starter Solenoid ........ .
Switch . . . . . . . . . . . . . . . . .
19
FIG.
35 ..

19
35 ..
Top RH side of Steering Column . . . . . . . . . . . . . . . . . . . . 3, 34 . 5, 51
PartofSteeringColumn ........................... 34 ... 51 ..
LH side of 1/P ................................................... .
CONN
202-18
202-19
202-22
202-22
202-22
[nUP,justrightofRadio,attachedtoAirBagBracket. 8 .... 15
Mounted to right side of SIR Bracket, behind 1/P . . . . . . 45
66
Bottom of RH side of Engine, above Starter Motor . . . . . 25
42
202-14
202-20
Under console, on base of shift control lever . . . . . . . . . . 37
202-24
54
COMPONENT
C200B (18 cavities)
C200D (48 cavities)
C210 (4 cavities) ........ .
C230 (10 cavities) ....... .
Gl03 (LTl) ............. .
Gl04 (L32)
PllO ................... .
Sl09 (LTl)
SllO (L32)
S205
S209
S215
S223
S245 (Automatic)
S257 (Automatic)
201-PG
LOCATION
Steering Column . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Under RH side of 1/P, behind kick panel . . . . . . . . . . . . . . 46
(2 rings, 2 wires) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
ECM breakout
ECM breakout
breakout
SYSTEM DIAGNOSIS
For Diagnosis refer to SECTION 90.
133 - 3
FIG.
CONN
72
202-2
72 ..
67
67 ..
202-2
202-16
202-7
42
46
35
38
38
HATCH RELEASE (A90)
.,1/PFUSE
BLOCK
COURTESY
FUSE 8
15AMP
SEE FUSE
BLOCK DETAILS
PAGE SA-11-7
~--gu_
-1-,
......._
.SORN
I
I
---.J
1 ORN
640
40
.50~Nl640
WITH AUO ,
TO KEYLESS
ENTRY RECEIVER
PAGE SA-132-1
I
I
.5 BLK
-1
l
L--
1576
~:LTE~~E
SWITCH
-~
5210. -
SEEFUSE
~ BLOCK DETAILS
PAGE SA-11-7
I
-I
.5 ORN
E13TC200C
.5BL: 1576
. .C2000
____
_ _ _ _ _ 5244
.5 BLK
40
1576
.5BLK11576
C1
C2
A1
.8 ORNiBLK
.35 TAN/WHT
434 (AUTOMATIC)
33 (MANUAL)
AUTOMATIC
rn
MANUAL
HATCH
RELEASE
ACTUATOR
.35 TAN,WHT
WITH
DAYTIME
RUNNING
LIGHTS (DRL)
WITHOUT
DAYTIME
RUNNING
LIGHTS (DRL)
-J-,
.35 TAN,WHlH
r" -
I
I
I
SEE GROUND
.5 BLK/WHT
DISTRIBUTION
SA-14-2, 3 (V6 VIN S)
451
llllii..._
,...- -
.8 BLK,WHT
.__ _ _ '
5109 (VS VIN P)

(V6 VIN 5)
-
5110
451
G103(V8VINP)
VIN 5)
..:.J_!Q!_ (V6
.35 TAN;WHT
33
.5 BLK
1550
PARK
BRAKE
._ INPUT
___
33
DAYTIME
RUNNING
I LIGHTS (DRL)
I MODULE
I
...I
"'"f:,
PARK B R A K E ( l ]
SWITCH
CLOSED WITH
PARK BRAKE ON
-
[lJ
PARK BRAKE
SWITCH
CLOSED WITH
PARK BRAKE ON
IMPORTANT:
EACH MOTOR CONTAINS

BREAKER (ECB).

RESISTANCE RETURNS TD
TERMINALS.
COMPONENT
(DRL) Module . . . . . . . . . .
201-PG
LOCATION
Mounted behind Radio and HV AC Controls, left of

I/P Compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Center of end panel, in Cargo Compartment . . . . . . . . . .
Mounted to right side of SIR Bracket, behind 1/P . . . . . .
Left of Steering Column, in knee bolster pad . . . . . . . . .
LH side ofl/P Carrier, on the side . . . . . . . . . . . . . . . . . . .
In console, at base of Park Brake Lever . . . . . . . . . . . . . .
7 ....
Hatch Release Actuator . . .
30
Hatch Release Relay . . . . .
45 . . .
Hatch Release Switch . . . .
38 . . .
1/P Fuse Block . . . . . . . . . . .
8 ....
Park Brake Switch . . . . . . .
22
Switch ................ . Under console, on base of shift control lever . . . . . . . . . . 37
C200C (13 cavities)
Steering Column . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 7
C200D (48 cavities)
Steering Column . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 7
C210 (4 cavities) ........ . Under RH side ofl/P, behind RH kick panel . . . . . . . . . . 46
G103 (LTl) ............. . RH side of Engine Block,just above Starter
(2 rings, 2 wires) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
G104 (L32)
G200
PllO
Compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 . . .
8109 (LTl)
ECM breakout
8110 (L32)
ECM breakout
S210
8211
Main Harn
S22B ................... . I/P Harn, approx 11 cm before DLC breakout
8234 (Automatic) ....... . I/P Harn, approx 4 cm from G201 breakout
8244 ................... . I/P Harn, approx 7 cm from DERM Module breakout
135 - 1
FIG.
CONN
12
47
66
57
15
39
202-17
202-20
202-22
54
202-24
72
202-2
72
67
202-2
202-16
42
46
16
35
Diagnosis)
System
1. Check that G400 is clean and tight.

2. Check PWR ACCY Fuse and Courtesy Fuse for
open. If either fuse is open, check for short to
ground through CKTs 640 and/or 40.
3. For vehicles with Manual Transmissions, the
"BRAKE" Indicator receives a ground through the
Park Brake Switch. Applying the Park Brake and
observing the "BRAKE" Indicator can be used as a
quick check of the ground CKT below 8228.
check. Use Test LightJ 34142 whenever possible.

SYSTEM DIAGNOSIS

SA -
135 - 2
HATCH RELEASE (A90)
Important:
For a better understanding of the Retained

Accessory Power (RAP) operation, refer to
Circuit Operation at the end of this section.
SYMPTOM TABLE
SYMPTOM
PROCEDURE
PAGE NUMBER
Hatch does not release when operating the Hatch

Release Switch.
Chart #1
SA-135-2
Hatch releases immediately at Ignition "ON" (in Park

or Neutral for Automatic Transmission or with Park
Brake "ON" for Manual Transmission).
Check for short to B + on CKT 1576 between Hatch

Release Switch and Hatch Release Relay.
Check for faulty Hatch Release Switch (stuck
closed).
If equipped with Keyless Entry, also refer to
SECTION SA-132.
Hatch Release operates from Keyless Entry and does

not operate from Hatch Release Switch.
Chart #2
SA-135-4
CHART #1
HATCH DOES NOT RELEASE WHEN OPERATING THE HATCH RELEASE SWITCH
IGNITION "ON."
WITH A TEST LIGHT TO GROUND, BACKPROBE HATCH RELEASE ACTUATOR TERM" A".
IS TEST LIGHT "ON"?

HATCH RELEASE RELAY TERM "C1" TO GROUND.
IS TEST LIGHT "ON"?
CHECK FOR SHORT TO B + IN CKT 56 BETWEEN HATCH

RELEASE ACTUATOR AND HATCH RELEASE RELAY.
CHECK FOR FAULTY HATCH RELEASE RELAY (STUCK CLOSED).
DISCONNECT HATCH RELEASE RELAY CONNECTOR.

MOMENTARILY CONNECT A FUSED JUMPER FROM
TERM "C1" TO TERM" A2" OF THE HATCH RELEASE
RELAY CONNECTOR.
DOES THE HATCH RELEASE ACTUATOR WORK?
CHECK COURTESY FUSE 8 FOR OPEN.

IF FUSE IS BLOWN, CHECK FOR SHORT TO GROUND THROUGH (KT 40.
CHECK FOR OPEN IN CKT 40 FROM 1/P FUSE BLOCK TO HATCH
RELEASE RELAY.
BACKPROBE HATCH RELEASE RELAY TERM "C2"

OPERA TE HATCH RELEASE SWITCH.
DID TEST LIGHT ILLUMINATE WHEN SWITCH WAS
OPERATED?
RECONNECT FUSED JUMPER.

BACKPROBE HATCH RELEASE ACTUATOR CONN TERM" A"
IS TEST LIGHT "ON"?
135 - 3
CONNECT A TESTLIGHTFROM HATCH RELEASE RELAY

CONNECTOR TERMINALS "A1" TO "C1".
SET PARK BRAKE ON MANUAL TRANS.
PLACE IN PARK OR NEUTRAL FOR AUTO TRANS.
IS TEST LIGHT "ON"?
AUTOMATIC
TRANSMISSION
CHECK FOR OPEN IN

GROUND CKT 434 TO
TRANSMISSION
POSITION SWITCH
TERM "B".
CHECK TRANSMISSION
POSITION SWITCH.
CHECK FOR OPEN IN
GROUND CKT 451
BETWEEN
TRANSMISSION
POSITION SWITCH
AND GROUND.
CHECK FOR POOR
CONNECTION ATC210
TERM "B".
CHECK FOR OPEN

IN GROUND CKT 33
FROM HATCH
RELEASE RELAY TO
PARK BRAKE
SWITCH ORA
FAULTY PARK
BRAKE SWITCH.
IF EQUIPPED WITH
DAYTIME RUNNING
LAMPS (DRL), ALSO
CHECK FOR POOR
CONNECTIONS AT
DA YTlME RUNNING
LAMPS MODULE
CONN C2
TERMINALS "D"
AND"E".
CHECK DIODE IN
DRL MODULE FOR
OPEN.
CHECK FOR OPEN
IN CKT 1134 TO
PARK BRAKE
SWITCH.
CHECK FOR
POOR
CONNECTIONS
AT HATCH
RELEASE
RELAY.
IF OK, REPLACE
HATCH
RELEASE
RELAY.
BACKPROBE HATCH RELEASE SWITCH CONN

TERM" A" WITH A TEST LIGHT TO GROUND AND
OPERA TE HATCH RELEASE SWITCH.
DOES TEST LIGHT ILLUMINATE WHEN SWITCH IS
OPERATED?
BACKPROBE
HATCH RELEASE
SWITCH
TERM "B" WITH A
TEST LIGHT TO
GROUND.
IS TEST LIGHT
CHECK FOR POOR

CONNECTION AT HATCH
RELEASE SWITCH OR FOR
OPEN IN CKT 1576
BETWEEN HATCH RELEASE
SWITCH AND HATCH
RELEASE RELAY.
"ON"?
CHECK PWR ACCY

FUSE 7 FOR OPEN.
IF FUSE IS OPEN,
CHECK FOR SHORT
TO GROUND
THROUGH CKT 640.
CHECK FOR OPEN
IN CKT640
BETWEEN 1/P FUSE
BLOCK AND HATCH
RELEASE SWITCH.
DISCONNECT HATCH RELEASE ACTUATOR.

CONNECT A TEST LIGHT TO THE HATCH RELEASE
ACTUATOR CONNECTOR FROM TERM" A" TO
TERM "B".
IS TEST LIGHT "ON"?

BETWEEN HATCH RELEASE RELAY
AND HATCH RELEASE ACTUATOR.
CHECK FOR POOR CONNECTIONS AT HATCH

RELEASE ACTUATOR.
IF OK, REPLACE HATCH RELEASE ACTUATOR.

HATCH RELEASE ACTUATOR AND G400,
OR FOR POOR CONNECTION AT G400.
CHECK FOR POOR

CONNECTIONS AT
HATCH RELEASE SWITCH.
IF OK, REPLACE HATCH
RELEASE SWITCH.
8A -
135 - 4
HATCH RELEASE (A90)

CHART #2
HATCH RELEASE OPERATES FROM KEYLESS ENTRY AND DOES NOT
OPERA TE FROM HATCH RELEASE SWITCH
IGNITION "ON."
WITH A TEST LIGHT TO GROUND, BACKPROBE HATCH RELEASE SWITCH
TERM "A" AND OPERATE HATCH RELEASE SWITCH.
IS TEST LIGHT "ON" WHEN OPERA TING SWITCH?
BACKPROBE HATCH RELEASE SWITCH TERM "B"

IS TEST LIGHT "ON"?

HATCH RELEASE SWITCH AND 5244.
CHECK PWR ACCY FUSE 7 FOR OPEN.

IF FUSE IS OPEN, CHECK FOR SHORT TO
GROUND THROUGH CKT 640.
CHECK FOR OPEN IN CKT 640 BETWEEN 1/P
FUSE BLOCK AND HATCH RELEASE SWITCH.
CIRCUIT OPERATION
The Hatch Release Relay has voltage applied from
the PWR ACCY Fuse which is controlled by the
Retained Accessory Power (RAP) Module. Voltage is
applied to the PWR ACCY Fuse for up to 10 minutes
after the Ignition is turned off, or for 35 seconds after
exiting the vehicle and closing the doors or whenever a
door is open. For a complete understanding of the
Retained Accessory Power (RAP) operation, refer to
SECTION SA-15.
The Hatch Release can be activated from within
the vehicle by operating the Hatch Release Switch
when the Ignition is in "ACCY", "RUN" or
"RETAINED ACCESSORY POWER" with the Park
Brake set for Manual Transmission or in "PARK" or
"NEUTRAL" position for Automatic Transmission.
Battery voltage is applied at all times to the
normally open contacts of the Hatch Release Relay
from Courtesy Fuse 8.
CHECK FOR POOR CONNECTIONS AT

HATCH RELEASE SWITCH.
IF OK, REPLACE HATCH RELEASE SWITCH.
When the Hat.ch Release Switch is operated, the

switch closes and battery voltage is applied to the coil
of the Hatch Release Relay. On vehicles with
Automatic Transmissions, the Hatch Release Relay
Coil receives a ground through the Transmission
Position Switch to Gl03 (VS VIN P) or Gl04
(V6 VIN S), the Hatch Release Relay can only be
energized with the Gear Selector in the "PARK" or
"NEUTRAL" position. On vehicles with Manual
Transmissions, the Hatch Release Relay Coil receives
a ground through the Park Brake Switch when the
Park Brake is "ON." For vehicles equipped with
Daytime Running Lamps (DRL), ground is provided
through the Park Brake Switch and a Circuit Isolation
Diode within the DRL Module.
When the Hatch Release Relay is energized and
the relay contacts close, battery voltage is applied to
the Hatch Release Actuator. The Hatch Release
Actuator contains an Electronic Circuit Breaker
(ECB). ECB resistance increases if motor is
overloaded. Resistance returns to normal after voltage
is removed from actuator terminals.
BLANK
135- 5
SA -

17E;;O;;R- -
-----11/P
,I FUSE
BLOCK
I DISTRIBUTION
PAGE SA-10-3
I
!GN
~~uu~
~--------t-J
1
.8 PNK
SEE FUSE
BLOCK DETAILS
PAGESA-11-4
... -
39
5206
.35 PNK
39
SEE CRUISE CONTROL

PAGE SA-34-1
TO AUTOMATIC
...
.35 LT BLU/8:r : :
.35 LT BLU/BLK
<II
TRANSMISSION ......
- - - - - - - - . 5238
583
PAGESA-21-6 (VS VINP)
35LTBLU/B~~583
TR
ANSM~[QJ
SHIFT
INTERRUPT
(BTSI) SOLENOID
rn
SEE STARTER ANO

CHARGING
PAGE SA-30-0
IMPORTANT:
LOOPED OUTSIDE OF
TAPED BUNDLE,
IN LENGTH.
"'":r15
.5 RUST
5257
"'"'.t"
i
FUSIBLE LINK (BTSI)

5 DK GRN
5245
575
TRANSMISSION
POSITION
SWITCH
r- - - - - - -
I
I
/ I
,N@D)(
2
I
\ R
'-.-~.-
L--
----J
SP:Lr
A
3 PPL
S PPL
C210
6 (V6 VIN S)
6 (VS VIN P)
COMPONENT
201-PG FIG.
LOCATION

Interrupt (BTSI) Solenoid In console, under PRNDL Display . . . . . . . . . . . . . . . . . . .
Fusible Link (BTSI) ..... . Under front part of console, approx 2 cm rearward of
Cigar Lighter breakout . . . . . . . . . . . . . . . . . . . . . . . . . . .
1/P Fuse Block .......... . LH side ofl/P Carrier, on the side . . . . . . . . . . . . . . . . . . .
Starter Solenoid ........ . Bottom of RH side of Engine, above Starter Motor . . . . .
Switch ................ . Under console, on base of shift control lever . . . . . . . . . .
C210 (4 cavities) ........ . Under RH side of 1/P, behind RH kick panel . . . . . . . . . .
PllO ................... . Right side in dash panel, Engine to Passenger
Compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
S206
breakout
S238 (Automatic)
1/P Harn, approx 20 cm from DERM Module breakout
S245 (Automatic)
Lighter breakout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
S257 (Automatic)
Lighter breakout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
37
138 - 1
CONN
54
21
38
8 . . . . 15
25
42
202-22
37
46
54
67
202-24
202-16
19
35
21
38
21
38
Diagnosis)
1. If Gages Fuse #9 is open, refer to Chart #3 in this
section.
2. Check Brake Switch Assembly for proper
adjustment.
3. Check Fusible Link between 8257 and S245. See
Wiring Schematic and Component Location.
4. If Transmission Shifter does not shift out of
"PARK," check linkage and cable for binding.
5. Check for poor connection at C210terminal "A".

SYSTEM DIAGNOSIS
SYMPTOM TABLE
SYMPTOM
PROCEDURE
PAGE NUMBER
Transmission does not shift out of "PARK" with brake

pedal depressed and Ignition Switch in "RUN."
Chart #1
8A-138-2
Transmission shifts out of "PARK" with Ignition Switch

in "RUN" and brake pedal not depressed.
Chart #2
8A-138-2
Gages Fuse #9 repeatedly blows whenever Ignition is

"ON" or when attempting to depress the brake pedal.
Chart #3
8A-138-3
/
8A -

CHART #1
TRANSMISSION DOES NOT SHIFT OUT OF "PARK" WITH BRAKE PEDAL
DEPRESSED AND IGNITION SWITCH IN "RUN"
TURN IGNITION SWITCH TO "RUN."

DISCONNECT BRAKE SWITCH ASSEMBLY CONN C2.
WITH A TEST LIGHT TO GROUND, BACKPROBE BRAKE
TRANSMISSION SHIFT INTERRUPT SOLENOID TERM "B".
IS TEST LIGHT "ON"?
RECONNECT BRAKE SWITCH ASSEMBLY CONN (2.

TRANSMISSION SHIFT INTERRUPT SOLENOID TERM "8".
IS TEST LIGHT "ON"?
INTERRUPT SOLENOID.
CHART #2
TRANSMISSION SHIFTS OUT OF "PARK" WITH IGNITION SWITCH
IN "RUN" AND BRAKE PEDAL NOT DEPRESSED

TRANSMISSION IN "PARK" POSITION.
DISCONNECT BRAKE TRANSMISSION SHIFT INTERRUPT SOLENOID CONN.
CONNECT A TEST LIGHT FROM BRAKE TRANSMISSION INTERRUPT SOLENOID CONN TERM "B" TO GROUND.
IS TEST LIGHT "ON''?

SWITCH ASSEMBLY CONN C2 TERM "A".
IS TEST LIGHT "ON"?
CONNECT A TEST LIGHT BETWEEN BRAKE TRANSMISSION

SHIFT INTERRUPT SOLENOID CONN TERMINALS "A" AND "8".
IS TEST LIGHT "ON"?

GROUND, BACKPROBE BRAKE
SWITCH ASSEMBLY CONN C2
TERM"B".
IS TEST LIGHT "ON"?

AT BRAKE TRANSMISSION SHIFT
INTERRUPT SOLENOID.
IF OK, REPLACE BTSI SOLENOID.

BETWEEN FUSE BLOCK AND
BRAKE SWITCH ASSEMBLY.
IF FUSE IS OPEN, GO TO
CHART #3.
CHECK FOR POOR

CONNECTIONS AT BRAKE
SWITCH ASSEMBLY.
IF OK, REPLACE BRAKE
SWITCH ASSEMBLY.
CHECK FOR OPEN IN

CKT 575 BETWEEN
INTERRUPT SOLENOID
AND 5245 INCLUDING
FUSIBLE LINK.
138 - 3
CHART #3
GAGES FUSE #9 REPEATEDLY BLOWS WHENEVER IGNITION IS "ON"
OR WHEN ATTEMPTING TO DEPRESS THE BRAKE PEDAL
REPLACE BLOWN FUSE.

DOES FUSE BLOW BEFORE ATTEMPTING TO
DEPRESS BRAKE PEDAL?
IF FUSE BLOWS WHEN BRAKE PEDAL

IS DEPRESSED, CHECK FOR SHORTED
BRAKE SWITCH ASSEMBL V AND
CONNECTIONS AT BRAKE SWITCH.
CIRCUIT OPERATION
The Brake Transmission Shift Interlock (BTSI) is
designed to interrupt shifting when energized. The
BTSI is energized whenever the Ignition Switch is in
"RUN," "BULB TEST" or "START" and is disabled
when the brake pedal is depressed.
The Brake Switch Assembly receives Ignition
voltage from Gages Fuse #9 in "RUN," "BULB TEST"
and "START." The TCC/Shift Interrupt Switch is part
of the Brake Switch Assembly and is normally closed,
providing voltage to the Brake Transmission Interrupt
(BTS[) Solenoid. The BTSI Solenoid gets its ground
path through CKT 575 then through the Transmission
Position Switch only when the Transmission Position
Switch is in the "PARK" or "NEUTRAL" position and
then to ground through CKT 6 to the Starter Solenoid
"S" terminal. When the BTSI Solenoid receives
voltage and the Transmission Position Switch is in the
"PARK" or "NEUTRAL" position, the BTSI Solenoid is
energized and prevents the Transmission Shift Lever
from being moved out of "PARK" or "NEUTRAL."
When the brake pedal is depressed, the Brake
Switch opens, removing voltage from the BTSI
Solenoid. This de-energizes the BTSI Solenoid,
allowing operation of the Shift Lever.

THROUGH A FAUL TV CONNECTOR OR IN WIRING.
CONNECT A DVM SET TO VOLTAGE ACROSS FUSE TERMINALS.
START BY DISCONNECTING ONE COMPONENT AT A TIME.
IF ALL RELATED COMPONENTS ARE DISCONNECTED AND SHORT
IS STILL PRESENT, LOCATE AND REPAIR SHORT IN WIRING.
POWER SEAT: DRIVER 6-WAY (AC3}
UP
UP
-
DEFOG/SEATS
CIRCUIT
BREAKER 12
3SAMP
____
SORN
1240
SORN
s2s2
1240
30RN
1240
-,1/PFUSE
BLOCK
UP
FRONT
OF SEAT
I
I
..J
DOWN
DOW~
FORWARD
ENTIRE
SEAT
._BACK
SEAT ACTIONS
TO REAR
DEFOGGER TIMER
PAGE BA-61-0
C310
SEAT
ASSEMBLY,
ORIVER
POWEi
SEAT
SWITCH
FORWARD
ENTIRE
SEAT
BACK
REAR
HEIGHT
FRONT
HEIGHT
FRONT
HEIGHT
,DOWN
ENTIRE
SEAT
UP
DOWN
REAR
HEIGHT
DOWN,
I
ENTIRE
SEAT
ECB
rn
REAR HEIGHT
MOTOR
2 BLK
14l0
IMPORTANT:
EACH MOTOR CONTAINS

. AN ELECTRONIC CIRCUIT
BREAKER (ECB).

TERMINALS.
3B:K1:::0
SEE GROUND
DISTRIBUTION
PAGE SA-14-10
~---111111. .
1 BLK
1050
'
~GJOS
Eo
aoDJ
[Jo o
co
___
......_
140 - 1
FODO
12085013
BLK
POWER SEAT SWITCH (AC3)
COMPONENT
Forward/Back Motor
(AC3 Power Seat) . . . . . . .
Front Height Motor
(AC3 Power Seat) . . . . . . .
1/P Fuse Block . . . . . . . . . . .
Power Seat Actuator
Assembly (AC3) . . . . . . . .
Power Seat Switch (AC3) .
Rear Height Motor
(AC3 Power Seat) . . . . . . .
C310 (2 cavities) . . . . . . . . .
G305 . . . . . . . . . . . . . . . . . . . .
201-PG
LOCATION
Under Driver's Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
FIG.
CONN
56
Under Driver's Seat .............................. . 37

56
LH side of 1/P Carrier, on the side .................. . 8 .... 15
202-22

On left side of Ori ver's Seat ........................ . 37
202-23
56
56

56
Between rear mounting bolt of Driver Seat near #3 Rail 6 .... 11
without AC3/ AQ9) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 . . . . 11
8252 . . . . . . . . . . . . . . . . . . . . I/P Harn, approx 22 cm from HV AC Control
Illumination Conn
Diagnosis)
1. Check Defog/Seats Circuit Breaker #12 by
operating the Rear Defogger.
2. Check that ground G305 is clean and tight.
3. Check for poor connections at Power Seat Switch
Connector or Motor Assembly connections.
4. If Defog/Seats Circuit Breaker opens whenever the
Power Seat Switch is operated, check for short to
ground through CKTs 282, 283, 284, 285, 286 and
287. Disconnecting motors one at a time can be
helpful.

abnormally high resistive circuits: Some test
useful in detecting res is ti ve circuits (see
SYSTEM DIAGNOSIS
8A -
140 - 2
POWER SEAT: DRIVER 6-WAY (AC3)

SYMPTOM TABLE
PROCEDURE
PAGE NUMBER
All Power Seat functions inoperative.
Chart #1
BA-140-2
Entire seat will not go "FORWARD" or "BACK," "UP"

or "DOWN" functions operate normally.
Chart #2
BA-140-3
Front Height wi II not go "UP" or "DOWN,"

"FORWARD" or "BACK" functions operate normally.
Chart #3
BA-140-4
Rear Height will not go "UP" or "DOWN,"

11
1
"FORWARD or "BACK' functions operate normally.
Chart #4
BA-140-5
Chart #5
BA-140-6
SYMPTOM
Entire seat will not go "UP' or "DOWN,'1 "FORWARD"

11
or "BACK functions operate normally.
CHART #1
ALL POWER SEAT FUNCTIONS INOPERATIVE
BACKPROBE POWER SEAT SWITCH

CONNECTOR WITH A TEST LIGHT BETWEEN
TERM 'T' AND GROUND.
LIGHTS
DOES NOT LIGHT
I
BACKPROBE POWER SEAT
SWITCH CONNECTOR WITH
THE TEST LIGHT BETWEEN
TERMINALS "F" & "C".

C310 TERM" A" OR OPEN IN CKT 1240.
LIGHTS
DOES NOT LIGHT
CHECK FOR POOR

CONNECTION AT
POWER SEAT SWITCH.
IF OK, REPLACE POWER
SEAT SWITCH.

AT C310 TERM "B" OR OPEN IN
CKT 1450.
CHART #2
ENTIRE SEAT WILL NOT GO "FORWARD" OR "BACK,"
"UP" OR "DOWN" FUNCTIONS OPERATE NORMALLY
BACKPROBE FORWARD/BACK MOTOR CONN WITH A

TEST LIGHT FROM TERM" A" TO GROUND.
POWER SEAT SWITCH TO "FORWARD."
LIGHTS
DOES NOT LIGHT
I
BACKPROBE FORWARD/BACK MOTOR CONN
WITH A TEST LIGHT FROM TERM "B" TO GROUND.
POWER SEAT SWITCH TO "BACK."
LIGHTS
CHECK FOR OPEN OR SHORT TO GROUND

IN CKT 285 OR POOR CONNECTION AT
POWER SEAT SWITCH CONN TERM "E".
IF OK, REPLACE POWER SEAT SWITCH.
DOES NOT LIGHT
BACKPROBE FORWARD/BACK MOTOR CONN WITH

A TEST LIGHT FROM TERM "A" TO TERM "B".
POWER SEAT SWITCH TO "FORWARD."
POWER SEAT SWITCH TO "BACK."
LIGHTS IN BOTH
POSITIONS
r----------------------------------,
I.
I
CHECK FOR POOR CO~N.~CTION AT ~O.~WARD/BACK :

MOTOR CONN TERM A OR TERM B .
IF OK, REPLACE MOTOR ASSEMBLY.
I
1
lI ___________________________________
Jt
REFER TO SECTION 10-10.

IN CKT 284 OR POOR CONNECTION AT
POWER SEAT SWITCH CONN TERM "D".
I
LIGHTS IN ONE POSITION OR
DOES NOT LIGHT AT ALL
I
REPLACE POWER SEAT SWITCH.
140 - 3
SA -
140 - 4

CHART #3
FRONT HEIGHT WILL NOT GO "UP" OR "DOWN,"
"FORWARD" OR "BACK" FUNCTIONS OPERATE NORMALLY
BACKPROBE FRONT HEIGHT MOTOR CONN WITH

A TEST LIGHT FROM TERM "B" TO GROUND.
POWER SEAT SWITCH TO "FRONT HEIGHT UP."
LIGHTS
DOES NOT LIGHT
BACKPROBE FRONT HEIGHT MOTOR

CONN WITH A TEST LIGHT FROM
TERM "A" TO GROUND.
POWER SEAT SWITCH TO "FRONT
HEIGHT DOWN."

POWER SEAT SWITCH CONN TERM "G"
OR OPEN IN CKT 286.
I
I
LIGHTS
DOES NOT LIGHT

TERM "B" TO TERM "A".
POWER SEAT SWITCH TO "ENTIRE
SEAT UP."

POWER SEAT SWITCH CONN TERM "H"
OR OPEN IN CKT 287.
I
I
LIGHTS
DOES NOT LIGHT
I
SEAT DOWN."
I
I
LIGHTS
DOES NOT LIGHT
r-1------------------------------,
'
L__
I
CHECK FOR POOR CONNECTION AT FRONT
I
,, ,,
HEIGHT MOTOR CONN TERM B OR TERM A . 1
:
REFER TO SECTION 10-10. ______________
II
II
CHART #4
REAR HEIGHT WILL NOT GO "UP" OR "DOWN,"
BACKPROBE REAR HEIGHT MOTOR CONN WITH A

TEST LIGHT FROM TERM "A" TO GROUND.
POWER SEAT SWITCH TO "REAR HEIGHT UP."
I
LIGHTS
DOES NOT LIGHT
BACKPROBE REAR HEIGHT MOTOR

TERM "B" TO GROUND.
POWER SEAT SWITCH TO "REAR
HEIGHT DOWN."

POWER SEAT SWITCH CONN TERM "A"
OR OPEN IN CKT 282.
IF OK, REPLACE POWER SEAT SWITCH .
LIGHTS
DOES NOT LIGHT

TERM" A" TO TERM "B".
SEAT UP."

POWER SEAT SWITCH CONN TERM "B"
OR OPEN IN CKT 283.
IF OK. REPLACE POWER SEAT SWITCH.
I
I
LIGHTS
DOES NOT LIGHT
REPLACE POWER SEAT SWITCH. ,

TERM "A" TO TERM "B".
SEAT DOWN."
I
I
LIGHTS
DOES NOT LIGHT
,--------------------------,

II
II
REAR HEIGHT MOTOR CONN TERM A
OR TERM "B".
REFER TO SECTION 10-10.
I
I
L---------------------------J
140 - 5
8A -

CHART #5
ENTIRE SEAT WILL NOT GO "UP" OR "DOWN,"
CAN FRONT HEIGHT ONLY, BE ADJUSTED?
BE ADJUSTED?

POWER SEAT SWITCH CONN OR
MOTOR ASSEMBLY CONNECTOR.
CIRCUIT OPERATION
There are three reversible motors that operate the
Power Seats. The front and back height of the seat are
operated by different motors. They can be raised or
lowered independently of each other. When the Entire
Seat Switch is pushed to the "UP" or "DOWN"
position, both motors run to move the front and back of
the seat at the same time.
The Forward/Back Motor is operated by the Entire
Seat Switch. When it is held in the "FORWARD"
position, battery voltage is applied through the switch
contacts and CKT 285 to the Forward/Back Motor.
The motor is grounded through CKT 284 and the
contact of the Entire Seat Switch to ground 0305. The
motor runs to drive the seat forward until the switch is
released.
In the "BACK" position, CKT 284 receives battery
voltage and CKT 285 is grounded. This reversed
polarity causes the motor to run in the opposite
direction and drive the seat backward.
REFER TO CHART #4, "REAR HEIGHT WILL NOT GO

'UP' OR 'DOWN,' 'FORWARD' OR 'BACK' FUNCTIONS
OPERATE NORMALLY," PAGE SA-140-5.
REFER TO CHART #3, "FRONT HEIGHT WILL NOT GO

'UP' OR 'DOWN,' 'FORWARD' OR 'BACK' FUNCTIONS
OPERATE NORMALLY," PAGE SA-140-4.
The Front and Rear Motors work in a similar way

when the Front or Rear Height Switch is operated.
To raise the entire seat, the Entire Seat Switch is
held in the "UP" position. This applies battery voltage
through CKT 282 and CKT 286 to the Rear Seat and
Front Seat Motors. The motors are grounded through
CKT 283 and CKT 287 and the Power Seat Switch to
0305. Both motors run to drive the entire seat up. A
similar action occurs to move the entire seat down.
Each Motor contains an Electronic Circuit Breaker
(ECB). ECB resistance increases if motor is
overloaded. Resistance returns to normal after voltage
is removed from motor terminals.
BLANK
POWER SEATS: ULTIMA (AQ9)
----,!!!'
r---SEE POWER
FUSE
I DISTRIBUTION
I PAGE SA-10-1
DEFOG;SEA rs
CIRCUIT
BREAKER _g
35AMP
L---TO REAR
DEFOGGER TIMER
PAGE SA-61-0
I BLOCK
I
I
____ J
ORN
5 ORN
......_ _5_
___
_ 1240
5252
1240
3 ORN
A
1240
,I,. C310
v,;.;;;
1
3 ORN
3 ORN
5320--------------------------------~
3 ORN!1240
1240
SEAT
ASSEMBLY,
DRIVER
3 ORN
30RN
..------------------- e
1240
CJOO
1240
5330
3 OR:~1240
POWER
SEAT
SWITCH.
DRIVER
DEFLATE
LUMBAR
INFLATE
DEFLATE
LATERAL
.SWHT
766
.5 GRY
764
SOLENOID
VALVE
ASSE MB_!:,'
----1
l'--...,,.--1
LUM BAJ!.
BLADDER
.5 BLK/
LATERAL
BLADDER
LATERAL
BLADDER
769
WHT
POWER
SEAT
CONTROL
MODULE
.35WHT
766
.35 GRY
764
.35 GRY!BLK
628
141 - 1
3 ORN
1240
. - - - - - - - - - - - - - - -......._____________________________________________________________ SEAT
ASSEMBLY,
PlllSENGER
3 ORN
POWER.-------P""--------------------------------------------------------.
-SEAT
SWITCH,
PASSENGER DEFLATE
LUMBAR
DEFLATE
LATERAL
INFLATE
INFLATE
...
...
_,,
_,,
K
SOLENOID
VALVE
ASSEMBLY
.5 GRY
764
.5 WHT
766
LUMBAR
BLADDER
.5 BLK,WHT
769
,___
_____
1~-------------------JF
l
l
.35 WHT
766
.35 GRY
764
.35 GRY'BLK
628
C305
LATERAL
BLADDER
LATERAL
BLADDER
8A -
141 - 2
t;SJ Cj5l Cj:jl It?
~CfHflCil
12064998
8-WA Y F METRI-PACK 280 SERIES
BLK
POWER SEAT CONTROL MODULE
12033944.
BLK
POWER SEAT SWITCH, DRIVER
POWER SEAT SWITCH, PASSENGER
'til ~ [ii] ltil Ci9

d'J c2J dJ Cil CQ
12064769
NAT
SOLENOID VALVE ASSEMBLY
COMPONENT
1/P Fuse Block . . . . . . . . . . .
PowerSeatSwitch,Driver
Power Seat Switch,
Passenger . . . . . . . . . . . . . .
Pump Assembly . . . . . . . . . .
Solenoid Valve Assembly .
C300 (6 cavities) ........ .
C305 (6 cavities) ........ .
C310 (2 cavities) ........ .
G305 ................... .
8252
8320
8330
8335
8340
8345
8350
8355
8360
201-PG
LOCATION
LH side ofl/P Carrier, on the side . . . . . . . . . . . . . . . . . . . 8 . . . .
Under Driver's Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
OnleftsideofDriver'sSeat ......................... 41
On right side of Passenger Seat .................... .
Under Driver's Seat .............................. .
Under Driver's Seat .............................. .
Under Driver Seat Assembly ...................... .
Under Passenger Seat Assembly ................... .
Between rear mounting bolt of Driver Seat near #3 Rail
without AC3/AQ9) .............................. .
1/P Harn, approx 22 cm from HVAC Control
Illumination Conn
Seat ,Jumper Harn, near rosebud under Driver Seat
Switch Conn
Control Module Conn
Control Module Conn
Driver Seat Harn, approx 18 cm from C300
Driver Seat Harn, approx 11 cm from C300
Driver Seat Harn, approx 20 cm from Solenoid Valve
Assembly Conn
Passenger Seat Harn, approx 22 cm from Power Seat
Switch Conn
FIG.
15
60
60
41
60
41
60
40,41 59,60
41
60
40 ... 59
6 .... 11
6 ....
141 - 3
CONN
202-22
202-22
202-23
202-23
202-24
202-16
202-16
11
Diagnosis)
1. If both Passenger and Driver Seat Functions
(Lumbar and Lateral) are inoperative, check
DEFOG/SEATS Circuit Breaker 12 for open.
Check that G305 is clean and tight.
Check for poor connections at C300.
Check for poor connections at C310 terminals
"A"and"B".
2. If Passenger Seat is inoperative and Driver's Seat
operates normally, check for poor connections at
C300 and C305, and for open in Seat Jumper
Harness.

SYSTEM DIAGNOSIS
SA -
141 - 4

SYMPTOM TABLE
SYMPTOM
rn
PROCEDURE
PAGE NUMBER
Important:
Charts #1 through #5 to be used for diagnosis of both Driver and/or Passenger Seat(s) .
Both seats inoperative and pump does not run.
Chart #1
8A-141-4
Lumbar bladder inoperative, but lateral bladders

operate normally within the same seat.
Chart #2
8A-141-6
Lateral bladders inoperative, but lumbar bladder

operates normally within the same seat.
Chart #3
8A-141-7
Bladder(s) inflate but do not deflate.
Chart #4
8A-141-7
Pump Assembly operates, but bladder(s) do not

inflate.
Chart #5
8A-141-8
Passenger Power Seat inoperative, Driver Power Seat

operates normally.
Chart #6
8A-141-9
Driver Power Seat inoperative, Passenger Power Seat

operates normally.
Chart #7
8A-141-10
One lateral bladder inoperative, and one lateral Check for:

bladder operates normally within the same seat.
- Pinched or punctured bladder tubing.
- Punctured bladder.
- Stuck Solenoid Valve within Solenoid Valve
Assembly.
- Open in CKT 765 from 5355 or 5360 to Solenoid
Valve Assembly terminal "H" or terminal "J".
CHART #1
BOTH SEATS INOPERATIVE AND PUMP DOES NOT RUN
WITH A TEST LIGHT TO GROUND, BACKPROBE C300 TERM "C" AND C305 TERM "C".
CONNECT A TEST LIGHT BETWEEN TERMINALS "C"

AND "D" OF C300.
IS TEST LIGHT "ON"?
WITH A TEST LIGHT TO GROUND, BACKPROBE THE

POWER SEAT CONTROL MODULE CONN TERM "F".
IS TEST LIGHT "ON"?
REPAIR OPEN IN CKT(S) 1240 TO DRIVER AND/OR PASSENGER

SEAT IN CIRCUIT(S) THAT DID NOT ILLUMINATE TEST LIGHT.
CHECK FOR POOR CONNECTIONS AT C310 TERM" A".
CHECK FOR OPEN IN DEFOG/SEATS CIRCUIT BREAKER 12.
IF CIRCUIT BREAKER 12 IS OPEN, CHECK FOR SHORT TO
GROUND THROUGH CKT 1240.
CHECK FOR OPEN IN GROUND CKT 1450 FROM C300

TERM "D" TO G305.
CHECK FOR POOR CONNECTION AT C310 TERM "B".
141 - 5
DISCONNECT THE POWER SEAT CONTROL MODULE CONNECTOR.

CONNECT A TEST LIGHT FROM TERM "F" TO TERM 'T' AT THE
POWER SEAT CONTROL MODULE CONNECTOR.
IS TEST LIGHT "ON"?
CONNECT A TEST LIGHT FROM TERM "F" TO TERM "B"

AT THE POWER SEAT CONTROL MODULE CONNECTOR.
IS TEST LIGHT "ON"?
REPAIR OPEN IN GROUND CKT 1450 BETWEEN POWER SEAT

CONTROL MODULE CONN TERM "E" AND C300 TERM "D".
CHECK THE TERMINALS IN THE POWER SEAT CONTROL MODULE

CONNECTOR FOR POOR CONNECTIONS.
WAS THERE ANY TERMINAL(S) CAUSING A POOR CONNECTION?
REPAIR OPEN IN GROUND CKT 1450 BETWEEN POWER SEAT

CONTROL MODULE CONN TERM "B" AND C300 TERM "D".
RECONNECT POWER SEAT CONTROL MODULE.

DISCONNECT PUMP ASSEMBLY CONNECTOR UNDER DRIVER SEAT.
CONNECT A TEST LIGHT BETWEEN TERMINALS" A" AND "B" OF
THE PUMP ASSEMBLY CONNECTOR.
WHILE OBSERVING TEST LIGHT, OPERATE THE DRIVER POWER SEAT
SWITCH (LUMBAR OR LATERAL) TO THE "INFLATE" POSITION.
DOES TEST LIGHT ILLUMINATE WHEN OPERATING SWITCH?
REPAIR OR REPLACE TERMINALS AS NECESSARY

TO ASSURE GOOD TERMINAL CONTACT.
RECONNECT PUMP ASSEMBLY CONNECTOR.

WITH AT EST LIGHT, BACKPROBE TERMINALS "C" AND "G" OF
THE POWER SEAT CONTROL MODULE CONNECTOR.
WHILE OBSERVING TEST LIGHT, OPERATE DRIVER POWER
SE~T SWITCH (LUMBAR OR LATERAL) TO THE "INFLATE" AND
"DEFLATE" POSITIONS.
DOES TEST LIGHT ILLUMINATE IN BOTH "INFLATE" AND
"DEFLATE" POSITIONS WHEN OPERATING SWITCH?
CHECK FOR POOR CONNECTIONS AT PUMP

ASSEMBLY CONNECTOR.
IF OK, REPLACE PUMP.
WITH A TEST LIGHT TO GROUND, BACKPROBE POWER SEAT

CONTROL MODULE CONNECTOR TERM "D".
WHILE OBSERVING TEST LIGHT, OPERA TE DRIVER POWER SEAT
DOES TEST LIGHT ILLUMINATE WHEN OPERA TING SWITCH?
CHECK FOR OPEN IN CKT 100, OR FOR OPEN

IN CKT 101 FROM POWER SEAT CONTROL
MODULE TO PUMP ASSEMBLY.
CHECK FOR POOR CONNECTION AT C300 TERM "C".

IF OK, REPAIR OPEN IN CKT 1240 BETWEEN C300 TERM "C"
AND POWER SEAT CONTROL MODULE TERM "F".
SA -
141 - 6

CHART #1 (continued}
BOTH SEATS INOPERATIVE AND PUMP DOES NOT RUN
WITH A TEST LIGHT TO GROUND, BACKPROBE DRIVER POWER

SEAT SWITCH CONN TERM "E".
WHILE OBSERVING TEST LIGHT, OPERA TE DRIVER POWER SEAT
CHECK CONNECTIONS AT POWER

SEAT CONTROL MODULE.
If OK, REPLACE POWER SEAT
CONTROL MODULE.
CHECK FOR POOR CONNECTIONS AT DRIVER POWER SEAT SWITCH.

If OK, REPLACE THE DRIVER POWER SEAT SWITCH.
CHECK FOR OPEN IN CKT 766 FROM POWER

SEAT CONTROL MODULE TERM "D" TO 5340.
CHART #2
LUMBAR BLADDER INOPERATIVE, BUT LATERAL BLADDERS
OPERATE NORMALLY WITHIN THE SAME SEAT
WITH A TEST LIGHT TO GROUND, BACKPROBE SOLENOID VALVE

ASSEMBLY CONN TERM "K".
WHILE OBSERVING TEST LIGHT, OPERA TE LUMBAR BLADDER WITH
THE POWER SEAT SWITCH TO "INFLATE" OR "DEFLATE" POSITION.

SWITCH CONN TERM "B".
WHILE OBSERVING TEST LIGHT, OPERATE LUMBAR BLADDER WITH
THE POWER SEAT SWITCH TO "INFLATE" OR "DEFLATE" POSITION.
DOES THE TEST LIGHT ILLUMINATE WHEN OPERATING SWITCH?
CHECK FOR OPEN IN CKT 763 BETWEEN POWER SEAT SWITCH

TERM "B" ANO SOLENOID VALVE ASSEMBLY TERM "K".
CHECK FOR POOR CONNECTION AT SOLENOID VALVE

CONN TERM "K".
CHECK FOR PINCHED OR PUNCTURED BLADDER TUBING.
CHECK FOR PUNCTURED LUMBAR BLADDER.
IF ABOVE ARE OK, REPLACE SOLENOID VALVE ASSEMBLY.
CHECK FOR POOR CONNECTION AT POWER

SEAT SWITCH CONN TERM "B".
141 - 7
CHART #3
LATERAL BLADDERS INOPERATIVE, BUT LUMBAR BLADDER
OPERATES NORMALLY WITHIN THE SAME SEAT
WITH A TEST LIGHT TO GROUND, BACKPROBE POWER SEAT SWITCH CONN TERM" A".
WHILE OBSERVING TEST LIGHT, OPERATE LATERAL BLADDER USING THE POWER SEAT
SWITCH TO THE "INFLATE" OR "DEFLATE" POSITION.
DOES THE TEST LIGHT ILLUMINATE WHEN OPERATING SWITCH?
WITH A TEST LIGHT TO GROUND, BACKPROBE SOLENOID VALVE CONN TERM "H".
WHILE OBSERVING TEST LIGHT, OPERATE LATERAL BLADDER USING THE POWER
SEAT SWITCH TO THE "INFLATE" OR "DEFLATE" POSITION.
CHECK FOR POOR CONNECTION AT SOLENOID VALVE CONN TERMINALS "H" AND
CHECK FOR PINCHED OR PUNCTURED BLADDER TUBING.
If ABOVE ARE OK, REPLACE SOLENOID VALVE.
"J".

POWER SEAT SWITCH CONN TERM "A".

POWER SEAT SWITCH CONN TERM "A"
AND SOLENOID VALVE CONN
TERMINALS "H" AND "J".
CHART #4
BLADDER(S) INFLATE BUT DO NOT DEFLATE
WITH A TEST LIGHT TO GROUND, BACKPROBE POWER SEAT SWITCH CONN TERM "C" .
WHILE OBSERVING TEST LIGHT, OPERATE POWER SEAT SWITCH TO THE "DEFLATE" POSITION.

CONTROL MODULE CONN TERM "H".
WHILE OBSERVING TEST LIGHT, OPERATE POWER SEAT
SWITCH TO THE "DEFLATE" POSITION.

SEAT SWITCH TERM "C".
CHECK FOR POOR CONNECTION AT POWER SEAT CONTROL

IJIODULE TERM "H".
IF OK, REPLACE POWER SEAT CONTROL MODULE.
~
(DRIVER SEAT):
REPAIR OPEN IN CKT 764 BETWEEN DRIVER POWER SEAT SWITCH
TERM "C" AND POWER SEAT CONTROL MODULE TERM "H".
(PASSENGER SEAT):
CHECK FOR OPEN IN CKT764 FROM PASSENGER POWER SEAT
SWITCH TO C30S TERM" A".
CHECK FOR OPEN IN CKT 764 IN SEAT JUMPER HARNESS FROM
C305 TERM "A" TO C300 TERM "A".
CHECK FOR OPEN IN CKT 764 FROM C300 TERM "A" TO 5345 TO
POWER SEAT CONTROL MODULE TERM "H".
SA -
141 - 8

CHART #5
PUMP ASSEMBLY OPERATES, BUT BLADDER(S) DO NOT INFLATE
(LATERAL BLADDERS): WITH A TEST LIGHT TO GROUND, BACKPROBE POWER SEAT SWITCH CONN TERM "A" .
(LUMBAR BLADDER): WITH A TEST LIGHT TO GROUND, BACKPROBE POWER SEAT SWITCH CONN TERM "8".
PRESS POWER SEAT SWITCH TO "INFLATE" POSITION WHILE OBSERVING TEST LIGHT .
(LATERAL BLADDERS): WITH A TEST LIGHT TO GROUND,

BACKPROBE SOLENOID VALVE CONN TERM "H" AND TERM
(LATERAL BLADDERS): WITH A TEST LIGHT TO GROUND,

BACKPROBE SOLENOID VALVE CONN TERM "F".
DISCONNECT POWER SEAT CONTROL MODULE .

USING A TEST LIGHT, PROBE POWER SEAT CONTROL MODULE
CONN TERM "A" TO GROUND.
PRESS POWER SEAT SWITCH TO "INFLATE" POSITION WHILE
OBSERVING TEST LIGHT.
RECONNECT POWER SEAT CONTROL MODULE .

DISCONNECT SOLENOID VALVE ASSEMBLY CONNECTOR .
CONNECT A TEST LIGHT BETWEEN SOLENOID VALVE
CONNECTOR TERMINALS "K" ANO "F".
USING LUMBAR CONTROL, PRESS POWER SEAT SWITCH TO
"INFLATE" POSITION WHILE OBSERVING TEST LIGHT.
E]
CHECK FOR OPEN BETWEEN POWER SEAT SWITCH AND

SOLENOID VALVE ASSEMBLY IN CKTS 763 AND/OR 765.
(LUMBAR BLADDER): WITH A TEST LIGHT TO GROUND,

BACKPROBE SOLENOID VALVE CONN TERM "F".
PRESS POWER SEAT SWITCH TO "INFLATE" POSITION
WHILE OBSERVING TEST LIGHT.
CHECK FOR POOR CONNECTIONS AT POWER SEAT SWITCH

"J".
(LUMBAR BLADDER): WITH A TEST LIGHT TO GROUND,

BACKPROBE SOLENOID VALVE CONN TERM "K".
PRESS POWER SEAT SWITCH TO "INFLATE" POSITION WHILE
OBSERVING TEST LIGHT.
DOES TEST LIGHT ILLUMINATE ON ALL CIRCUITS WHEN
OPERATING SWITCH?
CHECK FOR POOR CONNECTIONS AT SOLENOID VALVE .

CHECK FOR PINCHED OR PUNCTURED BLADDER TUBING
WITHIN INDIVIDUAL SEATS; ALSO CHECK BLADDER TUBING
IN SEAT JUMPER HARNESS.
CHECK FOR PUNCTURED BLADDER.
IF ABOVE CHECKS ARE OK, THE SOLENOID VALVE
ASSEMBLY MAY BE STUCK OR FAUL TY. REPLACE SOLENOID
VALVE ASSEMBLY.
CHECK FOR POOR CONNECTIONS AT SOLENOID

VALVE ASSEMBLY.
IF OK, REPLACE SOLENOID VALVE ASSEMBLY.
(DRIVER SEAT): REPAIR OPEN IN CKT 769 BETWEEN SOLENOID

VALVE AND POWER SEAT CONTROL MODULE.
(PASSENGER SEAT): CHECK FOR OPEN IN CKT 769 FROM

SOLENOID VALVE TO C305 TERM "F".
CHECK FOR OPEN IN CKT 628 FROM C305 TERM "F" TO C300
TERM "F".
CHECK FOR OPEN IN CKT 769 BETWEEN C300 TERM "F" AND
POWER SEAT CONTROL MODULE TERM "A", INCLUDING 5350.
CHECK FOR POOR CONNECTIONS AT POWER SEAT

CONTROL MODULE CONN TERM" A".
IF OK, REPLACE POWER SEAT CONTROL MODULE.
141 - 9
CHART #6
PASSENGER POWER SEAT INOPERATIVE, DRIVER POWER SEAT OPERATES NORMALLY
WITH A TEST LIGHT TO GROUND, BACKPROBE C305 TERM "C".

IS TEST LIGHT "ON"?
WITH A TEST LIGHT TO GROUND, BACKPROBE PASSENGER

POWER SEAT SWITCH CONN TERM "F".
IS TEST LIGHT "ON"?
REPAIR OPEN IN CKT 1240 IN SEAT JUMPER

HARNESS FROM C305 TERM "C" TO 5320.
WITH A TEST LIGHT TO GROUND, BACKPROBE C300 TERM "B".

PRESS PASSENGER POWER SEAT SWITCH (LUMBAR OR LATERAL)
TO "INFLATE" POSITION WHILE OBSERVING TEST LIGHT.
CHECK FOR POOR CONNECTION AT C305 TERM "C".

IF OK, REPAIR OPEN IN CKT 1240 BETWEEN C305
AND PASSENGER POWER SEAT SWITCH.
WITH A TEST LIGHT TO GROUND, BACKPROBE C305 TERM "B".

PRESS PASSENGER POWER SEAT SWITCH (LUMBAR OR LATERAL)
TO "INFLATE" POSITION WHILE OBSERVING TEST LIGHT.

IF OK, REPAIR OPEN IN CKT 766 BETWEEN C300 AND 5340.
WITH A TEST LIGHT TO GROUND, BACKPROBE PASSENGER POWER

SEAT SWITCH CONN TERM "E".
PRESS THE PASSENGER POWER SEAT SWITCH (LUMBAR OR
LATERAL) TO "INFLATE" POSITION WHILE OBSERVING TEST LIGHT.
CHECK FOR OPEN IN SEAT JUMPER HARNESS CKT 766

BETWEEN C305 AND C300.
CHECK FOR POOR CONNECTIONS AT PASSENGER POWER

SEAT SWITCH CONN TERM ''E''.
IF OK, REPLACE PASSENGER POWER SEAT SWITCH.

IF OK, REPAIR OPEN IN CKT 766 BETWEEN C305 AND
PASSENGER POWER SEAT SWITCH.
SA-141 -10 ELECTRICAL DIAGNOSIS

CHART #7
DRIVER POWER SEAT I NOPE RA TIVE,
PASSENGER POWER SEAT OPERA TES NORMALLY
WITH A TEST LIGHT TO GROUND, BACKPROBE DRIVER POWER SEAT SWITCH CONN TERM "F".
IS TEST LIGHT "ON"?
WITH A TEST LIGHT TO GROUND, BACKPROBE DRIVER POWER SEAT SWITCH

CONN TERM "E".
PRESS DRIVER POWER SEAT SWITCH (LUMBAR OR LATERAL) TO "INFLATE"
REPAIR OPEN IN CKT 766 BETWEEN DRIVER POWER SEAT

SWITCH TERM ''E'' AND 5340.
CIRCUIT OPERATION
Each seat incorporates a power inflate/power
deflate pneumatic system used for altering the contour
of the seat. This is accomplished by inflating and
deflating air bladders within each seat.
Both Power Seats utilize the same Power Seat
Control Module and Pump Assembly for operation.
The Power Seat Control Module and Pump Assembly
are mounted under the Driver Seat. A Seat Jumper
Harness from the Driver Seat connects the circuitry
and bladder tubing to the Passenger Seat.
Voltage is supplied at all times to both Power Seat
Switches through CKT 1240 from the DEFOG/SEATS
Circuit Breaker 12. When lateral/lumbar support is
requested, the Power Seat Switch applies voltage to
the selected solenoid at the Solenoid Valve Assembly.
CHECK FOR OPEN IN CKT 1240 BETWEEN DRIVER

POWER SEAT SWITCH TERM "f" AND 5330.
CHECK FOR POOR CONNECTIONS AT DRIVER

POWER SEAT SWITCH CONN TERMINALS "F"
AND "E".
IF OK, REPLACE DRIVER POWER SEAT SWITCH.
The Solenoid Valve Assembly is grounded through

the Power Seat Control Module. At the same time, the
Power Seat Switch applies battery voltage to the
selected inflate or deflate relay within the Power Seat
Control Module. The Power Seat Control Module
applies power to the Pump Assembly in either the
forward direction (inflate) or the reverse direction
(deflate).
The ground to the Solenoid Valve is electrically
opened when a pressure switch inside the Power Seat
Control Module senses a bladder full/empty condition.
In response to these conditions the Power Seat Control
Module shuts off the pump by opening the ground to
the Inflate or Deflate Relay until the Power Seat
Switch is released.
BLANK
141 - 11
8A-
POWER MIRRORS (DG7)
---111P
I FUSE
BLOCK
~I
PWR ACCY
15AMP
L---1 ORN
---.I
640
rn
r---s211
1 ORN
640
SEE FUSE
BLOCK DETAILS
PAGE 8A-11-7
!ORN
640
IMPORTANT:
EACH MOTOR CONTAINS

BREAKER (ECB).

TERMINALS.
~~l----41----l~--41--~-+~-..~~,~------------_L
A
- -
UP
LEFT
- -
RIGHT
- -
LEFT
RIGHT
.35 BLK
750
r-
~PSOO
-5220
.35WHT
81
~
\fJ.J '--"'-""
.35 V E i88
RIGHT/
LEFT
MOTOR
- -----5261
MIRROR
MOTOR
PACK
UP/
DOWN
MOTOR
B
.35 LT BLU
.35 LTBLU
88
82
.35BRN1WHT
j:::'
................................ .................
1498
5501
.35LTBLU
82
OUTSIDE
MIRROR,
!!!!
147 - 1
12064862
BLK
COMPONENT
1/P Fuse Block . . . . . . . . . . .
Outside Mirror, LH . . . . . . .
Outside Mirror, RH . . . . . .
Power Mirror Switch . . . . .
C200C (13 cavities)
C200D (48 cavities)
0200 . . . . . . . . . . . . . . . . . . . .
P500 . . . . . . . . . . . . . . . . . . . .
P600 . . . . . . . . . . . . . . . . . . . .
8211 . . . . . . . . . . . . . . . . . . . .
8220
8261
8500
8501
201-PG
LOCATION
LH side ofl/P Carrier, on the side . . . . . . . . . . . . . . . . . . . 8 ....
LH front door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
RH front door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Steering Column . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Steering Column . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Between RH door and "A" pillar . . . . . . . . . . . . . . . . . . . . . 32 . . .
l/P Harn, in center console breakout, approx 10 cm from
Main Harn
Mirror breakout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Cross Car Harn, approx 14 cm inboard of P600 . . . . . . . . 32
Cross Car Harn, approx 6 cm from Speaker breakout . . 17
Speaker breakout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
FIG.
15
31
31
33
CONN
202-22
202-23
202-23
202-23
72
202-2
72
202-2
16
49
49
49
49
31
31
Diagnosis)
System
1. Check PWR ACCY Fuse 7 in l/P Fuse Block. If

open, refer to Diagnostic Chart #5.
2. lf both mirrors are inoperative, check for poor
connections at the Power Mirror Switch.
3. Check that G200 is clean and tight.
4. If only one mirror operates properly, check for poor

connections at LH Outside Mirror or RH Outside
Mirror.
Refer to SECTION 10-6 for Outside Mirror
replacement.
POWER MIRRORS (DG7)

SYSTEM DIAGNOSIS

procedures.
rn
Important:
For a better understanding of Retained
Accessory Power (RAP) operation, refer to
Circuit Operation at the end of this section.
SYSTEM CHECK
ACTION
NORMAL RESULTS
[1]
Move Mirror Select Switch to "LEFT" position. LH Outside Mirror moves smoothly upward and
Operate Mirror Position Switch in "UP" and downward.
"DOWN" positions.
[2]
Operate Mirror Position Switch in the "LEFT" and LH Outside Mirror moves smoothly to the left and
right.
"RIGHT" positions.
[3]
Move Mirror Select Position to "RIGHT" position. RH Outside Mirror moves smoothly upward and
Operate Mirror Position Switch in "UP" and downward.
"DOWN" positions.
[4]
Operate Mirror Position Switch in the "LEFT" and RH Outside Mirror moves smoothly to the left and
right.
"RIGHT" positions.
SYMPTOM TABLE
SYMPTOM
PROCEDURE
PAGE NUMBER
Both mirrors do not operate in either ("UP/DOWN" or

"LEFT/RIGHT") mode.
Chart #1
BA-147-3
One mirror does not operate in the "UP/DOWN"

mode ("LEFT/RIGHT" mode operates normally).
Chart #2
BA-147-3
One mirror will not operate in the "LEFT/RIGHT"

mode ("UP/DOWN" mode operates normally).
Chart #3
BA-147-4
One mirror will not operate in either ("UP/DOWN" or

"LEFT/RIGHT") mode.
Chart #4
BA-147-4
PWR ACCY Fuse 7 repeatedly blows whenever Ignition

is "ON" or when attempting to operate Power
Mirrors.
Chart #5
BA-147-5
CHART #1
BOTH MIRRORS DO NOT OPERATE IN EITHER ("UP/DOWN" OR "LEFT/RIGHT") MODE
WITH A TEST LIGHT BACKPROBE FROM POWER

MIRROR SWITCH CONN TERM "H" TO GROUND.
IS TEST LIGHT "ON"7
WITH A TEST LIGHT BACKPROBE

BETWEEN POWER MIRROR SWITCH
CONN TERM "H" AND TERM "A".
IS THE TEST LIGHT "ON"7
CHECK FOR POOR CONNECTION AT C200 TERM "E9"

OR AT POWER MIRROR SWITCH CONN.
IF OK, REPAIR OPEN IN CKT 640 FROM FUSE BLOCK
TO POWER MIRROR SWITCH CONN TERM "H".

POWER MIRROR SWITCH CONN.
CHECK FOR POOR CONNECTION AT G200.

MIRROR CONN TERM "H".
IF OK, REPAIR OPEN IN CKT 750 FROM G200 TO
POWER MIRROR SWITCH CONN TERM "A".
CHART #2
ONE MIRROR DOES NOT OPERATE IN THE "UP/DOWN"
MODE ("LEFT/RIGHT" MODE OPERATES NORMALLY)
(LH): WITH A TEST LIGHT BACKPROBE FROM POWER MIRROR SWITCH CONN TERM "C" TO TERM "E" .
(RH): WITH A TEST LIGHT BACKPROBE FROM POWER MIRROR SWITCH CONN TERM"(" TO TERM "F".
PRESS MIRROR POSITION SWITCH TO "UP" WHILE OBSERVING THE TEST LIGHT .
I
(LH): WITH A TEST LIGHT BACKPROBE FROM OUTSIDE MIRROR

CONN TERM "D" TO TERM"(".
(RH): WITH A TEST LIGHT BACKPROBE FROM OUTSIDE MIRROR
CONN TERM "D" TO TERM "C".

IF OK, REPLACE POWER MIRROR SWITCH.
~RESS MIRROR POSITION SWITCH TO "UP" WHILE OBSERVING

THE TEST LIGHT.
I
(LH): CHECK FOR OPEN IN CKT 88 BETWEEN OUTSIDE MIRROR CONN

TERM "D" AND 5261.
IF OK, CHECK FOR OPEN IN CKT 89 BETWEEN OUTSIDE MIRROR CONN
TERM"(" AND POWER MIRROR SWITCH TERM "E".
(RH): CHECK FOR OPEN IN CKT 88 BETWEEN OUTSIDE MIRROR CONN

TERM "D" AND 5261.
IF OK, CHECK FOR OPEN IN CKT 1498 BETWEEN OUTSIDE MIRROR
CONN TERM "C' AND POWER MIRROR SWITCH CONN TERM "F".
(LH): CHECK FOR POOR CONNECTION AT

OUTSIDE MIRROR CONNECTOR. IF OK,
REPLACE THE MIRROR MOTOR PACK WITHIN
THE POWER MIRROR.
(RH): CHECK FOR POOR CONNECTION AT

OUTSIDE MIRROR CONNECTOR.
IF OK, REPLACE THE MIRROR MOTOR PACK
WITHIN THE POWER MIRROR.
SA -
147 - 4
POWER MIRRORS (DG7)

CHART #3
ONE MIRROR WILL NOT OPERATE IN THE "LEFT/RIGHT"
MODE ("UP/DOWN" MODE OPERATES NORMALLY)
(LH): WITH A TEST LIGHT BACKPROBE FROM POWER MIRROR SWITCH CONN TERM "D" TO TERM "B" .
(RH): WITH A TEST LIGHT BACKPROBE FROM POWER MIRROR SWITCH CONN TERM "G" TO TERM "B".
PRESS MIRROR POSITION SWITCH TO "LEFT" WHILE OBSERVING THE TEST LIGHT.
IS THE TEST LIGHT "ON"?
I
(LH): WITH THE TEST LIGHT BACKPROBE FROM OUTSIDE MIRROR CONN
(RH): WITH THE TEST LIGHT BACKPROBE FROM OUTSIDE MIRROR CONN
TERM "8" TO TERM" A".
PRESS MIRROR POSITION SWITCH TO "LEFT" WHILE OBSERVING THE TEST LIGHT.

IF OK, REPLACE POWER MIRROR
SWITCH.
(LH): CHECK FOR OPEN IN CKT 81 BETWEEN POWER MIRROR SWITCH CONN
TERM "D" AND OUTSIDE MIRROR CONN TERM "A".
IF OK, CHECK FOR OPEN IN CKT 82 BETWEEN 5501 AND OUTSIDE MIRROR
CONN TERM "8".
(RH): CHECK FOR OPEN IN CKT 881 BETWEEN POWER MIRROR SWITCH CONN
TERM "G" AND OUTSIDE MIRROR CONN TERM "A".
IF OK, CHECK FOR OPEN IN CKT 82 BETWEEN OUTSIDE MIRROR CONN
TERM "8" AND 5501.
(LH): CHECK FOR POOR CONNECTION

AT OUTSIDE MIRROR CONNECTOR.
IF OK, REPLACE THE MIRROR MOTOR
PACK WITHIN THE POWER MIRROR.
(RH): CHECK FOR POOR CONNECTION
AT OUTSIDE MIRROR CONNECTOR.
IF OK, REPLACE THE MIRROR MOTOR
PACK WITHIN THE POWER MIRROR.
CHART #4
ONE MIRROR WILL NOT OPERATE IN EITHER
("UP/DOWN" OR "LEFT/RIGHT") MODE
(LH): WITH A TEST LIGHT BACKPROBE FROM POWER MIRROR SWITCH CONN TERM "C" TO TERM "E" .
(RH): WITH A TEST LIGHT BACKPROBE FROM POWER MIRROR SWITCH CONN TERM "C" TO TERM "F".
PRESS MIRROR POSITION SWITCH TO "UP" WHILE OBSERVING THE TEST LIGHT.
(LH): WITH THE TEST LIGHT BACKPROBE FROM OUTSIDE

MIRROR CONN TERM "D" TO TERM "C".
(RH): WITH THE TEST LIGHT BACKPROBE FROM OUTSIDE
MIRROR CONN TERM "D" TO TERM "C".
PRESS THE MIRROR POSITION SWITCH TO "UP" WHILE

OBSERVING THE TEST LIGHT.
CHECK FOR OPEN IN CKT 88 BETWEEN OUTSIDE MIRROR

SWITCH CONN TERM "C" AND 5261.
(LH): CHECK FOR OPEN IN CKT 89 BETWEEN OUTSIDE
MIRROR SWITCH CONN TERM "E" AND OUTSIDE MIRROR
CONN TERM "C".
(RH): CHECK FOR OPEN IN CKT 1498 BETWEEN POWER
MIRROR SWITCH TERM "F" AND OUTSIDE MIRROR CONN
TERM "C".

AT POWER MIRROR SWITCH.
IF OK, REPLACE POWER MIRROR
SWITCH.
~
CHECK FOR POOR CONNECTION AT OUTSIDE MIRROR CONN .
(LH):
IF OK, REPLACE THE MIRROR MOTOR PACK WITHIN THE POWER
MIRROR.
(RH): CHECK FOR POOR CONNECTION AT OUTSIDE MIRROR CONN .

IF OK, REPLACE THE MIRROR MOTOR PACK WITHIN THE POWER
MIRROR.
147 - 5
CHART #5
PWR ACCY FUSE 7 REPEATEDLY BLOWS WHENEVER IGNITION IS "ON"
OR WHEN ATTEMPTING TO OPERATE POWER MIRRORS
REPLACE BLOWN FUSE.

DOES FUSE BLOW BEFORE ATTEMPTING TO OPERA TE POWER MIRRORS?
TEST POWER MIRROR SWITCH ONE FUNCTION AT A TIME UNTIL

FUSE BLOWS.
WHEN THE FUSE BLOWS, USE SCHEMATICS TO DETERMINE
WHAT CIRCUITS OR COMPONENTS COULD BE FAILING. USE A
TEST LIGHT OR DVM TO NARROW IN ON SHORT TO GROUND
POTENTIAL.
DISCONNECTING COMPONENTS IS HELPFUL WHEN TRYING TO
CHECK CIRCUITS THAT SHOULD NOT BE AT A GROUND
POTENTIAL.
CIRCUIT OPERATION
The Power Mirror System has voltage applied from
the PWR ACCY Fuse which is controlled by the
Retained Accessory Power (RAP) Module. Voltage is
applied to the PWR ACCY Fuse for up to 10 minutes
after Ignition is turned "OFF" or for 35 seconds after
exiting the vehicle and closing the doors. Voltage is
also applied whenever a door is open. For a complete
understanding of Retained Accessory Power (RAP)
operation, refer to "Retained Accessory Power (RAP):
KP2," page BA-15-0.
Each Outside Mirror has two reversible motors.
One adjusts the mirror up and down, and the other
adjusts the mirror right and left. These motors are
controlled by the Power :.\1:irror Switch. The Power
Mirror Switch contains a Mirror Position Switch. The
Mirror Position Switch is a four-position switch that
controls the polarity of the voltage to the motors. The
Power Mirror Switch also contains a Mirror Select
Switch, which directs the voltage to either the RH or
LH Outside Mirror. The Power Mirror Switch receives
battery voltage from the PWR ACCY Fuse through
CKT 640 and is permanently grounded at G200.
When the LH Outside Mirror is selected, the
Mirror Position Switch will control the motors of the
LH Outside Mirror. When the Mirror Position Switch
''UP" position is pressed, voltage is applied to the
Up/Down Motor of the LH Outside Mirror through
CKT 88. Ground will be provided to the Up/Down
Motor by the Outside Mirror Switch through CKT 89.
The Up/Down Motor in the LH Outside Mirror will run
and turn the LH Outside Mirror up.

THROUGH A FAUL TV COMPONENT OR IN WIRING.
CONNECT A DVM SET TO VOLTAGE ACROSS FUSE
TERMINALS. START BY DISCONNECTING ONE COMPONENT
AT A TIME.
IF ALL RELATED COMPONENTS ARE DISCONNECTED AND
SHORT IS STILL PRESENT, LOCATE AND REPAIR SHORT IN
WIRING.
When the Mirror Position Switch "DOWN"

position is pressed, voltage is applied to the Up/Down
Motor of the LH Outside .Vlirror through CKT 89, and
ground is provided through CKT 88. This will cause
the Up/Down Motor to rotate in the opposite direction
and turn the LH Outside Mirror down.
The Left/Right Motor of the LH Outside Mirror
operates in a similar manner. When the Mirror
Position Switch "LEFT" position is pressed, voltage is
applied to the Left/Right Motor of the LH Outside
Mirror through the CKT 81. Ground will be provided
to the Left/Right Motor by the Outside Mirror Switch
through CKT 82. The Left/Right Motor will run and
turn the LH Outside Mirror to the left.
When the Mirror Position Switch "RIGHT"
position is pressed, voltage is applied to the Left/Right
Motor of the LH Outside Mirror through the CKT 82
and ground is provided through CKT 81. This will
cause the Left/Right Motor to rotate in the opposite
direction and turn the LH Outside Mirror to the right.
The RH Outside Mirror is adjusted in the same
way when the Mirror Select Switch is moved to the
"RH" position, and the appropriate position switch is
operated.
SA -
RADIO
UX1 (CASSETTE WITH EQ) OR U1A (DISK WITH EQ) AND
UW2 (10 SPEAKER SOUND SYSTEM)
SEE INTERIOR LIGHTS
HOT AT ALL TIMES
HEADLIGHT
SWITCH
I - -\- - ,
I
I
1-
HEAD
II
__
IJili.,-
SEE POWER
DISTRIBUTION
PAGE SA-10-1
1/P FUSE
40
--~
I BLOCK
-I
I
.S GRV
,--...ii
-1,
.S VEL
SEE INTERIOR
U1A- DISK WITH EQ
(NIGHT CONDITION
INPUD
LEFT
-IL;:;;M;A;,N- -
-;;;N-;;O;N~T- -
:~
ORN
UX1 -CASSEITE w~AHD;g f1L~M;A;,N- -
SEE FUSE
BLOCK DETAILS
PAGE 8A11-7
5210
~:: ., . ~I:_____ .: :1~------~:~::~~,:. ~f~i~!:_____._

SEE EXTERIOR
.J
CJ
.5 BRN
IIP DIMMER
FUSE 13
5AMP--
II
I L
PARK
L--
I
I I
OFF
HOT AT ALL TIMES
:.
-B,;;.E~ -
(DIMMING INPUD
! IMPORTANT:
SPEAKER NEGATIVE CONNECTIONS ARE NOT AT GROUND POTENTIAL.
LEFT
LF'!2_N!_; -
- - -
RIGHT
_!.R~T .:_ -
RIGHT
_!R~T.;. -
AMPLIFIER
.!,.R9.!!T .:_ -
T___ sy9. ~ l
- G'!!!.U~ - C~T~L _!0!!_= ~) J
.SGR:J1a _______ .STA:~01-- .sDKGR:T11 ------.SLTGR:1:"oo - - - - - - - - - - - - -
3 :PNK
1
5304.
_ _ _. .___lllllllllll_ _ _ _ _~ - - - - - - - - 2 - ' - - - - - - - - - - - - - - S G R V - - . . . / l
I
5307.
.SGRV
118
.5 TAN
I
I
118
- - - - - - - - - - - - - ~ - -..- ..- ......-iiiii...._ ..___.5.TAN../l

201
201
.5 DK GRN
117
.5 LTGRN
200
.5 GRV
118
SPEAKER,
RIGHT
.5 DK GRN
.5 DK GRN
FRONT
117
201
SPEAKER,
FRONT
MIDRANGE
m,J~
B
.SLTGRN
1 BLK
200
650
5217-,
_ _ _ _ _ _ _..,_
__, SPEAKER,
3 BLK
RIGHT
FRONT
MIDRANGE
SPEAKER,
LEFT
FRONT
TWEETER
650
117
- - - - - - - - - - . 5511
.5 TAN
1 BLK
TWEETER
650
SEE GROUND
DISTRIBUTION
PAGES SA-14-7, 8, 9
-----------..
.5 GRV
5510
118
&
'
~4
ANTENNA
'
1 ORN
SPEAKER
ASSEMBLY,
LEFT REAR
(IN REAR QUARTER
TRIM PANEL)
40
'
M
I
D
R
A
N
G
E
w
E
E
T
E
R
'"
10
........
........
........
~I/
Ay
/
M
I
D
R
A
N
G
E
10
[/
Ay
.5 YEL
es302
116
'
'
'
'
.35 PNK
.5 GRY
'
.5 TAN
'
'
314
118
201
.SYEL
.5DKGRN
116
117
.5 BRN
.5LTGRN
199
.5 LT
200
115
BLU
.S DK
BLU
46
s, '
_______
__
_____
....;..__,........,
_ _ _1,_...__
............
_.._
23,
, ___
,
22, , _ _ _
10,
, __
21,.....;.,.._,......_
\
9, , _ _ _ _ _ _ _ _ _ AMPLIFIER
24,
,
12, \
11, '
'
RF+
RF-
1 BLK
650
LF- /
ON/OFF
INPUT
BATTERY
LR-
4y
,.
LR+
RR-
~
SUBWOOFERS
ONLY)
RR+
AUDIO INPUT SIGNALS
GROUND
LF +
AUDIO INPUT SIGNALS

OUTPUT
LEFT15'
.5 LTGRN/
BLK
"
LEFT+
16
1794
RIGHT+
RIGHT-
13 .,
"
.5 DK BLU/
WHT
346
.5 DK GRN
1795
.5LTBLU/
BLK
B
SPEAKER,
RIGHT REAR
SP
EAKER$]
LEFT
REAR
5UBWOOFER
(IN SAIL PANEL)
Al
SUBWOOFER
(IN SAIL PANEL)
315
'
150 - 1
SPEAKER
ASSEMBLY,
RIGHT REAR
(IN REAR
QUARTER
TRIM PANEL
SA -
150 - 2
RADIO
STEERING WHEEL RADIO CONTROLS: UK3
(INCLUDED WITH UX1 OR U1A RADIO ONLY)
SEE INTERIOR LIGHTS
1/P DIMMER
FUSE 13
5AMP
,1/PFUSE
BLOCK
I
I
I
L-
---.I
.5 GRY
.5 YEL
43
9
SEE INTERIOR
LIGHTS DIMMING
PAGE 8A-1171
RADIO,- .......__ ,,..-
.5 YEL
S224
43
UX1 CASSETTE WITH EQ

OR
-,
.,. t_ _- --------------------------------"~:~:~:;~-.::~~~::~,.,
SIR COIL
ASSEMBLY
~-~-----------------------------------------'
8
-------/l"-1,---+-----------------------11"--....---.
~ ILLUMINATION ~
~LAMPS
~
LH
STEERING
WHEEL
CONTROLS,
RADIO
1.~.
RH
1270
294
475
348
715
1180
2370
6980
VOLTAGE CHART (utilized in Chart #15)
(BLK)
VOLTAGE MEASURED
FROM
C217
TERM "C" TO GROUND (BACKPROBED
WITH SYSTEM CONNECTED).
SIR COIL
ASSEMBLY
VOLTAGE RANGE IN VOLTS

BUTTON PRESSED
LOW
HIGH
S217----1
PRE-SET
4.29
4.75
3 BLK 1650
VOLUME (UP)
3.61
4.12
VOLUME (DOWN)
3.07
3.51
PWR
2.50
2.98
AM/FM
1.97
2.41
SEEK (UP)
1.42
1.88
SEEK(DOWN)
.874
1.33
RCL
.285
.779
.5 B~KT6~!17 (BLK)
__.,,111111
5216. 3 BLK
-......
SEE GROUND
DISTRIBUTION
PAGES 8A-14-7, 8, 9
650
3 BLK
750
SEE PAGE SA-3-0

FOR PROPER
HANDLING
PROCEDURES
RADIO
ANY RADIO WITH UQO (BASE SPEAKERS)
HOT AT ALL TIMES
HEADLIGHT
SWITCH
I - -\- ,
I
I
II
1-
HEAD
OFF
PARK
L--
I
I
I11L
,1/PFUSE
BLOCK
I
I
__ ..J
1 ORN
.5 GRY
40
-411111
.....
~~-GG_H:_;_A_-1_1_0-4__.
1/P DIMMER
FUSE 13
SAMP
.SBR:r
SEE EXTERIOR
SEE INTERIOR
r--5_:-_R_1;.~::.~,-~;.;-;.-;;;,;;-;.;-;.-;;;.;;.3.;;Ss;.;:;.1:._~;.;-;.-;;;,;;-;.;-;.-;.;;;,-.;;-;.;-;.~-:.~..
:;.;~;.~;;.~..
:_~_:;.IN:.~.;;9.........-;.....
- ..-..----..-..----..-..---:..
o_,._N__4_:_1_ _ __ ,
ILLUMINATION
(NIGHT CONDITION
INPUT)
IGNITION INPUT
ILLUMINATION
(DIMMING INPUD
RADIO
UM6 - CASSETTE
UX1 - CASSETTE WITH EQ
UIA - DISK WITH EQ
BATTERY
"l"' ~
BLU
STEERING WHEEL
CONTROLS INPUT
! IMPORTANT:
SPEAKER NEGATIVE CONNECTIONS ARE NOT AT GROUND POTENTIAL.
TO STEE~ING WHEEL
RADIO CONTROLS
PAGE SA-150-2
(CKT179iALWAYS
PRESENTBUT ONLY
USED WITH UX1 OR
U1ARADIOS)
LEFT
REAR
POS
LEFT
REAR
NEG
19
.5 BRN
RIGHT
REAR
NEG
RIGHT
REAR
POS
LEFT
FRONT
POS
RIGHT
FRONT
NEG
RIGHT
FRONT
POS
GROUND
:GR:r,~---, --:::.~1-. :---.r----5
18
199
.5 YEL
LEFT
FRONT
NEG
116
.5 TAN
A
---8
201
.SLT GRN
------C
----[)
BARBED TYPE
CONNECTOR
200
C240
ANTENNA
.SGRY
1 BLK
.SLTGRN
SPEAKER,
LEFT
REAR
650
200
5217----,
(tIJ
3BLKl6SO
.SLT BLU
115
3BLK
A
P600
.5 DK BLU
46
~(ro
RIGHT
REAR
10
SEE GROUND
DISTRIBUTION
PAGESSA-14-7,8,9
5216 -
10
___c_G200
.5 DK GRN
117
.J
SA -
150 - 4
RADIO
12110088
LTGRY
AMPLIFIER
CAVITY
WIRE COLOR
CKT
ORN
40
BLK
DESCRIPTION
PAGE
POWER FEED FROM COURTESY FUSE 8
BA-11-7
650
GROUND
BA-14-9
PNK
314
RADIO SIGNAL - ON
BA-150-1
DKBLU
46
RIGHT REAR SPEAKER FE ED {POS)
BA-150-1
10
BRN
199
LEFT REAR SPEAKER FEED {POS)
BA-150-1
11
LTGRN
200
RIGHT FRONT SPEAKER FEED {POS)
BA-150-0, 1
12
TAN
201
LEFT FRONT SPEAKER FEED {POS)
BA-150-0, 1
13
LT BLU/BLK
315
RIGHT SUBWOOFER SPEAKER RETURN {NEG)
SA-150-1
14
DKGRN
1795
RIGHT SUBWOOFER SPEAKER FEED {POS)
BA-150-1
15
LT GRN/BLK
1794
LEFT SUBWOOFER SPEAKER RETURN {NEG)
BA-150-1
16
DKBLU/WHT
346
LEFT SUBWOOFER SPEAKER FEED{POS)
BA-150-1
21
LTBLU
115
RIGHT REAR SPEAKER RETURN {NEG)
SA-150-1
22
YEL
116
LEFT REAR SPEAKER RETURN (NEG)
BA-150-1
23
DKGRN
117
RIGHT FRONT SPEAKER RETURN {NEG)
BA-150-0, 1
24
GRY
118
LEFT FRONT SPEAKER RETURN {NEG)
BA-150-0, 1
C3
150 - 5
17
20
12047531
12047530
10-WAV F MICRO-PACK
BLK
4-WA V F MICRO-PACK
BLU
ElDDDDDEl
[I] []] II] II] []] II] II]
12065873
BLK
RADIO
CAVITY
WIRE COLOR
CKT
GRY
118
LEFT FRONT SPEAKER RETURN (NEG)
8A-150-0,3
TAN
201
LEFT FRONT SPEAKER FEED (POS)
8A-150-0,3
DKGRN
117
RIGHT FRONT SPEAKER RETURN (NEG)
8A-150-0,3
LTGRN
200
RIGHT FRONT SPEAKER FEED (POS)
8A-150-0, 3
BLK
650
GROUND
8A-14-7, 8, 9
BRN
PARK LAMP FEED
8A-150-0,3
GRY
POWER FEED FROM VP DIMMER FUSE #13
8A-150-0,3
PNK
314
(WITH UW2) RADIO SIGNAL - ON
8A-150-0, 1
YEL
43
POWER FEED FROM RADIO FUSE #17
8A-150-0,3
10
ORN
40
8A-11-7
17
LTBLU
115
RIGHT REAR SPEAKER RETURN
8A-150-1,3
18
DKBLU
46
RIGHT REAR SPEAKER FEED
8A-150-1,3
19
YEL
116
LEFT REAR SPEAKER RETURN
8A-150-1, 3
20
BRN
199
LEFT REAR SPEAKER FEED
SA-150-1,3
DKBLU
1796
STEERING WHEEL RADIO CONTROL SIGNAL
SA-150-1,2
DESCRIPTION
PAGE
C1
C3
C4(WITH UK3)
6
RADIO
COMPONENT
LOCATION
201-PG
Amplifier (part ofUW2
Speaker Option) . . . . . . . . Mounted behind Right Rear Armrest, on Rail ....... . 44 ...
Antenna . . . . . . . . . . . . . . . . Right rear quarter panel .......................... . 45,47
Headlight Switch . . . . . . . . LH side of I/P .................................... . 38 ...
I/P Fuse Block . . . . . . . . . . . LH side of I/P Carrier, on the side .................. . 8 ....
Radio . . . . . . . . . . . . . . . . . . . Center ofl/P Carrier .............................. . 39 ...
Speaker Assembly, Left Rear
(with UW2 Speakers) . . . Mounted in left Cargo Compartment trim ........... . 5 ....
Speaker Assembly, Right Rear
(with UW2 Speakers) . . . Mounted in right Cargo Compartment trim . . . . . . . . . . 44
Speaker, Left Front
(Base - UQO) . . . . . . . . . . . Mounted in left door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Speaker, Left Front Midrange
(with UW2 Speakers) . . . Mounted in left door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Speaker, Left Front Tweeter
(with UW2 Speakers) . . . Mounted in left door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Speaker, Left Rear
(Base - UQO) . . . . . . . . . . . Mounted in left sail panel . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Speaker, Left Rear Subwoofer
(with UW2 Speakers) . . . Mounted in left sail panel . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Speaker, Right Front
(Base - UQO) . . . . . . . . . . . Mounted in right door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 . . .
Midrange (with UW2
Speakers) . . . . . . . . . . . . . . Mounted in right door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 . . .
Tweeter (with UW2
Speakers) . . . . . . . . . . . . . . Mounted in right door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Speaker, Right Rear
(Base - UQO) . . . . . . . . . . . Mounted in right sail panel . . . . . . . . . . . . . . . . . . . . . . . . . 44
Speaker, Right Rear
Subwoofer (with UW2
Speakers) . . . . . . . . . . . . . . Mounted in right sail panel . . . . . . . . . . . . . . . . . . . . . . . . . 44 . . .
Radio (UK3) .......... . On Steering Wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . .
C240 (6 cavities) ........ . Under RH side ofl/P, behind kick panel . . . . . . . . . . . . . . 46
G200 ................... . Near base ofLH "A" pillar, bolted to I/P Mounting Stud
P500
P600
8210
S216
S217
S224
I/P Harn, approx 4 cm from Instrument Cluster breakout
8226
I/P Harn, approx 15 cm from last rosebud on RH
S300
rocker panel .............................. .
6
I/P Harn, approx 21 cm from last rosebud on RH
8301
rocker panel .... : . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
FIG.
CONN
64 . .
65, 71
57
15
58
202-9
202-14
202-22
202-15
8
64
31
31
31
8
8
31
31
31
64
64
3 ...
67
16
49
49
10
10
202-24
202-16
COMPONENT
LOCATION
S302
1/P Harn, approx 8 cm from last rosebud on RH

rocker panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
rocker panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
rocker panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
rocker panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mirror breakout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cross Car Harn, approx 7 cm from Power
Mirror breakout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
S304
S305
8307
S510
8511
201-PG
FIG.
10
10
10
10
32
49
17
31
150 - 7
CONN
(Perform before beg in n i n g
Diagnosis)
Sys t e m
Radio Inoperative:
1. For checking a speaker, use a "C" or "D" cell
Battery and momentarily connect and disconnect
it across the circuits to that speaker while
listening for a slight popping sound or watching for
the cone of the speaker to move in and out. If
either happens, the speaker and circuitry are
usually OK.
2. Check Fuse 8. If open, check for a short to ground
through CKT 40.
3. Check Fuse 17. If open, check for a short to ground
through CKT 43.
4. Make sure ground G200 is clean and tight.
Radio Noise:
A noise ~sniffer" may be used to aid in troubleshooting
Radio noise, see details on page SA-150-19. (For
definitions of the different types of Radio noise, refer to
"Noise Entry," page 8A-150-23.)
1. Test the Radio outside with the hood down.
2. Ignition noise on FM indicates a possible defective
High Energy Ignition (HEI) System. Refer to
SECTION 604.
3. If a test antenna is used, ground the base of the
antenna to the vehicle body.
4. When shielding components, use aluminum foil
tape (nickel tape works best) and ground both ends
of the shield.
General:
SYSTEM DIAGNOSIS

8A-
150 - 8
RADIO
rn
Important:
For a better understanding of Retained Accessory Power (RAP) operation, refer to "Retained Accessory
Power (RAP): KP2", page SA-15-0
SYMPTOM TABLE
SYMPTOM
No sound from any speaker, blank digital display.
PROCEDURE
PAGE NUMBER
Chart #1
8A-150-9
No sound from any speaker, digital display operates Check for disconnected connector C3 with major
normally, seek/scan and presets appear to operate wiring damage to front speakers or with balance to
rear only. If OK, service Radio.
normally.
Digital Display illuminated, with all Radio functions Check for a short to B + in CKT 1796 (UX1 or U1A
only). If OK, service Radio. Refer to SECTION 9A.
inoperative.
! IMPORTANT:
An open in CKT 1796 between DVM measuring
point and Radio will cause a reading of B + with any
button pressed, though there will not be a short to
B + in the circuit.
Some Radio functions are operational, others are not Service Radio, refer to SECTION 9A.
operational.
Loss of memory.
All I ights in Steering Whee! Control Buttons
inoperative (some lights are operational).
Check CKT 40 and connector C1 terminal "10" for an

open or poor connection. If OK, service Radio.
Chart #2
8A-150-10
One or more lights in Steering Wheel Control Buttons Replace Steering Wheel Radio Controls.
inoperative (some lights are operational).
Display does not dim when Park Lamps or Headlamps Check for open in CKT 9 to the Radio or poor
are turned "ON."
connection at Radio Connector C1 terminal "6". If OK,
service Radio.
Display dimming does not vary when using the 1/P Check for open in CKT 8 to Radio or poor connection
Dimmer Switch (assumes 1/P Dimmer Switch Circuit is at connector Cl terminal "7", refer to "Interior Lights
operating normally elsewhere).
Dimming," page 8A-117-0. If OK, service Radio. Refer
to SECTION 9A.
Weak Radio reception.
Chart #3
8A-150-11
Cassette Tape Player inoperative
Chart #4
8A-150-11
Cassette Tape Player weak.
Inspect and clean moving parts. Use a known good

cassette tape to retest. If Cassette Tape Player is still
weak, service Radio. Refer to SECTION 9A.
150 - 9
SYMPTOM TABLE
SYMPTOM
PROCEDURE
Compact Disk Player inoperative or skips.
PAGE NUMBER
Skipping over hard bumps may occur. Make sure disk

being used is not smudged or scratched. Smudges or a
scratch that is in a circular direction can cause the laser
to track improperly, causing skipping. If excessive
skipping occurs, service Radio. Refer to SECTION 9A.
Compact Disk Radio displays "ERR" for 5 seconds and The Optical Sensor is impaired by moisture or the disk
stay~ in Radio mode when a disk is inserted.
is in upside down.
No sound from one speaker.
Chart #5
BA-150-12
Both Subwoofer Speakers inoperative.
Chart #6
BA-150-12
Radio noise.
Chart #7
BA-150-13
Switch pop (noise).
Chart #14
BA-150-20
Noise caused by the use of power options in Suppress noise using Capacitor (PIN 1227894) across
Subwoofer Speakers only (UW2).
suspect component: motor, switch or solenoid.
All Steering Wheel Radio Controls inoperative (or
operate erratically).
Chart #15
BA-150-21
One or more Steering Wheel Radio Controls

inoperative (some controls are operational).
Chart #16
BA-150-22
CHART #1
NO SOUND FROM ANY SPEAKER, BLANK DIGITAL DISPLAY
REMOVE RADIO.
DISCONNECT RADIO CONN C1.
IGNITION "ON."
WITH A TEST LIGHT TO GROUND, PROBE RADIO CONN C1 TERM "9".
IS TEST LIGHT "ON"?
CONNECT TEST LIGHT FROM RADIO

CONN C1 TERM "1 O" TO GROUND.
IS TEST LIGHT "ON"?
CONNECT A TEST LIGHT BETWEEN RADIO

CONN C1 TERM "S" AND TERM "9".
IS TEST LIGHT "ON"?
CHECK FOR OPEN IN CKT 40, OR FOR SHORT TO GROUND

THROUGH CKT 40 CAUSING FUSE 8 TO BLOW.
CHECK FOR OPEN IN CKT 43, OR FOR SHORT

TO GROUND THROUGH CKT 43 CAUSING
FUSE 17 TO BLOW.
r-
-----------------------------,
.--'L-------------.
:
'
CHECK FOR POOR CONNECTIONS AT RADIO.

:
IF OK, SERVICE RADIO. REFER TO SECTION 9A. 1
'-------------~
L-------------------------------J
RADIO
CHART #2
ALL LIGHTS IN STEERING WHEEL CONTROL BUTTONS INOPERATIVE
ARE OTHER INTERIOR LIGHTS OPERATIONAL AND DIMMING PROPERLY?
DISCONNECT CONN C217.

PARK LIGHTS "ON."
TURN 1/P DIMMER SWITCH ALL THE WAY "ON"
(MAXIMUM BRIGHTNESS).
CONNECT A TEST LIGHT ACROSS C217 (HARNESS
SIDE) FROM TERM "8" TO TERM "D".
IS TEST LIGHT "ON"?
RECONNECT CONN C217.

DISABLE THE SUPPLEMENTAL INFLATABLE RESTRAINT
SYSTEM (SIR) AND REMOVE AND DISCONNECT INFLATOR
MODULE FROM STEERING WHEEL.
REFER TO SECTION 9JB, THEN RETURN TO THIS CHART.
CONNECT TEST LIGHT ACROSS COIL SIDE OF BLK4-WAY CONN
UNDER IN FLA TOR MODULE FROM TERM "8" TO TERM "D".
IS TEST LIGHT "ON"?
:
1
------------------,
REPAIR LIGHTING SYSTEM. :

REFER TO "INTERIOR LIGHTS I
DIMMING," PAGE BA-117-0. :
L--------------------J
CONNECT A TEST LIGHT FROM

C217 TERM "8" TO GROUND.
IS TEST LIGHT "ON"?
REPAIR OPEN IN
GROUND CKT 650.
SEE PAGE 8A-3-0

FOR PROPER
HANDLING
PROCEDURES
CHECK FOR POOR

CONNECTIONS.
IF OK, REPLACE STEERING
WHEEL RADIO CONTROLS.

BETWEEN 5224 AND C217.
CHECK FOR POOR

CONNECTION ATC217
TERM "8" AND TERM "D".
IF OK, REPLACE SIR COIL
ASSEMBLY.

{SIR). Refer to CAUTIONS in Section 9J under "ON-VEHICLE SERVICE" and
150 - 11
CHART #3
WEAK RADIO RECEPTION
rn
IMPORTANT:
IF SUBSTITUTING AN ANTENNA OR CABLE, BE SURE TO USE A BARBED
TYPE CONNECTOR. INCORRECT CONNECTORS MAY CAUSE POOR
RECEPTION OR DAMAGE TO CONNECTORS.
FM ONLY WEAK?
AM AND FM OR AM ONLY WEAK?
AM AND FM OR AM ONLY WEAK
FM ONLY WEAK
SUBSTITUTE A KNOWN GOOD ANTENNA.

GROUNDTHEBASEOFTHEANTENNATO
THE VEHICLE BODY OR CHASSIS.
RECEPTION STILL WEAK?
r-
----------,
:
:
SERVICE RADIO. :
REFERTO
SECTION 9A.
COMPARE FM RECEPTION TO
ANOTHER VEHICLE.
TUNE TO A WEAK STATION.
BOTH RADIOS RECEPTION SIMILAR?
WEAK FM RECEPTION MAY HAVE BEEN

DUE TO SIGNAL STRENGTH, TERRAIN OF
THE AREA, ELECTRICAL INTERFERENCE OR
ATMOSPHERIC CONDITIONS.
L------------...J
----------,
,-: SERVICE RADIO. :

I
REFER TO
I
I
I
I
SECTION 9A.
1
L------------...J
CHART #4
CASSETTE TAPE PLAYER I NO PERA TIVE
CHECK PLAYER FOR OBSTRUCTIONS.
OBSTRUCTION FOUND
NO OBSTRUCTION FOUND
SUBSTITUTE A KNOWN GOOD

CASSETTE TAPE.
DOES CASSETTE PLAYER
WORK?
r-
------------------------,
REMOVE OBSTRUCTION.
REFER TO SECTION 9A.
1
I
:
1
I
NOTICE: IMPROPERREMOVALMAY :
DAMAGE CASSETTE TAPE PLAYER.
L--------------------------~
r-
----------,
SERVICE RADIO. :
REFERTO
I
SECTION 9A.
:
L------------...J
RADIO
CHART #5
NO SOUND FROM ONE SPEAKER
DISCONNECT SPEAKER.
MEASURE AND NOTE RESISTANCE OF SPEAKER.
IS RESISTANCE APPROXIMATELY EQUAL TO RESISTANCE SHOWN ON THE SCHEMATIC(3-10 Q) FOR THAT
SPEAKER? (FOR THE REAR QUARTER TWEETER AND MIDRANGE SPEAKERS WIRED TOGETHER AS PART OF THE UW2
SPEAKER PACKAGE, MEASURE ACROSS EACH SPEAKER COIL SEPARATELY.)
DISCONNECT THE COMBINED RADIO CONNECTORS C1 AND C3,

OR THE AMPLIFIER CONNECTOR FOR THE SUBWOOFERS.
CHECK THE SUSPECT CIRCUITS FOR A SHORT TO B + OR GROUND.
ARE CIRCUITS OK?
REPLACE SPEAKER.
s
II
RECONNECT SPEAKER CONNECTOR.

MEASURE THE RESISTANCE AT THE RADIO CONNECTOR OR AMPLIFIER
CONNECTOR THROUGH THE SUSPECT CIRCUITS AND SPEAKER.
IS THE RESISTANCE APPROXIMATELY THE SAME AS WHEN
MEASURED RIGHT AT THE SPEAKER?
CHECK FOR POOR CONNECTION AT RADIO OR AMPLIFIER CONNECTOR.

IF OK, SERVICE RADIO OR AMPLIFIER (IF AVAILABLE, TRY REPLACING SPEAKER
WITH A KNOWN GOOD SPEAKER BEFORE REPLACING RADIO OR AMPLIFIER).
CHECK FOR POOR CONNECTION AT SPEAKER.

IF OK, REPAIR OPEN OR HIGH RESISTANCE IN
SUSPECT CIRCUITS.
CHART #6
BOTH SUBWOOFER SPEAKERS INOPERATIVE
DISCONNECT AMPLIFIER CONN.

CONNECT A TEST LIGHT FROM CONN TERM "1" TO TERM "4".
IS TEST LIGHT "ON"?
IGNITION "ON."
RADIO"ON."
USE A DVM TO CHECK
VOLTAGE AT AMPLIFIER CONN
TERM "8".
IS VOLTAGE APPROX B +?
CONNECT A TEST LIGHT FROM TERM "1" TO GROUND.

IS TEST LIGHT "ON"?
IGNITION "OFF."
RADIO "OFF."
DISCONNECT RADIO
CONNECTORS C1 AND C3.
CHECK AUDIO SIGNAL CIRCUITS
FOR OPENS BETWEEN
AMPLIFIER AND RADIO OR FOR
MAJOR WIRING DAMAGE.
TO AMPLIFIER.
IF OK, SERVICE AMPLIFIER.
REMOVE RADIO WHILE LEAVING CONNECTED.

RADIO STILL "ON."
DVM STILL SET ON VOLTAGE, BACKPROBE RADIO CONN C1 TERM "8".
IS VOLTAGE APPROX B +?
CHECK FOR POOR CONNECTION AT C1 TERM "8"

OR FOR SHORT TO GROUND IN CKT 314.
IF OK, SERVICE RADIO.
150 - 13
CHART #7
rn
RADIO NOISE
IMPORTANT:
IF NOISE IS ONLY PRESENT WHEN A SWITCH IS ACTIVATED, REFER TO CHART #13,
"SWITCH POP," BEFORE PROCEEDING.
PUT IGNITION IN POSITION WHERE NOISE OCCURS.

PUT RADIO IN SIMILAR MODE WHERE NOISE OCCURS (AM OR FM, STATION FREQUENCY, ETC.).
DISCONNECT ANTENNA COAX FROM RADIO.
IS NOISE ELIMINATED?
UNFASTEN RADIO AND LEAVE CONNECTORS CONNECTED.

MOVE THE RADIO IN AND OUT OF THE 1/P WITH ELECTRICAL
CONNECTIONS STILL A TT ACHED.
DOES NOISE CHANGE OR IS IT ELIMINATED?
REFER TO CHART #13, "RADIO NOISE ENTERING

THROUGH ANTENNA SYSTEM (FRONTWA Y NOISE)."
IF NOISE OCCURS WITH ENGINE NOT RUNNING, REFER TO CHART #9,

"RADIO NOISE ENTERING THROUGH HARNESS (BACKWAY NOISE) WHILE
ENGINE NOT RUNNING."
IF NOISE OCCURS WITH ENGINE RUNNING ONLY, REFER TO CHART #10,
"RADIO NOISE ENTERING THROUGH HARNESS (BACKWAY NOISE) WHILE
ENGINE RUNNING ONLY."
REFER TO CHART #8, "RADIO NOISE ENTERING

THROUGH RADIO (SIDEWAY NOISE)."
CHART #8
rn
RADIO NOISE ENTERING THROUGH RADIO (SIDEWAY NOISE)

IMPORTANT:
CHECK FOR TECHNICAL SERVICE BULLETINS RELATING TO RADIO NOISE BEFORE PROCEEDING.
ARE THERE ANY AFTERMARKET ADD-ON COMPONENTS INSTALLED IN VEHICLE? (PHONE, RADAR DETECTOR, ETC.)
DISCONNECT COMPONENT.
IS NOISE STILL PRESENT?
CHECK FOR A TIGHT GROUND G201 OR G200.

CHECK ROUTING OF HARNESSING NEAR RADIO. MOVE AWAY OR
REROUTE IF POSSIBLE.
ATTACH A SEPARATE BRAIDED GROUND STRAP FROM THE CASE
OF THE RADIO TO A CLEAN SOLID GROUND. REMOVE THE
ORIGINAL GROUND.
IF NOISE STILL PERSISTS, TRY WRAPPING HARNESS NEAR RADIO
WITH ALUMINUM TAPE (NICKEL TAPE WORKS BEST). ADD A
BRAIDED GROUND STRAP IN THE TAPE AT THE BEGINNING AND
END OF THE WRAPPING. ATTACH THE ENDS TO A SOLID GROUND.
IF NOISE STILL PERSISTS, CONTACT DELCO ELECTRONICS
TECHNICAL ASSISTANCE LINE.
CHECK FOR ANY HARNESS RUNNING NEAR

AFTERMARKETCOMPONENT. MOVE AWAY AS
NECESSARY.
CHECK FOR SOLID GROUND TO COMPONENT.
TRY INSTALLING A FILTER (PIN 1224205) BETWEEN
COMPONENT POWER FEED(S) AND GROUND.
IF NOISE PERSISTS WHEN COMPONENT IS PLUGGED
IN, CONSULT MANUFACTURER OF COMPONENT OR
LEAVE REMOVED FROM VEHICLE.
BA -
150 - 14
RADIO
CHART #9
RADIO NOISE ENTERING THROUGH HARNESS {BACKWAY NOISE}
WHILE ENGINE NOT RUNNING
rn
IMPORTANT:
BEFORE PROCEEDING:
- CHECK FOR ANY TECHNICAL SERVICE BULLETINS ON RADIO NOISE.
IGNITION IN POSITION WHERE COMPLAINT OCCURS.

RADIO SET TO SIMILAR MODE WHERE COMPLAINT OCCURS.
REMOVE ONE FUSE AT A TIME FROM THE FUSE BLOCKS (DO NOT
REMOVE THE "COURTESY" OR "RADIO" FUSES).
IS NOISE ELIMINATED WHEN A PARTICULAR FUSE IS REMOVED?
NOISE MAY HAVE BEEN DUE TO A POOR RECEPTION AREA.
DISCONNECT EACH COMPONENT FED BY CULPRIT

FUSE (SEE "FUSE BLOCK DETAILS," PAGES SA-11-0, 2)
UNTIL NOISE DISAPPEARS.
REMOVE EACH WIRE, ONE AT A TIME, FROM CULPRIT
COMPONENT CONNECTOR(S).
INSTALL P/N 1227894 BETWEEN TERMINAL OF
SUSPECT WIRE AND GROUND (BE SURE NOT TO
Fil TER OUT A SIGNAL THAT IS NECESSARY FOR A
COMPONENT'S OPERATION).
IF NOISE IS NOT ELIMINATED, REPLACE COMPONENT.
INSTALL A FILTER (PIN 1224205) BETWEEN RADIO

CONN C1 TERM "1 O" AND GROUND.
IF NOISE IS STILL PRESENT, THEN ATTACH A BRAIDED
GROUND STRAP FROM THE RADIO CHASSIS TO
NEAREST GROUND POINT. REMOVE ORIGINAL
RADIO GROUND FROM RADIO CONN C1 TERM "5".
IS NOISE ELIMINATED?
CHART #10
RADIO NOISE ENTERING THROUGH HARNESS (BACKWAY NOISE)
WHILE ENGINE RUNNING ONLY
[I] IMPORTANT:
BEFORE PROCEEDING:
- SERVICE ANY KNOWN DRIVEABILITV PROBLEMS.
- CHECK FOR ANY TECHNICAL SERVICE BULLETINS
ON THIS TYPE OF RADIO NOISE.
SET RADIO TO MODES WHERE NOISE OCCURS.

DISCONNECT GENERATOR 4-WA Y CONNECTOR.
START ENGINE.
STOP ENGINE AND

REINSTALL GENERATOR
CONNECTOR.
PERFORM CHART #11,
"IGNITION NOISE."
STOP ENGINE.
INSTALL A GENERATOR
CAPACITOR (P/N 1227895) TO
GENERATOR. CAPACITOR
SHOULD BE INSTALLED BETWEEN
THE WIRE ATTACHED ON STUD IN
BACK OF THE GENERATOR AND
NEAREST GROUND.
REINSTALL 4-WAY CONNECTOR
AND RESTART ENGINE. IF NOISE
PERSISTS, PERFORM CHART #12,
"GENERATOR WHINE."
150 - 15
SA -
RADIO
CHART #11
IGNITION NOISE
CHECK FOR LOOSE OR DEFECTIVE SPARK PLUG WIRES.

POOR CONNECTION OR BAD WIRES FOUND?
CHECK SPARK PLUG WIRING FOR PROPER FACTORY ROUTING.

SPARK PLUG WIRE ROUTING GOOD?
CHECK AND CLEAN PLUG WIRE BOOTS AND CAPS FOR SILICONE
GREASE MELTDOWN.
DAMAGED BOOTS OR CAPS OR SILICONE GREASE MELTDOWN?
CHECK AND CLEAN BATTERY CONNECTIONS AND CHASSIS GROUNDS.

BATTERY CONNECTIONS AND CHASSIS GROUNDS OK?
INSTALL P/N 3906145 IN POWER FEED TO IGNITION

COIL (FOR VB VIN P) OR TO ELECTRONIC IGNITION
MODULE (FOR V6 VIN S).
IF NOISE IS STILL PRESENT, ADD A BRAIDED GROUND
STRAP FROM THE CASE OF THE RADIO TO NEAREST
GROUND POINT. REMOVE ORIGINAL RADIO GROUND.
NOISE STILL PRESENT?
: CHECK FOR TECHNICAL :

SERVICE BULLETINS ON I
: IGNITION NOISE .
:
I
L---------------~
150 - 17
CHART #12
GENERATOR WHINE
DISCONNECTGENERATORCOMPLETELY.
RECONNECT GENERATOR.
START ENGINE.
NOISE PRESENT?
ALL ACCESSORIES TO "OFF."

IGNITION SWITCH TO "OFF."
USING DIGITAL MUL Tl METER J 39200, MEASURE
VOLTAGE FROM NEGATIVE BATTERY TERMINAL
TO GENERATOR CASE .
REFER TO CHART #7, "RADIO

NOISE," PAGE BA-150-13.
GREATER THAN 0.1 V DC
LESSTHAN0.1VDC
CHECK GROUND TERM ON BATTERY.

CHECK FOR COATED MOUNTING BOLTS ON
GENERATOR BRACKET.
RUN A TEMPORARY SEPARATE BRAIDED GROUND
STRAP FROM GENERATOR BODY TO A SOLID
GROUND POINT.
CHECK FOR FAULTY MOUNTING

OF GENERATOR TO ENGINE.
MAKE SURE ALL GROUND
STRAPS BETWEEN ENGINE AND
FRAME ARE CLEAN AND TIGHT.
INSTALL BRAIDED GROUND STRAP FROM RADIO

CASE TO NEAREST GROUND POINT, REMOVE
ORIGINAL RADIO GROUND.
~ - _____ - _ - - - - - - - - - _ - - - - - -- - _______ - , ~~NO...___ _ _ _ _---,
INSTALL A FILTER (P/N 1224205)AT THE RADIO CONN C1

TERM "9"' (GROUND SIDE TO RADIO).
IF NOISE IS STILL PRESENT, INSTALL ANOTHER FILTER
(P/N 1224205) AT THE RADIO CONN C1 TERM "10"
(GROUND SIDE TO RADIO).
IF NOISE IS STILL PRESENT. CHECK THE CHARGING
SYSTEM. REFER TO SECTION 603.
IF THE CHARGING SYSTEM IS FUNCTIONING NORMALLY,
CHECK FOR TECHNICAL SERVICE BULLETINS ON
:
:
1
:
:
1
L__GENERATOR WHINE. -- - - - - - - - - - - - - - - - - -- - _J
IF ANY OTHER ELECTRICAL

ACCESSORIES CAUSE RADIO
NOISE, REMOVE THE BRAIDED
GROUND STRAP AND ATTACH THE
ORIGINAL RADIO GROUND TO THE
STEERING COLUMN OR NEAREST
GROUND POINT.
RETEST FOR NOISE.
8A -
150 - 18
RADIO
rn
CHART #13
RADIO NOISE ENTERING THROUGH ANTENNA SYSTEM (FRONTWAY NOISE)
IMPORTANT:
IF SUBSTITUTING AN ANTENNA OR CABLE, BE SURE TO USE A BARBED TYPE CONNECTOR.
INCORRECT CONNECTORS MAY CAUSE POOR RECEPTION OR DAMAGE TO CONNECTORS.
SUBSTITUTE A KNOWN GOOD ANTENNA WHILE USING ORIGINAL CABLE .

GROUND BASE OF ANTENNA TO VEHICLE BODY OR CHASSIS .
~
A KNOWN GOOD CABLE.
ISSUBSTITUTE
!
IMPORTANT:
MAKE SURE ANTENNA WAS PROPERLY

MOUNTED AND GROUNDED.
IF OK, REPLACE ANTENNA.
LEAD-IN CABLE MUST HAVE A BARBED TYPE CONNECTION AT

RADIO.
~
~
ORIGINAL ANTENNA CABLE WAS DEFECTIVE OR MAY HAVE BEEN
INSTALL .47 fd CAPACITORS AT CONN C1 TERM "9" TO
ROUTED
GROUND
THROUGH AN AREA THAT WAS PICKING UP NOISE.
AND TERM "10" TO GROUND.
IF NOISE COMES BACK WHEN NEW CABLE IS INSTALLED,
IF NOISE IS STILL PRESENT, THEN ATTACH A BRAIDED
NARROW
IN ON NOISY AREA AND SHIELD CABLE. A NOISE

GROUND STRAP FROM THE RADIO CHASSIS TO NEAREST
SNIFFER SHOWN ON PAGE SA-150-19 IS HELPFUL (SEE
"CHECKING LEAD-IN CABLES" BEFORE REPLACING CABLE).
GROUND POINT. REMOVE ORIGINAL RADIO GROUND.

RETEST, IF NOISE STILL PRESENT SERVICE RADIO .
CHECKING RADIO MAST ANTENNAS
Unplug antenna lead-in at back of Radio and plug

a test antenna into Radio. Make sure test antenna
base is grounded to the vehicle chassis. Do not touch
the mast. Check Radio reception in an area away from
tall buildings, metal structures, power lines,
fluorescent lighting and power tools. Tune to high and
low ends of the dial on both AM and FM, checking
weak and strong station reception. If reception is OK,
the problem exists with antenna and/or its lead-in
cable. If reception is still poor with test antenna, check
for aftermarket equipment that may be causing
complaint. If OK, service Radio.
C-METAL
CASE
B - TIP FOR ANTENNA
(Barbed Tv.pe
Connector)
A - TIP FOR RADIO
D-METAL
CASE
Figure 3 Checking Lead-in Cables
CHECKING LEAD-IN CABLES
In case of continued reception or noise complaints,

always check the lead-in with a digital multimeter, see
Figure 3 and Table 1.
When checking resistance, cautiously wiggle the
lead-in tip and cable. The previous readings should
always be obtained. If not, some portion of the lead-in
is intermittent and lead-in should be replaced. Also
try:
1. Running a braided ground strap to the
antenna lead-in.
2. Changing the antenna lead-in.
3. Disconnecting the lead-in to check resistance.
Table 1 Lead-in Cable Resistance Values
Digital Multimeter
probes at points:
Resistance measured
in ohms
AandB
less than 0.2
CandD
less than 0.2
AandD
infinite
CandB
infinite
AandC
infinite
BandD
infinite
USE AND CONSTRUCTION OF A NOISE "SNIFFER"
The antenna sniffer can be used along with the

vehicle's Radio to locate "hot spots" which are
generating Radio noise interference. These "hot spots"
can be found in the harnesses, in the upper part of the
dash or even between the hood and winds hie Id.
The sniffer can be made from an old piece of
antenna lead-in from a mast or power antenna. The
longer the lead-in the better.
Make the antenna sniffer as shown in Figure 4.
The 2" section with the black coating and braided
shield stripped back becomes the antenna when the
sniffer is plugged into the Radio's antenna socket. It
can then be used to probe and search out "hot spots."
To use the noise sniffer:
1. While listening to the complaint noise,
disconnect the antenna and plug the sniffer
into the antenna socket.
2. Turn the Radio volume up.
3. Search for the noise source, keeping fingers off
the 2" probe.
When checking for noise on a wire, the best results
will be achieved when the sniffer is placed parallel to
the wire, see Figure 5.
USE AND CONSTRUCTION OF A HAND HELD NOISE
"SNIFFER"
A noise sniffer can be built from a personal

AM/FM stereo cassette player.
EQUIPMENT
Personal AM/FM stereo cassette tape player with

headphones
Four feet of 75 ohm antenna coax
One-half inch heat shrink tube the same diameter
as the coax
A drill and bit the same diameter as the coax
\
150 - 19
Book of matches or hair dryer

Soldering iron and solder
INSTRUCTION FOR THE PERSONAL TYPE RADIO

1. Strip 1/4" off both ends of the coax.
2.
Place the heat shrink over one end of the bare

wire. Fasten the heat shrink to the wire by
heating it (a match or a hair dryer).
3. Disassemble the Radio and locate the antenna.
4. Disconnect the antenna and fasten the bare end of
the coax to the antenna mount. A soldering iron
may be needed.
5. Feed the coax to the exterior of the Radio. Drill a
feed hole if necessary.
6. Reassemble the Radio.
To use the Radio sniffer, turn the Radio on AM and
select an appropriate station.
INSTRUCTION FOR THE PERSONAL TYPE CASSETTE
1. Strip 1/4" off each end of coax.
2.
Disassemble the cassette deck and locate the tape

head.
3. Remove the head and mount one end of the coax to
this point. A soldering iron may be needed.
4. Feed the coax to the exterior of the cassette deck.
Drill a feed hole if necessary.
5. Reassemble the cassette deck.
6. Feed the heat shrink tube through the other end of
the coax. DO NOT FASTEN THE HEAT
SHRINK.
7. Fasten the head to the open end of the coax. Use a
soldering iron.
8. Cover the exposed wires between the head and the
wire by positioning the heat shrink tube and
heating it.
To use the cassette sniffer, push "play." It will
work on the same idea as a metal detector.
NOISE
WHITE PLASTIC INS ULA TOR
CENTER CONDUCTOR WIRE
2'
~
"
,,~t
),
'(
~~
OF COAX SHIELD
CUT AWAY
Figure 4 - Antenna Sniffer
Figure 5 - Checking for Noise on a Wire
SA -
150 - 20
RADIO
CHART #14
SWITCH POP
DETERMINE WHICH SWITCH IS CAUSING A POP WHEN ACTIVATED.

DETERMINE SWITCH CONFIGURATION, SEE FIGURE 1 OR FIGURE 2.
INSTALLCAPACITOR(P/N 1227894)ATLOCATION .
POP STILL PRESENT?
INSTALLCAPACITOR(P/N 1227894)ATLOCATION
POP STILL PRESENT?
INSTALLCAPACITOR(P/N 1227894)ATLOCATION@.
POP STILL PRESENT?
r-
@.
-------------------------,
: CHECK FOR TECHNICAL SERVICE BULLETINS :

I ON SWITCH POP.
1
RETEST FOR NOISE.
L---------------------------~
B+
B+
B+
1
USER
ACTIVATOR
----------------,
I
USER
ACTIVATOR
SWITCH
.47 t
SWITCH
I
I
__._
I
----------,
I
I
.47 1
I
I
I
I
_._@
I
Figure 1 - Direct Switch Activated Device
!
,j:::
---------,
I
I
I
_.__
I
I
I
..J....
,,._ .47 1
I
I
..J....
,;-.. .47 1
I
I
I
LOAD
----.---------,
LOAD
..J....
,,._ .47 t
I
_i_@
Figure 2 - Relay Activated Device
.47 1
CHART #15
ALL STEERING WHEEL RADIO CONTROLS INOPERATIVE (OR OPERATE ERRATICALLY}
rn
IMPORTANT:
AN ADDITIONAL RADIO INPUT TEST <;:AN BE FOUND ON PAGE SA-150-22.
IGNITION "ON."
RADIO "ON."
BACKPROBE FROM CONN C217 TERM "C" TO
GROUND USING J 39200 DVM SET TO VOLTAGE.
MEASURE AND NOTE THE VOLTAGE WHILE
PRESSING EACH OF THE STEERING WHEEL RADIO
CONTROL BUTTONS.
COMPARE THE VOLTAGES TO THE CHART ON
PAGE SA-150-2.
DO THE VOLTAGES CHECK OUT OK?
DISCONNECT RADIO CONN C4 ONLY.

RADIO "ON."
ARE ALL RADIO FUNCTIONS OPERATIONAL AT RADIO?
r--L-------------,~----------~
: SERVICE RADIO. :
1
I
REFERTO
SECTION 9A.
L------------.J
r--~---------------~
WAS VOLTAGE B + WHEN ANY BUTTON WAS PRESSED?
: SERVICE RADIO.
:
L----------------~
r-
~...-----------------___. 1
--------------,
------------------------------.....
....
.A.
DISCONNECT RADIO CONN C4.

DISCONNECT CONN C217.
CHECK CKT 1796 FOR SHORT TO GROUND.
IS CIRCUIT OK?
CONNECT TEST LIGHTFROM C217

TERM "A" {HARNESS SIDE) TO GROUND.
IS TEST LIGHT "ON"?
r-
/;~1,. :
~ 1
:
:
1
:
:
:
1
---------- -----------------------,
DISABLE THE SUPPLEMENTAL INFLATABLE RESTRAINT :
(SIR) SYSTEM AND REMOVE AND DISCONNECT
INFLATOR MODULE FROM STEERING WHEEL (REFER
TO SECTION 9JB, THEN RETURN TO THIS CHART).

CHECK CKTS 43 AND 1796 OF THE SIR COIL ASSEMBLY
FOR OPENS OR SHORTS TO GROUND.
IF OK, REPLACE STEERING WHEEL CONTROLS.
IF STILL INOPERATIVE, SERVICE RADIO.
1
CHECK FOR OPEN IN CKT 1796 BETWEEN C217 AND

RADIO, OR FOR POOR CONNECTION AT RADIO.
IF OK, SERVICE RADIO.
CHECK FOR OPEN IN CKT 43 TO C217

TERM "A", OR FOR OPEN FUSE 17.
If FUSE 17 IS OPEN, CHECK FOR SHORT
TO GROUND THROUGH CKT 43.
L------------------------------------J
SEE Po\GE SA-3-0

FOR IROPER
HANDLING
PROCEDURES

SA -
150 - 22
RADIO
CHART #16
ONE OR MORE STEERING WHEEL RADIO CONTROLS INOPERATIVE
(SOME CONTROLS ARE OPERATIONAL)
rn
IMPORTANT:
ASSUME ALL FUNCTIONS OPERATE NORMALLY AT RADIO. IF THEY DO
NOT OPERATE NORMALLY, SERVICE RADIO. REFER TO SECTION 9A.
IGNITION "ON."
RADIO "ON."
BACKPROBE FROM CONN C217 TERM "C" TO GROUND USING J 39200
DVM SET TO VOLTAGE.
MEASURE AND NOTE THE VOLTAGE WHILE PRESSING EACH OF THE
STEERING WHEEL RADIO CONTROL BUTTONS.
COMPARE THE VOLTAGES TO THE CHART ON PAGE BA-150-2.
DO THE VOLTAGES CHECK OUT OK?
r- --------------,
: SERVICE RADIO.
:
1
REFER TO SECTION 9A. 1
L----------------~
RADIO INPUT TEST

1.
2.
3.
4.
5.
DISCONNECTCONNC217.
IGNITION "ON."
RADIO "ON."
USING SIGNAL GENERATOR 1/P TESTER J 33431-B,
SIMULA TE THE RESISTANCES EQUAL TO THE VALUES IN
THE STEERING WHEEL RADIO CONTROLS THAT DO NOT
OPERATE (SEE RESISTANCE CHART).
MOMENTARILY CONNECT THE SIMULATED RESISTANCES
FROM B + TO (217 TERM "C" (RADIO SIDE).
RESISTANCE CHART
SIMULATED
BUTTON
RESISTANCE FROM
TERM "A" TO
TERM "C" IN OHMS.
PRE~SET
1270
VOLUME (UP)
1564
VOLUME (DOWN)
1912
PWR
2387
AM/FM
3102
SEEK(UP)
4282
SEEK(DOWN)
6652
RCL
13632
CIRCUIT OPERATION
rn
NOISE ENTRY
FRONTWA Y NOISE
Important:
For Delco-Loe II Anti-theft Feature Operation
(available only on UlA Disk Radio option) or for
Radio Features and Controls Operation, refer to
SECTION9A.
The Radio receives battery voltage at all times on

CKT 40 from Fuse 8 to keep clock and preset station
memory alive when the Ignition is "OFF." With the
Ignition Switch in "ACCY", "RUN" or "RETAINED
ACCESSORY POWER (RAP)," voltage is applied to
CKT 43 from Fuse 17 to enable Radio operation.
When the Park Lights or Headlights are turned
"ON," voltage is applied to the Radio on CKT 9 from
the Headlight Switch. When voltage is applied to
CKT 9 at the Radio, the Radio will illuminate the
display. With the Headlights or Park Lights "ON," the
Radio display may be dimmed manually using the 1/P
Dimmer Switch. The 1/P Dimmer Switch varies the
voltage on CKT 8 to the Radio to control display
dimming.
Any noise which can be eliminated by unplugging

the antenna from the back of the Radio.
Some Causes:
Poor grounding of: the antenna base, the Radio or

some electrical component body parts.
Defective or marginal components: relays,
solenoid, switches and electric motors. Something
near the antenna coax or corrosion at antenna coax
connections.
Solutions:
Always verify grounding first. If more than one

component interferes, a poor ground probably exists.
Pinpoint the source: suppress, shield or replace.
Reroute noisy wires if necessary.
SIDEWAY NOISE
Any noise which gets quieter when the unit 1s

slowly removed from its mounting.
Some Causes:
Noisy wires or hoses behind or on top of the Radio

or antenna coax lead.
Solutions:
SPEAKERS: BASE
With the Base Speaker System, the audio signals

are amplified within the Radio, and the outputs go
directly to the speakers.
Suppress or shield the noisy wire or hose or reroute

it. Shield the Radio case. Use aluminum or nickel
tape and ground the tape whenever shielding (nickel
tape will also stop magnetic interference, aluminum
will not).
SPEAKERS: UW2 (10 SPEAKER SOUND SYSTEM)
For eight of the systems ten speakers, the audio

signals are amplified within the Radio and the outputs
go directly to the speakers.
The Amplifier is used to drive two subwoofers. The
Amplifier receives all the amplified signals coming
from the Radio. These signals are used to determine
the Amplifier's output to the subwoofers. The
Amplifier has separate power and ground inputs and is
turned "ON" and "OFF" from the control output of the
Radio on CKT 314.
BACKWAY NOISE
Any noise that can be heard at minimum volume

and not frontway or sideway noise.
Some Causes:
Poor grounding of the Radio or of unsuppressed

electrical components. Poorly routed wires or
defective suppression of electrical components.
Solutions:
Suppression can be installed at the source

(preferable), the Radio or both.
8A -
200 - 0
SERVICE PARTS INFORMATION

Service Parts Catalog
Component Name Used In Section SA
Reference Name
AJC Clutch Diode ........................ .

AJC Compressor Clutch ................... .
AJC Compressor Low Pressure Cut Off Switch
AJC Compressor Relay .................... .
AJC Evaporator Temperature Sensor ....... .
AJC Refrigerant Pressure Sensor .......... .
ABS Brake Pressure Valve Solenoid, LF .... .
ABS Brake Pressure Valve Solenoid, RF .... .
ABS Motor Pack ......................... .
ABS Relay .............................. .
Air Pump Relay .......................... .
Ambient Light Sensor .................... .
Amplifier (Part of UW2 Speaker Option) ... .
Antenna ................................ .
Arming Sensor, Dual Pole ................. .
Ashtray Lamp (Auto Trans) ............... .
Ashtray Lamp (Manual Trans) ............ .
Audio Alarm Module ..................... .
Automatic Transmission .................. .
Backup Lamp, LH ........................ .
Backup Lamp, RH ........................ .
Backup Light Switch (V6 VIN S Manual) .. .
Backup Light Switch (VS VIN P Manual) .. .
Battery ................................. .
Battery Junction Block ................... .
Blower Motor ............................ .
Blower Resistor .......................... .
Blower Switch (C41) ..................... .
Blower Switch (C60) ..................... .
Brake Combo Valve (ABS) ................ .
Brake Switch Assembly (All vehicles, use
1 conn on Manual) ...................... .
Brake Transmission Shift Interrupt (BTSI)
Solenoid ............................... .
Camshaft Position Sensor (V6 VIN S) ..... .
Center High Mounted Stop Light (CHMSL) .
Cigar Lighter ............................ .
Clutch Anticipate/Cruise Release Switch
(All V6 Manual) ........................ .
Clutch Start Switch ...................... .
Console Compartment Lamp .............. .
Convenience Center ...................... .
Coolant Fan, Primary .................... .
Coolant Fan, Secondary ................... .
Coolant Fan Relay, Primary ............... .
Coolant Fan Relay, Secondary ............. .
Crankshaft Position Sensor, HI Resolution
(V6 VIN S) ............................. .
Group
GMSPO #16039386
Not serviceable separately- Compressor, AJC . . . . . . . . . . . 9.17
Switch, A/C CMPR Low PRESS Cut Off . . . . . . . . . . . . . . . 9.172
Relay, FWD LMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.485
Switch, A/C MDL THERM CYCL . . . . . . . . . . . . . . . . . . . . 9.275
Sensor, AJC REFRIG PRESS . . . . . . . . . . . . . . . . . . . . . . . . . 9.275
Valve Kit, BRK M/CYL SOL . . . . . . . . . . . . . . . . . . . . . . . . . . 4.73
Valve Kit, BRK M/CYL SOL . . . . . . . . . . . . . . . . . . . . . . . . . . 4.73
Motor Kit, BRK M/CYL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.647
Relay, ELEK BRK CONT ............................ 4.72
Relay, FWD LMP ................................... 2.485
Sensor, Daytime Running LP AMB LGT . . . . . . . . . . . . . . 2.485
Amplifier, Low FREQ Audio . . . . . . . . . . . . . . . . . . . . . . . . . . 9.65
Antenna, RDO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.647
Sensor, INFL RST Arming . . . . . . . . . . . . . . . . . . . . . . . . . 14.865
Light Pipe from PRNDL Lamp (part of trim plate)
Standard Part
Alarm, ST Belt, IGN Key and LPS . . . . . . . . . . . . . . . . . . . . 9.765
Transmission, Auto . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.003
Standard Part
Standard Part
Switch, B/U LP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.698
Switch, B/U LP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.698
Battery, STOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.33
Block, Main WRG JUNC and Fuse . . . . . . . . . . . . . . . . . . . 2.483
Motor, Blower Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.015
Connector, BLO RES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.275
Switch, HTR CONT BLO . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.852
Switch, HTR and A/C CONT BLO . . . . . . . . . . . . . . . . . . . . 9.275
Valve, BRK COMB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.69
Switch, S/LP and TRANS CONV CLU . . . . . . . . . . . . . . . . 4.115
Solenoid, A/TRNS SHFT LK CONT . . . . . . . . . . . . . . . . . .
Sensor, CM/SHF Position . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lamp, High MT Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lighter, CIG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.054
2.383
2.679
9.709
Switch, Clutch PED POSN . . . . . . . . . . . . . . . . . . . . . . . . . .

Switch, M/TRNS CLU Start . . . . . . . . . . . . . . . . . . . . . . . . .
Socket, FRT Console LP . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Not serviceable - Packard Part
Motor Kit, ENG COOL Fan (ELEC) . . . . . . . . . . . . . . . . . .
Motor Kit, ENG COOL Fan (ELEC) . . . . . . . . . . . . . . . . . .
Relay, ENG Air Cooling (ELEC) . . . . . . . . . . . . . . . . . . . . .
Relay, ENG Air Cooling (ELEC) . . . . . . . . . . . . . . . . . . . . .
4.054
4.054
10.275
1.055
1.055
1.055
1.055
Sensor, CR/SHF POSN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.383

Reference Name
Crankshaft Position Sensor, LOW Resolution

(V6 VINS) ............................. .
Cruise Control Module .................... .
Cruise Release Brake Switch (All with K34) .
(VS Manual with K34, 2 pin) ............. .
Data Link Connector (DLC) ............... .
Daytime Running Lights (DRL) Module .... .
Diagnostic Energy Reserve Module (DERM) .
Discriminating Sensor, Forward ........... .
Discriminating Sensor, Passenger
Compartment .......................... .
Distributor .............................. .
Dome Lamp ............................. .
Door Illumination Lamp, LH .............. .
Door Illumination Lamp, RH .............. .
Door Jamb Switch, LH .................... .
Door Jamb Switch, RH .................... .
Door Lock Actuator, LH .................. .
Door Lock Actuator, RH .................. .
Electronic Brake Control Module (EBCM) .. .
Electronic Ignition Module (V6 VIN S) .... .
Engine Control Module (ECM) ............ .
Engine Coolant Heater ................... .
Engine Coolant Heater Cord .............. .
Engine Coolant Level Sensor (VS VIN P) .. .
Engine Coolant Temperature (ECT) Sensor .
Engine Coolant Temperature Gage Sensor ...
Purge Solenoid Valve ....................
Valve ...................................
Express Down Module .....................
Fog Lamp, Left Front . . . . . . . . . . . . . . . . . . . . . .
Fog Lamp, Right Front . . . . . . . . . . . . . . . . . . . .
Fog Light Relay ...........................
Fog Light Switch . . . . . . . . . . . . . . . . . . . . . . . . . .
Forward/Back Motor (AC3 Power Seat) . . . . .
Front Height Motor (AC3 Power Seat) . . . . . .
Fuel Gage Sender .........................
Fuel Injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel Pump Prime Connector . . . . . . . . . . . . . . .
Fuel Pump Relay . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel Tank Unit . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fusible Link (BTSI) . . . . . . . . . . . . . . . . . . . . . . .
Fusible Links . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
I Group
Sensor, CR/SHF POSN .............................. 2.383

Module, CRCONT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.887
Switch, CRCONT REL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.887
Switch, CRCONT REL CLU SW . . . . . . . . . . . . . . . . . . . . . 3.887
Connector, ECM Data Link . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.53
Module, HDLP Auto CONT . . . . . . . . . . . . . . . . . . . . . . . . . . 2.485
Module, INFL RST RESV ENGY . . . . . . . . . . . . . . . . . . . . 14.865
Sensor, INFL RST FIEND SH MET . . . . . . . . . . . . . . . . . . 14.856
Sensor, INFL RST PASS COMPT .................. . 14.865
Distributor ........................................ . 2.361
Bulb, LP DM ...................................... . 8.991
Standard Part
Standard Part
Switch, DR Jamb (Double Pole) . . . . . . . . . . . . . . . . . . . . . . 11.95
Switch, DR Jamb (Single Pole) . . . . . . . . . . . . . . . . . . . . . . 11.95
Actuator, FRT S/D LK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.485
Actuator, FRT S/D LK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.485
Module, Electronic BRK CONT . . . . . . . . . . . . . . . . . . . . . . . 4. 72
Module, IGN Coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.17
Controller, ECM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.67
Engine Coolant Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.152
Engine Coolant Heater Cord . . . . . . . . . . . . . . . . . . . . . . . . . 1.152
Module, ENG COOL LVL IND . . . . . . . . . . . . . . . . . . . . . . . 1.203
Sensor,CoolantTEMP (ENG Unit) ................... 1.15
Sensor, ENG COOL TEMP . . . . . . . . . . . . . . . . . . . . . . . . . . 3.682
Valve,EVAPEMISCNSTRPurgeSOLVLV ...........
3.13
Valve, EGR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.67

Module, P/W CONT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.783
Bulb, w/Socket, Fog LP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.991
Bulb, w/Socket, Fog LP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.991
Relay, Headlamp/Fog LP . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.485
Switch, Fog LP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.485
Motor, D/Seat ADJR (w/GROM and INS) . . . . . . . . . . . . 11.556
Motor, D/Seat ADJR (w/GROM and INS) . . . . . . . . . . . . . 11.556
Sender, Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.107
Injector, Fuel Injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.3
Pump, Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.9
Connector, Fuel Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.9
Relay, F/PMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.9
See: Fuel Pump or Fuel Sender
Fusible Link Wire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8. 965
Fusible Link Wire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.965
Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.275
SA -
200 - 2


Component Name Used In Section BA
Reference Name
Hatch Release Actuator . . . . . . . . . . . . . . . . . . . .

Hatch Release Relay ......................
Hatch Release Switch . . . . . . . . . . . . . . . . . . . . .
Hazard Flasher . . . . . . . . . . . . . . . . . . . . . . . . . . .
Headlamp Door Motor Assembly, LH . . . . . . . .
Headlamp Door Motor Assembly, RH . . . . . . .
Headlamp, Left ...........................
Headlamp, Right . . . . . . . . . . . . . . . . . . . . . . . . . .
Headlight Dimmer Switch . . . . . . . . . . . . . . . . .
Headlight Doors Module . . . . . . . . . . . . . . . . . . .
Headlight Switch . . . . . . . . . . . . . . . . . . . . . . . . .
Heater/Vent/Air Conditioning (HVAC)
Control Assembly . . . . . . . . . . . . . . . . . . . . . . . .
High Blower Relay . . . . . . . . . . . . . . . . . . . . . . . .
Horn Relay ...............................
Horn Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Horn #1 (A note) . . . . . . . . . . . . . . . . . . . . . . . . .
Horn #2 (F note) . . . . . . . . . . . . . . . . . . . . . . . . . .
Hydraulic Modulator Assembly . . . . . . . . . . . . .
1/P Compartment Lamp . . . . . . . . . . . . . . . . . . . .
1/P Dimmer Switch . . . . . . . . . . . . . . . . . . . . . . . .
1/P Fuse Block . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Idle Air Control (IAC) Motor . . . . . . . . . . . . . . .
Ignition Coil Module (VS VIN P) . . . . . . . . . . .
Ignition Coil (VS VIN P) ..................
Ignition Key Lock Cylinder . . . . . . . . . . . . . . . .
Ignition Key Warning Switch . . . . . . . . . . . . . .
Ignition Switch . . . . . . . . . . . . . . . . . . . . . . . . . . .
lnflator Module, Driver . . . . . . . . . . . . . . . . . . . .
Inflator Module, Passenger . . . . . . . . . . . . . . . . .
Instrument Cluster . . . . . . . . . . . . . . . . . . . . . . . .
Intake Air Temperature (IAT) Sensor . . . . . . .
Isolation Diode (Low Coolant) . . . . . . . . . . . . . .
Isolation Diode (RAP) . . . . . . . . . . . . . . . . . . . . .
Isolation Diode (Wipers) . . . . . . . . . . . . . . . . . . .
Keyless Entry Receiver . . . . . . . . . . . . . . . . . . . .
Knock Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
License Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Low Coolant Relay . . . . . . . . . . . . . . . . . . . . . . . .
Manifold Absolute Pressure (MAP) Sensor . . .
Manual Transmission .....................
Marker Lamp, Left Front . . . . . . . . . . . . . . . . . .
Marker Lamp, Left Rear . . . . . . . . . . . . . . . . . . .
Marker Lamp, Right Front . . . . . . . . . . . . . . . . .
Marker Lamp, Right Rear . . . . . . . . . . . . . . . . . .
Mirror Motor Pack . . . . . . . . . . . . . . . . . . . . . . . .
Multi-Function Lever . . . . . . . . . . . . . . . . . . . . .
I Group
Actuator, Deck Lid REL . . . . . . . . . . . . . . . . . . . . . . . . . . . . lZ.942

Relay, R/CMPT Lid REL . . . . . . . . . . . . . . . . . . . . . . . . . . . 12.243
Switch, R/CMPT Lid REL . . . . . . . . . . . . . . . . . . . . . . . . . . 12.243
Flasher, Hazard LP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.575
Actuator, HDLP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.76
Actuator, HDLP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.76
Sealbeam, HDLP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.727
Sealbeam, HDLP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.727
Switch, DIMR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.459
Module, HDLP OPG DR ACTR CONT . . . . . . . . . . . . . . . . 2.755
Switch, Headlamp/Fog Lamp . . . . . . . . . . . . . . . . . . . . . . . . 2.485
Control, Heater and A/C Control . . . . . . . . . . . . . . . . . . . . . 9.273
Relay, FWD LMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.485
Relay, Horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.815
Switch, STRG WHL Horn . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.819
Horn, High Note . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.81
Horn, Low Note . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.81
Valve ASM, BRK PRESS MOD (Components Serviceable) 4. 73
Bulb, Glove Box LP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.991
Switch, 1/P LP DIMR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.49
Block, Main WRGJUNC and Fuse . . . . . . . . . . . . . . . . . . . 2.483
Valve Kit, TBI Idle Air CONT . . . . . . . . . . . . . . . . . . . . . . . . 3.82
Module, Ignition Coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.383
Coil, Ignition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.17
Cylinder, STRG COL LK and IGN SW . . . . . . . . . . . . . . . . 2.188
Switch, IGN Key Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.195
Switch, IGN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.188
Module, INFL RST STRG WHL (Inflator) . . . . . . . . . . . . 14.865
Module, INFL RST 1/P (Inflator) . . . . . . . . . . . . . . . . . . . . 14.865
Cluster, INST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.735
Sensor, A/CL Air TEMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.682
GMSPO #8907 496
GMSPO #8907 496
GMSPO #8907 496
Receiver, R/CON DR LK . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.485
Sensor, Knock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.383
Standard Part
Relay, FWD LMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.485
Sensor, MAP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.682
Transmission, Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.003
Standard Part
Standard Part
Standard Part
Standard Part
Motor, 0/S RR View MIR . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.185
Lever, T/SIG, HDLP D/SW, CRCONT ACTR, WSW
and WSWA ....................................... 2.897
200 - 3

Component Name Used In Section 8A
Reference Name
Oil Level Sensor ..........................

Oil Pressure Sensor . . . . . . . . . . . . . . . . . . . . . . .
Outside Mirror, LH ........................
Outside Mirror, RH .......................
Oxygen Sensor, LH . . . . . . . . . . . . . . . . . . . . . . . .
Oxygen Sensor, RH . . . . . . . . . . . . . . . . . . . . . . . .
Park Brake Switch ........................
Park/Turn Lamp, Left Front . . . . . . . . . . . . . . .
Park/Turn Lamp, Right Front . . . . . . . . . . . . . .
PASS-Key II Decoder Module .............
Power Door Lock Switch, LH . . . . . . . . . . . . . . .
Power Door Lock Switch, RH . . . . . . . . . . . . . . .
Power Mirror Switch . . . . . . . . . . . . . . . . . . . . . .
Power Seat Actuator Assembly (AC3) . . . . . . .
Power Seat Control Module (AQ9 Power Seat)
Power Seat Motor . . . . . . . . . . . . . . . . . . . . . . . . .
Power Seat Switch (AC3) . . . . . . . . . . . . . . . . . .
Power Seat Switch, Driver (AQ9) . . . . . . . . . . .
Power Seat Switch, Passenger (AQ9) . . . . . . . .
Power Window Switch, LH . . . . . . . . . . . . . . . . .
Power Window Switch, RH . . . . . . . . . . . . . . . . .
PRNDL Illumination Lamp (Auto Trans) . . .
Pump Assembly (AQ9 Power Seat) . . . . . . . . . .
Radio (Base) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rear Defogger Grid . . . . . . . . . . . . . . . . . . . . . . . .
Rear Defogger Switch . . . . . . . . . . . . . . . . . . . . .
Rear Defogger Timer/Relay . . . . . . . . . . . . . . . .
Rear Dome Light Switch . . . . . . . . . . . . . . . . . . .
Rear Height Motor (AC3 Power Seat) . . . . . . .
Rearview Mirror ..........................
Retained Accessory Power (RAP) Module . . . .
Reverse Lockout Solenoid (VS VIN P Manual)
Seat Belt Switch . . . . . . . . . . . . . . . . . . . . . . . . . .
Secondary Air Injection Pump Assembly . . . .
SIR Coil Assembly . . . . . . . . . . . . . . . . . . . . . . . .
Solenoid Valve Assembly (AQ9 Power Seat) .
Speaker Assembly, Left Rear
(With UW2 Speakers) ....................
Speaker Assembly, Right Rear
(With UW2 Speakers) . . . . . . . . . . . . . . . . . . . .
Speaker, Left Front Midrange
(With UW2 Speakers) ....................
Speaker, Left Front Tweeter
(With UW2 Speakers) ....................
Speaker, Left Front (Base - UQO) . . . . . . . . . . .
Speaker, Left Rear Subwoofer
(With UW2 Speakers) . . . . . . . . . . . . . . . . . . . .
Group
Sensor,ENGOilLVL ............................... 1.516

Sensor, Oil Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.8
Mirror, 0/S RR View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.185
Mirror, 0/S RR View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.185
Sensor, OXY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.682
Sensor, OXY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.682
Switch, Parking BRK Alarm . . . . . . . . . . . . . . . . . . . . . . . . . 4.589
Standard Part
Standard Part
Module, Theft DTRNT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.195
Switch, DR LK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.485
Switch, DR LK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.485
Switch, 0/S R/CON RR View MIR SEL . . . . . . . . . . . . . . . 10.186
Actuator, D/Seat ADJR (w/MOT and SUPT) . . . . . . . . . 11.556
Module, P/Seat PNEU CONT . . . . . . . . . . . . . . . . . . . . . . . 11.378
Motor, D/Seat AD,JR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.556
Switch, D/Seat ADJR . . . . . . . . . . . . . . . . . . . . . . .. . . . .. . 11.558
Switch, D/Seat PNEU Pump and VLV . . . . . . . . . . . . . . . 11.378
Switch, P/Seat PNEU Pump and VLV . . . . . . . . . . . . . . . 11.378
Switch, SI WDO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.777
Switch, SI WDO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.777
Lamp, Instrument PNL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.515
Pump, ST INFL D/Seat PNE U . . . . . . . . . . . . . . . . . . . . . . 11.378
Radio, Radio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.65
Part of Rear Glass
Switch, R/WDO DEFG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9. 778
Timer, R/WDO DEFG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.744
Switch, R/CMPT LidLock . . . . . . . . . . . . . . . . . . . . . . . . . . 12.243
Motor, D/Seat ADJR (w/GROM and INS) . . . . . . . . . . . . 11.556
Mirror, US RR View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.185
Module, Retained Accessory Power . . . . . . . . . . . . . . . . . . 10.485
Part of Transmission Exchange Program
Part of Driver's Seat Belt Buckle . . . . . . . . . . . . . . . . . . . . 14.875
Pump, SECD Air INJN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.66
Coil Kit, INFL RST STRG WHL MDL . . . . . . . . . . . . . . . 14.865
Valve, D/Seat Pneumatic 3 SOL . . . . . . . . . . . . . . . . . . . . . 11.378
Speaker, RDO R/Q TR PNL . . . . . . . . . . . . . . . . . . . . . . . . . . 9.665
Speaker, RDO R/Q TR PNL . . . . . . . . . . . . . . . . . . . . . . . . . . 9.665
Speaker, RDO FRT SID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.665
Speaker, RDO FRT SID (Tweeter) . . . . . . . . . . . . . . . . . . . . 9.665
Speaker, RDO FRT SID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.65
Speaker, RDO QTR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.665


Reference Name
Speaker, Left Rear (Base- UQO) . . . . . . . . . . . .

Speaker, Right Front Midrange
(With UW2 Speakers) . . . . . . . . . . . . . . . . . . . .
Speaker, Right Front Tweeter
(With UW2 Speakers) ....................
Speaker, Right Front (Base- UQO) . . . . . . . . .
Speaker, Right Rear Subwoofer
(With UW2 Speakers) ....................
Speaker, Right Rear (Base- UQO) . . . . . . . . . . .
Starter Enable Relay ......................
Starter Motor .............................
Starter Solenoid ..........................
Steering Wheel Controls, Radio (UK3) . . . . . .
Tachometer Filter (VS VIN P) . . . . . . . . . . . . .
Taillamp, LH . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Taillamp, RH . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tail/Stop/Turn Lamp, LH Inboard . . . . . . . . . .
Tail/Stop/Turn Lamp, LH Outboard . . . . . . . . .
Tail/Stop/Turn Lamp, RH Inboard . . . . . . . . . .
Tail/Stop/Turn Lamp, RH Outboard . . . . . . . . .
Throttle Position (TP) Sensor . . . . . . . . . . . . . . .
Torque Converter Clutch (TCC) Solenoid . . . .
Transmission Position Switch . . . . . . . . . . . . . .
Turn Flasher . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Turn/Hazard Switch Assembly . . . . . . . . . . . . .
U nderhood Electrical Center . . . . . . . . . . . . . . .
Vehicle Speed Sensor ......................
Washer Pump Motor . . . . . . . . . . . . . . . . . . . . . .
Wheel Speed Sensor, Left Front . . . . . . . . . . . . .
Wheel Speed Sensor, Rear . . . . . . . . . . . . . . . . . .
Wheel Speed Sensor, Right Front . . . . . . . . . . .
WindowMotor,LH ........................
Window Motor, RH . . . . . . . . . . . . . . . . . . . . . . . .
Wiper Motor Assembly ....................
Wiper/Washer Switch Assembly ............
I Group
Speaker, RDO RR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.665

Speaker, RDO FRT SID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.665
Speaker, RDO FRT SID (Tweeter) . . . . . . . . . . . . . . . . . . . . 9.665
Speaker, RDO FRT SID . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 9.65
Speaker, RDO QTR .................................. 9.65
Speaker, RDO RR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.665
Relay, Theft DTRNT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.195
Motor, STRTR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.041
Switch, STRTR SOL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.1
Switch, RDO CONT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.649
Filter, Tachometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.75
Standard Part
Standard Part
Standard Part
Standard Part
Standard Part
Standard Part
Sensor, Throttle Position (EFI) . . . . . . . . . . . . . . . . . . . . . . 3.764
Valve, TCC SOL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.122
Switch, Park/NEU POSN . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.054
Flasher, T/SIG LP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.892
Switch, T/SIG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.895
Part of Harness, U/Hood LP WRG . . . . . . . . . . . . . . . . . . . . . 8.89
Sensor, VEH SPD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.682
Pump, WSW A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.153
Sensor, WHL SPD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.71
Wheel, RR WHL SPD SEN Reluctor
Sensor, WHL SPD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.71
Motor,FRTSIDWDOREG ......................... 10.783
Motor, FRT SID WDO REG . . . . . . . . . . . . . . . . . . . . . . . . . 10.783
Motor, WSW ...................................... 10.150
Switch, WSW and WSWA . . . . . . . . . . . . . . . . . . . . . . . . . . 10.163
BLANK
200 - 5
SA - 201
-0

BRAKE/CLUTCH
PEDAL BRACKET
CRUISE RELEASE/
BRAKE SWITCH
CLUTCH
PEDAL
I
CLUTCH ANTICIPATE/
CRUISE RELEASE
SWITCH
(V6 VIN S)
CRUISE RELEASE/
CLUTCH SWITCH
(VS VIN P)
CLUTCH JUMPER
HARNESS
Figure 1 - Under LH Side of 1/P
CLUTCH JUMPER
HARNESS
ELECTRICAL DIAGNOSIS . SA- 201
CLUTCH ANTICIPATE/
CRUISE RELEASE
SWITCH CONNECTOR
FORWARD
LAMP HARNESS
CLUTCH ANTICIPATE/
CRUISE RELEASE
SWITCH CONNECTOR
&L32 &M49 EXC K34
&L32 &M49 &K34

FORWARD
LAMP HARNESS
[TI IMPORTANT:
LT1 &MN6 WITHOUT K34,

DOES NOT HAVE A CLUTCH
JUMPER HARNESS.
CRUISE RELEASE/
CLUTCH SWITCH
CONNECTOR
&LT1 &MN6 &K34

Figure 2 - Clutch Jumper Harness Combinations - Manual (M49 or MN6)
-1
SA -
201 - 2
STEERING WHEEL
CONTROLS, RADIO
CONNECTOR
INFLATOR MODULE,
DRIVER CONNECTOR
INFLATOR MODULE
BRACKET
STEERING WHEEL
ASSEMBLY
STEERING WHEEL ~ - - - ~
CONTROLS, RADIO
Figure 3 - Steering Wheel Controls
STEERING COLUMN
MULTI-FUNCTION
LEVER
Figure 4 - Steering Column
TURN/HAZARD
SWITCH ASSEMBLY
IGNITION KEY
LOCK CYLINDER
SIR COIL
ASSEMBLY
IGNITION
KEY WARNING
SWITCH
,. /
/
WIPER/WASHER
SWITCH ASSEMBLY/,.,.
,.
/
,. /
IGNITION
SWITCH
HEADLIGHT
DIMMER
SWITCH
Figure 5- Steering Column Internals
-3
SA -
201 - 4
Figure 6 - Center Rear on Roof Panel
REAR DEFOGGER
GRID CONNECTOR
(LEFT SIDE)
C420
Figure 7 - Bottom Side of Hatch, Shown Upside Down
LH REAR
QUARTER PANEL
SPEAKER, LEFT REAR

CONN (WITH BASE UQO)
SPEAKER, LEFT REAR
SUBWOOFER CONN
(WITH UW2)
SPEAKER ASSEMBLY,
LEFT REAR CONNECTOR
(WITH UW2)
Figure 8 - LH Rear Quarter Panel
1/PWIRING
HARNESS
FUEL TANK
UNIT JUMPER
ABS REAR WHEEL SPEED
\\P5s
Figure 9 - Forward of LH Side of Rear Axle
-5
SA -
201 - 6
$301
Figure 10 - RH Rocker Panel
#2 FLOOR
PAN RAIL
Figure 11 - LH Rocker Panel
DAYTIME RUNNING
LIGHTS (DRL) MODULE
HVACDUCT
Figure 12 - Under Center of 1/P
HINGE
PILLAR
---
Figure 13 - Behind LH Dash Mat
-7
SA -
201 - 8
FRONT Of._
VEHlCLE ...
ELECTRONIC
BRAKE CONTROL
MODULE (EBCM)
5272
5270
LH HINGE PILLAR
Figure 14- Under LH Side of 1/P
DAYTIME RUNNING
LIGHTS (DRL)
MODULE
JC"~
v~~+;-
PASSKEYII
DECODER MODULE
Q~O,a
DIAGNOSTIC
ENERGY RESERVE
MODULE (DERM)
Figure 15 - Rear View of 1/P Carrier
ELECTRICAL DIAGNOSIS BA -
201 - 9
CROSS CAR HARNESS
Figure 16 -1/P Grounds
(FOR A MORE GENERA0 VIEW OF THIS AREA

REFER TO FIG. 49
PAGE SA-201-32)
DASH MAT
RETAINED ACCESSORY
POWER (RAP) MODULE
Figure 17 - Center of Dash Mat Above Floor Tunnel
SA - 201
- 10
WIPER MOTOR
BRACKET
~-.....___ WIPER MOTOR

ASSEMBLY
VIEWA
Figure 18- Inside LH Side of Cowl
FORWARD
LAMP
HARNESS
Figure 19 - LH Wheelhouse
OIL PRESSURE
SENSOR
CRANKSHAFT POSITION
SENSOR (HI RES) PIGTAIL
Figure 20 - LH Side of Engine (VG VIN S)
LEFT FRONT
FRAME RAIL
SECONDARY
AIR INJECTION
PUMP ASSEMBLY
G109
Figure 21 - LH Front Frame Rail
201 - 11
SA -
201 - 12
Figure 22 - Rear of Engine (V6 VIN S)

MANIFOLD
ABSOLUTE
PRESSURE
(MAP) SENSOR
Figure 23 - Top Rear RH Side of Engine (V6 VIN S)
CAMSHAFT POSITION
SENSOR CONNECTOR
(HARNESS SIDE)
EVAPORATIVE
EMISSION (EVAP)
CANISTER PURGE
SOLENOID VALVE
OXYGEN
SENSOR, LH
Figure 24 - LH Side of Engine {VG VIN S)
Figure 25 - Lower Front of Engine (VG VIN S)

GENERATOR
GENERATOR
CONNECTOR
A/C COMPRESSOR
CLUTCH CONNECTOR
Figure 26 - Front RH Side of Engine (VB VIN P)
Figure 27 - Top Front RH Side of Engine (VB VIN P)
ECM BRACKET
VIEWA
Figure 28 - Right Rear of Engine Compartment
- 15
SA -
201 - 16
ELECTRICAL D~IA~G~N~O~S~IS_ _ _ __
ONVERTER
TORQUHE(~CC) SOLENOID
CLUTC
CONNECTOR
OMATIC
~~NSMISSION
. on (MDS)
Figure 29 - LH Side of Autom atic Transm1ss1
POWER DOOR
LOCK SWITCH, LH
CONNECTOR
POWER WINDOW
SWITCH, LH
CONNECTOR
- 17
POWER MIRROR
SWITCH CONNECTOR
DOOR
ILLUMINATION
DOOR LOCK
ACTUATOR, LH
CONNECTOR
SPEAKER,
LEFT FRONT
TWEETER (UW2)
CONNECTOR
Figure 31 - Behind LH Door Trim (RH Door Similar)
FORWARD LAMP
HARNESS
Figure 32 - RH Side of Front Fascia (LH Similar)
SA - 201 -18 ELECTRICAL DIAGNOSIS

POWER DOOR
LOCK SWITCH, LH
Figure 33 - LH Door Armrest

A/C COMPRESSOR
LOW PRESSURE
CUT OFF SWITCH
A/C COMPRESSOR
AND CONDENSOR HOSE
RH SHOCK
TOWER
A/C REFRIGERANT
PRESSURE SENSOR
""'
Figure 34 - Above RH Shock Tower (Rearward)
ENGINE COOLANT
HEATER CORD
(V6 VIN S)
- 19
ENGINE COOLANT
LEVEL SENSOR
FORWARD
LAMP
HARNESS
HORN#2
(F NOTE)
Figure 35 - Engine Compartment
ENGINE COOLANT
HEATER CORD
(VS VIN P)
CRUISE
CONTROL
MODULE
Figure 36 - Engine Compartment
SA -
201 - 20
Figure 37 - LH Side of Manual Transmission (MNG) (VS VIN P)
- 21
CIGAR LIGHTER
CONNECTOR
CONSOLE
COMPARTMENT
LAMP
Figure 38 - LH Side, Under Console - Automatic (MDS)
ARMING SENSOR,
DUAL POLE
CONNECTOR
Figure 39 - LH Side, Under Console - Manual (M49 or MNG)
CONSOLE
COMPARTMENT
LAMP
ENGINE COOLANT
TEMPERATURE (ECT)
SENSOR
G102
Figure 40 - Front LH Side of Engine (VS VIN P)
201 - 23
ENGINE COOLANT
TEMPERATURE
GAGE SENSOR

S127
OXYGEN
SENSOR, LH
.
41 - LH Side of Engine (VS VIN P)
Figure
STARTER ____..,~
MOTOR
Figure 42 - Back RH Side of Engine (VS VIN P)
201 - 25
SA -
201 - 26

EVAPORATIVE
EMISSION (EVAP)
CANISTER PURGE
SOLENOID VALVE
INJECTOR #4
Figure 43 - RH Side of Engine (VS VIN P)
MANIFOLD
ABSOLUTE
PRESSURE
(MAP) SENSOR
Figure 44 - Top Front LH Side of Engine {VG VIN S)

CRANKSHAFT
POSITION
SENSOR
(LOW RES)
ENGINE
A/C COMPRESSOR
CLUTCH
CONNECTOR
'-
0
Figure 45 - RH Side of Engine (VG VIN S)
IDLE AIR CONTROL

(IAC) MOTOR
/J )
THROTILE
POSITION (TP) /
SENSOR
"'
l /
INTAKE AIR
TEMPERATURE
(IAT) SENSOR
CONNECTOR
Figure 46 - Top Front RH Side of Engine (V6 VIN S)
- 29
SA -
201 - 30
S405
S402
S401
C400
.............._
-..........._
1/PWIRING
~ A R N ESS
"
~
Figure 47 - LH Rear Cargo Compartment
201 - 31
5440
C430
REAR FASCIA
LICENSE LAMP
Figure 48 - Rear Fascia
SA - 201
- 32
ISOLATION
DIODE (RAP)
CROSS CAR
HARNESS
S261
RETAINED ACCESSORY
POWER (RAP) MODULE
(FOR A CLOSE UP VIEW OF
THESE 2 MODULES
SEE FIG.17
PAGE SA-201-9)
Figure 49 - Dash Panel with Cross Car Harness
BACKUP LAMP, LH
TAIL/STOP/TURN
LAMP, RH INBOARD
BACKUP
LAMP, RH
TAIL/STOP/TURN
LAMP, LH INBOARD
TAIL/STOP/TURN
LAMP, LH OUTBOARD
C430
RR FASCIA HARNESS
REAR FASCIA
Figure 50 - Rear of Vehicle
- 33
TAIL/STOP/TURN
LAMP, RH OUTBOARD
SA -
201 - 34
1/PWIRING
HARNESS
SIR COIL
ASSEMBLY
CONNECTOR
Figure 51 - Bottom of Steering Column
IGNITION SWITCH
STEERING COLUMN
,.........~-.;..;;:., C215
(NOT ATTACHED
TO COLUMN)
Figure 52 Bottom of Steering Column
201 - 35
SA -
201 - 36

ABS BRAKE PRESSURE
VALVE SOLENOID, RF
UNDERHOOD
ELECTRICAL CENTER
..,,'-...._
S190
Figure 53 - Front LH Side of Engine Compartment
ELECTRICAL DIAGNOSIS SA- 201 - 37
BRAKE
TRANSMISSION
SHIFT INTERRUPT
(BTSI) SOLENOID
TRANSMISSION
POSITION
SWITCH
Figure 54 - RH Side Under Console - Automatic (MDS)
DISTRIBUTOR
iiu..:
"'...;
HEIGHT
MOTOR
POWERS~
ACTUATOR
ASSEMBLY
I
Figure 55 - Front of Engine {VS VIN P)
POWER SEAT
SWITCH
Figure 56 - Bottom of Driver Seat {AC3)
SA -
201 - 38
,1/PWIRING
HARNESS
VIEWB
VIEWA
Figure 57 _ LH Side of 1/P
(WITHOUT UK3)
C3
C4
Figure 58 - Center of 1/P
- 39
SA -
201 - 40
L-~~~
&, l--~~
I
I
L-1
~
C305
Figure 59 - Under Passenger Seat (AQ9)
- 41
PUMP ASSEMBLY
SOLENOID VALVE
ASSEMBLY
POWER SEAT
SWITCH, DRIVER
(PASSENGER SWITCH
SIMILAR)
Figure 60 - Under Driver's Seat (AQ9)
SA -
201 - 42
RH HINGE PILLAR
Figure 61 - Behind RH Kick Panel
Figure 62 - Lower RH Side of Engine (VS VIN P)
201 - 43
VIEWS
HEADLAMP
MOUNTING
PANEL
VIEWA
C165
Figure 63 - Headlamp Area
SA - 201
- 44
RH REAR
QUARTER
PANEL
SPEAKER, RIGHT REAR

CONNECTOR (WITH
BASE UQO)
SPEAKER, RIGHT REAR
SUBWOOFER
CONNECTOR
(WITH UW2)
AMPLIFIER
(WITH UW2)
SPEAKER ASSEMBLY,
RIGHT REAR CONNECTOR
(WITH UW2)
Figure 64 - RH Rear Quarter Panel
HEATER/VENT/AIR
CONDITIONING (HVAC)
CONTROL ASSEMBL V
Figure 65 - Center of 1/P
STARTER ENABLE RELA V AND

HATCH RELEASE RELA V
Figure 66 - Behind RH Side of 1/P
- 45
SA - 201
- 46
A/C EVAPORATOR
TEMPERATURE
SENSOR AND PROBE
Figure 67 - Behind Lower RH Side of 1/P
DISCRIMINATING
SENSOR.PASSENGER
COMPARTMENT
Figure 68 - General Harness Routing View
- 47
kANTENNA
~
~
ANTENNA
CONNECTOR
FROM HARNESS
WASHER
BOTTLE
Figure 69 - Front of Vehicle, Forward of Tie Bar
Figure 71 - Right Rear Quarter Panel
C200C
WHEEL SPEED SENSOR

LEFT FRONT (ABS)
Figure 70 - Inward Side of Steering Knuckle

(Right Side Similar)
CROSS CAR
HARNESS
Figure 72 - Between LH Kick Panel and Steering

Column
SA -
202 - 0
C100
ENGINE HARNESS TO
FORWARD LAMP
HARNESS
12065425
10-WAY F METRlPACK 150 SERIES
BLK
DESCRIPTION
CAVITY
WIRE COLOR
CKT
PNK
639
POWER FEED FROM INJECTOR FUSE 9
SA-20-2
DKGRN/WHT
459
A/C COMPRESSOR RELAY CONTROL
SA-64-0
DKGRN
59
A/C COMPRESSOR CLUTCH SOLENOID FEED
SA-64-0, 1
TAN
800
SERIAL DATA SIGNAL
SA-50-0
BRN
436
SA-20-1
(V6 VIN S),
PAGE
SA-21-1
(VS VIN P)
F
BRN
541
POWER FEED FROM FANS/SOLS FUSE 6
SA-11-11
PNK
239
POWER FEED FROM IGNITION FUSE 11
SA-11-14
DKBLU
473
SECONDARY COOLANT FAN RELAY CONTROL
SA-31-1
DKGRN
335
PRIMARY COOLANT FAN RELAY CONTROL
SA-31-0, 1
PNK
839
SA-20-2
C110
ENGINE HARNESS (V6 VIN S)
TO INJECTOR JUMPER
HARNESS
12065425
BLK
CAVITY
WIRE COLOR
CKT
BLK
1744
FUEL INJECTOR #1 OUTPUT
8A-20-2
LTGRN/BLK
1745
8A-20-2
PNK/BLK
1746
8A-20-2
LT BLU/BLK
844
8A-20-2
BLK/WHT
845
8A-20-2
YEL/BLK
846
8A-20-2
PNK
639
8A-20-2
PNK
839
8A-20-2
BLK
470
SENSOR REFERENCE GROUND
8A-20-0
VEL
410
COOLANT TEMPERATURE SENSOR SIGNAL
8A-20-0
DESCRIPTION
PAGE
SA -
202 - 2

C2000
e, DDDDDDDDDDDDDe
1 11 11 ILJ, LJI 11 11--1,
"I II II In
@ nl II II I"
1 11 11 I ~ ~ I II II 1
A DDDDDDDDDDDDDDDDDA
1
06
81
86
11
12077822
M - CONNECTOR
F TERMINAL
48-WA Y M METRI-PACK MIXED SERIES
BLK
C200A

1/P HARNESS
c1 AH DD DD DD DD DD DD DD DD D All
\
12047842
BLK

1/P HARNESS
C2008
81
C11
01
1_1_ ...11
,_,__
II
11___II
t::j 2j
II
II
II
II
II
II
I
I
I
86
C6
D6
12084183
BLK

1/P HARNESS
C200C
IAlDDDDDD DODD DDDAnl

\
12047840
GRY

CAVITY
WIRE COLOR
CKT
A1
DKGRN/WHT
817
VEHICLE SPEED SIGNAL TO CRUISE CONTROL MODULE
8A-33-0
A3
LTGRN
867
ABS FAILURE FEED TO 1/P SOLID STATE
8A-81-1
A4
YEL
820
CENTER HIGH MOUNTED STOPLAMP FEED
8A-110-1
AS
TAN/WHT
33
BRAKE INDICATOR WARNING SIGNAL
8A-44-0
A6
ORN
52
BLOWER SWITCH OUTPUT HIGH
8A63-0
A7
DKGRN
29
HORN FEED
8A40-0
A9
DKBLU
1537
"LOW TRACTION" INDICATOR CONTROL
8A-81-3
A12
TAN
800
SERIAL DATA SIGNAL
8A500
A14
BRN
1811
8A44-1
A15
WHT
1810
8A-44-1
A16
VEL
317
FOG LIGHTS ON RELAY FEED
8A-100-2
A17
YELJBLK
68
LOW COOLANT INDICATOR - LATCHED GROUND
8A81-2
B1
PNK
IGNITION SWITCH OUTPUT HOT IN RUN AND CRANK
8A-10-2
82
ORN
300
IGNITION SWITCH OUTPUT - HOT IN RUN
8A10-3
83
PPL
34
FOG LIGHTS ON INDICATOR FEED
8A-100-1
84
PPL
65
HVAC BLOWER MOTOR FEED
8A63-0
85
YEL
10
HEADLIGHTS ON OUTPUT
8A-1000
86
RED
702
BATTERY FEED FROM FUSIBLE LINK Z
8A-10-1
C1
RED
102
A/B
BATTERY FEED FROM FUSIBLE LINKE (DOUBLE WIRE)
8A-10-2
C2
RED
1002
BATTERY FEED FROM FUSIBLE LINK F
8A-10-1
C3
LTGRN
11
HI BEAM HEADLAMP POWER FEED
8A-1000
cs
VEL
IGNITION SWITCH OUTPUT CRANK
8A-10-3
C6
BRN
4A/4B
IGNITION SWITCH OUTPUT ACCESSORY (DOUBLE WIRE)
8A-10-3
01
BLK/WHT
1751
SUPPLEMENTAL INFLATABLE RESTRAINTS GROUND (DOUBLE WIRE)
8A-47-1
02
DKGRN
348
SUPPLEMENTAL INFLATABLE RESTRAINTS INFLATOR OUTPUT (DOUBLE WIRE)
8A-47-0, 1
03
YEL
143
WIPER/WASH FUSE OUTPUT
8A-11-8
04
BRN
PARK LAMPS FEED
8A-110-2,3
05
LTBLU
14
LEFT FRONT TURN SIGNAL LAMP FEED
8A-110-2, 3
06
DKBLU
15
RIGHT FRONT TURN SIGNAL LAMP FEED
8A-110-2, 3
E1
WHT
156
COURTESY LAMP OUTPUT (SWITCHED GROUND)
8A-114-0
E2
BRN
IGNITION SWITCH OUTPUT ACCESSORY AND RUN
8A-10-2
E3
ORN
40
COURTESY FUSE OUTPUT
DESCRIPTION
PAGE
8A-11-7
SA -
202 - 4

CAVITY
WIRE COLOR
CKT
DESCRIPTION
E4
RED
102
BATTERY FEED FROM FUSIBLE LINKE
8A-10-2
ES
TAN
159
KEY-IN-IGNITION SWITCH OUTPUT
8A-76-0
E6
DKBLU
75
RETAINED ACCESSORY POWER RELAY OUTPUT COMMON CONTACT ACCESSORY
8A-15-0
E7
GRY
1/P DIMMER FUSE 13 OUTPUT TO LH AND RH DOOR ILLUMINATION LAMPS
8A-117-1
E9
ORN
640
POWER ACCESSORY FUSE 7 OUTPUT
8A-11-7
E10
PNK
39
GAGES FUSE 9 OUTPUT FOR KEYLESS ENTRY MODULE
8A-11-4
E11
BRN
341
WINDOWS CIRCUIT BREAKER OUTPUT
8A-120-0
E12
PNK
70
RETAINED ACCESSORY POWER COMMON CONTACT IGN 3
8A-15-0
E13
BLK
56
HATCH RELEASE FEED TO KEYLESS ENTRY MODULE
8A-135-0
PAGE
C215
'
~PIN IMIL IK I
l0
IH IG IF
FORWARD LAMP
le l DJ ~~~~~SrJ ~~;J~~~ING
0
06294509
11-WAY F PACK-CON I
BLK

CAVITY
WIRE COLOR
CKT
DESCRIPTION
YEL
143
A/B
POWER FROM WIPER/WASH FUSE 14/POWER TO WINDSHIELD WIPER MOTOR MODULE

(DOUBLE WIRE)
8A-91-0
DKGRN
113
WINDSHIELD WIPER SWITCH SIGNAL - ON
8A-91-0
GRY
112
WINDSHIELD WIPER SWITCH SIGNAL - LOW/PULSE/MIST
8A-91-0
PPL
92
WINDSHIELD WIPER SWITCH SIGNAL - HIGH
8A-91-0
PNK
94
WINDSHIELD WASHER SWITCH SIGNAL
8A-91-0
GRY/BLK
87
CRUISE CONTROL SWITCH SIGNAL - RESUME/ACCEL
8A-34-0
DKBLU
84
CRUISE CONTROL SWITCH SIGNAL - SET/COAST
8A-34-0
GRY
397
CRUISE CONTROL SWITCH SIGNAL - ON
8A-34-0
PNK
139
E/F
POWER FROM A/C COMPRESSOR RELAY/POWER TO CRUISE RELEASE SWITCHES

(DOUBLE WIRE)
8A-34-0
PAGE
ELECTRICAL DIAGNOSIS 8A-
202- 5
C216
1/P HARNESS TO
STEERING COLUMN
HARNESS
12004147
11-WAY F PACK-CON I
BLK

CAVITY
WIRE COLOR
CKT
TAN
159
LTGRN
G
H
H
J
J
DESCRIPTION
PAGE
KEY-IN-IGNITION SWITCH OUTPUT
8A-76-0
80
KEY-IN-IGNITION SWITCH TO AUDIO ALARM MODULE
8A-76-0
BLK
28
HORN RELAY FEED (SWITCHED GROUND)
8A-40-0
LTBLU
LTBLU/WHT
14
1414
LEFT FRONT TURN SIGNAL TO 1/P INDICATOR AND TURN LAMP (DOUBLE WIRE)
(WITH T61) LEFT FRONT TURN SIGNAL TO 1/P INDICATOR AND TURN LAMP (DOUBLE
WIRE)
8A-110-0
RIGHT FRONT TURN SIGNAL TO 1/P INDICATOR AND TURN LAMP (DOUBLE WIRE)
(WITH T61) RIGHT FRONT TURN SIGNAL TO 1/P INDICATOR AND TURN LAMP (DOUBLE
WIRE)
8A-110-0
8A-110-0
DKBLU
DKBLU/WHT
15
1415
8A-110-0
BRN
27
HAZARD FLASHER OUTPUT
8A-110-0
PPL
16
TURN SIGNAL FLASHER OUTPUT
8A-110-0
YEL
18
LEFT REAR TURN SIGNAL
8A-110-1
DKGRN
19
RIGHT REAR TURN SIGNAL
8A-110-1
LTBLU
20
STOPLAMP FEED
8A-110-0
8A 202 6 ELECTRICAL DIAGNOSIS
C220
ENGINE HARNESS
TO 1/P HARNESS
12064769
WHT

CAVITY
WIRE COLOR
CKT
DESCRIPTION
RED
225
ALTERNATOR FEED TO INSTRUMENT CLUSTER
SA-30-1
TAN
31
OIL PRESSURE FEED TO INSTRUMENT CLUSTER
SA-81-0
BRN
1174
OIL LEVEL FEED TO INSTRUMENT CLUSTER
SA-81-1
GRY
48
(MANUAL) CLUTCH ANTICIPATE SIGNAL
SA-20-7
GRY
120
FUEL PUMP MOTOR FEED
SA-20-S
(V6 VIN S),
SA-21-5
(VS VIN P)
DKGRN/WHT
817
SA-33-0
DKGRN/WHT
465
FUEL PUMP RELAY CONTROL
SA-20-5
(V6 VIN S),
PAGE
SA-21-5
(VS VIN P)
K
DKGRN
135
COOLANT TEMPERATURE FEED TO INSTRUMENT CLUSTER
SA-81-1
202 - 7
C230
It? Ci!? Ci5J ctil Ci9
ENGINE HARNESS TO
1/P HARNESS
12i~c2:ichca
12064871
BLU

CAVITY
WIRE COLOR
CKT
BRN/WHT
419
SERVICE ENGINE SOON INDICATOR FEED
SA-81-3
WHT/BLK
448
DIAGNOSTIC REQUEST SIGNAL
SA-50-0
WHT
121
TACHOMETER SIGNAL TO INSTRUMENT CLUSTER
SA-81-0
DKBLU
229
THEFT DETERRENT FUEL ENABLE FEED
SA-133-1
DKGRN/WHT
762
A/C REQUEST SIGNAL
SA-64-0, 1
PNK
439
SA-11-4
LTBLU/BLK
583
(AUTOMATIC) TCC SWITCHED POWER FEED
SA-20-6
(V6 VIN S),
DESCRIPTION
BRN
141
(MANUAL) POWER FROM TURN B/U FUSE #2 TO BACKUP SWITCH
ORN/BLK
434
(AUTOMATIC) PARK/NEUTRAL FEED FROM TRANSMISSION POSITION SWITCH
LTGRN
24
TAN/BLK
422
(MANUAL) BACKUP LAMP FEED

(AUTOMATIC) TORQUE CONVERTER CLUTCH CONTROL
PAGE
SA-21-6
(VS VIN P)
SA-112-0
SA-20-6
{V6 VIN S),
BA-21-6
(VS VIN P)
SA-112-0
SA-20-6
(V6 VIN S),
SA-21-6
(VS VIN P)

C405B
1/P HARNESS TO FUEL
SENDER/REAR WHEEL
SPEED SENSOR HARNESS
12092789
10-WAY M METRI-PACK 150, 280 SERIES
BLK
C405A
C405C
FUEL TANK UNIT
HARNESS TO
1/PHARNESS
REAR WHEEL
SPEED SENSOR
HARNESS TO
1/P HARNESS
12092859
12092800
4-WA Y F METRI-PACK MIXED SERIES
WHT
BLK

CAVITY
WIRE COLOR
CKT
A1
GRY
120
DESCRIPTION
FUEL PUMP MOTOR FEED
PAGE
BA-20-5
(V6 VIN S),
BA-21-5
(VB VIN P)
A2
PPL
30
FUEL GAGE SENSOR SIGNAL
BA-20-5
(V6 VIN S},
BA-21-5
(VB VIN P)
A3
BLK
1050
GROUND
BA-20-5
(V6 VIN S),
BA-21-5
(VB VIN P)
C2
BLK
1811
WHEEL SPEED SENSOR RETURN
BA-44-1
C3
WHT
1810
WHEEL SPEED SENSOR SIGNAL
BA-44-1
202 - 9
12110088
LTGRY
AMPLIFIER
**CAVITiES NOT LISTED ARE NOT USED

CAVITY
WIRE COLOR
CKT
ORN
40
POWER FEED FROM COURTESY FUSE 8
SA-11-7
BLK
650
GROUND
BA-14-9
PNK
314
RADIO SIGNAL ON
SA-150-1
DKBLU
46
RIGHT REAR SPEAKER FEED (POS)
8A150-1
10
BRN
199
LEFT REAR SPEAKER FEED (POS)
SA-150-1
11
LTGRN
200
8A150-0, 1
12
TAN
201
SA-150-0, 1
13
LTBLU/BLK
315
RIGHT SUBWOOFER SPEAKER RETURN (NEG)
8A150-1
14
DKGRN
1795
RIGHT SUBWOOFER SPEAKER FEED (POS)
8A150-1
15
LT GRN/BLK
1794
LEFT SUBWOOFER SPEAKER RETURN (NEG)
BA-150-1
16
DKBLU/WHT
346
LEFT SUBWOOFER SPEAKER FEED (POS)
SA-150-1
21
LTBLU
115
RIGHT REAR SPEAKER RETURN (NEG)
8A150-1
22
YEL
116
LEFT REAR SPEAKER RETURN (NEG)
SA-150-1
23
DKGRN
117
SA-150-0, 1
24
GRY
118
8A150-0, 1
DESCRIPTION
PAGE
12065425
BLK

DESCRIPTION
CAVITY
WIRE COLOR
CKT
GRY
397
8A-34-0
DKBLU
84
8A-34-0
GRY/BLK
87
8A-34-0
BRN
86
8A-34-0
BLK
150
GROUND
8A-14-6
PNK
139
POWER FEED FROM A/C-CRUISE FUSE #12
8A-34-0
YEL
820
8A-34-1
DKGRN/WHT
817
8A-34-1
PAGE
'i51 I:& Ci5J ct? Ct? Cj5J

~ c2I OJ c2J & [Qi - 12020043
BLK
**CAIIITIES NOT LISTED ARE NOT USED

DESCRIPTION
CAVITY
WIRE COLOR
CKT
BLKJWHT
451
GROUND
8A-14-1,2,3
WHT/BLK
448
DIAGNOSTIC REQUEST, ECM
8A-20-0,
8A-21-3
TAN/BLK
422
TORQUE CONVERTER CLUTCH (TC() CONTROL SIGNAL
8A-20-0,
8A-21-6
BLKJWHT
1455
PROGRAM INPUT, KEYLESS ENTRY MODULE
8A-132-1
PPL
326
DIAGNOSTIC REQUEST, DIAGNOSTIC ENERGY RESERVE MODULE (DERM)
8A-47-0
TAN
800
SERIAL DATA LINE, DIAGNOSTIC ENERGY RESERVE MODULE (DERM),

ELECTRONIC BRAKE CONTROL MODULE (EBCM) AND ECM
8A-50-0
PAGE
12092689
YEL
DIAGNOSTIC ENERGY RESERVE MODULE (DERM)

CAVITY
WIRE COLOR
CKT
DESCRIPTION
A1
BLKJWHT
1751
GROUND
SA-14-4
A2
BLK
650
GROUND
SA-14-8, 9
Al
PNK
1401
DUAL ARMING SENSOR FEED - PASSENGER - 36 VOLT
SA-47-1
A4
YEUBLK
236
DUAL ARMING SENSOR FEED- DRIVER - 36 VOLT
SA-47-1
AS
LTGRN
1400
DUAL ARMING SENSOR SIGNAL - DRIVER
SA-47-1
A6
LTGRN/WHT
1837
DUAL ARMING SENSOR SIGNAL - PASSENGER
SA-47-1
A7
WHT/BLK
1403
INFLATOR FEED - PASSENGER
8A-47-1
AS
PPL
326
DIAGNOSTIC ENABLE SIGNAL
SA-47-0
A9
YEL
1139
SA-47-0, 1
A10
YEL
1139
SA-47-0, 1
A12
BLKJWHT
1751
GROUND
SA-14-4
81
BRN
358
AIR BAG INDICATOR LAMP FEED
SA-47-0
82
PNK
39
8A-11-4
87
DKGRN
348
SIR INFLA TOR OUTPUT
SA-47-1
88
DKGRN
348
SIR INFLA TOR OUTPUT
SA-47-1
89
WHT
347
INFLATOR FEED- DRIVER
SA-47-1
810
PPL
806
POWER FEED FROM CRANK FUSE #17
SA-11-8
811
TAN
800
SERIAL DA TA SIGNAL
SA-50-0
PAGE
(1
C2
[] [Il [Il [] [Il [] [] [] [Il [Il [Il [] [] [Il [Il []
@@@@@@@@@@@@@@@@
@@@@@@@@@@@@@@@@
([] ([] ([] ([] ([] ([] ([] ([] ([] ([] ([] I]] ([] I]] ([] ([]
'E::::I
E::] \
12110626
12110113

LTGRY
DK RED
rn
IMPORTANT:
TPA'S WILL HAVE A CAVITY REFERENCE OF C AND D,
CONNECTOR BODY REFERS TO A AND 8.

CA\IITY
WIRE COLOR
CKT
A3
TAN
833
RIGHT FRONT WHEEL SPEED SENSOR RETURN
BA-44-1
A4
DKGRN
872
RIGHT FRONT WHEEL SPEED SENSOR SIGNAL
8A-44-1
AS
BRN
1811
BA-44-1
A6
WHT
1810
BA-44-1
A7
YEL
873
LEFT FRONT WHEEL SPEED SENSOR RETURN
BA-44-1
AB
LTBLU
830
LEFT FRONT WHEEL SPEED SENSOR SIGNAL
8A-44-1
A9
LTBLU
1289
RIGHT FRONT SOLENOID FEED
BA-44-0
A11
TAN
800
SERIAL DATA SIGNAL
BA-50-0
B1
DKGRN
1288
LEFT FRONT SOLENOID FEED
8A-50-0
B2
LTGRN
867
ABS FAILURE INPUT TO INSTRUMENT CLUSTER (SOLID STATE)
8A-44-0
B3
PNK
1632
ABS ENABLE FEED TO RELAY
BA-44-1
84
TAN/WHT
33
"BRAKE" INDICATOR LAMP (SWITCHED GROUND)
8A-44-0
BS
DKBLU
1537
"LOW TRAC" INDICATOR LAMP CONTROL
8A-44-1
810
ORN
440
POWER FEED FROM ABS BAT FUSE #1
8A-44-1
811
BRN
641
POWER FEED FROM ABS IGN FUSE #5
8A-44-1
812
LT BLU
820
8A-44-0
DESCRIPTION
PAGE
SA -
12129077
BLK
HEADLIGHT SWITCH
CAVITY
WIRE COLOR
CKT
BRN
BLK
650
YEL
DESCRIPTION
PAGE
PARK LAMP FEED
SA-100-0
GROUND
SA-14-8
10
HEADLIGHTS ON
SA-100-0
GRY
BA-100-0
ORN
240
SA-100-0
RED
702
SA-100-0
12110259
GRN

DESCRIPTION
CAVITY
WIRE COLOR
CKT
A1
ORN
340
POWER FEED FROM ECM BAT FUSE #4
BA-11-6
A2
PNK
439
BA-11-4
A3
DKBLU
229
FUEL ENABLE SIGNAL
BA-133-1
A4
YEUBLK
625
BA-133-0, 1
AS
GRY
728
BA-133-1
BS
BLK/WHT
451
GROUND
BA-14-1, 2, 3
87
PPUWHT
1074
BA-133-1
88
WHT/BLK
1073
SA-133-1
PAGE
C3
202 - 15
17
20
12047531
12047530
10-WAY F MICRO-PACK
BLK
4-WAY F MICRO-PACK
BLU
EJDDDDDEI
[] [] [] [] [] [] []
12065873
BLK
RADIO
CAVITY
WIRE COLOR
CKT
GRY
118
SA-150-0, 3
TAN
201
SA-150-0, 3
DKGRN
117
SA-150-0, 3
LTGRN
200
SA-150-0, 3
BLK
650
GROUND
SA-14-7,8,9
BRN
PARK LAMP FEED
SA-150-0,3
GRY
SA-150-0, 3
PNK
314
(WITH UW2) RADIO SIGNAL - ON
SA-150-0, 1
YEL
43
POWER FEED FROM RADIO FUSE #17
SA-150-0, 3
10
ORN
40
SA-11-7
17
LTBLU
115
RIGHT REAR SPEAKER RETURN
SA-150-1, 3
18
DKBLU
46
RIGHT REAR SPEAKER FEED
SA-150-1, 3
19
YEL
116
LEFT REAR SPEAKER RETURN
SA-150-1,3
20
BRN
199
LEFT REAR SPEAKER FEED
SA-150-1, 3
DKBLU
1796
STEERING WHEEL RADIO CONTROL SIGNAL
SA-150-1, 2
DESCRIPTION
PAGE
C1
C3
C4(WITH UK3)

[!]00
E:::I
12047950
BLK
ENGINE HARNESS TO
DISTRIBUTOR JUMPER (VS VIN P)
000
12064762
GRY
REAR BODY HARNESS TO 1/P HARNESS
12015664
BLK
ENGINE HARNESS TO 1/P HARNESS
C217
Ilfl r:2:J Q~:11:~] r

L.l
12092162
12110295
GRY
ABS MOTOR PACK
BLK
SIR COIL ASSEMBLY HARNESS TO 1/P HARNESS
STEERING WHEEL CONTROLS, RADIO
12064752
12092761
BLK
YEL
CROSS CAR HARNESS TO 1/P HARNESS

SEAT JUMPER HARNESS TO DRIVER SEAT HARNESS
SEAT JUMPER HARNESS TO PASSENGER SEAT HARNESS
BLOWER RESISTOR
ARMING SENSOR, DUAL POLE
CAVITY
PLUG
C2
C1
r;s:i It? Ci:? I:&
12010503
rlJ&uf:i~
4-WAY M/FWEATHER PACK TWR

WHT
AUTOMATIC TRANSMISSION (TCC) - V6 VIN S
12064766
12064998
8-WA Y F METRI-PACK
150 SERIES
BLU
8-WA Y F METRI-PACK
280 SERIES
BLK
DAYTIME RUNNING LIGHTS (DRL) MODULE
12034342
5-WAY F WEATHER PACK SERIES
BLK
AUTOMATIC TRANSMISSION (TCC) - V8 VIN P
12059401
4-WAY F METRI-PACK 150.1 SERIES
PULL-TO-SEAT
BLOWER RESISTOR
SEE C240
GRY
DISTRIBUTOR
12033704
BLK
c
D
CLUTCH ANTICIPATE/CRUISE RELEASE SWITCH

(V6 WITH MANUAL)
12084420
CONVENIENCE CENTER
REFER TO PAGE 8A-76-1
6-WA Y F METRI-PACK 150 PULL-TO-SEAT

BLK
ELECTRONIC IGNITION MODULE-VG VIN S

A
17
@@@@@@@@@@@@@@@@
1@@@@@@@@@@@@@@@@16
12129025 (BODY)
32-WAY F MICRO-PACK
G~
12129022 (TPA)
TPA MICRO-PACK 100W
C~
B
17
@@@@@@@@@@@@@@@@
1@@@@@@@@@@@@@@@@16
12129025(BODY)
32-WAY F MICRO-PACK
GRY
12129021 (TPA)
TPA MICRO-PACK 100W
BLK
c
17
@@@@@@@@@@@@@@@@
1@@@@@@@@@@@@@@@@16
12129025 (BODY)
32-WAY F MICRO-PACK
GRY
12129023 (TPA)
TPA MICRO-PACK 100W
BLU
ENGINE CONTROL MODULE (ECM)-V6 VIN S
e.1 e. eJ eJ,o eJ
eJ,2
e. e. e.
~6
e.
12065885
12065887
22-WAY F MICRO-PACK
GRY
GRN
12065886
12065888
22-WAY F MICRO-PACK
22-WAY F MICRO-PACK
BRN
RED
ENGINE CONTROL MODULE (ECM) - VS VIN P
202 - 19
SA - 202 - 20 ELECTRICAL.DIAGNOSIS
12065292
4-WAY F METRI-PACK 150 PULL-TO-SEAT
BLK
EXHAUST GAS RECIRCULATION (EGR)
SOLENOID VALVE V6 VIN S
E1 EJ B
BBB
12110541
BLK
FUEL PUMP RELAY
HATCH RELEASE RELAY
STARTER ENABLE RELAY
12015356
5WA Y F METRI-PACK 150 480 SERIES
BLK
EXPRESS DOWN MODULE
12129068
I I Ic I I
I I I I I
A
BLK
GENERATOR
12045688
BLK
FOG LIGHT SWITCH
HATCH RELEASE RELAY

SEE FUEL PUMP RELAY
C1
15300030
12078082

BLK

PULL-TO-SEAT
BLK
C2
IDLE AIR CONTROL (IAC) MOTOR V6 VIN S
15300029
BLK
HEADLIGHT DOORS MODULE
12103419
4-WAY M/F WEATHER PACK TWR
BLK
IDLE AIR CONTROL (IAC) MOTOR VS VIN P
12020813
BLK
12040754
12015664
BLK
HEATER/VENT/AIR CONDITIONING (HVAC)
CONTROL ASSEMBLY

PULL TO-SEAT
BLK
IGNITION COIL MODULE VS VIN P

1/P FUSE BLOCK

REFER TO PAGE 8A-11-0
06294641
4-WAY F MIXED SERIES
BLK
C2
12064766
BLU
12010966
5-WAY F 56 SERIES
BLU
IGNITION SWITCH
~lt?fl?ct?
~~[f][~J
12064998
BLK
KEYLESS ENTRY RECEIVER
POWER SEAT CONTROL MODULE (AQ9)
12065803
BLK
INSTRUMENT CLUSTER
BLOCKED
_....-J~CAVITY
12034060
12065401
NAT(WHT)
GRY
1/P DIMMER SWITCH
OIL PRESSURE SENSOR
POWER SEAT CONTROL MODULE

(AQ9 POWER SEAT)
SEE KEYLESS ENTRY RECEIVER (C2)
12066498
BLK
OUTSIDE MIRROR
LH AND RH
oa[]
co
!Do o
----FODO
12085013
BLK
POWER SEAT SWITCH (AC3)
12004680
NAT
POWER DOOR LOCK SWITCH
LH AND RH
12033944
BLK
POWER SEAT SWITCH (AQ9)
DRIVER AND PASSENGER
0
12064862
12048027
BLK
GRY
POWER MIRROR SWITCH
POWER WINDOW SWITCH, LH

AQ
Qe
STARTER ENABLE RELAY

SEE FUEL PUMP RELAY
CJ
cQ
Qo
CJ
eQ
12033945
STEERING WHEEL CONTROLS, RADIO

SEEC217
BLK
POWER WINDOW SWITCH, RH
TORQUE CONVERTER CLUTCH (TCC) SOLENOID

SEE AUTOMATIC TRANSMISSION (TCC)
12047785
~I
In
BLK
REARVIEW MIRROR
12015307
BLK
12052854

REFER TO PAGE SA-11-2
BLK
RETAINED ACCESSORY POWER (RAP) MODULE
ct?~ Ci5J It?~

c2J r21 c2:J ch CQ
12064769
12129126
NAT
BLK
SOLENOID VALVE ASSEMBLY (AQ9)
WIPER MOTOR ASSEMBLY
BLANK
202 - 25
8A -
203 - 0
HARNESS ROUTING VIEWS
C100
P100
C200A, 8, C, D
PSOO
C240
C300
C305
HARNESS LEGEND
Forward Lamp Harness
CHMSL Jumper Harness
Engine Harness
10
Distributor Jumper Harness (V8 VIN P)
1/P Harness
11
Wheel Speed Sensor Jumper Harness
Cross Car Harness
12
RR Wheel Speed Sensor Jumper Harness
Rear Body Harness
13
Fuel Tank Unit Pigtail
Hatch Harness
14
Steering Column Harness
RR Fascia Harness
15
Headlamp Jumper Harness
Injector Harness (VG VIN S)
16
Seat Jumper Harness (with AQ9)
CONNECTOR LEGEND
PAGE
FIGURE
CONNECTOR
C100 (10 cavities)
Engine Harn to Forward Lamp Harn, behind LH

wheelhouse attached to ECM Bracket
201-15
28
202-0
Cl 10 (10 cavities)
(VG VIN S)
Engine Harn to Injector Harn, top center of Intake

Manifold
201-12
22
202-1
Cl 20 (2 cavities)
Forward Lamp Harn to Wheel Speed Sensor Jumper

Harn, mounted to LH Frame Rail
C130 (2 cavities)
Forward Lamp Harn to Wheel Speed Sensor Jumper

Harn, mounted to RH Frame Rail
C140 (4 cavities)
(V8 VIN P)
Engine Harn to Distributor Jumper Harn, right side of

Intake Plenum, attached to EVAP Solenoid Valve
201-26
43
202-16
C160 (3 cavities)
Forward Lamp Harn to Headlamp Jumper Harn,

behind LH Headlamp Door Bracket
201-43
63
C165 (3 cavities)
Forward Lamp Harn to Headlamp Jumper Harn,

behind RH Headlamp Door Bracket
201-43
63
C200A
( 17 cavities)
Forward Lamp Harn to 1/P Harn, between LH kick

panel and Steering Column
201-47
72
202-2
C200B
( 18 cavities)
Forward Lamp Harn to 1/P Harn, between LH kick

panel and Steering Column
201-47
72
202-2
C200C
( 13 cavities)
Cross Car Harn to 1/P Harn, between LH kick panel

and Steering Column
201-47
72
202-2
C200D
(48 cavities)
1/P Harn side, between LH kick panel and Steering

Column
201-47
72
202-2
C210 (4 cavities)
1/P Harn to Engine Harn, under RH side of 1/P behind

RH kick panel
201-46
67
202-16
C215 (11 cavities)
Forward Lamp Harn to Steering Column Harn, near

base of Steering Column
201-35
52
202-4
1993 2F
REV 11-18-92 {1
HARNESS ROUTING VIEWS

CONNECTOR LEGEND
PAGE
FIGURE
CONNEClOR
C216 ( 11 cavities)
1/P Harn to Steering Column Harn, attached to base

of Steering Column
201-34
51
202-5
C217 (4 cavities)
1/P Harn to SIR Coil Assembly Harn, near base of

Steering Column
201-34
51
202-16
C220 (10 cavities)

kick panel
201-46
67
202-6
C230 (10 cavities)

kick panel
201-46
67
202-7
C240 (6 cavities)
Cross Car Harn to 1/P Harn, under RH side of 1/P

behind kick panel
201-46
67
202-16
C250 (2 cavities)
Forward Lamp Harn to Clutch Jumper Harn, near

Brake/Clutch Pedal Bracket
201-1
C270 (2 cavities)
1/P Harn to Clutch Jumper Harn, near Brake/Clutch

Pedal Bracket
201-1
C300 (6 cavities)
(withAQ9)
Seat Jumper Harn to Driver Seat Harn, under Driver

Seat Assembly
201-41
60
202-16
C305 (6 cavities)
(with AQ9)
Seat Jumper Harn to Passenger Seat Harn, under

Passenger Seat Assembly
201-40
59
202-16
C310 (2 cavities)
(with AC3 or
AQ9)
1/P Harn to Driver Seat Harn (with AC3) or Seat

Jumper Harn (with AQ9), between rear mounting
bolts of driver seat
201-6
11
C400 (6 cavities)
1/P Harn to Rear Body Harn, LH rear Cargo

Compartment
201-30
47
202-16
C405A
(4 cavities)
Fuel Tank Unit Pigtail to 1/P Harn, part of Pass Thru

Connector forward of rear axle
201-5
202-8
C405B
(10 cavities)
1/P Harn side, part of Pass Thru Connector forward of

rear axle
201-5
202-8
C405C
(4 cavities)
Rear Wheel Speed Sensor Jumper Harn to 1/P Harn,

part of Pass Thru Connector forward of rear axle
201-5
202-8
C410 (3 cavities)
1/P Harn to Hatch Harn, center of roof near dome

lamp
201-4
C420 (2 cavities)
Hatch Harn to CHMSL Jumper Harn, LH side of hatch

between hatch frame and plastic panel
201-4
C430 (2 cavities)
Rear Body Harn to Rear Fascia Harn, between rear

fascia and rear end panel on LH side
201-33
50
BLANK
203- 3
LIGHTING SYSTEMS AND HORNS 881
SECTION 88
LIGHTING SYSTEMS AND HORNS

result.
CONTENTS
General Description ........................ 8B-2
Halogen Bulbs .......................... 8B-2
Exterior Lighting ........................ 8B-2
Backup Lamps ........................ 8B-2
(Canadian Only) . . . . . . . . . . . . . . . . . . . . . 8B-2
Front Fog Lamp Assemblies . . . . . . . . . . . . . 8B-2
Front Sidemarker Lamps ................ 8B-2
Hazard Lamp Flasher Assembly .......... 8B-2
Headlamp Assemblies .................. 8B-2
High-Mount Stoplamp Assembly ......... 8B-3
Parking and Turn Signal Lamp
Assemblies ......................... 8B-3
Rear License Lamp Assembly ............ 8B-3
Rear Sidemarker Lamp Assemblies . . . . . . . . 8B-3
Taillamp Assemblies ................... 8B-3
Turn Signal Lamp Flasher Assembly ...... 8B-3
Interior Lighting . . . . . . . . . . . . . . . . . . . . . . . . . 8B-3
Ashtray Lamp ........................ 8B-3
Automatic Transmission Indicator Lamp . . . 8B-3
Console Lamp . . . . . . . . . . . . . . . . . . . . . . . . 8B-3
Dome and Reading Lamps ............... 8B-3
Front Side Door Courtesy Lamps . . . . . . . . . 8B-3
Heater and Air Conditioning Control
Lamp ............................. 8B-3
Instrument Panel Compartment Lamp . . . . . . 8B-4
Horn Assemblies . . . . . . . . . . . . . . . . . . . . . . . . 8B-4
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8B-4
Lighting System Troubleshooting . . . . . . . . . . . 8B-4
Horn Assemblies . . . . . . . . . . . . . . . . . . . . . . . . 8B-4
Horn Tone Poor . . . . . . . . . . . . . . . . . . . . . . . 8B-4
Exterior Lighting . . . . . . . . . . . . . . . . . . . . . . . . 8B-4
Backup Lamps . . . . . . . . . . . . . . . . . . . . . . . . 8B-4
(Canadian Only) ......... Refer to Section 8C
Front Fog Lamp Assemblies . . . . . . . . . . . . . 8B-4

Front Fog Lamp Aiming Procedure . . . . . . . . 8B-4
Front Sidemarker Lamp . . . . . . . . . . . . . . . . . 8B-5
Hazard Lamp Flasher Assembly . . . . . . . . . . 8B-5
Headlamp Assemblies . . . . . . . . . . . . . . . . . . 8B-5
Headlamp Opening Door Actuator
Control Module Assembly . . . . . . . . . . . . . 8B-7
Headlamp Aiming by Screen Method . . . . . . 8B-7
Headlamp Aiming Alternate Procedure . . . . . 8B-9
Headlamp Aiming After a Collision . . . . . . . 8B-9
High-Mount Stoplamp Assembly ......... 8B-9
Parking and Turn Signal Lamp
Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . 8B-9
Rear License Lamp Assembly . . . . . . . . . . . 8B-10
Rear Sidemarker Lamp Assemblies . . . . . . . 8B-11
Taillamp Assemblies . . . . . . . . . . . . . . . . . . 8B-11
Turn Signal Lamp Flasher Assembly . . . . . 8B-12
Interior Lighting . . . . . . . . . . . . . . . . . . . . . . . . 8B-12
Ashtray Lamp ....................... 8B-12
Automatic Transmission Indicator
Lamp ............................ 8B-13
Console Lamp ....................... 8B-13
Dome Lamp ......................... 8B-13
Front Reading Lamps .................. 8B-13
Front Side Door Courtesy Lamps ........ 8B-14
Lamp ............................ 8B-14
Instrument Panel Compartment Lamp ..... 8B-14
Horns ................................ 8B-14
Current Adjustment ................... 8B-14
Horn Assemblies . . . . . . . . . . . . . . . . . . . . . 8B- l 4
Horn Relay .......................... 8B-15
Specifications ............................ 8B-15
Fastener Tightening Specifications . . . . . . . . . 8B-15
Bulb Usage Chart ....................... 8B-16
Special Tools ............................ 8B-16
88-2 LIGHTING SYSTEMS AND HORNS
GENERAL DESCRIPTION
HALOGEN BULBS
Some bulbs in this vehicle may contain halogen gas.
CAUTION: Halogen bulbs contain a gas
under pressure. Handling a bulb
improperly could cause it to shatter
into flying glass fragments. To help
avoid personal injury:
Turn off lamp assembly and allow
bulb to cool before changing
bulbs. Leave switch assembly off
until bulb change is complete.
Always wear eye protection when
changing a halogen bulb.
Handle bulb only by its base.
Avoid touching glass.
Do not drop or scratch bulb. Keep
moisture away.
Place used bulb in new bulb's
carton and dispose of it properly.
Keep halogen bulbs out of the
reach of children.
Switching to high-beam headlamps will turn off the

front fog lamp assemblies. Switching back to low-beam
headlamps will turn the front fog lamp assemblies on
again.
The front fog lamp assemblies must be aimed for
proper illumination of the road. Fog lamp aim should be
checked when a new bulb is installed or if service or
repairs in the front end area may have disturbed the fog
lamp mountings.
Front Sidemarker Lamps

The front sidemarker lamps are housed within the
parking and turn signal lamp assembly. They will come on
when the headlamps or parking lamps are on. The front
sidemarker lamps also have reflectors that will shine
when struck by light whether or not the vehicle's lamps
are on.
If the headlamps or parking lamps are off when a
turn is signalled, the appropriate front sidemarker lamps
will flash in unison with the front turn signal lamp on the
same side. If the headlamps or parking lamps are on when
a turn is signalled, the front sidemarker lamp and front
turn signal lamp will flash alternately.
Hazard Lamp Flasher Assembly
The backup lamps are part of the taillamp assemblies. They are located on the innermost side of the taillamp assembly next to the taillamp filler. They will come
on when the transmission is shifted into "REVERSE."
On vehicles with an automatic transmission assembly, the
backup lamps are activated by the park/neutral position
switch assembly. On vehicles with a manual transmission,
they are activated by a backup lamp switch which is part
of the transmission assembly. For more information, refer
to SECTION 7A or 7B.
The hazard warning flashers are part of the turn

signal circuit. The hazard warning switch is on the right
side of the steering column assembly. Pressing in on the
hazard warning switch button causes the front and rear
turn signal lamps and front sidemarker lamps to flash.
Pulling on the hazard warning switch knob will tum off
the hazard warning flashers.
The hazard warning flashers will work with the
ignition switch in any position. When the hazard warning
flashers are "ON," the turn signals do not work. The
hazard lamp flasher assembly is in the convenience center
behind the instrument panel assembly on the knee bolster
bracket. For more information on the hazard warning
switch assembly, refer to SECTION 3F.
Daytime Running Lamps (Canadian Only)
Headlamp Assemblies
All Canadian vehicles are equipped with daytime

running lamps. The daytime running lamp system
includes a solid state module, a relay and a light sensor.
The system lights low-beam headlamps at reduced intensity when the ignition switch is in the "RUN" position
during daylight. The daytime running lamp system is
designed to light the low-beam headlamps at full intensity,
and the parking and taillamps when low light conditions
are present.
The headlamp assemblies are controlled by the

headlamp switch located on the headlamp and instrument
panel lamp dimmer switch assembly to the left of the
steering column assembly. They will come on with the
ignition switch in any position. Turning the headlamp
switch all the way to the right turns on the headlamps.
Turning the headlamp switch all the way to the left turns
off the headlamps.
Headlamp low beam and high beam are controlled
by the headlamp dimmer switch lever assembly on the left
side of the steering column assembly. When the headlamps are on, pulling the lever assembly toward the driver
until the switch clicks changes the lamp from low beam to
high beam, or from high beam to low beam. An indicator
lamp on the instrument cluster assembly will come on
when the high-beam headlamps are on.
The headlamps must be aimed for proper illumination of the road. Headlamp aim should be checked
whenever a new headlamp assembly is installed or service
repairs to the front end area may have disturbed the
headlamp assembly or its mountings.
EXTERIOR LIGHTING
Backup Lamps
Front Fog Lamp Assemblies

The fog lamp switch assembly is below the headlamp and instrument panel lamp dimmer switch assembly
to the left of the steering column assembly. To use the
front fog lamp assemblies, first tum on the headlamps or
parking lamps. Then push the right side of the fog lamp
switch to turn on the front fog lamp assemblies. Push the
left side of the switch to turn off the front fog lamp
assemblies.
The front fog lamp assemblies should not be used as
a substitute for the headlamps.
rn
Important
Some state and local laws specify requirements for

headlamp aim. These laws must be followed.
High-Mount Stoplamp Assembly

The high-mount stoplamp assembly is in the center
of the rear end spoiler assembly. It will illuminate whenever the brake pedal assembly is pushed down. The lamp
is powered separately from the taillamp assemblies
through a circuit in the stoplamp switch assembly.
Parking and Turn Signal Lamp Assemblies

The parking lamps can be turned on by turning the
headlamp switch to the first position on the right. The
parking lamps can be turned off by turning the headlamp
switch to the left. If the parking lamps are on and the ignition switch is off, a warning tone will sound as a reminder
to turn the lamps off.
When the turn signals are activated, the appropriate
front parking lamps flash to signal a turn. The turn signal
works only when the ignition switch is on and the hazard
lamp flashers are turned off.
The turn signals are controlled by the turn signal
lever assembly on the left side of the steering column
assembly. Moving the lever all the way up or down (past
the detent) will turn on the turn signals. When the turn is
completed, the lever assembly will return to horizontal
and the tum signals will stop flashing.
For changing lanes or shallow turns where the steering wheel assembly does not tum far enough to cancel the
signal, move the signal only to the first detent and hold it
there. When the lever assembly is released, it will return
to horizontal and the turn signal will cancel. For more
information, refer to SECTION SA.
Rear License Lamp Assembly

The rear license lamp assembly will come on when
the headlamps or parking lamps are on. The rear license
lamp assembly is mounted on the rear bumper fascia
above the license plate.
Rear Sidemarker Lamp Assemblies

The rear sidemarker lamp assemblies are mounted
on the rear bumper fascia.
The rear sidemarker lamp assemblies will come on
when the headlamps or parking lamps are on. The rear
sidemarker lamp assemblies also have reflectors that will
shine when struck by light whether or not the vehicle's
lamps are on.
Taillamp Assemblies
The taillamps, backup lamps and tum signal lamps
are part of the taillamp assembly.
Turning on either the headlamps or parking lamps
will tum on the taillamps. When the brake pedal is pushed
down, the taillamps glow brighter to serve as stoplamps.
The turn signals are controlled by the tum signal
lever assembly on the left side of the steering column
assembly. Moving the lever all the way up or down (past
the detent) will tum on the turn signals. When the turn is
completed, the lever assembly will return to neutral and
the turn signals will stop flashing. If the brake pedal is
held down when a turn is signalled, one side will flash and
the other will stay on brightly.
For changing lanes or shallow turns where the steering wheel assembly does not turn far enough to cancel the
signal, move the lever assembly only to the first detent.
When the lever assembly is released, it will return to
neutral and the turn signals will cancel.
Turn Signal Lamp Flasher Assembly

The turn signal lamp flasher assembly is mounted
behind the instrument panel assembly on the driver knee
bolster bracket.
INTERIOR LIGHTING
For information on the warning/indicator lamps,
cluster lamps, etc., refer to SECTION SC. For circuit
information, refer to SECTION 8A.
Ashtray Lamp
An ashtray lamp is available on vehicles with a
manual transmission. It is mounted beneath the ashtray
and it will come on when the parking lamps or headlamps
are turned on.
Automatic Transmission Indicator Lamp

The automatic transmission indicator lamp will
illuminate the automatic transmission control indicator
located on the front floor console assembly on vehicles
equipped with an automatic transmission. It will come on
when the parking lamps or headlamps are turned on.
Console Lamp
The console lamp is mounted on the front floor
console transmission shift opening trim plate assembly. It
lights when the console compartment door is opened.
Dome and Reading Lamps

The dome lamp is located on the roof above the rear
seat assembly. It will come on when a door is opened or
when the inside lamp is turned on. To turn on the interior
lamps, rotate the interior lights thumbwheel switch,
located to the left of the headlamp switch, full up.
The front reading lamps are part of the inside rearview mirror assembly. Use the switch to turn a reading
lamp on or off when the doors are closed. With the doors
open, the reading lamps are always on.
For more information on the dome and reading
lamps, refer to SECTION 10-9 and SECTION 10-2.
Front Side Door Courtesy Lamps

The front side door courtesy lamps are mounted
behind the front side door inside handle bezel assemblies.
They come on when the parking lamps or headlamps are
turned on to illuminate the door handles and controls.
Heater and Air Conditioning Control Lamp

The heater and air conditioning control lamp is
mounted on the back of the heater and air conditioning
control assembly. It will come on when the parking lamps
884 LIGHTING SYSTEMS AND HORNS

or headlamps are turned on to illuminate the heater and air

conditioning controls.
Instrument Panel Compartment Lamp

The instrument panel compartment lamp lights
when the instrument panel compartment door is opened.
EXTERIOR LIGHTING
HORN ASSEMBLIES
To replace a backup lamp bulb, refer to "Taillamp

Assemblies" under "On-Vehicle Service" in this section.
Pushing the pads on the left-hand or right-hand

center of the steering wheel assembly sounds the horn
assemblies by closing the horn relay. For wiring and
circuit information, refer to SECTION 8A.
DIAGNOSIS
For wiring diagrams and other diagnosis information on properly repairing wiring harnesses, connectors,
etc., refer to SECTION 8A.
LIGHTING SYSTEM TROUBLESHOOTING

Most lighting problems are caused by loose connectors, open or shorted wiring, burned-out bulbs, bad switch
assemblies, an inadequate ground or blown fuses. Check
these items first and then refer to SECTION 8A.
HORN ASSEMBLIES
If the horn assemblies do not blow, or blow constantly, follow the diagnostic procedures in SECTION.8A.
Horn Tone Poor

1. Horn tone poor
tighten horn bolts/screws in
mounting area, or correct poor connections or
ground.
2. Low-pitched moan - sounds like "mooing." Caused
by current too high. Adjust current. Refer to
"Horns" under "On-Vehicle Service" in this
section.
3. Weak tone - current too low. Correct poor connections or ground, or adjust current. Refer to "Horns"
4. Weak, strained tone - remove foreign object in horn.
5. Harsh vibration - bend bracket so horn assembly is
not touching sheet metal.
ON-VEHICLE SERVICE
When replacing a part that requires a special procedure (such as a lens and housing assembly sealed
together), follow the instructions normally included in the
replacement parts package.
When removing a part that requires special sealing
items (such as sealing washers), be sure to reinstall those
items when replacing the part. Also, if any body sealing
items (grommets, etc.) are disturbed, be sure to repair
them so the passenger compartment remains properly
sealed.
Take care to prevent waterleaks if sealing surfaces
are disturbed. Damaged gaskets must be replaced. If
necessary, use sealer (body caulking compound or equivalent) in critical areas or any area where the gasket doesn't
seal properly.
Backup Lamps
Front Fog Lamp Assemblies

Figure 1
l++I

2. Front bumper fascia lower deflector. Refer to
SECTION 10-4.
3. Bolts/screws (3) attaching front fog lamp assembly
(1) to front bumper impact bar (4).
4. Front fog lamp assembly (1) from front bumper
impact bar (4).
5. Nuts (2) from front bumper impact bar (4), if
necessary.
l++I
Install or Connect

section.
1. Nut (2) to front bumper impact bar (4), if removed.
l~I
Tighten
Nuts (2) to 10 Nm (89 lb. in.).

2. Front fog lamp assembly (1) to front bumper impact
bar (4)..
3. Bolts/screws (3) attaching front fog lamp assembly
(1) to front bumper impact bar (4).
l~I
Tighten

SECTION 10-4.
5. Lower vehicle.
Front Fog Lamp Aiming Procedure

Horizontal aim is not adjustable on this vehicle.
Vertical aim is done by an adjusting screw located at the
top center of the front fog lamp assembly.
Prepare vehicle:
A. Make sure all components are in place, if other
service has been performed on vehicle.
B. Make sure vehicle has 1/2 tank of fuel or less.
C. Move vehicle to level area and park 7.6 m
(25 feet) away from target screen.
D. Measure from center of front fog lamp
assembly to ground line.
LIGHTING SYSTEMS AND HORNS 88-5
1
1
2
3
4
I.
LAMP ASSEMBLY, FRONT FOG

NUT, FRONT FOG LAMP, 10 Nm (89 LB. IN.)
BOLT/SCREW, FRONT FOG LAMP, 10 Nm (89 LB. IN.)
BAR, FRONT BUMPER IMPACT
'
-~ii.----3
PC2001-8B-F-RP
Figure 1 - Front Fog Lamp Assemblies
E. Turn front fog lamp assemblies on. Top edge of

high intensity zone to be 102 mm (4 inches)
below centerline of front fog lamp assembly.
F. Adjust front fog lamp assembly as required,
using adjusting screw at top center of front fog
lamp assembly.
Front Sidemarker Lamp

For replacement of front sidemarker lamp bulb, refer
to "Parking and Tum Signal Lamp Assemblies" under
Hazard Lamp Flasher Assembly

Figure2

Hazard lamp flasher assembly (6) by pulling from
convenience center.

Hazard lamp flasher assembly (6) to convenience
center.
Headlamp Assemblies
Headlamp Bulb Replacement
Figure 3

1.
2.
3.
4.
Open hood assembly.

Bolts/screws (44).
Headlamp bezel (43).
Headlamp bolts/screws attaching mounting ring to
headlamp opening housing assembly (49).
5. Headlamp mounting ring.
7. Sealed-beam headlamp assembly.
A CONVENIENCE CENTER ~...i;;;;='

5 RELAY, HORN
6 FLASHER ASSEMBLY, HAZARD LAMP
PC1002-8B-F-RP
Figure 2 - Horn Relay and Hazard Lamp Flasher Assembly

I.
2.
3.
4.
5.
6.

section.
Sealed-beam headlamp assembly.
Headlamp mounting ring.
Headlamp bolts/screws attaching mounting ring to
headlamp opening housing assembly (49).
Tighten securely.
Headlamp bezel (43).
Top of headlamp bezel (43) must be flush to
inner surface of headlamp opening door (42).
Bolts/screws (44).
l~I Tighten
41 BOLT/SCREW, HEADLAMP OPENING DOOR,

1.7 Nm (15 LB. IN.)
42 DOOR, HEADLAMP OPENING
43 BEZEL, HEADLAMP
44 BOLT/SCREW, HEADLAMP BEZEL, 1.7 Nm (15 LB. IN.)
45 BRACKET, HEADLAMP OPENING HOUSING
46 BOLT/SCREW, HEADLAMP OPENING DOOR BRACKET
47 BRACKET, HEADLAMP OPENING DOOR
48 BRACKET, HEADLAMP INTERMEDIATE
49 HOUSING ASSEMBLY, HEADLAMP OPENING
53 ACTUATOR ASSEMBLY, HEADLAMP
56 NUT, HEADLAMP OPENING HOUSING
57 BOLT/SCREW, HEADLAMP OPENING HOUSING
!VIEWA!
PC2003-BB-F-RP
Figure 3 - Headlamp Assemblies
7. Close hood assembly.

Headlamp Opening Housing Assembly and
Door Replacement
Figure 3

1. Raise headlamp manually by turning knob on headlamp actuator assembly (53).
2. Bolts/screws (44 ).
3. Headlamp bezel (43).
5. Headlamp opening door (42).
6. Nuts (56) and bolts/screws (57) attaching headlamp
opening housing assembly (49) to headlamp opening housing bracket (45).
7. Headlamp opening housing assembly (49) from
headlamp opening housing bracket (45).
9. Opening door bracket (47).
10. Intermediate bracket (48).
11. Actuator assembly (53) from headlamp opening
housing bracket (45), if necessary, by removing
attaching nut and bolts/screws.

1.
2.
3.
4.

section.
Actuator assembly (53) to headlamp opening
housing bracket (45), if removed, by installing
attaching nut and bolts/screws.
Intermediate bracket (48) to headlamp opening
Opening door bracket (4 7) on top of intermediate
bracket (48).
Bolts/screws (46).
12) Adjust
Gaps and flushness of headlamp opening door
(42) to surrounding area using bolts/screws
(46).
Tighten securely.
5. Headlamp opening housing assembly (49) to headlamp opening housing bracket (45).
6. Bolts/screws (57) and nuts (56) attaching headlamp
opening housing assembly (49) to headlamp opening housing bracket (45).
Tighten securely.
7. Headlamp opening door (42).

l~I
Tighten

9. Headlamp bezel (43).
l~I
Tighten

11. Lower headlamp.
Headlamp Opening Door Actuator Control

Module Assembly
Figure 4

1. Front air intake duct. Refer to SECTION 6E3.
3. Door actuator module assembly (50) from air intake
duct (52).

2. Door actuator module assembly (50) to air intake

duct (52).
4. Front air intake duct. Refer to SECTION 6E3.
Headlamp Aiming by Screen Method

Figures 5 and 6
Horizontal aim is corrected by an adjusting screw on
the outer side of the headlamp capsule assembly. Vertical
aim is corrected by an adjusting screw in the top center of
the assembly.
It is desirable to have a specific aiming area in a
darkened location. This area should be large enough to
accommodate the vehicle, plus an additional 25 feet
measured from the face of the headlamp capsule assemblies to the front of the visual screen.
The floor on which the vehicle rests must be flat
with the bottom of the screen. If the floor is not
level, then compensation must be made.
The aiming screen should be 5 feet high by 12 feet
wide with a matte white surface, well shaded from
outside light, and properly adjusted to the floor on
which the vehicle stands. The screen must be
provided with a vertical center line, two laterally
adjustable vertical tapes, and a vertically adjustable
horizontal tape.
[I] Important
For each vehicle checked, the horizontal lines
or tape on the screen must be adjusted.
Vehicles of the same model and year will have
50 MODULE ASSEMBLY, HEADLAMP OPENING DOOR
ACTUATOR CONTROL
51 BOLT/SCREW, HEADLAMP AUTOMATIC CONTROL
MODULE
52 DUCT, FRONT AIR INTAKE
PC2004-IIBF-r
Figure 4 - Headlamp Opening Door Actuator Control

Module Assembly
different standing height for the headlamp capsule assemblies.

Provisions should be made for moving the screen, so
that it can be aligned parallel with the rear axle. This
will allow for a horizontal line drawn perpendicular
from the center line of the screen to pass through the
center point between the two capsule assemblies.
Once the screen has been set up in a permanent location, a reference line is to be painted on the floor to
identify the proper location of the headlamp capsule
assemblies when they are being aimed (Figure 5).
- If a regular commercial aiming screen is not
available, the screen may consist of a vertical
wall having a clear uninterrupted area approximately 6 feet high by 12 feet wide, finished
with a washable non-gloss white paint.
1. Prepare vehicle for checking beam aim as follows:

A. Completely assemble all components on
vehicle.
B. Fuel load to be 1/2 tank or less.

Only other load in vehicle is the driver.
C. Position vehicle so it is square with aiming
screen, and with the headlamp capsule assemblies directly over reference line which has
been painted on floor.
3.66 m (12') MINIMUM

DISTANCE BETWEEN
HEADLAMPS
ADJUSTABLE
VERTICAL TAPES
ADJUSTABLE
HORIZONTAL TAPE
DIAGRAM OF LIGHT SCREEN
PAINTED REFERENCE LINE
A CENTERLINE OF LAMPS, TRANSFER MEASUREMENT

FROM VEHICLE TO WALLJSCREEN
PC2005-8B-F-RP
Figure 5 - Visual Headlamp Aiming Preparation
D. Locate vertical line on aiming screen so that it

is in line with center of rear window and over
hood (Figure 5).
E. Mark center of front and rear windows with
narrow tape. Use these "sights" to locate center of vehicle.
Move the vehicle or the screen until the
center line of the screen comes into alignment with the two points.
F. Close doors.
G. Rock vehicle sideways to stabilize suspension.
2. With headlamps on high beam, observe center of
high intensity zone on screen.
11
Adjust
Horizontal aim using horizontal adjusting

screw if center is more than:
102 mm (4 inches) RIGHT of straight
ahead.
102 mm (4 inches) LEFT of straight
ahead.
Vertical aim using vertical adjusting screw if
center is more than:
51 mm (2 inches) ABOVE the horizontal
line.
64 mm (2.5 inches) BELOW the horizontal line.
3. Switch headlamps on to low beam, and observe left
and top edges of high intensity zone on screen.
VERTICAL CENTERLINE
STRAIGHT AHEAD OF
LAMP CENTER
---------t
VERTICAL AIM-HIGH
INTENSITY ZONE
CENTERED ON (H)
LIMITS.
HORIZONTAL CENTERLINE
LOCATED AT LEVEL OF
LAMP CENTER
------+-+--......__ _.,__
- --CENTER HIGH---
- INTENSITY ZONE- - -
-- -1---~---\H
- - -
LATERAL AIM-HIGH
INTENSITY ZONE
CENTERED ON (V)
LIMITS
AIM INSPECTION FOR HIGH-BEAM HEADLAMP
VERTICAL CENTERLINE
STRAIGHT AHEAD OF
LAMP C E N T E R - - - - - - ~
LATERAL AIM-LEFT EDGE

OF HIGH INTENSITY ZONE
AT(V)
LIMITS-----"'---"---!---!
AIM INSPECTION FOR LOW-BEAM HEADLAMP
PC2006-8B-F-RP
Figure 6 - Visual Headlamp Aim Limits
le) Adjust
Important
Aim adjusting tools should be carefully

selected since one full tum of an adjusting
screw will move the aim approximately 89 mm
(3.5 inches) when measured at 25 feet.
Horizontal aim using horizontal adjusting

screw if left edge is more than:
- 102 mm (4 inches) RIGHT of straight
ahead.
- 102 mm (4 inches) LEFT of straight
ahead.
Vertical aim using vertical adjusting screw if
top edge is more than:
- 51 mm (2 inches) ABOVE the horizontal
line.
- 64 mm (2.5 inches) BELOW the horizontal line.
Headlamp Aiming Alternate Procedure

If a headlamp testing machine is used, it should give
results equivalent to those obtained using the screen
method. It should be in good repair and adjustment, and
should be used in accordance with the manufacturer's
instructions. The machine using a photoelectric cell or
cells to determine aim should also have a visual screen
upon which the beam pattern is projected proportional to
its appearance and aim on a screen at 25 feet. Such visual
screen should be plainly visible to the operator and should
have horizontal and vertical reference lines to permit
visual appraisal of the lamp beam.
Tool Required:
J 25300-B Headlamp Aimer

A. Completely assembly all components on
vehicle.
B. Place vehicle on level surface.
Vehicle must be level. If necessary, pads
may be used on uneven floors.
C. Stop all other work on vehicle.
D. Close doors.
E. Rock vehicle sideways to stabilize suspension.
2. Install headlamp aimer J 25300-B to headlamp
assembly.
3. Calibrate mechanical aimers (conforming to SAE
J602):
A. Set master fixture to "O" U/D and "O" R/L.

B. Calibrate aimers on master fixture to read "O"
and "O" R/L.
le) Adjust
Horizontal aim using horizontal adjusting screw.
- 102 mm (4 inches) left to 102 mm (4 inches)
right.
Vertical aim using vertical adjusting screw.
- 51 mm (2 inches) up to 64 mm (2.5 inches)
.
down.
Headlamp Aiming After a Collision

A. Completely assemble all components on
vehicle.
B. Place vehicle on level surface.
Vehicle must be level. If necessary, pads
may be used on uneven floors.
C. Stop all other work on vehicle.
D. Close doors.
E. Rock vehicle sideways to stabilize suspension.
NOTICE: Horizontal aim of headlamp capsule
assembly must be done first. Adjusting vertical aim
first will result in incorrect headlamp aim.
2. Headlamp aim may be accomplished using a wall
and visual aiming. Refer to "Headlamp Aiming by
Screen Method" in this section.
High-Mount Stoplamp Assembly

Figure 7

1. Bolts/screws (11) from stoplamp assembly ( 10).
2. Stoplamp assembly (10) from rear end spoiler
assembly (13).
3. Nut (12), if necessary.
5. Bulbs and sockets from stoplamp assembly (10).
6. Bulbs from sockets.

1.
2.
3.
4.
5.
6.

section.
Bulbs to sockets.
Bulbs and sockets to stoplamp assembly (10).
Nut (12), ifremoved.
Stoplamp assembly (10) to rear end spoiler
assembly (13).
Bolts/screws (11) to stoplamp assembly (10).
l~I Tighten
Parking and Turn Signal Lamp Assemblies

Figure B


6. Front sidemarker lamp bulb ( 16) and parking and
turn signal lamp bulb (17) from sockets.

section.
1. Front sidemarker lamp bulb (16) and parking and
tum signal lamp bulb ( 17) to sockets.
2. Front sidemarker lamp bulb ( 16), parking and turn
signal lamp bulb ( 17) and sockets to parking and
turn signal lamp assembly (14).
3. Parking and tum signal lamp assembly (14) to shelf
on front bumper fascia.
4. Bolts/screws (15) to parking and tum signal lamp
assembly (14).
l~I Tighten
A
B
10
11
TAPE
STOPLAMP ASSEMBLY, HIGH-MOUNT
BOLT/SCREW, HIGH-MOUNT STOPLAMP,
1.7 Nm (15 LB. IN.)
12 NUT, HIGH-MOUNT STOPLAMP
13 SPOILER ASSEMBLY, REAR END

SECTION 10-4.
6. Lower vehicle.
PC2007-88-F-RP
Rear License Lamp Assembfy
Figure 7 - High-Mount Stoplamp Assembly
Figure9
SECTION 10-4.
3. Bolts/screws (15) from parking and tum signal lamp
assembly (14).
4. Parking and tum signal lamp assembly (14) from
shelf on front bumper fascia.
5. Front sidemarker lamp bulb (16), parking and turn
signal lamp bulb (17) and sockets from front parking
and tum signal lamp assembly (14).

1. Bolts/screws (18) from rear license lamp assembly
(20).
2. Rear license lamp assembly (20) from rear bumper
fascia (25).
3. Bulb (19) and socket from rear license lamp assembly (20).
4. Bulb (19) from socket.
A SOCKET
14
15
16
17
PC2008-8BFRP
Figure 8 - Parking and Turn Signal Lamp Assemblies

1.
2.
3.
4.

section.
Bulb (19) to socket.
Bulb (19) and socket to rear license lamp assembly
(20).
Rear license lamp assembly (20) to rear bumper
fascia (25).
Bolts/screws (18) to rear license lamp assembly
(20).
!~I Tighten
Rear Sidemarker Lamp Assemblies

Figure 10

1. Bolts/screws (22) from rear sidemarker lamp
assembly (23).
2. Rear sidemarker lamp assembly (23) from rear
bumper fascia (25).
3. Bulb (24) and socket from rear sidemarker lamp
assembly (23).
4. Bulb (24) from socket.
18
25
A
18
19
20
21
SOCKET
BOLT/SCREW, REAR LICENSE LAMP, 1.9 Nm (17 LB. IN.)
BULB, REAR LICENSE LAMP
LAMP ASSEMBLY, REAR LICENSE
HARNESS ASSEMBLY, REAR LICENSE AND REAR
SIDEMARKER LAMP WIRING
25 FASCIA, REAR BUMPER
PC2009-BB-F-RP
Figure 9 - Rear License Lamp Assembly

1.
2.
3.
4.

section.
Bulb (24) to socket.
Bulb (24) and socket to rear sidemarker lamv
assembly (23).
Rear sidemarker lamp assembly (23) to rear bumper
fascia (25).
Bolts/screws (22) to rear sidemarker lamp assembly
(23).
l~I Tighten
Taillamp Assemblies
Figure 11

1. Reposition rear compartment trim assembly.
2. Nuts (31) attaching taillamp assembly (26) to rear
end panel assembly.
3. Taillamp assembly (26) from rear end panel
assembly.
4. Taillamp filler (40), if necessary.
Both taillamp assemblies (26) must be
removed to replace taillamp filler (40).
-----
23
22
,/:'~.,..
A SOCKET
22 BOLT/SCREW, REAR
SIDEMARKER LAMP, 1.4 Nm (12 LB. IN.)
23 LAMP ASSEMBLY, REAR SIDE MARKER
24 BULB, REAR SIDEMARKER LAMP
25 FASCIA, REAR BUMPER
PC1009-8B-F-RP
Figure 10 - Rear Sidemarker Lamp Assemblies
5. Taillamp, tum signal and backup lamp bulbs (27, 28

and 30) and sockets from taillamp assembly (26).
and 30) from sockets.

section.
and 30) to sockets.
26
A
B
C
26
27
28
30
31
40
BACKUP LAMP OPENING

TURN SIGNAL LAMP OPENING
TAILLAMP OPENING
TAILLAMP ASSEMBLY
BULB, TAILLAMP
BULB, TURN SIGNAL
BULB, BACKUP LAMP
NUT, TAILLAMP, 4 Nm (35 LB. IN.)
FILLER. TAILLAMP
PC2011-8B-F-RP
Figure 11 - Taillamp Assemblies

and 30) and sockets to taillamp assembly (26).
Rotate socket 90 degrees in taillamp assembly
(26) to lock and secure.
3. Taillamp filler (40), if removed.
4. Taillamp assembly (26) to rear end panel assembly.
5. Nuts (31) attaching taillamp assembly (26) to rear
end panel assembly.
l~I Tighten
Nuts (31) to 4 Nm (35 lb. in.).
6. Position rear compartment trim assembly.
Turn Signal Lamp Flasher Assembly
INTERIOR LIGHTING
For information on warning/indicator lamps, instrument cluster lamps, etc., refer to SECTION 8C. For
circuit information, refer to SECTION 8A.
Ashtray Lamp
Bulb Replacement

1. Open ashtray opening cover.
2. Ashtray.
3. Pull bulb, socket and shield through opening in front
floor console assembly.
Figure 12
4. Bulb and socket from shield.
1. Clip (33) from driver knee bolster bracket.

3. Flasher assembly (32) from clip (33), if necessary.
f++l tnstall or Connect

1. Flasher assembly (32) to clip (33), if removed.
3. Clip (33) to driver knee bolster bracket.

1. Bulb to socket.
2. Shield to bulb and socket.
3. Bulb, socket and shield to opening in front floor
console assembly.
4. Ashtray.
5. Close ashtray opening cover.
Dome Lamp
Figure 13
CONNECTOR,
ELECTRICAL
32 FLASHER ASSEMBLY,
TURN SIGNAL LAMP
33 CLIP, TURN SIGNAL
LAMP FLASHER
Loosen enough to pull dome lamp housing
assembly (34) from headlining trim finish
panel assembly.
2. Dome lamp housing assembly (34) by pulling from
headlining trim finish panel assembly.
4. Bulb (36) from dome lamp housing assembly (34).
PC1011-8B-F-RP
Figure 12 - Turn Signal Lamp Flasher Assembly
Automatic Transmission Indicator Lamp
1.
2.
3.
Bulb Replacement

1. Front floor console transmission opening trim plate
assembly.
2. Bulb and socket from front floor console transmission opening trim plate assembly.

1. Bulb to socket.
2. Bulb and socket to front floor console transmission
opening trim plate assembly.
3. Front floor console transmission opening trim plate
assembly.
Snap in place to secure.
4.

section.
Bulb (36) to dome lamp housing assembly (34).
Dome lamp housing assembly (34).
Use locating pins to position dome lamp housing assembly (34) to headlining trim finish
panel assembly.
Bolts/screws (35).
l~I Tighten
Front Reading Lamps

Bulb Replacement

1. Lamp lens from inside rearview mirror assembly,
using a flat-bladed tool.
2. Bulb from socket, using a flat-bladed tool.
Console Lamp
Bulb Replacement

1. Open front floor console compartment door.
2. Console lamp and retainer from front floor console
transmission shift opening trim plate assembly.
4. Retainer from console lamp, if necessary.
35-ii-"ft'O......

1. Retainer to console lamp, if removed.
2. Bulb to socket.
3. Lamp and retainer to opening in front floor console
transmission shift opening trim plate assembly until
retainer is seated.
4. Close front floor console compartment door.
IVIEWA
A
B
34
35
36
PIN, LOCATING
HOUSING ASSEMBLY, DOME LAMP
BOLT/SCREW, DOME LAMP, 1.7 Nm (15 LB. IN.)
BULB, DOME LAMP
PC2013-88-F-RP
Figure 13 - Dome Lamp Housing Assembly

1. Bulb into socket.
2. Lens to inside rearview mirror assembly by snapping into place.
Front Side Door Courtesy Lamps

Bulb Replacement

1. Front side door inside handle bezel bolt/screw.
2. Front side door inside handle bezel assembly.
3. Bulb and socket from front side door inside handle
bezel assembly.

1. Bulb to socket.
2. Bulb and socket to front side door inside handle
bezel assembly.
3. Front side door inside handle bezel assembly.
4. Front side door inside handle bezel bolt/screw.
l~I Tighten
Front side door inside handle bezel bolt/screw
to 1.4 Nm (12 lb. in.).
Heater and Air Conditioning Control Lamp

Bulb Replacement

1. Instrument panel accessory trim plate assembly.
2. Heater and air conditioning control bolts/screws.
3. Heater and air conditioning control assembly.
5. Bulbs and sockets from heater and air conditioning
control assembly.
6. Bulbs from sockets.

section.
1. Bulbs to sockets.
2. Bulbs and sockets to heater and air conditioning
control assembly.
4. Heater and air conditioning control assembly.
5. Heater and air conditioning control bolts/screws.
l~I Tighten
screws to 1.9 Nm (17 lb. in.).
6. Instrument panel accessory trim plate assembly.
Instrument Panel Compartment Lamp

Bulb Replacement

1. Open instrument panel compartment door.
2. Instrument panel compartment lamp and retainer
from instrument panel assembly.
4. Retainer from instrument panel compartment lamp,
if necessary.

1. Retainer to instrument panel compartment lamp, if
removed.
2. Bulb to socket.
3. Lamp and retainer to opening in instrument panel
assembly until retainer is seated.
4. Close instrument panel compartment door.
HORNS
Current Adjustment
Figure 14
Current draw for a horn assembly while operating
should be 4.5 to 5.5 amperes at 11.5 to 12.5 volts. High
current (more than 20 amperes) indicates an overheated
winding or shorted horn assembly: replace the horn
assembly. A current reading of about 18 amperes means
contacting points are not open: adjust horn current.
No current reading indicates a broken connection or
an open circuit due to a broken lead or overheated horn
assembly. An overheated horn assembly must be replaced.
No current reading may also mean contact points are
open: adjust horn assembly.
Adjust
1. Increase current - turn adjustment screw (55)

clockwise.
2. Decrease current - turn adjustment screw (55)
counterclockwise.
3. Current adjustments should be made 1/4 turn (90
degrees) at a time.
Horn Assemblies
Figure 15

55 SCREW, HORN ADJUSTMENT
PC1017-BB-B-RP
Figure 14 - Horn Adjustment

SECTION 10-4.
4. Bolt/screw (39) from horn assembly (37 or 38).
5. Horn assembly (37 or 38) from right-hand engine
compartment side outer rail assembly.
HORN ASSEMBLY, F NOTE
HORN ASSEMBLY, A NOTE
BOLT/SCREW, HORN, 27 Nm (20 LB. FT.)
PC1014-8B-F-RP
Figure 15 - Horn Assemblies

SECTION 10-4.
5. Lower vehicle.
Horn Relay

section.
2. Horn assembly (37 or 38) to right-hand engine
compartment side outer rail assembly.
Use "F" and "A" designations on inboard side
of horn assembly (37 or 38).
3. Bolt/screw (39) to horn assembly (37 or 38).
!~I
A
37
38
39
Figure2
The horn relay (5) is in the convenience center,
behind the instrument panel assembly on the driver knee
bolster bracket.

Horn relay (5) from convenience center.
Tighten
Horn relay (5) to convenience center.
SPECIFICATIONS
Dome Lamp Bolt/Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1. 7 N m ( 15 lb. in.)
Front Fog Lamp Bolt/Screw ........................................... 10 Nm (89 lb. in.)
Front Fog Lamp Nut ................................................. 10 Nm (89 lb. in.)
Front Side Door Inside Handle Bezel Bolt/Screw ......................... 1.4 Nm (12 lb. in.)
Heater and Air Conditioning Control Bolt/Screw ......................... 1.9 Nm (17 lb. in.)
Headlamp Bezel Bolt/Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1. 7 N m ( 15 lb. in.)
Headlamp Opening Door Bolt/Screw ................................... 1.7 Nm (15 lb. in.)
High-Mount Stoplamp Bolt/Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.7 Nm (15 lb. in.)
Hom Bolt/Screw .................................................... 27 Nm (20 lb. ft.)
Parking Lamp Bolt/Screw ............................................ 1.7 Nm (15 lb. in.)
Rear License Lamp Bolt/Screw ....................................... 1.9 Nm (17 lb. in.)
Rear Sidemarker Lamp Bolt/Screw .................................... 1.4 Nm (12 lb. in.)
Taillamp Nut ........................................................ 4 Nm (35 lb. in.)
BULB USAGE CHART
Exterior Lamps
Trade No.
Interior Lamps
Backup
Front Fog
Front Sidemarker
Headlamp
High-Mount Stoplamp
Parking and Turn Signal
Rear License
Rear Sidemarker
Tai Ila mp
Turn Signal
1156
Ashtray*
Automatic Transmission Indicator (PRNDU
Cluster Illumination
Console
Dome
Front Reading
Front Side Door Courtesy
Instrument Panel Compartment
Turn Signal Indicator
Warning/Indicator (excluding Turn Signal Indicator)
885
194
H-4666
921
2397
194
194
194
2057
Trade No.
194
73
161
194
561
212-2
70
37
194
161
PC74
*Manual transmission only.
PC2016-8B-F-RP
SPECIAL TOOLS
J 25300-B
G]
HEADLAMP AIMER
MC0023-8B.f.RP
INSTRUMENT PANEL, GAGES AND CONSOLE 8C-1
SECTION SC
INSTRUMENT PANEL, GAGES

AND CONSOLE
CAUTION: This vehicle is equipped with Supplemental Inflatable Restraint {SIR). Refer to
injury, or otherwise unneeded SIR system repair.
result.
CONTENTS
General Description ........................ SC-2
Auxiliary Fuse Block . . . . . . . . . . . . . . . . . . . . . SC-2
Controls
AM/FM Stereo and Clock Radio
Assembly .............. Refer to Section 9A
Data Link Connector
(DLC) . . . . . . . . . . . . . . . . . Refer to Section 6E
Assembly ........ Refer to Section lBl or IC
Convenience Center ...................... 8C-2
Electronic Control Module
(ECM) . . . . . . . . . . . . . . . . Refer to Section 6E
Daytime Running Lamps (DRL)
(Canadian Only) ..................... SC-2
Frorrt Floor Console Assembly . . . . . . . . . . . . . SC-2
Instrument Cluster Assembly ............... 8C-2
Gages ............................... SC-3
Instrument Panel . . . . . . . . . . . . . . . . . . . . . . . . SC-4
Instrument Panel Switches . . . . . . . . . . . . . . . . . SC-4
Headlamp and Instrument Panel Lamp
Dimmer Switch Assembly . . . . . . . . . . . . . SC-4
Lid Release Switch Assembly ............ SC-4
Rear Fog Lamp Switch Assembly . . . . . . . . . SC-4
Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SC-4
Daytime Running Lamp (DRL) Ambient
Light Sensor (Canadian Only) .......... SC-4
Vehicle Speed Sensor (VSS) Buffer . . . . . . . SC-4
Warning/Indicator Lamps . . . . . . . . . . . . . . . . . SC-5
"CRUISE" (Cruise Control)
Indicator Lamp . . . . . . . . . . . . . . . . . . . . . . SC-5
"FASTEN SAFETY BELTS" Indicator
Lamp ............................. SC-5
'HIGH BEAM" Indicator
Lamp . . . . . . . . . . . . . . . . . Refer to Section SB
"TURN SIGNAL" Indicator Lamps ....... 8C-5
Cluster Warning Lamps . . . . . . . . . . . . . . . . . SC-5
Fluid Warning Center . . . . . . . . . . . . . . . . . . . SC-6
Warning/Reminder Chimes . . . . . . . . . . . . . . . . SC-6
Ignition Key Warning . . . . . . . . . . . . . . . . . . SC-6
Fasten Seat Belt Assembly Warning . . . . . . . SC-6
. Lig~ts-on Warning . . . . . . . . . . . . . . . . . . . . . SC-6

Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SC-6
On-Vehicle Service . . . . . . . . . . . . . . . . . . . . . . . . 8C-6
Service Precautions . . . . . . . . . . . . . . . . . . . . . . 8C-6
Disabling the SIR System . . . . . . . . . . . . . . . SC-7
Enabling the SIR System . . . . . . . . . . . . . . . . SC-7
Handling Electrostatic Discharge (ESD)
Sensitive Parts . . . . . . . . . . . . . . . . . . . . . . . . SC-7
Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8C-7
AM/FM Stereo and Clock Radio
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . SC-7
Heater and Air Conditioning
Control Assembly . . . . . . . . . . . . . . . . . . . SC-9
Data Link Connector (DLC) . . . . . . . . . . . . . SC-9
Daytime Running Lamp (DRL)
Components (Canadian Only) ......... 8C-10
Daytime Running Lamp Ambient Light
Sensor Assembly . . . . . . . . . . . . . . . . . . . SC-10
Sensor Module Assembly ............ SC-10
Driver Knee Bolster Assembly and Deflector . SC-10
Engine Oil Level Indicator Control and
Low Engine Coolant Indicator
Module Assemblies . . . . Refer to Section 6B
Front Floor Console Assembly . . . . . . . . . . . . 8C-10
Compartment Lamp Switch . . . . . . . . . . . . . SC-12
Headlamp Automatic Beam Control
Switch Assembly . . . . . . . . . . . . . . . . . . . SC-12
Storage Tray ......................... SC-12
Transmission Plate Assembly . . . . . . . . . . . SC-13
Heat, Ventilation and Air Conditioning
Ducts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SC-13
Air Distributor Assembly ............... SC-13
Defogger Outlet Duct Assembly ......... SC-14
Floor Air Outlet Duct Assembly ......... SC-14
Outer Air Outlet Duct Assemblies . . . . . . . . SC-15
Heater and Air Conditioning Evaporator
and Blower Module Assembly .......... SC-15
Instrument Cluster Assembly .............. SC-16
Instrument Panel Carrier . . . . . . . . . . . . . . . . . SC-17
8C2 INSTRUMENT PANEL, GAGES AND CONSOLE

Instrument Panel Insulator . . . . . . . . . . . . . . . . 8C- l 8
Instrument Panel Switches ................ 8C-18
Dimmer Switch Assembly . . . . . . . . . . . . 8C- l 8
Lid Release Switch Assembly ........... 8C-19
Rear Fog Lamp Switch Assembly . . . . . . . . 8C-19
Instrument Panel Wiring Harness Assembly .. 8C-20
Auxiliary Fuse Block . . . . . . . . . . . . . . . . . . 8C-20
Convenience Center ................... 8C-20
Odometer Repair Notice Label ............ 8C-21
Sensors
Buffer . . . . . . . . . . . . . . . . . Refer to Section 9B
Sound Insulator Assembly . . . . . . . . . . . . . . . . 8C-22
GENERAL DESCRIPTION
AUXILIARY FUSE BLOCK
The fuse block is a part of the body wiring harness
assembly. It is attached by a bracket on the left front hinge
pillar and is accessed through a removable panel on the
instrument panel carrier.
For diagnosis, refer to SECTION 8A.
CONVENIENCE CENTER
The convenience center is part of the body wiring
harness assembly. It is attached to a bracket located on the
cowl below the instrument panel carrier to the left of the
steering column assembly.
The audio alarm assembly, vehicle speed sensor
(VSS) buffer, and hazard lamp flasher are attached to the
convenience center. The turn signal lamp flasher is opposite the convenience center to the right of the steering
column assembly and the knee bolster bracket.
For diagnosis of the convenience center and components, refer to SECTION 8A.
DAYTIME RUNNING LAMPS (DRL)

(CANADIAN ONLY)
All Canadian vehicles are equipped with daytime
running lamps. The daytime running lamp system
includes a solid state control module assembly, a relay and
an ambient light sensor assembly. The system lights the
low-beam headlamps at a reduced intensity when the ignition switch is in the "RUN" position during daylight. The
daytime running lamp system is designed to light the lowbeam headlamps at full intensity, and the parking lamps
and taillamps when low light conditions are present.
FRONT FLOOR CONSOLE ASSEMBLY

The console assembly fits over the tunnel in the floor
of the vehicle and extends from under the center of the
instrument panel assembly to the rear seat area. The console assembly consists of two major assemblies. The
lower console assembly forms the side and rear walls of
the complete console structure, while the upper console
assembly forms the top of the structure.
The upper console assembly has a cigarette lighter
and an ashtray with a coinholder and mat, or a cassette
holder. The upper console assembly also houses the transmission shift lever. For vehicles without the cassette
Trim Panel Cluster Bezel Assembly, Upper

Trim Panel Assembly and Compartments
Instrument Panel Cluster Trim Plate
Bezel Assembly ....................
Instrument Panel Compartment ..........
Instrument Panel Fuse Block Access
Door Assembly ....................
Instrument Panel Upper Trim Panel
Assembly .........................
Passenger Side SIR Module Assembly ......
Warning/Reminder Chimes ...............
Alarm Assembly .....................
Specifications ............................
8C-22
8C-22
8C-23
8C-23
8C-24
8C-24
8C-25
8C-25
8C-26
8C-26
holder in the upper console area, the cigarette lighter and

ashtray are set just below the transmission shift lever in
the center of the console assembly. The parking brake is in
a recess in the right side of the console assembly.
Below the transmission shift lever, toward the rear
of the vehicle, is a cupholder with a mat. In the rear of the
console assembly is a storage compartment. The storage
compartment contains a tray for cassette tapes or compact
discs. The storage compartment has a padded door that
serves as a front seat center armrest.
INSTRUMENT CLUSTER ASSEMBLY

The instrument cluster assembly is centered above
the steering column assembly in the instrument panel and
is removable from the rear of the panel (toward the steering wheel assembly). The instrument cluster assembly
contains instruments that provide the driver with vehicle
performance information.
The headlamp switch assembly, remote hatch
release and the optional foglamp switch assembly are
located on the left side of the cluster assembly.
Gages in the instrument cluster assembly include a
fuel gage, an engine coolant temperature gage, and a
voltmeter. A speedometer with an odometer and a trip
odometer is included, along with a tachometer.
The instrument cluster assembly has indicator lamps
for the headlamp high beam symbol, fasten seat belt
assembly, turn signal directional arrows and five lamps
for illumination.
The cluster assembly also contains warning indicator lamps for "ANTILOCK," "BRAKE," "CHARGE,"
"OIL," "FASTEN SAFETY BELT," "SERVICE
ENGINE SOON," "INFL REST" (inflatable restraint)
and "TEMPERATURE."
Electric power is directed to the appropriate lamps
and gages of the instrument cluster assembly by a flexible
printed circuit attached to the back of the instrument
cluster case. Two multiple connectors and the snap-in
bulb sockets help to hold the printed circuit to the back of
the instrument cluster assembly.
The instrument cluster assembly is non-serviceable,
except as noted in this section, and must be replaced as a
unit.
When an instrument cluster assembly is replaced,
the law requires the odometer reading of the replacement
unit to be set to register the same mileage as the prior
odometer. If the same mileage cannot be set, the law
INSTRUMENT PANEL, GAGES AND CONSOLE BC-3

requires the replacement odometer to be set at zero and a
label be installed on the driver's door frame to show the
previous odometer reading and the date of replacement.
Refer to "Odometer Repair Notice Label" in this section.
Gages
Engine Coolant Temperature Gage
The coolant temperature sending unit is mounted to
the engine at a point where it is exposed to the coolant
being circulated through the engine cooling passages. The
sending unit contains a temperature-sensitive variable
resistor that senses and reacts to coolant temperature.
Resistance decreases as temperature increases.
When electric power is supplied to the engine coolant temperature gage, a current flows through the gage to
the variable resistor and then to a ground at the engine.
The position of the gage pointer is determined by the
strength of the current flowing through the gage. When
the engine coolant is cold, resistance is high, the current
flow is low, and the pointer indicates a cold reading. As
coolant temperature increases, the resistance of the sending unit resistor decreases and the pointer moves toward
the center of the gage. Prolonged driving or idling in very
hot weather may cause the pointer to move beyond this
point. An overheat condition exists if the pointer goes into
the red zone at the upper limit of the scale.
Dial calibrations go far above the normal boiling
point of water - 100C (212F) - because the cooling
system is pressurized. The increase in pressure also
increases the boiling temperature of the coolant, permitting it to reach temperatures above those possible with a
non-pressurized system without boiling. The higher operating temperature of the cooling system that results gives
greater cooling efficiency and other benefits.
Fuel Gage
The fuel gage sending unit is mounted on the top
surface of the fuel tank. The fuel level sender itself consists of a float that rides on the surface of the fuel in the
tank, and a variable resistor controlled by the float arm.
When electric power is supplied to the fuel gage, current
flows through the gage to the variable resistor and then to
ground. The position of the gage pointer is determined by
the strength of the current flowing through the gage.
Jf the tank is full, the resistance of the variable resistor is high (90 ohms) and the current flow through the
gage is at a minimum. This causes the pointer to indicate
the "F" mark on the gage dial.
Jf the fuel level is low, the resistance of the variable
resistor is also low and current flow through the gage is
high. This causes the pointer to show a low fuel level
reading. Intermediate fuel levels cause the pointer to indicate the corresponding position between "F" and "E."
Oil Pressure Gage

The oil pressure gage indicates the pressure of the
lubricating oil flow provided by the engine oil pump. The
oil pressure gage sending unit is a variable resistor
mounted to the engine block so it will sense the oil pressure in a main oil passage just downstream from the
engine oil pump. When electric power is supplied to the
gage, current flows through the gage to the resistor in the

sending unit and then to ground at the engine block. The
position of the oil pressure gage pointer is determined by
the strength of the current flowing through the gage.
When oil pressure is low, the resistance of the sending unit also is low and current flow through the gage is
high. This causes the gage indicator needle to show a low
pressure reading. As oil pressure increases, the resistance
of the sending unit resistor also increases and current flow
through the gage is reduced. Under normal conditions, the
oil pressure reading should be between 138 and 414 kPa
(20 and 60 psi). Engine oil pressure never should fall
below a reading of 28 kPa (4 psi), even at idle.
Speedometer
The electric speedometer does not have a speedometer cable. The source of speed information is a small permanent magnet alternating current generator called a
vehicle speed sensor (VSS), mounted on the transmission
assembly. The shaft of the VSS fits into a pinion gear at
the transmission output shaft in the same manner as the
speedometer cable of a mechanical speedometer system.
The transmission output shaft rotates and turns the permanent magnet near a coil within the vehicle speed sensor.
This generates an alternating current in the coil with a frequency that is proportional to the speed of the vehicle.
The alternating current from the VSS is sent to the
VSS buffer.
The VSS buffer modifies the current to a series of
direct current pulses at a frequency proportional to the
speed of the vehicle. These pulses form a vehicle speed
signal that is transmitted to the speedometer.
At the speedometer, a solid state circuit uses the
speed signal to regulate the distribution of current from
the fuse block to two electromagnetic coils at right angles
to each other near the base of the speedometer pointer
pivot. At the base of the speedometer pointer pivot is a
magnet that is acted upon by the magnetic fields of the
two coils. The relative strength of the two magnetic fields
determines the position of the magnet and accordingly, the
position of the speedometer pointer.
Pulses from the solid state circuit also are used to
drive a small electric stepper motor. The stepper motor
turns the numbered wheels of the odometer and the trip
odometer. The numbered wheels are geared so when any
one wheel completes a revolution, the next wheel to the
left is turned one-tenth of a revolution. Every tenth of a
revolution advances the displayed number by one unit.
The trip odometer can be reset to zero at any time so the
driver can record the distance traveled from any selected
starting point.
Tachometer
Voltage pulses from the ignition primary circuit are
transmitted through the tachometer terminal of the ignition distributor. These pulses are used by the tachometer
to position the gage pointer to a setting corresponding to
the engine speed in revolutions per minute (rpm).
NOTICE: Never attempt to check resistance across
the tachometer terminals or the tachometer may be
damaged.
BC-4 INSTRUMENT PANEL, GAGES AND CONSOLE
Voltmeter
The voltmeter is an instrument that shows the voltage of the vehicle electrical system and indicates the ability of the charging system to keep the storage battery
assembly charged. The voltmeter is wired in parallel with
other circuits in the vehicle.
When the engine is running, the voltmeter indicates
charging system voltage. If the engine is not running and
the ignition switch is in the "RUN" or "START" position, the voltmeter will show battery voltage. The voltmeter can be used as a first step in diagnosing many electrical
problems. Battery voltage drop can be seen while the
engine is cranking. After the engine is running, generator
output voltage is indicated.
It is normal for the voltmeter to read between 11 and
13 volts during extended idle or just after starting. As the
electrical load is increased, or in stop-and-go driving, the
pointer may rotate temporarily to the bottom of the scale.
A voltmeter reading continuously below 11 volts or above
16 volts indicates an electrical system problem.
INSTRUMENT PANEL
The instrument panel and related parts form a rigid
structure that encloses and supports many components on
or near the passenger compartment side of the cowl. The
top of the instrument panel is attached to the cowl next to
the base of the windshield near both outboard ends by
bolts/screws, and at the center by a support bracket. The
bottom of the instrument panel is attached to a stamped
metal tie bar that adds to the rigidity of the structure. A
sound insulator panel is attached to the support bracket
and the cowl on the passenger side of the panel to conceal
the components under the instrument panel and provide a
finished appearance.
The steering column assembly is clamped in place at
the left side of the instrument panel. Below and to both
sides of the steering column assembly is an instrument
panel driver knee bolster assembly. An impact-absorbing
pad covers the top of the instrument panel. Trim covers
and trim plates accent the appearance of the exposed rear
face of the instrument panel.
The air conditioning module case is attached to the
cowl. Air ducts connect the case outlets to floor outlets,
windshield defroster outlets, side window defogger outlets and a high level outlet in the center of the instrument
panel. A high level air outlet is provided at each end of the
instrument panel. The air conditioning module and ducts
are concealed within the instrument panel structure.
Canadian vehicles equipped with daytime running
lamps have a headlamp automatic control ambient light
sensor assembly installed flush with the top surface of the
instrument panel upper trim panel assembly under the
windshield defroster nozzle grille assembly.
To the left of the steering column assembly, mounted
on the cowl, is the convenience center with the hazard
flasher unit, horn relay, audio alarm and turn signal flasher
unit. Attached to the convenience center is the vehicle
speed sensor buffer.
A headlamp switch with a thumbwheel dimmer control and an optional foglamp switch are mounted in the
instrument panel to the left of the instrument cluster
assembly. The headlamp switch controls headlamps,

parking and sidemarker lamps, taillamps, interim lamps
and instrument panel lamps. The dimmer control regulates the intensity of instrument panel illumination.
The instrument panel wiring harness assembly is
installed within the instrument panel area.
INSTRUMENT PANEL SWITCHES

The headlamp and instrument panel lamp dimmer
switch assembly may also contain a twilight sentinel
switch and a headlamp switch indicator lamp, if the
vehicle is equipped with a twilight sentinel option.
For more information, refer to SECTION 8B or
SECTION 9C.
Lid Release Switch Assembly

The lid release switch assembly releases the rear lid
of the vehicle automatically. The lid release switch assembly is located on the left-hand side of the instrument panel
below the headlamp controls and foglamp switch assembly.
Rear Fog Lamp Switch Assembly

The rear fog lamp switch assembly is of the rocker
type and activates the exterior fog lamps in the front and
rear of the vehicle. The rear fog lamp switch assembly is
located on the left-hand side of the instrument panel
below the headlamp controls.
SENSORS
Daytime Running Lamp (DRL) Ambient Light
Sensor (Canadian Only)
The headlamp automatic control ambient light (daylight) sensor assembly is located to the right of the heat
and air conditioning duct in the center of the instrument
panel.
As the intensity of light reaching the sensor assembly increases, the electrical resistance of the sensor assembly decreases. When the DRL control module assembly
senses a low resistance in the sensor assembly, the module
assembly allows voltage to be applied to the DRL diode
assembly and then to the low-beam headlamps. Due to the
voltage drop across the diode assembly, the low-beam
headlamps are on a reduced intensity.
As the intensity of light reaching the sensor assembly decreases, the electrical resistance of the sensor
assembly increases. When the DRL module assembly
senses a high resistance in the sensor assembly, the module assembly closes an internal relay and allows the lowbeam headlamps to come to full intensity.
Vehicle Speed Sensor (VSS) Buffer

The vehicle speed sensor (VSS) buffer is mounted
on the convenience center. For service procedures, refer to
"Vehicle Speed Sensor (VSS) Buffer" under "On-Vehicle Service" in this section. For more information, refer
to SECTION 9B.
WARNING/INDICATOR LAMPS
"CRUISE" (Cruise Control) Indicator Lamp
The "CRUISE" (cruise control) indicator lamp
comes on when the cruise control switch is engaged. For
more information, refer to SECTION 9B.
"FASTEN SAFETY BELTS" Indicator Lamp

The "FASTEN SAFETY BELTS" indicator lamp
will always go on for 4 to 8 seconds whenever the ignition
switch is in "RUN," "BULB TEST," or "START,"
whether the driver's seat belt assembly is buckled or
unbuckled.
For more information, refer to "Warning/Reminder
Chimes" in this section or SECTION 10-11.
"TURN SIGNAL" Indicator Lamps

The left or right turn indicator lamp will illuminate
when the multifunction lever on the left side of the steering column assembly is moved to signal a turn. The turn/
hazard switch in the steering column assembly receives an
on-and-off flashing current from the fuse block and the
turn signal flasher unit in the convenience center when the
ignition switch is in the "RUN," "START" or "BULB
TEST" position. The tum/hazard switch routes the current to circuits that feed the left or right front turn signal
lamp, left or right rear tail/stop/tum signal lamps when the
multifunction lever is moved. The circuit to the left or
right front turn signal lamp, and cornering and sidemarker
lamps has a branch that feeds the appropriate turn indicator lamp in the instrument cluster assembly, causing it to
flash when the exterior lamps are indicating a turn.
When the hazard warning button on the right side of
the steering column assembly is pressed in, the left and
right front turn signal lamps, cornering and sidemarker
lamps, and rear tail/stop/tum signal lamps all flash, and
both turn signal indicator lamps in the instrument cluster
flash. Power for the hazard warning system reaches the
tum/hazard switch from the fuse block and the hazard
flasher in the convenience center. Power is supplied with
the ignition switch in any position. When the hazard
warning system is flashing, the turn signal circuits are
inoperative.
Cluster Warning Lamps

"INFL REST" Indicator Lamp
The "INFL REST" (inflatable restraint) indicator
lamp will light to warn the driver of a potential supplemental inflatable restraint (SIR) system problem that
could prevent the proper deployment of the air bag in an
accident. When the ignition switch is first turned on, the
lamp will flash a number of times to verify proper operation of the lamp circuit and the diagnostic/energy reserve
module (DERM). The lamp also will flash SIR trouble
codes to aid diagnosis when the designated data link connector (DLC) is grounded with the ignition on. In addition, a Scan Tool can be used to read trouble codes
remaining in the "history" memory of the DERM and to
clear all "history" codes after repair. For additional
information, including service precautions, refer to SECTION 91.
"OIL" Pressure Indicator Lamp The "OIL"

pressure indicator lamp comes on to warn the driver
when the engine oil pressure is low. Battery voltage is
applied to one side of the bulb. A ground path is
provided by the engine oil pressure switch, which closes
when the oil pressure is below 28 kPa (4 psi). This tests
the bulb when the ignition switch is turned on to start the
engine. After the engine starts and normal oil pressure
builds up, the engine oil pressure switch opens and the
"OIL" pressure indicator lamp goes out.
"SERVICE ENGINE SOON" Indicator Lamp
The "SERVICE ENGINE SOON" indicator lamp
in the instrument cluster will come on during engine starting to serve as a bulb and system check. It should go off
after the engine starts unless a problem has been detected
by the system.
The engine control module (ECM) performs a continual self-diagnosis of certain control functions and
causes the "SERVICE ENGINE SOON" lamp to remain
on when the engine is running if a problem is detected.
The "SERVICE ENGINE SOON" lamp may remain on
for only ten seconds if the problem is an intermittent one.
In any event, the ECM will store in memory a 2-digit or
3-digit trouble code if a problem is detected. When the
data link connector (DLC) test connection is grounded,
the ECM will cause the "SERVICE ENGINE SOON"
lamp to flash the code for each trouble condition detected
by self-diagnosis. The code or codes will aid further diagnosis and correction of the condition.
"SHIFT" Upshift Indicator Lamp
For vehicles with manual transmissions, the
"SHIFT" upshift indicator lamp in the instrument cluster
assembly will illuminate to indicate the best transmission
shift point, based on engine speed and load. The
"SHIFT" lamp is controlled by the electronic control
module (ECM) in response to engine rpm input (for
engine speed), vehicle speed sensor (VSS) and throttle
position sensor (TPS) inputs (for engine load), and coolant temperature input.
The ECM compares engine speed and vehicle speed
inputs to determine what gear the manual transmission is
in and illuminates the "SHIFT" lamp when a shift to the
next higher gear would provide acceptable performance
without overloading the engine. It is normal for the
upshift indicator lamp to come on for a moment when
downshifting to a lower gear if the accelerator pedal is not
released completely. It is also normal for the lamp to flash
on and off at times if the driver changes the position of the
accelerator pedal while accelerating. The lamp should not
light when driving in 5th gear or when the accelerator
pedal is released.
Coolant "TEMP" (Temperature) Indicator Lamp
The coolant "TEMP" (temperature) indicator lamp
comes on to warn the driver of high coolant temperature.
With the ignition switch in "RUN," "BULB
TEST" or "START," voltage from the fuse block is
applied to the coolant "TEMP" (temperature) indicator
lamp. In "BULB TEST" or "START," the lamp is
grounded through the ignition switch so that the bulb can
be tested. In "RUN," current through the bulb can be
grounded through the coolant temperature switch. The
8C-6 INSTRUMENT PANEL, GAGES AND CONSOLE

switch closes when the coolant temperature exceeds
128C (262F) and the lamp glows.
Fluid Warning Center

The fluid warning center is part of the heat and air
conditioning control assembly. The following low fluid
indicators are part of the center:
"LOW COOLANT" Indicator
With a low coolant level, the circuit made by the low
coolant probe has very high resistance (over 50,000
ohms). The low engine coolant indicator module assembly senses the voltage change at the low coolant level
input and provides ground to the "LOW COOLANT"
indicator and the indicator lights up. The "LOW COOLANT" indicator is grounded for 1.5 seconds when the
ignition switch is initially turned "ON," causing the
"LOW COOLANT" indicator to light.
"LOW FUEL" Indicator
The resistance of the fuel tank unit circuit decreases
as the fuel in the tank decreases. When the resistance goes
below a certain point, approximately 1/8 of a tank of fuel,
the low fuel module applies voltage to the "LOW FUEL"
indicator. The fluid warning center provides ground at the
low fuel module. The circuit is completed and the indicator lights up.
"LOW OIL" Indicator
The "LOW OIL" indicator ground is controlled by
the engine oil level indicator control module assembly. To
check for a low oil condition, the low oil module looks for
a ground through the oil level switch after the ignition
switch has been turned to "OFF" or "LOCK."
The low oil module assembly checks for a low oil
condition 32 minutes after the ignition switch is turned to
"OFF" or "LOCK," if the previous ignition cycle was
less than 12 minutes. If the previous ignition cycle was
longer than 12 minutes, the low oil module assembly
checks for a low oil condition 3 minutes after the ignition
switch is turned to "OFF" or "LOCK."
When the low oil module assembly loses the ground
through the oil level switch (oil level switch open indicating low oil level), the low oil assembly module grounds
the "LOW OIL" indicator for the duration of the next
ignition cycle.
When the low oil module assembly is grounded
through the oil level switch, the low oil module assembly
grounds the "LOW OIL" indicator for a bulb test when
the ignition switch is turned to "RUN" during the next
ignition cycle. The bulb test takes four to five seconds.
"LOW SOLVENT" Indicator
The windshield washer solvent tank has a switch
which closes when the washer solvent level becomes too
low. At this time, voltage is applied to the "LOW SOLVENT" indicator. The fluid warning center provides
ground, the circuit is completed and the indicator lights.
WARNING/REMINDER CHIMES
The audio alarm module sounds a chime to bring
attention to one or more of several conditions. These
conditions are: 1) the lights are on and the ignition switch

is not in "RUN," "BULB TEST," or "START;" 2) the
ignition key is in the ignition switch when the driver's
door is open; 3) the seatbelt assembly is unbuckled when
the ignition switch is in "RUN," "BULB TEST," or
"START" and 4) the turn signal has been on for more
than a half mile. Voltage is applied at all times through the
fuse block to power the solid state audio alarm module.
Ignition Key Warning

Whenever the key is in the ignition switch and the
driver's door is open, the module is grounded. This
sounds the alarm.
Fasten Seat Belt Assembly Warning

With the ignition switch in "RUN," "BULB
TEST," or "START," voltage is applied through the fuse
block to the audio alarm module. With the driver's seat
belt assembly unbuckled, the module is grounded through
the seat belt switch. The "FASTEN SAFETY BELTS"
indicator always goes on for 4 to 8 seconds when the ignition switch is turned to "RUN," "BULB TEST," or
"START." The fasten seat belts alarm, however, only
sounds if the seat belt is unbuckled and the ignition switch
is in "RUN," "BULB TEST," or "START."
Lights-on Warning
When the headlamp switch is in "HEAD" or
"PARK," voltage is applied to the audio alarm module.
When the ignition switch is in "RUN," "BULB TEST,"
or "START," voltage is applied through the fuse block to
the module. These two voltages are sensed and the alarm
assembly is not sounded.
When the ignition switch is not in "RUN," "BULB
TE~T" or "START," the module loses voltage. The
aud10 alarm module senses change. If voltage is still available, it is applied to sound the alarm. The alarm can be
turned off by turning the headlamp switch to "OFF." The
module no longer senses voltage from the headlamp
switch, so the alarm assembly does not sound.
DIAGNOSIS
For diagnosis of instrument panel, cluster, electrical
system (including individual wire color information and
applicable precautions for testing solid state electronic
devices and systems), refer to SECTION 8A.
ON-VEHICLE SERVICE
It may be necessary to color coat some replacement
components before installing them in the vehicle. For
information regarding this procedure, refer to SECTION
10-1.
SERVICE PRECAUTIONS
or around SIR components or SIR wiring, follow the procedures listed below
to temporarily disable the SIR system.
Failure to follow procedures could
result in possible air bag deployment,
personal injury, or otherwise unneeded
SIR system repairs.
INSTRUMENT PANEL, GAGES AND CONSOLE SC-7

The diagnostic energy reserve module (DERM) can
maintain sufficient voltage to cause a deployment for up
to ten minutes after the ignition switch is turned "OFF" or
the storage battery is disconnected. Many of the service
procedures require disconnection of the "AIRBAG" fuse
and the inflator module circuits from the deployment
loops to avoid an accidental deployment.

1. Turn steering wheel assembly so vehicle's tire and
2.
3.
4.
5.
6.
7.
wheel assemblies are pointing straight ahead.

Turn ignition switch to "LOCK."
"AIR BAG" fuse from fuse block.
Left-hand instrument panel sound insulator assembly, refer to "Sound Insulator Assembly" in this
section.
Connector position assurance (CPA) and yellow
two-way SIR harness connector at base of steering
column assembly.
Instrument panel compartment door assembly, refer
to "Instrument Panel Compartment" in this section.
Connector position assurance (CPA) and yellow
two-way SIR connector located near yellow 24-way
Important
With "AIR BAG" fuse removed and ignition switch

in "RUN," air bag indicator lamp on instrument
panel cluster assembly will light. This is normal
operation and does not indicate an SIR fault.

2. Yellow two-way SIR harness connector at base of

steering column assembly and connector position
assurance (CPA) located near yellow 24-way DERM
connector on instrument panel wiring harness
assembly.
3. Instrument panel compartment door assembly, refer
to "Instrument Panel Compartment" in this section.
4. Yellow two-way SIR connector and connector position assurance (CPA) at base of steering column
assembly.
5. Left-hand instrument panel sound insulator, refer to
"Sound Insulator Assembly" in this section.
6. "AIR BAG" fuse to fuse block.
7. Tum ignition switch to "RUN" and verify air bag
indicator flashes 7 to 9 times and then turns off. If
indicator does not respond as stated, refer to SECTJON 9J-A.
NOTICE: The instrument panel and cluster contain
electrostatic discharge (ESD) sensitive parts. When
handling an electronic part that is identified as being
ESD sensitive, the service technician should follow

the guidelines in SECTION OA. Following these
guidelines will reduce any possible electrostatic
charge buildup on the service technician's body and
the electronic part.
HANDLING ELECTROSTATIC DISCHARGE

(ESD) SENSITIVE PARTS
NOTICE: When handling an electronic part that has
an BSD-sensitive sticker, refer to SECTION OA.
Follow these guidelines to reduce any possible
build-up of electrostatic charge:
Do not open package until time when part is to be
installed.
Avoid touching electrical terminals of part.
Before removing part from its package, ground
package to known good ground on vehicle.
Always touch known good ground before handling
part. This should be repeated while handling part.
Do it more often after sliding across seat, sitting
down from standing position, or walking a distance.
Not all parts that can be damaged by ESD have and
ESD label. Components that can be damaged by ESD are:
AM/FM stereo radio assembly/radio control
Antilock brake system EBCM assembly
Automatic day/night mirror
CalPak
Chime module
Cruise control module
Electronic automatic air conditioning control assembly
Electronic spark control module
MEM-CAL (memory and calibration unit)
PROM (programmable read only memory) calibrator
Supplemental inflatable restraint (SIR) DERM module and resistor module
Twilight sentinel amplifier
CONTROLS
AM/FM Stereo and Clock Radio Assembly
Figures 1 and 2

1. Trim plate assembly (15) from instrument panel
assembly (40).
2. Bolt/screw (63) from instrument panel tie bar
assembly, if necessary.
3. Retainer (62) and bolt/screw (65) from bracket (27).
4. Radio assembly (66).
5. Bolts/screws (67) attaching brackets (68) to instrument panel carrier.
6. Brackets (68) and attached radio assembly (66) from
7. Instrument panel wiring harness electrical connectors from radio assembly (66).
SC-8 INSTRUMENT PANEL, GAGES AND CONSOLE

8. Bolts/screws (65) and nuts (64) attaching radio
assembly (66) to brackets (68), if necessary.
9. Radio assembly (66) from brackets (68), if necessary.

1. Brackets (68) to radio assembly (66), ifremoved.
2. Bolts/screws (65) and nuts (64) attaching brackets
(68) to radio assembly (66), if removed.
l~I Tighten
15 PLATE ASSEMBLY, INSTRUMENT PANEL ACCESSORY

TRIM
40 PANEL ASSEMBLY, INSTRUMENT
Nuts (64) to 2.8 Nm (25 lb. in.).

3. Instrument panel wiring harness electrical connectors to radio assembly (66).
4. Brackets (68) and attached radio assembly (66) to
PC2001-8CF-RP
Figure 1 - Instrument Panel Accessory Trim Plate Assembly
67
67
27
40
62
63
64
65
66
67
68
BRACKET, REAR RADIO

PANEL ASSEMBLY, INSTRUMENT
RETAINER, RADIO (PUSH-ON)
BOLT/SCREW, REAR RADIO BRACKET,
1.9 Nm (17 LB. IN.)
NUT, RADIO BRACKET, 2.8 Nm (25 LB. IN.)
BOLT/SCREW, RADIO
RADIO ASSEMBLY, AM/FM STEREO AND CLOCK
BOLT/SCREW, RADIO BRACKET, 1.8 Nm (16 LB. IN.)
BRACKET, RADIO
PC2002-8C-FRP
Figure 2 - AM/FM Stereo and Clock Radio Assembly

5. Bolts/screws (67) attaching brackets (68) to instrument panel carrier.
l~I
Tighten

6. Radio assembly (66) to instrument panel assembly
(40).
7. Retainer (62) and bolt/screw (65) to bracket (27).
8. Bolt/screw (63) to instrument panel tie bar assembly,
if removed.
l~I
Tighten

9. Trim plate assembly (15) to instrument panel assembly (40).

Assembly
l++I
Install or Connect

1. Control assembly (82) to panel assembly (40).
l~I
Tighten

3. Temperature control cable electrical connector and
vacuum wiring harness electrical connector through
hole in panel assembly (40) and over reinforcement
(85).
4. Bezel assembly. Refer to "Instrument Panel Cluster
Trim Plate Bezel Assembly" in this section.
Figure 3
l++I
3. Bolts/screws (81) attaching control assembly (82) to

panel assembly (40).
1. Bezel assembly. Refer to "Instrument Panel Cluster

2. Temperature control cable electrical connector and
vacuum wiring harness electrical connector from
over reinforcement (85).
Figure 4
The data link connector (DLC) is part of the instrument panel wiring harness assembly. Refer to SECTION
8A.
!++I
1. Two bolts/screws (61) attaching DLC to bracket

(60).
25
40
85
A CONNECTOR, TEMPERATURE CONTROL CABLE

ELECTRICAL
B CONNECTOR, VACUUM WIRING HARNESS ELECTRICAL
CONTROL, 1.9 Nm (17 LB. IN.)
82 CONTROL ASSEMBLY, HEATER AND AIR
CONDITIONING
85 REINFORCEMENT, INSTRUMENT PANEL
PC20038CFRP .
Figure 3 - Heater and Air Conditioning Control Assembly
A CONNECTOR, INSTRUMENT PANEL WIRING HARNESS

ENGINE CONTROL MODULE DATA LINK ELECTRICAL
B CONNECTOR, INSTRUMENT CLUSTER TURN SIGNAL
FLASHER ELECTRICAL
25 BAR ASSEMBLY, INSTRUMENT PANEL TIE
60 BRACKET, INSTRUMENT PANEL KNEE BOLSTER
61 BOLT/SCREW, INSTRUMENT PANEL WIRING HARNESS
ENGINE CONTROL MODULE DATA LINK CONNECTOR,
1.5 Nm (13 LB. IN.)
PC0004-8CFRP
Figure 4 - Data Link Connector (DLC)

2. Three instrument panel bolts/screws attaching
bracket (60) to instrument panel carrier, if necessary.

1. Three instrument panel bolts/screws attaching
bracket (60) to instrument panel carrier, if removed.
l~I
Tighten
Instrument panel bolts/screws to 1.9 Nm (17

lb. in.).
2. Two bolts/screws (61) attaching DLC to bracket
(60).
l~I
Tighten
DAYTIME RUNNING LAMP (DRL)

COMPONENTS (CANADIAN ONLY)
Sensor Assembly
Figure 5

1. Grille (70) from instrument panel upper trim panel
assembly.
Gently unsnap grille (70).
2. Sensor assembly (88) from grille (70).
Twist counterclockwise.
3. Sensor assembly (88) from instrument panel wiring
harness grille electrical connector.
retainers on daytime running lamp ambient light

sensor module electrical connectors.
3. Instrument panel wiring harness assembly from
under and behind bar assembly (25).

1. Route instrument panel wiring harness assembly
behind and under bar assembly (25).
2. Daytime running lamp ambient light sensor module
electrical connectors to module assembly (71).
When connecting, push, click, then tug on daytime running lamp ambient light sensor electrical connector, not wire.
3. Slide module assembly (71) onto heat and air conditioning duct assembly.
DRIVER KNEE BOLSTER ASSEMBLY AND

DEFLECTOR
Figure 6

1. Bolts/screws (4) from bolster assembly (3) at deflector (49) and instrument panel tie bar assembly
2. Bolster assembly (3) from dual lock retainers on
3. Nuts (48) from studs (74).
4. Deflector (49) from studs (74).

1.
2.
3.

1. Sensor assembly (88) to instrument panel wiring
harness grille electrical connector.
2. Sensor assembly (88) to grille (70).
Twist clockwise.
3. Grille (70) to instrument panel upper trim panel
assembly.
Snap into place.

Sensor Module Assembly
Figures

1. Module assembly (71) from heat and air conditioning duct assembly.
2. Instrument panel wiring harness electrical connectors from module assembly (71) by depressing lock
4.

Deflector (49) to studs (74).
Nuts (48) to studs (74).
Bolster assembly (3) to dual lock retainers on instrument panel carrier.
Position bolster assembly (3) for best fit and
apply pressure on retainers to secure.
Bolts/screws (4) to bolster assembly (3) at deflector
(49) and instrument panel tie bar assembly.
l~I
Tighten
FRONT FLOOR CONSOLE ASSEMBLY

Figure 7

1. Bolts/screws (34) attaching console assembly (33)
to instrument panel center support bracket and
manual floor console bracket.
2. Bolt/screw (35) attaching console assembly (33) to
instrument panel assembly.
to bracket (37).
71
71
jv1EWB I
A HARNESS ASSEMBLY, INSTRUMENT PANEL WIRING

B DUCT ASSEMBLY, HEAT AND AIR CONDITIONING
C CONNECTOR, DAYTIME RUNNING LAMP AMBIENT
LIGHT SENSOR GRILLE ELECTRICAL
D CONNECTOR, DAYTIME RUNNING LAMP AMBIENT
LIGHT SENSOR MODULE ELECTRICAL
70 GRILLE, DAYTIME RUNNING LAMP AMBIENT LIGHT
SENSOR
71 MODULE ASSEMBLY, DAYTIME RUNNING LAMP
AMBIENT LIGHT SENSOR
75 CARRIER, INSTRUMENT PANEL
88 SENSOR ASSEMBLY, DAYTIME RUNNING LAMP
AMBIENT LIGHT
jv1Ewc I
PC00058CFRP
Figure 5 - Daytime Running Lamp Ambient Light Sensor Module Assembly
8C12 INSTRUMENT PANEL, GAGES AND CONSOLE

3. Bolt/screw (35) attaching console assembly (33) to
instrument panel assembly.
l~I
Tighten

to instrument panel center support bracket and
manual floor console bracket.
l~I
Tighten
Compartment Lamp Switch

74
74
Figure 8

1. Switch (93) and retainer (94) from opening in console assembly (33).
2. Retainer (94) from switch (93).
A
3
4
40
48
49
74
jv1EWA
RETAINER, DUAL LOCK
BOLSTER ASSEMBLY, INSTRUMENT PANEL DRIVER
KNEE
BOLT/SCREW, INSTRUMENT PANEL DRIVER KNEE
BOLSTER, 1.9 Nm (17 LB. IN.)
PANEL ASSEMBLY, INSTRUMENT
NUT, INSTRUMENT PANEL DRIVER KNEE BOLSTER
DEFLECTOR
DEFLECTOR, INSTRUMENT PANEL DRIVER KNEE
BOLSTER
STUD, INSTRUMENT PANEL DRIVER KNEE BOLSTER
DEFLECTOR
PC2006-8C-F-RP

1. Retainer (94) to switch (93).
2. Switch (93) and retainer (94) down through opening
in console assembly (33).
Be sure retainer (94) is seated in console
assembly (33).
Headlamp Automatic Beam Control Switch

Assembly
Figure 6 - Driver Knee Bolster Assembly and Deflector
Figure9
4. Console assembly (33).

1. Console assembly (33).
A. Route wiring connectors through appropriate
openings.
B. Insert parking brake assembly through
appropriate opening.
C. Locating pin on console assembly (33) into
hole in shifter bracket drive.
D. Position console assembly (33) to floor of
vehicle.
to bracket (37).
l~I

1. Unsnap bezel (42) from console (41).
2. switch assembly (43) from bezel (42).

1. Switch assembly (43) into bezel (42).
2. Bezel (42) into console (41).
Storage Tray
Figure 10

Tray (30 or 32) from console storage area.
Tighten
Depress dual lock fasteners on either side of

tray (30 or 32).
INSTRUMENT PANEL, GAGES AND CONSOLE 8C-13
33
34
37
-- -.......
' .....
,"'
.,
.......
A CONNECTOR, CIGARETIE LIGHTER WIRING HARNESS

ELECTRICAL
33 CONSOLE ASSEMBLY, FRONT FLOOR
34 BOLT/SCREW, FRONT FLOOR CONSOLE,
8 Nm (71 LB. IN.)
35 BOLT/SCREW, INSTRUMENT PANEL,
5.5 Nm (49 LB. IN.)
36 BOLT/SCREW, FRONT FLOOR CONSOLE BRACKET,
8 Nm (71 LB. IN.)
37 BRACKET, FRONT FLOOR CONSOLE
PC2007-BC-F-RP
Figure 7 - Front Floor Console Assembly
Transmission Plate Assembly
~94
93
Figure 11

1. Retainers attaching plate assembly (28 or 29) to console assembly (33).
2. Plate assembly (28 or 29).

93 SWITCH, INSTRUMENT PANEL COMPARTMENT LAMP
94 RETAINER, INSTRUMENT PANEL COMPARTMENT
LAMP SWITCH
PC0009-BC-F-RP
Figure 8 - Compartment Lamp Switch
1. Plate assembly (28 or 29) to console assembly (33).

Position plate assembly (28 or 29) over shifter
stem, initially inserting forward end of plate
assembly (28 or 29) into console assembly
(33).
2. Retainers attaching plate assembly (29) to console
assembly (33).
Apply pressure, snap into place and secure.
HEAT, VENTILATION AND AIR

CONDITIONING DUCTS
Air Distributor Assembly

Tray (30 or 32) into console storage area.
Apply pressure to secure dual lock fasteners.
Figure 12

1. Instrument panel carrier. Refer to "Instrument Panel
Carrier" in this section.
29
28
B
B
A
43
42
SECTION A-A

41 CONSOLE, TRIM PLATE
42 BEZEL, HEADLAMP AUTOMATIC BEAM CONTROL
SWITCH
43 SWITCH ASSEMBLY, HEADLAMP AUTOMATIC
CONTROL AND HEADLAMP AUTOMATIC BEAM
CONTROL
PC20098CFRP
Figure 9 - Headlamp Automatic Beam Control Switch

Assembly
A STEM, SHIFTER
B RETAINER
28 PLATE ASSEMBLY, FRONT FLOOR CONSOLE
TRANSMISSION (MANUAL)
29 PLATE ASSEMBLY, FRONT FLOOR CONSOLE
TRANSMISSION (AUTOMATIC)
33 CONSOLE ASSEMBLY, FRONT FLOOR PC
_ C-F-RP
2011 8
Figure 11 - Transmission Plate Assembly
2. Route heater control cable assembly and vacuum

wiring harness assembly over reinforcement in carrier (75).
Align cable and wire assemblies with depression in distributor assembly (54).
3. Bolts/screws (55) attaching distributor assembly
(54) to carrier (75).
l~I Tighten
4. Instrument panel carrier (75). Refer to "Instrument
Panel Carrier" in this section.
Defogger Outlet Duct Assembly

Figure 12

30 TRAY, FRONT FLOOR CONSOLE TAPE/DISC STORAGE
(TAPE)
32 TRAY, FRONT FLOOR CONSOLE TAPE/DISC STORAGE
(DISC)
PC20108C-F-RP
Figure 1O - Storage Tray
2. Bolts/screws (55) attaching distributor assembly

(54) to carrier (75).
3. Distributor assembly (54) from carrier (75).

NOTICE: See "NOTICE" on page 8C-1 of this section.
1. Distributor assembly (54) to carrier (75).
1. Duct assembly (56) from distributor assembly (54).

2. Duct assembly (56) from carrier (75).

1. Duct assembly (56) to carrier (75).
2. Duct assembly (56) to distributor assembly (54).
Floor Air Outlet Duct Assembly

Figure 13

1. Bolts/screws (47) attaching duct assembly (46) to
52 DUCT ASSEMBLY, INSTRUMENT PANEL OUTER AIR

OUTLET
53 BOLT/SCREW, INSTRUMENT PANEL OUTER AIR
OUTLET, 1.9 Nm (17 LB. IN.)
54 DISTRIBUTOR ASSEMBLY, WINDSHIELD DEFROSTER
NOZZLE AND AIR
55 BOLT/SCREW, AIR DISTRIBUTOR DUCT,
1.9 Nm (17 LB. IN.)
56 DUCT ASSEMBLY, SIDE WINDOW DEFOGGER OUTLET
'~~~ IVIEW A I
PC2012-8C-F-RP
Figure 12 - Heat, Ventilation and Air Conditioning Ducts
2. Duct assembly (46).

1. Duct assembly (46) to module assembly (45).
l~I Tighten

1. Duct assembly (52) to carrier (75).
carrier (75).
l~I Tighten
Outer Air Outlet Duct Assemblies

Figure 12

carrier (75).
2. Duct assembly (52).
HEATER AND AIR CONDITIONING

EVAPORATOR AND BLOWER MODULE
ASSEMBLY
Figure 13

1. Bolts/screws (44) attaching module assembly (45) to
carrier (75).
46

EVAPORATOR AND BLOWER MODULE,
5.5 Nm (49 LB. IN.)
EVAPORATOR AND BLOWER
46 DUCT ASSEMBLY, FLOOR AIR OUTLET
47 BOLT/SCREW, FLOOR AIR OUTLET DUCT,
1.9 Nm (17 LB. IN.)
47
IVIEWA I
PC0012-SC-F-RP
Figure 13 - Heater and Air Conditioning Evaporator and Blower Module Assembly
2, Module assembly (45).
l++l
lnstall or Connect

1. Module assembly (45) to carrier (75).
carrier (75).
l~I
Tighten
INSTRUMENT CLUSTER ASSEMBLY

79
Figure 14
l++I
1. Instrument panel upper trim panel assembly. Refer

to "Instrument Panel Upper Trim Panel Assembly"
in this section.
2. Bolts/screws (79) attaching cluster assembly (78) to
carrier (75).
3. Cluster assembly (78) from carrier (75).
l++l
lnstall or Connect

1. Cluster assembly (78) to carrier (75).
2. Bolts/screws (79) attaching cluster assembly (78) to
carrier (75).

78 CLUSTER ASSEMBLY, INSTRUMENT
79 BOLT/SCREW, INSTRUMENT CLUSTER
.
'
2.2 Nm (20 LB. IN.)
PC2014-8C-F-RP
Figure 14 - Instrument Cluster Assembly
l~I
Tighten

to "Instrument Panel Upper Trim Panel Assembly"
in this section.
INSTRUMENT PANEL CARRIER

75
Figure 15
l++I
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.

BC-1 of this section.
Sound insulator assembly from both sides of
vehicle. Refer to "Sound Insulator Assembly" in
this section.
Removable top assembly. Refer to SECTION 10-9.
Window rail trim panel assembly. Refer to SECTION 10-6.
Knee bolster assembly and deflector. Refer to
"Driver Knee Bolster Assembly and Deflector" in
this section.
Disable SIR. Refer to "Disabling the SIR System"
in this section.
NOTICE: Remove stoplamp switch before fully
lowering the steering column assembly. Failure to
do so may cause the stoplamp switch to become
damaged or thrown out of adjustment resulting in a
malfunctioning stoplamp switch or premature brake
wear.
Stoplamp switch. Refer to SECTION 5.
Steering column assembly. Refer to SECTION 3F.
Gently lower steering column assembly.
Trim panel assembly. Refer to "Instrument Panel
Upper Trim Panel Assembly" in this section.
Trim plate assembly. Refer to "AM/FM Stereo and
Clock Radio Assembly" in this section.
Bezel assembly. Refer to "Instrument Panel Cluster
Instrument cluster assembly. Refer to "Instrument
Cluster Assembly" in this section.
Radio assembly. Refer to "AM/FM Stereo and
Temperature control assembly. Refer to "Heater and
Air Conditioning Control Assembly" in this section.
Left side duct assemblies. Refer to "Heat, Ventilation, and Air Conditioning Ducts" in this section.
Transmission gear shift knob, cover and console
assemblies. Refer to "Front Floor Console Assembly" in this section.
Fuse block. Refer to "Auxiliary Fuse Block" in this
section.
Assembly line data link connector. Refer to "Instrument Panel Wiring Harness Assembly" in this section.
Hazard and chime assembly. Refer to "Warning/Reminder Chimes'' in this section.
Upper bolts/screws (9).
Lower nuts (8).
Reposition carrier (75).
Air duct assembly. Refer to "Heat, Ventilation and
Air Conditioning Ducts'' in this section.
A WIRE ASSEMBLY, CROSS CAR WIRING HARNESS

GROUND
B WIRE ASSEMBLY, INSTRUMENT PANEL WIRING
HARNESS GROUND
C WIRE ASSEMBLY, INSTRUMENT PANEL WIRING
HARNESS GROUND
D WIRE ASSEMBLY, INSTRUMENT PANEL WIRING
HARNESS GROUND
8 NUT, INSTRUMENT PANEL, 25 Nm (18 LB. FT.)
9 BOLT/SCREW, INSTRUMENT PANEL,
1.9 Nm (17 LB. IN.)
PC2015-8C-F-RP
Figure 15 - Instrument Panel Assembly Mounting
23. Audio alarm assembly. Refer to "Alarm Assembly"

in this section.
24. Wiring harness assembly from carrier (75). Refer to
'Instrument Panel Wiring Harness Assembly" in
this section.
25. Carrier (75).
l++I
1.
2.
3.
4.
5.
6.
Install or Connect

Carrier (75).
Wiring harness assembly to carrier (75). Refer to
"Instrument Panel Wiring Harness Assembly" in
this section.
Audio alarm assembly. Refer to "Alarm Assembly"
in this section.
Air duct assembly. Refer to "Heat, Ventilation and
Air Conditioning Ducts" in this section.
Position carrier (75)
Lower nuts (8).
l~I
Tighten
Lower nuts (8) to 25 Nm (18 lb. ft.).

7. Upper bolts/screws (9).
l~I
Tighten
Upper bolts/screws (9) to 1.9 Nm (17 lb in.).

8. Hazard and chime assembly. Refer to "Warning/Re9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
minder Chimes" in this section.

Assembly line data link connector. Refer to "Instrument Panel Wiring Harness Assembly" in this section.
Fuse block. Refer to "Auxiliary Fuse Block" in this
section.
Transmission gear shift knob, cover and console
assemblies. Refer to "Front Floor Console Assembly" in this section.
Left side duct assemblies. Refer to "Heat, Ventilation and Air Conditioning Ducts" in this section.
Temperature control assembly. Refer to '' Heater and
Air Conditioning Control Assembly" in this section.
Radio assembly. Refer to "AM/FM Stereo and
Instrument cluster assembly. Refer to "Instrument
Cluster Assembly" in this section.
Bezel assembly. Refer to "Instrument Panel Cluster
Trim plate assembly. Refer to "AM/FM Stereo and
Trim panel assembly. Refer to "Instrument Panel
Upper Trim Panel Assembly" in this section.
Steering column assembly. Refer to SECTION 3F.
Gently raise steering column assembly into
place.
Stoplamp switch. Refer to SECTION 5.
CAUTION: Refer to "Caution" on page
8C-1 of this section.
Enable SIR. Refer to "Enabling the SIR System" in
this section.
Knee bolster assembly and deflector. Refer to
"Driver Knee Bolster Assembly and Deflector" in
this section.
Window rail trim panel assembly. Refer to SECTION 10-6.
24. Removable top assembly. Refer to SECTION 10-9.

25. Sound insulator assembly. Refer to "Sound Insulator Assembly" in this section.
INSTRUMENT PANEL INSULATOR

Figure 16

1. Retainers (7) attaching insulator (26) to carrier (75).
2. Insulator (26) from tape (24) that is attached to carrier (75).

1. Insulator (26) to tape (24) that is attached to carrier
(75).
2. Retainers (7) attaching insulator (26) to carrier (75).
INSTRUMENT PANEL SWITCHES

Figure 17

1. Switch assembly (83) from carrier (75).
2. Instrument panel wiring harness electrical connectors from switch assembly (83).

NOTICE: When installing switch assembly, do not
put pressure on switch knob or dimmer thumbwheel.
Failure to follow these instructions may result in
damage to the switch assembly.
1. Switch assembly (83) to instrument panel wiring
harness electrical connectors.
24
7
24
26
75
RETAINER, INSTRUMENT PANEUNSULATOR

TAPE, INSTRUMENT PANEL INSULATOR FASTENER
INSULATOR, INSTRUMENT PANEL
CARRIER, INSTRUMENT PANEL
PC00168C-F-RP
Figure 16 - Instrument Panel Insulator

ELECTRICAL
B CONNECTOR, INSTRUMENT PANEL WIRING HARNESS
ELECTRICAL
83 SWITCH ASSEMBLY, HEADLAMP AND INSTRUMENT
PANEL LAMP DIMMER

ELECTRICAL
3 BOLSTER ASSEMBLY, INSTRUMENT PANEL DRIVER
KNEE
31 SWITCH ASSEMBY, REAR COMPARTMENT LID
RELEASE
PC2018-8CF-RP
Figure 18 - Lid Release Switch Assembly
Rear Fog Lamp Switch Assembly

PC20178C-F-RP
Figure 17 - Headlamp and Instrument Panel Lamp Dimmer

Switch Assembly
Figure 19

l. Bezel assembly (5). Refer to "Instrument Panel
Cluster Trim Plate Bezel Assembly" in this section.
2. Switch assembly (83) to carrier (75).
2. Switch assembly (38) from instrument panel wiring

harness electrical connector.
3. Switch assembly (38) from bezel assembly (5).
Lid Release Switch Assembly

Figure 18

l. Driver knee bolster assembly. Refer to "Driver
Knee Bolster Assembly and Deflector" in this section.
2. Switch assembly (31) from instrument panel wiring

3. Switch assembly (31) from bolster assembly (3).

l. Switch assembly (31) to bolster assembly (3).

3. Driver knee bolster assembly. Refer to "Driver
Knee Bolster Assembly and Deflector" in this section.

ELECTRICAL
B INSULATOR, INSTRUMENT PANEL WIRING HARNESS
5 BEZEL ASSEMBLY, INSTRUMENT PANEL CLUSTER
.
TRIM PLATE
38 SWITCH ASSEMBLY, REAR FOG LAMP
PC2019-8CF-RP
Figure 19 - Rear Fog Lamp Switch Assembly

1. Auxiliary fuse block to carrier (75).
2. Bolt/screw (86).
1. Switch assembly (38) to bezel assembly (5).

3. Bezel assembly (5). Refer to "Instrument Panel
Cluster Trim Plate Bezel Assembly" in this section.
l~I Tighten
Convenience Center
INSTRUMENT PANEL WIRING HARNESS

ASSEMBLY
Figure22
Refer to Figure 20 for instrument panel wiring harness assembly routing.

1. Bolts/screws (87) attaching convenience center to
tie bar assembly (25).
Auxiliary Fuse Block
2. Convenience center.
Figure21

1. Bolt/screw (86) connecting auxiliary fuse block to
carrier (75).
2. Auxiliary fuse block.

1. Convenience center to tie bar assembly (25).

l~I Tighten
PC2020-8C-F-RP
Figure 20 - Instrument Panel Wiring Harness Routing
~75
A
87
25
A CONVENIENCE CENTER, INSTRUMENT PANEL WIRING

HARNESS
CONVENIENCE CENTER, 1.5 Nm (13 LB. IN.)
A FUSE BLOCK, INSTRUMENT PANEL WIRING HARNESS

AUXILIARY
75 CARRIER INSTRUMENT PANEL
FUSE BLOCK 1.5 Nm (13 LB. IN.)
PC0021-BC-F-RP
PC0020-BC-F-RP
Figure 21 - Auxiliary Fuse Block
Figure 22 - Convenience Center
A copy of the label must be retained in compliance

with the retention requirements specified in the
"Guidelines for General Motors Odometer Policy."
ODOMETER REPAIR NOTICE LABEL

Figure 23
rn
Important
1. Clean area around left B-pillar where odometer

repair notice label is to be attached.
Label area is to be clean and free from plastisol
or any foreign material that could affect adhesion of odometer repair notice label.
2. Properly fill out all necessary information on odometer repair notice label.
Sign and date odometer repair notice label.
When repairing an instrument cluster assembly, the

law requires the odometer reading of the replacement unit to be set to register the same mileage as the
prior odometer. If the same mileage cannot be set,
the law requires that the replacement odometer be
set to zero and a label be installed on the driver's
door frame to show the previous reading and the date
of replacement.
------..oo=o=ME=TE~R=RE=AA,=~R=E,.....:-:::CE=ME~NTl-~~A
n.fOOOtTlOJll'~"'~"""Sat
,.4Nlto ~ rU*ilfo ..a ro
ltlllO o
was 1111111..ACIO . . ,,. ..,. OOOflllltfl.11 SU'
" ZUIG . . _ . ~ NOt

11\.,M;IJlliltlllfWl
ro .,......
_ _ _ _ _ -.cso,i
----''""''"'
o:t ..11...,oouc:10 _ _
" - -..,...fl
- ....,.,,...
JIOIA&I. U,W
'9&1.fllllAfOilOJ""'SV.IIL
A LABEL, ODOMETER REPAIR NOTICE
Figure 23 - Odometer Repair Notice Label
PC2023-BC-F-RP

3. Remove backing and attach odometer repair notice
label to left B-pillar.
SOUND INSULATOR ASSEMBLY

Figure24
Left Side
3. Insulator assembly (10) from instrument panel carrier.

A.Detach forward flange on insulator assembly
(10) from boss on heater and air conditioning
module assembly.
B. Unhook flange on insulator assembly (10)
from under side kick panel assembly.

1. Retainer (13) from instrument panel carrier.
2. Insulator assembly (14) from instrument panel carrier.
A. Unhook flange on insulator assembly (14)
from side kick panel assembly.
B. Detach tab on insulator assembly (14) from
retainer on instrument panel carrier.

1. Insulator assembly (14) to instrument panel carrier.
A. Attach tab on insulator assembly (14) to
retainer on instrument panel carrier.
B. Hook flange on insulator assembly (14) to side
kick panel assembly.
2. Retainer (13) to instrument panel carrier.
1. Insulator assembly (10) to instrument panel carrier.

A.Hook flange on insulator assembly (10) over
side kick panel assembly.
B. Attach forward flange on insulator assembly
(10) to boss on heater and air conditioning
module assembly.
2. Retainer (12) to insulator assembly (10).
3. Retainer (11) to boss on heater and air conditioning
module assembly.
TRIM PANEL CLUSTER BEZEL ASSEMBLY,

UPPER TRIM PANEL ASSEMBLY AND
COMPARTMENTS
Instrument Panel Cluster Trim Plate Bezel
Assembly
Right Side
Figure25
1. Retainer (11) from boss on heater and air conditioning module assembly.
2. Retainer (12) from insulator assembly (10).
1. Locator pins attaching bezel assembly (5) to carrier

(75).
2. Bezel assembly (5) from carrier (75).
c
c
A
B
C
D
10
11
12
13
14
LEFT SIDE
A
RIGHTSIDE
FLANGE
TAB
INSULATOR ASSEMBLY, INSTRUMENT PANEL SOUND
RETAINER, INSTRUMENT PANEL SOUND INSULATOR
INSULATOR ASSEMBLY, INSTRUMENT PANEL SOUND
12
PC2024-8C-FRP
Figure 24 - Sound Insulator Assembly
INSTRUMENT PANEL, GAGES AND CONSOLE 8C23

Align hinge.

1. Bezel assembly (5) onto carrier (75).
2. Locator pins attaching bezel assembly (5) to carrier
(75).
Instrument Panel Compartment

The instrument panel compartment is part of the
instrument panel carrier. The door, lock assembly and
lamp are serviceable. The lamp switch is part of the body
wiring harness assembly. For further information, refer to
SECTION 8B.
l~I Tighten
Bolts/screws (20 and 90) to 2.8 Nm (25 lb.
in.).
Instrument Panel Compartment Door Lock

Assembly
Figure26

1. Open door assembly (89).
Instrument Panel Compartment Door Assembly
Figure26
2. Three bolts/screws (92) attaching lock assembly

(91) to door assembly (89).
3. Lock assembly (91) from door assembly (89).

1. Bolts/screws (20 and 90) attaching hinge to instrument panel carrier.
2. Open door assembly (89).
3. Door assembly (89) from instrument panel carrier.

1. Lock assembly (91) to door assembly (89).
2. Three bolts/screws (92) attaching lock assembly
(91) to door assembly (89).
Align and tighten bolts/screws (92).
3. Close door assembly (89).

1. Door assembly (89) onto instrument panel carrier.
2. Close door assembly (89).
3. Bolts/screws (20 and 90) attaching hinge to instrument panel carrier.
Instrument Panel Compartment Lamp Switch
Figure27

1. Switch (96) and retainer (95) from carrier (75).
2. Retainer (95) from switch (96).

1. Retainer (95) to switch (96).
2. Switch (96) and retainer (95) down through opening
in carrier (75).
Be sure retainer (95) is seated into carrier (75).
Instrument Panel Fuse Block Access Door

Assembly
Figure28

Door assembly (2) from carrier (75).
A PIN, LOCATOR
5 BEZEL ASSEMBLY, INSTRUMENT PANEL CLUSTER
TRIM PLATE
PC2025-8C-F-RP
Figure 25 - Instrument Panel Cluster Trim Plate Bezel

Assembly

Door assembly (2) to carrier (75).
A. Align tabs on door assembly (2) with front
edge of carrier (75).
B. Align locator pins on door assembly (2) with

holes on carrier (75) and apply pressure.
'""
~20
'"-----.j
91
89

INSTRUMENT PANEL
20 BOLT/SCREW, INFLATABLE RESTRAINT CONTROL
MODULE BRACKET, 2.8 Nm (25 LB. IN.)
89 DOOR ASSEMBLY, INSTRUMENT PANEL
COMPARTMENT
90 BOLT/SCREW, INSTRUMENT PANEL COMPARTMENT
DOOR, 2.8 Nm (25 LB.IN.)
91 LOCK ASSEMBLY, INSTRUMENT PANEL
COMPARTMENT DOOR
92 BOLT/SCREW, INSTRUMENT PANEL COMPARTMENT
DOOR LOCK
!VIEWS
PC2026-8C-F-RP
Figure 26 - Instrument Panel Compartment Door and Lock Assembly
2. Panel assembly (1) from carrier (75).

1. Panel assembly (1) to carrier (75).
A. Align panel assembly (1), using locator pins.
B. Apply pressure to rear of panel assembly (1),
engaging dual lock fasteners with mating surface.
2. Panel assembly (1) to lower windshield support.
Engage dual lock fasteners with mating surface.
PASSENGER SIDE SIR MODULE ASSEMBLY

95 RETAINER, INSTRUMENT PANEL COMPARTMENT
LAMP SWITCH
96 SWITCH, INSTRUMENT PANEL COMPARTMENT LAMP
PC2027-8C-F-RP
Figure 27 - Instrument Panel Compartment Lamp Switch
Instrument Panel Upper Trim Panel

Assembly
Figure29

1. Panel assembly (1) from lower windshield support.
Figures 26 and 30

1. Bolts/screws (20) attaching bracket assembly (19) to
2. Bracket assembly (19) from instrument panel carrier.
bracket assembly (19).
4. Module assembly (18).

1. Module assembly (18) into bracket assembly (19).
18
19
17 BOLT/SCREW, INFLATABLE RESTRAINT INSTRUMENT

A LOCK ASSEMBLY, DUAL
2 DOOR ASSEMBLY, INSTRUMENT PANEL FUSE BLOCK
ACCESS
PANEL MODULE, 2.8 Nm (25 LB. IN.)

INSTRUMENT PANEL
19 BRACKET ASSEMBLY, INFLATABLE RESTRAINT
INSTRUMENT PANEL MODULE
PC20288C-F-RP
Figure 28 - Instrument Panel Fuse Block Access Door

Assembly

bracket assembly (19).
l~I
Figure 30 - Passenger Side SIR Module Assembly
WARNING/REMINDER CHIMES
Alarm Assembly
Tighten

3. Bracket assembly (19) to instrument panel carrier.
4. Bolts/screws (20) attaching bracket assembly ( 19) to
l~I
PC00308C-F-RP
Figure 31

Alarm assembly (97) from convenience center.
Tighten
Alarm assembly (97) to convenience center.
75
75
A PIN, LOCATOR
B FASTENER,DUALLOCK
C SUPPORT, LOWER WINDSHIELD
1 PANEL ASSEMBLY, INSTRUMENT PANEL UPPER TRIM
PC2029-8C-F-RP
Figure 29 - Instrument Panel Upper Trim Panel Assembly
A CONVENIENCE CENTER, INSTRUMENT PANEL WIRING

HARNESS
97 ALARM ASSEMBLY, SEATBELT AND IGNITION KEY
AND
PC0031-8C-F-RP
Figure 31 - Seat Belt and Ignition Key and Alarm Assembly
SPECIFICATIONS
Air Distributor Duct Bolt/Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.9 Nm (17 lb. in.)
Floor Air Outlet Duct Bolt/Screw ...................................... 1.9 Nm (17 lb. in.)
Front Floor Console Bolt/Screw ......................................... 8 Nm (71 lb. in.)
Front Floor Console Bracket Bolt/Screw .................................. 8 Nm (71 lb. in.)
Heater and Air Conditioning Control Bolt/Screw ......................... 1.9 Nm (17 lb. in.)
Heater and Air Conditioning Evaporator and Blower Module Bolt/Screw ...... 5.5 Nm (49 lb. in.)
Inflatable Restraint Control Module Bracket Bolt/Screw .................... 2.8 Nm (25 lb. in.)
Inflatable Restraint Instrument Panel Module Bolt/Screw . . . . . . . . . . . . . . . . . . . 2.8 Nm (25 lb. in.)
Instrument Cluster Bolt/Screw ........................................ 2.2 Nm (20 lb. in.)
Instrument Panel Bolt/Screw (Upper) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.9 Nm (17 lb. in.)
Instrument Panel Bolt/Screw (Lower) .................................. 5.5 Nm (49 lb. in.)
Instrument Panel Compartment Door Bolt/Screw . . . . . . . . . . . . . . . . . . . . . . . . . 2.8 Nm (25 lb. in.)
Instrument Panel Driver Knee Bolster Bolt/Screw ......................... 1.9 Nm (17 lb. in.)
Instrument Panel Nut ................................................ 25 Nm (18 lb. ft.)
Instrument Panel Outer Air Outlet Bolt/Screw ............................ 1.9 Nm (17 lb. in.)
Instrument Panel Wiring Harness Convenience Center Bolt/Screw ............ 1.5 Nm (13 lb. in.)
Instrument Panel Wiring Harness Engine Control Module Data Link
Connector Bolt/Screw ............................................. 1.5 Nm (13 lb. in.)
Instrument Panel Wiring Harness Fuse Block Bolt/Screw ................... 1.5 Nm (13 lb. in.)
Radio Bracket Bolt/Screw ............................................ 1.8 Nm (16 lb. in.)
Radio Bracket Nut .................................................. 2.8 Nm (25 lb. in.)
Rear Radio Bracket Bolt/Screw ....................................... 1.9 Nm (17 lb. in.)
WINDSHIELD WIPER/WASHER SYSTEM
8E-1
SECTION SE

(PULSE)
NOTICE: Refer to Battery Disconnect Caution in Section OA.
part number fastener is not available, a fastener of equal size and strength (or stronger) may be used. The correct
torque value must be used when installing fasteners that require it. If the above conditions are not followed, parts or
system damage could result.
CONTENTS
General Description ....................... 8E-1
Circuit Operation ....................... 8E-1
Diagnosis ............................... 8E-3
Component Locations ................... 8E-3
Troubleshooting Hints ................... 8E-3
System Diagnosis ...................... 8E-3
On-Vehicle Service ....................... 8E-10
Washer Pump Replacement .............. 8E-10
Washer Reservoir Replacement ........... 8E-10
Wiper Arm Replacement ................. 8E-10
Wiper Blade Assembly Replacement ....... 8E-11
Wiper Blade Element Replacement ........ 8E-13
Windshield Washer ..................... 8E-13
GENERAL DESCRIPTION
Figure 1
The windshield wiper/washer system consists of

a permanent magnet depressed park wiper motor
assembly, wiper linkage assemblies, wiper arm and
blade assemblies, a washer pump mounted on a washer
fluid reservoir and a wiper/washer switch assembly
(Figure 1).
Pulse and timing functions, along with the demand wash function, are controlled by a printed circuit
board in the wiper motor cover assembly. The wiper
motor also is equipped with RFI (radio frequency
interference) suppression.
Depressed park positioning is accomplished by
an external drive mechanism on the wiper motor
assembly.
Wiper Motor Assembly Replacement ....... 8E-13

Wiper Linkage Assembly Replacement ..... 8E-14
Off-Vehicle Service ....................... 8E-15
Wiper Motor Cover Assembly Replacement . 8E-15
Wiper Chatter Repair ..................... 8E-16
Windshield Glass Cleaning ............... 8E-16
Blade Element Cleaning ................. 8E-16
Wiper Arm Tip Pressure Check ........... 8E-16
Blade Element Set Check ................ 8E-17
Specifications ........................... 8E-18
Fastener Tightening Specifications ......... 8E-18
Special Tools ............................ 8E-18
CIRCUIT OPERATION
Figure2
Wiper Operation
In addition to the features of a conventional (nonpulse) wiper system (mist, low and high speeds), the
pulse type windshield wiper/washer system includes
an operating mode in which the wipers make single
sweeps with an adjustable time interval between
sweeps. The time interval is controlled by a solid state
timer in the wiper motor cover assembly. The duration
of the delay interval is determined by the delay resistor in the wiper/washer switch assembly.
When the wiper switch is turned OFF, the wiper
motor returns the wipers to end of sweep (inner wipe)
position, the wiper motor reverses and activates its
external depressed park mechanism to lower the wipers to park position.
Pulse Operation
With the wiper switch in DELAY (pulse), battery

voltage is applied to the wiper motor connector at terminal "B" through CKT 143. Voltage also is applied
to terminal "D" through CKT 113 and terminal "E''
through CKT 112.
The length of delay time between sweeps is controlled by the variable pulse delay resistor. The delay
is adjustable from 1 to 22 seconds, nominally.
Figure 1 - Wiper/Washer Switch Assembly
8E-2
ACCY
(NOT USED)
.._
-,11p
I FUSE
BLOCK
II
I
_______ _ __ ...
1 YEL
1 VEL
143
WIPER/WASHER
SWITCH ASSEMBLY
WASHER
SWITCH
MIST
MIST
OFF
e e
e e
HI
LO
PULSE
PULSE
360!2
6
8
0
K
24Kil
94
.8 PNK
WIPER/
WASHER
REQUEST
INPUT
WIPERS
DELAY
INPVT
WIPER
INTERLOCK
INPUT
WIPERS
ENABLE
ISOLA-i
TION
DIODE
(WIPERS)
SOLID
STATE
PARK
POSITION
1-------------'
I------------,
1--------,
END OF
SWEEP
SWITCH
(OPEN AT
END OF
"SWEEP"
AND
"PARK"
POSITION)
----------------
T2
Tl
1--...;:;.;.;.;.;.;=---+-------.
INPUT
.8 RED
(PT()
.--+~-+~-+-~LOW
SPEED
RELAY
I
I
PARK
RELAY
PARK
SWITCH
(CLOSED
UNTIL WIPERS
IN "PARK")
228
GROUND
PARK
WIPERS----CONTROL
WIPER MOTOR
ASSEMBLY
.8 BLK
1SO
Figure 2 - Wiper/Washer System Electrical Schematic
SEE GROUND
DISTRIBUTION
SECTION8A
DIAGNOSIS
Low Speed Operation
In the LO position of the wiper switch, battery

voltage is applied to the wiper motor connector at terminal "B" through CKT 143 and terminal "E" through
CKT 112, with voltage applied to terminal "D" through
CKT 113.
The circuit board supplies power to the wiper
motor, which runs continuously through the low speed
relay.
High Speed Operation
In the HI position of the wiper switch, battery

voltage is applied at terminals "B", "C" and "E" of
the wiper motor assembly through CKTs 143, 92 and
112. Voltage also is applied to terminal "D" through
CKT 113.
Park Position Operation
When turned OFF from any position, the wipers

complete the last sweep and park. When the wiper
switch is in OFF, the wiper motor assembly has battery voltage applied to terminal "B" only, from CKT
143. When the end of sweep switch opens, the control
circuit reverses the wiper motor which activates the
external depressed park mechanism. The wiper motor
continues to run until the park switch opens.
Washer Operation
When the washer switch is turned to ON, battery

voltage is applied to terminal "D" of the wiper motor
assembly through CKT 113. The washer switch also
applies voltage to terminal "A" which turns ON the
washer pump through CKTs 94 and 228. The wiper
motor has voltage applied through the low speed relay
and operates at low speed for 2 to 4 wipes.
When the washer switch is held ON, the wiper
motor circuit board will keep the washer pump ON
only as long as the washer switch is held ON.
If the wipers had been in DELAY, LO or HI,
they would return to that operation after the wash cycle.
If in OFF, they then return to park position after 2 to 4
wipes.
COMPONENT LOCATIONS
Refer to Figure 4 for a list of component locations.
Figure2
Make the following checks before beginning System Diagnosis.

1. Check fuse 14. If open, check for short to ground
through CKT 143 and replace fuse.
2. Check that all system connectors are mated firmly.
3. If washer does not operate, check that:
- Washer reservoir is filled.
- Hoses are correctly attached.
- Hoses are not cut, kinked or pinched.
- Nozzles are not clogged.
- Connector seal at washer pump is not damaged
or missing.
4. Check for binding or broken wiper arm linkage.
SYSTEM DIAGNOSIS
Perform the System Check (Figure 5), then refer to
the Symptom Table (Figure 6) for the appropriate
A BLK
Mist Operation
When the wiper switch is moved to MIST and

released, the wipers make one sweep at low speed and
return to park position. If the wiper switch is held in
MIST, the wipers will continue to operate until the
switch is released. The circuit operation is the same as
that of low speed.
SE-3
B YEL
C PPL
D DKGRN
E GRY
Figure 3 - Wiper Motor Wiring Harness Connector
8E-4
COMPONENT
I/P Fuse Block .................
Isolation Diode (Wipers) ........
Washer Pump .................
Wiper Motor Assembly .........
.
.
.
.
Wiper/Washer Switch Assembly .. .

C200B (18 cavities) ............ .
C200D (48 cavities)
C215 (11 cavities) ..............
Gl06 ........................
PlOO .........................
SI 13 .........................
.
.
.
.
LOCATION
LH side of I/P carrier, on the side
Approx. 20 cm (8 in.) from C215
Front of vehicle, below engine hood latch
Rear of LH shock tower, mounted to dash panel below LH
wiper mount
In left side of steering column, actuated by multi-function lever
Part of forward lamp harness, between LH kick panel and steering
column
Part of I/P harness, between LH kick panel and steering
column
Near base of steering column
Near top LH side of radiator, in top of T-bar
Left side in dash panel, engine to passenger compartment
Forward lamp harness, approx. 13 cm (5 in.) from electrical center
breakout
Figure 4 - Component Locations
SYSTEM CHECK
NORMAL OPERATION
ACTION
[1]
Turn ignition switch to RUN.
Press washer switch to ON.
Wipers operate at LO speed. Washer sprays windshield as long as washer switch is held in ON position. After releasing switch, washer stops and wipers
return to park position after 2 to 4 sweeps.
[2]
Turn wiper switch to DELAY (pulse mode).
[3]
Wiper switch in DELAY.
Press washer switch ON.
Wipers make one complete sweep, then pause for 1

to 22 seconds before making next sweep. The pause
time is adjusted by turning the wiper switch through
the delay range.
Washer sprays windshield as long as washer switch

is held ON. Wipers run at low speed while spraying
and continue for 2 to 4 sweeps after washer switch is
released. Wipers then return to pulse operation.
[4]
Turn wiper switch to LO.
Wipers run continuously at low speed.
[5]
Wipers run continuously at faster speed.
Turn wiper switch to HI.

[6]
Turn wiper switch to OFF.
Wipers return to park position at low speed.
[7]
Turn wiper switch to MIST, then release.
Wipers make one complete sweep, then return to park

position.
Figure 5 - Wiper/Washer System Check
SE-5
PROCEDURE
PAGE
Wipers do not operate in any mode.
Chart 1
8E-5
Wipers run when switch is "OFF."
Chart 2
8E-6
SYMPTOM
No low speed mode.
Replace wiper/washer switch

assembly.
No high speed mode.
Chart 3
Wipers operate only when switch is in HI position,

but run at low speed.
Check for open or poor connection in

CKT 143 between wiper/washer
switch CONN C215 TERM "D" and
wiper motor CONN TERM "B". If OK,
replace wiper motor assembly.
8E-7
Low speed, pulse delay and mist modes inoperative

(high speed mode OK).
Chart 4
8E-7
Pulse delay operates incorrectly or not at all.
Chart 5
8E-8
Wipers stop randomly and do not park when switch is

moved to "OFF."
Chart 6
8E-8
Wipers do not operate when washer switch is activated.
Chart 7
8E-9
Washer does not operate.
Chart 8
8E-9
Figure 6- Symptom Table
CHART 1
WIPERS DO NOT OPERATE IN ANY MODE
BACKPROBE WITH A TEST LIGHT FROM WIPER/WASHER SWITCH
CONN C215 TERM "D" TO GROUND.
IS TEST LIGHT "ON"?
WIPER SWITCH TO "HI".

CONNECT TEST LIGHT FROM CONN C215 TERM "G" TO GROUND.
IS TEST LIGHT "ON"?
REPAIR OPEN OR POOR CONNECTION IN CKT 143 TO WIPER/

WASHER SWITCH ASSEMBLY. IF FUSE 14 IS OPEN, CHECK
FOR SHORT TO GROUND IN RELATED CKTS. RELATED CKTS
WILL DEPEND ON WHETHER FUSE BLOWS BEFORE OR
AFTER SYSTEM OPERATION.
DISCONNECT WIPER MOTOR CONNECTOR.

CONNECT TEST LIGHT FROM WIPER MOTOR CONN TERM "C" TO
GROUND.
IS TEST LIGHT "ON"?
CHECK FOR POOR CONNECTION AT CONN C215 TERM "D"

OR OPEN IN PIGTAIL (CKT 143) TO WIPER/WASHER SWITCH
ASSEMBLY.
IF OK, REPLACE WIPER/WASHER SWITCH ASSEMBLY.
8E-6
CONNECT TEST LIGHT FROM WIPER MOTOR CONN TERM "C" TO

TERM "A".
IS TEST LIGHT "ON"?
REPAIR OPEN OR POOR CONNECTION IN CKT 92 BETWEEN

CONN C215 AND WIPER MOTOR ASSEMBLY.
THEN, CONTINUE DIAGNOSIS IN OPPOSITE BOX OF CHART.
CHECK FOR POOR CONNECTION TO WIPER MOTOR ASSEMBLY.

IF OK, RELACE WIPER MOTOR ASSEMBLY.
REPAIR OPEN OR POOR CONNECTION IN GROUND CKT 150.
CHART2
WIPERS RUN WHEN SWITCH IS "OFF"
WIPER SWITCH "OFF."
DISCONNECT WIPER/WASHER SWITCH CONN C215.
I
WIPER MOTOR KEEPS RUNNING
WIPER MOTOR PARKS
I
USING A DVM, MEASURE VOLTAGE FROM CONN C215
(VEHICLE SIDE) TERM "E" TO GROUND.
MORE THAN 1 VOLT
LESS THAN 1 VOLT (APPROX. 0 VOLT)
RECONNECT WIPER/WASHER SWITCH CONN C215.

USING THE DVM, MEASURE VOLTAGE FROM WIPER MOTOR
CONN TERM "D" TO GROUND.

USING THE DVM, MEASURE VOLTAGE FROM WIPER
MOTOR CONN TERM "C" TO GROUND.
MORE THAN 1 VOLT
CHECK FOR SHORTED WIRES IN PIGTAIL TO WIPER/WASHER

SWITCH ASSEMBLY.
IF OK, REPLACE WIPER/WASHER SWITCH ASSEMBLY .
LESS THAN 1 VOLT
REPAIR B+ CONNECTION
TOCKT 113.
REPLACE WIPER MOTOR

COVER ASSEMBLY.
OVOLT
I
REPLACE WIPER MOTOR
COVER ASSEMBLY.
[;]
REPAIR SHORT TO B+ IN
CKT92.
8E-7
CHART3
NO HIGH SPEED MODE
DO WIPERS OPERATE AT ALL WITH WIPER SWITCH IN "HI"?
IGl',IITION SWITCH TO "RUN".

WIPER SWITCH TO "HI".
CONNECT A TEST LIGHT BETWEEN WIPER/WASHER SWITCH
CONN C215 TERM "G" AND GROUND.
IS TEST LIGHT "ON"?
REPLACE WIPER/WASHER SWITCH ASSEMBLY.

CONNECT TEST LIGHT BETWEEN HARNESS TERM "C" AND
GROUND.
IS TEST LIGHT "ON"?
CHECK FOR POOR CONNECTION AT CONN C215 OR FOR OPEN

IN PIGTAIL TO WIPER/WASHER SWITCH ASSEMBLY.
CHECK FOR POOR CONNECTION TO WIPER MOTOR

ASSEMBLY.
IF OK, REPLACE WIPER MOTOR ASSEMBLY.
CHART4
LOW SPEED, PULSE DELAY AND MIST MODES INOPERATIVE
(HIGH SPEED MODE OK)

WIPER SWITCH TO "LO."
USING A DVM, MEASURE VOLTAGE FROM WIPER/WASHER
SWITCH CONN C215 TERM "E" TO GROUND.
MORE THAN 1 VOLT

USING THE DVM, MEASURE VOLTAGE FROM WIPER MOTOR
CONN TERM "D" TO GROUND.
MORE THAN 1 VOLT
I
REPLACE WIPER MOTOR COVER ASSEMBLY.
CHECK FOR POOR CONNECTION AT CONN C215 OR FOR

OPEN IN PIGTAIL TO WIPER/WASHER SWITCH ASSEMBLY.
I
REPAIR OPEN IN CKT 113.1
8E-8

CHART 5
PULSE DELAY OPERATES INCORRECTLY OR NOT AT ALL
IGNITION SWITCH "OFF".

WIPER SWITCH TO "DELAY".
WITH A DIGITAL MULTIMETER SET TO OHMS SCALE, MEASURE
RESISTANCE THROUGH WIPER/WASHER SWITCH ASSEMBLY
FROM CONN C215 TERM "D" TO TERM "F".
MOVE WIPER SWITCH THROUGH ENTIRE DELAY RANGE, ONE
NOTCH AT A TIME.
DOES RESISTANCE VARY FROM APPROXIMATELY 39 kfi TO
680 kn? (SEE FIGURE 2.)

IGNITION SWITCH TO "RUN".
USING A DVM, MEASURE VOLTAGE FROM WIPER
MOTOR CONN TERM "E" TO GROUND.
APPROX. 0 VOLT
CHECK CKT 112 FOR OPEN OR POOR CONNECTION.

IF OK, REPLACE WIPER MOTOR COVER ASSEMBLY.
CHART6
WIPERS STOP RANDOMLY AND DO NOT PARK WHEN SWITCH IS MOVED TO "OFF"
IGNITION SWITCH TO "RUN".
WIPER SWITCH "OFF."
DO WIPERS PARK?
USING A DVM, MEASURE VOLTAGE FROM CONN C215

(VEHICLE SIDE) TERM "E" TO GROUND.

USING THE DVM, MEASURE VOLTAGE FROM CONN TERM "D
TO GROUND.
REPAIR SHORT TO B+ IN CKT 113.
8E-9
CHART7
WIPERS DO NOT OPERATE WHEN WASHER SWITCH IS ACTIVATED

CONNECT A TEST LIGHT BETWEEN WIPER/WASHER SWITCH
CONN C215 TERM "E" AND GROUND.
ACTIVATE WASHER SWITCH AND OBSERVE TEST LIGHT.
IS TEST LIGHT "ON"?
CHECK FOR OPEN IN CKT 113 OR FOR POOR CONNECTION AT

CONN C215 OR AT WIPER MOTOR ASSEMBLY.
IF OK, REPLACE WIPER MOTOR COVER ASSEMBLY.
CHECK FOR OPEN IN WIPER/WASHER SWITCH ASSEMBLY

PIGTAIL AND CONNECTION.
CHARTS
WASHER DOES NOT OPERATE
DISCONNECT WASHER PUMP CONNECTOR.
CONNECT A TEST LIGHT BETWEEN TERMINALS "A" AND "B"
OF PUMP CONNECTOR.
ACTIVATE WASHER SWITCH.
IS TEST LIGHT "ON"?
CONNECT THE TEST LIGHT BETWEEN WASHER PUMP CONN

TERM "A" AND GROUND.
IS TEST LIGHT "ON"?
CHECK FOR POOR CONNECTION TO WASHER PUMP.

IF OK, REPLACE WASHER PUMP.
CONNECT THE TEST LIGHT BETWEEN WIPER/WASHER

SWITCH CONN C215 TERM "H" AND GROUND.
IS TEST LIGHT "ON"?
CHECK FOR POOR CONNECTION AT CONN C215 TERM "H".

CHECK FOR OPEN IN CKT 94, CKT 228 OR ISOLATION DIODE.
SE-10 WINDSHIELD WIPER/WASHER SYSTEM
ON-VEHICLE SERVICE
WASHER PUMP REPLACEMENT
Figure 8
I!

2. Electrical connector (3).
3. Place drain pan under vehicle.
4. Washer pump (4) from reservoir (2) using suitable pliers.
5. Washer hose assembly (5) from pump.
I!
1.
RESERVOIR, WASHER
Important
Make sure washer pump is pushed all the

way into washer reservoir seal.
Electrical connector (3).
Refill washer reservoir.
3.
4.
5.
WASHER RESERVOIR REPLACEMENT

Figures 7 and 8
I!
A
2
3
4
5
Washer fluid.
Two scrivets ( 1, Figure 7) from top of washer
reservoir (2).
3. Drive vehicle onto rack.
5. Raise vehicle on rack.
6. Splash guard and mounting screws.
7. Two scrivets (1) from bottom of washer reservoir.
8. Washer reservoir and pump (4, Figure 8).
9. Electrical connector (3) and washer hose assembly (5).
10. Washer pump from reservoir.
Install or Connect
3.
4.
5.
6.
7.
8.
!!
rn
Tool Required:
J 39637 Wiper Arm Puller
1.
Important
Make sure washer pump is pushed all the

way into washer reservoir seal.
Washer hose assembly (5) and electrical connector (3).
Washer reservoir with 2 scrivets (1, Figure 7) at

bottom of reservoir.
Splash guard with mounting screws.
Lower vehicle on rack.
Negative battery cable, then drive vehicle off rack.
Two scrivets ( 1) at top of washer reservoir.
Washer fluid.
WIPER ARM REPLACEMENT
section.
Washer pump (4, Figure 8) in washer reservoir (2).
GUARD, SPLASH
RESERVOIR, WASHER
PUMP, WASHER
HOSE ASSEMBLY, WASHER
Figure 8 - Washer Reservoir Removal
1.
2.
2.
Figure 7 - Washer Reservoir (Top Front View)
Install or Connect
rn
1.
SCRIVET (4)
Washer hose assembly (5).

Washer pump (4) in washer reservoir (2) using
pliers.
2.
!!
2.
Operate wipers at lowest DELAY setting, then

shut off wipers at inner wipe (end of sweep) position. At tip of blade assembly, mark windshield
to aid at installation. See Figure 11 for wipe pattern and inner wipe positions.
Lift wiper arm nut cover and remove nut (7,
Figure 9).
lL~ !inspect
[I] Important
Run wipers and check for proper wipe pattern (Figure 11).
Shut off wipers and check for correct park
position.
Do not grasp plastic spoiler of wiper arm.

3. Wiper arm (6, Figure 10) from linkage drive shaft
using J 39637.
4. Wiper blade assembly, if required. See "Wiper
Blade Assembly Replacement."
!I
Install or Connect
NOTICE: See "Notice" on page 8E- l of this

section.
1. Wiper blade assembly, if removed. See "Wiper
2. Wiper arm (6) on linkage drive shaft, with tip of
blade assembly aligned with mark made at
removal.
[I] Important
If wipers could not be stopped at inner wipe
position for wiper arm removal, position
blade tip(s) according to dimensions given
in Figure 11.
3. Nut (7, Figure 9) on linkage drive shaft.
rn
Important
It may be necessary to allow for some movement of a wiper arm when its nut is being
tightened. If wiper arm moves away from
desired alignment mark, loosen nut (7) and
reposition wiper arm.
1~1
4.
Tighten
Nut (7) to 32 Nm (24 lb. ft.) while holding

wiper arm.
Close nut cover.
A COVER, NUT
6 ARM, WIPER
7 NUT, 32 Nm (24 LB. FT.)
Figure 9 - Wiper Arm Nut Removal
SE-11
WIPER BLADE ASSEMBLY REPLACEMENT

Figures 12 and 13
lJ
[I] Important
Do not grasp plastic spoiler of wiper arm.
1. If wiper arms have not been removed, lift wiper
arm (6, Figure 12) until it locks into service-up
position.
[I] Important
Use care when removing or installing a blade
assembly (8). Inadvertent bumping can cause
the wiper arm to toggle back and strike the
windshield.
2. Press down on locking tab of blade pivot, then
pull blade assembly downward to disengage it
from hook of wiper arm.
!!
Install or Connect
Position pivot of blade assembly (8, Figure 13)

in hook of wiper arm (6), then pull blade assembly upward until locking tab of blade pivot engages slot in arm hook.
2. Carefully lower wiper arm and blade assembly
onto windshield.
1.
ARM, WIPER
Figure 1O - Wiper Arm Removal
8E-12
A PAINT LINE
8 LH BLADE INNER WIPE POSITION
C 95-125 mm (3-3/4- 5 IN.)
D TOP EDGE OF MOLDING
A
B
C
D
6
8
HOOK.ARM
TAB, LOCKING
PIVOT, BLADE
SPOILER, PLASTIC
ARM, WIPER
BLADE
ASSEMBLY,
WIPER
E BLADE TIP
F RH BLADE INNER WIPE POSITION
G 87-117 mm (3-1/2 - 4-1/2 IN.)
Figure 11 - Wipe Pattern and Inner Wipe Positions
Figure 12 - Wiper Blade Assembly Removal
A
B
C
D
6
8
SLOT, HOOK
TAB, LOCKING
PIVOT, BLADE
SPOILER, PLASTIC
ARM, WIPER
BLADE
ASSEMBLY,
WIPER
Figure 13 - Wiper Blade Assembly Installation

WIPER BLADE ELEMENT REPLACEMENT
Figures 14 and 15
!!
PULL
1. Wiper blade assembly from wiper arm. See

"Wiper Blade Assembly Replacement."
2. Blade element (9, Figure 14) has two notches at
one end which are engaged by the bottom claw
set of blade assembly. At notched end, pull blade
element from blade assembly.
!!
A HEEL END OF BLADE ASSEMBLY

B NOTCH (2)
C CLAW SET
9 ELEMENT, BLADE
Install or Connect
NOTICE: The heel end of the wiper blade assembly is the end nearest to the base of the wiper arm.
Figure 14 - Wiper Blade Element Removal
[I] Important
Replacement blade elements have three plastic caps which retain the two metal flexor
strips. Do not remove these caps before the
element is installed.
1. At heel end of blade assembly, slide blade element (9, Figure 15), notched end last, into blade
claw sets. The plastic retainer caps will be forced
off as element is fully inserted.
2. Be certain that the two element notches are engaged by last claw set and that all other claws are
properly engaged in slots of element on both sides.
3. Wiper blade assembly on wiper arm. See "Wiper
A
9
CAP, RETAINING (3)

ELEMENT, BLADE
WINDSHIELD WASHER
Figures 11 and 16
A correctly operating windshield wiper/washer

system has a spray pattern that cleans 75% of the wipe
pattern (Figure 11) within ten wiper cycles.
If a washer nozzle (10, Figure 16) becomes
plugged, apply air pressure. If a nozzle remains plugged,
the nozzle must be replaced.
B
WIPER MOTOR ASSEMBLY

REPLACEMENT
CLAW ENGAGED IN NOTCH

WRONG
RIGHT
Figu,es 16 through 19
!!
Tool Required:
J 39232 Wiper Linkage Separator
Wiper arm and blade assemblies. See "Wiper Arm
Replacement."
3. LH cowl panel and hood seal.
4. Washer hose assembly (11, Figure 16) from LH
cowl panel.
1.
C SLOT
D CLAW IN ELEMENT SLOT
E CLAW AGAINST METAL FLEXOR
Figure 15 - Wiper Blade Element Installation
SE-13
SE-14
5.
6.
7.
8.
9.
10.
11.
!!
Electrical connector from wiper motor assembly

(17, Figure 17).
Screw (14) and nut (20).
Socket of RH linkage assembly (13) from ball of
LH linkage assembly (15) using J 39232 (see Figure 18).
LH linkage assembly.
Screw (19, Figure 17).
Pull wiper motor assembly free from slots of
bracket (16).
Socket of RH linkage assembly from crank arm
ball of wiper motor assembly using J 39232 (see
Figure 18).
Install or Connect
Tool Required:
J 39529 Wiper Linkage Installer
A
B
C
10
11
section.
[ [ ) Important
1.
2.
3.
When installing wiper motor assembly, make

certain that the crank arm is in inner wipe
position as shown in Figure 17. The crank
arm drive pin must be engaged in the cam
pocket.
Press socket of RH linkage assembly (13) into
engagement with crank arm ball of wiper motor
assembly (17) using J 39529 (see Figure 19).
Wiper motor assembly ( 17, Figure 17) with two
locator pads ( 18) pressed fully into slots of bracket
(16).
Screw (19).
,~, Tighten
4.
5.
6.
Screw (19) to 10 Nm (7.5 lb. ft.).

LH linkage assembly (15) without attaching parts.
Press socket of RH linkage assembly into engagement with ball of LH linkage assembly using
J 39529 (see Figure 19).
Attach LH linkage assembly with screw (14,
Figure 17) and nut (20).
,~, Tighten
Screw (14) and nut (20) to 10 Nm (7.5 lb.

ft.).
7. Electrical connector to wiper motor assembly.
8. Washer hose assembly (11, Figure 16) to LH cowl
panel and washer nozzle (10).
11. Wiper arm and blade assemblies. See "Wiper Arm
Replacement."
SCRIVET (8)
PANEL, RH COWL
PANEL, LH COWL
NOZZLE, WASHER (2)
HOSE ASSESMBLY, WASHER
Figure 16 - Cowl Panels and Washer Components
WIPER LINKAGE ASSEMBL V

REPLACEMENT
!!
Tool Required:
J 39232 Wiper Linkage Separator
Wiper arm and blade assemblies. See "Wiper Arm
Replacement."
3. Washer hose assembly (11, Figure 16) from LH
cowl panel.
4. Screw (14, Figure 17) and nut (20).
5. Socket of RH linkage assembly (13) from ball of
LH linkage assembly (15) using J 39232 (see Figure 18).
6. LH linkage assembly.
7. Three screws (12, Figure 17).
8. Socket of RH linkage assembly from crank arm
ball of wiper motor assembly (17) using J 39232
(see Figure 18).
9. RH linkage assembly from slotted plenum access
hole.
1.
!!
Install or Connect
Tool Required:
J 39529 Wiper Linkage Installer
NOTICE: See "Notice" on page 8E-l of this

section.
OFF-VEHICLE SERVICE
1. RH linkage assembly (13, Figure 17) through
2.
3.
4.
5.
6.
7.
slotted plenum access hole.

Three screws (12) finger tight.
Align RH linkage assembly.
Press socket of RH linkage assembly into engagement with crank arm ball of wiper motor
assembly (17) using J 39529 (see Figure 19).
LH linkage assembly (15, Figure 17) without attaching parts.
Press socket of RH linkage assembly into engagement with ball of LH linkage assembly using J 39529 (see Figure 19).
Screw (14, Figure 17) and nut (20).
1~1
Tighten
Screw (14), nut (20) and three screws (12)

to 10 Nm (7.5 lb. ft.).
WIPER MOTOR COVER ASSEMBLY

REPLACEMENT
Figures 20 and 21
!!
1. Three screws (21, Figure 20) using Torx screwdriver.

2. Cover assembly (22).
!!
Install or Connect

section.
1.
8. Washer hose assembly to LH cowl panel and

washer nozzle (10).
10. Wiper arm and blade assemblies. See "Wiper Arm
Replacement."
2.
Cover assembly (22, Figure 20).
rn
Important
Before installing the cover assembly, make

certain that the inner wipe cam is positioned
as shown in Figure 21.
Three screws (21, Figure 20).
14
16
)
18
19
A CRANK ARM DRIVE PIN IN CAM POCKET
12 SCREW (3), 10 Nm (7.5 LB. FT.)

13 LINKAGE ASSEMBLY, RH
14 SCREW, 10 Nm (7.5 LB. FT.)

15 LINKAGE ASSEMBLY, LH
SE-15
16
17
18
19
20
BRACKET, WIPER MOTOR

MOTOR ASSEMBLY, WIPER
PAD, LOCATOR (2)
SCREW, 10 Nm (7.5 LB. FT.)
NUT, 10 Nm (7.5 LB. FT.)
Figure 17 - Linkage and Wiper Motor Assemblies
8E-16
Figure 18 - J 39232 Wiper Linkage Separator (Typical Usage)
Figure 19 - J 39529 Wiper Linkage Installer (Typical Usage)
,~, Tighten
Screws (21) to 2 Nm (18 lb. in.).

21
WIPER CHATTER REPAIR

22
Some vehicles may exhibit a condition where the

windshield wipers chatter and/or wipe unevenly. Several items may contribute to this condition. To completely repair this condition ALL items listed should
be checked and repaired as necessary.
WINDSHIELD GLASS CLEANING

Clean windshield with windshield cleaner, GM
PN 1050011 or equivalent. The cleaner used should be
one which will not harm paint finish or scratch glass.
The glass is clean when water no longer "beads", but
"sheets" across entire glass surface.
BLADE ELEMENT CLEANING

Lift each blade assembly off windshield and clean
element with a cloth saturated in full strength washer
solution. Rinse blade assemblies with water.
CAUTION: Avoid prolonged skin contact with washer
solution.
WIPER ARM TIP PRESSURE CHECK

1. Run wipers at lowest DELAY setting, then shut
wipers off at inner wiper (end of sweep) position.
21
22
23
SCREW (3), 2 Nm (18 LB. IN.)

COVER ASSEMBLY
MOTOR, WIPER
Figure 20 - Wiper Motor Cover Assembly Replacement

2. Remove blade assemblies from wiper arms, providing protection for windshield surface.
3. Attach a scale to wiper arm hook and measure
the force required to lift wiper arm perpendicular
to windshield to normal working height (height
with blade assembly attached).
4. If the force required is not within the specifications given below, the wiper arm should be
replaced.
Tip Pressure - RH Wiper Arm - 9-11 N
(32.5-39.5 oz.)
LH Wiper Arm-10-12 N
(36.0-43.0 oz.)
A CAM, INNER WIPE
-0-
BLADE ELEMENT SET CHECK

Figure22
Remove wiper blade assemblies from wiper arms.

Look down the length of the blade element. The rubber element which contacts the glass must be on the
center line of the blade assembly :::: 15 degrees. Replace the element if necessary.
A
Figure 21 - Inner Wipe Cam Position for
Cover Assembly Installation
A BLADE ELEMENT SHOULD NOT BE BENT

MORE THAN 15 IN EITHER DIRECTION
FROM CENTER LINE
9 ELEMENT, BLADE
Figure 22 - Blade Element Set Check
SE-17
SE-18
SPECIFICATIONS
Linkage Assembly Nut (20) ................................... . 10 Nm (7.5 lb. ft.)
Linkage Assembly Screws (12 and 14) ........................... . 10 Nm (7.5 lb. ft.)
Wiper Arm Nuts (7) ........................................... . 32 Nm (24 lb. ft.)
Wiper Motor Assembly Screw (19) ............................. . 10 Nm (7.5 lb. ft.)
Wiper Motor Cover Assembly Screws (21) ....................... . 2 Nm (18 lb. in.)
SPECIAL TOOLS
1.
2.
3.
J 39637
J 39232
J 39529
1.
2.
3.
WIPER ARM PULLER

WIPER LINKAGE SEPARATOR
WIPER LINKAGE INSTALLER
ACCESSORIES 91
SECTION 9
ACCESSORIES
CONTENTS
Audio Systems ........................................................... Section 9A
Cruise Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section 9B
Theft Deterrent Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section 9D
Engine Coolant Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section 9E
Supplemental Inflatable Restraint (SIR) System Introduction ........................ Section 9J
Supplemental Inflatable Restraint (SIR) System Diagnosis ........................ Section 9J-A
Supplemental Inflatable Restraint (SIR) System Removal
and Installation Procedures ............................................... Section 9J-B
Remote Keyless Entry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section 9K
AUDIO SYSTEMS 9A-1
SECTION 9A
AUDIO SYSTEMS
injury or otherwise unneeded SIR system repairs.
result.
CONTENTS
Speaker Systems ........................
Base Audio System ....................
Optional Audio System .................
Radio Fixed Antenna Assembly ............
Radio Assemblies ........................
FM Stereo ...........................
AMAX Stereo Certification ..............
Radio Assembly Controls .................
ETR AM/FM Stereo/Cassette (UM6) ........
Radio Assembly Operation ..............
Cassette Tape Player ...................
ETR AM/FM Stereo/Cassette/
Equalizer (UXl) .......................
Cassette Tape Player ...................
ETR AM/FM Stereo/Compact Disc
Player/Equalizer (UlA) .................
9A-l
9A-1
9A-1
9A-1
9A-1
9A-1
9A-2
9A-2
9A-2
9A-2
9A-2
9A-3
9A-3
9A-3
9A-4
9A-5
9A-5
GENERAL DESCRIPTION
All radio assemblies have electronic memory for
preselected station function.
SPEAKER SYSTEMS
Base Audio System
There are two front speaker assemblies, one in each
front side door, and two rear speaker assemblies mounted
in the rear sail panel. These speaker locations allow for a
full, high fidelity sound.
Standard radio front side door speaker assemblies
are 6 inches round and 4 ohms. Radio rear speaker assemblies are 6 inches round and 10 ohms.
High performance extended range speaker assemblies are standard with full ETR system.
Compact Disc Player . . . . . . . . . . . . . . . . . . . 9A-5

Setting Delco-Loe II Anti-Theft Feature . . . . . . 9A-6
Unlocking Secured Radio Assembly after
Power Loss ........................... 9A-6
Determining Factory Backup Unlocking Code
for Secured Radio Assembly ............. 9A-6
Diagnosis ................................ 9A-6
Audio System Diagnosis . . . . . . Refer to Section 8A
Radio Fixed Antenna Assembly Diagnosis .... 9A-6
On-Vehicle Service ........................ 9A-7
Tape Player and Cassette Care . . . . . . . . . . . . . . 9A-7
Compact Disc Care . . . . . . . . . . . . . . . . . . . . . . 9A-7
Radio Assembly ............. Refer to Section 8C
Speaker Assemblies . . . . . . . . . . . . . . . . . . . . . . 9A-7
Radio Suppression Equipment .............. 9A-7
Radio Fixed Antenna Assembly ............ 9A-7
Specifications ............................. 9A-8
Fastener Tightening Specifications .......... 9A-8
Special Tools ............................. 9A-8
Optional Audio System

The premium speaker system is available on the
UXl and UlA radio assemblies. It consists of four front
speaker assemblies, two in each front side door, and six
rear speaker assemblies, two mounted in the rear sail
panel, and four mounted in the rear compartment trim
panel assembly. The amplifier is located under the right
rear armrest assembly.
RADIO FIXED ANTENNA ASSEMBLY

The fixed antenna assembly is designed to provide
good radio omni-directional reception in moderate fringe
areas.
RADIO ASSEMBLIES
Figures 1 through 3
All 2000 series radio assemblies feature ETR (electronically tuned receiver) tuning, vacuum fluorescent display, AM-FM stereo, seek and scan tuning, and digital
clock display. Three radio assemblies are available.
9A2 AUDIO SYSTEMS

AM/FM Stereo Cassette (UM6) .
AM/FM Stereo/Cassette/Equalizer (UXl) with
Steering Wheel Radio Controls.
AM/FM Stereo/Compact Disc/Equalizer (UlA)
with Steering Wheel Radio Controls.
All radio assemblies use four speaker assemblies:
two speaker assemblies mounted in the front side doors
and two in the rear sail panel.
The optional audio system uses ten speakers and an
amplifier: four speaker assemblies mounted in the front
side doors, two speaker assemblies in the rear sail panel
and four speaker assemblies in the rear compartment trim
panel assembly. The amplifier is under the right rear armrest assembly.
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NC20001-9A-F-RP
Figure 1 - UM6 Radio
FM Stereo
All factory-equipped sound systems with an FM
stereo radio assembly will switch to stereo operation
whenever an FM stereo broadcast is being received, and
an indicator in the dial will light. Stereo operation means
the radio is separating a stereo broadcast back into the
original two channels, called "left" and "right." Stereo
sound is noticeably more realistic to the ear.
Although FM is normally static-free, reception can
be limited by terrain, atmospheric conditions, station
strength and distance from the transmitter. Buildings or
other obstructions can cause momentary static, flutter or
station swapping. If reception is poor, tuning to a stronger
station will bring improvement.
AMAX Stereo Certification

All optional radio assemblies are AMAX certified .
These receivers can reproduce the fidelity sound now
transmitted by all AM stations but not received on all AM
radio assemblies.
Some improvements are high fidelity, adjustable
receiver band width (wide for high fidelity or narrow to
cut out any interference), noise cancellation, full stereo
sound, new frequencies received and external antenna
assembly capability.
The range of most AM stations is greater than FM,
especially at night. The longer range, however, can cause
stations to interfere with each other. AM is also subject to
noise pick-up from storms, power lines, etc. AMAX
certification reduces many of these problems.
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Figure 3 - U1 A Radio
ETR AM/FM STEREO/CASSETTE (UM6)

RADIO ASSEMBLY CONTROLS
When the radio assembly is first turned on, the frequency will appear on the display for five seconds, and
then the display will return to the time display. To recall
the frequency, simply push in the upper knob or the
"RCL" button while the radio assembly is turned on. The
frequency will appear on the display for five seconds.
When the ignition lock cylinder is in the "LOCK" or
"OFF" position, the radio display is blank. To display the
time when the ignition lock cylinder is in the "OFF" or
"LOCK" position, simply push the upper knob or the
"RCL" button. The time will display for five seconds.
Then the display will turn blank.
Figure 1
Radio Assembly Operation

Upper Knob
This knob turns the radio assembly on and off.
Rotate knob to control volume. The control ring behind
the knob is the balance control.
Tum the ring clockwise to move speaker balance to
the right and counterclockwise to move speaker balance
to the left. Press the knob to select the other side of the
tape when playing a cassette.
AUDIO SYSTEMS 9A-3
Lower Knob
Turn the knob to manually select radio stations.
When the radio assembly is on and the tape player is off,
press the knob to choose either the AM or the FM band.
The control ring behind the lower knob fades the
sound between the front and rear speaker assemblies.
Bass and Treble Controls

Slide the "TREBLE" lever up to increase treble and
down to decrease treble. Slide the "BASS" lever up to
increase bass and down to decrease bass.
If a station is weak and noisy, move the "TREBLE"
lever down to reduce the noise.
Push Buttons
To preset four AM stations and four FM stations:
1. Tune in desired station.
2. Press "SET." Within five seconds, press a station
button.
To preset three additional AM stations and three
additional FM stations:
2. Press "SET." Within five seconds, press any two
adjacent buttons simultaneously.
The radio will tune to the preselected station when
the push button or button pair is pressed.
Button pairing allows for seven AM and seven FM
stations to be preset for a total of fourteen preset stations.
If electrical power is interrupted by a blown fuse or a
discharged battery, the stations must be reset.
Clock
To set the clock display on a 2000 series radio
assembly, the ignition lock cylinder must be in the
"ACCESSORY" or "RUN" position and the radio
assembly must be off. To set the clock:
1. Push "SET."
2. Within five seconds, push and hold "SEEK T "

until the correct hour appears.
3. Then press and hold "SEEK" until the correct
minute appears.
"SCAN" is a two-button sequence. To "SCAN" to

the next higher station, press "SEEK" and hold it there
while you press "SEEK T-" To "SCAN" to the next
lower station, press "SEEK T " and hold it there while
you press "SEEK . " The radio will move to the next
strong station. It will pause there a few seconds, then
move to the next strong station. When the radio reaches
the end of the band, it will return to the other end of the
band and continue to "SCAN." This will continue until
the "SCAN" mode is terminated. To terminate the
"SCAN" mode, press both buttons again or press the
upper knob.
Cassette Tape Player

To play a tape, the ignition lock cylinder must be
in the "ACCESSORY" or "RUN" position and the
receiver/tape player must be turned on. Insert the cassette
squarely through the door, exposed tape side of the cassette first. When the tape is fully inserted, the radio will
turn off and the tape will begin playing.
To advance the tape, press the "..,_,, (forward)
button. To reverse the tape, press the " ..... " (reverse)
button. To resume tape play from fast forward or reverse,
press the "STOP-EJECT" button lightly. When the tape
reaches the end of a side, it will automatically reverse and
play the other side of the tape. To :i;esume listening to the
radio or to eject the tape, push the "STOP-EJECT"
button.
The cassette player is turned off by ejecting the tape,
turning the power knob (upper knob) or rotating the ignition lock cylinder to "LOCK," "OFF" or "START."
When this occurs, the tape player will either eject the
cassette automatically or the internal tape drive and roller
will retract automatically. This is to protect the tape player
and cassette tape.
For the best operation of the cassette player do
not use cassette tapes longer than 30 minutes per side
(60 minutes total, both sides).
Tape Direction Indicators

The direction the tape is being played is indicated by
indicator arrows. When the indicator arrow on the left side
is on, the tape direction is to the left. When the indicator
arrow on the right side is on, the tape direction is to the
right.
ETR AM/FM
STEREO/CASSETTE/EQUALIZER (UX1)
Figure2

"PWR" (Power)
Push this button to turn the radio assembly on or off.
Seek and Scan Feature

The 2000 series radio assemblies have "SEEK" and
"SCAN" features for electronic station tuning up and
down the band.
Push the "SEEK or T " and the radio will tune to
next higher or lower station with enough signal strength to
be heard clearly, and stay there.
Upper Knob
Rotate knob to control volume. Press the knob to
silence the sound. The control ring behind the knob is the
balance control.
Turn the ring clockwise to move speaker balance to
the right and counterclockwise to move speaker balance
to the left. Press the knob to select the other side of the
tape when playing a cassette.
9A-4 AUDIO SYSTEMS

Lower Knob
Turn: the knob to manually select radio stations.
When the radio assembly is on and the tape player is off,
press the knob to choose either the AM or FM (FMl or
FM2) band.
The control ring behind the lower knob fades the
sound between the front and rear speaker assemblies.
Graphic Equalizer
The five-band graphic equalizer allows adjustment
of bass, midrange and treble. Move control up to increase
frequency range or down to decrease frequency range.
Note that 60 and 250 denote bass; lK denotes midrange;
3.5K and lOK denote treble.
Generally, the lK control is placed in the center (detent) position, while the bass and treble controls are
adjusted upwards to varying degrees. Since the lOK control has the most influence on treble, it may produce high
frequency hiss when fully up. If this occurs, move it down
until the hiss disappears.
Push Buttons
To preset five AM stations, five FMl stations and
five FM2 stations:
2. Press "SET." Within five seconds, press a station
button.
The radio will tune to the pre-selected station when
the push button is pressed.
If electrical power is interrupted by a blown fuse or a
discharged battery, all preset stations must be reset.
Clock
To set the clock display, the ignition lock cylinder
must be in the "ACCESSORY" or "RUN" position and
the radio assembly must be off. To set the clock:
1. Push "SET."
2. Within five seconds, push and hold "SEEK .....i"
3. Then press and hold "SEEK..,..,, until the correct
minute appears.
Seek Feature
Push the "SEEK .....i or ..... " and the radio will tune to
next higher or lower station with enough signal strength to
be heard, and stay there.
"RCL" (Recall)
Press this to switch between time and radio frequency on the display while the radio is on.
Steering Wheel Controls
The buttons on the steering wheel can also control
some functions of the audio system:
Turn audio system on or off.
Adjust volume.
Choose AM, FMI or FM2.

Use "SEEK" and "RECALL."
Choose preset stations on push buttons.
Cassette Tape Player

To play a tape, the ignition lock cylinder must be in
the "ACCESSORY" or "RUN" position and the receiver/tape player must be turned on. Insert the cassette
squarely through the door, exposed tape side of the cassette first. When the tape is fully inserted, the radio will
turn off and the tape will begin playing.
Forward Button
Press "FWD" to advance tape. To stop forward
motion, press "PROG" lightly.
Reverse Button
Press "REV" to reverse direction. To stop reverse

motion, press "PROG" lightly.
Tape Eject Button
Press "EJECT" to eject tape.
For best results, 120 minute tapes are not recommended.
Reversing Sides
Press the upper left knob (volume knob) to play the
other side of the tape. When the end of tape is reached, it
automatically reverses direction and plays the other side.
Tape Indicator Lamps
When the left arrow indicator lamp is lit, the top side
of the tape is playing. When the right arrow indicator lamp
is lit, the bottom side of the tape is playing.
"NEXT"
Press "NEXT" when you want to hear the next

selection now (before the present selection is finished).
For "NEXT" to work properly, there must be at
least three blank seconds between selections.
"PREV" (Previous)
Press "PREY" to play a selection again.
"PROG" (Program)
Press "PROG" to switch from one side of the tape to

the other.
"ST-PL" (Stop/Play)
Press "ST/PL" to stop tape from playing. The radio

will resume playing. "ST/PL" will also restart the tape at
the point where it stopped.
Tape Equalization Button
Select the 70 sec (chrome or metal) tape by
pressing "Cr02" button in, or 120 sec (standard) by
leaving "Cr02" button out.
AUDIO SYSTEMS 9A-5
ETA AM/FM STEREO/COMPACT DISC

PLAYER/EQUALIZER (U1 A)
Figure 3

"PWR" (Power)
Push this button to tum radio assembly on or off.
Steering Wheel Controls

The buttons on the steering wheel can also control
some functions of the audio system:
Turn audio system on or off.
Adjust volume.
Choose AM, FMl or FM2.
Use "SEEK" and "RECALL."
Choose preset stations on push buttons.
Upper Knob
Compact Disc Player
Rotate knob to control volume. Press knob to silence

the sound. The control ring behind the knob is the balance
control. Tum the ring clockwise to move speaker balance
to the right and counterclockwise to move speaker balance to the left.
With the radio assembly on, insert disc into slot,

label side up (player pulls it in). "CD" will appear on the
display and track 1 will begin to play. If disc comes back
out and "ERR" appears on display, check to see if:
Disc is upside down. .
Disc is dirty, scratched or wet.
Too much moisture is in the air.
Temperature is too hot or too cold.
Lower Knob
Rotate knob to tune radio stations manually. Press
knob to alternately select AM or FM (FMl or FM2) band.
Rotate control behind lower knob to adjust the sound
between front and rear speaker assemblies.
Graphic Equalizer
The five-band graphic equalizer allows adjustment
of bass, midrange and treble: Move control up to increase
frequency range or down to decrease frequency range.
Note that 60 and 250 denote bass; lK denotes midrange;
3.5K and lOK denote treble.
Generally, the lK control is placed in the center
(detent) position, while the bass and treble controls are
adjusted upwards to varying degrees. Since the lOK control has the most influence on treble, it may produce high
frequency hiss when fully up. If this occurs, move it down
until the hiss disappears.
Push Buttons
To preset five AM stations, five FMl stations and
five FM2 stations, use the following procedure:
2. Push "SET." Within five seconds, push one of the
five push buttons.
3. Repeat these steps for each push button.
Clock
To set the clock display, the ignition lock cylinder
must be in the "ACCESSORY" or "RUN" position and
the radio assembly must be off. To set the clock:
1. Push "SET."
2. Within five seconds, push and hold "SEEK ..... "
3. Then push and hold "SEEK ~,, until the correct
minute appears.
"RCL" (Recall)
Press "RCL" to see current track number. Press
"RCL" again within five seconds to see time elapsed in
current track on the display.
"PREV" (Previous)
Press "PREY" to play track again. If held or pressed
more than once, the disc will return to previous track. If
"PREY" is pressed within eight seconds from start of
track, the disc will go to the beginning of the previous
track and begin to play. If "PREY" button is pressed after
eight seconds into the track, the disc will go to the beginning of the current track and begin to play.
"NEXT"
Press "NEXT" when you want to hear the next track
now (before the present track is finished). If "NEXT" is
held or pressed more than once, the disc will advance
farther.
"FWD" (Forward)
Press and hold "FWD" to quickly advance within a
track. Release it to resume playing.
"REV" (Reverse)
Push "REV" and hold it to return quickly to a
favorite passage on the disc. Release it to resume playing.
"ROM" (Random)
Press this button and the player chooses a random
order of tracks to play. When the final random track has
been played, the disc will play the same random selection
again. Press "RDM" again for a different selection of
tracks.
Seek Feature
Press "SEEK ~ or ..... " and the radio will tune to
the next higher or lower station with enough signal
strength to be heard clearly, and stay there.
"COMP" (Compression)
Push "COMP" to make loud and soft passages more
nearly equal in volume.
9A-6 AUDIO SYSTEMS

"ST-PL" (Stop/Play)
Press "ST-PL" to stop disc from playing. The radio
will resume playing. "ST-PL" will also restart the disc.
The disc will resume playing at the point where it stopped.
"EJCT" (Eject)
Push this to eject the disc and resume radio play.
SETTING DELCO-LOC II ANTI-THEFT

FEATURE
Delco-Loe II is a security feature which can be used
or ignored. If ignored, the radio assembly will play normally. If used, the radio assembly will be useless if stolen
because it won't tum on.
This is how to enter a secret code into the radio
assembly. If battery power is lost for any reason, the secret
code must be entered again before the radio assembly will
tum on.
1. Write down any 6-digit number and keep in safe
place.
2. Tum ignition to "ACCESSORY" or "RUN" position.
3. Press "PWR" to turn radio assembly off.
4. Press "PREY" and "FWD" together and hold until
" --- " shows on display.
5. Do not wait more than 15 seconds between each
step.
6. Press "SET" and "000" appears on the display.
7. Press "SEEK -<11111 or..,..,, and hold until first digit of
code appears.
8. Tum the lower knob to make second and third digits
appear.
9. Press the lower knob ("000" appears).
10. Press "SEEK -<11111 or ..,..,, and hold until fourth digit of
code appears.
11. Tum the lower knob to make last two digits of code
appear.
12. Press the lower knob ("rEP" appears for 5 seconds,
then "000" appears).
13. Repeat steps 6 through 11. "SEC" will then be seen
on display, meaning radio assembly is secured.
UNLOCKING SECURED RADIO ASSEMBLY

AFTER POWER LOSS
When battery power is reapplied to a secured radio
assembly, the radio assembly won't tum on and "LOC"
appears on the display. Enter the secret customer or factory backup code as follows: (Do not pause more than
15 seconds between steps.)
1. Tum ignition to "ACCESSORY" or "RUN" position.
2. Press "SET" and "000" appears on display.
3. Press "SEEK -<11111 or ..,..,, and hold until first digit of
secret code appears.
4. Turn the lower knob to make second and third digits
of code appear.
5. Press the lower knob and "000" appears on display.
6. Press "SEEK -<11111 or..,..,, and hold until fourth digit of

secret code appears.
7. Turn the lower knob to make fifth and sixth digits of
code appear.
8. Press the lower knob ("SEC" appears and radio assembly can be turned on). Radio assembly stays in
secured mode. To remove customer code and deactivate the security feature, factory unlocking code
must be entered again, repeating steps 2 through 8.
DETERMINING FACTORY BACKUP

UNLOCKING CODE FOR SECURED RADIO
ASSEMBLY
If the security is activated and the radio assembly is
disconnected from battery power, the radio assembly will
display "LOC." The radio assembly will not tum on until
the correct unlocking code is entered. If the customer code
is lost or unavailable, use the following procedures to
determine the factory backup code. This procedure
requires a tone dialing telephone.
1. Turn ignition to "ACCESSORY" or "RUN" position.
2. Press and hold "COMP" and "RDM" (push buttons 2 and 3). After three seconds, digits 1 through 3
of radio identification number will be displayed.
Write them down.
3. Press lower knob. Digits 4 through 6 of radio identification number will be displayed. Write them down.
4. Using tone dialing telephone, call 1-800-537-5140
(U.S. and Canada) or (317) 451-8965.
5. When computer advises, enter dealer code or radio
shop account number using telephone keypad, then
press "*".
6. When advised, enter six-digit radio identification
number obtained in steps 2 and 3, then press "*".
Computer will respond with unlocking code. Write
it down.
7. To unlock secured radio, refer to "Unlocking
Secured Radio Assembly after Power Loss" in this
section.
DIAGNOSIS
AUDIO SYSTEM DIAGNOSIS
For information on audio system diagnosis, refer to
SECTION 8A.

DIAGNOSIS
Unplug antenna lead-in at back of radio assembly
and plug a test antenna into the radio assembly. Make sure
test antenna base is grounded to the vehicle chassis and
keep hands off of antenna. Check radio reception in an
area away from electrical interferences. These include tall
buildings, metal structures, power lines, fluorescent lighting and power tools. Tune to high and low ends of the dial
on both AM and FM, checking weak and strong station
reception. If reception is OK, problem exists with antenna
assembly and/or its lead-in cable. If reception is still poor,
refer to SECTION 8A.
AUDIO SYSTEMS 9A-7
ON-VEHICLE SERVICE
RADIO ASSEMBLY
Refer to SECTION 8C for removal and installation
procedures.
TAPE PLAYER AND CASSETTE CARE

SPEAKER ASSEMBLIES
Tape Head and Capstan Cleaning

Figure 4
Two parts should be cleaned on the tape player, the
head and the capstan. Since they can be reached through
the tape door, leave the tape player in the vehicle. This
service should be performed every 100 hours of cassette
operation.
To clean the head and capstan, use a cotton swab
dipped in rubbing alcohol.
A cassette cleaning kit may also be used to clean the
head and capstan. Follow instructions on the kit to clean
the tape player.
Do not contact the tape head with magnetized tools.
If the head becomes magnetized, it will degrade every
cassette played in the player.
No service is performed on the cassettes. The cassette manufacturer handles warranties of cassettes. The
test cassette used by the dealer should be stored in its
container to keep the tape clean. Store cassette away from
extreme heat and direct sunlight.
For removal and installation of radio front side

door speakers, refer to SECTION 10-6. For removal and
installation of rear speaker assemblies, refer to SECTION
10-7.
[I] Important
All Delco sound systems have ungrounded speakers. Installing add-on tape players, CBs or other units
which use the vehicle speakers may damage your
Delco sound system, and is not recommended.
RADIO SUPPRESSION EQUIPMENT

Figures
When installing a new radio assembly, or when
noise is a problem, ensure that radio suppression equipment is present and properly installed. Refer to "Noise
Diagnostic Charts" in SECTION 8A for determining
locations.

Figure 5
COMPACT DISC CARE

Handle discs carefully. Store in protective case away
from sun, heat and dust. If surface is soiled, dampen a
clean, soft cloth in a solution of mild neutral detergent and
wipe clean. Mini discs called "singles" (about 3 inches in
diameter) will not eject and should not be used.
Tool Required:
J 38536-A Antenna Bezel Socket

1. Using J 38536-A loosen nut (2).
2. Antenna base from spare tire bracket.
3. Nut (2) and bezel (1).
4. Top of antenna base (3) from rear quarter panel.
5. Cable (4) from antenna base (3).

section.
1. Cable (4) into antenna base (3).
2. Top of antenna base (3) into hole in rear quarter
panel.
3. Bezel (1) to antenna base (3) and secure with nut (2)
(finger tighten only).
4. Bottom of antenna base (3) into spare tire bracket.
G20003-9A
Figure 4 - Cleaning Cassette Player
l~I Tighten
Nut (2) to 4 Nm (35 lb. in.) using J 38536-A.
9A8 AUDIO SYSTEMS
A
B
1
2
3
4
PANEL, REAR QUARTER

BRACKET, SPARE TIRE
BEZEL, FIXED MAST ANTENNA
NUT, FIXED MAST ANTENNA
BASE, ANTENNA
CABLE, INSTRUMENT PANEL HARNESS
PC0001-9A-F-RP
Figure 5 - Antenna Mounting
SPECIFICATIONS
Radio Antenna Nut ................................................... 4 Nm (35 lb. in.)
SPECIAL TOOLS
1.
J 38536-A
1. ANTENNA BEZEL SOCKET
PC0002-9A-FRP
CRUISE CONTROL 98-1
SECTION 98
CRUISE CONTROL
result.
CONTENTS
General Description . . . . . . . . . . . . . . . . . . . . . . . . 9B-1
Cruise Control Module Assembly . . . . . . . . . . . 9B-1
Cruise Control Switch Assemblies . . . . . . . . . . 9B-1
Speed Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . 9B-1
Vehicle Speed Sensor (VSS) Assembly . . . . . 9B-1
Functional Control Switches . . . . . . . . . . . . . . . 9B-2
Off-On-Resume/Accelerate Switch ........ 9B-2
Set/Coast Button Switch . . . . . . . . . . . . . . . . 9B-2
Diagnosis ................................ 9B-4
On-Vehicle Service . . . . . . . . . . . . . . . . . . . . . . . 9B-13
GENERAL DESCRIPTION
Cruise control is a speed control system that maintains a desired vehicle speed under normal driving conditions. However, steep grades up or down may cause
variations in the selected speeds. The electronic cruise
control system has the capability to cruise, coast, resume
speed, accelerate, and "tap-up" and "tap-down."
The main parts of the cruise control system are the
functional control switches, cruise control module assembly, vehicle speed sensor assembly and cruise control
release switch, stoplamp and torque converter clutch
(TCC) switch, and clutch (5.7L LTl engine) or clutch
anticipate (3.4L L32 engine) switch assemblies.
The cruise control system uses a cruise control module assembly to obtain the desired vehicle cruise operation. Two important components in the module assembly
help to do this. One is an electronic controller and the
second is an electric stepper motor. The controller monitors vehicle speed and operates the electric stepper motor.
The motor moves a ribbon and throttle linkage, in
response to the controller, to maintain the desired cruise
speed. The cruise control module assembly contains a low
speed limit which will prevent system engagement below
a minimum speed of 40 km/h (25 mph). The operation of
the controller is controlled by functional control switches
located on the turn signal and headlamp dimmer switch
and cruise control actuator and windshield wiper and
windshield washer lever assembly.
Cruise control release switch, stoplamp and TCC
switch, and clutch or clutch anticipate switch assemblies
are provided to disengage the cruise system. The switch
assemblies are mounted on the brake and accelerator and
clutch pedal bracket. When the brake pedal or clutch
pedal is depressed, the cruise control system is electrically
disengaged and the throttle is returned to the idle position.
CRUISE CONTROL MODULE ASSEMBLY

The cruise control module assembly is mounted on
the left engine compartment inner side rail assembly. The
Cruise Control Switch Assemblies .........

Engagement Switch .....................
Cruise Control Module Assembly ..........
Cruise Control Cable Assembly ...........
Cable Assembly Replacement ...........
Cable Assembly Adjustment . . . . . . . . . . . .
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fastener Tightening Specification . . . . . . . . . .
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9B-13
9B-14
9B-14
9B-16
9B-16
9B-17
9B-17
9B-17
9B-17
module assembly has an electronic controller and an

electric stepper motor to vary the throttle with each different cruise control mode. The module assembly is not
serviceable.
CRUISE CONTROL SWITCH ASSEMBLIES

The cruise control release switch, stoplamp and
TCC switch, and clutch or clutch anticipate switch assemblies are used to disengage the cruise control system. A
release switch assembly, a stoplamp and TCC switch
assembly, and a clutch or clutch anticipate switch assembly mounted on the brake pedal bracket assembly disengage the system electrically when the brake pedal or
clutch pedal is depressed. This is done by activating the
brake cut-out input to the cruise control module assembly.
The speed of the vehicle at brake actuation will be stored
in the memory of the system. The stoplamp and TCC
switch assembly has a three-wire stoplamp connector and
a two-wire TCC connector on automatic transmission
only. The cruise control release switch assembly has a
two-wire cruise control disable connector. The clutch
switch assembly (5.7L LTl engine) has a two-wire cruise
control disable connector and the clutch anticipate switch
assembly (3.4L L32 engine) has a four-wire cruise control
disable connector.
SPEED SENSOR
Vehicle Speed Sensor (VSS) Assembly
The vehicle speed sensor (VSS) assembly is
mounted to the automatic transmission assembly and produces an alternating current (ac) signal. The frequency of
this signal is proportional to the speed at which the automatic transmission assembly output shaft rotates, which
in turn, is proportional to the speed of the vehicle.
The ac signal produced by the VSS assembly is supplied to the engine control module (ECM), cruise control
module assembly and instrument cluster assembly;
The signal to the ECM, cruise control module
assembly and speedometer assembly is at a rate of 4000
pulses per mile. The ECM, cruise control module
982 CRUISE CONTROL

assembly and speedometer assembly internally convert
the number of pulses per mile per second to determine
vehicle speed.
For removal procedure, refer to SECTION 7A or to
SECTION 8A for diagnostic information.
FUNCTIONAL CONTROL SWITCHES

Off-On-Resume/Accelerate Switch
Figure 1
The "OFF-ON-RIA" switch (2) has three positions.
This switch turns the cruise control system "ON" and
"OFF" and also returns cruise control operation to the
last speed setting when momentarily moved toward the
"RIA" (RESUME/ACCELERATE) position after braking. Do not hold the "OFF-ON-RfA" switch (2) in the
"RIA" position. Relea,se it immediately. If the "OFF-ONR/A" switch (2) is held in the "R/A" position for more
than one second, the system goes into the acceleration
mode. To accelerate the vehicle, move the "OFF-ONR/A" switch (2) to the"R/A" position and hold it there
until the vehicle reaches the desired speed. When the
"OFF-ON-RfA" switch (2) is released, the system will
maintain the new cruise speed. In order to use the acceleration mode, the "OFF-ON-R/A" switch (2) must be in
the "ON" position and the vehicle must be above the low
speed limit of 40 km/h (25 mph).
The "OFF-ON-RfA" switch (2) can also be used to
"tap-up" vehicle speed. In order to do this the cruise control system must be engaged and operating. "Tapping-up" is done by quickly pressing the "OFF-ON-RfA"
switch (2) toward the "RIA" position and quickly releasing it, or "tapping" the "OFF-ON-R/A" switch (2). Do
not hold the "OFF-ON-RIA" switch (2) in the "R/A"
position, or the system will go into the acceleration mode.
"Tap-up" is a function in which cruise speed can be
increased by 1.6 km/h (1 mph) increments (one tap =
1.6 km/h (1 mph) increase).
Set/Coast Button Switch

Figure 1
The cruise control "SET/COAST" button switch
(3) (located in the end of the turn signal and headlamp

2 SWITCH, OFF-ON-RESUME/ACCELERATE
3 SWITCH, SET/COAST BUTTON
PC0001-9B-F-RP
Figure 1 - Cruise Control Actuator Lever Assembly (Typical)
dimmer switch and cruise control actuator and windshield

wiper and windshield washer lever assembly) has two
positions - "NORMAL" and "DEPRESSED."
The Set Position- With the "SET/COAST" button

switch depressed and then released ( vehicle speed
must exceed the low speed limit point, and the
"OFF-ON-RfA" switch (2) must be in the "ON"
position), the cruise speed will be set at the speed the
vehicle was going when the "SET/COAST" button
switch (3) was released. Vehicle cruise speed will be
within 1.6 km/h (1 mph) of the actual speed at
engaged speed. The system will cruise until either
the "OFF-ON-RIA" switch (2) is moved to "OFF,"
the ignition switch is turned "OFF," and/or the
"SET/COAST" button switch (3) is pushed in fully
and held. Pushing the brake pedal assembly releases
the "SET/COAST" button switch (3) but not the
resume capability.
The Coast Position - With the "SET/COAST"
button switch (3) fully depressed, the driver can
raise or lower vehicle speed. To increase speed, the
driver can accelerate to a new speed, fully depress
the "SET/COAST" button switch (3) and release
the button. The cruise control module assembly
"forgets" the previously set speed. An increased
control speed can be more easily set with the "OFFON-R/A" switch (2) as previously described. To
decrease cruise speed, the "SET/COAST" button
switch (3) is held in, disengaging the cruise system,
which allows the throttle to return to the idle position. When the vehicle has slowed to the desired
cruise speed, releasing the "SET/COAST" button
switch (3) will re-engage the system at the new
selected speed.
The "Tap Down" Position - To "tap down" the
cruise must be engaged and operating. "Tappingdown" is done by quickly pressing and releasing the
"SET/COAST" button switch (3), or "tapping" the
"SET/COAST" button switch (3). Do not hold the
"SET/COAST" button switch (3) in the depressed
position or the system will go into the coast mode.
"Tap-down" is a function in which cruise speed can
be decreased by 1.6 km/h (1 mph) increments (one
tap= 1.6 km/h (I mph) decrease). The accelerator
pedal assembly may be depressed at any time to
override the cruise system. Release of the accelerator pedal assembly will return the vehicle to the previously set cruise speed.
CAUTION: To keep the vehicle under
control, and to prevent possible personal injury and vehicle damage, the
cruise control should not be used on
slippery or winding roads or in traffic of
heavy or varying volume. When traveling down a steeply graded hill, the
cruise control should be disengaged
by depressing the brake pedal assembly lightly. The automatic transmission
assembly can then be shifted into a
lower gear range to help control vehicle
speed.
CRUISE CONTROL 98-3
BLANK
98-4 CRUISE CONTROL
ELECTRICAL DIAGNOSIS (K34)
AIC
CRUISE
FUSE 12
20AMP
"7E;;:'O~R-, UNDERHOOD
DISTRIBUTION
ELECTRICAL
PAGE 8A103
CENTER
I
I
I
_______ J
----139
~S165. . . . . . . . . . . . . . .8.PN.K
. . . . . . . . . . . . . . . . . . . .(iM!IIII. . . . . . . . . . . .. . .
139
.8PNK
r--
SEE FUSE
BLOCK DETAILS
PAGE 8A1114
rn
139
/_..!;;;;;;I=- ---=~,
.8 PNK
139
ALL MANUAL TRANS

VEHICLES USE A CLUTCH
JUMPER HARNESS.
.8 PNK
I CRUISE
I SWITCH
MANUAL
IMPORTANT:
I
I
I
I
139
OFF
RIA
OFF
ON
- .. ON
RIA
.35 P:K11::
~,-V6-VI_N_S-,
CLUTCH ANTICIPATE/
CRUISE RELEASE SWITCH
(4 CAVITY DUAL SWITCH)
(OPEN WITH
CLUTCH PEDAL
DEPRESSED)
PAGE 8A207
~,-V8-V-IN-P-,
r-\- ,
I
I
-1
Al
.35 BRNIWBHT
CRUISE
RELEASE/
I CLUTCH
SWITCH
I (2 CAVITY)
_______K
(OPEN WITH
CLUTCH PEDAL
DEPRESSED)
.35GRY
.35 GRY/BLK
35
6
_ BR:1
A
C250
86
'
'" - -- - --- - - - - -- -- ---~.;
C250
[ ] CRUISE RELEASE/
BRAKE SWITCH
(OPEN WITH
BRAKE DEPRESSED)
.35 BRN
397
379
CRUISE RELEASE/[]
BRAKE SWITCH
(OPEN WITH
BRAKE DEPRESSED)
.35 DK BLU
AJ
.35 BRN
250
C
86
.~ ------BRAKE
INPUT
--- - --
1
I
I
I
I
1 __
50
.-
,MULTI-FUNCTION
LEVER
84
87
CRUISE CONTROL 98-5
----,!Le:
FUSE
STOP/HAZARD
FUSE 6
20AMP
I BLOCK
I
I
___ J
BRAKEr-~~~~~~~~;;...~~~__;;;.;,,.:..~~~~~
TCC/SHIFT
SWITCH
BRAKE LIGHT
INTERRUPT
ASSEMBLY CRUISE RELEASE
SWITCH
SWITCH
(NORMALLY
(NORMALLY
OPEN)
CLOSED)
r- - - 4000 PULSES
PER MILE,
SPEED
OUTPUT
.8 YEL
.SLTBLU
8
TO AUTO TRANS
PAGE 8A-20-6 (V6 VIN S)
SA-21-6 (V8 VIN P)
NOT USED WITH
MANUAL TRANS
(V6 VIN S) .S DK GRNIWHT
(VS VIN P) .35 DK GRNIWHT
820
20
TO TURN/HAZARD
SWITCH ASSEMBLY
PAGES8A-110-0, 1
5243
r---------------
ENGINE
CONTROL
I MODULE
I (ECM)
"'
I ~
L----.J ~
28
!!. (BLK) (V6 VIN S)
"1
(BRN) (V8 VIN P)
817
TO CENTER
SYEL_ ....~ HIGH MOUNTED
STOP LIGHT (CHM SL)
820
PAGESA-110-1
[I] IMPORTANT:
.35 DK GRNIWHT
817
---------i...
BRAKE SIGNAL INPUT MUST BE

PULLED LOW THRU CENTER HIGH
MOUNTED STOPLAMP BULB OR
CRUISE CONTROL WILL NOT WORK.
.35 DK GRNIWHT
.8 YEL
...
TO INSTRUMENT
CLUSTER
PAGE SA-81-0
820
.35 DK GRNIWHT
817
TO ELECTRONIC
~ BRAKE CONTROL
- - -.....
VEHICLE SPEED
SENSOR INPUT
BRAKE
INPUT
STEPPER~
MOTOR
12V
ALL OTHER
VEHICLES
st!
SV
I
('
"'1;,. . .
_._G109
35BLf 50
SEE GROUND
DISTRIBUTION
PI\GE 8A14-6
I
I
EARLY PRODUCTION
VEHICLES
'
MECHANICAL
LINK (CABLE)
TO THROTTLE BODY
~-5113
3BLK.150
......-..J106
SEE PAGE 8A-3-0

FOR MEASURING
ANO HANDLING
PROCEDURES
98-6 CRUISE CONTROL
12065425
BLK

DESCRIPTION
CAVITY
WIRE COLOR
CKT
GRY
397
98-4
DKBLU
84
98-4
GRY/BLK
87
98-4
BRN
86
98-4
BLK
150
1650
GROUND (EARLY PRODUCTION VEHICLES)

GROUND (All OTHER VEHICLES)
8A-14-6
8A-14-6
PNK
139
POWER FEED FROM A/C-CRUISE FUSE #12
98-4
YEL
820
98-5
DKGRN/WHT
817
98-5
PAGE
B
17
@@@@@@@@@@@@@@@@
,@@@@@@@@@@@@@@@@16
12129025 {BODY)
GRY
12129021{TPA)
TPA MICRO-PACK 100W
BLK
ENGINE CONTROL MODULE (V6 VIN S)
12065888
BRN
ENGINE CONTROL MODULE (VS VIN P)
CRUISE CONTROL 98-7
'
FORWARD LAMP
~PIN IMIL IKI J lolH IGIF IE 1 DJ ~~~~~~ ~~i~~~~ING

06294509
11-WAY F PACK-CON I
BLK
SECTION
SA-201-PG
COMPONENT
LOCATION

Clutch Anticipate/
(all V6 Manual) . . . . . . . . . Mounted in clutch pedal bracket (4 cavity conn) . . . . . . 0 . . . .
of wheelhouse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 . . .
(2 cavity conn) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
(VS Manual with K34) . . Mounted in clutch pedal bracket (2 cavity conn) . . . . . . 0
19
19
1/P Fuse Block .......... . LH side ofl/P Carrier, on the side .................. . 8
Multi-Function Lever ... . Left Arm on Steering Column ...................... . 2 ....
of wheelhouse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
C200A (17 cavities)
C200D (48 cavities)
Steering Column . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
C215 (11 cavities) ....... . Near base of Steering Column . . . . . . . . . . . . . . . . . . . . . . 35
C250 (2 cavities) ........ . Forward Lamp Harn to Clutch Jumper Harn or Switch,
Gl06 ................... . Near top LH side ofradiator, in top ofT-Bar . . . . . . . . . . 19
Gl09 ................... . Braided ground strap, bolted to left front frame rail (some
vehicles will have 1 ring terminal in addition to
ground strap) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 . . .
8113
Center breakout
8165
Center breakout
8242
8243
I/P Harn, approx 1 cm from Fuel Pump Relay breakout 7
8271
inboard of PlOO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
FIG.
CONN
1 ...
202-17
36 . .
202-10
1
1
35 ..
202-18
35 ..
15 ..
4
202-19
202-22
36
202-24
72
202-2
72 ..
52 ..
67 ..
202-2
202-4
202-6
1,2
35
21
13
14
98-8 CRUISE CONTROL

Diagnosis)
System
1. Check that Cruise Control Module Linkage is

connected and moving freely.
2. Check Cruise Cable Adjustment.
3. Check for poor connection at G106 or G109.
Make sure ABS DTC(s) are diagnosed first. An
open CHMSL Circuit will set a DTC and also
disable the Cruise Control Module. Check for
burnt CHMSL Bulbs.

SYSTEM DIAGNOSIS

procedure(s).
If speedometer is inoperative, refer to "Vehicle
Speed Sensor," page SA-33-2.
SYSTEM CHECK
ACTION
NORMAL RESULTS
[1]
Drive vehicle above 25 mph .

Cruise Switch to "ON."
Depress Set Switch once and release .
Remove foot from accelerator pedal .
[2]
Depress and hold Set Switch until vehicle speed
decreases
by 4 to 5 mph.
Release Set Switch .
[3]
Depress and hold RIA Switch until vehicle speed
increases
by 4 to 5 mph.
Release RIA Switch .
Vehicle maintains set speed.
Vehicle decelerates and maintains a new lower set

speed, if speed is above 25 mph.
Vehicle accelerates and maintains a new higher set

speed.
[4]
Depress brake pedal slightly .
Cruise Control disengages. Memory unchanged.
Depress RIA Switch once and release .
Vehicle accelerates to and maintains previous set

speed.
[5]
[6]
Depress RIA Switch once and release (less than 3/4 Vehicle speed increases by 1 mph and maintains new
of a second).
set speed.
CRUISE CONTROL 98-9
SYSTEM CHECK
NORMAL RESULTS
ACTION
[7]
Depress Set Switch once and release (less than 3/8 Vehicle speed decreases by 1 mph and maintains new
of a second).
set speed.
[8]
Depress Set and RIA Switches simultaneously.
Vehicle put in Non-Cruise mode with memory

unchanged.
Depress RIA Switch once and release.
Vehicle accelerates to and maintains previous set

speed.
Cruise Switch to "OFF."
Cruise Control disengages. Memory is lost.
[9]
[10]
ADDITIONAL SYSTEM CHECK

The following Procedure may be used as a System
Check to verify operation of the Cruise Control System
after repairs.
Set Park Brake.
Start Engine.
Move Cruise Switch to "OFF."
Move Cruise Switch to "ON" and then wait at
least 3 seconds before doing next step.
Fully depress and hold brake pedal.

Push Cruise Set Switch in and hold.
Hold Cruise Slider Switch in "RIA" position.
After 10 seconds, release brake pedal while
still holding RIA and Set Switches.
Engine RPM should increase momentarily
then return to normal.
SYMPTOM TABLE
PROCEDURE
PAGE NUMBER
Speedometer
Chart #1
98-10
Crui1e Control will not resume, accelerate, tap-up or

tap-down.
Chart #2
98-12
SYMPTOM
Cruise Control will not engage.

operates normally.
Crui1e Control will not engage.

not operate.
Speedometer does See"Vehicle Speed Sensor," page 8A-33-2.
98-10 CRUISE CONTROL

CHART #1
CRUISE CONTROL WILL NOT ENGAGE
(ASSUMES SPEEDOMETER OPERATES NORMALLY)
TURN IGNITION SWITCH TO "OFF."

DISCONNECT CRUISE CONTROL MODULE CONNECTOR.
CONNECT TEST LIGHT FROM CONN TERM "F" TO GROUND.
IS TEST LIGHT "ON"?
CONNECT TEST LIGHT FROM CONN TERM "F"

TOTERM"E".
IS TEST LIGHT "ON"?
CHECK FOR POOR CONNECTION AT CRUISE CONTROL MODULE.

IF OK, REPAIR OPEN IN CKT 139 TO CRUISE CONTROL MODULE.
CRUISE SLIDER SWITCH "ON" AND IGNITION

SWITCH STILL IN "RUN."
CONNECT TEST LIGHT FROM CONN
TERMINALS "B" AND "C" TO GROUND.
IS TEST LIGHT "ON" AT EITHER CONNECTOR?
CHECK FOR POOR CONNECTION AT CRUISE

CONTROL MODULE.
IF OK, REPAIR OPEN IN GROUND CKT 1 SO OR
CKT 1650 TO CRUISE CONTROL MODULE.
CONNECT TEST LIGHT FROM CONN TERM "A"

TO GROUND.
IS TEST LIGHT "ON"?
CHECK CKT 84 (TERM "B") OR CKT 87 (TERM "C") FOR SHORT TO B +.

IF OK, REPLACE MUL Tl-FUNCTION LEVER.
CONNECT TEST LIGHT FROM CONN TERM "D"

TO GROUND.
IS TEST LIGHT "ON"?
BACKPROBE TERM "M" OF C21 S WITH TEST LIGHT TO GROUND.

IS TEST LIGHT "ON"?

MUL Tl-FUNCTION LEVER.
CHECK FOR OPEN IN CKT 397 BETWEEN MULTI-FUNCTION
LEVER AND CRUISE CONTROL MODULE, OR CKT 139
FROM C21 S TERM "M" TO MUL Tl-FUNCTION LEVER.
CONNECT TEST LIGHT FROM CONN TERM "G"

TO GROUND.
IS TEST LIGHT "ON"?
REPAIR OPEN IN
CKT 139 BETWEEN
S16SANDC215
TERM"M".
BACKPROBE C250 TERM "B" WITH A TEST LIGHT TO GROUND.

IS TEST LIGHT "ON"?
(AUTOMATIC)
CHECK FOR OPEN IN
CKT 86 OR POOR
CONNECTION AT C250.
IF OK, REPLACE CRUISE
RELEASE/BRAKE
SWITCH.
(MANUAL)
CHECK FOR POOR CONNECTIONS AT
VARIOUS COMPONENTS IN CRUISE
JUMPER HARNESS.
BACKPROBE SWITCH CONNECTORS
TO LOCATE BAD COMPONENT OR
OPEN IN CKT. REPLACE OR REPAIR.
REPAIR
OPEN IN
CKT 139.
CRUISE CONTROL 98-11

FROM CONNECTOR
TERM "B" TO GROUND.
PRESS AND HOLD SET
SWITCH.
IS TEST LIGHT "ON"?
BACKPROBE BRAKE SWITCH ASSEMBLY CONN C1

TERM "B" WITH A TEST LIGHT TO GROUND.
IS TEST LIGHT "ON"?
CHECK FOR POOR

CONNECTION AT BRAKE
SWITCH ASSEMBLY.
CHECK FOR OPEN IN CKT 820.
IF OK, REPLACE BRAKE SWITCH
ASSEMBLY.
CONNECT 1/P TESTER (J 33431) TO

VEHICLE SPEED SENSOR CONN.
SET TESTER TO 60 Hz.
WITH DVM, MEASURE
FREQUENCY OF SIGNAL AT
CONN TERM "K".

AT CRUISE CONTROL MODULE.
CHECK FOR PROPER OPERATION
OF MECHANICAL LINK CABLE.
IF OK, REPLACE CRUISE CONTROL
MODULE.
PERFORM ADDITIONAL SYSTEM
CHECK ON PAGE 98-9 TO VERIFY
REPAIRS.
BACKPROBE TERM "K" OF C215 WITH A TEST LIGHT TO GROUND.

PRESS AND HOLD SET SWITCH.
IS TEST LIGHT "ON"?

AT C215 TERM "K".
TO CRUISE CONTROL MODULE.

OR REPAIR OPEN IN CKT 817.

TERM "K".
CHECK FOR OPEN IN CKT 84 INSIDE
STEERING COLUMN.
r-
---------------------,
CHECK FOR PROPER HOOKUP OF

1/P TESTER.
IF OK, REFER TO "VEHICLE SPEED
SENSOR," PAGE 8A-33-0 FOR
ADDITIONAL DIAGNOSIS.
:
:
I
:
1
:
:
1
L-----------------------J

CHART #2
CRUISE CONTROL WILL NOT RESUME, ACCELERATE, TAP-UP OR TAP-DOWN

CRUISE CONTROL SWITCH TO "ON."
BACKPROBE C215 WITH A TEST LIGHT FROM TERM
PRESS RESUMEiACCEL SWITCH.
IS TEST LIGHT ON?
CHECK FOR OPEN IN CKT 87 BETWEEN C215

AND CRUISE CONTROL MODULE.
ALSO CHECK FOR POOR CONNECTION AT
CRUISE CONTROL MODULE TERM "C".
IF OK, REPLACE CRUISE CONTROL MODULE.
CIRCUIT OPERATION
The Electro-Motor Cruise Control is a speed
control system which maintains a desired vehicle
speed under normal driving conditions. The system
has the capability to CRUISE, COAST, RESUME
SPEED,ACCELERATE, TAP-UP AND TAP-DOWN.
An Electronic Controller and Electric Motor are
contained in the Cruise Control Module. The
Controller monitors vehicle speed and operates the
Electric Motor. In response to the Controller, the
motor moves a connecting strap that is attached to the
Cruise Control Cable. The Cable moves the Throttle
Linkage to vary throttle position in order to maintain
the desired cruise speed. The Cruise Control Module
contains a low speed limit which will prevent system
engagement below a minimum speed, about 25 mph.
The module is controlled by mode control switches
located on the Multi-Function Lever.
"J" TO GROUND.

IN CKT 87 IN STEERING COLUMN, OR
POOR CONNECTION AT C215 TERM "J".
If OK, REPLACE MUL Tl-FUNCTION LEVER.
With the Ignition Switch in "RUN," battery

voltage is applied to terminal "F" of the Cruise Control
Module. When the Slider Switch is moved to the "ON"
position, battery voltage is applied to terminal "A" of
the Cruise Control Module Connector. If the brake
pedal is not depressed, battery voltage is present at
module terminal "D". If the brake pedal is depressed,
battery voltage is present at module terminal "G".
Terminal "G" must see current flow through the
CHMSL bulb for cruise to operate properly. When the
Slider Switch is moved to the "RIA" position, battery
voltage is applied to terminal "C" of the module. With
the Set Switch depressed, battery voltage is present at
Cruise Module terminal "B". Cruise Module
Connector terminal "K" is the speed signal terminal.
In operation, voltage will oscillate between a high of 4
to 5 volts and a low of near ground. Cruise Module
terminals "H" and "J" are not used. Ground is at
module terminal "E".
ON-VEHICLE SERVICE
(6), stoplamp and TCC switch assembly (7), and

clutch switch assembly (5) or clutch anticipate
switch assembly (4) into pedal assembly with
bracket (20 or 21) until retainer on release switch
assembly (6), stoplamp and TCC switch assembly
(7), or clutch switch assembly (5) or clutch anticipate assembly (4) is fully seated.
CRUISE CONTROL SWITCH ASSEMBLIES

Figure 2
Adjustment
The release switch assembly (6) must be adjusted at
the same time the stoplamp and torque converter clutch
(TCC) switch is adjusted. The clutch switch assembly (5)
or clutch anticipate switch assembly (4) cannot be
adjusted until after clutch pedal assembly (20) is installed.
NOTICE: Make sure to apply the proper amount of

force to the brake pedal assembly during adjustment.
Too much force could damage the vacuum booster
assembly. Too little could cause dragging brakes.
NOTICE: Proper stoplamp switch assembly adjustment is essential. Improper stoplamp switch assembly adjustment will cause brake drag and excessive
brake lining wear.
2. Slowly pull brake or clutch pedal assembly rearward

with a force of 222 N (50 pounds) until "click"
sounds can no longer be heard. At this point, release
switch assembly (6), stoplamp and TCC switch
assembly (7), and clutch switch assembly (5) or
clutch anticipate assembly (4) will have moved
retainers to their original position.
Adjust
1. To adjust, depress brake pedal assembly or clutch
pedal assembly and insert release switch assembly
20
21
A
B
C
D
E
F
MANUAL TRANSMISSION
G CONNECTOR, ELECTRICAL
H - WITH 3.4L L32 ENGINE
J WITH 5.7L LT1 ENGINE
4 SWITCH ASSEMBLY, CRUISE CONTROL CLUTCH
ANTICIPATE
5 SWITCH ASSEMBLY, CRUISE CONTROL CLUTCH
6 SWITCH ASSEMBLY, CRUISE CONTROL RELEASE
7 SWITCH ASSEMBLY, STOPLAMP AND TORQUE
CONVERTER CLUTCH
19 SWITCH ASSEMBLY, CLUTCH START
21 PEDAL ASSEMBLY, BRAKE AND ACCELERATOR (WITH
BRACKET)
Figure 2 - Cruise Control Switch Assemblies
PC0002-9B-FRP
l@I Measure
The release switch assembly and stoplamp and TCC
switch assembly contacts should be open at 25.4 mm
( 1 inch) or less of pedal assembly travel, and occur at
the same time or before the onset of braking. The
brake pedal assembly travel can be up to 25.4 mm
(1 inch) before the cruise control system disengages.
Replacement

1. Left-hand
assembly.
instrument
panel
sound
insulator
switch assembly (7), and clutch switch assembly (5)
or clutch anticipate switch assembly (4), if
equipped, from
(20 or 21).
pedal assembly with bracket
A
B
C
1
COVER, ACCESS
TANG
PC0003-98-F-RP
Figure 3 - Engagement Switch

1. Release switch asembly (6), stoplamp and TCC
switch assembly (7), and clutch switch assembly (5)
or clutch anticipate switch assembly (4), if
equipped, to pedal assembly with bracket (20 or 21 ).
3. Left-hand
instrument
panel
sound
insulator
assembly.
Adjust
Release switch assembly (6), stoplamp and

TCC switch assembly (7), and clutch switch
assembly (5) or clutch anticipate switch assembly (4) as outlined above.
ENGAGEMENT SWITCH
Figure 3
The engagement switch cannot be serviced. The
complete turn signal and headlamp dimmer switch and
cruise control actuator and windshield wiper and windshield washer lever assembly must be replaced as an
assembly.

2. Steering column access cover.

Make sure windshield wiper switch is in the
"OFF" position.
4. Lever assembly (1) by pulling it straight out.

1. Lever assembly (1).
Align tang on lever assembly (I) to notch on
column assembly (8) and push in until fully
seated.
3. Steering column access cover.
4. Battery negative cable assembly
CRUISE CONTROL MODULE ASSEMBLY

Figure4
The cruise control module assembly ( 11) is mounted
on the left engine compartment inner side rail assembly
using two cruise control module bracket bolts/screws
(16).

1. Accelerator control cable splash shield bolts/screws.
2. Accelerator control cable splash shield.
3. Left-hand front bumper fascia lower deflector. Refer
to SECTION 10-4.
4. Cruise control cover (13) to access connectors.
5. Electrical connector from cruise control module
assembly (11).
6. Cruise control cable assembly from cruise control
module assembly. Refer to "Cable Assembly
8. Cruise control module assembly (11) with bracket
assembly (12) from left engine compartment inner
side rail assembly.
9. Bolts/screws ( 10) attaching cruise control module
assembly (11) to bracket assembly (12).

10
12
13
A
10
11
12
13
14
BOLT/SCREW, CRUISE CONTROL, 6 Nm (53 LB. IN.)
MODULE ASSEMBLY, CRUISE CONTROL
BRACKET ASSEMBLY, CRUISE CONTROL MODULE
COVER, CRUISE CONTROL
14 CABLE ASSEMBLY, CRUISE CONTROL

15 HARNESS ASSEMBLY, FORWARD LAMP WIRING
16 BOLT/SCREW, CRUISE CONTROL MODULE BRACKET,
10 Nm (89 LB. IN.)
17 RAIL ASSEMBLY, ENGINE COMPARTMENT INNER SIDE
PC0004-9B-F-RP
Figure 4 - Cruise Control Module Assembly
10. Cruise control module assembly (11) from bracket

assembly (12).
l++I
!~I
Tighten
Install or Connect

section.
1. Cruise control module assembly (11) to bracket

assembly (12).
2. Bolts/screws ( 10) attaching cruise control module
assembly (11) to bracket assembly (12).
3. Cruise control module assembly (11) with bracket

assembly (12) to left engine compartment inner side
rail assembly.
!~I
Tighten

5. Cable assembly to module assembly. Refer to
"Cable Assembly Replacement" in this section.
B
6. Electrical connector to cruise control module assembly (II).

7. Cruise control cover (13) over connectors.
8. Left-hand front bumper fascia lower deflector. Refer
to SECTION 10-4.
9. Accelerator control cable splash shield.
A
B
11
14
RIBBON
BEAD
CABLE ASSEMBLY, CRUISE CONTROL
10. Accelerator control cable splash shield bolts/screws.

PC0005-9B-F-RP
Figure 5 - Cable Bead to Cruise Control Module Assembly
l~I
Tighten
Accelerator control cable splash shield bolts/

screws to 1.9 Nm (17 lb. in.).
9816 CRUISE CONTROL
A
B
C
D
11
14
RIBBON
RIBBON MUST NOT BE TWISTED
MARKINGS IN YELLOW FOR LT1 ENGINE, PINK FOR L32 ENGINE
BEAD
PC000&-98-F-RP
Figure 6 - Pulling Cruise Control Cable Assembly
11
Adjust
Cable assembly, if necessary. Refer to "Cable

Assembly Adjustment" in this section.
CRUISE CONTROL CABLE ASSEMBLY

Figures 5 through 7
The cable assembly (14) is connected between the
cruise control module assembly (11) and the throttle body
lever.
Cable Assembly Replacement

1. Cable assembly (14) and conduit from engine
bracket.
2. Cable end fitting from throttle body lever stud.
3. Cruise control retainer (18) at cruise control module
assembly
4. Cable assembly (14) from cruise control module
assembly (11).
A. Compress conduit tangs and pull out of cruise
control module housing. (11).
B. Disconnect cable bead from cruise motor band
end fitting on cruise control module assembly
(11).
C. Note routing and remove cable assembly (14)
from vehicle.

1. Cable assembly (14) to cruise control module
assembly (11).
A. Attach cable bead to cruise motor ribbon end
fitting on cruise control module assembly (11).
B. Pull engine end of cable assembly (14) until it
is taut.
A
B
C
D
11
14
18
CONDUIT
TANG
HOUSING
ENDFITIING
RETAINER, CRUISE CONTROL
PC0007-98-F-RP
Figure 7 - Installing Cruise Control Cable Assembly to Cruise

Control Module Assembly
C. Turn engine end of cable assembly until ribbon

is flat.
[Il Important
Ribbon must not be twisted.
- Slide cable conduit fitting over ribbon
and snap into module housing assuring
that both tangs are engaged.

2. Cruise control retainer (18) at cruise control module
assembly (11 ).
3. Cable assembly (14) to vehicle.
Use routing noted during removal.
4. Cable end fitting to throttle body lever stud.
5. Cable assembly (14) and conduit to engine bracket.
11
Adjust
Cable assembly. Refer to "Cable Assembly
Cable Assembly Adjustment

With throttle closed, lock cable conduit by pressing
down on lock button.
A. When cable assembly is in unlocked position
and throttle is closed, cable adjustment spring
removes appropriate amount of slack.
B. Lock button must be fully extended to allow
proper adjustment spring operation prior to
locking.
SPECIFICATIONS
Accelerator Control Cable Splash Shield Bolt/Screw . . . . . . . . . . . . . . . . . . . . . . 1.9 Nm (l 7 lb. in.)
Cruise Control Bolt/Screw ............................................. 6 Nm (53 lb. in.)
Cruise Control Module Bracket Bolt/Screw ............................... 10 Nm (89 lb. in.)
SPECIAL TOOLS
1.
J 39200
.J,Haoo
AUTOMOTIVE OMM KIT
1. FLUKE 87 KIT
PC0008-9B-F-RP
THEFT DETERRENT SYSTEMS 90-1
SECTION 90
THEFT DETERRENT SYSTEMS

CAUTION: This vehicle is equipped with the Supplemental Inflatable Restraint (SIR). Refer to
number is not available, a fastener of equal size and strength (or stronger) may be used. Fasteners that are not
result.
CONTENTS
PASS-Key 11 System ....................
System Operation . . . . . . . . . . . . . . . . . . . . . . . .
System Components . . . . . . . . . . . . . . . . . . . . .
Ignition Key Assembly .................
Steering Column Lock and Ignition
Cylinder Assembly ..................
Theft Deterrent Module Assembly ........
Ignition Input .........................
Key Resistor Inputs ....................
Starter Enable Output ...................
Fuel Enable Output ....................
Security Indicator Lamp Output ..........
Theft Deterrent Relay Assembly ..........
Engine Control Module (ECM) ...........
90-1
90-1
90-1
90-1
90-1
90-2
90-2
90-2
90-2
90-2
90-3
90-3
90-3
90-3
GENERAL DESCRIPTION
PASS-Key II SYSTEM
The personal automotive security system (PASSKey II) is standard equipment on this vehicle. The system is designed to prevent vehicle theft by disabling the
engine unless an ignition key assembly with a specific
electrical resistance is used in the ignition cylinder assembly. The components of the system are the ignition key
assembly, the ignition cylinder assembly, the theft deterrent module assembly, the theft deterrent relay assembly,
and the engine control module (ECM).
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-4
On-Vehicle Service . . . . . . . . . . . . . . . . . . . . . . . 90-17
Ignition Key Assembly . . . . . . . . . . . . . . . . . . 90-17
Copying Ignition Key Assemblies . . . . . . . . 90-17
Replacing Lost Ignition Key Assemblies . . 90-17
Steering Column Lock and Ignition Cylinder
Assembly .............. Refer to Section 3F5B
Theft Deterrent Module Assembly . . . . . . . . . 90-17
Theft Deterrent Relay Assembly . . . . . . . . . . . 90-18
(ECM) . . . . . . . . . . . . . . . . . . Refer to Section 6E
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-18
Fastener Tightening Specifications . . . . . . . . . 90-18
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90-18
the proper pulse width modulate (PWM) signal on the fuel

enable input, it will not provide fuel to the engine.
If the wrong resistance value is sensed when the
ignition switch is in the "RUN" position, the theft deterrent module assembly will not ground the starter enable
circuit and will not output the fuel enable PWM signal for
approximately three minutes. This prevents the engine
from starting and discourages the thief from trying key
codes (resistance values) at random.
If the correct resistance value is sensed when the
ignition switch is in the "RUN" position, the theft deterrent module assembly will ground the starter enable circuit and output the fuel enable PWM signal. This will
allow the engine to start normally.
SYSTEM OPERATION
SYSTEM COMPONENTS
The PASS-Key 11 system is designed to prevent

the engine from starting if the proper resistance is not
sensed from the ignition key assembly. Of the 15 key
codes (resistance values) available, only one will work
with each theft deterrent module assembly.
Figure 1
The PASS-Key 11 system prevents the engine from

starting by controlling the theft deterrent relay assembly
and the ECM fuel enable input. If the ECM does not sense
Ignition Key Assembly

The ignition ke~ assembly for vehicles equipped
with the PASS-Key II system is arr assembly of a typical
square ignition key blank and resistor assembly. The ignition key blank and resistor assembly are not serviceable
separately. There are 15 different ignition key assemblies,
90-2 THEFT DETERRENT SYSTEMS

each with a different resistance value. The ignition key
assembly also has mechanical cuts similar to non-PASSKey n ignition key assemblies.
module assembly has inputs from the ignition circuit and

the resistor assembly. The theft deterrent module assembly has outputs to the starter enable circuit, the fuel enable
circuit, and the security lamp circuit.
Important
When servicing the PASS-Key n system, obtain

all ignition key assemblies, if possible, and verify
proper values with tool J 35628-A, VATS/PASS
Interrogator. Refer to "Copying Ignition Key
Steering Column Lock and Ignition Cylinder

Assembly
Figure2
The ignition cylinder assembly in vehicles equipped
with the PASS-Key n system contains a set of electrical
contacts used to measure the resistor assembly in the ignition key assembly. When servicing the ignition cylinder
assembly, be certain to maintain proper wire routing. A
two pin connector at the base of the steering column
assembly connects the contacts to the vehicle wiring. The
connector is also used for diagnostic purposes. The ignition cylinder assembly also performs all functions of ignition cylinder assemblies on non-PASS-Key n vehicles.
When replacing an ignition cylinder assembly, it will be
necessary to make new ignition key assemblies which
match the PASS-Key n key code of the theft deterrent
module assembly and the mechanical cut of the new ignition cylinder assembly.
rn
Ignition Input
The ignition input is used to tum the theft deterrent
module assembly on. When the theft deterrent module assembly is turned on, it will read the resistor assembly and
control the outputs accordingly. When the theft deterrent
module assembly is turned off the resistor assembly is not
read, and the theft deterrent relay assembly and fuel
enable output will not allow the engine to start. When the
ignition switch is in the "OFF" position, the battery input
to the theft deterrent module assembly will draw about 1
milli-amp.
Key Resistor Inputs

The key resistor inputs are used to determine if the
correct ignition key assembly is being used to start the
vehicle. The key resistor inputs are read only when the
theft deterrent module assembly is first turned on. If the
key code (resistance value) of the ignition key assembly
matches the value stored in the theft deterrent module
assembly, the theft deterrent relay assembly and fuel
enable output will allow the vehicle to start. If the resistance value of the ignition key assembly does not match
the value stored in the theft deterrent module assembly,
the relay assembly and fuel enable output will not allow
the vehicle to start.
Starter Enable Output
Important
The wire routing for the contacts inside the steering

column assembly is critical.
Theft Deterrent Module Assembly

The theft deterrent module assembly contains the
logic of the PASS-Key n system. The theft deterrent
The starter enable circuit controls the theft deterrent

relay assembly. When the theft deterrent module assem~ly sees the proper resistance at the ignition key assembly,
1t grounds the starter enable circuit which allows the
engine to be cranked. If the theft deterrent module assembly does n?t s~e the proper resistance at the ignition key
assembly, 1t will not ground the starter enable circuit.
1 MODULE ASSEMBLY, THEFT DETERRENT

2 KEY ASSEMBLY, THEFT DETERRENT IGNITION
3 CYLINDER ASSEMBLY, STEERING COLUMN LOCK AND
IGNITION
4 RELAY ASSEMBLY, THEFT DETERRENT
5 MODULE, ENGINE CONTROL
Figure 1 - PASS-Key 11 System Components (Typical)
PC00019D-F-RP
THEFT DETERRENT SYSTEMS 9D3
A PROPER WIRE ROUTING FROM STEERING COLUMN

LOCK AND IGNITION CYLINDER ASSEMBLY
(DO NOT TWIST WIRES)
B CUT OFF WIRE RETAINER LEG
ON ORIGINAL CONNECTION WHEN REPLACING
STEERING COLUMN LOCK AND IGNITION
CYLINDER ASSEMBLY
2 KEY ASSEMBLY, THEFT DETERRENT IGNITION
3 CYLINDER ASSEMBLY, STEERING COLUMN LOCK
AND IGNITION
PC6003-9D-D-RP
Figure 2 - Ignition Cylinder Assembly Wire Routing
Fuel Enable Output
Theft Deterrent Relay Assembly
The fuel enable circuit is an output from the theft

deterrent module assembly and an input to the ECM.
When the theft deterrent module assembly sees the proper
resistance at the ignition key assembly, it will output a
pulse width modulated (PWM) signal to the ECM. If the
theft deterrent module assembly does not see the proper
resistance at the ignition key assembly, it will not output
the PWM signal to the ECM.
The relay assembly is used to stop the engine from

cranking if the correct resistance is not sensed at the ignition key assembly. It prevents the engine from cranking
by opening the circuit to the starter solenoid switch.
Security Indicator Lamp Output

The "SECURITY" lamp circuit is an indicator lamp
output. The lamp output will be grounded during a five
second "bulb test" at key on, at any time that the theft
deterrent module assembly is preventing the engine from
starting, or if the theft deterrent module assembly is not
properly programmed.

The ECM reads the fuel enable circuit to determine
if fuel injection should be allowed. If the fuel enable
PWM signal is not present, the ECM will not allow fuel
injection. If the PWM signal is present, the ECM will
allow fuel injection and normal engine operation.
The ECM has some diagnostic features associated
with the fuel enable input, including diagnostic trouble
codes. For details, refer to SECTION 6E.
ELECTRICAL DIAGNOSIS: PASS--KeyII

(PERSONALIZED AUTOMOTIVE SECURITY SYSTEM)
-y---
HOT AT ALL TIMES
r- I
',
ACCY
1 IGNITION
SWITCH
START , - -
LOC; ...... _ ......

OFF
RUN
-:u~s :
TEST
L-------
5Y~r?C5J C2000
C200B
5 YEL
r-
1
I
I
S YEL
CRANK
FUSE 17
3AMP
__
-,1/P
FUSE
BLOCK
,--
5 : EL
I
......
--1
.----------------------.....
I
5
5223
S ::L
~~-----------------------:.~ll:t:'f.'
AI
TO DIAGNOSTIC
ENERGY RESERVE
MODULE
PAGE SA-47-0
5 OK GRN
All
575
S DK GARN
C;~:~~
5 DK GR:);75
, ,
.5 RUST
575
5245 . . . . . . . . .. .
5 DK G~N
TRANSMISSION
(CLOSE~w;~~
CLUTCH PEDAL [_ ]
DEPRESSED)
POSITION
SWITCH
FUSIBLE
LINK (BTSI)
575
1 DK GRN
r- - - - - - ,
I
I
I
\ R
~, N
B
5 PPL
.8 VEL/BLK
2 ,
-..... #..
)I
-----J
5P:1
'~---------- ________
575
rn
IMPORTANT:
FUSIBLE LINK (BTSI) 15
LOOPED OUTSIDE OF TAPED
BUNDLE, APPROXIMATELY
12.5 CM IN LENGTH.
TO BRAKE
TRANSMISSION
SHIFT INTERRUPT
(BTSI) SOLENOID
PAGES SA-20-6,
SA-21-6
___./
3 PPL (V6 VIN S)

5 PPL (V8 VIN P)
r'
..
SEE PAGE SA-3-0

FOR PROPER
HANDLING
PROCEDURES
S -
........
62 5. . . . . . . . . . . .m,(
,,-----'=M=A~N~U=AL;;;;;!________,,.:,~-----=l=A=UT=O~M=AT=IC==------..
"I STARTER
SOLENOID
I
I
I
..

AV~
--,~
SEE PAGE SA-3-0

FOR MEASURING
AND HANDLING
PROCEDURES
FUSE
I BLOCK
I
I
ECM BAT
FUSE 4
10 AMP
_ _ ...J
L---.S PNK
SEE FUSE
BLOCK DETAILS
PAGESA-11-4
........ _
,...- -
.8 ORN
~=-,1
439
340
5205
1---<D
1 ---
I
I
A13~
INSTRUMENT
CLUSTER
I
I
~
I
,~, "'
I
J;.
625
I
I
I
I
SEE FUSE
BLOCK DETAILS
PAGE SA-11-6
A4A
A2
AS
ENGINE CONTROL
I MODULE (KM)
FUEL
ENABLE
I
I
1!_Gf!!,L
.J
-'!,
C (BLU) (V6 VIN S)

!<_ (GRY) (VS VIN P)
23
19
(V6 VIN S) .5 DK BLU

(VS VIN P) .35 DK BLU
"~:1,. ---~o~
.8YEL/BLK
"SECURITY"
INDICATOR
'"I
r ;' - - I
229
'"
A1
..-~~---"""'~~~~~~~"'"'~~~~~--'r"'~~~~~~~"'"'~~~~~~~~~~~~~~~~~~-,pASS-Key11
DECODER
MODULE
----,
I
I
I
I
I
I
IGNITION
INDICATOR CONTROL
L_
START
ENABLE
PWM
FUEL ENABLE
SIGNAL
BATTERY
SOLID STATE
DETECTOR
AND TIMER
SV REF
SIGNAL
GROUND
"we,.:,[,,, ___________ ____"m,w:,1,,,

A
.35 WHT
-~
""'w:l,,
IGNITION KEY
LOCK CYLINDE~
5215----,
.35 WHT
.5 BLK 'WHT
J.;s
[I] IMPORTANT:
ANY NEW PASS-KeyII

DECODER MODULE WILL
AUTOMATICALLY PROGRAM
TO THE RESISTANCE OF THE
KEY (OR INTERROGATOR
SETTING) BEING USED AT THE
FIRST IGNITION "ON" CYCLE.
THIS CAN ONLY BE DONE
ONCE FOR THE LIFE OF THE
MODULE.
C210
1~
5109 (VIN P). -
(VINS)
.8 BLK/WHT
RESISTOR
SENSING
CONTACTS
0
KE~-
SEE GROUND
DISTRIBUTION
PAGESSA-14-1,2,3
451
__G103 (VINP)
G104 (VIN S)
IGNITION
k___T.
P110
.SBLK,'W
I
I
ELECTRICAL DIAGNOSIS: PASS-KeyII
12110259
GRN

DESCRIPTION
CAVITY
WIRE COLOR
CKT
A1
ORN
340
POWER FEED FROM ECM BAT FUSE #4
SA-11-6
A2
PNK
439
SA-11-4
A3
DKBLU
229
FUEL ENABLE SIGNAL
90-5
A4
YEUBLK
625
90-4, 5
AS
GRY
728
90-5
BS
BLK/WHT
451
GROUND
SA-14-1, 2, 3
87
PPUWHT
1074
90-5
BS
WHT/BLK
1073
90-5
COMPONENT
Clutch Start Switch
(ECM) (V6 VIN S) . . . . . .
(ECM) (V8 VIN P) .... .
1/P Fuse Block .......... .
Ignition Key Lock Cylinder
Instrument Cluster ...... .
PASS- KeyII Decoder
Module . . . . . . . . . . . . . . . .
Starter Enable Relay . . . . .
Starter Solenoid . . . . . . . . .
Switch . . . . . . . . . . . . . . . . .
PAGE
SECTION
SA-201-PG FIG.
LOCATION
19
35

19
35
Top RH side of Steering Column . . . . . . . . . . . . . . . . . . . . 3, 34 . 5, 51
Part of Steering Column . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 . . . 51 ..
LH side of I/P ................................................... .
CONN
202-18
202-19
202-22
202-22
202-22
In 1/P,just right of Radio, attached to Air Bag Bracket . 8 . . . . 15

Mounted to right side of SIR Bracket, behind 1/P . . . . . . 45
66
Bottom of RH side of Engine, above Starter Motor . . . . . 25
42
202-14
202-20
Under console, on base of shift control lever . . . . . . . . . . 37
202-24
54
SECTION
SA-201-PG
COMPONENT
LOCATION
C200B (18 cavities)

Part of I/P Harn, between LH kick pane I and
Steering Column . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Under RH side ofl/P, behind kick panel . . . . . . . . . . . . . . 46
(2 rings, 2 wires) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Compartment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
ECM breakout
ECM breakout
breakout
Lighter breakout ................................. 21
C2000 (48 cavities)

C210 (4 cavities) ........ .
C230 (10 cavities) ....... .
G103 (LTI) ............ ..
G104 (L32)
PllO ................... .
8109 (LTI)
8110 (L32)
8205
8209
8215
8223
8245 (Automatic)
8257 (Automatic)
FIG.
CONN
72
202-2
72
67
67
202-2
202-16
202-7
42
46
35
38
38
Diagnosis)
6.
Sys t e m
1. Check the Ignition Key for a cracked resistor pellet

or a pellet that is dirty or coated. Also check that
the Ignition Key is free from excess plastic around
the resistor pellet contacts.
2. Check owner's Ignition Key using the J 35628-A
PASS-KeyII Interrogator or equivalent. If the
Key Code window shows "E", replace the owner's
key. (See "Key Replacement," page 90-15.)
3. Check the key pellet sensing contacts in the
Ignition Lock Cylinder by looking into the key
opening. If the contacts are damaged or not silver
in color, replace the Lock Cylinder.
4. Check for an open "ECM IGN Fuse 5" or "ECM
BATT Fuse 4". Also check the I/P Fuse Block
contacts for each fuse.
5. If the Starter Enable Relay must be replaced, also
check CKT 6 to the Starter Solenoid for a possible
short. A short may have caused the relay to fail.
7.
To check the contacts to the key and the wires in

the Steering Column, disconnect the connector
near the base of the column. Use the J 39200 DVM
set on "MIN MAX" to measure the resistance back
to the key at this connector while you turn and
adjust the Steering Wheel. If there is any change
or intermittent reading, replace the Lock Cylinder
and the Steering Column wires that come with it.
See SECTION 3F5.
"Troubleshooting Procedures," page 8A-4-0l.

8.
9.

Refer to "Intermittents" on this page.
SYSTEM DIAGNOSIS
procedures.
INTERMITTENTS
(]] Important:
Additional information for detecting Electrical

Intermittents can be found on page 8A-4-8.
The most likely causes of intermittent no start no

crank complaints due to the PASS-KeyII SYSTEM
are either an incorrect resistance measurement of the
Ignition Key or an intermittent relay.
Incorrect resistance measurements checks:
If one key works and not the other, clean or

replace the faulty key.
If condition is present with all keys,
indications are that the lock cylinder is
dirty/defective or there is a fault in the key
resistance circuit wiring, connections or
contacts.
A method for checking the key resistance
circuit with an ohmmeter is a follows:
I. Use the J 39200 DVM to measure
resistance across key contacts while
removed from vehicle.
2. Disconnect the PASS-KeyII Decoder
Module, insert key in Ignition. With the
J 39200 set to "MIN MAX", measure
resistance across terminals "B8" and "B7''
of the Decoder Module Harness Connector.
Listen for an audible tone from the DVM.
This would indicate a fluctuating
resistance, while manipulating the
harness and rotating the Steering Wheel
from side to side. If the resistance
fluctuates, check the wiring and wiring
connections to the lock cylinder for an
intermittent (Ex:
poor
connection
or broken wire inside the insulation). If

the resistance is not within 5 ohms of the
resistance measured on the key when it
was removed from the vehicle, check for a
dirty or defective lock cylinder.
3. Rotate key throughout all positions and
monitor for a resistance change. This
would indicate a change of over 5 ohms
indicates a problem with the lock cylinder
or key contacts.
Intermittent relay checks:
If the "SECURITY" Indicator comes on for 5
seconds and then goes off, the relay is most
likely the problem. Check connections to
relay, if OK, install a new relay.
If the "SECURITY" Indicator remains "ON"
past the 5 second bulb check when the vehicle
will not crank, the relay is not the problem.
If it is necessary to turn the key to crank
several times before the Engine will crank, the
relay is probably intermittent. Check
connections to relay, if OK, install a new relay.
If the vehicle cannot be started immediately
after a fault, the relay is not the problem.
Some other areas to check include the following:
Check that the connector to the PASS-KeyII
Decoder Module is tight and terminals are
clean.
Check for History Diagnostic Trouble Code 46
in ECM, intermittent fuel enable CKT 229.
See SECTION 6E3.
Check power and ground to the module while
manipulating the harness.
During an Ignition Cycle the "SECURITY"
Indicator will illuminate and remain "ON"
while a problem is detected in the key
resistance circuits (for at least 1 minute) and
will turn "OFF" if the fault goes away.
Lightly tapping the Decoder Module will
determine if the module is intermittent.
Intermittents are typically not the Decoder
Module.
Thermal cycle Starter Enable Relay and
Decoder Module and reinstall in vehicle to
induce fault.
[I] Important:
Perform the Diagnostic Circuit Check described

in SECTION 6E3 to be certain no trouble codes
are stored in ECM memory which may lead to
misdiagnosis, specifically Code 46, indicating a
problem in the PASS-Key@II Fuel Enable
circuit.
SYSTEM CHECK
NORMAL RESULTS
ACTION
[1]
Observe "SECURITY" Indicator.
"SECURITY" Indicator illuminates for approximately 5

seconds then goes "OFF."
[2]
Position Switch in "PARK."
(Manual Transmission)
Clutch Start Switch closed (depress Clutch Pedal).
Ignition switch to "START."
Engine starts.
[3]
Engine stops.
[4]
Disconnect PASS-KeyII Connector at base of
Steering Column.
Connect the male and female parts to the mating
connectors on the pigtails from the J 35628-A
Interrogator or equivalent.
Insert the customer's Ignition Key into the Key
Code Reader on the J 35628-A Interrogator.
Press the On-Off Rocker Switch to the "ON"
position.
A number from 1 to 15 will appear on the display
of the Interrogator indicating the electrical code
of the key ("E" indicates error).
Set the Key Code Selector on the J 35628-A
Interrogator to a code which is different from the
Vehicle will not crank.
code read on the Key Code Reader display.
illuminated.
Turn Ignition Switch to "ST ART."
"SECURITY" Indicator is
[5]
(Perform this step within the 3 minute shut-down

period).
Disconnect and remove the J 35628-A
Interrogator.
Vehicle will not crank'.
Reconnect connectors at base of Steering Column. illuminated.
Turn Ignition Switch to "START."
[6]
Turn Ignition Switch to "OFF."

Wait 3 to 4 minutes.
Observe the Indicator.
When Indicator goes "OFF," turn Ignition Switch
to "START."
Engine starts.
"SECURITY" Indicator is

SYMPTOM TABLE
(Always note condition of "SECURITY" Indicator when fault occurred.)
SYMPTOM
PROCEDURE
PAGE NUMBER
Engine does not crank; "SECURITY" Indicator

illuminates for approximately 5 seconds (bulb check)
then goes out.
Chart #1
9D-11
Engine cranks but won't start; "SECURITY" Indicator

illuminates for approximately 5 seconds (bulb check)
then goes out.
Chart #2
9D-12
"SECURITY" Indicator "ON" steady (not flashing);

Engine starts.
Chart #3
9D-12
"SECURITY" Indicator never illuminates; Engine starts.
Chart #4
9D-13
Engine does not crank; "SECURITY" Indicator "ON" Perform Lock Cylinder
page 90-13 (Chart #5).
steady (not flashing).
and
Engine does not crank; "SECURITY" Indicator Perform Lock Cylinder and
"FLASHING."
Harness Test on
Harness Test
on
Engine does not crank; "SECURITY" Indicator does not Check for battery voltage at PASS-KeyII Decoder
Module Conn term "A 1".
illuminate at Ignition "ON."
Check for battery voltage at PASS-KeyII Decoder
Module Conn term "A2".
Check for ground at PASS-KeyII Decoder Module
Conn term "BS".
If power and ground wires to PASS-KeyII Decoder
Module are OK, replace PASS-KeyII Decoder Module.
"SECURITY" Indicator "FLASHING"; Engine starts.
This symptom is present when an unprogrammed

module is put in a vehicle that has an open or short to
ground in the Lock Cylinder Contacts or CKTs 1073 or
1074, or with a damaged key.)
Perform Lock Cylinder and Harness Test on
CHART #1
ENGINE DOES NOT "CRANK"; "SECURITY" INDICATOR ILLUMINATES
FOR APPROXIMATELY 5 SECONDS (BULB CHECK) THEN GOES OUT
[I] IMPORTANT:
r-----------------------------------------------------------,
ON A VEHICLE WITH A MANUAL TRANSMISSION, AN EASY CHECK OF THE DECODER

:
MODULE ANO STARTER ENABLE RELAY IS TO LOOK FOR BATTERY VOLTAGE AT THE
I
CLUTCH START SWITCH WHEN THE IGNITION IS TURNED TO "START." DISCONNECT THE
:
CONNECTOR TO THE CLUTCH START SWITCH AND CONNECT A TEST LIGHT FROM TERM "A" :
TO GROUND.
IF TEST LIGHT IS "ON" WHEN IGNITION IS TURNED TO "START," REFER TO "STARTER AND
I
_ CHARGING," PAGE SA-30-0. IF LIGHT STAYS "OFF," CONTINUE WITH CHART. _______ --~
DISCONNECT STARTER ENABLE RELAY.

ATTACH A TEST LIGHT BETWEEN STARTER ENABLE RELAY CONN TERM "A1" AND B +.


TERM "C1" ANO GROUND.
CHECK FOR OPEN IN CKT 5 OR OPEN

IN POWER FEED THROUGH AND
INCLUDING IGNITION SWITCH.
ATTACH A 30 AMP FUSED JUMPER BETWEEN STARTER

ENABLE RELAY CONN TERM "C1" AND TERM" A2".
DOES ENGINE CRANK?

BETWEEN STARTER ENABLE RELAY
CONN TERM "C1" ANO 5223.
r-
CHECK FOR POOR CONNECTION TO RELAY.

IF OK, REPLACE STARTER ENABLE RELAY.
ALSO CHECK CKT 6 TO THE STARTER SOLENOID
FOR A POSSIBLE SHORT. A SHORT MAY HAVE
CAUSED THE RELAY TO FAIL.
CHECK FOR POOR CONNECTION OR OPEN IN CKT 625.

IF OK, REPLACE PASS-KeyII DECODER MODULE.
----------------------,
: REFER TO "STARTER AND CHARGING," :

I PAGE SA-30-0.
1
L------------------------~
9012 THEFT DETERRENT SYSTEMS

CHART #2
ENGINE CRANKS BUT WON'T START; "SECURITY" INDICATOR ILLUMINATES
FOR APPROX 5 SECONDS (BULB CHECK) THEN GOES OUT
[I] IMPORTANT:
DISCONNECT PASS-KeyII DECODER MODULE.

WITH A DVM MEASURE VOLTAGE BETWEEN PASS-KeyII
DECODER MODULE CONN TERM" Al" AND GROUND.
IS MEASURED DC VOLTAGE APPROX + SV?
r-
---------------------,
:
'
:
:
:
CHECK CKT 229 FOR AN OPEN

OR SHORT BETWEEN DECODER
MODULE CONN TERM" Al" AND
(ECM). ALSO CHECK FOR POOR
CONNECTIONS TO MODULES.
IF OK, REFER TO SECTION 6E3.
FOLLOW "ENGINE CRANKS BUT
WILL NOT RUN," CHART A-3.
:
:
I
IGNITION SWITCH "OFF."

RECONNECT MODULE.
MEASURE VOLTAGE AGAIN AT TERM "Al".
IS MEASURED DC VOLT AGE APPROX + 2 .SV?
CHECK FOR POOR CONNECTION.

IF OK, REPLACE PASS-KeyII
DECODER MODULE.
L-----------------------
r-
------------------,
: REFER TO SECTION 6E3; FOLLOW:

' "ENGINE CRANKS BUT WILL NOT I
: RUN," CHART A-3.
:
L---------------------J
CHART #3
"SECURITY" INDICATOR "ON" STEADY (NOT FLASHING); ENGINE STARTS
[I] IMPORTANT:

IS "SECURITY" INDICATOR ILLUMINATED?
----------------------------,
CHECK FOR SHORT TO GROUND ON CKT 728

BETWEEN PASS-KeyII DECODER MODULE
CONN TERM" AS" AND INSTRUMENT
CLUSTER CONN TERM" A3".
CHECK INSTRUMENT CLUSTER PRINTED
CIRCUIT FOR SHORTS AND REPAIR/REPLACE
AS NECESSARY.
REFER TO SECTION BA-81.
L------------------------------
PERFORM LOCK CYLINDER AND HARNESS TEST ON PAGE 90-13 (CHART #5).
IF KEYS, LOCK CYLINDER AND LOCK CYLINDER HARNESS ARE OK, REPLACE
PASS-KeyII DECODER MODULE. (THE PASS-KeyII DECODER MODULE IS
PROGRAMMED WITH A FAULT ENABLE MODE. IN THIS MODE THE "SECURITY"
INDICATOR WILL STAY "ON" STEADY IF A FAILURE OCCURRED, IN THE LOCK
CYLINDER OR CKTS 1073 OR 1074, DURING THE PREVIOUS IGNITION CYCLE.)
CHART #4
"SECURITY" INDICATOR NEVER ILLUMINATES; ENGINE STARTS
[I) IMPORTANT:
ATTACH A 10 AMP FUSED JUMPER BETWEEN PASS-KeyII DECODER
MODULE CONN TERM" AS" (HARNESS SIDE) ANO GROUND.
DOES "SECURITY" INDICATOR ILLUMINATE?
r- ---------------------------------------------------------,
:
I
:
:
I
CHECK FOR POOR CONNECTION OR OPEN IN CKT 728 BETWEEN PASS-KeyII DECODER
:
MODULE CONN TERM "AS" ANO INSTRUMENT CLUSTER CONN TERM "A3".
1
CHECK FOR OPEN IN CKT 39 BETWEEN INSTRUMENT CLUSTER CONN TERM" A 13" AND S209. :
INSPECT INSTRUMENT CLUSTER PRINTED CIRCUIT ANO INDICATOR LAMP, REPAIR/REPLACE
AS NECESSARY.
SEE "INSTRUMENT CLUSTER," PAGE SA-81-0 FOR BACK VIEW AND PIN OUT OF CLUSTER.
1

AT PASS-KeyII DECODER
MODULE.
IF OK, REPLACE PASS-KeyII
DECODER MODULE.
L-----------------------------------------------------------J
CHART #5
rn
LOCK CYLINDER AND HARNESS TEST

IMPORTANT:
TO AVOID MISDIAGNOSIS, DO NOT PERFORM THIS TEST UNLESS DIRECTED BY SYMPTOM TABLE OR CHART.
INSERT IGNITION KEV INTO PASS-KeyII INTERROGATOR J 35628-A.

TURN THE INTERROGATOR "ON."
READ THE "KEY CODE" SHOWN ON THE DISPLAY OF THE INTERROGATOR.
IS THE DISPLAYED "KEY CODE" A VALUE OF "1" THROUGH "15"?
WRITE DOWN THE DISPLAYED "KEV CODE."

TURN THE INTERROGATOR "OFF."
CONNECT THE INTERROGATOR TO THE 2-WAV IGNITION SWITCH LOCK CYLINDER
HARNESS CONNECTOR AT THE BASE OF THE STEERING COLUMN.
INSERT THE IGNITION KEV INTO THE IGNITION SWITCH LOCK CYLINDER.
TURN THE INTERROGATOR "ON."
WHILE OBSERVING THE DISPLAY ON THE INTERROGATOR, TURN THE IGNITION SWITCH
SLOWLY TO THE "START" POSITION.
DOES THE DISPLAYED "KEV CODE" VALUE MATCH THE VALUE OBSERVED IN STEP 1?
CLEAN ANO RETEST THE KEY.

IF THE "KEY CODE" IS
INVALID, REPLACE THE KEY.
SEE "KEY REPLACEMENT,"
PAGE 90-15.
FRONTPROBE WITH A TEST LIGHT THE 2WA Y

CONNECTOR AT THE BASE OF THE STEERING COLUMN
BETWEEN TERM "B" (DECODER MODULE SIDE) AND B +.
DOES THE TEST LIGHT ILLUMINATE?
CHECK CKT 1073 FOR AN OPEN, SHORT

TO B + OR SHORT TO GROUND.
IF OK, REPLACE PASSKeyII DECODER
MODULE.
----------------------------------,
CHECK FOR POOR CONNECTION.

:
IF OK, REPLACE IGNITION SWITCH LOCK CYLINDER AND I
HARNESS (REFER TO SECTION 3FS.)
:
~------------------------------------~

PROBE WITH A TEST LIGHT PASSKeyII DECODER MODULE
CONNECTOR BETWEEN TERM "BS" AND B +.

TERMINALS "BS" OR "87" TO
MODULE, OR OPEN IN CKT 1074.
IF OK, REPLACE PASSKeyII
DECODER MODULE.
DUPLICATION OF KEYS
KEY REPLACEMENT (SPARE KEY AVAILABLE)
CR]
KEY CODE READER
({)
The J 35628-A Interrogator or equivalent must be

used to determine the proper electrical code of the key.
1. Insert the customer's spare Ignition Key into the
Key Code Reader on the J 35628-A Interrogator.
2. Press the On-Off rocker switch to the "ON"
position.
3. A number from 1 to 15 will appear in the window
designating the electrical code of the key.
4. Cut a new key having the electrical code
determined from the ,J 35628-A Interrogator.
5. Start the Engine using the new key to insure that
the key is correct both mechanically and
electrically.
PASS-KeyII Interrogator J 35628-A
SEE PAGE SA-J-0
FOR PROPER
HANDLING
PROCEDURES
KEY CODE AND RESISTANCE CHART
electrical code. Use the 4-minute Timer on the

35628-A Interrogator to indicate the
4-minute interval. Start the Timer by
depressing the "Start" rocker switch. The red
indicator will turn off at the end of a four
minute interval. This procedure must be
repeated until the Engine can be started. Cut
a new key having the electrical code which
allowed the vehicle to start.
PELLET CODE
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
KEY RESISTANCE IN OHMS

Nominal
Low
High
402
523
681
887
1130
1470
1870
2370
3010
3740
4750
6040
7500
9530
11800
386
502
654
852
1085
1411
1795
2275
2890
3590
4560
5798
7200
9149
11328
438
564
728
942
1195
1549
1965
2485
3150
3910
4960
6302
7820
9931
12292
KEY REPLACEMENT
(NO SPARE KEY AVAILABLE)
1. If the Ignition Key is lost and there is no spare key,

determine the mechanical code from the code on
the Ignition Key Lock Cylinder. The code may also
be determined from the dealer invoice for the
vehicle, or from the Chevrolet Zone Office.
2. Cut a new key to this mechanical code. Use a
blank PASS-KeyII test key which has no
resistance pellet. This key will be used to operate
the Ignition Switch for the remaining steps.
3. Remove the hush panel under the Steering
Column and disconnect the two-cavity connector
leading into the Steering Column.
4. Close the LH door.
5. Insert the male half of the connector (1/P Harness)
into the female pigtail connector from the
J 35628-A Interrogator.
6. Set the Key Code Selector on the Interrogator
(J 35628-A or equivalent) to "l".
7. Attempt to start Engine using the key made in
step 2.
If Engine starts, the Key Code Selector is set to
the correct electrical code. Cut a new key
having this electrical code. The new key will
be the customer's replacement key.
If Engine does not start, turn Ignition Switch
to "OFF," then turn the Key Code Selector to
the next higher position. Wait four minutes
and attempt to start the Engine using the new
PROGRAMMING A NEW DECODER MODULE
(I] Important:
Any new PASS-KeyII Decoder Module will

automatically program to the resistance of the
key (or interrogator setting) being used at the
first Ignition "ON" cycle. This can only be done
once for the life of the module.
New decoder modules are unprogrammed. Before

the system will function properly after a new module
has been installed, it must be programmed to the code
that matches the customer's keys. Programming a
new module is very simple:
1. Install the new, unprogrammed decoder module.
2. Insert one of the customer's keys in the ignition
lock cylinder and turn it to the "ON" position. It's
a good idea to start the Engine at this time to
verify system operation.
3. Observe the "SECURITY" Indicator Lamp:
The indicator lamp should light for about five
seconds and then go out. If the wiring or
contacts to the Key Resistance Pellet or the
key is defective or intermittent and a new
module is installed, the Engine will start but
the "SECURITY" Indicator will flash at a rate
of one flash per second until the Ignition
Switch is turned off. This indicates that the
module did not program and that the system
components, wiring and contacts should be
checked for a fault.
(I] Important:
Before connecting the Interrogator to the

ignition lock cylinder circuit, always verify
vehicle key code and set the code into the
Interrogator using "key code" knob. This
will
prevent
programming
an
unprogrammed decoder module with an
undesired key code.

CIRCUIT OPERATION
PASS-KeyII is a theft deterrent system which
prevents the vehicle from starting if the Ignition Key
"Resistance Code" is not
recognized by the
PASS-KeyII Decoder Module. If the Resistance Code
is not recognized, the Engine is prevented from
starting in two ways: battery voltage from the
Ignition Switch to the starter is disabled by a Starter
Enable Relay and fuel to the fuel injectors is stopped
without the presence of a fuel enable signal.
Resistor sensing contacts are located in the
Ignition Key Lock Cylinder. These contact the Key
Resistor Pellet on the key when it is inserted. When
the lock is rotated, Ignition voltage is applied to the
PASS-KeyII Decoder Module and pellet resistance is
read at this time. The Pellet resistance is read across
terminals "B7'' and "BS" which is then compared
against the resistance value stored in the Module.
If the Key Resistance Pellet is the proper
resistance, terminal "A4" is grounded, energizing the
Starter Enable Relay. At the same time, a signal is
applied at terminal "A3" to enable the Engine Control
Module (ECM). When this signal is received by the
ECM, it allows fuel injector pulses to begin.
If the Key Resistor Pellet is the wrong value, the
PASS-KeyII Decoder Module will shut down for
3 minutes + or - 18 seconds. During this interval,
there will be no output at terminals "A3" or "A4" and
the "SECURITY" Indicator will illuminate. The
Ignition Switch input is ignored during this shut down
period. For this reason, the timer will run and the
"SECURITY" Indicator will remain illuminated with
Ignition on or off.
Once the timer has completed its 3 minute + or 18 second shut down, the next time Ignition is cycled
from off to on, the PASS-KeyII Decoder Module timer
is reset. A key having the correct code can then be
used to start the Engine.
"SECURITY" INDICATOR OPERATION

The "SECURITY" Indicator is controlled directly
by the PASS-KeyII Decoder Module. The following
describes the modes of indicator operation:
l. When the Ignition is put in "RUN," "BULB
TEST," or "START," the "SECURITY" Indicator
illuminates for about 5 seconds as a bulb check.
2. If the PASS-KeyII Decoder Module is actively in
the shut down mode and thus preventing the
vehicle from starting, the indicator will be
illuminated (grounded) by the PASS-KeyII
Decoder Module for 3 minutes + or - 18 seconds
after Ignition is turned on.
3. If the resistor sensing contacts or CKTs 1073 or
1074 are open or shorted, or if a defective key is
being used at the time Ignition is turned on, the
"SECURITY" Indicator will flash at a rate of once
per second and the Engine will not start; however,
the 3 minute + or - 18 second lockout will not be
activated. Additionally, if an unprogrammed
module is present and there is an open or short, or
if a defective key is being used the PASS-KeyII
Decoder Module will not program a key code, the
"SECURITY" Indicator will flash at a rate of once
per second, and the Engine will start.
4. Lock Cylinder CKTs 1073 and 1074 are
continuously monitored and if a fault is detected in
these circuits for 1 minute, the indicator will turn
"ON." If the fault condition goes away for
1 minute, the indicator will turn "OFF" and the
system will function as normal. If a lock cylinder
circuit fault (lock cylinder contacts or wiring
becomes open or shorted, or if a defective key is
detected) while the Engine is "RUNNING", the
vehicle can be restarted. The "SECURITY"
Indicator will illuminate during this Ignition cycle
while the fault is present. When a fault condition
is present at the time Ignition is cycled off, the
vehicle will not be protected by the PASS-KeyII
System and the indicator will be illuminated
whenever the Ignition is on, until the fault is
corrected. This is called the Fault Enable Mode.
ON-VEHICLE SERVICE
THEFT DETERRENT MODULE ASSEMBLY
IGNITION KEY ASSEMBLY
Figure 3
Copying Ignition Key Assemblies
Tool Required:
J 35628-A VATS/PASS Interrogator
To copy an ignition key assembly, it is necessary to
first determine which PASS-Key 11 key code (resistance
value) is needed. The ignition key assembly being copied
must be tested to determine the key code. The ignition key
assembly may be tested using J 35628-A. To use
J 35628-A, turn the tool on, make sure the tool wiring
connectors are disconnected and insert the ignition key
assembly into the tool lock cylinder. The "Key Code
Reader" will display the key code of the ignition key
assembly. Obtain an ignition key blank matching this
key code and cut it to match the original ignition key
assembly.
Replacing Lost Ignition Key Assemblies

Tool Required:
J 35628-A VATS/PASS Interrogator
To replace lost ignition key assemblies it is necessary to determine the mechanical cut and the electrical key
code.
The mechanical and electrical key codes are
recorded on the vehicle invoice. If these codes are available, use them to create a new ignition key assembly. If
they are not, follow the procedure below.
The mechanical cut must be determined first. The
mechanical cut can be determined from the key code on
the ignition cylinder assembly or from the original key
"knock outs." If the mechanical cut cannot be determined, the ignition cylinder assembly should be replaced.
Make an ignition key blank with the correct mechanical
cut to use while determining the proper electrical key
code.
To determine the proper electrical key code, use
J 35628-A and the following procedure:
1. Instrument panel assembly. Refer to SECTION 8C.

3. Theft deterrent module assembly (1) from inflatable
restraint bracket assembly (7).

2. Theft deterrent module assembly (1) to inflatable
restraint bracket assembly (7).
3. Bolts/screws (6) by first securing lower right bolt/
screw (6) and then securing upper left bolt/screw
(6).
!~I Tighten
[I] Important
1.
2.
3.
4.
5.
6.
Do not disconnect yellow two-way SIR connector.

Connect J 35628-A wiring to PASS-Key n dash
connector at base of steering column assembly. Do
not connect to steering column wiring.
Turn J 35628-A on and place key code switch to "1"
and attempt to start engine with proper mechanically
cut key. If engine starts, key code is " 1."
If engine does not start, turn ignition off and press
4-minute timer on J 35628-A.
When timer light goes out, place key code switch to
"2" and attempt to start engine. If engine starts, key
code is "2."
Continue trying different key codes until proper key
code is found.
Make new ignition key assembly with proper key
code and mechanical cut.
1 MODULE ASSEMBLY, THEFT DETERRENT
6 BOLT/SCREW, THEFT DETERRENT MODULE, 1.9 Nm
(17 LB. IN.)
PC00039DFRP
Figure 3 - Theft Deterrent Module Assembly
9018 THEFT DETERRENT SYSTEMS

THEFT DETERRENT RELAY ASSEMBLY
Figure 4
If the relay assembly is determined to be inoperative, it should be replaced.
a
A --r--E-?,
W:i~~II

3. Relay assembly (8) from inflatable restraint bracket
assembly (7).
4. Electrical connector from relay assembly (8).

1. Electrical connector to relay assembly (8).
8 RELAY ASSEMBLY, THEFT DETERRENT
2. Relay assembly (8) to inflatable restraint bracket

assembly (7).
PC0004-90-F-RP
Figure 4 - Theft Deterrent Relay Assembly
SPECIFICATIONS
Theft Deterrent Module Bolt/Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.9 Nm (17 lb. in.)
SPECIAL TOOLS
1.
1. VATS/PASS INTERROGATOR
PC0005-9DF-RP
ENGINE COOLANT HEATER 9E-1
SECTION 9E
ENGINE COOLANT HEATER

result.
CONTENTS
General Description . . . . . . . . . . . . . . . . . . . . . . . . 9E-1
On-Vehicle Service . . . . . . . . . . . . . . . . . . . . . . . . 9E-1
Engine Coolant Heater Assembly
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . 9E-1
GENERAL DESCRIPTION
The engine coolant heater assembly is used to heat
engine coolant, making it easier to start the engine in cold
climates. It is installed into the engine block assembly at a
water jacket plug location. An engine coolant heater cord
assembly is routed inside the engine compartment. The
heater assembly is rated at 600 watts and uses a 110-volt
ac power supply. For electrical diagram of engine coolant
heater assembly, refer to ELECTRICAL DIAGNOSIS
8A-32.
ON-VEHICLE SERVICE
ENGINE COOLANT HEATER ASSEMBLY
REPLACEMENT
Figures 1 and 2
l++I
CAUTION: Perform this operation when

the engine is cool or personal injury
may result.
2. Drain engine coolant from engine block assembly
into an approved container. Refer to SECTION 6B.
3. Cord assembly from heater assembly (1).
4. Loosen bolt/screw (2).
NOTICE: When removing the engine coolant heater

assembly from the engine block assembly, be careful
not to score the machined surface of the plug hole.
5. Heater assembly (1) carefully from plug hole.
If removing heater assembly (1) permanently,
install water jacket plug into plug hole and
replace engine coolant. For engine coolant replacement procedures, refer to SECTION 6B.
Engine Coolant Heater Cord Assembly

Replacement .......................... 9E-2
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9E-3
Fastener Tightening Specifications . . . . . . . . . . 9E-3
l~I
Clean
Plug hole.
- Remove burrs, sealer, paint and other rough
spots.
l++I
Install or Connect
NOTICE: The element must not touch the engine

block assembly inner wall in the installed position or
damage to the engine block assembly and heater
assembly could result.
section.
1. Apply coat of engine coolant heater lubricant, GM
PIN 9985164 or equivalent, to 0-ring and walls of
plug holes.
2. Engine coolant heater assembly (1) into plug hole.
A. Insert heating element end of heater assembly
(1) into plug hole.
B. Line up heater assembly (1) with plug hole and
push it straight into place.
C. Rotate heater assembly (1) so that center electrical contact and bolt/screw (2) are in line horizontally.
D. Turn bolt/screw (2) so that yoke presses
against engine block assembly inner wall.
l~I
Tighten

CAUTION: Engine coolant heater cord
assembly must not touch the engine,
hot pipes, manifold or any moving
parts or damage to the vehicle and possible personal injury may result.
3. Cord assembly to heater assembly (1).
4. Lower vehicle.
9E-2 ENGINE COOLANT HEATER
t'
!VIEWA
SECTION A-A
A
B
C
1
2
0-RING
WALL, ENGINE BLOCK
PLUG HOLE
HEATER ASSEMBLY, ENGINE COOLANT
BOLT/SCREW, ENGINE COOLANT HEATER,
1.9 Nm (17 LB. IN.)
A
B
C
D
1
2
0-RING
WALL, ENGINE BLOCK
PLUG HOLE
ELEMENT, HEATING
HEATER ASSEMBLY, ENGINE COOLANT
BOLT/SCREW, ENGINE COOLANT HEATER,
1.9 Nm (17 LB. IN.)
PC0001-9E-F-RP
Figure 1 - Engine Coolant Heater Assembly (5.7L LT1

Engine)
5. Replace engine coolant. Refer to SECTION 6B.
ENGINE COOLANT HEATER CORD

ASSEMBLY REPLACEMENT
Figures 3 and 4
PC0002-9E-F-RP
Figure 2 - Engine Coolant Heater Assembly (3.4L L32

Engine)

CAUTION: Engine coolant heater cord
assembly must not touch the engine,
hot pipes, manifold or any moving
parts, or damage to the vehicle and
possible personal injury may result.
NOTICE: See "Notice" on page 9E-1 of this section.
1. Note position and routing of cord assembly (3) for

proper placement during installation.
2. Cord assembly (3) from heater assembly (1).
1. Cord assembly (3) to vehicle routing as noted during

removal.
3. Cord straps (4 ).
2. Cord straps (4).
4. Cord assembly (3) from vehicle routing.
3. Cord assembly (3) to heater assembly (1).
ENGINE COOLANT HEATER 9E-3
1 HEATER ASSEMBLY, ENGINE COOLANT

3 CORD ASSEMBLY, ENGINE COOLANT HEATER
4 STRAP, ENGINE COOLANT HEATER CORD
3 ~
1 HEATER ASSEMBLY, ENGINE COOLANT
:'" ~ " '
3 CORD ASSEMBLY, ENGINE COOLANT HEATER
4 STRAP, ENGINE COOLANT HEATER CORD
PC0003-9E-F-RP
PC0004-9E-F-RP
Figure 3 - Engine Coolant Heater Cord Assembly (5.7L LT1

Engine)
Figure 4 - Engine Coolant Heater Cord Assembly (3.4L L32

Engine)
SPECIFICATIONS
Engine Coolant Heater Bolt/Screw .. _.................................. 1.9 Nm (17 lb. in.)
SIR INTRODUCTION 9J-1
SECTION 9J

(SIR) SYSTEM INTRODUCTION
CAUTION: This vehicle is equipped with Supplemental Inflatable Restraint (SIR). Refer
to CAUTIONS in this section under "ON-VEHICLE SERVICE" and the SIR Component and
Wiring Location view in this section before performing service on or around SIR
deployment, personaf injury, or otherwise unneeded SIR system repairs.
CONTENTS
General Description 9J-1
System Description 9J-1
SIR Component and Wiring Location
View 9J-3
Component Description 9J-4
DERM 9J-4
"AIR BAG" Warning Lamp
9J-4
Dual Pole Arming Sensor 9J-4
Discriminating Sensors 9J-5
SIR Coil Assembly 9J-6
Passenger lnflator Module Jumper
9J-6
lnflator Modules 9J-6
Steering Column
9J-6
Knee Bolster 9J-6
Definitions 9J-6
Diagnosis Section 9J-A
On-Vehicle Service 9J-8
Service Precautions 9J-8
Disabling the SIR System 9J-8
Enabling the SIR System 9J-8
Handling/Installation/Diagnosis 9J-9
Sensors
9J-9
lnflator Modules
Live (Undeployed} lnflator Module
Shipping Procedures for Live
(Undeployed) lnflator Modules
lnflator Module Scrapping Procedure
Deployment Outside Vehicle
(Driver lnflator Module)
9J-9
9J-9
9J-9
9J-9
9J-10
GENERAL DESCRIPTION
The Supplemental Inflatable Restraint (SIR)
system helps supplement the protection offered by the
driver and front passenger seat belts by deploying an
air bag from the center of the steering wheel and from
the top of the right side of the instrument panel
(Figure 1). The air bag deploys when the vehicle is
involved in a frontal crash of sufficient force up to 30
degrees off the centerline of the vehicle (Figure 2). To
further absorb the crash energy there is a knee bolster
located beneath the instrument panel for both the
driver and passenger and the steering column is
collapsible.
Deployment Outside Vehicle

(Passenger lnflator Module) 9J-17
Deployment Inside Vehicle
(Vehicle Scrapping
Procedure) 9J-17
Deployed lnflator Module
Handling 9J-21
After an Accident 9J-21
Accident With DeploymentComponent Replacement and
Inspections 9J-22
Accident With or Without Deployment Component Inspections
9J-22
Sensor Replacement Guidelines
9J-22
Removal and Installation
Procedures Section 9J-B
Wiring Repair 9J-23
Terminal Repair KitJ 38125-A 9J-23
SIR Connector (Plastic Body and
Terminal Metal Pin) Repair
9J-23
SIR Wire Pigtail Repair 9J-23
SIR Wire Repair 9J-23
SIR System Wire Splice Repair 9J-24
Alternative Repair Methods
9J-24
9J-24
Connector Position Assurance (CPA)
Terminal Position Assurance (TPA)
9J-25
Special Tools
9J-25
SIR Driver/Passenger Load Tool
9J-25
SYSTEM DESCRIPTION
The main portions of the SIR system are the
deployment loops and the Diagnostic Energy Reserve
Module (DERM). The main function of the deployment
loops is to supply current through the inflator
modules, which will cause deployment of the air bags
in the event of a frontal crash of sufficient force, up to
30 degrees off the centerline of the vehicle.
The dual pole arming sensor, SIR coil assembly
(driver side only), passenger inflator module jumper
(passenger side only), inflator modules, passenger
compartment discriminating sensor, and forward
discriminating sensor make up the deployment loops.
9J-2 SIR INTRODUCTION
. - - - - - TO PASSENGER
36VLR
DUAL POLE
ARMING
SENSOR
(J]
(I]
DEPLOYED AIR BAG
IJJ
SEAT BELT
PASS.
INFLATOR
MODULE
PASS. INFLATOR
MODULE JUMPER
KNEE BOLSTER
95 6227-9J
Figure 1 - Restraint Devices
t~---SHORTING BARS
_j
DRIVER
INFLATOR
MODULE
PASSENGER
COMPARTMENT
DISCRIMINATING
SENSOR
C200B: 02 :
(2008
7-7-92
NS 11427
Figure 3 - Deployment Loop
NS11315
Figure 2 - SIR System "Deployment Window"
The dual pole arming sensor switches power to the

inflator modules on the high side (power side) of the
deployment loops. Either of the discriminating
sensors can supply ground to the inflator modules on
the low side (ground side) of the loop. The inflator
modules are only supplied sufficient current to deploy
when the dual pole arming sensor and at least one of
the two discriminating sensors are closed
simultaneously.
A function of the Diagnostic Energy Reserve

Module (DERM) is to supply the deployment loops
with a 36 Volt Loop Reserve (36 VLR) to ensure
sufficient energy to deploy the air bags if the ignition
feed to the dual pole arming sensor is lost during a
frontal crash.
Another function of the DERM is electrical system
diagnostics. The DERM monitors the circuit in
conjunction with the resistors in the dual pole arming
sensor and the discriminating sensors. These resistors
make it possible for the DERM to detect circuit and
component malfunctions within the deployment loops.
The DERM monitors the voltage drop across each
component within the loop during normal, nondeployment conditions. If the monitored voltages fall
outside of expected limits, the DERM will indicate a
malfunction through the storage of a diagnostic
trouble code and the illumination of the "AIR BAG"
warning lamp.
PASSENGER COMPARTMENT DISCRIMINATING SENSOR
STEERING COLUMN SUPPORT BRACKET
FRONT END TIE BAR
FORWARD DISCRIMINATING SENSOR
HVACDUCT
5
7
9
10
11
PASSENGER INFLA TOR MODULE

1/P COMPARTMENT DOOR ASSEMBLY
DUAL POLE ARMING SENSOR
FLOOR TUNNEL
SIR COIL ASSEMBL V
DERM
12
13
SIR WIRING HARNESS
14
DRIVER INFLATOR MODULE HARNESS CONNECTOR
DRIVER INFLATOR MODULE

NS 11453
Figure 4 - SIR Component and Wiring Location View

COMPONENT DESCRIPTION
DERM
NOTICE: Do not open the DERM case for any
reason. Touching the connector pins or soldered
components may cause electrostatic discharge
damage. Repair of a malfunctioning DERM is by
replacement only.
The DERM (Diagnostic Energy Reserve Module) is
designed to perform the following functions in the SIR
system:
I. Energy Reserve - The DERM maintains two 36
Volt Loop Reserve (36 VLR) energy supplies to
provide deployment energy when the vehicle
voltage is low or lost in a frontal crash.
2. Malfunction Detection - The DERM performs
diagnostic monitoring of SIR system electrical
components.
3. Malfunction Recording - The DERM provides
SIR system diagnostic trouble code
information through a scan tool or the "AIR
BAG" warning lamp.
4. Driver Notification - The DERM warns the
vehicle driver of SIR system malfunctions by
controlling the "AIR BAG" warning lamp.
5. Frontal Crash Recording - The DERM records
the SIR system status during a frontal crash.
The DERM is connected to the SIR wiring harness
by a 24-way connector. This harness connector uses a
shorting bar across certain terminals in the contact
area. This shorting bar connects the "AIR BAG"
warning lamp to ground when the DERM connector is
disconnected. This will cause the "AIR BAG" warning
lamp to come "ON" steady whenever the ignition
switch is at the RUN, BULB TEST or START positions
with the DERM disconnected.
"AIR BAG" Warning Lamp

Battery voltage is applied to the "AIR BAG"
warning lamp when the ignition switch is at the RUN,
BULB TEST or START positions. The DERM controls
the lamp by providing ground with a lamp driver. The
"AIR BAG" warning lamp is used in the SIR system to
do the following:
1. Verify lamp and DERM operation by flashing
seven times when the ignition switch is first
turned "ON."
2. Warn the vehicle driver of SIR electrical
system malfunctions which could potentially
affect the operation of the SIR system. These
malfunctions could result in non-deployment
in case of a frontal crash or deployment for
conditions less severe than intended.
SIR COIL ASSEMBLY

2
INFLATOR MODULE CONNECTOR
STEERING COLUMN CONNECTOR

NS 15297
Figure 5 - SIR Coil Assembly
3. Provide diagnostic information by flashing the

diagnostic trouble codes when the "Flash
Code" diagnostic mode is enabled.
The "AIR BAG" warning lamp is the key to driver
notification of SIR system malfunctions. For proper
lamp operation, refer to "SIR Diagnostic System
Dual Pole Arming Sensor

The dual pole arming sensor is a protective switch
located in the high side (power side) of the deployment
loops. The dual pole arming sensor is calibrated to
close at low level velocity changes (lower than the
discriminating sensors). This ensures that the inflator
modules are connected directly to the "36 VLR"
outputs of the DERM or "Ignition l" voltage when
either discriminating sensor closes.
The dual pole arming sensor consists of: a sensing
element, two sets of normally open switch contacts,
diagnostic resistors, and diodes. The sensing element
closes both sets of switch contacts when the velocity of
the vehicle changes at a rate indicating a potential
need for deployment.
Two of the diagnostic resistors are connected in
parallel with the switch contacts. This allows a small
amount of current to flow through each of the
deployment loops during normal, non-deployment
operation. This current flow results in voltage drops
across each component in the deployment loops.
3
4
3
SIR COIL ASSEMBLY
!VIEWA!
INFLATOR MODULE
CONNECTOR POSITION ASSURANCE (CPA)
SIR BRACKET ASSEMBLY
INFLATOR MODULE HARNESS CONNECTOR
PASSENGER INFLATOR MODULE
1/PTRIM PAD
NS11318
Figure 6A- Driver lnflator Module (Camaro)
!VIEWA!
6
SIR COIL ASSEMBLY
2
Figure 7 - Passenger lnflator Module
The DERM monitors these voltage drops to detect

circuit or component malfunctions. There are two
additional diagnostic resistors within the dual pole
arming sensor which allow the DERM to monitor the
voltage supplied to the high side of the deployment
loops. These monitored voltages are used by the
diagnostic logic of the DERM to make a more precise
determination of the actual deployment loop
malfunction.
The diodes within the dual pole arming sensor
provide isolation between the "36 VLR" outputs of the
DERM and the vehicle electrical system "Ignition 1"
voltage. The presence of the diodes prevent a direct
continuity measurement through the dual pole arming
sensor resistors to terminals "A", "B" or "C".
NS 11320
REDUNDANT STEERING WHEEL CONTROLS
DRIVER INFLATOR MODULE
CONNECTOR POSITION ASSURANCE (CPA)
IN FLA TOR MODULE HARNESS CONNECTOR
HORN LEAD
NS11319
Figure 68 - Driver lnflator Module (Firebird)
Discriminating Sensors
The discriminating sensors are protective switches
wired in parallel on the low side (ground side) of the
deployment loops. These sensors are calibrated to
close with velocity changes which are severe enough to
warrant deployment.
The discriminating sensors consist of a sensing
element, normally open switch contacts and a
diagnostic resistor. The sensing element closes the
switch contacts when the vehicle velocity changes are
severe enough to warrant deployment.

A diagnostic resistor is connected in parallel with
the switch contacts within each of the discriminating
sensors. These parallel resistors supply the ground
path for the current passing through the deployment
loops during normal, non-deployment operation. This
current flow results in voltage drops across each
component within the deployment loops. The DERM
monitors these voltage drops to detect circuit or
component malfunctions.
SIR Coil Assembly

The SIR coil assembly consists of two current
carrying coils. They are attached to the steering
column and allow rotation of the steering wheel while
maintaining continuous contact of the driver
deployment loop to the driver inflator module.
There is a shorting bar on the yellow 2-way
connector at the base of the steering column which
connects the SIR coil to the SIR wiring harness. The
shorting bar shorts the circuits of the SIR coil and
driver inflator module when the yellow 2-way
connector is disconnected. The circuit to the driver
inflator module is shorted in this way to help prevent
unwanted deployment of the air bag when servicing
the steering column or other SIR system components.
There is a shorting bar on the driver inflator

module side of the upper steering column connector
which connects the SIR coil to the driver inflator
module. The shorting bar shorts across the driver
inflator module circuits when the upper steering
column connector is disconnected. The circuit to the
driver inflator module is shorted in this way to help
prevent unwanted deployment of the air bag when
servicing the driver inflator module, the steering
column or other SIR system components.
There is a shorting bar on the passenger inflator
module connector which connects to the passenger
inflator module jumper. The shorting bar shorts
across the passenger inflator module circuit when
disconnected. The circuit to the passenger inflator
module is shorted in this way to help prevent
the passenger inflator module, the instrument panel or
other SIR system components.
Steering Column
The steering column is energy absorbing and is
designed to compress in a frontal crash to decrease the
chance of injury to the driver. A steering column
reinforcement is also used for additional support.
Passenger lnflator Module Jumper
Knee Bolster
The passenger inflator module jumper consists of

two current carrying wires. They are attached to the
passenger inflator module pigtail and also to the SIR
wiring harness behind 1/P compartment door
assembly.
There is a shorting bar on the side of the passenger
inflator module jumper which connects to the SIR
wiring harness. The shorting bar shorts the circuits of
the passenger inflator module jumper and the
passenger inflator module when disconnected from the
SIR wiring harness. The circuit to the passenger
inflator module is shorted in this way to help prevent
the passenger inflator module, the instrument panel,
or other SIR system components.
The knee bolster is used to absorb energy and

control the forward movement of the vehicle's front
seat occupants, during a frontal crash, by limiting leg
movement.
lnflator Modules
B + - Battery Voltage, the voltage available at the

battery at the time of the indicated measurement.
With the key "ON" and the engine not running, the
system voltage will likely be between 12 and 12.5
volts. At idle the voltage may be 14 to 16 volts. The
voltage could be as low as 10 volts during engine
cranking.
The inflator modules consist of an inflatable bag

and an inflator (a canister of gas-generating material
and an initiating device). When the vehicle is in a
frontal crash of sufficient force to close the dual pole
arming sensor and, at least, one of the discriminating
sensors simultaneously, current flows through the
deployment loops. Current passing through the
initiator ignites the material in the inflator module.
The gas produced from this reaction rapidly inflates
the air bag.
DEFINITIONS:
AIR BAG - An inflatable cloth cushion designed to
deploy in certain frontal crashes. It supplements the
protection offered by the seat belts by distributing the
impact load more evenly over the vehicle occupant's
head and torso.
ASYNCHRONOUS - Performed in a nonperiodic
fashion, i.e. no defined time or interval.
BULB CHECK - The DERM will cause the "AIR BAG"

warning lamp to flash seven times and then go "OFF"
whenever the ignition switch transitions to the RUN
position from any other ignition switch position.

"CONTINUOUS MONITORING" - Tests performed by
the DERM on the SIR system every 100 milliseconds
while "Ignition l" voltage is in the normal operating
voltage range at the DERM.
DATA LINK CONNECTOR - (DLC) Formerly
"ALDL", a connector which is connected by wires to
multiple on-board computers allowing communication
with an off-board computer such as a scan tool.
DATUM LINE -A base line parallel to the plane of the
underbody or frame from which all vertical
measurements originate.
DEPLOY - To inflate the air bag.
DEPLOYMENT LOOP - The circuits which supply
current to the driver inflator module or the passenger
inflator module to deploy the air bag.
DERM - Diagnostic Energy Reserve Module which
provides reserve energy to the deployment loops and
performs diagnostic monitoring of all system
components.
DIAGNOSTIC TROUBLE CODE - (DTC) Formerly
"Code," a numerical designator used by the DERM to
indicate specific SIR system malfunctions.
DRIVER CURRENT SOURCE - An output of the
DERM which injects current into the driver inflator
module circuit during the "Initiator Assembly
Resistance Test."
DRIVER INFLATOR MODULE - An assembly located
in the steering wheel hub consisting of an inflatable
bag, an inflator, and an initiator.
DUAL POLE ARMING SENSOR-A sensor connected
to the high side (power side) of both deployment loops
which is calibrated to supply voltage to each of the
inflator modules when the vehicle velocity changes are
severe enough to warrant preparation for deployment
of the air bags.
EEPROM - Electrically Erasable Programmable R~ad
Only Memory. Memory which retains its contents
when power is removed from the DERM.
FORWARD DISCRIMINATING SENSOR - A sensor
on the low side (ground side) of the deployment loops
which is calibrated to ground the inflator modules
when the vehicle velocity changes are severe enough
to warrant deployment of the air bags.
HIGHER PRIORITY FAULT - Each diagnostic trouble
code is assigned a priority based on the detectability
with other DTCs present. The priority corresponds to
OJ
IGNITION SWITCH HARNESS CONNECTOR
r'i"l
TURN SIGNAL, HAZARDS AND HORN
L!..J HARNESS CONNECTOR
'3'
L=-..1
'4'
REDUNDANT RADIO CONTROL HARNESS

CONNECTOR (FIREBIRD WITH UK3)
IGNITION LOCK CYLINDER (PASS-KEY)
~ HARNESS CONNECTOR
STEERING COLUMN (YELLOW 2-WAY)

HARNESS CONNECTOR
NS11321
Figure 8. Base of Steering Column Connector
the detectability of the malfunction ONLY, and does

NOT relate to the criticality of the malfunction with
respect to deployment or non-deployment under any
given condition.
IGNITION CYCLE - The voltage at the DERM
"Ignition l" inputs, with the ignition switch "ON," is
within the normal operating voltage range for at least
ten seconds before turning the ignition switch "OFF."
IGNITION 1 - A battery voltage (B +) circuit which is
only powered with the ignition switch in the RUN,
BULB TEST or START positions.
INITIATOR - The electrical component inside the
inflator module which, when sufficient current flows,
sets off the chemical reaction that inflates the air bag.
"INITIATOR ASSEMBLY RESISTANCE TEST" Tests performed once each ignition cycle when no
malfunctions are detected during "Turn-ON" or
"Continuous Monitoring." This test checks for shorts
to "Ignition 1" in the deployment loops, verifies the
integrity of the discriminating sensor interconnect
circuit and measures the resistance of each Inflator
Assembly consisting of: 1) Initiator, 2) Coil Assembly
(driver side only), 3) Passenger Inflator Module
Jumper (passenger side only), 4) Connectors and
associated wiring.

NORMAL OPERATING VOLTAGE RANGE - The
voltage measured between the DERM "Ignition l"
terminals and "Ground" terminals is between 7.25 and
16 volts.
PASSENGER COMPARTMENT DISCRIMINATING
SENSOR-A sensor on the low side (ground side) of the
deployment loops which is calibrated to ground the
inflator modules when the vehicle velocity changes are
severe enough to warrant deployment of the air bags.
36 VLR DELAY - Charging of the 36 VLR power

supplies is inhibited briefly during "Turn-ON." This
allows detection of certain malfunctions related to
"Ignition 1" voltage which cannot be tested with 36
volts present.
ON-VEHICLE SERVICE
SERVICE PRECAUTIONS
or around SIR components or SIR wiring,
follow the procedures listed below to
temporarily disable the SIR system.
Failure to follow procedures could result
injury or unneeded SIR system repairs.
PASSENGER CURRENT SOURCE - An output of the

DERM which injects current into the passenger
inflator module circuit during the "Initiator Assembly
Resistance Test."
PASSENGER INFLATOR MODULE - An assembly
located in the right side of the 1/P beneath the 1/P trim
pad consisting of an inflatable bag, an inflator and an
initiator.
PASSENGER INFLATOR MODULE JUMPER - An
assembly of two current carrying wires which connects
the passenger inflator module to the deployment loop.
SCAN TOOL - An off-board computer used to read
diagnostic information from on-board computers via
the data link connector.
SIR - Supplemental Inflatable Restraint.
SIR COIL ASSEMBLY - An assembly of two current
carrying coils in the deployment loop that allows the
rotation of the steering wheel while maintaining the
continuous contact of the deployment loop to the driver
inflator module.
SIR WIRING HARNESS - The wires and connectors
that electrically connect the components in the SIR
system.
"10 MINUTE LOOP TEST" - Portions of the "Initiator
Assembly Resistance Test" are repeated every ten
minutes during an ignition cycle. These are the check
for shorts to "Ignition" 1 in the deployment loops and
the check for an open discriminating sensor
interconnect circuit.
"TURN-ON" - Tests which the DERM performs on the
SIR system once during each ignition cycle
immediately after "Ignition 1" voltage is applied to the
DERM and before "Continuous Monitoring."
36 VLR - The 36 Volt Loop Reserve energy supply
from the DERM which provides deployment power
when vehicle voltage is low or lost in a frontal crash.

cause a deployment for up to two minutes after the
disconnection of the AIR BAG fuse and the inflator
module circuits from the deployment loops to avoid an

key.
1. AIR BAG fuse from 1/P fuse block.
2. Lower sound insulator panel-LH, refer to
SECTION SC.
3. Connector Position Assurance (CPA) and yellow
2-way connector at the base of the steering column.
4. 1/P compartment door assembly, refer to SECTION
SC.
2-way connector located near the yellow 24-way
DERM harness connector.
rn
Important
With the AIR BAG fuse removed and ignition

switch "ON" the "AIR BAG" warning lamp will be
"ON." This is normal operation and does not
indicate an SIR system malfunction.
1.

Yellow 2-way connector and Connector Position
Assurance (CPA) located near the yellow 24-way
DERM harness connector.

SC.
3. Yellow 2-way connector and Connector Position
Assurance (CPA) at the base of the steering
column.
4. Lower sound insulator panel-LH, refer to
SECTION SC.
5. AIR BAG fuse to 1/P fuse block.
Turn ignition switch to "RUN" and verify that the
"AIR BAG" warning lamp flashes seven times and
then turns "OFF." If it does not operate as
Handling/Installation/Diagnosis
1. Driver and passenger inflator modules should not
be stored at temperatures above 65C (150F).
2. Discriminating sensors, dual pole arming sensors,
driver and passenger inflator modules, or DERMs
should not be used if they have been dropped from
a height of91.4 centimeters (3 feet) or more.
3. When a discriminating sensor or a dual pole
arming sensor is replaced, it MUST be oriented
with the arrow on the sensor pointing toward the
front of the vehicle. It is very important for
discriminating sensors and dual pole arming
sensors to be located flat on the mounting surface,
parallel to the vehicle datum line. It is important
that the sensor mounting surface is free of any dirt
or other foreign material.
4. Do not apply power to the SIR system unless all
components are connected or a diagnostic chart
requests it, as this will set a diagnostic trouble
code.
5. The "SIR Diagnostic System Check" must be the
starting point of any SIR diagnostics. The "SIR
Diagnostic System Check" will verify proper "AIR
BAG" warning lamp operation and will lead you to
the correct chart to diagnose any SIR system
malfunctions. Bypassing these procedures may
result in extended diagnostic time, incorrect
diagnosis and incorrect parts replacement.
SENSORS
All sensors are specifically calibrated to the
vehicle and are keyed to the SIR wiring harness.
Caution should be used to ensure proper location of
the sensors to the mounting bracket. Refer to
SECTION 9J-B for removal and installation of
sensors.
CAUTION: During service procedures, be

very careful when handling a sensor.
Never strike or jar a sensor. Under some
circumstances, it could cause deployment
and result in personal injury or improper
operation of the Supplemental Inflatable

Restraint (SIR) system. All sensors and
mounting bracket bolts must be carefully
torqued to assure proper operation.
Never power up the SIR system when any
sensor is not rigidly attached to vehicle,
since the sensor could be activated when
not attached and could result in
deployment.
INFLATOR MODULES
Live (Undeployed) lnflator Module
Special care is necessary when handling and
storing a live (undeployed) inflator module. The rapid
gas generation produced during deployment of the air
bag could cause the inflator module, or an object in
front of the inflator module, to be thrown through the
air in the unlikely event of an accidental deployment.
CAUTION: When carrying a live inflator

module, make sure the bag opening is
pointed away from you. Never carry the
inflator module by the wires or connector
on the underside of the module. In case
of an accidental deployment, the bag will
then deploy with minimal chance of
injury. When placing a live inflator
module on a bench or other surface,
always face the bag and trim cover up,
away from the surface. Never rest a
steering column assembly on the steering
wheel with the inflator module face
down and column vertical. This is
necessary so that a free space is provided
to allow the air ba~ to expand in the
Otherwise, personal injury may result.
Shipping Procedures For Live (Undeployed)
lnflator Modules
General Motors dealers should refer to the latest
General Motors Service Bulletins for proper SIR
inflator module shipping procedures.
lnflator Module Scrapping Procedure

During the course of a vehicle's useful life, certain
situations may arise which will necessitate the
disposal of a live (undeployed) inflator module. This
information covers proper procedures for disposing of a
live inflator module.
Before a live inflator module can be disposed of, it
must be deployed. Live inflator modules must not be
disposed of through normal refuse channels.
ALWA VS CARRY
INFLA TOR MODULE
WITH TRIM COVER
AWAY FROM BODY.
ALWA VS PLACE
INFLA TOR MODULE
ON WORKBENCH
WITH TRIM COVER
UP, AWAY FROM
LOOSE OBJECTS.
on handling SIR systems involved with GM-1241. If a

vehicle is the subject of a campaign affecting inflator
modules, DO NOT DEPLOY the inflator module.
Follow instructions in the Campaign Service Bulletin
for proper disposition of the inflator module.
If an inflator module is replaced under warranty,
DO NOT DEPLOY the air bag. The inflator module
may need to be returned, undeployed, to Inland Fisher
Guide. Refer to procedures shown in the appropriate
Service Bulletin regarding SIR shipping procedures.
In situations which require deployment of a live
(undeployed) driver inflator module, deployment may
be accomplished inside or outside the vehicle. The
method employed depends upon the final disposition of
the particular vehicle, as noted in "Deployment
Outside Vehicle" and "Deployment Inside Vehicle" in
this section.
Deployment Outside Vehicle (Driver Inflater Module)
LS 8590
Figure 9. Proper Live Inflater Module Handling
CAUTION: Failure to follow proper

Supplemental Inflatable Restraint {SIR)
inflator module disposal procedures can
inflator modules must not be disposed of
through normal refuse channels. The
undeployed inflator module contains
substances that can cause severe illness
or personal injury if the sealed container
is damaged during disposal. Disposal in
any manner inconsistent with proper
procedures may be a violation of federal,
state, and/or local laws.
If a vehicle is the subject of a Product Liability
Report related to the SIR system and is subject to a
Preliminary Investigation (GM-1241), DO NOT
DEPLOY the inflator module and DO NOT ALTER
the SIR system in any manner. Refer to the applicable
Service Bulletin on SIR shipping procedures for details
Deployment outside the vehicle is proper when the

vehicle is to be returned to service. This includes, for
example, situations in which the vehicle will be
returned to useful service after a functionally or
cosmetically deficient driver inflator module is
replaced.
Deployment and disposal of a
malfunctioning driver inflator module is, of course,
subject to any required retention period.
For deployment of a live ( undeployed) driver
inflator module outside the vehicle, the deployment
procedure must be followed exactly. Always wea_r
safety glasses during this deployment procedure until
a deployed driver inflator module is scrapped or until
an undeployed driver inflator module is shipped.
Before performing the procedures you should be
familiar with servicing the SIR system and with
proper handling of the driver inflator module.
Procedures should be read fully before they are
performed.
The following procedure requires use of J 38826
SIR Deployment Harness with appropriate pigtail
adapter. Do not attempt procedure without J 38826
and adapter.
CAUTION: Failure to follow procedures

in the order listed may result in personal
injury. Never connect deployment
harness to any power source before
connecting deployment harness to the
driver inflator module. Deployment
harness shall remain shorted and not be
connected to a power source until the air
bag is to be deployed. The driver inflat~r
module will immediately deploy the air
bag when a power source is connected t_o
it. Wear safety glasses throughout this
entire deployment and disposal
procedure.
[I] Important
This information applies only to driver inflator

modules. Refer to "Deployment Outside Vehicle
(Passenger lnflator Module)" in this section for
information on passenger inflator module
scrapping.
1.
Turn ignition switch to "LOCK," remove key and

put on safety glasses.
Inspect J 38826 SIR Deployment Harness and
appropriate pigtail adapter for damage. If harness
or pigtail adapter is damaged, discard and obtain a
replacement.
Short the two SIR deployment harness leads
together by fully seating one banana plug into the
other. SIR deployment harness shall remain
shorted and not be connected to a power source
until the air bag is to be deployed (Figure 10).
Connect the appropriate pigtail adapter to the SIR
deployment harness (Figure 10).
Remove driver inflator module from vehicle. Refer
to SECTION 3F.
Remove horn lead from the back of the driver
inflator module.
Remove all horn buttons and steering wheel
control buttons from driver inflator module, if
applicable.
2.
3.
4.
5.
6.
7.
CAUTION: When storing a live inflator

module or when leaving a live inflator
module unattended on a bench or other
surface, always face the bag and trim
cover up and away from the surface. This
is necessary so that a free space is
provided to allow the air bag to expand
in the unlikely event of accidental
deployment.
Failure to follow
procedures may result in personal injury.
8.
Place the driver inflator module on a work bench

or other surface away from all loose or flammable
objects with its vinyl trim cover facing up, away
from the surface (Figure 11).
9. Clear a space on the ground about 185 cm (six feet)
in diameter where the driver inflator module is to
be deployed. A paved, outdoor location where
there is no activity is preferred. If an outdoor
location is not available, a space on the shop floor
where there is no activity and sufficient
ventilation is recommended. Ensure no loose or
flammable objects are within the deployment area
(Figure 12).
10. Place the driver inflator module, with its vinyl
trim cover facing up, on the ground in the space
just cleared (Figure 12).
11. Stretch the SIR deployment harness and pigtail

adapter from the driver inflator module to its full
length (Figure 13).
12. Place a power source near the shorted end of the
SIR deployment harness.
Recommended
application: 12 volts minimum, 2 amps minimum.
A vehicle battery is suggested.
13. Connect the driver inflator module to the pigtail
adapter on the SIR deployment harn.ess.
Deployment harness shall remain shorted and not
be connected to a power source until the air bag is
to be deployed. The driver inflator module will
immediately deploy the air bag when a power
source is connected to it (Figure 14).
[I] Important
Ensure that the pigtail adapter is firmly

seated into the driver inflator module
connector. Failure to fully seat the connectors
may leave the shorting bar located in the
driver inflator module connector functioning
(shorted) and may result in non-deployment of
the driver inflator module.
14. Verify that the area around the driver inflator

module is clear of all people and loose or
flammable objects.
15. Verify that the driver inflator module is resting
with its vinyl trim cover facing up.
16. Notify all people in the immediate area that you
intend to deploy the driver inflator module. The
deployment will be accompanied by a substantial
report which may startle the uninformed.
17. Separate the two banana plugs on the SIR
deployment harness (Figure 15).
CAUTION: Deployment harness shall

remain shorted and not be connected to a
power source until the air bag is to be
deployed. The driver inflator module will
immediately deploy the air bag when a
power source is connected to it.
Connecting the deployment harr.,ess to
the power source should always be the
last step prior to deployment in the
inflator module deployment procedure.
Failure to follow procedures in the order
listed may result in personal injury.
NOTICE: When air bag deploys, the rapid gas
expansion will create a substantial report. Notify
all people in the immediate area that you intend to
deploy the driver inflator module.
~~=============:;r
~==================~e~~
SIR
DEPLOYMENT
HARNESS
CAUTION: SIR deployment harness shall remain shorted and

not be connected to a power source until the air bag is to be deployed.
NS 14187
Figure 10 Shorting the SIR Deployment Harness Wires
VINYL TRIM COVER MUST FACE UP
NS 14188
Figure 11 Proper Storage of lnflator Module
....
.,,,, .,,.,,,,,,
/
------
''
'
VINYL TRIM COVER MUST FACE UP
........................ _____
.......
_________
........
NS 14189
Figure 12 - Provide Adequate Clearance for the Air Bag to Deploy
CAUTION: SIR deployment harness shall

remain shorted and not be connected to
a power source until the air bag is to be
deployed.
I. ------.
STRETCH SIR DEPLOYMENT HARNESS & PIGTAIL ADAPTER TO FULL L E N G T H - - - - - - - - ' - !
NS 14190
Figure 13- Stretching the SIR Deployment Harness and Pigtail Adapter

NOTICE: When the air bag deploys, the driver
inflator module may jump about 30 cm (one foot)
vertically. This is a normal reaction of the driver
inflator module to the force of the rapid gas
expansion inside the air bag.
18. Connect the SIR deployment harness wires to the
power source to immediately deploy the driver
inflator module. Recommended application: 12
volts minimum, 2 amps minimum. A vehicle
battery is suggested (Figure 16).
19. Disconnect the SIR deployment harness from the
power source.
20. Short the two SIR deployment harness leads
together by fully seating one banana plug into the
other (Figure 10).
21. In the unlikely event that the driver inflator
module did not deploy after following these
procedures, proceed immediately with Steps 26
through 29. If the driver inflator module did
deploy, proceed with Steps 22 through 25.
22. Put on a pair of shop gloves to protect your hands
from possible irritation and heat when handling
the deployed driver inflator module.
After the driver inflator module has been
deployed, the surface of the air bag may contain a
powdery residue. This powder consists primarily of
cornstarch (used to lubricate the bag as it inflates) and
byproducts of the chemical reaction. Sodium
hydroxide dust (similar to lye soap) is produced as a
byproduct of the deployment reaction. The sodium
hydroxide then quickly reacts with the atmospheric
moisture and is converted to sodium carbonate and
sodium bicarbonate (baking soda). Therefore, it is
unlikely that sodium hydroxide will be present after
deployment. As a precaution, however, gloves and
safety glasses are recommended to prevent any
possible irritation of the skin or eyes.
CAUTION: Safety precautions must be

observed when handling a deployed
inflator module. After deployment, the
metal surfaces of the inflator module will
be very hot. Allow the inflator module to
cool before handling any metal portion
of it. Do not place the deployed inflator
module near any flammable objects.
Failure to follow procedures may result in
fire or personal injury.
After a driver inflator module has been deployed,

the metal canister and surrounding areas of the driver
inflator module will be very hot. Do not touch the
metal areas of the driver inflator module for about ten
minutes after deployment. If the deployed driver
inflator module must be moved before it is cool, wear
gloves and handle by the air bag or vinyl trim (Figure
17).
23. Disconnect the pigtail adapter from the driver
inflator module as soon after deployment as
possible. This will prevent damage to the pigtail
adapter or SIR deployment harness due to possible
contact with the hot driver inflator module
canister. The pigtail adapter and SIR deployment
harness are designed to be reused. They should,
however, be inspected for damage after each
deployment and replaced if necessary.
24. Dispose of the deployed driver inflator module
through normal refuse channels after it has cooled
for at least 10 minutes.
25. Wash your hands with mild soap and water
afterward.
NOTICE: The remaining steps are to be followed

in the unlikely event that the driver inflator
module did not deploy after following these
procedures.
26. Ensure that the SIR deployment harness has been
disconnected from the power source and that its
two banana plugs have been shorted together by
fully seating one banana plug into the other
(Figure 10).
27. Disconnect the pigtail adapter from the driver
inflator module.

cover up and away from the surface. This
is necessary so that a free space is
provided to allow the air bag to expand
in the unlikely event of accidental
deployment.
Failure to follow
procedures may result in personal injury.
28. Temporarily store the driver inflator module with
its vinyl trim cover facing up, away from the
surface upon which it rests.
29. Call the Technical Assistance group for further
assistance.
CAUTION: SIR deployment harness shall remain shorted and not

be connected to a power source until the air bag is to be deployed.
SIR
DEPLOYMENT
HARNESS
PIGTAIL
ADAPTER
~~~\~~
INFLATOR
MODULE
NS 14191
Figure 14 Connecting the SIR Deployment Harness to the Inflater Module
_.....
ij~~~~~~~~~~~~~~==~
~==================~~
~
NS 14192
Figure 15 Separating the Two Shorted Banana Plugs

CAUTION: The lnflator Module will immediately deploy
the air bag when a power source is connected to it.
+
~-====P~
BATTERY
+
BATTERY
NS14193
Figure 16 Connecting to a Power Source
NS 14194
Figure 17 Handling a Hot, Deployed lnflator Module
~ - ,- " y- . . /
MINIMUM 16 cm (SIX INCHES)
~~STRIP 13
mm (1/2 INCH) OF INSULATION

NS 14461
Figure 18 - Cutting the Harness Connector Wires

Deployment Outside Vehicle (Passenger Inflater
Module)
CAUTION: Failure to follow proper SIR

state and/or local laws.
General Motors dealers should refer to the latest
General Motors Service Bulletins for proper live
(undeployed) passenger inflator module scrapping and
disposal procedures. All others should contact a local
General Motors dealership for proper live passenger
inflator module scrapping and disposal procedures.
Deployed passenger inflator modules may be disposed
of through normal refuse channels.
Deployment Inside Vehicle (Vehicle Scrapping
Procedure)
Deployment inside vehicle is proper when the

vehicle is to be destroyed or salvaged for component
parts. This includes, but is not limited to, the
following situations:
1. The vehicle has completed its useful life.
2. The vehicle has been damaged beyond repair
in a non-deployment type accident.
3. The vehicle has been stripped or damaged
beyond repair in a theft.
4. The vehicle will be salvaged for component
parts to be used on a vehicle with a different
Vehicle Identification Number (VIN) as
opposed to being rebuilt as the same VIN.
Never use SIR components from another
vehicle. This is done to ensure SIR system
integrity since only new SIR system

components, with the exception of
remanufactured parts as noted below, may be
used in servicing an SIR equipped vehicle.
Remanufactured parts purchased from an
authorized General Motors dealer may be used
for SIR repairs.
CAUTION: Failure to follow proper SIR

state and/or local laws.
1. Turn ignition switch to "LOCK," remove key and
put on safety glasses.
2. Remove all loose objects from front seats.
3. Disconnect driver inflator module, yellow 2-way
connector located at the base of the steering
column.
4. Cut the driver inflator module yellow 2-way
harness connector from the vehicle leaving at
least 16 cm (six inches) of wire at the connector
(Figure 18).
5. Strip 13 mm (1/2 inch) of insulation from each wire
lead of the connector (Figure 18).
6. Cut two 460 cm (15 feet) deployment wires from
0.8 mm2 (18 gage) or thicker multistrand wire.
These wires will be used to fabricate the driver
deployment harness.
7. Strip 13 mm (112 inch) of insulation from both ends
of the wires cut in the previous step.
8. Short the wires by twisting together one end from
each (Figure 19). Deployment wires shall remain
until the air bag is to be deployed.

in the order listed could result in personal
injury. Never connect deployment wires
to any power source before connecting
deployment wires to the inflator module
leads. Deployment wires shall remain
shorted and not be connected to a power
source until the air bag is to be deployed.
The inflator module will immediately
deploy the air bag when a power source
is connected to it. Wear safety glasses
throughout this entire deployment and
disposal procedure.

11. Twist together, bend and tape the remaining
connector wire lead to the remaining deployment
wire (Figure 20-C).
12. Connect the deployment harness to the driver
inflator module, yellow 2-way connector at the
base of the steering column. Route deployment
harness out the driver side of the vehicle (Figure
21) .
CAUTION: Deployment wires shall

remain shorted and not be connected
to a power source until the air bag
is to be deployed.
---~.-:__';-
.....__~~~~~~--v-
-~~~~~~-/
MINIMUM 460 cm (15 FEET) FOR DRIVER SIDE

MINIMUM 610 cm (20 FEET) FOR PASSENGER SIDE
SHORT THE TWO DEPLOYMENT WIRES TOGETHER
NS 14311
Figure 19 - Shorting the Deployment Wires

is to be deployed.
_ __ , ) ~
TWIST TOGETHER SECURELY
_ __ , ) ~
BEND FLAT
WRAP WITH TAPE
REPEAT PROCEDURE
NS 14462
Figure 20 - Fabricating the Deployment Harness
9.
Twist together one connector wire lead to one

deployment wire. The connection should be
mechanically secure (Figure 20-A).
10. Bend twisted connection made in the previous step
flat and wrap tightly with electrical tape to
insulate and secure (Figure 20-B).

deployed. The inflator module will
Connecting the deployment wires to the
power source should always be the final
step in the inflator module deployment
procedure. Failure to follow procedures
injury.
13. Disconnect passenger inflator module, yellow
2-way connector located behind the 1/P
compartment door assembly.
14. Cut the passenger inflator module jumper harness
connector from the vehicle leaving at least 16 cm
(six inches) of wire at the connector (Figure 22).
15. Strip 13 mm (112 inch) of insulation from each wire
lead of the connector (Figure 22).
16. Cut two 610 cm (20 feet) deployment wires from
0.8mm2 (18 gage) or thicker multistrand wire.
These wires will be used to fabricate the passenger
deployment harness.
17. Strip 13 mm (1/2 inch) of insulation from both ends
of the wires cut in the previous step.
18. Short the wires by twisting together one end from
each (Figure 19). Deployment wires shall remain
until the air bag is to be deployed.

injury. Never connect deployment wires
to any power source before connecting
deployment wires to the inflator module
leads. Deployment wires shall remain
shorted and not be connected to a power
source until the air bag is to be deployed.
The inflator module will immediately
deploy the air bag when a power source
is connected to it. Wear safety glasses
throughout this entire deployment and
disposal procedure.
19. Twist together one connector wire lead to one
deployment wire. The connection should be
mechanically secure (Figure 23-A).
STRETCH DEPLOYMENT HARNESS TO ITS FULL LENGTH
Figure 21 - Prepare Deployment Harness for In-Vehicle Deployment
-------'--~~~~--
---....r
,/

is to be deployed.
MINIMUM 16 cm (SIX INCHES)
STRIP 13
TWIST TOGETHER SECURELY
mm (1/2 INCH) OF INSULATION
NS 14463
Figure 22 - Cutting the Harness Connector Wires
20. Bend twisted connection made in the previous step

flat and wrap tightly with electrical tape to
insulate and secure (Figure 23-B).
21. Twist together, bend and tape the remaining
connector wire lead to the remaining deployment
wire (Figure 23-C).
22. Connect the deployment harness to the passenger
inflator module jumper, yellow 2-way connector
located behind the I/P compartment door
assembly. Route deployment harness out the
passenger side of the vehicle (Figure 24).

injury.
23. Verify that the inside of the vehicle and the area
surrounding the vehicle are clear of all people and
loose or flammable objects.
~""'
J~.
~r-------15~
BEND FLAT
WRAP WITH TAPE
REPEAT PROCEDURE
NS 14464
Figure 23 - Fabricating the Deployment Harness
24. Stretch the driver and passenger deployment

harnesses to their full length (Figures 21 and 24).
25. Completely cover windshield area and front door
window openings with a drop cloth, blanket or
similar item. This reduces the possibility of injury
due to possible fragmentation of the vehicle's glass
or interior.

26. Notify all people in the immediate area that you
intend to deploy the air bags. The deployment will
be accompanied by a substantial report which may
startle the uninformed.
27. Separate the two ends of the driver deployment
harness wires (Figure 25).
with atmospheric moisture and is converted to sodium

carbonate and sodium bicarbonate (baking soda).
Therefore, it is unlikely that sodium hydroxide will be
present after deployment. As a precaution, however,
gloves and safety glasses are recommended to prevent
any possible irritation of the skin or eyes.

injury.
CAUTION: Safety precautions must be

observed when handling a deployed
inflator module. After deployment, the
metal surfaces of the inflator module will
be very hot. Allow the inflator module to
cool before handling any metal portion
of it. Do not place the hot deployed
inflator module near any flammable
objects. Failure to follow procedures
could result in fire or personal injury.
NOTICE: When the air bag deploys, the rapid gas

expansion will create a substantial report. Notify
all people in the immediate area that you intend to
deploy the air bags.
28. Connect the driver deployment harness wires to a
power source to immediately deploy the driver
inflator module. Recommended application: 12
volts minimum, 2 amps minimum. A vehicle
battery is suggested (Figure 25).
29. Separate the two ends of the passenger deployment
harness wires (Figure 26).

injury.
30. Connect the passenger deployment harness wires
to a power source to immediately deploy the
passenger inflator module. Recommended
application: 12 volts minimum, 2 amps minimum.
A vehicle battery is suggested (Figure 26).
After an inflator module has been deployed, the
surface of the air bag may contain a powdery residue.
This powder consists primarily of cornstarch (used to
lubricate the bag as it inflates) and byproducts of the
chemical reaction. Sodium hydroxide dust (similar to
lye soap) is produced as a byproduct of the deployment
reaction. The sodium hydroxide then quickly reacts
After an inflator module has been deployed, the

metal canister and surrounding areas of the inflator
module will be very hot. Do not touch the metal areas
of the inflator module for about 10 minutes after
deployment. If the deployed inflator module must be
moved before it is cool, wear gloves and handle by the
air bag or vinyl trim.
31. Short the driver deployment harness wires by
twisting together one end from each. Repeat this
procedure for the passenger deployment harness.
32. Carefully remove drop cloth from vehicle and clean
off any fragments or discard drop cloth entirely.
33. Disconnect driver deployment harness and
passenger deployment harness from vehicle and
discard.
34. In the unlikely event that either or both of the
inflator modules did not deploy after following
these procedures, proceed immediately with Steps
36 through 38.
35. With both air bags deployed the vehicle may be
scrapped in the same manner as a non-SIR
equipped vehicle.
36. Remove the undeployed inflator module(s) from
the vehicle. For driver inflator module refer to
SECTION 3F, for passenger inflator module refer
to SECTION 9J-B.

cover up, away from the surface. This is
to allow the air ba~ to expand in the
in personal injury.
NS 13977
Figure 24 - Prepare Deployment Harness for In-Vehicle Deployment

SEPARATE SHORTED ENDS OF DEPLOYMENT
WIRES AND CONNECT TO POWER SOURCE
BATTERY
NS 13978
Figure 25 - Separate Shorted End of Deployment Harness and Connect to Power Source
SEPARATE SHORTED ENDS OF DEPLOYMENT
WIRES AND CONNECT TO POWER SOURCE
BATTERY
[;r
NS 13980
Figure 26 - Separate Shorted End of Deployment Harness and Connect to Power Source
37. Temporarily store the inflator module with the air

bag opening facing up, away from the surface upon
which it rests.
38. Call the Technical Assistance group for further
assistance.
Deployed lnflator Module Handling

After the inflator module has been deployed, the

present after deployment. As with many service
procedures, you should wear gloves and safety glasses.
REPAIRS AND INSPECTIONS REQUIRED AFTER

AN ACCIDENT
rn
Important
If any SIR system components are damaged, they

must be replaced. If SIR component mounting
points are damaged, they must be repaired or
replaced.
Never use SIR parts from another vehicle. This

does not include remanufactured parts purchased
from an authorized GM dealer, they may be used
for SIR repairs.
Do not attempt to service forward discriminating
sensors, passenger compartment discriminating
sensors, dual pole arming sensors, SIR coil
assemblies, driver inflator modules, passenger
inflator modules or DERMs. Service of these items
is by replacement only.
Verify the part number of replacement inflator
modules. Some GM inflator modules look identical
but contain different internal components.
CAUTION: Proper operation of the

sensors and Supplemental Inflatable
Restraint (SIR) system requires that any
repairs to the vehicle structure return it
to the original production configuration.
Deployment requires, at a minimum,
replacement of the sensors in the area of
accident damage, the inflator modules
and dimensional inspection of the
steering column. Any visible damage to
the DERM mounting bracket requires
replacement, sensors in the area of
accident damage must be replaced and
the steering column must be
dimensionally inspected, whether
deployment has occurred or not.
Accident With Deployment - Component
Replacement and Inspections
Certain SIR components must be replaced or
inspected for damage after a frontal crash involving
air bag deployment. Those components are:
Driver Inflator Module.
Passenger lnflator Module.
Sensors, if in the area of accident damage.
rn
Important
Refer to "Sensor Replacement Guidelines"

for important information on sensor
replacement in both deployment and nondeployment collisions.
SIR Coil Assembly - Inspect wiring and

connector for any signs of scorching, melting,
or damage due to excessive heat. Replace if
damaged.

Certain SIR and restraint system components
must be inspected after any crash, whether the air bag
deployed or not. Those components are:
Steering Column - Dimensionally inspect per

"Checking Steering Column For Accident
Damage" in SECTION 3F5B.
[I] Important
Refer to "Sensor Replacement Guidelines" for

important information on sensor replacement
in both deployment and non-deployment
collisions.
Knee Bolster and Mounting Points - Inspect
for any distortion, bending, cracking, or other
damage.
1/P Steering Column Reinforcement Plate Inspection for any distortion, bending,
cracking, or other damage.
1/P Braces - Inspect for any distortion, bending,
cracking, or other damage.
Seat Belts and Mounting Points - Refer to
SECTION 10-11.

SIR sensor replacement policy requires
replacement of the sensors in the area of accident
damage only.
The "area of accident damage" is defined as that
area of the vehicle which is crushed, bent or damaged
in other ways. An example might be a significant
front end collision in which the forward portions of the
vehicle have contacted another vehicle, tree,
guardrail, etc. In this example, sensor(s) on the front
of the vehicle, such as the radiator tie bar, would
require replacement, since that portion of the vehicle
was damaged in the accident. Sensors in the
passenger compartment, such as the passenger
compartment discriminating sensor and the dual pole
arming sensor would not require mandatory
replacement. Of course, if the DERM sets a diagnostic
trouble code and the diagnostic chart leads to a
malfunctioning sensor that was not in the area of
accident damage, that sensor should also be replaced.
Sensors in the area of accident damage should be
replaced even if those sensors do not appear to be
damaged. Do not attempt to determine whether a
sensor is OK -- ALWAYS replace if it is in the area of
accident damage.
Also, if a sensor is in an area of accident damage,
but the SIR system has not been deployed, replace the
sensor. The sensor bracket may be slightly bent,
wiring may be damaged, etc. and the sensor might not
work properly in another collision. Again, do not
attempt to determine whether a sensor is OK -ALWAYS replace if it is in the area of accident
damage.

WIRING REPAIR
SIR Wire Pigtail Repair
Special wiring repair procedures have been

developed for use on the Supplemental Inflatable
Restraint (SIR) system due to the sensitive nature of
the circuitry. These instructions must be followed
If the wiring pigtail (a wire or wires attached

directly to the device, not by a connector) is damaged,
the entire component (with pigtail) must be replaced.
Examples of "pigtail" components are the passenger
inflator module and the SIR coil assembly. Absolutely
no wire, connector, or terminal repairs are to be
attempted on the passenger inflator module or the SIR
coil assembly.
whenever servicing the SIR system wiring.
Terminal Repair Kit J 38125-A

Essential tool kit J 38125-A contains special
"sealed splices" for use in repairing SIR system wiring.
A special crimping tool, heat torch, and instruction
manual for these splices are also included.
Two critical features of the sealed splices are a
special heat shrink sleeve with sealing adhesive to
produce an environmentally sealed splice and a cross
hatched (knurled) core crimp to provide necessary
contact integrity for the sensitive, low energy circuits.
Terminal Repair Kit J 38125-A also serves as a
generic terminal repair kit. The kit contains a large
sampling of common GM electrical terminals and the
correct tools to attach them to wires and remove them
from connectors. The terminals in the kit are not to be
used to replace damaged SIR system terminals unless
specifically indicated by the terminal package. The
DERM terminal repair assembly pack is included in

J 38125-A for SIR use.
SIR Connector (Plastic Body and Terminal

Metal Pin) Repair
If any connector or terminal in the SIR wiring
harness (except pigtails) is damaged, the component
should be repaired using one of the connector repair
assembly packs. These kits include an instruction
sheet and the sealed splices which will be used to splice
the new wires, connector, and terminals to the
harness. The splice crimping tool, which is color keyed
to match the splices from Terminal Repair Kit
J 38125-A, must be used to apply these splices.
The terminals in the SIR system are made of a
special metal to provide necessary contact integrity for
the sensitive, low energy circuits. These terminals are
only available in the connector repair assembly packs,
do not substitute any other terminals for those in the
assembly packs.
If individual terminals are damaged on the DERM
they should be repaired using the DERM terminal
repair assembly pack. If individual terminals are
damaged on any other SIR connector, the entire
connector should be replaced using the appropriate
connector repair assembly pack. It may be necessary
to replace the entire SIR wiring harness.
Color Splice
sleeve
Crimp tool
nest color
Wire gage
AWG/ (metric)
Salmon
(yellow-pink)
Red
20, 18/
(0.5, 0.8)
Blue
Blue
16, 14/
(1.0, 2.0)
Yellow
Yellow
12, 10/
(3.0, 5.0)
Crimp and Seal Splice Chart
SIR Wire Repair

If any wire except the pigtail is damaged, the wire
should be repaired by splicing in a new section of wire
of the same gauge size (.5, .8, 1.0, etc.). The sealed
splices and splice crimping tool from Terminal Repair
Kit J 38125-A must be used for these repairs. The
following wiring repair procedures must be used to
ensure the integrity of the sealed splice application.
Step One: Open the Harness

wire insulation damage use a sewing "seam ripper"
(available from sewing supply stores) to cut open the
harness. The crimp and sealed splice sleeves may be
used on all types of insulation except tefzel and coaxial
and may only be used to form a one-to-one splice.
Step Two: Cut the Wire

possible. You may need the extra length of wire later
if you decide to cut more wire to change the location of
a splice. You may have to adjust splice locations to
make certain that each splice is at least 40 mm (1.5 in.)
away from other splices, harness branches, or
connectors.
Step Three: Strip the Insulation

NOTICE: The following procedures must be
followed in the order listed. If wire strands are
damaged, the procedure must be repeated until a
clean strip with all wire strands intact is obtained.
SPLICE BEFORE CRIMPING
SPLICE AFTER CRIMPING
SPLICE AFTER HEATING
9S 822S-9J
9S 8226-9J
Figure 27 - Splice Crimp Tool J 38125-8
Figure 28 - Seal Splice Sequence
If it is necessary to add a length of wire to the

existing harness, be certain to use the same size as the
original wire.
the schematic and convert the metric size to the
equivalent AWG size or use an AWG wire gage.
If unsure about the wire size, begin with the
largest opening in the wire stripper and work down
until achieving a clean strip of the insulation. Strip
approximately 7.5 mm (5/16 in.) of insulation from
each wire to be spliced. Be careful to avoid nicking or
cutting any of the strands. Check the stripped wire for
nicks or cut strands. If the wire is damaged, repeat
this procedure after removing the damaged section.
sleeve. Repeat Steps 4 and 5 for opposite end of the

splice.
Step Six:
Splice
Shrink the Insulation around the
Using the heat torch apply heat where the barrel is

crimped. Gradually move the heat barrel to the open
end of the tubing, shrinking the tubing completely as
the heat is moved along the insulation. A small
amount of sealant will come out of the end of the
tubing when sufficient shrinking is achieved (Figure
28).
SIR System Wire Splice Repair

Step Four:
Sleeve
Select and Position the Splice
Select the proper sealed splice sleeve according to

wire size. The splice sleeves and tool nests are color
coded (see chart).
Using the J 38125-8 Splice Crimp Tool (Figure 27),
position the splice sleeve in the proper color nest of the
hand crimp tool. Place the splice sleeve in the nest so
that the crimp falls midway between the end of the
barrel and the stop.
The sleeve has a stop in the middle of the barrel to
prevent the wire from going further (Figure 28). Close
the hand crimper handles slightly to hold the splice
sleeve firmly in the proper nest.
Step Five:
and Crimp
Insert Wires Into Splice Sleeve
Insert the wire into the splice sleeve until it hits

the barrel stop and close the handles of the crimp tool
tightly until the crimper handles open when released
(Figure 28). The crimper handles will not open until
the proper amount of pressure is applied to the splice
If any of the original equipment splices (three

wires or more) in the SIR wiring harness are damaged
they should be repaired by applying a new splice (not
sealed) from the Terminal Repair Kit J 38125-A.
Carefully follow the instructions included in the kit for
proper splice clip application. Cloth duct tape may be
substituted for splice tape if necessary.
Alternative Repair Methods

No alternative repair methods are available for
the SIR system wiring and components.
Connector Position Assurance (CPA)

The Connector Position Assurance (CPA) is a
small plastic insert that is inserted through the
locking tabs of all of the SIR system connectors. The
purpose of the CPA is to assure the connector halves
are securely connected and they cannot vibrate apart.
The CPA must be in place to ensure good contact
between the SIR mating terminals.
J 38125-A TERMINAL REPAIR KIT

2
J 38826 SIR DEPLOYMENT HARNESS
LS 8806-9J
Terminal Position Assurance (TPA)

The Terminal Position Assurance (TPA) insert is
similar to the plastic "combs" used in ECM connectors.
The function of the TPA is to keep the terminal
securely seated in the connector body. The TPA is not
to be removed from the connector body unless a
terminal must be removed for replacement.
SPECIAL TOOLS
CAUTION: To avoid deployment when
troubleshooting the SIR system, do not
use electrical test equipment such as a
battery powered or ac powered
voltmeter, ohmmeter, etc., or any type of
electrical equipment other than that
specified in this manual. Do not use a
non-powered probe type tester.
Instructions in this manual must be
followed carefully, otherwise personal
injury may result.
SIR DRIVER/PASSENGER LOAD TOOL
The SIR Driver/Passenger Load Tool J 38715 is
used only when called for in this section. It is used as
a diagnostic aid and safety device to prevent
inadvertent inflator module deployment.
The load tool has four yellow connectors attached

to its case. The three small connectors are electrically
functional and serve as resistive load substitutions.
The large dummy connector does not serve as a load
substitution but merely takes the physical place of the
DERM connector when needed.
No more than two connectors are used at any time.
One of the small connectors is used to substitute the
load of the driver inflator module when it is connected
at the top of the column to the SIR coil assembly.
Another small connector is used to substitute the load
of the driver inflator module and the SIR coil assembly
when it is connected at the base of the column to the
SIR wiring harness. The third small connector is used
to substitute for the load of the passenger inflator
module when connected to the passenger inflator
module jumper or to the passenger inflator module
harness connector. The large dummy connector
separates the shorting bar in the DERM harness
connector when it is connected to it in place of the
DERM.
By substituting the resistance of the load tool
when called for, a determination can be made as to
whether an inflator circuit component is causing
system malfunction and which component is causing
the malfunction. The load tool should be used only
when specifically called for in the diagnostic
procedures.
SIR SYSTEM DIAGNOSIS 9J-A-1
SECTION 9J-A

(SIR) SYSTEM DIAGNOSIS
CAUTION: To avoid deployment when troubleshooting the SIR system, do not use
electrical test equipment such as a battery powered or ac powered voltmeter,
ohmmeter, etc., or any type of electrical equipment other than that specified in this
manual. Do not use a non-powered probe type tester. Instructions in this manual must
be followed carefully, otherwise personal injury may result.
CONTENTS
Diagnosis
Diagnostic Trouble Codes
Reading and Clearing Diagnostic
Trouble Codes
"Flash Code" Diagnostics
Scan Tool Diagnostics
Use of Special Tools
SIR Driver/Passenger Load Tool
SIR Diagnostic System Check
Circuit Description
Notes on System Check Chart
Diagnostic Aids
SIR Connector Body Face Views
Chart A History Diagnostic Trouble Code
Diagnosis ( 1 of3)
Chart B "Flash Code" Diagnosis
Chart C "AIR BAG" Warning Lamp Comes
"ON" Steady
Chart D "AIR BAG" Warning Lamp Does
NotCome"ON"(1of2)
Chart E "AIR BAG" Warning Lamp Does
Not Come "ON" Steady During Crank
Chart F "AIR BAG" Warning Lamp Flashes

7 Times and Then Flashes OTC 12
Chart G DERM Cannot Communicate
Through the Serial Data Circuit
OTC 14 Dual Pole Arming Sensor
Disconnected
OTC 15 Passenger Initiator Circuit
Resistance High

Resistance Low
OTC 17 Passenger Initiator
Circuit Open
OTC 18 Discriminating Sensor
Interconnect Open

Voltage High (1 of 3)
DTC21 Driver Initiator Circuit
Resistance High

9J-A-2
9J-A-2
9J-A-2
9J-A-2
9J-A-2
9J-A-2
9J-A-2
9J-A-4
9J-A-4
9J-A-4
9J-A-4
9J-A-6
9J-A-8
9J-A-14
9J-A-16
9J-A-18
9J-A-22
9J-A-24
9J-A-26
9J-A-28
9J-A-30
9J-A-32
9J-A-34
9J-A-36
9J-A-38
9J-A-44
OTC 22 Driver Initiator Circuit

Resistance Low
OTC 23 Driver Initiator Circuit
Voltage High
OTC 24 Initiator Circuit Voltage Low
(1 of 3)
OTC 25 Initiator Circuit Short to
Ignition ( 1 of 2)
OTC 26 Driver Initiator Circuit Open
OTC 28 Current Sink or Source Failure
OTC 31 Driver Loop Energy Reserve
Feed Open
OTC 34 Dual Pole Arming Sensor Ignition
Feed Open
OTC 35 Discriminating Sensor Open or
Missing ( 1 of 2)
OTC 36 Passenger Loop Energy Reserve
Feed Open
OTC 42 Loop Energy Reserve Voltage
Low

OTC 43 Driver Source Feed Low
OTC 44 Passenger Source Feed Low
OTC 51 Frontal Crash Detected
OTC 52 Data Area Full

OTC 53 Driver Side Low High Resistance
OTC 54 Passenger Side Low High

Resistance
OTC 55 DERM Incompatibility
OTC 61 SIR Indicator Circuit Failure
OTC 62 Redundant SIR Indicator
Circuit Failure
OTC 71 and/or 75 Internal DERM Fault
OTC 81 Driver Ignition Diode Open
OTC 82 Passenger Ignition Diode Open
OTC 83 (History OTC 83), Driver Reserve
Di ode Shorted
OTC 84 (History OTC 84), Passenger

Reserve Diode Shorted
SIR Special Tools
9J-A-46
9J-A-48
9J-A-50
9J-A-56
9J-A-60
9J-A-62
9J-A-64
9J-A-66
9J-A-68
9J-A-72
9J-A-74
9J-A-76
9J-A-78
9J-A-80
9J-A-82
9J-A-84
9J-A-86
9J-A-88
9J-A-90
9J-A-92
9J-A-94
9J-A-96
9J-A-98
9J-A-100
9J-A-102
9J-A-104
9J-A-2 SIR SYSTEM DIAGNOSIS
DIAGNOSIS
DIAGNOSTIC TROUBLE CODES
The "SIR Diagnostic System Check" must always
be the starting point of any SIR system diagnosis. The
"SIR Diagnostic System Check" checks for proper "AIR

BAG" warning lamp operation and checks for SIR
diagnostic trouble codes using "Flash Code" or scan
tool methods.
1. Current Diagnostic Trouble Codes - Malfunctions
that are presently being detected. Current
diagnostic trouble codes are stored in RAM
(Random Access Memory).
2. History Diagnostic Trouble Codes - All
malfunctions detected since the last time the
history memory was cleared. History diagnostic
trouble codes are stored in EEPROM (Electrically
Erasable Programmable Read Only Memory).
Reading and Clearing Diagnostic Trouble

Codes
Current diagnostic trouble codes can be read by
using "Flash Code" or scan tool diagnostics. The
presence of history diagnostic trouble co?es can _be
determined by using "Flash Code" diagnostics
however, a scan tool must be used to determine what
they are.
History diagnostic trouble codes can only be
cleared by using scan tool diagnostics. If a scan tool is
not available, inform the owner of the information
stored in the history record and suggest it be cleared
upon the next visit to a GM dealership.
"Flash Code" Diagnostics

"Flash Code" diagnostics can only be used to read
current diagnostic trouble codes and to determine if
history diagnostic trouble codes are present.. "Flas_h
Code" diagnostics cannot be used to clear diagnostic
trouble codes. Grounding terminal "K" of the data
link connector pulls the "Diagnostic Request" input
terminal "A8" of the DERM low and signals the DERM
to enter the "Flash Code" diagnostic display mode.
The DERM displays diagnostic trouble codes by
flashing the "AIR BAG" warning lamp in the
instrument cluster with the "SIR Indicator" output
terminal "Bl". Each diagnostic trouble code displayed
consists of a number of flashes which represent the
tens or first digit, a 1/2 second pause, then a number of
flashes which represent the ones or second digit. Each
diagnostic trouble code is flashed once before moving
on to the next one. After all diagnostic trouble codes
have been displayed, the entire sequence will be
repeated until ground is removed from terminal "K" of
the data link connector.
Two special diagnostic trouble codes exist when

reading in the "Flash Code" mode, DTC 12 and DTC
13. DTC 12 will always be the first diagnostic trouble
code displayed when the "Flash Code" mode is enabled.
DTC 12 is not an indication of a SIR malfunction, but
an indication that the "Flash Code" mode has been
enabled. If there are no current or history diagnostic
trouble codes present the DERM will continue to flash
DTC 12 until ground is removed from the data link
connector at terminal "K". DTC 13 will be displayed if
there are history diagnostic trouble codes. To read the
history diagnostic trouble codes use of a scan tool is
required.
Scan Tool Diagnostics

A scan tool can be used to read current and history
diagnostic trouble codes and to clear all diagnostic
trouble codes after a repair is completed. The scan tool
must be updated to communicate with the SIR system
through a replaceable cartridge before it can be used
for SIR diagnostics. To use the scan tool, connect it to
the data link connector and turn the ignition switch
"ON." The scan tool reads serial data from the DERM
"Serial Data" output terminal "Bll" to the data link
connector terminal "M".
USE OF SPECIAL TOOLS

CAUTION: To avoid deployment when
troubleshooting the SIR system, do not
use electrical test equipment such as a
battery powered or ac powered
voltmeter, ohmmeter, etc., or any type of
electrical equipment other than that
specified in this manual. Do not use a
non-powered probe type tester.
Instructions in this manual must be
followed carefully, otherwise personal
injury may result.
You should be familiar with the tools listed in this
section under the heading "SPECIAL TOOLS." You
should be able to measure voltage, resistance, and
current. You should be familiar with the proper use of
a scan tool such as the Tech 1 Diagnostic Computer
TK-0 the SIR Driver/Passenger Load Tool J 38715,
and the DVM (Digital Multimeter) J 39200.
SIR DRIVER/PASSENGER LOAD TOOL

The SIR Driver/Passenger Load Tool J 38715 is
used only when called for in this section. It is used as a
diagnostic aid and safety device to prevent inadvertent
inflator module deployment.

The load tool has four yellow connectors attached
to its case. The three small connectors are electrically
functional and serve as resistive load substitutions.
The large dummy connector does not serve as a load
substitution but merely takes the physical place of the
DERM connector when needed.
No more than two connectors are used at any time.
One of the small connectors is used to substitute the
load of the driver inflator module when it is connected
at the top of the column to the SIR coil assembly.
Another small connector is used to substitute the load
of the driver inflator module and the SIR coil assembly
when it is connected at the base of the column to the
SIR wiring harness. The third small connector is used
to substitute for the load of the passenger inflator
module when connected to the passenger inflator
module jumper or to the passenger inflator module
harness connector. The large dummy connector
separates the shorting bar in the DERM harness
connector when it is connected to it in place of the
DERM.
By substituting the resistance of the load tool
when called for, a determination can be made as to
whether an inflator circuit component is causing
system malfunction and which component is causing
the malfunction. The load tool should be used only
when specifically called for in the diagnostic
procedures.
CAUTION: To avoid deployment when troubleshooting the SIR system, do not use
electrical test equipment such as a battery powered or ac powered voltmeter,
ohmmeter, etc., or any type of electrical equipment other than that specified in this
manual. Do not use a non-powered probe type tester. Instructions in this manual must
be followed carefully, otherwise personal injury may result.
SIR DIAGNOSTIC SYSTEM CH ECK

The diagnostic procedures used in this section are
designed to find and repair SIR system malfunctions.
To get the best results, it is important to use the
diagnostic charts and follow the sequence listed below.
A. PERFORM THE "SIR DIAGNOSTIC SYSTEM
CHECK."
The "SIR Diagnostic System Check" must be the
starting point of any SIR diagnostics. The "SIR
Diagnostic System Check" checks for proper "AIR
BAG" warning lamp operation, the ability of the
DERM to communicate through the "Serial Data"
circuit and whether SIR diagnostic trouble codes
exist.
B. REFER TO THE PROPER DIAGNOSTIC CHART
AS DIRECTED BY THE "SIR DIAGNOSTIC
SYSTEM CHECK."
The "SIR Diagnostic System Check" will lead you
to the correct chart to diagnose any SIR system
C. REPEAT THE "SIR DIAGNOSTIC SYSTEM

CHECK" AFTER ANY REPAIR OR
DIAGNOSTIC PROCEDURES HAVE BEEN
PERFORMED.
Performing the "SIR Diagnostic System Check"
after all repair or diagnostic procedures will
ensure that the repair has been made correctly and
that no other malfunctions exist.
CIRCUIT DESCRIPTION
When the ignition switch is first turned "ON,"
"Ignition l" voltage is applied from the AIR BAG fuse
to the DERM at the "Ignition 1" input terminals "A9"
and "AlO" and from the GAGES fuse to the DERM at
the "Redundant Indicator Ignition l" input terminal
"B2". The DERM responds by flashing the "AIR BAG"
warning lamp 7 times while performing tests on the
SIR system.
When the engine is being cranked, "Ignition 1"
voltage is applied from the CRANK fuse to the DERM
at the "Crank" input terminal "BIO". The DERM
responds by grounding the "SIR Indicator" output
terminal "Bl" until "Ignition l" voltage is removed
from the "Crank" input. This results in the "AIR

BAG" warning lamp being "ON" steady during
cranking.
After cranking the DERM will flash the "AIR
BAG" warning lamp 6 times and perform tests on the
SIR system.
NOTES ON SYSTEM CHECK CHART:

l.
2.
3.
4.
5.
6.
7.
8.
9.
10.
The "AIR BAG" warning lamp should flash 7 times

after ignition is first turned "ON."
The "AIR BAG" warning lamp should remain
"ON" steady during cranking.
After cranking, the "AIR BAG" warning lamp
should flash 6 times then go "OFF."
The "AIR BAG" warning lamp has successfully
completed the "Bulb Check."
This test checks for the proper operation of the
"Serial Data" circuit. This test will also determine
whether history diagnostic trouble codes are stored
and, if so, identify them.
When the "AIR BAG" warning lamp flashes 4
times during "Bulb Check" this indicates a
malfunction in the redundant lamp driver
circuitry. These malfunctions are diagnosed by
DTC 62 chart.
Improper operation of the "AIR BAG" warning
lamp is indicated. This test differentiates a
warning lamp stays "ON" condition from a
warning lamp does not come "ON" condition.
This check differentiates a current diagnostic
trouble codes exist condition from a "Flash Code"
diagnostics enabled when not requested condition.
The "AIR BAG" warning lamp has successfully
completed the "Bulb Check" and indicates current
diagnostic trouble codes exist.
This test checks for proper operation of the "Serial
Data" circuit. This test will also identify the
stored diagnostic trouble codes and whether they
are current or history.
DIAGNOSTIC AIDS:
The order in which diagnostic trouble codes are
diagnosed is very important. Failure to diagnose the
diagnostic trouble codes in the order specified may
result in extended diagnostic time, incorrect diagnosis,
and incorrect parts replacement.
CD.
SIR DIAGNOSTIC SYSTEM CHECK
NOTE"AIRBAG"WARNINGLAMPASIGNITIONSWITCH
IS TURNED "ON."
DOES WARNING LAMP FLASH 7 TIMES?
r- - - - - - - - - - - - ,
l _____________
GOTOCHARTE. J1
NOTE "AIR BAG" WARNING LAMP AFTER STARTING

DOES WARNING LAMP FLASH 6 TIMES THEN GO "OFF"?
DOES WARNING LAMP

COME "ON STEADY?
---------,
L _GOTODTC62.J
r- -----------,
GOTO CHART 0.
GOTOCHARTC.
r-
-----------,
L-------------.J
NO CURRENT SIR DIAGNOSTIC TROUBLE CODES EXIST.

IS A SCAN TOOL AVAILABLE FOR FURTHER DIAGNOSIS?
-----------,
GOTOCHARTB.
l-------------J
GOTOCHARTF. .J
L_____________
G)
CURRENT SIR DIAGNOSTIC TROUBLE CODES EXIST.

IS A SCAN TOOL AVAILABLE FOR FURTHER DIAGNOSIS?
r- -----------,
L. - GO TO CHART B. J

CONNECT SCAN TOOL TO DATA LINK CONNECTOR,
FOLLOW DIRECTIONS AS GIVEN IN THE SCAN TOOL
INSTRUCTION MANUAL.
IGNITION SWITCH "ON."
REQUEST SIR DIAGNOSTIC TROUBLE CODE DISPLAY,
RECORD All HISTORY DIAGNOSTIC TROUBLE
CODES, SPECIFYING AS SUCH, ON REPAIR ORDER.
NO SIR DIAGNOSTIC
TROUBLE CODES
ARE DISPLAYED
HISTORY DIAGNOSTIC
TROUBLE CODES ARE
DISPLAYED
SIR SYSTEM IS
FUNCTIONAL AND FREE
OF MALFUNCTIONS. NO
FURTHER DIAGNOSIS IS
REQUIRED.

CONNECT SCAN TOOL TO DATA LINK CONNECTOR,
FOLLOW DIRECTIONS AS GIVEN IN THE SCAN TOOL
INSTRUCTION MANUAL.
REQUEST SIR DIAGNOSTIC TROUBLE CODE DISPLAY,
RECORD ALL DIAGNOSTIC TROUBLE CODES SPECIFYING
AS CURRENT OR HISTORY ON REPAIR ORDER.
SCAN TOOL
INDICATES "NO
DATA RECEIVED"
r--- ----,

WHEN OTC 52 IS SET, GO
TO OTC 52 CHART.
TO OTC 71 CHART.
TO OTC 83 CHART.
TO OTC 84 CHART.
FOR All OTHER HISTORY
DIAGNOSTIC TROUBLE
CODES GO TO CHART A
(PAGE 1 OF 3).
I . GOTO
I
I
I
IL ________
CHARTG. JI
DIAGNOSTIC TROUBLE
CODES ARE DISPLA YEO

WHEN OTC 51 IS SET, GO TO OTC 51
CHART.
CHART.
CHART.
DIAGNOSE REMAINING CURRENT
DIAGNOSTIC TROUBLE CODES
FROM LOWEST TO HIGHEST.
WHEN ONLY HISTORY DIAGNOSTIC
TROUBLE CODES EXIST GO TO
CHART A (PAGE 1 OF 3).
7-2-92
NS 13277
10
11
12
0 0 0 0 0 0 0 0 0 0 0 De
lg] lg] lg] lg] lg] lg] IQ] IQ] lg] [gJ IQ] [gJ
DERM
Passenger Jumper Harness and

lnflatorConnectors (Male)
Passenger Jumper Harness and
lnflator Connectors (Female)
Dual Pole Arming Sensor Harness

Connector
Passenger Compartment Discriminating

Sensor Harness Connector
Steering Column Harness Connector
Forward Discriminating Sensor

Harness Connector
ALL SIR SYSTEM CONNECTORS ARE YELLOW
Figure 1 - SIR Connector Body Face Views
10-28-92
NS 15413
BLANK
AIRBAG 15A
TO IGNITION
5204
SWITCH ~ 1 1 3 9 A Y E L ~ - - - - - - - - - - - - - - - - - - - - - 1 1 3 9 C YEL
. - - - - - - - - - - 1 1 3 9 8 YEL__/ \
1139E YEL
DERM
IGNITION1
IGNITION I
.----------------------------~236YEUBLK
DRIVER 36 VLR
.----------------------------1400LTGRN
DRIVER
SOURCE SENSE
PASS. 36 VLR
...-------------------------1401PNK
~--------------------1837LTGRN/WHT
. - - - - - - - - 1 4 0 3 8 WHT/BLK-----,
_j_~---650AA BLK
PASS. SOURCE
SENSE
REDUNDANT
INDICATOR
GROUND
PASS. SIDE HIGH
PASS. SIDE LOW
CRANK
SERIAL DATA
5225
'---------------326PPL
l ' - - - - - - - - - - - - - - - - - - - - - 3 4 7 A WHT
'--TO
_ _ _G_A_G_E_S_1_0_A_ _ _ _ _S_2_0_6-----348ADKGRN
PASSENGER
COMPARTMENT
DISCRIMINATING
3488 IGNITION ~ 3 9 A P N K - - - - - - - - - - - - - 3 9 H PNK

DK GRN SWITCH
39CPNK
c2oool
INSTRUMENT CLUSTER
;-- 02 ~
DIAG. REQUEST
DRIVER SIDE
HIGH
DRIVER SIDE
LOW
REDUNDANT
INDICATOR
IGNITION 1
L.- - ..J
348F
-/fc200B
DK GRN L348G DK GRN
(AMARO
358
BRN
"AIR BAG"
FIREBIRD AS
WARNING
A7
8.45 KQ
L--L~_!,11!__ .J
17518 BLK/WHT-y-11s1A BLK/WHTv,,...---,
1751E BLK/WHT
_
C200B
01 : ( C200D
L--..J
1751F BLK/WHT
1751C B L K / W H T - - - - - - - - ~
SIR INDICATOR
SHORTING BAR
GROUND
GROUND
7-9-92
NS 11608
CHART A
(Page 1 of 3)
HISTORY DIAGNOSTIC TROUBLE CODE DIAGNOSIS

When the DERM recognizes "Ignition 1" voltage, applied to terminal "A9" and "AlO", is in the normal
operating voltage range the "AIR BAG" warning lamp is flashed 7 times to verify operation. At this time the
DERM performs "Turn-ON" tests followed by "Continuous Monitoring" tests. When no malfunctions are detected
the DERM proceeds to the "Initiator Assembly Resistance Test." When a malfunction is detected the DERM sets
a current diagnostic trouble code and illuminates the "AIR BAG" warning lamp. The DERM will clear current
diagnostic trouble codes and move them to a history file when the malfunction is no longer detected and/or the
ignition switch is cycled, except for DTC 51. DTC 51 can only be cleared using a scan tool "Clear Codes"
command.

1. Since performing the "SIR Diagnostic System
Check" properly ensures correct operation of the
"AIR BAG" warning lamp, no malfunction is
indicated.
2. Checks for opens in the high side of the
deployment loops or shorts to ground in the low
side of the deployment loops.
3. Checks for shorts to B + in the deployment loops.
4.
Checks for an improperly connected dual pole

arming sensor.
5. Checks for an open in the "Ignition l" feed to the
deployment loops.
6. Checks for a condition which would prevent either
"36 VLR" power supply from fully charging.
7. Checks for conditions which the DERM interprets
as an open in the "Driver 36 VLR" circuit.
WHEN MEASUREMENTS ARE REQUESTED IN THIS CHART USE J 39200

DVM WITH CORRECT TERMINAL ADAPTER FROM J 35616-A. WHEN A
CHECK FOR PROPER CONNECTION IS REQUESTED REFER TO
"INTERMITTENTS AND POOR CONNECTIONS" IN SECTION 8A-4. WHEN
A WIRE REPAIR IS REQUESTED USE J 38125-A TERMINAL REPAIR KIT
AND REFER TO "SIR WIRE REPAIR" IN SECTION 9J.
G)
CHART A
(Page 1 of 3)
HISTORY DIAGNOSTIC TROUBLE

CODE DIAGNOSIS
THESE DIAGNOSTIC TROUBLE CODES INDICATE A MALFUNCTION EXISTED IN THE" AIR BAG"
WARNING LAMP CIRCUITRY. THE MALFUNCTION WAS ADDRESSED IN THE "SIR DIAGNOSTIC
SYSTEM CHECK" BY CHART C OR CHART D.
CLEAR SIR DIAGNOSTIC TROUBLE CODES AND REPEAT "SIR DIAGNOSTIC SYSTEM CHECK."
CHECK FOR PROPER CONNECTION TO DERM AT TERMINALS "Al" AND "A4" AND TO DUAL
POLE ARMING SENSOR AT TERMINALS "B", "C", "E", AND "G".
CHECK FOR CUT, PINCHED, OR RUBBED THROUGH WIRES WHICH COULD CAUSE A SHORT TO
GROUND IN ORB+ CKT 347, CKT 348 OR CKT 1403.
PERFORM OTC 25 DIAGNOSTICS INSPECTING THE INDICATED CIRCUITS FOR CUT, PINCHED,
OR RUBBED THROUGH WIRES WHICH COULD CAUSE A SHORT TO B +.
\.!:.J
ENSURE DUAL POLE ARMING SENSOR HARNESS CONNECTOR IS SECURELY CONNECTED TO

DUAL POLE ARMING SENSOR AND CPA IS INSTALLED.
CHECK FOR PROPER CONNECTION TO DUAL POLE ARMING SENSOR AT TERMINAL" A".
:
I
I
:0
CONTINUE WITH
DIAGNOSIS ON NEXT I
I
PAGE.
1
~---------------~
CHECK CKT 236 AND CKT 1401 FOR CUT, PINCHED, OR RUBBED THROUGH WIRES WHICH
COULD CAUSE A SHORT TO GROUND ORB+.
CHECK FOR PROPER CONNECTION TO DERM AT TERMINALS" A4" AND" AS" AND TO DUAL POLE
ARMING SENSOR AT TERMINALS "B" AND "D".
CHECKCKT 1400 FORA CUT, PINCHED, OR RUBBED THROUGH WIRE WHICH COULD CAUSE A
SHORT TO B+.
8-26-92
NS15414
TO IGNITION
AIR BAG 15A
5204
SWITCH ~ 1139A Y E L - - - t l r - - - - - - - - - - - - - - - - 1 1 3 9 C YEL
. - - - - - - - - - - 1 1 3 9 8 YEL
1139E YEL
DERM
IGNITION 1
IGNITION1
.----------------------------~236YEUBLK
DRIVER 36 VLR
,----------------------------1400LTGRN
DRIVER
SOURCE !iENSE
PASS.36VLR
....-------------------------1401PNK
.----------------------1837LTGRN/WHT
.....-------14038 WHT/BLK-----,
_j__----650AA BLK
PASS. SOURCE
SENSE
REDUNDANT
INDICATOR
GROUND
PASS. SIDE HIGH
PASS. SIDE LOW
CRANK
SERIAL DATA
PASSENGER
COMPARTMENT
DISCRIMINATING
SENSOR
DIAG. REQUEST
DRIVER SIDE
HIGH
DRIVER SIDE
LOW
REDUNDANT
INDICATOR
IGNITION 1
39CPNK
INSTRUMENT CLUSTER
r-------,
CA MARO
FIREBIRD
AS
"AIR BAG"
WARNING
LAMP
358
BRN
A7
L-------..J
17518 BLK;WHT -y-1751A BLK;WHTos;.,---,

1751E BLK;WHT
_
C200B
01 : ( C200D
,... __ .J '------1751F BLK;WHT
1751C BLK;WHT----------'
SIR INDICATOR
SHORTING BAR
GROUND
GROUND
7-9-92
NS 11608
CHART A
(Page 2 of 3)

When the DERM recognizes "Ignition l" voltage, applied to terminal "A9" and "AlO", is in the normal
command.

8. Checks for conditions which the DERM interprets
as an open in the "Passenger 36 VLR" circuit.
9. Check for an open or high resistance in the driver
inflator module circuitry.
10. Checks for an open or high resistance in the
passenger inflator module circuitry.
11. Checks for shorts which would cause the resistance
of the inflator modules measured by the DERM to
be too low.
12. Checks for an open in CKT 348E.

13. Checks for an open in CKT 3488.
14. Checks for shorts from the "36 VLR" circuits to
diagnostic circuits or a short which decreases the
effective resistance at the high side of the
deployment loops.
15. Checks for shorts which the DERM interprets as
an open driver ignition diode.
CHART A
(Page 2 of 3)

CODE DIAGNOSIS
r
'
-------------------,
GO TO CHART A (PAGE 1 OF 3). '
~---------------------~
G)
CHECK FOR PROPER CONNECTION TO DERM AT TERMINALS "A3" AND "A6" AND TO DUAL
POLE ARMING SENSOR AT TERMINALS "C" AND "F".
CHECK CKT 1837 FOR A CUT, PINCHED, OR RUBBED THROUGH WIRE WHICH COULD CAUSE A
SHORT TO B+.
CHECK FOR PROPER CONNECTION TO DERM AT TERMINAL "89", SIR COIL ASSEMBLY AT
TERMINALS "A" AND "B",AND DRIVER INFLATORMODULE AT TERMINALS "A" AND "8".
CHECK FOR PROPER CONNECTION TO DERM AT TERMINAL" A7", PASSENGER INFLATOR

MODULE JUMPER AT TERMINALS "A" AND "B", AND PASSENGER IN FLA TOR MODULE AT
TERMINALS" A" AND "B".
CHECK FOR CUT, PINCHED, OR RUBBED THROUGH WIRES WHICH COULD CAUSE A SHORT
BETWEEN: CKT 347 AND CKT 348, CKT 347 AND CKT 1403, CKT 348 AND CKT 1403.
CHECK FOR PROPER CONNECTION OF CKT 348E TO PASSENGER INFLATOR MODULE

HARNESS CONNECTOR TERMINAL "B" AND CONNECTOR C200D TERMINAL "02".
CHECK FOR PROPER CONNECTION OF CKT 3488 TO STEERING COLUMN HARNESS

CONNECTOR TERMINAL "B" AND CONNECTOR C200D TERMINAL "02".
,..-
-----------,
:
:
CONTINUE WITH
DIAGNOSIS ON
NEXTPAGE.
~-------------....1
BETWEEN: CKT 347 AND CKT 236, CKT 347 AND CKT 1400, CKT 347 AND CKT 1401, CKT 347
AND CKT 1837, CKT 348 AND CKT 236, CKT 348 ANDCKT 1400, CKT 348 AND CKT 1401, CKT
348 AND CKT 1837, CKT 1403 AND CKT 236, CKT 1403 AND CKT 1400, CKT 1403 AND CKT
1401, CKT 1403 AND CKT 1837.
BETWEEN: CKT 1400ANDCKT 236, CKT 1400 AND CKT 1401 .
7-2-92
NS 15415
TO IGNITION
AIR BAG 15A
5204
SWITCH ~ 1 1 3 9 A Y E L ~ - - - - - - - - - - - - - - - - - - 1 1 3 9 ( YEL
.----------1139BYEL_/ \
1139EYEL
.----------------------------~236YEUBLK
.---------------------------~1400LTGRN
.--------------------------1401PNK
..----------------------1837LTGRN/WHT
. - - - - - - - - 1 4 0 3 8 WHT/BLK-----,
PASS.
_j_~--650AA BLK
INFLATOR
PASS. INFLATOR
MODULE
MODULE JUMPER
~1403CWHT/BLK
L..::::::fi-0-348H DK GRN
SHORTING BARS
DERM
IGNITION1
IGNITION1
DRIVER 36 VLR
DRIVER
SOURCE SENSE
PASS.36 VLR
PASS. SOURCE
SENSE
REDUNDANT
INDICATOR
GROUND
---1403A WHT/BLK
PASS. SIDE HIGH
- - - - 3 4 8 ( DK GRN
PASS. SIDE LOW
__j
CRANK
SERIAL DATA
5225
...._--------------326PPL
'-------------------~347AWHT
'--T-O_ _ _
G_A~G~ES-10~A-----S2_0_6-----348ADKGRN
PASSENGER
COMPARTMENT
01sc;~~~~ARTING
3488 IGNITION ~ 3 9 A P N K - - - w - - - - - - - - 3 9 H PNK

DK GRN SWITCH
39CPNK
c20ool
INSTRUMENT CLUSTER
[ ~~
348F
- .?tc2ooe
DK GRN ~ L348G DK GRN
DIAG. REQUEST
DRIVER SIDE
HIGH
DRIVER SIDE
LOW
REDUNDANT
INDICATOR
IGNITION 1
r-------,
I
I
CA MARO
FIREBIRD
AS
"AIRBAG"
WARNING
LAMP
358
BRN
A7
L-------~
17518 BLK/WHT -y-1751A BLKiWHToe).r---,

1751E BLK/WHT
_
C200B
01 : ( C200D
L---' --------17S1F BLK/WHT
1751( B L K / W H T - - - - - - - - ~
SIR INDICATOR
SHORTING BAR
GROUND
GROUND
7-9-92
NS 11608
CHART A
(Page 3 of 3)

DERM performs "Turn-On" tests followed by "Continuous Monitoring" tests. When no malfunctions are detected
command.
19. Checks for an open or short to ground in the
"Passenger Source Sense" circuit.
16. Checks for shorts which the DERM interprets as
20. Checks for an open in the "Driver Side Low"
circuit.
an open passenger ignition diode.
17. Checks for improper connections to the
21. Checks for an open in the "Passenger Side Low"
circuit.
discriminating sensors.
18. Checks for an open or short to ground in the
"Driver Source Sense" circuit.
CHART A
(Page 3 of 3)

CODE DIAGNOSIS
WERE YOU SENT HERE FROM
CHART A (PAGE 2 OF 3)?
r- --------------------,
1
GO TO CHART A (PAGE 2 OF 3). 1
L----------------------l
CLEARSIR
DIAGNOSTIC TROUBLE
CODES AND REPEAT
"SIR DIAGNOSTIC
SYSTEM CHECK".
CHECK FOR PROPER CONNECTION TO FORWARD DISCRIMINATING SENSOR AT

TERMINALS" A" AND "B" AND PASSENGER COMPARTMENT DISCRIMINATING SENSOR AT
TERMINALS" A" AND "C".
CLEAR SIR DIAGNOSTIC TROUBLE CODES AND REPEAT "SIR DIAGNOSTIC SYSTEM CHECK".
CHECK FOR PROPER CONNECTION TO DERM AT TERMINAL" AS" AND TO DUAL POLE
ARMING SENSOR AT TERMINAL "D".
CHECK FOR CUT, PINCHED, OR RUBBED THROUGH WIRE WHICH COULD CAUSE A SHORT
BETWEEN CKT 1400 AND GROUND.
CHECK FOR PROPER CONNECTION TO DERM AT TERMINAL" A6" AND TO DUAL POLE
ARMING SENSOR AT TERMINAL "F".
CHECK FOR CUT, PINCHED, OR RUBBED THROUGH WIRE WHICH COULD CAUSE A SHORT
BETWEEN CKT 1837 AND GROUND.
CHECK FOR PROPER CONNECTION TO DERM AT TERMINAL "BS".

BETWEEN: CKT 1837 ANDCKT 236,CKT 1837 ANDCKT 1401.
CHECK FOR PROPER CONNECTION TO DERM AT TERMINAL "87".

7-2-92
NS 15416
TO IGNITION
AIR BAG 15 A
5204
SWITCH ~ 1 1 3 9 A Y E L ~ - - - e - - - - - - - - - - - - - - - - - - 1 1 3 9 C Y E L
.........- - - - - - - - 1 1 3 9 8 YEL__/ \
1139E YEL
DERM
IGNITION I
IGNITION I
,.........---------------------------236YEUBLK
DRIVER 36 VLR
.-----------------------------~1400LTGRN
DRIVER
SOURCE SENSE
PASS. 36 VLR
~------------------------1401PNK
.------------------------1837LTGRN/WHT
.........- - - - - - 1 4 0 3 8 WHT/BLK----~
_1__~--650AA BLK
PASS. SOURCE
SENSE
REDUNDANT
INDICATO~
GROUND
PASS. SIDE HIGH
PASS. SIDE LOW
CRANK
SERIAL DATA
5225
'----------------326PPL
=-+--t A t-+.......-c,,.---t
_..,.{._ 8
{
l'--J'l'--------------------347AWHT
'---TO---G~A~G~E~S~1~0~A-----S-2_0_6----~348ADKGRN
3488 IGNITION ~ 3 9 A PNK---e----------39H PNK
DK GRN SWITCH
39CPNK
tSHORTING BARS
PASSENGER
COMPARTMENT
c2oool
,-DISCRIMINATING
IL. 02
__ .JI
SENSOR
348F
- .lfc2000
DK GRN L348G [?_!( GRN
DIAG. REQUEST
DRIVER SIDE
HIGH
DRIVER SIDE
LOW
REDUNDANT
INDICATOR
IGNITION 1
INSTRUMENT CLUSTER
,--------,
I
CA MARO
FIREBIRD
AS
"AIRBAG"
WARNING
358
BRN
A7
L--L~_!A!__ ..
17518 8LK/WHT ~1751A 8LK/WHTv,,...--,
-L._
c 2000
01
1751E BLK/WHT
c2000
--------1751F BLK,WHT
L.- - .J
1751C8LK/WHT~---------'
SIR INDICATOR
SHORTING BAR
GROUND
GROUND
7-9-92
NS 11608
CHART B
11
11
FLASH CODE DIAGNOSIS
command.

1. This test determines whether "Flash Code"
diagnostics can be enabled.
2. This test checks for a good ground at the data link
connector.
3. This test checks for an open in the "Diagnostic
Request" circuit.
This test checks for a short to B + in the

"Diagnostic Request" circuit.
5. This test determines whether further diagnosis is
required.
6. This test determines whether only history or both
current and history diagnostic trouble codes exist.
4.
CHART B
NOTICE:
IT IS RECOMMENDED THAT "FLASH CODE" DIAGNOSIS NOT BE USED FOR SIR

SYSTEM DIAGNOSIS. CURRENT DIAGNOSTIC TROUBLE CODES 81 ANO 82 ARE NOT FLASHED.
THEREFORE, WHEN THE "AIR BAG" WARNING LAMP FLASHES SEVEN TIMES THEN COMES
"ON" ANO ONLY OTC 12 OR OTCs 12 AND 13 ARE FLASHED, IT IS NECESSARY TO PERFORM
THE DIAGNOSTICS FOR OTC 81 ANO OTC 82.
"FLASH CODE"
DIAGNOSIS
WHEN MEASUREMENTS ARE REQUESTED IN THIS CHART USE J 39200 OVM WITH
CORRECT TERMINAL ADAPTER FROM J 35616-A. WHEN A CHECK FOR PROPER
CONNECTION IS REQUESTED REFER TO "INTERMITTENTS ANO POOR CONNECTIONS" IN
SECTION BA-4. WHEN A WIRE REPAIR IS REQUESTED USE J 38125-A TERMINAL REPAIR KIT
ANO REFER TO "SIR WIRE REPAIR" IN SECTION 9J .
~
\....:..I
/"'"",

CONNECT JUMPER ON DATA LINK CONNECTOR FROM TERMINAL "A" TO TERMINAL "K".
DOES "AIR BAG" WARNING LAMP FLASH 7 TIMES THEN FLASH OTC 12?

REMOVE JUMPER ON DATA LINK CONNECTOR.
MEASURE RESISTANCE FROM DLCTERMINAL "A" TO GROUND.
IS RESISTANCE 5.00 OR LESS?
[$]
~
DRIVER AND
DISCONNECT
PASSENGER INFLATOR MODULES,
YELLOW 2-WAY CONNECTORS

LOCATED NEAR THE BASE OF THE
STEERING COLUMN AND BEHIND
THE 1/P COMPARTMENT DOOR
ASSEMBLY.
DISCONNECT DERM.
MEASURE RESISTANCE FROM DLC
TERMINAL "K" TO DERM HARNESS
CONNECTOR TERMINAL "AS".
s
0
REPAIR OPEN IN CKT

450 FROM DAT A
LINK CONNECTOR
TO GROUND, REFER
TO SECTION SA-14.
REPEAT "SIR
DIAGNOSTIC
SYSTEM CHECK."

CHECK FOR PROPER CONNECTION
AT DLC TERMINAL "K" AND DERM
HARNESS CONNECTOR TERMINAL
"AS".
IF BOTH CONNECTIONS ARE GOOD
REPLACE DERM, REFER TO
SECTION 9J-B
G)
~
ARE ANY OTHER DIAGNOSTIC
TROUBLE CODES FLASHED?
REPAIR OPEN
IN CKT326.
IGNITION SWITCH
"OFF."
REPAIR SHORT
FROM CKT 326 TO
B+.
~
SIR SYSTEM MAY BE
FUNCTIONAL AND FREE
OF MALFUNCTIONS.
(SEE NOTICE ABOVE)
IS OTC 13 THE ONLY

OTHERCODEFLASHED?

MEASURE VOLTAGE ON DLC
FROM TERMINAL "K" TO
TERMINAL" A".
[$]
RECORD ALL FLASHED

DIAGNOSTIC TROUBLE
CODES ON REPAIR
ORDE.R.
WHEN OTC 51, 52, 55,
71 OR 75 IS CURRENT
GO TO THE
APPROPRIATE
DIAGNOSTIC CHART.
AFTER A REPAIR,
CHARTS REQUEST SIR
DIAGNOSTIC TROUBLE
CODES TO BE CLEARED.
SINCE THIS REQUIRES A
SCAN TOOL SKIP THIS
AND REPEAT "SIR
DIAGNOSTIC SYSTEM
CHECK."
DIAGNOSE REMAINING
DIAGNOSTIC TROUBLE
CODES FROM LOWEST
TO HIGHEST.
(SEE NOTICE ABOVE)
RECONNECT ALL SIR SYSTEM COMPONENTS, ENSURE ALL COMPONENTS ARE PROPERL y MOUNTED.
REPEAT "SIR DIAGNOSTIC SYSTEM CHECK."
CURRENT
DIAGNOSTIC
TROUBLE CODES
MAY NOT EXIST.
(SEE NOTICE ABOVE)
ADVISE VEHICLE
OWNER THAT
HISTORY
DIAGNOSTIC
TROUBLE CODES
EXIST WHICH
SHOULD BE
VERIFIED AND
CLEARED WHEN A
SCAN TOOL
BECOMES
AVAILABLE.
INTERMITTENT
CONDITIONS
SHOULD BE
DIAGNOSED USING
A SCAN TOOL AND
CHART A.
I
8-25-92
NS 11322
AIR BAG 15A

TO IGNITION
5204
SWITCH ~ 1139A YEL ~ - - - - - - - - - - - - - - - - - - - - - - 1 1 3 9 ( YEL
.----------1139BYEL_/ \
1139EYEL
.---------------------------~236YEUBLK
.----------------------------1400LTGRN
..-------------------------1401PNK
.----------------------1837LTGRN/WHT
....-------14038 WHT/BLK-----.
_j_----650AA BLK
DERM
IGNITION1
IGNITION1
DRIVER 36 VLR
DRIVER
SOURCE ,ENSE
PASS. 36VLR
PASS. SOURCE
SENSE
REDUNDANT
INDICATOR
GROUND
PASS. SIDE HIGH
PASS. SIDE LOW
CRANK
SERIAL DATA
5225
L---------------326PPL
l'--------------------347AWHT
'-T-O_ _ _G_A_G_E_S_1_0_A_ _ _ _ _S_2_0_6_ _ _ _ _ 348ADKGRN
PASSENGER
COMPARTMENT
DISCRIMINATING
SENSOR
3488 IGNITION ~ 3 9 A P N K - - - e - - - - - - - - 3 9 H PNK

DK GRN SWITCH
39C PNK
c2oool
r ,
INSTRUMENT CLUSTER
I
02
L.- -
DIAG. REQUEST
DRIVER SIDE
HIGH
DRIVER SIDE
LOW
REDUNDANT
INDICATOR
IGNITION 1
I
...J
348F
- }k2ooe
CA MARO
358
BRN
"AIRBAG"
FIREBIRD AS
WARNING
A7
L--l~~--.J
17518 BLK/WHT-y-1751A BLK/WHTos;.,--,
1751E BLKiWHT
_
(2008
01 : ( C200D
._ __ ..J -----1751FBLK/WHT
1751( B L K / W H T - - - - - - - - - - '
SIR INDICATOR
SHORTING BAR
GROUND
GROUND
H-92
NS 11608
CHARTC
"AIR BAG" WARNING LAMP COMES "ON" STEADY
When the ignition switch is first turned "ON," "Ignition 1" voltage is applied from the GAGES fuse to
"Redundant Indicator Ignition 1," terminal "B2" and to the "AIR BAG" warning lamp which is connected to "SIR
Indicator," terminal "Bl". The AIR BAG fuse applies system voltage to the "Ignition l" inputs, terminals "A9"
and "AlO". The DERM responds by flashing the "AIR BAG" warning lamp 7 times. If "Ignition l" is outside of
the normal operating voltage range, the "AIR BAG" warning lamp will come "ON" solid with no DTCs set.
When the engine is being cranked, battery voltage is applied from the CRANK fuse to the DERM at the
"Crank" input. The DERM responds by grounding the "SIR Indicator" output until battery voltage is removed
from the "Crank" input. This results in the "AIR BAG" warning lamp being "ON" during cranking.
After cranking, the DERM will flash the "AIR BAG" warning lamp 6 times.

1. An open AIR BAG fuse would cause the "AIR
BAG" warning lamp to come "ON" steady.
2. A disconnected DERM harness connector will
cause the warning lamp to come "ON" steady via
the shorting bar from terminal "Al" to terminal
"Bl".
3. This test checks for an open in the "Ignition 1"
circuitry to the DERM.
4.
This test checks for a short from the "SIR

Indicator" circuit to ground.
5. This test checks for a short from the "Crank" input
circuit to B +.
6. This test checks whether a short to ground caused
AIR BAG fuse to open.
7. This test determines whether the short to ground
is due to a malfunctioning dual pole arming sensor
or a short in the wiring.
CHARTC
OVM WITH CORRECT TERMINAL ADAPTER FROM J 35616-A. WHEN A
"INTERMITTENTS ANO POOR CONNECTIONS" IN SECTION 8A-4. WHEN
A WIRE REPAIR IS REQUESTED USE J 38125-A TERMINAL REPAIR KIT
AND REFER TO "SIR WIRE REPAIR" IN SECTION 9J.
I
r'
~
"-V
11
11

REMOVE ANO INSPECT AIR BAG FUSE.
IS FUSE GOOD?
7esl
G).
INSPECT DERM HARNESS CONNECTOR

CONNECTION TO DERM.
IS IT SECURELY CONNECTED TO THE OERM?
G).
DISCONNECT DERM.
CHECK FOR PROPER CONNECTION
TO DERM AT TERMINALS "A9"
AND "A10".
IF OK, THEN MEASURE
RESISTANCE FROM EACH
TERMINAL OF THE AIR BAG FUSE
FUSE HOLDER TO OERM HARNESS
CONNECTOR TERMINAL" A9".
IS EITHER MEASUREMENT 5.0Q OR
LESS?
INSTALL AIR BAG FUSE.

DISCONNECT DRIVER AND
PASSENGER INFLATOR MODULES,
YELLOW 2-WAY CONNECTORS
LOCATED NEAR THE BASE OF
STEERING COLUMN ANO BEHIND
THE 1/P COMPARTMENT DOOR
ASSEMBLY.
CONNECT DERM HARNESS
CONNECTOR TO J 38715 SIR
DRIVER/PASSENGER LOAD TOOL.
DOES THE" AIR BAG" WARNING
LAMP COME "ON"?
Ci)

REPLACE DERM, REFER TO SECTION 9J-B.
I
EJ
INSTALL AIR BAG

FUSE.
REPEAT "SIR
DIAGNOSTIC
SYSTEM CHECK."
REPAIR SHORT TO
GROUND IN CKT
1139, REFER TO
SECTION 8A-11.
RECONNECT DUAL
POLE ARMING
SENSOR.
REPLACE AIR BAG
FUSE.
REPEAT "SIR
DIAGNOSTIC
SYSTEM CHECK."
REPLACE DUAL
POLE ARMING
SENSOR, REFER
TO SECTION 9J-B.
INSTALL AIR BAG
FUSE.
REPEAT "SIR
DIAGNOSTIC
SYSTEM CHECK."
EJ

DISCONNECT SIR DRIVER/PASSENGER LOAD TOOL
MEASURE VOLTAGE ON DERM HARNESS CONNECTOR
FROM TERMINAL "810" TO TERMINAL" A 1" (GROUND).
DISCONNECT DUAL
POLE ARMING SENSOR.
REPLACE AIR BAG FUSE.
IGNITION SWITCH
"ON," WAIT 10
SECONDS, THEN
IGNITION SWITCH
"OFF."
REMOVE AND INSPECT
AIR BAG FUSE.
IS FUSE GOOD?
REPAIR OPEN IN CKT

1139.
RECONNECT DERM.
INSTALL AIR BAG FUSE.
REPEAT "SIR
DIAGNOSTIC SYSTEM
CHECK."
EJ
REPLACE AIR BAG FUSE.

IGNITION SWITCH "ON," WAIT 10
SECONDS, THEN IGNITION SWITCH "OFF."
REMOVE ANO INSPECT AIR BAG FUSE .
IS FUSE GOOD?
PROPERLY CONNECT
OERM HARNESS
CONNECTOR TO
OERM.
INSTALL AIR BAG
FUSE.
REPEAT "SIR
DIAGNOSTIC SYSTEM
CHECK."
G:
AIR BAG" WARNING LAMP

COMES 0N" STEADY

DISCONNECT SIR DRIVER/PASSENGER LOAD TOOL.
REPAIR SHORT FROM CKT 358 TO GROUND .
I REPAIR SHORT FROM CKT 806 TO B +.
RECONNECT ALL SIR SYSTEM COMPONENTS, ENSURE ALL COMPONENTS ARE PROPERLY MOUNTED.
7-2-92
NS 15417
AIRBAG 1SA
TO IGNITION
S204
SWITCH ~ 1 1 3 9 A Y E L ~ - - - - - - - - - - - - - - - - - - - 1 1 3 9 C Y E L
...---------1139BYEL_/ \
1139EYEL
...---------------------------~236YEUBLK
...--------------------------1400LTGRN
.------------------------~1401PNK
...--------------------1837LTGRN/WHT
. - - - - - - - - 1 4 0 3 8 WHT/BLK-----,
PASS.
_j_---6SOAA BLK
INFLATOR
PASS. INFLATOR
MODULE
MODULE JUMPER
~1403CWHT/BLK
l...::::::li-0-348H DK GRN
SHORTING BARS
DERM
IGNITION!
IGNITION I
DRIVER 36 VLR
DRIVER
SOURCE SENSE
PASS. 36 VLR
PASS. SOURCE
SENSE
REDUNDANT
INDICATOR
GROUND
---1403A WHT/BLK
PASS. SIDE HIGH
- - - - 3 4 8 C DK GRN
PASS. SIDE LOW
_j
CRANK
SERIAL DATA
5225
~------------~326PPL
1 ' - - - - - - - - - - - - - - - - - - - - 3 4 7 A WHT
'---TO---G~A~G=E=s~1~0A~----s2_0_6-----J48ADKGRN
3488 IGNITION - ~ 3 9 A P N K - - - - - - - - - 3 9 H PNK
DK GRN SWITCH
39C PNK
c200DI
.-INSTRUMENT CLUSTER
I 02 I
DIAG. REQUEST
DRIVER SIDE
HIGH
DRIVER SIDE
LOW
REDUNDANT
INDICATOR
IGNITION 1
L...- - .J
348F
-/lc2ooe
CA MARO
FIREBIRD
AS
"AIRBAG"
WARNING
LAMP
358
BRN
A7
L-------..1
1751E BLICJWHT
17518 BLK/WHT-y-1751A BLK/WHTv,.---,

_
C200B
01 : ( C200D
L - - .J -------1751 F BLK/WHT
1751C B L K / W H T - - - - - - - -
SIR INDICATOR
SHORTING BAR
GROUND
GROUND
7-9-92
NS 11608
CHARTD
(Page 1 of 2)
"AIR BAG" WARNING LAMP DOES NOT COME "ON"

Indicator," terminal "Bl". The AIR BAG fuse applies system voltage to the "Ignition 1" inputs, terminals "A9"
and "AlO". The DERM responds by flashing the "AIR BAG" warning lamp 7 times.

1. This test determines whether the malfunction is in
the DERM circuitry or in the instrument cluster
power feed circuitry.
2. This test confirms the integrity of the "Redundant
Indicator Ignition 1" circuit.
3. This test checks for an open in the "SIR Indicator"
circuit, instrument cluster circuitry, and "AIR
BAG" warning lamp bulb.
4. This test checks whether the open is due to a bad

bulb.
5. This test determines whether the malfunction is
an open in the "SIR Indicator" circuit or an open in
the instrument cluster.
6. This test checks for a good ground to the SIR
system.
7. This test determines whether the malfunction is a
short from the "SIR Indicator" circuit to B + or a
malfunctioning DERM.
CHARTD
(Page 1 of 2)

"INTERMITTENTS AND POOR CONNECTIONS" IN SECTION 8A-4.
WHEN A WIRE REPAIR IS REQUESTED USE J 38125-A TERMINAL
REPAIR KIT AND REFER TO "SIR WIRE REPAIR" IN SECTION 9J.
I
8 .
APPLY PARKING BRAKE AND TURN IGNITION SWITCH "ON."

DOES THE "BRAKE" WARNING LAMP COME "ON"?
:~----------------------4

MEASURE RESISTANCE ON DERM HARNESS CONNECTOR
FROM TERMINAL "82" TO TERMINAL "81 ".
IS RESISTANCE 5.0 Q TO 25.0 Q?
REMOVE INSTRUMENT CLUSTER.

CHECK FOR PROPER CONNECTION TO INSTRUMENT
CLUSTER AT CONNECTOR TERMINAL "C16" (CAMARO),
TERMINAL "A7" (FIREBIRD).
IF OK, THEN REMOVE AND INSPECT" AIR BAG" BULB.
IS BULB GOOD?
s
0
INSTALL BULB.
MEASURE RESISTANCE FROM
INSTRUMENT CLUSTER
HARNESS CONNECTOR
TERMINAL "(16" ((AMARO),
TERMINAL" A7" (FIRE BIRD) TO
DERM HARNESS CONNECTOR
TERMINAL "81 ".
IS RESISTANCE 5.0 Q OR LESS?
REPLACE BULB.
INSTALL INSTRUMENT
CLUSTER.

INSTALL
INSTRUMENT
CLUSTER.
MEASURE RESISTANCE ON DERM HARNESS

CONNECTOR FROM TERMINAL" A 1" TO
TERMINAL" A2".
s
0
[$]
SERVICE INSTRUMENT
CLUSTER.
INSTALL INSTRUMENT
CLUSTER.

REPAIR OPEN IN CKT 39H .
RETURN TO STEP 1
[$
-------------------~
GO TO CHART D (PAGE 2 OF 2). :
[$]
8J

DISCONNECT DERM .
CHECK FOR PROPER CONNECTION TO DERM AT TERMINAL "81 ".
IF OK, THEN IGNITION SWITCH "ON.''
MEASURE VOLTAGE ON DERM HARNESS CONNECTOR FROM
TERMINAL "82" TO TERMINAL "A12" (GROUND).
AIR BAG'' WARNING LAMP

DOES NOT COME ' 0N"
[$]
11
DISCONNECT INSTRUMENT
CLUSTER.
CONNECT DERM HARNESS
CONNECTOR TO J 38715 SIR
DRIVER/PASSENGER LOAD
TOOL DERM CONNECTOR.
MEASURE VOLTAGE FROM
INSTRUMENT CLUSTER
HARNESS CONNECTOR
TERMINAL "C16" ((AMARO),
TERMINAL" A 7" (FIRE BIRD)
TO GROUND.
,.
~
REPAIR SHORT FROM
CKT 358 TO B + .
INSTALL INSTRUMENT
CLUSTER.
REPAIR OPEN
IN CKT 1751A.
REPLACE DERM, REFER

TO SECTION 9J-B.
INSTALL INSTRUMENT
CLUSTER.
RECONNECT ALL SIR SYSTEM COMPONENTS, ENSURE ALL COMPONENTS ARE PROPERLY MOUNTED. ,
8-26-92
NS 15418
AIRBAG 15A
TO IGNITION
5204
SWITCH ~ 1 1 3 9 A Y E L ~ - - - - - - - - - - - - - - - - - - - 1 1 3 9 C Y E L
,-----------1139BYEL__/ \
1139EYEL
.----------------------------236YELJBLK
,--------------------------~1400LTGRN
.-------------------------1401PNK
.--------------------~1837LTGRNMIHT
-------1403BWHT/BLK-----,
PASS.
_L.---650AA BLK
INFLATOR
PASS. INFLATOR
MODULE
MODULE JUMPER
...---1403A WHT/BLK
~1403CWHT/BLK
L::::::ti-0-348H DK GRN
SHORTING BARS
- - - - 3 4 8 C DK GRN
_j
DERM
IGNITION1
IGNITION1
DRIVER 36 VLR
DRIVER
SOURCE SENSE
PASS. 36VLR
PASS. SOURCE
SENSE
REDUNDANT
INDICATOR
GROUND
PASS. SIDE HIGH
PASS. SIDE LOW
CRANK
SERIAL DATA
5225
'--------------~326PPL
l ' - - - - - - - - - - - - - - - - - - - - 3 4 7 A WHT
'---TO
_ _ _G_A_G_E_S_1-0A_ _ _ _ _
S2_0_6----~348ADKGRN
3488 IGNITION ~ 3 9 A P N K - - - - - - - - - 3 9 H PNK
PASSENGER
DK GRN SWITCH
39CPNK
c2oool
COMPARTMENT
INSTRUMENT CLUSTER
DISCRIMINATING
:~
02
SENSOR
L. __ ..,
I
I
348F
-/1c2ooe
CAMARO
358
DK GRN l348G DK GRN
BRN
"AIRBAG"
FIREBIRD AS
WARNING
A7
LAMP
L-------.J
1751 B BLKMIHT
1751 A BLKMIHT ~ . - __ ,
1751 E BLKMIHT
c 2000
01
c2000
_
L----' ~----1751FBLKMIHT
1751C B L K M I H T - - - - - - - ~
DIAG. REQUEST
DRIVER SIDE
HIGH
DRIVER SIDE
LOW
REDUNDANT
INDICATOR
IGNITION 1
r-------,
-y-
SIR INDICATOR
SHORTING BAR
GROUND
GROUND
7-9-92
NS 11608
CHARTD
(Page 2 of 2)
"AIR BAG" WARNING LAMP DOES NOT COME "ON"

8. This test checks whether power is available to the
instrument cluster power feed circuit.
9. This test checks for a short from the instrument
cluster power feed circuit to ground.
10. This test determines whether the short to ground

is due to a short in the wiring or a malfunctioning
DERM.
due to an open power feed circuit from the GAGES
fuse to the instrument cluster or an open power
feed to the GAGES fuse.
CHART D
(Page 2 of 2)
11
AIR BAG'' WARNING LAMP DOES NOT COME '0N"
WERE YOU SENT HERE FROM CHART D {PAGE 1 OF 2)?
G)
r-

REMOVE AND INSPECT GAGES FUSE.
IS FUSE GOOD?

PASSENGER INFLA TOR
MODULES, YELLOW 2-WAY
CONNECTORS LOCATED
NEAR THE BASE OF THE
STEERING COLUMN AND
BEHIND THE 1/P
COMPARTMENT DOOR
ASSEMBLY.
DISCONNECT DERM.
REPLACE GAGES FUSE.
IGNITION SWITCH "ON,"
WAIT 10 SECONDS.
REMOVE AND INSPECT
GAGES FUSE.
IS FUSE GOOD?
REPAIR SHORT TO
GROUND IN CKT 39.
REPLACE GAGES FUSE.
-------------------,
GO TO CHART D (PAGE 1 OF 2). I
L---------------------J
REPLACE GAGES FUSE.

IGNITION SWITCH "ON," WAIT 10 SECONDS, THEN
REMOVE AND INSPECT GAGES FUSE.
IS FUSE GOOD?

CHECK FOR PROPER CONNECTION TO INSTRUMENT CLUSTER
AT TERMINAL "013" (CAMARO), TERMINAL "AS" {FIRE BIRD).
IF OK, THEN MEASURE RESISTANCE FROM INSTRUMENT
CLUSTER HARNESS CONN ECTOR TERMINAL "013" (CAMARO),
TERMINAL" AS" (FIREBIRD) TO EACH TERMINAL OF THE
GAGESFUSEFUSEHOLDE~
IS EITHER MEASUREMENT 5.0Q OR LESS?

INSTALL GAGES FUSE.
REPAIR OPEN IN
POWER FEED TO
GAGES FUSE, REFER TO
SECTION SA-10.
INSTALL GAGES FUSE.
REPLACE DERM,
REFER TO
SECTION 9J-B.
INSTALL GAGES
FUSE.
RECONNECT ALL SIR SYSTEM COMPONENTS, ENSURE

ALL COMPONENTS ARE PROPERLY MOUNTED.
10-29-92
NS 15419
AIRBAG 15A
TO IGNITION
5204
SWITCH ~ 1 1 3 9 A Y E L - - - - - - - - - - - - - - - - - 1 1 3 9 C Y E L
. - - - - - - - - - 1 1 3 9 8 YEL
1139E YEL
DERM
IGNITION 1
IGNITION 1
.----------------------------236YEUBLK
DRIVER 36 VLR
.--------------------------~1400LTGRN
DRIVER
SOURCE SENSE
PASS. 36 VLR
.-------------------------1401PNK
.--------------------~1837LTGRN/WHT
. - - - - - - - - 1 4 0 3 8 WHT/BLK-----,
_j_~--650AA BLK
PASS. SOURCE
SENSE
REDUNDANT
INDICATOR
GROUND
PASS. SIDE HIGH
PASS. SIDE LOW
CRANK
SERIALDAlA
5225
,...__--------------326PPL
~------------------347AWHT
'--T-O
_ _ _G_A_G~E~S~10_A_ _ _ _ _
S2_0_6----~J48ADKGRN
3488 IGNITION ~ 3 9 A P N K - - - - - - - - - 3 9 H PNK
DK GRN SWITCH
39( PNK
c2oool
r-,
INSTRUMENT CLUSTER
I 02 I
L--..J
I
I
348F
-_;fc2ooe
CA MARO
358
DK GRN L348G DK GRN
BRN
"AIRBAG"
FIREBIRD AS
WARNING
A7
8.45 Kil
LAMP
DIAG. REQUEST
DRIVER SIDE
HIGH
DRIVER SIDE
LOW
REDUNDANT
INDICATOR
IGNITION 1
r-------,
L-------..J
17518 BLK/WHT-y-11s1A BLK/WHTov.r--,

_
C200B
01 :(' C200D
1... __ ..J
1751( B L K / W H T - - - - - - - -
SIR INDICATOR
SHORTING BAR
1751E BLK/WHT
GROUND
1751F BLK/WHT
GROUND
7-9-92
NS 11608
CHART E
''AIRBAG" WARNING LAMP DOES NOT COME "ON" STEADY DURING CRANK

1. This test checks whether the malfunction is due to
an open CRANK fuse.
2. This test checks for a proper signal to the "Crank"
input during cranking.
3. This test determines whether the lack of a proper
crank signal is due to an open "Crank" input
circuit or an open power feed to the CRANK fuse.
4.
5.
This test checks whether the CRANK fuse is open

due to a short to ground in the "Crank" input
circuit.
This test determines whether the short to ground
is in the wiring harness or in the DERM.
CHART E
AIR BAG" WARNING LAMP DOES NOT
COME "ON" STEADY DURING CRANK
II
WHEN MEASUREMENTS ARE REQUESTED IN THIS CHART, USE J 39200 DVM WITH CORRECT TERMINAL
ADAPTER FROM J 35616-A. WHEN A CHECK FOR PROPER CONNECTION IS REQUESTED REFER TO
"INTERMITTENTS AND POOR CONNECTIONS" IN SECTION 8A-4. WHEN A WIRE REPAIR IS REQUESTED
USE J 38125-A TERMINAL REPAIR KIT AND REFER TO "SIR WIRE REPAIR" IN SECTION 9J.

REMOVE AND INSPECT CRANK FUSE.
IS FUSE GOOD?
[$]
G).

REMOVE CRANK FUSE.
MEASURE RESISTANCE
FROM EACH TERMINAL
OFTHECRANKFUSEFUSE
HOLDER TO DERM
HARNESS CONNECTOR
TERMINAL "810".
IS EITHER MEASUREMENT
5.0Q OR LESS?

CHECK FOR PROPER
CONNECTION AT DERM
HARNESS CONNECTOR
TERMINAL "810".
IF CONNECTION IS GOOD
REPLACE DERM, REFER
TO SECTION 9J-B.
G)
[$]

PASSENGERINFLATOR
MODULES, YELLOW 2-WA Y
CONNECTORS LOCATED
NEAR THE BASE OF THE
STEERING COLUMN AND
BEHIND THE 1/P
COMPARTMENT DOOR
ASSEMBLY.
DISCONNECT DERM .
REPLACE CRANK FUSE .
START ENGINE, THEN
REMOVE AND INSPECT
CRANK FUSE.
IS FUSE GOOD?
INSTALL CRANK FUSE .

REPEAT "SIR
DIAGNOSTIC SYSTEM
CHECK."
REPLACE CRANK FUSE.

START ENGINE, THEN IGNITION SWITCH "OFF."
REMOVE AND INSPECT CRANK FUSE.
IS FUSE GOOD?

DISCONNECT DRIVER AND PASSENGER INFLATOR
MODULES, YELLOW 2-WAY CONNECTORS LOCATED
NEAR THE BASE OF THE STEERING COLUMN AND BEHIND
THE 1/P COMPARTMENT DOOR ASSEMBLY.
DISCONNECT DERM.
FROM TERMINAL "810" TO TERMINAL" A 1" (GROUND)
WHILE STARTING ENGINE.
IS VOLTAGE GREATER THAN 7.25 VOLTS?
[$]
REPAIR OPEN IN CKT 806. ,
INSTALL CRANK FUSE.
REPAIR OPEN IN POWER

FEED TO CRANK FUSE,
REFER TO SECTION 8A-10.
REPAIR SHORT FROM

CKT 806 TO GROUND.
REPLACE CRANK FUSE.
REPLACE DERM,
REFER TO SECTION 9J-B.
INSTALL CRANK FUSE.
RECONNECT ALL SIR SYSTEM COMPONENTS, ENSURE ALL COMPONENTS ARE PROPERLY MOUNTED.
10-29-92
NS 11323
AIRBAG 15A
TO IGNITION
S204
SWITCH ~ 1 1 3 9 A Y E L ~ - - - - - - - - - - - - - - - - - - 1 1 3 9 C Y E L
--------1139BYEL__/ \
1139EYEL
DERM
IGNITION 1
IGNITION 1
.----------------------------236YEUBLK
DRIVER 36 VLR
.----------------------------~1400LTGRN
DRIVER
SOURCE SENSE
PASS. 36 VLR
~-----------------------1401PNK
.-----------------------1837LTGRN/WHT
.....-------14038 WHT/BLK---~
_l_,---650AA BLK
PASS. SOURCE
SENSE
REDUNDANT
INDICATOR
GROUND
PASS. SIDE rflGH
PASS. SIDE LOW
CRANK
SERIAL DATA
S225
~------------~326PPL
l'----'"l'-------------------347AWHT
'---TO--~G~A~G~E=s~10~A=------S2_0_6-----348ADKGRN
3488 IGNITION ~ 3 9 A P N K - - - - - - - - - - 3 9 H PNK
PASSENGER
DK GRN SWITCH
39CPNK
COMPARTMENT
C200DI
INSTRUMENT CLUSTER
DISCRIMINATING
~
SENSOR
._ 02
__
I
I
348F
-/fc2008
CA
MARO
358
BRN
"AIRBAG"
B
FIREBIRD AS
WARNING
A7
8.45 Kil
LAMP
r- .J
DIAG. REQUEST
DRIVER SIDE
HIGH
DRIVER SIDE
LOW
REDUNDANT
INDICATOR
IGNITION 1
r-------,
17518 8LK/WHT -y-1751A 8LK/WHT~,--,

-=:C2008/._
1751( 8 L K / W H T - - - - - - - ~
L-------..J
1751E BLK/WHT
~! .Jk:: C200D
1751 F 8LK/WHT
SIR INDICATOR
SHORTING BAR
GROUND
GROUND
7-9-92
NS 11508
CHART F
"AIR BAG" WARNING LAMP FLASHES 7 TIMES
AND TH EN FLASH ES OTC 12
When the ignition switch is first turned "ON," Ignition 1 voltage is applied from the GAGES fuse to

1. This test checks for a short to ground on the
"Diagnostic Request" circuit. Since grounding of
the "Diagnostic Request" circuit enables
diagnostics, i.e. flashes DTC 12, this ground must
be supplied by the DERM or the wiring.
CHART F
11
AIR BAG" WARNING LAMP FLASHES 7 TIMES

AND THEN FLASHES OTC 12
WHEN MEASUREMENTS ARE REQUESTED IN THIS CHART, USE J 39200 OVM WITH
CORRECT TERMINAL ADAPTER FROM J 3S616-A. WHEN A CHECK FOR PROPER
CONNECTION IS REQUESTED, REFER TO "INTERMITTENTS AND POOR CONNECTIONS"
IN SECTION SA-4. WHEN A WIRE REPAIR IS REQUESTED, USE J 38125-A TERMINAL
REPAIR KIT ANO REFER TO "SIR WIRE REPAIR" IN SECTION 9J.
I

DISCONNECT DRIVER AND PASSENGER INFLATOR MODULES, YELLOW 2-WAY CONNECTORS LOCATED
NEAR THE SASE OF THE STEERING COLUMN AND 8EHIND THE 1/P COMPARTMENT DOOR ASSEMBLY.
DISCONNECT DERM.
MEASURE RESISTANCE AT DATA LINK CONNECTOR FROM TERMINAL "K" TO TERMINAL "A" (GROUND).
IS RESISTANCE 10.0Q OR LESS?
REPAIR SHORT FROM CKT 326 TO GROUND.


10-29-92
NS11324
TO IGNITION
AIR BAG 15 A
S204
SWITCH ~ 1 1 3 9 A Y E L ~ - - - - - - - - - - - - - - - - - - 1 1 3 9 ( YEL
.----------1139BYEL__/ \
1139EYEL
~--------------------------~236YEUBLK
.----------------------------1400LTGRN
.--------------------------1401PNK
.----------------------1837LTGRN/WHT
..--------14038 WHT/BLK-----.
PASS.
_j_~---6SOAA BLK
INFLATOR
PASS. INFLATOR
MODULE
MODULE JUMPER
---1403A WHT/BLK
~1403CWHT/BLK
~348HDKGRN
SHORTING BARS
- - - - 3 4 8 ( DK GRN
_j
DERM
IGNITION 1
IGNITION 1
DRIVER 36 VLR
DRIVER
SOURCE SENSE
PASS. 36 VLR
PASS. SOURCE
SENSE
REDUNDANT
INDICATOR
GROUND
PASS. SIDE HIGH
PASS. SIDE LOW
CRANK
SERIAL DATA
5225
,__--------------326PPL
'-------------------~347AWHT
'---TO---G~A~G=E=s~,~O~A-----S-2_0_6-----348ADKGRN
3488 IGNITION ~ 3 9 A P N K - - - - - - - - - - - - 3 9 H PNK
PASSENGER
DK GRN SWITCH
39CPNK
COMPARTMENT
C200DI
INSTRUMENT CLUSTER
DISC:~~~NoAtNG
[ ~~
I
I
348F
- .?k2ooe
CA
MARO
358
DK GRN L348G DK GRN
BRN
"AIRBAG"
.-------------1 B
FIREBIRD AS
WARNING
A7
8.45 KQ
L - _L~~_P__ .J
17518 BLK/WHT -y-1751A BLK/WHT~r--,
1751E BLK/WHT
DIAG. REQUEST
DRIVER SIDE
HIGH
DRIVER SIDE
LOW
REDUNDANT
INDICATOR
IGNITION 1
,--------,
-=-
C2008/L.
1751( B L K / W H T - - - - - - - - ~
~~ .Jk:' C200D
1751 F BLl<JWHT
SIR INDICATOR
SHORTING BAR
GROUND
GROUND
7-9-92
NS 11508
CHARTG
DERM CANNOT COMMUNICATE THROUGH THE SERIAL DATA CIRCUIT
operating voltage range the "AIR BAG" warning lamp is flashed 7 times to verify operation and serial data
communication is enabled. At this time the DERM performs "Turn-On" tests followed by "Continuous
Monitoring" tests. When no malfunctions are detected the DERM proceeds to the "Initiator Assembly Resistance
Test." When a malfunction is detected the DERM sets a current diagnostic trouble code and illuminates the "AIR
BAG" warning lamp. The DERM will clear current diagnostic trouble codes and move them to a history file when
the malfunction is no longer detected and/or the ignition switch is cycled, except for DTC 51. DTC 51 can only be
cleared using a scan tool "Clear Codes" command.

1. An improper connection to the data link connector
will prevent communications from being
established.
2. This test checks for a short to ground in the "Serial
Data" circuit.
3.
This test checks for an open in the "Serial Data"

circuit.
4. This test checks for a short to B + in the "Serial
Data" circuit. Once the integrity of the "Serial
Data" circuit has been confirmed, including proper
connections, the DERM must be malfunctioning.
CHARTG
DERM CANNOT COMMUNICATE
THROUGH THE SERIAL DATA
CIRCUIT
WHEN MEASUREMENTS ARE REQUESTED IN THIS CHART USE J 39200 DVM WITH
CONNECTION IS REQUESTED REFER TO "INTERMITTENTS AND POOR CONNECTIONS"
IN SECTION 8A-4. WHEN A WIRE REPAIR IS REQUESTED, USE J 38125-A TERMINAL
I
CHECK FOR PROPER CONNECTION OF SCAN TOOL TO DATA LINK CONNECTOR. ,

IS THE CONNECTION GOOD?

DISCONNECT DRIVER AND PASSENGER INFLATOR MODULES, YELLOW
2-WAY CONNECTORS LOCATED NEAR THE BASE OF THE STEERING
COLUMN AND BEHIND THE 1/P COMPARTMENT DOOR ASSEMBLY.
DISCONNECT DERM .
MEASURE RESISTANCE ON DATA LINK CONNECTOR FROM TERMINAL
"M" TO TERMINAL "A" (GROUND).
IS RESISTANCE s.on OR LESS?
PROPERLY CONNECT SCAN TOOL TO DATA

LINK CONNECTOR.
[$]
MEASURE RESISTANCE FROM DA TA LINK CONNECTOR TERMINAL

"M" TO DERM HARNESS CONNECTOR TERMINAL "811 ".
--. REPAIR SHORT FROM CKT 800 TO GROUND.

MEASURE VOLTAGE ON DATA LINK CONNECTOR FROM
TERMINAL "M" TO TERMINAL" A" (GROUND).
--. REPAIR OPEN IN CKT 800. I

CHECK FOR PROPER CONNECTION AT DATA LINK CONNECTOR
TERMINAL "M" AND DERM HARNESS CONNECTOR TERMINAL "811 ".
IF BOTH CONNECTIONS ARE GOOD REPLACE DERM, REFER TO
SECTION 9J-B.

REPAIR SHORT FROM CKT 800 TO B + .
RECONNECT ALL SIR SYSTEM COMPONENTS, ENSURE ALL COMPONENTS ARE PROPERLY MOUNTED .
I
10-29-92
NS 11325
AIRBAG 15A
TO IGNITION
5204
SWITCH ~ 1139A Y E L - - , . ; : - - - - - - - - - - - - - - - - - - - - 1 1 3 9 C YEL
. . . . . - - - - - - - - - 1 1 3 9 8 YEL__/ \
DERM
IGNITION 1
1139E YEL
.---------------------------~236YEUBLK
.....-------------------------~1400LTGRN
DUAL
POLE . - - - - - - - - - - - - - - - - - - - - - - - - - 1 4 0 1 P N K
ARMING
SENSOR
1837 LTGRN/WHT
14038 WHT/BLK
DRIVER
SOURCE SENSE
PASS. 36 VLR
PASS. SOURCE
SENSE
PASS. SIDE HIGH
PASS. SIDE LOW
347AWHT
DRIVER
INFLATOR
MODULE
DRIVER SIDE
HIGH
DRIVER SIDE
LOW
348F
DKGRN
1751C
PASSENGER
COMPARTMENT
DISCRIMINATING
SENSOR
BLKIWHTl
GROUND
6-30-92
NS11316
DTC 14
DUAL POLE ARMING SENSOR DISCONNECTED
The DERM monitors the voltage at the "Driver Source Sense" terminal "A5", the "Passenger Source Sense"
terminal "A6", the "Driver Side High" terminal "B9", the "Passenger Side High" terminal "A7", the "Driver Side
Low" terminal "BS" and the "Passenger Side Low" terminal "B7'' during the "Continuous Monitoring'' tests.
When all voltages are simultaneously below a specified value for 500 milliseconds DTC 14 sets.
Test Conditions: Tested every 100 milliseconds during the "Continuous Monitoring" tests.
Failure Conditions: DTC 14 will set when the voltages at terminals "A5", "A6", "B9", "A7'', "BS" and "B7'' of
the DERM harness connector are simultaneously below a specified value for 500 milliseconds.
Action Taken: DERM turns "ON" the "AIR BAG" warning lamp and sets a diagnostic trouble code.
Conditions to Clear: DTC 14 will clear when the voltage at terminal "A5", "A6", "B9", "A7'', "BS" or "B7" of
DERM harness connector is above specified value for 500 milliseconds.

1. This test checks for a situation which prevents a
proper connection of the dual pole arming sensor to
the SIR wiring harness. It is highly unlikely that
an intermittent condition has set this DTC as this
would require a poor connection at terminals "A",
"B" and "C" or at terminals "D", "E", "F" and "G".
DTC14
DUAL POLE ARMING SENSOR DISCONNECTED
WAS THE "SIR DIAGNOSTIC SYSTEM CHECK" PERFORMED?
G)

DISCONNECT DRIVER AND PASSENGER INFLATOR MODULES,
YELLOW 2-WAY CONNECTORS LOCATED NEAR THE BASE OF
THE STEERING COLUMN AND BEHIND THE 1/P
COMPARTMENT DOOR ASSEMBLY.
DISCONNECT DUAL POLE ARMING SENSOR HARNESS
CONNECTOR FROM DUAL POLE ARMING SENSOR AND
RECONNECT.
IS DTC 14 CURRENT?

RECONNECT All SIR SYSTEM COMPONENTS,
ENSURE All COMPONENTS ARE PROPERLY MOUNTED."
: GO TO THE "SIR DIAGNOSTIC SYSTEM CHECK" :

All COMPONENTS ARE PROPERLY MOUNTED.
CLEAR SIR DIAGNOSTIC TROUBLE CODES.
7-1-92
NS 11326
TO IGNITION
AIR BAG 15 A
5204
SWITCH ~ 1 1 3 9 A Y E L - - - J J : ; : - - - - - - - - - - - - - - - - - - - 1 1 3 9 C Y E L
.....---------1139BYEL_/ \
DERM
IGNITION 1
1139EYEL
.....--------------------------~236YEUBLK
.---------------------------~1400LTGRN
DUAL
POLE . . . . . - - - - - - - - - - - - - - - - - - - - - - - - 1 4 0 1 P N K
ARMING
SENSOR
14038 WHT/BLK
PASS. INFLATOR
MODULE JUMPER
PASS.
~1403CWHT/BLK
INFLATOR
{
MODULE
348H DK GRN
i8_
1403A WHT/BLK
PASS. SIDE HIGH
1----348( DK GRN
PASS. SIDE LOW
SHORTING BARS
DRIVER
INFLATOR
MODULE
347AWHT
DRIVER SIDE
HIGH
DRIVER SIDE
LOW
348F
DKGRN
1751C
PASSENGER
COMPARTMENT
DISCRIMINATING
SENSOR
BlklWHTl
GROUND
6-30-92
NS11316
OTC 15
PASSENGER INITIATOR CIRCUIT RESISTANCE HIGH
During the "Initiator Assembly Resistance Test" the DERM grounds the "Driver Side Low" terminal "B8"
and turns "ON" the passenger current source at the "Passenger Side High" terminal "A7". This causes a known
amount of current to flow through the passenger initiator circuit. By monitoring the difference between the
voltage at the "Passenger Side High" terminal "A7" and the "Passenger Side Low" terminal "B7'' the DERM
calculates the combined resistance of the passenger inflator module, passenger inflator module jumper, harness
wiring CKTs 1403A and 348C and connector terminal contact.
Test Conditions: Tested once each ignition cycle during the "Initiator Assembly Resistance Test" when: 1) No
"higher priority faults" are detected during "Turn-ON," 2) No "higher priority faults" are detected during
"Continuous Monitoring" for one second, 3) No "CRANK" signal present, 4) "Ignition l" voltage is above a
specified value.
Failure Conditions: DTC 15 will set when the combined resistance of the passenger inflator module,
passenger inflator module jumper CKT 1403C, harness wiring CKT 1403A and connector terminal contact is
above a specified value.
Conditions to Clear: DTC 15 will clear each time the ignition switch is turned "OFF."
the passenger inflator module circuitry or in the
DERM wiring harness circuitry.
an open in CKT 1403A or a malfunctioning
DERM.
3.
This test determines whether the malfunction is in

the passenger inflator module or the passenger
inflator module jumper.
DTC 15
PASSENGER INITIATOR CIRCUIT
RESISTANCE HIGH

"INTERMITTENTS AND POOR CONNECTIONS" IN SECTION SA-4.
G)

DISCONNECT DRIVER AND PASSENGER IN FLA TOR MODULES, YELLOW 2-WA Y CONNECTORS LOCATED NEAR
THE BASE OF THE STEERING COLUMN AND BEHIND THE 1/P COMPARTMENT DOOR ASSEMBLY.
CHECK FOR PROPER CONNECTION TO PASSENGER INFLATOR MODULE JUMPER AT TERMINALS "A" AND "B".
IF OK THEN CONNECT J 38715 SIR DRIVER/PASSENGER LOAD TOOL TO STEERING COLUMN HARNESS
CONNECTOR AND PASSENGER INFLATOR MODULE HARNESS CONNECTOR.
IS OTC 15 CURRENT?

DISCONNECT DERM.
CHECK FOR PROPER CONNECTION TO DERM AT
TERMINAL "A7".
IF OK THEN MEASURE RESISTANCE FROM DERM
HARNESS CONNECTOR TERMINAL" A7" TO
PASSENGER INFLATOR MODULE HARNESS
G)
: GO TO THE "SIR DIAGNOSTIC SYSTEM CHECK." :
REPLACE DERM,
RECONNECT ALL SIR SYSTEM
COMPONENTS, ENSURE ALL
COMPONENTS ARE
PROPERLY MOUNTED.
REPEAT "SIR DIAGNOSTIC
SYSTEM CHECK."
IN CKT 1403A.

DISCONNECT PASSENGER INFLATOR MODULE PIGTAIL
CONNECTOR FROM PASSENGER INFLA TOR MODULE JUMPER.
CHECK FOR PROPER CONNECTION TO PASSENGER INFLATOR
MODULE AT TERMINALS "A" AND "B".
IF OK THEN DISCONNECT PASSENGER INFLATOR MODULE
HARNESS CONNECTOR FROM SIR DRIVER/PASSENGER LOAD
TOOL AND RECONNECT TO PASSENGER INFLATOR MODULE
JUMPER.
CONNECT SIR DRIVER/PASSENGER LOAD TOOL TO INFLATOR
MODULE SIDE OF PASSENGER INFLATOR MODULE JUMPER.
IS OTC 15 CURRENT?

REPLACE PASSENGER
INFLATOR MODULE,

IN PASSENGER INFLATOR
MODULE JUMPER.
RECONNECT ALL SIR SYSTEM COMPONENTS,

ENSURE ALL COMPONENTS ARE PROPERLY MOUNTED.
10-29-92
NS11327
TO IGNITION
AIR BAG 15A
5204
SWITCH ~ 1 1 3 9 A Y E L ~ - - - - - - - - - - - - - - - - - - 1 1 3 9 C Y E L
.----------1139BYEL__/ \
DERM
IGNITION 1
1139EYEL
,~-------------------------~236YEUBLK
.--------------------------~1400LTGRN
DUAL
POLE . . . - - - - - - - - - - - - - - - - - - - - - - - - 1 4 0 1 P N K
ARMING
SENSOR
14038 WHT/BLK
DRIVER
SOURCE SENSE
PASS. 36 VLR
PASS. SOURCE
SENSE
PASS. SIDE HIGH
PASS. SIDE LOW
DRIVER
INFLATOR
MODULE
347AWHT
348A DKGRN
DRIVER SIDE
HIGH
DRIVER SIDE
LOW
348F
DKGRN
1751C
PASSENGER
COMPARTMENT
DISCRIMINATING
SENSOR
BLKIWHTl
GROUND
6-30-92
NS11316
DTC 16
PASSENGER INITIATOR CIRCUIT RESISTANCE LOW
and turns "ON" the passenger current source at the "Passenger Side High" terminal "A7". This causes a known
amount of current to flow through the passenger initiator circuit. By monitoring the difference between the
voltage at the "Passenger Side High" terminal "A 7'' and the "Passenger Side Low" terminal "B7'' the DERM
calculates the combined resistance of the passenger inflator module, passenger inflator module jumper, harness
wiring CKTs 1403A and 348C and connector terminal contact.
Test Conditions: Tested once each ignition cycle during the "Initiator Assembly Resistance Test" when: 1)
No "higher priority faults" are detected during "Turn-ON," 2) No "higher priority faults" are detected during
specified value.
Failure Conditions: DTC 16 will set when the combined resistance of the passenger inflator module,
passenger inflator module jumper, harness wiring CKTs 1403A and 348C and connector terminal contact is
below a specified value.

1. DTC 16 and 22 will set simultaneously when the
"Driver Side High" circuit is shorted to the
"Passenger Side High" circuit due to parallel
current paths.
the passenger inflator module circuitry or in the
3.
4.
This test checks for a short from the "Passenger

Side High" circuit to the "Passenger Side Low" or
"Driver Side Low" circuit. If no short is found, the
DERM is malfunctioning.
DTC 16
PASSENGER INITIATOR CIRCUIT
RESISTANCE LOW
@-
8
REPAIR KIT AND REFER TO "SIR WIRE REPAIR" IN SECTION 9J .
IS OTC 22 ALSO CURRENT?

THE STEERING COLUMN AND BEHIND THE 1/P COMPARTMENT
DOOR ASSEMBLY.
CONNECT J 38715 SIR DRIVER/PASSENGER LOAD TOOL TO
STEERING COLUMN HARNESS CONNECTOR AND PASSENGER
INFLATOR MODULE HARNESS CONNECTOR.
15 DTC 16 CURRENT?
[$]

DISCONNECT DERM.
FROM TERMINAL" A7" TO TERMINAL "87".

SECTION 9J-B.
COMPONENTS ARE PROPERLY
MOUNTED.
SYSTEM CHECK."

NEAR THE BASE OF THE STEERING COLUMN AND
BEHIND THE 1/P COMPARTMENT DOOR ASSEMBLY.
REPAIR SHORT FROM CKT 347 TO CKT 1403.
G)
IGNITION SWITCH"OFF."
DISCONNECT PASSENGER INFLATOR MODULE
PIGTAIL CONNECTOR FROM PASSENGER INFLATOR
MODULE JUMPER,
DISCONNECT PASSENGER INFLATOR MODULE
HARNESS CONNECTOR FROM SIR
DRIVER/PASSENGER LOAD TOOL AND RECONNECT
TO PASSENGER INFLATOR MODULE JUMPER.
CONNECT SIR DRIVER/PASSENGER LOAD TOOL TO
INFLATOR MODULE SIDE OF PASSENGER INFLATOR
MODULE JUMPER.
IGNITION SWITCH"ON."
IS OTC 16 CURRENT?
REPAIR SHORT FROM

CKT 1403A TO CKT 348.
L-----------------------------J
--------------------------,
GO TO THE "SIR DIAGNOSTIC SYSTEM CHECK."
IGNITION SWITCH
"OFF."
REPAIR SHORT
FROM CKT 1403C
TOCKT348H.

REPLACE PASSENGER
INFLATOR MODULE,

COMPONENTS, ENSURE ALL COMPONENTS
ARE PROPERLY MOUNTED.
CLEAR SIR DIAGNOSTIC TROUBLE CODES .
10-29-92
NS 11383
TO IGNITION
AIR BAG 15A
5204
SWITCH ~ 1139A YEL----Jt;:--------------------1139C YEL
.....---------1139BYEL__/ \
DERM
IGNITION 1
1139EYEL
....--------------------------~236YELJBLK
~------------------------~1400LTGRN
DUAL
POLE . . . . . - - - - - - - - - - - - - - - - - - - - - - - - 1 4 0 1 P N K
ARMING
SENSOR
14038 WHT/BLK
PASS. SIDE HIGH
PASS. SIDELOW
DRIVER
INFLATOR
MODULE
347AWHT
DRIVER SIDE
HIGH
DRIVER SIDE
LOW
348E
DKGRN
348F
DKGRN
1751C
PASSENGER
COMPARTMENT
DISCRIMINATING
SENSOR
BLKIWHTl
GROUND
6-30-92
NS 11316
OTC 17
PASSENGER INITIATOR CIRCUIT OPEN
When there is an open in the passenger inflator module jumper or the passenger inflator module the
resistance between "Passenger Side High" terminal "A 7" and "Passenger Side Low" terminal "B7'' increases.
This causes a larger voltage drop from the "Passenger Side High" to the "Passenger Side Low" across a resistor
inside the DERM which connects these two terminals together. The increase in the voltage difference between
"Passenger Side High" and "Passenger Side Low" is detected by the DERM during the "Continuous Monitoring"
tests and DTC 17 is set.
Failure Conditions: DTC 17 will set when the voltage difference between "Passenger Side High" terminal
"A 7"and "Passenger Side Low" terminal "B7" is above or equal to a specified value for 500 milliseconds.
Conditions to Clear: DTC 17 will clear when the voltage difference between "Passenger Side High" terminal
"A7" and "Passenger Side Low" terminal "B7" is below a specified value for 500 milliseconds.

1. This test checks whether the DERM has set the
diagnostic trouble code falsely.
OTC 17
PASSENGER INITIATOR CIRCUIT OPEN
,........___~~~~~~~~~~~~~~~~~~~~-,r-

----------------------------,
GO TO THE "SIR DIAGNOSTIC SYSTEM CHECK." 1
L------------------------------1

DISCONNECT DRIVER AND PASSENGER IN FLA TOR MODULES, YELLOW 2-WA Y CONNECTORS LOCATED NEAR
CHECK FOR PROPER CONNECTION TO PASSENGER INFLATOR MODULE JUMPER AT TERMINALS "A" AND "8".
IF OK THEN CONNECT J 3871 S SIR DRIVER/PASSENGER LOAD TOOL TO PASSENGER INFLATOR MODULE
HARNESS CONNECTOR.
IS OTC 17 CURRENT? (OTC 26 WILL BE CURRENT DUE TO DISCONNECTED DRIVER INFLATOR MODULE.)

DISCONNECT PASSENGER INFLATOR MODULE PIGTAIL
CONNECTOR FROM PASSENGER INFLATOR MODULE JUMPER.
CHECK FOR PROPER CONNECTION TO PASSENGER INFLATOR
MODULE AT TERMINALS "A" AND "B".
IF OK, THEN DISCONNECT PASSENGER INFLATOR MODULE
HARNESS CONNECTOR FROM SIR DRIVER/PASSENGER LOAD
TOOL AND RECONNECT TO PASSENGER INFLATOR MODULE
JUMPER.
CONNECT SIR DRIVER/PASSENGER LOAD TOOL TO INFLATOR
MODULE SIDE OF PASSENGER INFLATOR MODULE JUMPER.
IS OTC 17 CURRENT? (OTC 26 WILL BE CURRENT DUE TO
DISCONNECTED DRIVER INFLATOR MODULE.)

REPLACE PASSENGER INFLATOR MODULE, REFER TO
SECTION 9J-B.


REPAIR OPEN IN PASSENGER INFLATOR MODULE
JUMPER.
10-29-92
NS 11384
TO IGNITION
AIR BAG 15 A
S204
SWITCH ~ 1 1 3 9 A YEL ~ - - e - - - - - - - - - - - - - - - - 1 1 3 9 C YEL
--------1139BYEL_/ \
DERM
IGNITION 1
1139EYEL
--------------------------~236YEUBLK
.--------------------------~1400LTGRN
DUAL
POLE - - - - - - - - - - - - - - - - - - - - - - - - 1 4 0 1 P N K
ARMING
SENSOR
14038 WHT/BLK
PASS. SIDE HIGH
PASS. SIDE LOW
DRIVER
INFLATOR
MODULE
347AWHT
348A DKGRN
DRIVER SIOE
HIGH
DRIVER SIDE
LOW
348E
DKGRN
348F
DKGRN
1751C
PASSENGER
COMPARTMENT
DISCRIMINATING
SENSOR
BLKIWHTl
GROUND
6-30-92
NS11316
OTC 18
DISCRIMINATING SENSOR INTERCONNECT OPEN
and measures the voltage at "Driver Side Low" and "Passenger Side Low." The DERM then grounds "Passenger
Side Low" terminal "B7'' and again measures the voltage at "Driver Side Low" and "Passenger Side Low." For a
properly operating circuit the voltage measurements during each of these tests will be below a specified value.
When the voltage measured at either "Driver Side Low" or "Passenger Side Low," but not both, is above a
specified value during either test DTC 18 is set.
Test Conditions: Tested during the "Initiator Assembly Resistance Test" and the "10 Minute Loop Test"
when: 1) No "higher priority faults" are detected during "Turn-ON," 2) No "higher priority faults" are detected
during "Continuous Monitoring" for one second, 3) No "CRANK" signal present, 4) "Ignition l" voltage is above
a specified value.
Failure Conditions: DTC 18 will set when the voltage measured at either "Driver Side Low" or "Passenger
Side Low," but not both, is above a specified value while the DERM attempts to ground either of these terminals.
Conditions to Clear: DTC 18 will clear when the voltages measured at both "Driver Side Low" and
"Passenger Side Low" are below specified value while the DERM grounds each of the terminals.

1. This test checks whether the malfunction is in the
wiring harness. The wiring harness malfunction
would be a high resistance rather than an open.
An open would set a different diagnostic trouble
code.
2.

the wiring harness or in the DERM. The wiring
harness malfunction would be a high resistance
rather than an open. An open would set a different
diagnostic trouble code.
DTC18
DISCRIMINATING SENSOR
INTERCONNECT OPEN

I
$
DVM WITH CORRECT TERMINAL ADAPTER FROM J 3S616-A. WHEN A
I
G).
----------------- ---------,
LGO TO THE "SIR DIAGNOSTIC SYSTEM CHECK.''_ J

DISCONNECT DRIVER AND PASSENGER INFLA TOR MODULES, YELLOW 2-WAY CONNECTORS LOCATED
NEAR THE BASE OF THE STEERING COLUMN AND BEHIND THE 1/P COMPARTMENT DOOR ASSEMBLY.
DISCONNECT CONNECTOR C200B FROM CONNECTOR C200D .
MEASURE RESISTANCE FROM C200D TERMINAL "02" TO STEERING COLUMN HARNESS CONNECTOR
TERMINAL "B".
G) MEASURE RESISTANCE FROM C200D TERMINAL "02" TO

PASSENGER INFLATOR MODULE HARNESS CONNECTOR
TERMINAL "B".
REPAIR HIGH RESISTANCE IN CKT 3488.1
DERM, REFER TO SECTION 9J-B .

REPLACE
REPAIR HIGH RESISTANCE IN CKT 348E.

I
I
7-8-92
NS 11328
TO IGNITION
AIR BAG 1SA
5204
SWITCH ~ 1 1 3 9 A Y E L ~ - - - - - - - - - - - - - - - - - - 1 1 3 9 C Y E L
.---------1139BYEL_/ \
DERM
IGNITION 1
1139EYEL
.---------------------------~236YEUBLK
.--------------------------~1400LTGRN
DUAL
POLE . . . . - - - - - - - - - - - - - - - - - - - - - - - - 1 4 0 1 P N K
ARMING
SENSOR
14038 WHT/BLK
PASS. SIDE HIGH
PASS. SIDE LOW
DRIVER
INFLATOR
MODULE
347AWHT
DRIVER SIDE
HIGH
DRIVERSICE
LOW
348F
DKGRN
1751C
PASSENGER
COMPARTMENT
DISCRIMINATING
SENSOR
BLKIWHTl
GROUND
6-30-92
NS11316
DTC 19
(Page 1 of 3)
PASSENGER INITIATOR CIRCUIT VOLTAGE HIGH

During normal, non-deployment operation of the SIR system, a small amount of current flows through both
the driver and passenger deployment loops. The diagnostic resistors within the dual pole arming sensor and the
discriminating sensors along with the resistance of the inflator modules cause voltage drops within the
deployment loops. The DERM monitors the voltage at "Passenger Side Low" terminal "B7" to detect shorts or
opens within the passenger deployment loop. When the measured voltage is above a specified percentage of
"Passenger 36 VLR" for 500 milliseconds DTC 19 is set.
Failure Conditions: DTC 19 will set when the voltage measured at "Passenger Side Low" terminal "B7'' is
above a specified percentage of"Passenger 36 VLR" for 500 milliseconds and DTC 35 is not set.
Conditions to Clear: DTC 19 will clear when the voltage measured at "Passenger Side Low" terminal "B7'' is
within a specified percentage of "Passenger 36 VLR" for 500 milliseconds.
1. DTC 19 and 24 together means that there is an
open between the passenger inflator module
harness connector and the forward lamp
interconnect. This causes the voltage to increase
at "Passenger Side Low" due to the loss of a ground
path. This also causes the voltage to decrease at
"Driver Side Low" due to decreased current flow
through the discriminating sensor network.
2.
This test checks for decreased resistance in the

driver side diagnostic resistors of the dual pole
arming sensor.
3. This test checks for decreased resistance in the
passenger side diagnostic resistors of the dual pole
arming sensor.
4. This test checks for a short from the high side of
the driver deployment loop to "Driver 36 VLR."
an open in CKT 348E or a malfunctioning DERM.
DTC 19
WAS THE "SIR DIAGNOSTIC
SYSTEM CHECK" PERFORMED?
.
@]
{Page 1 of 3)

NO
r ----------------------------,
LGO TO THE "SIR DIAGNOSTIC SYSTEM CHECK." J
WHEN MEASUREMENTS ARE REQUESTED IN THIS CHART

USE J 39200 DVM WITH CORRECT TERMINAL ADAPTER
FROM J 35616-A. WHEN A CHECK FOR PROPER CONNECTION
IS REQUESTED REFER TO "INTERMITTENTS AND POOR
CONNECTIONS" IN SECTION BA-4. WHEN A WIRE REPAIR IS
REQUESTED USE J 38125-A TERMINAL REPAIR KIT AND REFER
TO "SIR WIRE REPAIR" IN SECTION 9J .
01 is_
DTC 24 ALSO CURRENT?
@]
?\...:.,'

DISCONNECT DRIVER AND PASSENGER INFLA TOR MODULES,
YELLOW 2-WA Y CONNECTORS LOCATED NEAR THE BASE OF
THE STEERING COLUMN AND BEHIND THE 1/P COMPARTMENT
DOOR ASSEMBLY.
DISCONNECT DERM AND DUAL POLE ARMING SENSOR.
INSPECT DUAL POLE ARMING SENSOR HARNESS CONNECTOR
FOR BACKED OUT AND/OR SHORTED TERMINALS.
IF OK THEN MEASURE RESISTANCE ON DUAL POLE ARMING
SENSOR FROM TERMINAL "D" TO TERMINAL "E".
IS RESISTANCE 12.5 kQ OR LESS?
MEASURE RESISTANCE ON DUAL

POLE ARMING SENSOR FROM
TERMINAL "F" TO TERMINAL "G".
MEASURE RESISTANCE ON DUAL

POLE ARMING SENSOR HARNESS
CONNECTOR FROM TERMINAL
"E" TO TERMINAL "B".

NEAR THE BASE OF THE STEERING COLUMN AND
BEHIND THE 1/P COMPARTMENT DOOR ASSEMBLY.
MEASURE RESISTANCE FROM DRIVER INFLATOR
MODULE HARNESS CONNECTOR TERMINAL "B" TO
REPLACE DUAL POLE

ARMING SENSOR,
REPAIR OPEN
IN CKT 348E.
[$]
'-.:..,I
El

SECTION 9J-B.
RECONNECT All SIR
SYSTEM COMPONENTS,
ENSURE All COMPONENTS
SYSTEM CHECK."
REPLACE DUAL POLE

ARMING SENSOR,
[$]
---------------,
: CONTINUE WITH DIAGNOSIS :

I
ON NEXT PAGE.
L------------------~
REPAIR SHORT FROM

CKT 347 TO CKT 236.
RECONNECT All SIR SYSTEM COMPONENTS, ENSURE

8-26-92
NS 11329
TO IGNITION
AIR BAG 15A
S204
SWITCH ~ 1 1 3 9 A Y E L ~ - - - - - - - - - - - - - - - - - - 1 1 3 9 C YEL
. - - - - - - - - - - 1 1 3 9 8 YEL_/ \
DERM
IGNITION 1
1139E YEL
~--------------------------236YELJBLK
..-------------------------~1400LTGRN
DUAL
POLE . - - - - - - - - - - - - - - - - - - - - - - - - - - - 1 4 0 1 P N K
ARMING
SENSOR
14038 WHT/BLK
PASS. SIDE HIGH
PASS. SIDE LOW
347A WHT
DRIVER
INFLATOR
MODULE
348ADKGRN
DRIVER SIDE
HIGH
DRIVER SIDE
LOW
348E
DKGRN
348F
DKGRN
1751C
PASSENGER
COMPARTMENT
DISCRIMINATING
SENSOR
BLKIWHTl
GROUND
6-30-92
NS 11316
OTC 19
(Page 2 of 3)

deployment loops. The DERM monitors the voltage at "Passenger Side Low" terminal "B7'' to detect shorts or
above a specified percentage of"Passenger 36 VLR" for 500 milliseconds and DTC 35 is not set.
Conditions to Clear: DTC 19 will clear when the voltage measured at "Passenger Side Low" terminal "B7'' is
within a specified percentage of"Passenger 36 VLR" for 500 milliseconds.
the passenger deployment loop to "Passenger 36
VLR."
the driver deployment loop to "Passenger 36 VLR."
the passenger deployment loop to "Driver Source
the driver deployment loop to "Driver Source
Sense."
Sense."
the passenger deployment loop to "Passenger
the driver deployment loop to "Passenger Source
Source Sense."
Sense."
13. This test checks for a short from the low side of the
driver deployment loop to "Driver 36 VLR."
the passenger deployment loop to "Driver 36
VLR."
OTC 19
(Page 2 of 3)
PASSENGER INITIATOR
CIRCUIT
VOLTAGE HIGH
MEASURE RESISTANCE ON DUAL POLE ARMING SENSOR HARNESS
CONNECTOR FROM TERMINAL "E" TO TERMINAL"(".
: GO TO OTC 19 :
1 (PAGE 1 OF 3). 1

CONNECTOR FROM TERMINAL "E" TO TERMINAL "D".
REPAIR SHORT FROM

CKT 347 TO CKT 1401.

CONNECTOR FROM TERMINAL 'T' TO TERMINAL "F".
REPAIR SHORT FROM


CONNECTOR FROM TERMINAL "G" TO TERMINAL "C".
REPAIR SHORT FROM


CONNECTOR FROM TERMINAL "G" TO TERMINAL "D".
REPAIR SHORT FROM

CKT 1403 TO CKT 1401.

CONNECTOR FROM TERMINAL "G" TO TERMINAL "F".
REPAIR SHORT FROM

CKT 1403 TO CKT 1400.
MEASURE RESISTANCE FROM STEERING COLUMN HARNESS

CONNECTOR TERMINAL "B" TO DUAL POLE ARMING
SENSOR HARNESS CONNECTOR TERMINAL "B".
REPAIR SHORT FROM

CKT 1403 TO CKT 1837.

ENSURE ALL COMPONENTS ARE PROPERLY
MOUNTED.

CONNECTOR FROM TERMINAL "G" TO TERMINAL "B".
'13\
r- - - - - - - - - - - - - - - - - - - - - - - - - - - ,
I CONTINUE WITH DIAGNOSIS ON NEXT PAGE. 1
L----------------------------J
7-8-92
NS11330
AIRBAG 15A
TO IGNITION
5204
SWITCH ~ 1 1 3 9 A Y E L - - - - - - - - - - - - - - - - - 1 1 3 9 C Y E L
~--------1139BYEL
DERM
IGNITION 1
1139EYEL
.---------~-----------------236YEUBLK
....-------------------------~1400LTGRN
DUAL
POLE . . . - - - - - - - - - - - - - - - - - - - - - - - - 1 4 0 1 P N K
ARMING
SENSOR
14038 WHT/BLK
PASS. SIDE HIGH
PASS. SIDE LOW
DRIVER
INFLATOR
MODULE
347A WHT
DRIVER SIDE
HIGH
DRIVER SIDE
LOW
348E
DKGRN
348F
DKGRN
1751C
PASSENGER
COMPARTMENT
DISCRIMINATING
SENSOR
BLK,WHTl
GROUND
6-30-92
NS11316
OTC 19
(Page 3 of 3)

deployment loops. The DERM monitors the voltage at "Passenger Side Low" terminal "B7'' to detect shorts or
above a specified percentage of "Passenger 36 VLR" for 500 milliseconds and DTC 35 is not set.
Conditions to Clear: DTC 19 will clear when the voltage measured at "Passenger Side Low" terminal "87'' is
within a specified percentage of"Passenger 36 VLR" for 500 milliseconds.
driver deployment loop to "Passenger 36 VLR."
driver deployment loop to "Driver Source Sense."
driver deployment loop to "Passenger Source
Sense."
17. This test checks for. increased resistance of the
diagnostic resistor in the forward discriminating
sensor.

increased resistance of the diagnostic resistor in
the passenger compartment discriminating sensor
or a malfunctioning DERM.
DTC 19
(Page 3 of 3)
PASSENGER INITIATOR
CIRCUIT
VOLTAGE HIGH
WERE YOU SENT HERE FROM OTC 19 (PAGE 2 OF 3)?
\!Y
\!31
r,6'
~
\.!..!)
@:

CONNECTOR FROM TERMINAL "B" TO DUAL POLE ARMING
SENSOR HARNESS CONNECTOR TERMINAL "C".
--------,
I GOTO OTC 19 1
L(PAGE 2 OF 3). J

SENSOR HARNESS CONNECTOR TERMINAL "D".
REPAIR SHORT FROM


SENSOR HARNESS CONNECTOR TERMINAL "F".
REPAIR SHORT FROM

DISCONNECT FORWARD DISCRIMINATING SENSOR.

MEASURE RESISTANCE ON FORWARD DISCRIMINATING SENSOR
FROM TERMINAL" A" TO TERMINAL "B".
REPAIR SHORT FROM

DISCONNECT PASSENGER COMPARTMENT DISCRIMINATING SENSOR.

MEASURE RESISTANCE ON PASSENGER COMPARTMENT
DISCRIMINATING SENSOR FROM TERMINAL" A" TO TERMINAL "C".
REPLACE FORWARD DISCRIMINATING

SENSOR, REFER TO SECTION 9J-B.

RECONNECT ALL SIR SYSTEM COMPONENTS, ENSURE ALL
COMPONENTS ARE PROPERLY MOUNTED.
REPLACE PASSENGER COMPARTMENT

DISCRIMINATING SENSOR, REFF.R TO
SECTION 9J-B.

MOUNTED.
8-25-92
NS 11331
AIRBAG 15A
TO IGNITION
5204
SWITCH ~ 1 1 3 9 A Y E L ~ - - - - - - - - - - - - - - - - - - 1 1 3 9 C YEL
. - - - - - - - - - - 1 1 3 9 8 YEL__/ \
DERM
IGNITION 1
1139E YEL
.---------------------------~236YEUBLK
.--------------------------~1400LTGRN
DUAL
POLE . - - - - - - - - - - - - - - - - - - - - - - - - - 1 4 0 1 P N K
ARMING
SENSOR
14038 WHT/BLK
PASS. SIDE HIGH
PASS. SIDE LOW
DRIVER
INFLATOR
MODULE
347AWHT
3488
. _ _ _ - - - - - - ~ - - - - - - - - - - - - - ~ DKGRN
DRIVER SIDE
HIGH
DRIVER SIDE
LOW
348E
DKGRN
348F
DKGRN
1751C
PASSENGER
COMPARTMENT
DISCRIMINATING
SENSOR
BLK/WHTl
GROUND
6-30-92
NS 11316
DTC21
DRIVER INITIATOR CIRCUIT RESISTANCE HIGH
During the "Initiator Assembly Resistance Test" the DERM grounds the "Passenger Side Low" terminal "BT'
and turns "ON" the driver current source at the "Driver Side High" terminal "B9". This causes a known amount
of current to flow through the driver initiator circuit. By monitoring the difference between the voltage at the
"Driver Side High" terminal "B9" and the "Driver Side Low" terminal "B8" the DERM calculates the combined
resistance of the driver inflator module, SIR coil assembly, harness wiring CKTs 347A and 348A and connector
terminal contact.
specified value.
Failure Conditions: OTC 21 will set when the combined resistance of the driver inflator module, SIR coil
assembly, harness wiring CKT 347 A and connector terminal contact is above a specified value.
Conditions to Clear: OTC 21 will clear each time the ignition switch is turned "OFF."

the driver inflator module circuitry or in the
an open in CKT 347A or a malfunctioning DERM.
3.

the driver inflator module or the SIR coil
assembly.
DTC21
DRIVER INITIATOR CIRCUIT
RESISTANCE HIGH


DISCONNECT DRIVER AND PASSENGER INFLATOR MODULES, YELLOW 2-WAY CONNECTORS LOCATED NEAR THE
BASE OF THE STEERING COLUMN AND BE HIND 1/P COMPARTMENT DOOR ASSEMBLY.
CHECK FOR PROPER CONNECTION TO STEERING COLUMN CONNECTOR AT TERMINALS" A" AND "B".
IF OK THEN CONNECT J 38715 SIR DRIVER/PASSENGER LOAD TOOL TO STEERING COLUMN HARNESS CONNECTOR
AND PASSENGER INFLATOR MODULE HARNESS CONNECTOR.
IS OTC 21 CURRENT?

DISCONNECT DERM.
TERMINAL "89".
IF OK THEN MEASURE RESISTANCE FROM DERM
HARNESS CONNECTOR TERMINAL "89" TO
STEERING COLUMN HARNESS CONNECTOR
TERMINAL "A".
: GO TO THE "SIR DIAGNOSTIC SYSTEM CHECK". :
REPLACE DERM,
COMPONENTS ARE
PROPERLY MOUNTED.
SYSTEM CHECK".
IN CKT347A.

DISCONNECT SIR DRIVER/PASSENGER LOAD TOOL FROM
STEERING COLUMN HARNESS CONNECTOR.
REMOVE INFLATOR MODULE FROM STEERING WHEEL,
REFER TO SECTION 3F.
INFLATOR MODULE CONNECTOR ON STEERING COLUMN.
RECONNECT STEERING COLUMN CONNECTOR TO
STEERING COLUMN HARNESS CONNECTOR.
IS OTC 21 CURRENT?

REPLACE DRIVER
INFLA TOR MODULE,

REPLACE SIR COIL, REFER
TO SECTION 3F5B.

CLEAR SIR DIAGNOSTIC TROUBLE CODtS.
REPEAT "SIR DIAGNOSTIC SYSTEM CHECK".
10-16-92
NS 11333
TO IGNITION
AIR BAG 15A
5204
SWITCH ~ 1 1 3 9 A Y E L ~ - - - - - - - - - - - - - - - - - - 1 1 3 9 C Y E L
r - - - - - - - - - 1 1 3 9 8 YEL
DERM
IGNITION 1
1139E YEL
.----------------------------236YELJBLK
~------------------------~1400LTGRN
DUAL
POLE . - - - - - - - - - - - - - - - - - - - - - - - - - 1 4 0 1 P N K
ARMING
SENSOR
14038 WHT/BLK
PASS. SIDE HIGH
PASS. SIDE LOW
DRIVER
INFLATOR
MODULE
347AWHT
DRIVER SIDE
HIGH
DRIVER SIDE
LOW
348E
DKGRN
348F
DKGRN
1751C
PASSENGER
COMPARTMENT
DISCRIMINATING
SENSOR
BUOWHTl
GROUND
6-30-92
NS 11316
DTC22
DRIVER INITIATOR CIRCUIT RESISTANCE LOW
During the "Initiator Assembly Resistance Test" the DERM grounds the "Passenger Side Low" terminal "B7''
of current to flow through the driver initiator circuit. By monitoring the difference between the voltage at the
"Driver Side High" terminal "B9" and the "Driver Side Low" terminal "B8" the DERM calculates the combined
resistance of the driver inflator module, SIR coil assembly, harness wiring CKTs 347A and 348A and connector
terminal contact.
specified value.
Failure Conditions: DTC 22 will set when the combined resistance of the driver inflator module, SIR coil
assembly, harness wiring CKTs 347A and 348A and connector terminal contact is below a specified value.
1. DTC 16 and 22 will set simultaneously when the
"Driver Side High" circuit is shorted to the
"Passenger Side High" circuit due to parallel
current paths.
the driver inflator module circuitry or in the
3. This test checks for a short from the "Driver Side

High" circuit to the "Driver Side Low" or
"Passenger Side Low" circuit. If no short is found
the DERM is malfunctioning.
assembly.
DTC22
RESISTANCE LOW
l!D
r
---------------------------,

"INTERMITTENTS AND POOR CONNECTIONS" IN SECTION 8A-4. WHEN A
WIRE REPAIR IS REQUESTED USE J 38125-A TERMINAL REPAIR KIT AND
REFER TO "SIR WIRE REPAIR" IN SECTION 9J.
G)f IS DTC 16 ALSO CURRENT? I
]
,,,--...,
~

DISCONNECT DRIVER AND PASSENGER INFLATOR MODULES, YELLOW
2-WAY CONNECTORS LOCATED NEAR THE BASE OF THE STEERING
COLUMN AND BEHIND THE 1/P COMPARTMENT DOOR ASSEMBLY.
CONNECT J 38715 SIR DRIVER/PASSENGER LOAD TOOL TO STEERING
COLUMN HARNESS CONNECTOR AND PASSENGER INFLATOR MODULE
HARNESS CONNECTOR.
IS DTC 22 CURRENT?
N~

DISCONNECT DRIVER AND PASSENGER
INFLATOR MODULES, YELLOW 2-WA Y
CONNECTORS LOCATED NEAR THE BASE OF THE
STEERING COLUMN AND BEHIND THE 1/P

DISCONNECT DERM.
MEASURE RESISTANCE ON DERM HARNESS CONNECTOR FROM
TERMINAL "88" TO TERMINAL "89".
REPLACE DERM, REFER TO SECTION

9J-B.
COMPONENTS ARE PROPERLY
MOUNTED.
REPEAT "SIR DIAGNOSTIC SYSTEM
CHECK."
L------------------------------l
~
~
REPAIR SHORT FROM

(KT 347 TO CKT 348.
IGNITION SWITCH"OFF."
DISCONNECT SIR DRIVER/PASSENGER LOAD
TOOL FROM STEERING COLUMN HARNESS
CONNECTOR .
REMOVE INFLATOR MODULE FROM STEERING
WHEEL, REFER TO SECTION 3F.
CONNECT SIR DRIVER/PASSENGER LOAD TOOL
TO INFLA TOR MODULE CONNECTOR ON
STEERING COLUMN.
RECONNECT STEERING COLUMN CONNECTOR
TO STEERING COLUMN HARNESS CONNECTOR.
IGNITION SWITCH"ON."
IS DTC 22 CURRENT?
.
]
IGNITION SWITCH
"OFF."
REPLACE SIR COIL,
REFER TO
SECTION 3F5B.
IGNITION SWITCH
"OFF."
REPLACE DRIVER
INFLATOR
MODULE. REFER TO
SECTION 3F.

MOUNTED.
10-16-92
NS 11334
TO IGNITION
AIR BAG 1 SA
5204
SWITCH ~ 1139A Y E L - - J t ; ; - - - - - - - - - - - - - - - - - - - 1 1 3 9 C YEL
....---------1139BYEL_/ \
DERM
IGNITION 1
1139EYEL
~-------------------------~236YEUBLK
....-------------------------~1400LTGRN
DUAL
POLE ~ - - - - - - - - - - - - - - - - - - - - - - - 1 4 0 1 P N K
ARMING
SENSOR
1837 LT GRN!WHT
14038 WHT/BLK
PASS. SIDE HIGH
PASS. SIDE LOW
347AWHT
DRIVER
INFLATOR
MODULE
DRIVER SIDE
HIGH
DRIVER SIDE
LOW
348F
DKGRN
1751C
PASSENGER
COMPARTMENT
DISCRIMINATING
SENSOR
BLKIWHTl
GROUND
6-30-92
NS 11316
DTC23
DRIVER INITIATOR CIRCUIT VOLTAGE HIGH
deployment loops. The DERM monitors the voltage at "Driver Side Low" terminal "BS" to detect shorts or opens
within the driver deployment loop. When the measured voltage is above a specified percentage of "Driver 36
VLR" for 500 milliseconds OTC 23 is set.
Test Conditions: Tested every 100 milliseconds during the "Con.tinuous Monitoring" tests.
Failure Conditions: DTC 23 will set when the voltage measured at "Driver Side Low" terminal "B8" is above
a specified percentage of"Driver 36 VLR" for 500 milliseconds and OTC 35 is not set.
Conditions to Clear: DTC 23 will clear when the voltage measured at "Driver Side Low" terminal "B8" is
within a specified percentage of"Driver 36 VLR" for 500 milliseconds.

1. DTCs 23 and 24 together means that there is an
open between the driver inflator module harness
connector and the forward lamp interconnect. This
causes the voltage to increase at "Driver Side Low"
due to the loss of a ground path. This also causes
the voltage to decrease at "Passenger Side Low"
due to decreased current flow through the
discriminating sensor network.
2.
This test determines whether the malfunction is

an open in CKT 348B or a malfunctioning DERM.
DTC23
VOLTAGE HIGH
,..........__~~~~~~~~~~~~~~~~~~~~--,r-

IGNITION SWITCH "Off."

MEASURE RESISTANCE FROM DRIVER INFLATOR MODULE
HARNESS CONNECTOR TERMINAL "B" TO PASSENGER
INFLATOR MODULE HARNESS CONNECTOR TERMINAL "B".

----------------------------,
L------------------------------~
r -----------------------------,
: GO TO AND FOLLOW OTC 19 (PAGE 1 OF 3).
:
I MALFUNCTIONS WHICH SET OTC 19 AND OTC 23 1
: SIMULTANEOUSLY ARE DIAGNOSED IN OTC 19
:
I CHARTS.
I
L------------------------------~

8-26-92
NS 11337
TO IGNITION
AIR BAG 15 A
5204
SWITCH ~ 1139A Y E L - 1 ' * ; : - - - - - - - - - - - - - - - - - - - 1 1 3 9 C YEL
---------1139BYEL_/ \
DERM
IGNITION 1
1139EYEL
--------------------------~236YEUBLK
.--------------------------~1400LTGRN
DUAL
POLE ~ - - - - - - - - - - - - - - - - - - - - - - - 1 4 0 1 P N K
ARMING
SENSOR
1837LT GRN!WHT
14038 WHT/BLK
PASS. SIDE HIGH
PASS. SIDE LOW
347AWHT
DRIVER
INFLATOR
MODULE
DRIVER SIDE
HIGH
DRIVER SIDE
LOW
3488
C:._ ___:=::=:::::==:=..J.---------------,DKGRN
348E
DKGRN
348F
DKGRN
1751C
PASSENGER
COMPARTMENT
DISCRIMINATING
SENSOR
BLK.WHTl
GROUND
6-30-92
NS11316
DTC24
(Page 1 of 3)
INITIATOR CIRCUIT VOLTAGE LOW

deployment loops. The DERM monitors the voltages at "Driver Side Low" terminal "B8" and "Passenger Side
Low" terminal "B7'' to detect shorts or opens within the deployment loops. When the measured voltage at
terminal "B8" or "B7'' is below a specified percentage of its respective "36 VLR" for 500 milliseconds DTC 24 is
set.
Test Conditions: Tested every 100 milliseconds during the "Continuous Monitoring" test.
Failure Conditions: DTC 24 will set when the voltage measured at "Driver Side Low" terminal "B8" is below
a specified percentage of "Driver 36 VLR" or when the voltage measured at "Passenger Side Low" terminal "B7''
is below a specified percentage of "Passenger 36 VLR" for 500 milliseconds.
within a specified percentage of "Driver 36 VLR" and the voltage measured at "Passenger Side Low" terminal
"B7'' is within a specified percentage of "Passenger 36 VLR" for 500 milliseconds.
occurring in the steering column circuitry.
occurring in the passenger inflator module
circuitry.
DTC24
(Page 1 of 3)
INITIATOR CIRCUIT
VOLTAGE LOW
---------------------------~
: GO TO THE "SIR DIAGNOSTIC SYSTEM CHECK."
I
I
~------------------------------J
WHEN MEASUREMENTS ARE REQUESTED IN THIS CHART, USE J 39200 DVM WITH
CONNECTION IS REQUESTED, REFER TO "INTERMITTENTS AND POOR CONNECTIONS"
IN SECTION SA-4. WHEN A WIRE REPAIR IS REQUESTED USE J 38125-A TERMINAL

DISCONNECT DRIVER INFLATOR MODULE, YELLOW 2-WAY CONNECTOR AT THE BASE OF THE STEERING
COLUMN, LEAVE PASSENGER INFLATOR MODULE CONNECTED.
CONNECT SIR DRIVER/PASSENGER LOAD TOOL J 38715 TO DRIVER INFLATOR MODULE HARNESS CONNECTOR .
IS OTC 24 CURRENT?

DISCONNECT PASSENGER INFLATOR MODULE,
YELLOW 2-WAY CONNECTOR LOCATED BEHIND THE
1/P COMPARTMENT DOOR ASSEMBLY.
CONNECTOR, LEAVE DRIVER INFLATOR MODULE
HARNESS CONNECTOR CONNECTED TO LOAD TOOL.
IS OTC 24 CURRENT?
$_
r
---------------------------~
: CONTINUE WITH DIAGNOSIS ON NEXT PAGE.

REMOVE AND INSPECT SIR COIL AND CONNECTING
WIRES FOR DAMAGE. DETERMINE AND REPAIR THE
CAUSE OF DAMAGE AND REPLACE SIR COIL, REFER TO
SECTION 3F5B.
I
I
~------------------------------~

REMOVE LOWER SOUND INSULATOR PANEL-RH, REFER TO
SECTION SC, TO ACCESS PASSENGER INFLA TOR MODULE.
INSPECT INFLATOR MODULE WIRES AND CONNECTOR FOR
CUTTING OR PINCHING WHICH COULD CAUSE A SHORT. IF
ANY DAMAGE IS DETECTED REPLACE INFLA TOR MODULE,
REFER TO SECTION 9J-B, DETERMINE AND REPAIR THE
CAUSE OF DAMAGE.
IF INFLATOR MODULE IS OK, INSPECT PASSENGER
INFLATOR MODULE JUMPER WIRES FOR DAMAGE.
DETERMINE AND REPAIR THE CAUSE OF DAMAGE AND
REPAIR THE JUMPER WIRE.

REPEAT "SIR DIAGNOSTIC SYSTEM CHECK" .
10-30-92
NS 16054
AIR BAG 15A

TO IGNITION
5204
SWITCH ~ 1 1 3 9 A Y E L - - - - - - - - - - - - - - - - - 1 1 3 9 C YEL
.---------1139BYEL
DERM
IGNITION 1
1139EYEL
....---------------------------236YEUBLK
.--------------------------~1400LTGRN
DUAL
POLE . - - - - - - - - - - - - - - - - - - - - - - - - - 1 4 0 1 P N K
ARMING
SENSOR
14038 WHT/BLK
PASS. INFLA TOR
MODULE JUMPER
PASS.
~1403CWHT/BLK
INFLATOR
{
MODULE
~
348H DK GRN
1403A WHT/BLK
PASS. SIDE HIGH
---348C DK GRN
PASS. SIDI LOW
SHORTING BARS
DRIVER
INFLATOR
MODULE
347AWHT
DRIVER SIDE
HIGH
DRIVER SIDE
LOW
348F
DKGRN
1751C
PASSENGER
COMPARTMENT
DISCRIMINATING
SENSOR
BLKIWHTl
GROUND
6-30-92
NS 11316
DTC24
(Page 2 of 3)

deployment loops. The DERM monitors the voltages at "Driver Side Low" terminal "B8" and "Passenger Side
terminal "B8" or "B7" is below a specified percentage of its respective "36 VLR" for 500 milliseconds OTC 24 is
set.
Failure Conditions: OTC 24 will set when the voltage measured at "Driver Side Low" terminal "B8" is below
is below a specified percentage of"Passenger 36 VLR" for 500 milliseconds.
Conditions to Clear: OTC 24 will clear when the voltage measured at "Driver Side Low" terminal "88" is
"B7" is within a specified percentage of"Passenger 36 VLR" for 500 milliseconds.

3. This test checks for a partial short across the
diagnostic resistor in the forward discriminating
sensor.
4. This test checks for a partial short across the
diagnostic resistor in the passenger compartment
discriminating sensor.
5.
This test checks for a short from the

discriminating sensor interconnect circuit to
ground.
driver deployment loop or passenger deployment
loop to ground.
the driver deployment loop to ground.
DTC24
(Page 2 of 3)
INITIATOR CIRCUIT
VOLTAGE LOW
-@.-----------------
: GO TO OTC 24 (PAGE 1 OF 3).
I
I
-------------------~

MEASURE RESISTANCE OF FORWARD DISCRIMINATING SENSOR FROM TERMINAL" A" TO TERMINAL "B" .
IS RESISTANCE LESS THAN 8.36 kQ?
$1
[$]

MEASURE RESISTANCE OF PASSENGER COMPARTMENT
DISCRIMINATING SENSOR FROM TERMINAL "A" TO TERMINAL "B".
--.-

SENSOR, REFER TO SECTION 9J-B .
$1
DISCONNECT CONNECTOR C200B FROM CONNECTOR C2000.

MEASURE RESISTANCE ON PASSENGER COMPARTMENT
DISCRIMINATING SENSOR HARNESS CONNECTOR FROM
TERMINAL" A" TO TERMINAL"(" (GROUND).
- ~

DISCRIMINATING SENSOR, REFER TO
SECTION 9J-B.
$1
[$]
RECONNECT CONNECTOR C200B TO CONNECTOR C2000.

DISCONNECT DERM .
CHECK FOR PROPER CONNECTION TO DERM AT TERMINALS" A3"
AND"A4".
IF OK, THEN MEASURE RESISTANCE ON DERM HARNESS CONNECTOR
FROM TERMINAL "BS" TO TERMINAL" A 1" (GROUND).
$1

FROM TERMINAL "B9" TO TERMINAL" A 1" (GROUND).
r
I
--------------------------,
CONTINUE WITH DIAGNOSIS ON NEXT PAGE. 1
L----------------------------~
REPAIR SHORT FROM CKT 348F OR CKT 348G
TO GROUND.
REPAIR SHORT FROM CKT 348A, 3488, 348C

OR 348E TO GROUND.
REPAIR SHORT FROM CKT 347 TO GROUND. I

ENSURE All COMPONENTS ARE PROPERLY
MOUNTED.
11-16-92
NS 11336
AIR BAG 15A

TO IGNITION
S204
SWITCH ~ 1 1 3 9 A Y E L - - - - - - - - - - - - - - - - - - 1 1 3 9 C Y E L
.----------1139BYEL
DERM
IGNITION 1
1139E YEL
~--------------------------~236YEUBLK
...--------------------------~1400LTGRN
DUAL
POLE ~ - - - - - - - - - - - - - - - - - - - - - - - - 1 4 0 1 P N K
ARMING
SENSOR
14038 WHT/BLK
PASS. SIDE HIGH
PASS. SIDE LOW
347AWHT
DRIVER
INFLATOR
MODULE
DRIVER SIDE
HIGH
DRIVER SIDE
LOW
3488
c:__ _ _=:::::::==:==~~---------------,DKGRN
348E
DKGRN
348F
DKGRN
1751C
PASSENGER
COMPARTMENT
DISCRIMINATING
SENSOR
Bll<MIHTl
GROU"ID
6-30-92
NS11316
DTC24
(Page 3 of 3)

deployment loops. The DERM monitors the voltages at "Driver Side Low" terminal "BB" and "Passenger Side
terminal "BB" or "B7'' is below a specified percentage of its respective "36 VLR" for 500 milliseconds DTC 24 is
set.
Failure Conditions: DTC 24 will set when the voltage measured at "Driver Side Low" terminal "BB" is below
is below a specified percentage of "Passenger 36 VLR" for 500 milliseconds.
Conditions to Clear: DTC 24 will clear when the voltage measured at "Driver Side Low" terminal "EB" is
"B7'' is within a specified percentage of"Passenger 36 VLR" for 500 milliseconds.
11. This test checks for high resistance in the "Driver

the passenger deployment loop to ground.
9. This test checks for an open in the driver
deployment loop diagnostic resistor of the dual
pole arming sensor.
10. This test checks for an open in the passenger
deploym~nt loop diagnostic resistor of the dual
pole armmg sensor.
36 VLR" circuit.
12. This test checks for high resistance in the
"Passenger 36 VLR" circuit.
13. This test checks for an open in the high side of the
driver deployment loop.
an open in the high side of the passenger
deployment loop or a malfunctioning DERM.
DTC24
G)
INITIATOR CIRCUIT
~GOTO OTC 24 (PAGE 2 OF 3).
..
DISCONNECT DUAL POLE ARMING SENSOR .

CHECK FOR PROPER CONNECTION TO THE DUAL POLE ARMING SENSOR AT
TERMINAL "B", "C", "E" AND "G".
IF OK THEN MEASURE RESISTANCE ON DUAL POLE ARMING SENSOR
CONNECTOR FROM TERMINAL "D" TO TERMINAL "E".
IS RESISTANCE GREATER THAN 12.9 kQ?
(Page 3 of 3)
~---------------~OLTAGE LOW

FROM TERMINAL u A 7" TO TERMINAL" A 1" (GROUND).
MEASURE RESISTANCE ON DUAL POLE ARMING SENSOR CONNECTOR FROM

TERMINAL "F" TO TERMINAL "G".
IS RESISTANCE GREATER THAN 12.9 kQ?
MEASURE RESISTANCE FROM DUAL POLE ARMING SENSOR HARNESS

CONNECTOR TERMINAL "B" TO DERM HARNESS CONNECTOR TERMINAL" A4".
s
s

CONNECTOR TERMINAL "C" TO DERM HARNESS CONNECTOR TERMINAL" A3".

CONNECTOR TERMINAL ''E'' TO DERM HARNESS CONNECTOR TERMINAL "B9".
s
.
s
I

CONNECTOR TERMINAL "G" TO DERM HARNESS CONNECTOR TERMINAL "A7".

10-16-92
NS 11338
REPAIR SHORT FROM

CKT 1403 TO GROUND.
REPLACE DUAL POLE ARMING SENSOR,


I
I
REPAIR HIGH RESISTANCE IN CKT 236.
REPAIR HIGH RESISTANCE IN CKT 1401.1

REPEAT "SIR DIAGNOSTIC SYSTEM
CHECK."
TO IGNITION
AIR BAG 15A
5204
SWITCH ~ 1139A Y E L - - , . ; : - - - - - - - - - - - - - - - - - - - 1 1 3 9 C YEL
.----------1139BYEL__/ \
DERM
IGNITION 1
1139EYEL
,---------------------------~236YEUBLK
.--------------------------~t400LTGRN
DUAL
POLE . - - - - - - - - - - - - - - - - - - - - - - - - - 1 4 0 1 P N K
ARMING
SENSOR
14038 WHT/BLK
PASS. SIDE HIGH
PASS. SIDE LOW
DRIVER
INFLATOR
MODULE
347AWHT
DRIVER SIDE
HIGH
DRIVER SIDE
LOW
348F
DKGRN
1751C
PASSENGER
COMPARTMENT
DISCRIMINATING
SENSOR
BLKIWHTl
GROUND
6-30-92
NS11316
DTC25
(Page 1 of 2)
INITIATOR CIRCUIT SHORT TO IGNITION

During the "Initiator Assembly Resistance Test" the DERM grounds the "Driver Side Low" terminal "BS"
Side Low" terminal "B7'' and again measures the voltage at "Driver Side Low" and "Passenger Side Low." For a
When the voltages measured at both "Driver Side Low" and "Passenger Side Low" are above a specified value
during both tests DTC 25 is set.
a specified value.
Failure Conditions: DTC 25 will set when the voltages measured at both "Driver Side Low" and "Passenger
Side Low" are above a specified value while the DERM attempts to ground each of these terminals.
Conditions to Clear: DTC 25 will clear when the voltage measured at either "Driver Side Low" or "Passenger
Side Low" is below a specified value while the DERM grounds either of these terminals.

occurring in the steering column circuitry.
occurring in the passenger inflator module
circuitry.
DTC25
(Page 1 of 2)
WAS THE ffSIR DIAGNOSTIC SYSTEM CHECK" PERFORMED?
@]
INITIATOR CIRCUIT
SHORT TO IGNITION
@---------------------------~
I
I
~------------------------------~
WHEN MEASUREMENTS ARE REQUESTED IN THIS CHART, USE J 39200 DVM WITH
CONNECTION IS REQUESTED, REFER TO fflNTERMITTENTS AND POOR CONNECTIONS"
IN SECTION SA-4. WHEN A WIRE REPAIR IS REQUESTED USE J 38125-A TERMINAL
I
SWITCH "OFF."
IGNITION
DISCONNECT DRIVER IN FLA TOR MODULE, YELLOW 2-WA Y CONNECTOR AT THE BASE OF THE STEERING
COLUMN,
LEAVE PASSENGER INFLATOR MODULE CONNECTED.
SIR DRIVER/PASSENGER LOAD TOOL J 38715 TO DRIVER IN FLA TOR MODULE HARNESS CONNECTOR .
CONNECT
SWITCH "ON."
IGNITION
IS OTC 25 CURRENT?
I

DISCONNECT PASSENGER INFLA TOR MODULE,
YELLOW 2-WAY CONNECTOR LOCATED BEHIND THE
1/P COMPARTMENT DOOR ASSEMBLY.
CONNECTOR, LEAVE DRIVER INFLA TOR MODULE
HARNESS CONNECTOR CONNECTED TO LOAD TOOL.
IS OTC 25 CURRENT?

REMOVE AND INSPECT SIR COIL AND CONNECTING
WIRES FOR DAMAGE. DETERMINE AND REPAIR THE
CAUSE OF DAMAGE AND REPLACE SIR COIL, REFER TO
SECTION 3F5B.
$.---------------------------~ $
~
: CONTINUE WITH DIAGNOSIS ON NEXT PAGE.
~------------------------------~

REMOVE LOWER SOUND INSULATOR PANEL-RH.REFER TO
SECTION SC, TO ACCESS PASSENGER INFLATOR MODULE.
INSPECT INFLATOR MODULE WIRES AND CONNECTOR FOR
CUTTING OR PINCHING WHICH COULD CAUSE A SHORT. IF
ANY DAMAGE IS DETECTED REPLACE INFLATOR MODULE,
REFER TO SECTION 9JB, DETERMINE AND REPAIR THE
CAUSE OF DAMAGE.
IF INFLATOR MODULE IS OK, INSPECT PASSENGER
INFLATOR MODULE JUMPER WIRES FOR DAMAGE.
DETERMINE AND REPAIR THE CAUSE OF DAMAGE AND
REPAIR THE JUMPER WIRE .

10-30-92
NS 11339
TO IGNITION
AIR BAG 15 A
5204
SWITCH ~ 1 1 3 9 A Y E L ~ - - - - - - - - - - - - - - - - - - 1 1 3 9 C Y E L
.---------1139BYEL__/ \
DERM
IGNITION 1
1139EYEL
....---------------------------236YEUBLK
,--------------------------~1400LTGRN
DUAL
POLE . . - - - - - - - - - - - - - - - - - - - - - - - - 1 4 0 1 P N K
ARMING
SENSOR
14038 WHT/BLK
DRIVER
SOURCE SENSE
PASS. 36 VLR
PASS. SOURCE
SENSE
PASS. SIDE HIGH
PASS. SIDELOW
DRIVER
INFLATOR
MODULE
347AWHT
DRIVER SIDE
HIGH
DRIVER SIDE
LOW
3488
.___ _ _ _ _ __ _ _ , . . - - - - - - - - - - - - - ~ D K G R N
348E
DKGRN
348F
DKGRN
1751C
PASSENGER
COMPARTMENT
DISCRIMINATING
SENSOR
BLKIWHTl
GROUND
6-30-92
NS11316
DTC25
{Page 2 of 2)
INITIATOR CIRCUIT SHORT TO IGNITION
During the "Initiator Assembly Resistance Test" the DERM grounds the "Driver Side Low" terminal "BS"
Side Low" terminal "B7" and again measures the voltage at "Driver Side Low" and "Passenger Side Low." For a
When the voltages measured at both "Driver Side Low" and "Passenger Side Low" are above a specified value
during both tests OTC 25 is set.
a specified value.
Failure Conditions: OTC 25 will set when the voltages measured at both "Driver Side Low" and "Passenger
Side Low" are above a specified value while the DERM attempts to ground each of these terminals.
Conditions to Clear: OTC 25 will clear when the voltage measured at either "Driver Side Low" or "Passenger
Side Low" is below a specified value while the DERM grounds either of these terminals.

the driver deployment loop to B +.

the passenger deployment loop to B + .
due to a short from the low side of the driver and
passenger deployment loops to B + or a
DTC25
(Page 2 of 2)
INITIATOR CIRCUIT
SHORT TO IGNITION
,.;-,.
\.V
: GO TO OTC 25 (PAGE 1 OF 2).

DISCONNECT DERM, DUAL POLE ARMING SENSOR AND SIR
DRIVER/PASSENGER LOAD TOOL.
TERMINAL "89" TO TERMINAL" A 1" (GROUND).
~-------------------~

TERMINAL "A7" TO TERMINAL "A1" (GROUND).

REPAIR SHORT FROM CKT 347 TO B +.

TERMINAL "88" TO TERMINAL" A 1" (GROUND).
IS VOLTAGE 1 VOLTORLESS?


WHEN DIAGNOSING HISTORY OTC 25 DO NOT
REPLACE DERM, SKIP THIS STEP.


8-20-92
NS 11609
AIRBAG 15A
TO IGNITION
5204
SWITCH ~ 1 1 3 9 A Y E L - - - - - - - - - - - - - - - - - 1 1 3 9 C Y E L
.---------1139BYEL
DERM
IGNITION 1
1139EYEL
.....---------------------------236YEUBLK
.--------------------------~1400LTGRN
DUAL
POLE . . . . . - - - - - - - - - - - - - - - - - - - - - - - - 1 4 0 1 P N K
ARMING
SENSOR
1837 LT GRN/WHT
14038 WHT/BLK
PASS. SIDE HIGH
PASS. SIDE LOW
DRIVER
INFLATOR
MODULE
347AWHT
3488
~------~.....---------------,DKGRN
DRIVER SIDE
HIGH
DRIVER SIDE
LOW
348E
DKGRN
348F
DKGRN
1751C
PASSENGER
COMPARTMENT
DISCRIMINATING
SENSOR
BLKIWHTl
GROUND
6-30-92
NS 11316
DTC26
DRIVER INITIATOR CIRCUIT OPEN
When there is an open in the driver inflator module or the SIR coil assembly the resistance between "Driver
Side High" terminal "B9" and "Driver Side Low" terminal "B8" increases. This causes a larger voltage drop from
the "Driver Side High" to the "Driver Side Low" across a resistor inside the DERM which connects these two
terminals together. The increase in the voltage difference between "Driver Side High" and "Driver Side Low" is
detected by the DERM during the "Continuous Monitoring" tests and DTC 26 is set.
Failure Conditions: DTC 26 will set when the voltage difference between "Driver Side High" terminal "B9"
and "Driver Side Low" terminal "B8" is above or equal to a specified value for 500 milliseconds.
Conditions to Clear: DTC 26 will clear when the voltage difference between "Driver Side High" terminal
"B9" and "Driver Side Low" terminal "B8" is below a specified value for 500 milliseconds.

1. This test checks whether the DERM has set the
diagnostic trouble code falsely.
assembly.
DTC26
DRIVER INITIATOR CIRCUIT OPEN
WHEN MEASUREMENTS ARE REQUESTED IN THIS CHART USE

J 39200 DVM WITH CORRECT TERMINAL ADAPTER FROM
J 35616-A. WHEN A CHECK FOR PROPER CONNECTION IS
REQUESTED REFER TO "INTERMITTENTS AND POOR
CONNECTIONS" IN SECTION SA-4. WHEN A WIRE REPAIR IS
REQUESTED USE J 38125-A TERMINAL REPAIR KIT AND REFER
TO "SIR WIRE REPAIR" IN SECTION 9J .
~--------------------------1
L------------------------------l
' GO TO THE "SIR DIAGNOSTIC SYSTEM CHECK." '

CHECK FOR PROPER CONNECTION TO STEERING COLUMN
CONNECTOR AT TERMINALS "A" AND "B".
IF OK THEN CONNECT J 38715 SIR DRIVER/PASSENGER LOAD
TOOL TO STEERING COLUMN HARNESS CONNECTOR.
DISCONNECTED PASSENGER INFLA TOR MODULE).

REMOVE DRIVER INFLATOR MODULE FROM STEERING WHEEL,
CONNECT SIR DRIVER/PASSENGER LOAD TOOL TO IN FLA TOR
MODULE CONNECTOR ON STEERING COLUMN.
RECONNECT STEERING COLUMN CONNECTOR TO STEERING
COLUMN HARNESS CONNECTOR.
DISCONNECTED PASSENGER INFLATOR MODULE) .

REPLACE DRIVER INFLATOR MODULE, REFER TO SECTION 3F.


REPLACE SIR COIL ASSEMBLY, REFER TO SECTION 3F5B.
10-16-92
NS 11452
TO IGNITION
AIR BAG 15 A
5204
SWITCH ~ 1139A Y E L - - 4 1 1 r - - - - - - - - - - - - - - - - 1 1 3 9 C YEL
. - - - - - - - - - - 1 1 3 9 8 YEL
DERM
IGNITION 1
1139E YEL
r-----------------------------~236YEUBLK
.---------------------------~1400LTGRN
~gfi
.--------------------------1401PNK
ARMING
SENSOR
14038 WHT/BLK
1837 LT GRNtWHT
PASS. INFLATOR
MODULE JUMPER
PASS.
~1403CWHT/BLK
INFLATOR
{
MODULE
~
348H DK GRN
DRIVER
SOURCE SENSE
PASS. 36 VLR
PASS. SOURCE
SENSE
1403A WHT/BLK
PASS. SIDE HIGH
---348C DK GRN
PASS. SIDE LOW
SHORTING BARS
347AWHT
DRIVER
INFLATOR
MODULE
DRIVER SIDE
HIGH
DRIVER SIDE
LOW
348E
DKGRN
348F
DKGRN
1751C
PASSENGER
COMPARTMENT
DISCRIMINATING
SENSOR
BLKIWHTl
GROUND
6-30-92
NS 11316
DTC28
CURRENT SINK OR SOURCE FAILURE
and turns "ON" the driver current source at the "Driver Side High" terminal "B9". The DERM then grounds the
"Driver Side Low" terminal "B8" and turns "ON" the passenger current source at the "Passenger Side High"
terminal "A 7''. During each of these tests the DERM monitors voltage at "Driver Side Low," "Passenger Side
Low," the difference between "Driver Side High" and "Driver Side Low" and the difference between "Passenger
Side High" and "Passenger Side Low." When the measured values are outside the expected range DTC 28 is set.
"Continuous Monitoring" for one second, 3) No "CRANK" Signal present, 4) "Ignition l" voltage is above a
specified value.
Failure Conditions: DTC 28 will set when the voltage measured at "Driver Side Low" or "Passenger Side
Low" is below a specified value while its respective initiator resistance is in range or when the voltage measured
at "Driver Side Low" or "Passenger Side Low" is above a specified value.
Action Taken: The DERM turns "ON" the "AIR BAG" warning lamp and sets a diagnostic trouble code.

1. This test checks whether the malfunction is in the
wiring harness. The wiring harness malfunction
would be a high resistance rather than an open.
An open would set a different diagnostic trouble
code.
2.

the wiring harness or in the DERM. The wiring
harness malfunction would be a high resistance
rather than an open. An open would set a different
diagnostic trouble code.
DTC28
CURRENT SINK OR SOURCE
FAILURE
$
---------------------------,
' GO TO THE "SIR DIAGNOSTIC SYSTEM CHECK."
L------------------------------J'
G)

DISCONNECT CONNECTOR C200B FROM CONNECTOR C200D .
MEASURE RESISTANCE FROM C200D TERMINAL "02" TO STEERING COLUMN HARNESS CONNECTOR
TERMINAL "B".
IS RESISTANCE 5.0 !1 OR LESS?
MEASURE RESISTANCE FROM C200D TERMINAL "02" TO

PASSENGER INFLATOR MODULE HARNESS CONNECTOR
TERMINAL "B".
IS RESISTANCE 5.0 !1 OR LESS?

RECONNECT ALL SIR SYSTEM COMPONENTS; ENSURE
REPAIR HIGH RESISTANCE IN CKT 348E.
$J
RECONNECT All SIR SYSTEM COMPONENTS, ENSURE

All
SIR DIAGNOSTIC TROUBLE CODES .
CLEAR
7-8-92
NS 11328
TO IGNITION
AIR BAG 15A
S204
SWITCH ~ 1 1 3 9 A Y E L ~ - - - - - - - - - - - - - - - - - - 1 1 3 9 C Y E L
~ - - - - - - - 1 1 3 9 8 YEL__/ \
DERM
IGNITION 1
1139E YEL
.----------------------------236YEUBLK
.---------------------------~1400LTGRN
DUAL
POLE . - - - - - - - - - - - - - - - - - - - - - - - - - - 1 4 0 1 P N K
ARMING
SENSOR
14038 WHT/BLK
PASS. SIDE HIGH
PASS. SIDE LOW
347AWHT
DRIVER
INFLATOR
MODULE
DRIVER SIDE
HIGH
DRIVER SIDE
LOW
3488
L.:__ ___::=:::::===::::..J.-----------------,DKGRN
348E
DKGRN
348F
DKGRN
1751C
PASSENGER
COMPARTMENT
DISCRIMINATING
SENSOR
BLK/WHTl
GROUND
6-30-92
NS 11316
DTC31
DRIVER LOOP ENERGY RESERVE FEED OPEN
During the "Continuous Monitoring" tests the DERM monitors the voltage at "Driver Source Sense" terminal
"A5." When the circuit is operating normally the measured voltage will be slightly less than "Driver 36 VLR." If
the "Driver 36 VLR" circuit opens the voltage measured at "Driver Source Sense" will decrease to slightly less
than "Ignition l" voltage. When the voltage measured at "Driver Source Sense" is within a specified range of
"Ignition 1" for 500 milliseconds DTC 31 is set.
Test Conditions: Tested every 100 milliseconds during "Continuous Monitoring" tests.
Failure Conditions: DTC 31 will set when the voltage measured at "Driver Source Sense" terminal "A5" is
within a specified range of"lgnition 1" for 500 milliseconds.
Conditions to Clear: DTC 31 will clear when the voltage measured at "Driver Source Sense" terminal "A5" is
outside the specified range of "Ignition 1" which sets the diagnostic trouble code, for 500 milliseconds.

1. This test checks for an open in the "Driver 36
VLR" circuit.
2. This test checks for high resistance, but not an
open, in the "Driver Source Sense" circuit.
3.
4.
This test chec.ks for a short from the "Driver

Source Sense" circuit to B +.
due to the dual pole arming sensor or a
DTC31
DRIVER LOOP ENERGY
RESERVE FEED OPEN
[$]
@
I

WHEN A WIRE REPAIR IS REQUESTED USE J 38125-A TERMINAL REPAIR
KIT AND REFER TO "SIR WIRE REPAIR" IN SECTION 9J.
L------------------~

DISCONNECT DRIVER AND PASSENGER INFLA TOR MODULES, YELLOW 2-WAY CONNECTORS LOCATED
CHECK FOR PROPER CONNECTION TO DUAL POLE ARMING SENSOR AT TERMINALS "B" AND "D" .
IF OK, THEN DISCONNECT DERM .
CHECK FOR PROPER CONNECTION TO DERM AT TERMINALS "A4" AND "AS" .
IF OK THEN MEASURE RESISTANCE FROM DERM HARNESS CONNECTOR TERMINAL "A4" TO DUAL POLE
ARMING SENSOR HARNESS CONNECTOR TERMINAL "B".
MEASURE RESISTANCE FROM DERM HARNESS CONNECTOR

TERMINAL" AS" TO DUAL POLE ARMING SENSOR HARNESS
CONNECTOR TERMINAL "O".

TERMINAL" AS" TO TERMINAL" A 12" (GROUND).
IS VOLT AGE 1 VOLT OR LESS?
[$]

RECONNECT DERM ANO DUAL POLE ARMING SENSOR .
MEASURE VOLTAGE FROM DUAL POLE ARMING SENSOR HARNESS
CONNECTOR TERMINAL "D" TO GROUND BY BACKPROBING.
IS VOLTAGE GREATER THAN 31 VOLTS?
7-14- 92
NS 11430
---------------,
: GO TO THE "SIR DIAGNOSTIC :

I
I SYSTEM CHECK."


..

MOUNTED.
TO IGNITION
AIR BAG 15A
5204
SWITCH ~ 1 1 3 9 A Y E L ~ - - - e - - - - - - - - - - - - - - - 1 1 3 9 C Y E L
11398 YEL__/ \
DERM
IGNITION 1
1139E YEL
.-----------------------------~236YEUBLK
DRIVER 36 VLR
.-----------------------------1400LTGRN
DRIVER
SOURCE SENSE
PASS. 36 VLR
r----------------------~1401PNK
14038 WHT/BLK
PASS. INFLA TOR

MODULE JUMPER
PASS.
~1403CWHT/BLK
INFLATOR
{
MODULE
B
348H DK GRN
1403A WHT/BLK
PASS. SIDE HIGH
---348CDKGRN
PASS. SIDE LOW
SHORTING BARS
DRIVER
INFLATOR
MODULE
347AWHT
DRIVER SIDE
HIGH
DRIVER SIDE
LOW
348E
DKGRN
348F
DKGRN
1751C
PASSENGER
COMPARTMENT
DISCRIMINATING
SENSOR
BLKIWHTl
GROUND
6-30-92
NS 11316
DTC34
DUAL POLE ARMING SENSOR IGNITION FEED OPEN
During the "Turn-ON" tests, performed at the beginning of each ignition cycle, the DERM delays the
charging of the "Driver 36 VLR" and "Passenger 36 VLR" power supplies. While the delay is active the DERM
measures the voltage at the "Driver 36 VLR" terminal "A4", "Passenger 36 VLR" terminal "A3", "Driver Source
Sense" terminal "A5", and "Passenger Source Sense" terminal "A6". When the voltage measured at the two "36
VLR" power supplies indicates they are in a discharged state and the voltage measured at each "Source Sense"
terminal is a specified amount below "Ignition l" voltage DTC 34 is set.
Test Conditions: Tested once each ignition cycle during the "Turn-ON" tests while the "36 VLR Delay" is
active.
Failure Conditions: DTC 34 will set when, with both "36 VLR" power supplies in a discharged state, the
voltage measured at "Driver Source Sense" terminal "A5" and "Passenger Source Sense" terminal "A6" are
simultaneously a specified amount below "Ignition l" voltage and no "higher priority faults" are detected.
Conditions to Clear: DTC 34 will clear when, with both "36 VLR" power supplies in a discharged state, the
voltage measured at "Driver Source Sense" terminal "A5" and "Passenger Source Sense" terminal "A6" are
simultaneously within specified range of "Ignition 1" voltage. When neither the failure nor clear conditions are
met, the state of the diagnostic trouble code from the previous ignition cycle is used.

1. This test checks for an open in the "Ignition l"
circuit between the splice and the dual pole arming
sensor.
internal to the dual pole arming sensor or due to a
DTC34
IGNITION FEED OPEN
[$]
WHEN MEASUREMENTS ARE REQUESTED IN THIS CHART USE J 39200 DVM
WITH CORRECT TERMINAL ADAPTER FROM J 35616-A. WHEN A CHECK FOR
PROPER CONNECTION IS REQUESTED REFER TO "INTERMITTENTS AND POOR
CONNECTIONS" IN SECTION BA-4. WHEN A WIRE REPAIR IS REQUESTED USE
J 38125-A TERMINAL REPAIR KIT AND REFER TO "SIR WIRE REPAIR" IN
SECTION 9J.
~
---L
- - - - -- - - ----- - - _, __ - -
-,
GO TO THE "SIR DIAGNOSTIC SYSTEM CHECK." j

CHECK FOR PROPER CONNECTION TO DUAL POLE ARMING SENSOR AT TERMINAL "A" .
IF OK THEN DISCONNECT DERM .
MEASURE RESISTANCE FROM DERM HARNESS CONNECTOR TERMINAL" A9" TO DUAL POLE ARMING
SENSOR HARNESS CONNECTOR TERMINAL" A".
[$]
RECONNECT DUAL POLE ARMING SENSOR .

FROM TERMINAL" AS" TO TERMINAL" A 1" (GROUND}.

I
[$]

REPLACE DERM, REFER TO SECTION 9J-B .

REFER TO SECTION 9J-8.
I
I

7-7-92
NS 11663
TO IGNITION
AIR BAG 15 A
5204
SWITCH ~ 1 1 3 9 A Y E L ~ - - - - - - - - - - - - - - - - - - 1 1 3 9 C Y E L
r----------1139BYEL__/ \
DERM
IGNITION 1
1139EYEL
.---------------------------~236YELJBLK
..-------------------------~1400LTGRN
DUAL
POLE . - - - - - - - - - - - - - - - - - - - - - - - - - 1 4 0 1 P N K
ARMING
SENSOR
14038 WHT/BLK
PASS. INFLATOR
MODULE JUMPER
PASS.
~1403CWHT/BLK
INFLATOR
{
MODULE
~
348H DK GRN
1403A WHT/BLK
PASS. SIDE HIGH
1.----348C DK GRN
PASS. SIDE LOW
SHORTING BARS
347AWHT
DRIVER
INFLATOR
MODULE
DRIVER SIDE
HIGH
DRIVER SIDE
LOW
348F
DKGRN
1751C
PASSENGER
COMPARTMENT
DISCRIMINATING
SENSOR
BLK,WHTl
GROUND
6-30-92
NS11316
DTC35
(Page 1 of 2)
DISCRIMINATING SENSOR OPEN OR MISSING

During normal, non-deployment operation of the SIR system a small amount of current flows through both
deployment loops. The DERM monitors the voltage at "Driver Side Low" terminal "88" and "Passenger Side
Low" terminal "B7'' to detect shorts or opens within the deployment loops. When the measured voltage at either
terminal is within a specified percentage of its respective "36 VLR" power supply for 500 milliseconds DTC 35 is
set.
Failure Conditions: DTC 35 will set when the voltage measured at "Driver Side Low" terminal "B8" or at
"Passenger Side Low" terminal "87'' is within a specified percentage of its respective "36 VLR" power supply
voltage for 500 milliseconds.
Conditions to Clear: DTC 35 will clear when the voltages measured at "Driver Side Low" terminal "88" and
"Passenger Side Low" terminal "87" are both above or below the percentage of their respective "36 VLR" power
supply which sets DTC 35.

1. This test checks for an open inside the forward
2. This test checks for an open ground feed to the
forward discriminating sensor.
3.
4.
This test checks for an open inside the passenger

compartment discriminating sensor.
This test checks for an open ground feed to the
passenger compartment discriminating sensor.
DTC35
(Page 1 of 2)
WAS THE "SIR DIAGNOSTIC SYSTEM

CHECK" PERFORMED?

1NTERMITTENTS AND POOR CONNECTIONS" IN SECTION 8A-4. WHEN
A WIRE REPAIR IS REQUESTED USE J 38125-A TERMINAL REPAIR KIT AND
f,"\
~
---------------------------,
GO TO THE "SIR DIAGNOSTIC SYSTEM CHECK." 1
L-----------------------------~
DISCONNECT DRIVER AND PASSENGER INFLATOR MODULES, YELLOW 2-WAY CONNECTORS LOCATED NEAR THE
BASE OF THE STEERING COLUMN AND BEHIND THE 1/P COMPARTMENT DOOR ASSEMBLY.
CHECK FOR PROPER CONNECTION TO FORWARD DISCRIMINATING SENSOR AT TERMINALS "A" AND "B".
IF OK THEN MEASURE RESISTANCE ON FORWARD DISCRIMINATING SENSOR FROM TERMINAL "A" TO TERMINAL "B".
MEASURE RESISTANCE FROM FORWARD DISCRIMINATING

SENSOR HARNESS CONNECTOR TERMINAL "B" TO GROUND.


DISCRIMINATING SENSOR, REFER TO
SECTION 9J-B.

MOUNTED.

CHECK FOR PROPER CONNECTION TO PASSENGER COMPARTMENT
DISCRIMINATING SENSOR AT TERMINALS "A" AND "C".
IF OK, THEN MEASURE RESISTANCE ON PASSENGER COMPARTMENT
DISCRIMINATING SENSOR FROM TERMINAL" A" TO TERMINAL "C".
MEASURE RESISTANCE FROM PASSENGER COMPARTMENT

DISCRIMINATING SENSOR HARNESS CONNECTOR TERMINAL
"C" TO GROUND.
r-
---------------------------1
~ _____________________________
CONTINUE WITH DIAGNOSIS ON NEXT PAGE. JI
7-7-92
NS 11662
AIRBAG 15A
TO IGNITION
5204
SWITCH ~ 1139A Y E L - - - - 4 1 r - - - - - - - - - - - - - - - - 1 1 3 9 C YEL
---------1139BYEL
DERM
IGNITION 1
1139EYEL
.---------------------------~236YEUBLK
--------------------------1400LTGRN
DUAL
POLE . . . . - - - - - - - - - - - - - - - - - - - - - - - ~ 1 4 0 1 P N K
ARMING
SENSOR
14038 WHT/BLK
PASS. INFLATOR
MODULE JUMPER
PASS.
~1403CWHT/BLK
INFLATOR
{
~
348H DK GRN
MODULE
1403A WHT/BLK
PASS. SIDE HIGH
---348C DK GRN
PASS. SIDE LOW
SHORTING BARS
347AWHT
DRIVER
INFLATOR
MODULE
DRIVER SIDE
HIGH
DRIVER SIDE
LOW
3488
.___ _ _ _ _ __ _ _ , . . - - - - - - - - - - - - - - - - , D K G R N
348E
DKGRN
348F
DKGRN
1751C
PASSENGER
COMPARTMENT
DISCRIMINATING
SENSOR
BLKIWHTl
GROUND
6-30-92
NS 11316
DTC35
(Page 2 of 2)

During normal, non-deployment operation of the SIR system a small amount of current flows through both
deployment loops. The DERM monitors the voltage at "Driver Side Low" terminal "B8" and "Passenger Side
Low" terminal "B7'' to detect shorts or opens within the deployment loops. When the measured voltage at either
terminal is within a specified percentage of its respective "36 VLR" power supply for 500 milliseconds DTC 35 is
set.
Failure Conditions: DTC 35 will set when the voltage measured at "Driver Side Low" terminal "B8" or at
"Passenger Side Low" terminal "B7'' is within a specified percentage of its respective "36 VLR" power supply
voltage for 500 milliseconds.
Conditions to Clear: DTC 35 will clear when the voltages measured at "Driver Side Low" terminal "B8" and
"Passenger Side Low" terminal "B7'' are both above or below the percentage of their respective "36 VLR" power
supply which DTC 35.

5. This test checks for an open in the discriminating
sensor interconnect circuit to the passenger
compartment discriminating sensor.
6. This test checks for an open in the discriminating

sensor interconnect circuit to the forward
due to decreased resistance of the diagnostic
resistors in the dual pole arming sensor or a
DTC35
(Page 2 of 2)
WERE YOU SENT HERE FROM DTC 35 (PAGE 1 OF 2)?
G). . ---D-IS_C_O_N_N_E_C_T_CO_N_N-EC_T_O_R_C_20_0_B_F_RO_M_C_O_N_N_EC_T_O_R_C_2_00_D_.--,
.
G)
[GO~~~~~
is-(;;~;;~;;)~: J
MEASURE RESISTANCE FROM C200B TERMINAL "D2" TO

PASSENGER COMPARTMENT DISCRIMINATING SENSOR
HARNESS CONNECTOR TERMINAL" A".
IS RESISTANCE 5.0 0 OR LESS?
MEASURE RESISTANCE FROM C200B TERMINAL

"D2" TO FORWARD DISCRIMINATING SENSOR
HARNESS CONNECTOR TERMINAL "A".
DISCONNECT DUAL POLE ARMING SENSOR.

MEASURE RESISTANCE ON DUAL POLE ARMING SENSOR
CONNECTOR FROM TERMINAL "D" TO TERMINAL "E"
AND FROM TERMINAL "F" TO TERMINAL "G".
IS EACH MEASUREMENT GREATER THAN 12.56 kn?


REFER TO SECTION 9JB.

7-7-92
NS 11428
TO IGNITION
AIR BAG 15 A
S204
SWITCH ~ 1 1 3 9 A Y E L ~ - - - - - - - - - - - - - - - - - - 1 1 3 9 C Y E L
.---------1139BYEL__/ \
DERM
IGNITION 1
1139EYEL
..----------------------------236YELJBLK
..--------------------------~1400LTGRN
DUAL
POLE ~ - - - - - - - - - - - - - - - - - - - - - - - 1 4 0 1 P N K
ARMING
SENSOR
14038 WHT/BLK
PASS. SIDE HIGH
PASS. SIDE LOW
347AWHT
DRIVER
INFLATOR
MODULE
DRIVER SIDE
HIGH
DRIVER SIDE
LOW
3488
L:__ ___::::::=::::::==::::..J.----------------,DKGRN
348E
DKGRN
348F
DKGRN
1751C
PASSENGER
COMPARTMENT
DISCRIMINATING
SENSOR
BLICIWHTl
GROUND
6-30-92
NS11316
DTC36
PASSENGER LOOP ENERGY RESERVE FEED OPEN
During the "Continuous Monitoring" tests the DERM monitors the voltage at "Passenger Source Sense"
terminal "A6". When the circuit is operating normally the measured voltage will be slightly less than
"Passenger 36 VLR." If the "Passenger 36 VLR" circuit opens the voltage measured at "Passenger Source Sense"
will decrease to slightly less than "Ignition l" voltage. When the voltage measured at "Passenger Source Sense"
is within a specified range of"Ignition 1" for 500 milliseconds DTC 36 is set.
Failure Conditions: OTC 36 will set when the voltage measured at "Passenger Source Sense" terminal "A6"
is within a specified range of"Ignition l" for 500 milliseconds.
Conditions to Clear: OTC 36 will clear when the voltage measured at "Passenger Source Sense" terminal
"A6" is outside the specified range of"Ignition l" which sets the diagnostic trouble code, for 500 milliseconds.
1. This test checks for an open in the "Passenger 36
VLR" circuit.
2. This test checks for high resistance, but not an
open, in the "Passenger Source Sense" circuit.
3.
This test checks for a short from the "Passenger

Source Sense" circuit to B +.
due to the dual pole arming sensor or a
DTC36
PASSENGER LOOP EN ERG y

RESERVE FEED OPEN
s
WHEN MEASUREMENTS ARE REQUESTED IN THIS CHART, USE J 39200
CHECK FOR PROPER CONNECTION IS REQUESTED, REFER TO
"INTERMITTENTS AND POOR CONNECTIONS" IN SECTION 8A-4. WHEN
A WIRE REPAIR IS REQUESTED USE J 38125-A TERMINAL REPAIR KIT AND
REFER TO "SIR WIRE REPAIR" IN SECTION 9J .
r
----------------,
: GO TO THE "SIR DIAGNOSTIC :
I
I SYSTEM CHECK."
L-------------------J
.
G::

DISCONNECT DRIVER AND PASSENGER INFLATOR MODULES, YELLOW 2-WAY CONNECTORS LOCATED NEAR THE BASE OF
THE STEERING COLUMN AND BEHIND THE 1/P COMPARTMENT DOOR ASSENBLY.
CHECK FOR PROPER CONNECTION TO DUAL POLE ARMING SENSOR AT TERMINALS "C" AND "F" .
IF OK THEN DISCONNECT DERM .
CHECK FOR PROPER CONNECTION TO DERM AT TERMINALS "A3" AND "A6" .
IF OK THEN MEASURE RESISTANCE FROM DERM HARNESS CONNECTOR TERMINAL" A3" TO DUAL POLE ARMING SENSOR
HARNESS CONNECTOR TERMINAL "C".
MEASURE RESISTANCE FROM DERM HARNESS CONNECTOR

TERMINAL" A6" TO DUAL POLE ARMING SENSOR HARNESS
CONNECTOR TERMINAL "F".
~
0

TERMINAL" A6" TO TERMINAL A 1" {GROUND).
G:

RECONNECT DERM AND DUAL POLE ARMING SENSOR.
CONNECTOR TERMINAL "F" TO GROUND BY BACKPROBING.
IS VOLTAGE GREATER THAN 31 VOLTS?
. REPAIR OPEN IN CKT 1401. I
REPAIR HIGH RESISTANCE IN CKT 1837 .
SWITCH "OFF."
I
IGNITION
REPAIR SHORT FROM CKT 1837 TO B + .
[$]
[$

REFER TO SECTION 9J-B .

MOUNTED.

7-7-92
NS 11667
TO IGNITION
AIR BAG 15A
5204
SWITCH ~ 1 1 3 9 A Y E L - - - - - - - - - - - - - - - - - 1 1 3 9 C Y E L
. - - - - - - - - - - 1 1 3 9 8 YEL
DERM
IGNITION 1
1139E YEL
~--------------------------236YELJBLK
.--------------------------~1400LTGRN
DUAL
POLE . - - - - - - - - - - - - - - - - - - - - - - - - - 1 4 0 1 P N K
ARMING
SENSOR
14038 WHT/BLK
PASS. SIDE HIGH
PASS. SIDE LOW
DRIVER
INFLATOR
MODULE
347AWHT
DRIVER SIDE
HIGH
DRIVER SIDE
LOW
348F
DKGRN
1751C
PASSENGER
COMPARTMENT
DISCRIMINATING
SENSOR
BLKIWHTl
GROUND
6-30-92
NS11316
DTC42
LOOP ENERGY RESERVE VOLTAGE LOW
During the "Turn-ON" tests, performed at the beginning of each ignition cycle, the DERM delays charging of
the "Driver 36 VLR" terminal "A4" and "Passenger 36 VLR" terminal "A3" power supplies. After the delay has
expired both "36 VLR" power supplies are allowed to charge. The DERM monitors each "36 VLR" power supply
to ensure each has charged to a voltage above a specified value within 30 seconds after "Ignition l" voltage is first
applied to the DERM. When either "36 VLR" power supply does not reach the specified voltage within the
allowed time or, once reaching the specified voltage, falls below it for 500 milliseconds, DTC 42 is set.
Test Conditions: Tested each ignition cycle at "Turn-ON" to detect a charge time failure and, after charging,
tested every 100 milliseconds during the "Continuous Monitoring" tests.
Failure Conditions: DTC 42 will set when the voltage at either "36 VLR" power supply does not exceed a
specified value within 30 seconds after "Ignition 1" voltage is first applied to the DERM or, once having reached
the specified value, either "36 VLR" power supply voltage falls below the specified value for 500 milliseconds.
Conditions to Clear: DTC 42 will clear when the voltages measured at "Driver 36 VLR" terminal "A4" and
"Passenger 36 VLR" terminal "A3" are above a specified value for 500 milliseconds.

1. This test checks for a short from the "Passenger 36
VLR" circuit to ground.
2. This test checks for a short from the "Driver 36
VLR" circuit to ground.
3. This test checks for a short from the "Driver 36
VLR" circuit to B +.
4.
5.
This test checks for a short from the "Passenger 36

VLR" circuit to B +.
due to a short internal to the dual pole arming
sensor or a malfunctioning DERM.
DTC42
[$]
CHECK FOR PROPER CONNECTION IS REQUESTED, REFER TO
"INTERMITTENTS AND POOR CONNECTIONS" IN SECTION SA-4. WHEN
A WIRE REPAIR IS REQUESTED, USE J 38125-A TERMINAL REPAIR KIT
AND REFER TO "SIR WIRE REPAIR" IN SECTION 9J .

FROM TERMINAL" A4" TO TERMINAL" A 12" (GROUND).
IS RESISTANCE 5.0 fl OR LESS?
8J

TERMINAL "A4" TO TERMINAL" A12" (GROUND).
[$]

[$]
: GO TO THE "SIR
: DIAGNOSTIC
I SYSTEM CHECK."
I
I
I
I
I
L..-----------....J

DISCONNECT DRIVER AND PASSENGER IN FLA TOR MODULES, YELLOW 2-WAY CONNECTORS LOCATED NEAR THE
BASE OF THE STEERING COLUMN AND BEHIND THE 1/P COMPARTMENT DOOR ASSEMBLY.
DISCONNECT DERM .
MEASURE RESISTANCE ON DERM HARNESS CONNECTOR FROM TERMINAL" A3" TO TERMINAL" A 12" (GROUND).
IS RESISTANCE 5.0 fl OR LESS?
~
.- - - - - - - - - ,
r-
LOOP ENERGY
RESERVE
VOLTAGE LOW

RECONNECT DERM AND DUAL POLE ARMING SENSOR .
IGNITION SWITCH "ON," WAIT 30 SECONDS .
CONNECTOR TERMINAL "B" TO GROUND AND TERMINAL"(" TO
GROUND BY BACKPROBING.
IS EITHER MEASUREMENT LESS THAN 32.5 VOLTS?
REPAIR SHORT FROM

CKT 236 TO GROUND.


[$]

REPLACE DERM, REFER TO SECTION 9J-B .
REPLACE DUAL POLE ARMING

I
7-7-92
NS 1>403

REPEAT "SIR DIAGNOSTIC SYSTEM CH ECK."
TO IGNITION
AIR BAG 15A
5204
SWITCH ~ 1 1 3 9 A Y E L ~ - - - - - - - - - - - - - - - - - - 1 1 3 9 C Y E L
.....--------1139BYEL_/ \
DERM
IGNITION 1
1139EYEL
.----------------------------236YEUBLK
.....-------------------------~1400LTGRN
DUAL
POLE - ~ - - - - - - - - - - - - - - - - - - - - - - - 1 4 0 1 P N K
ARMING
SENSOR
14038 WHT/BLK
PASS. SIDE HIGH
PASS. SIDE LOW
347AWHT
DRIVER
INFLATOR
MODULE
DRIVER SIDE
HIGH
DRIVER SIDE
LOW
348F
DKGRN
1751C
PASSENGER
COMPARTMENT
DISCRIMINATING
SENSOR
BLK/WHTl
GROUND
6-30-92
NS 11316
DTC43
DRIVER SOURCE FEED LOW
During normal, non-deployment operation of the SIR system the DERM monitors the voltage supplied
through the dual pole arming sensor to the high side of the driver deployment loop at the "Driver Source Sense"
terminal "A5". This measured voltage will have a value approximately equal to "Driver 36 VLR." When the
voltage measured at "Driver Side Low" terminal "88" is in its normal operating range, indicating driver
deployment loop integrity has been maintained, while simultaneously the voltage measured at "Driver Source
Sense" is a specified amount below "Driver 36 VLR" for 500 milliseconds DTC 43 is set.
Failure Conditions: DTC 43 will set when the voltage measured at "Driver Side Low" terminal "88" is within
a specified percentage of "Driver 36 VLR" while simultaneously the voltage measured at "Driver Source Sense"
terminal "A5" is a specified amount below "Driver 36 VLR" for 500 milliseconds.
within a specified percentage of "Driver 36 VLR" while simultaneously the voltage measured at "Driver Source
Sense" terminal "A5" is within a specified amount of"Driver 36 VLR" for 500 milliseconds.

1. This test checks for an open in "Driver Source
Sense" circuit.
2. This test checks for a short from the "Driver
Source Sense" circuit to ground.
3.
The test determines whether the malfunction is

due to increased resistance across the "Driver
Source Sense" resistor in the dual pole arming
DTC43
DRIVER SOURCE FEED LOW

DVM WITH CORRECT TERMINAL ADAPTER FROM J 3561'6-A. WHEN A
"INTERMITTENTS AND POOR CONNECTIONS" IN SECTION BA-4.
REPAIR KIT AND REFER TO "SIR WIRE REPAIR" IN SECTION 9J .
~
.--------------------------,
r
I
L-----------------------------~
.
SWITCH "OFF."
IGNITION
DISCONNECT DRIVER AND PASSENGER IN FLA TOR MODULES, YELLOW 2-WA Y CONNECTORS LOCATED
'-.:_.I
NEAR THE BASE OF THE STEERING COLUMN BEHIND THE 1/P COMPARTMENT DOOR ASSEMBLY.
DISCONNECT DERM.
CHECK FOR PROPER CONNECTION TO DERM AT TERMINAL" AS".
IF OK THEN DISCONNECT DUAL POLE ARMING SENSOR.
CHECK FOR PROPER CONNECTION TO DUAL POLE ARMING SENSOR AT TERMINAL "D" .
IF OK, MEASURE RESISTANCE FROM DUAL POLE ARMING SENSOR HARNESS CONNECTOR TERMINAL
"D" TO DERM HARNESS CONNECTOR TERMINAL "AS".
IS RESISTANCE 5.0 il OR LESS?
[$]
G)

FROM TERMINAL" AS" TO TERMINAL" A 1" (GROUND).
IS RESISTANCE 5.0 il OR LESS?
'?
~

CONNECTOR FROM TERMINAL "D" TO TERMINAL ''E''.
IS RESISTANCE 12.9 kil OR MORE?

[$]
REPAIR SHORT FROM CKT 1400 TO GROUND. ,
I
I


8-20-92
NS 15404
TO IGNITION
AIR BAG 15A
5204
SWITCH ~ 1 1 3 9 A Y E L - - - - - - - - - - - - - - - - - - 1 1 3 9 C Y E L
. . - - - - - - - - - - 1 1 3 9 8 YEL
DERM
IGNITION 1
1139E YEL
.----------------------------~236YEUBLK
.---------------------------~1400LTGRN
DUAL
POLE . - - - - - - - - - - - - - - - - - - - - - - - - - - 1 4 0 1 P N K
ARMING
SENSOR
14038 WHT/BLK
PASS. SIDI HIGH
PASS. SIDI LOW
DRIVER
INFLATOR
MODULE
347AWHT
348A DKGRN
3488
'--------~r--------------,DKGRN
DRIVER SIDE
HIGH
DRIVER SIDE
LOW
348E
DKGRN
348F
DKGRN
1751C
PASSENGER
COMPARTMENT
DISCRIMINATING
SENSOR
BLKIWHTl
GROUND
6-30-92
NS 11316
DTC44
PASSENGER SOURCE FEED LOW
During normal, non-deployment operation of the SIR system the DERM monitors the voltage supplied
through the dual pole arming sensor to the high side of the passenger deployment loop at the "Passenger Source
Sense" terminal "A6". The measured voltage will have a value approximately equal to "Passenger 36 VLR."
When the voltage measured at "Passenger Side Low" terminal "B7'' is in its normal operating range, indicating
passenger deployment loop integrity has been maintained, while simultaneously the voltage measured at
"Passenger Source Sense" is a specified amount below "Passenger 36 VLR" for 500 milliseconds DTC 44 is set.
within a specified percentage of "Passenger 36 VLR" while simultaneously the voltage measured at "Passenger
Source Sense" terminal "A6" is a specified amount below "Passenger 36 VLR" for 500 milliseconds.
Conditions 'to Clear: DTC 44 will clear when the voltage measured at "Passenger Side Low" terminal "BT' is
within a specified percentage of "Passenger 36 VLR" while simultaneously the voltage measured at "Passenger
Source Sense" terminal "A6" is within a specified amount of"Passenger 36 VLR" for 500 milliseconds.

1. This test checks for an open in the "Passenger
Source Sense" circuit.
2. This test checks for a short from the "Passenger
Source Sense" circuit to ground.
3.

due to increased resistance across the "Passenger
Source Sense" resistor in the dual pole arming
DTC44
PASSENGER SOURCE FEED LOW
r-"'--~~~~~~~~~~~~~~~~~~~~-,r

---------------------------,
LGO TO THE "SIR DIAGNOSTIC SYSTEM CHECK." J

DISCONNECT DRIVER AND PASSENGER INFLATOR MODULES, YELLOW 2-WAY CONNECTORS LOCATED NEAR
DISCONNECTDERM.
CHECK FOR PROPER CONNECTION TO DERM AT TERMINAL "A6".
IF OK THEN DISCONNECT DUAL POLE ARMING SENSOR.
CHECK FOR PROPER CONNECTION TO DUAL POLE ARMING SENSOR AT TERMINAL "F".
IF OK, THEN MEASURE RESISTANCE FROM DUAL POLE ARMING SENSOR HARNESS CONNECTOR TERMINAL "F"
TO DERM HARNESS CONNECTOR TERMINAL" A6".


CONNECTOR FROM TERMINAL "F" TO TERMINAL "G".
IS RESISTANCE 12.9 kQ OR MORE?


REPEAT "SIR DIAGNOSTIC SYSTEM CHECK".

8-21-92
NS 15405
TO IGNITION
AIR BAG 15 A
5204
SWITCH ~ 1 1 3 9 A Y E L ~ - - - - - - - - - - - - - - - - - - - - - - 1 1 3 9 C Y E L
r----------1139BYEL_/ \
DERM
IGNITION 1
1139EYEL
.----------------------------~236YEUBLK
.---------------------------~1400LTGRN
DUAL
POLE r - - - - - - - - - - - - - - - - - - - - - - - - - - 1 4 0 1 P N K
ARMING
SENSOR
PASS. SIDE HIGH

PASS. SIDE LOW
DRIVER
INFLATOR
MODULE
347AWHT
DRIVER SIDE
HIGH
DRIVER SIDE
LOW
348E
DKGRN
348F
DKGRN
'
FORWARD
DISCRIMINATING
SENSOR
I
1751C
BLK/WHT
PASSENGER
COMPARTMENT
DISCRIMINATING
SENSOR
02
1751E BLK/WHT
GROUND
~~;"jL1751F BLK/WHT
6-30-92
NS 11316
OTC 51
FRONTAL CRASH DETECTED
Closure of the dual pole arming sensor is detected when the voltage measured at "Driver Side High" terminal
"B9" or at "Passenger Side High" terminal "AT' is within a specified amount of its respective deployment loop
supply voltage. Closure of either discriminating sensor is detected when the voltage measured at "Driver Side
Low" terminal "BS" or at "Passenger Side Low" terminal "B7'' is within a specified amount of ground potential.
When both conditions are met simultaneously on either the driver side or passenger side for not less than 250
microseconds "Crash Data" is recorded and DTC 51 is set.
Test Conditions: Conditions are monitored whenever the DERM is functioning normally.
Failure Conditions: DTC 51 will set when closure of the dual pole arming sensor and at least one of the
discriminating sensors is detected for not less than 250 microseconds on either the driver side or passenger side.
Action Taken: DERM turns "ON" the "AIR BAG" warning lamp, records "Crash Data," and sets a diagnostic
trouble code.
Conditions to Clear: DTC 51 can only be cleared by using a scan tool "Clear Codes" command.

1. Ifinflator module(s) has not deployed, DTC 51 may
have set falsely.
2. If DTC 51 has set with no signs of frontal impact,
the diagnostic trouble code has set falsely.
3.
4.
5.
This test checks for a DERM malfunction setting

the diagnostic trouble code.
This test determines whether the diagnostic
trouble code was set inadvertently during
diagnosis or by a DERM malfunction.
When a frontal crash has occurred, it is necessary
to perform the indicated procedures to ensure the
SIR system is fully functional.
DTC 51
FRONTAL CRASH DETECTED
r
:

HAS INFLATOR MODULE(S) DEPLOYED?
------------------,
GO TO THE "SIR DIAGNOSTIC :
SYSTEM CHECK."
1
L--------------------~
INSPECT FRONT OF VEHICLE AND

UNDERCARRIAGE FOR SIGNS OF IMPACT.
NO SIGNS OF IMPACT

IS OTC 51 SET?
SIGNS OF IMPACT

WAS OTC 51 SET WHEN THE "SIR
DIAGNOSTIC SYSTEM CHECK"
WAS FIRST PERFORMED?

REPLACE COMPONENTS AND PERFORM INSPECTIONS AS

DIRECTED IN "REPAIRS AND INSPECTIONS REQUIRED AFTER
AN ACCIDENT" IN SECTION 9J.


SYSTEM CHECK."
8-21-92
MS 13303
TO IGNITION
AIR BAG 15A
5204
SWITCH ~ 1 1 3 9 A Y E L ~ - - - - - - - - - - - - - - - - - - - - 1 1 3 9 C Y E L
--------1139BYEL__/ \
DERM
IGNITION 1
1139EYEL
.----------------------------236YELJBLK
,--------------------------~1400LTGRN
DUAL
POLE - - - - - - - - - - - - - - - - - - - - - - - - 1 4 0 1 P N K
ARMING
SENSOR
14038 WHT/BLK
DRIVER
SOURCE SENSE
PASS. 36 VLR
PASS. SOURCE
SENSE
PASS. SIDE HIGH
PASS. SIDE LOW
347AWHT
DRIVER
INFLATOR
MODULE
3488
_ _ _ _ _ _ __ _ _ , - - - - - - - - - - - - - - - . DK GRN
DRIVER SIDE
HIGH
DRIVER SIDE
LOW
348E
DKGRN
348F
DKGRN
1751C
PASSENGER
COMPARTMENT
DISCRIMINATING
SENSOR
BLK/WHTl
GROUND
6-30-92
NS 11316
DTC 52
DATA AREA FULL
When there is a frontal crash of sufficient force to activate the dual pole arming sensor and at least one of the
two discriminating sensors, simultaneously OTC 51 is set. At this time the DERM will record information
regarding SIR system status and vehicle status in EEPROM. OTC 52 will set when the DERM has stored
information regarding eight frontal crash events.
Test Conditions: Tested each time the DERM stores or attempts to store information regarding a frontal
crash event.
Failure Conditions: OTC 52 will set when the DERM attempts to store frontal crash information and finds
the EE PROM data area full.
Conditions to Clear: OTC 52 can be cleared by using a scan tool "Clear Codes" command. If, at the next
ignition "ON" after receiving a "Clear Codes" command, the DERM detects the data area is full a history
diagnostic trouble code is set. This allows the "AIR BAG" warning lamp to illuminate should any additional
malfunctions be detected.
OTC 52
DATA AREA FULL

GO TO THE "SIR
DIAGNOSTIC
SYSTEM CHECK."
:
:
1
~--------------~
1-9-92
MS 13304
TO IGNITION
AIR BAG 15 A
5204
SWITCH ~ 1139A Y E L - - > - - - - - - - - - - - - - - - - - 1 1 3 9 C YEL
.----------1139BYEL
DERM
IGNITION 1
1139EYEL
,----------------------------~236YEUBLK
.----------------------------1400LTGRN
DUAL
POLE , - - - - - - - - - - - - - - - - - - - - - - - - - - 1 4 0 1 P N K
ARMING
SENSOR
14038 WHT/BLK
PASS. SIDE HIGH
PASS. SIDE LOW
347AWHT
DRIVER
INFLATOR
MODULE
DRIVER SIDE
HIGH
DRIVER SIDE
LOW
348E
DKGRN
348F
DKGRN
1751C
PASSENGER
COMPARTMENT
DISCRIMINATING
SENSOR
BLKIWHTl
GROUND
6-30-92
NS 11316
OTC 53
DRIVER SIDE LOW HIGH RESISTANCE
and turns "ON" the passenger current source at the "Passenger Side High" terminal "A7''. This causes a known
amount of current to flow through the passenger initiator circuit allowing this resistance to be calculated. The
normal, non-deployment current flow through the driver deployment loop is also affected since the DERM is
supplying ground through a resistor bypassing the ground supplied by the resistance of the discriminating sensor
network. When the voltage difference between "Driver Side High" terminal "89" and "Driver Side Low"
terminal "B8" is above a specified value DTC 53 is set.
"Continuous Monitoring" for one second, 3) No "CRANK" signal present, 4) "Ignition 1" voltage is above a
specified value.
Failure Conditions: DTC 53 will set when the voltage difference between "Driver Side High" terminal "B9"
and "Driver Side Low" terminal "B8" is above a specified value.

due to a high resistance or open in the "Driver Side
Low" circuit between the DERM and the steering
column harness connector or a malfunctioning
DERM.
DTC53
DRIVER SIDE LOW HIGH
RESISTANCE
WHEN MEASUREMENTS ARE REQUESTED IN THIS

CHART USE J 39200 DVM WITH CORRECT TERMINAL
ADAPTER FROM J 35616-A. WHEN A CHECK FOR
PROPER CONNECTION IS REQUESTED REFER TO
"INTERMITTENTS AND POOR CONNECTIONS" IN
SECTION BA-4. WHEN A WIRE REPAIR IS REQUESTED
USE J 38125-A TERMINAL REPAIR KIT AND REFER TO "SIR
WIRE REPAIR" IN SECTION 9J.
G)

DISCONNECT DRIVER AND PASSENGER INFLATOR MODULES, YELLOW 2-WAY CONNECTORS LOCATED NEAR
DISCONNECT DERM.
CHECK FOR PROPER CONNECTION TO DERM AT TERMINAL "88".
IF OK THEN MEASURE RESISTANCE FROM DERM HARNESS CONNECTOR TERMINAL "BB" TO STEERING
COLUMN HARNESS CONNECTOR TERMINAL "B".

REPAIR OPEN OR HIGH RESISTANCE IN CKT 348A.

7-7-92
NS 15406
AIRBAG 15A
TO IGNITION
5204
SWITCH ~ 1 1 3 9 A Y E L - - - - - - - - - - - - - - - - - 1 1 3 9 C Y E L
. . - - - - - - - - - - 1 1 3 9 8 YEL
DERM
IGNITION 1
1139E YEL
.----------------------------236YEUBLK
.--------------------------~1400LTGRN
DUAL
POLE . - - - - - - - - - - - - - - - - - - - - - - - - - 1 4 0 1 P N K
ARMING
SENSOR
14038 WHT/BLK
PASS. SIDE HIGH
PASS. SIDE LOW
DRIVER
INFLATOR
MODULE
347AWHT
3488
~------__.,----------------,DKGRN
DRIVER SIDE
HIGH
DRIVER SIDE
LOW
348E
DKGRN
348F
DKGRN
1751C
PASSENGER
COMPARTMENT
DISCRIMINATING
SENSOR
BLKIWHTl
GROUND
6-30-92
NS 11316
DTC54
PASSENGER SIDE LOW HIGH RESISTANCE
of current to flow through the driver initiator circuit allowing the resistance to be calculated. The normal, nondeployment current flow through the passenger deployment loop is also affected since the DERM is supplying
ground through a resistor bypassing the ground supplied by the resistance of the discriminating sensor network.
When the voltage difference between "Passenger Side High" terminal "A7" and "Passenger Side Low" terminal
"BT' is above a specified value DTC 54 is set.
"Continuous Monitoring" for one second, 3) No "CRANK" signal present, 4) "Ignition 1" is above a specified
value.
Failure Conditions: DTC 54 will set when the voltage difference between "Passenger Side High" terminal
"A 7" and "Passenger Side Low" terminal "B7'' is above a specified value.

due to a high resistance or open in the "Passenger
Side Low" circuit between the DERM and the
passenger inflator module harness connector or a
DTC54
PASSENGER SIDE LOW
HIGH RESISTANCE
WHEN MEASUREMENTS ARE REQUESTED IN THIS

CHART USE J 39200 DVM WITH CORRECT
TERMINAL ADAPTER FROM J 35616-A. WHEN A
CHECK FOR PROPER CONNECTION IS REQUESTED
REFER TO "INTERMITTENTS AND POOR
CONNECTIONS" IN SECTION SA-4. WHEN A WIRE
REPAIR IS REQUESTED USE J 38125-A TERMINAL
REPAIR KIT AND REFER TO "SIR WIRE REPAIR" IN
SECTION 9J.
G)

DISCONNECT DRIVER AND PASSENGER
INFLATOR MODULES, YELLOW 2-WAY
CONNECTORS LOCATED NEAR THE BASE OF
DISCONNECT DERM.
TERMINAL "87".
IF OK THEN MEASURE RESISTANCE FROM
DERM HARNESS CONNECTOR TERMINAL "87"
TO PASSENGER INFLATOR MODULE JUMPER
IS RESISTANCE 5.0il OR LESS?

MOUNTED.
REPAIR OPEN OR HIGH RESISTANCE IN CKT 348C.

7-1-92
NS 15407
TO IGNITION
AIR BAG 15A
5204
SWITCH ~ 1 1 3 9 A Y E L - 1 * ; : " - - - e - - - - - - - - - - - - - - - - 1 1 3 9 C Y E L
....--------1139BYEL__/ \
DERM
IGNITION 1
1139EYEL
.----------------------------236YELJBLK
....-------------------------~1400LTGRN
DUAL
POLE . - - - - - - - - - - - - - - - - - - - - - - - - - 1 4 0 1 P N K
ARMING
SENSOR
14038 WHT/BLK
PASS. SIDE HIGH
PASS. SIDE LOW
347AWHT
DRIVER
INFLATOR
MODULE
348A DKGRN
DRIVER SIDE
HIGH
DRIVER SIDE
LOW
348F
DKGRN
1751C
PASSENGER
COMPARTMENT
DISCRIMINATING
SENSOR
BLK.WHTl
GROUND
6-30-92
NS11316
DTC 55
DERM INCOMPATIBILITY
and measures the voltage at "Driver Source Sense" terminal "A5", "Passenger Source Sense" terminal "A6" and
"Driver Side Low" terminal "BS". The DERM monitors "Driver Source Sense" to ensure that "Driver 36 VLR" is
fully charged and supplying voltage to the high side of the driver deployment loop. When this condition is met,
the measurement at "Passenger Source Sense" indicates no voltage is being supplied to the high side of the
passenger deployment loop and grounding "Passenger Side Low" does not ground "Driver Side Low," DTC 55 is
set.
specified value.
Failure Conditions: DTC 55 will set when, with "Driver 36 VLR" supplying power to the high side of the
driver deployment loop, "Passenger Source Sense" indicates no voltage is being applied to the high side of the
passenger deployment loop and grounding "Passenger Side Low" does not ground "Driver Side Low."
DTCSS
DERM INCOMPATIBILITY

,.
------------.,:
GO TO THE "SIR
DIAGNOSTIC
SYSTEM CHECK."
:
1
~--------------~
1-9-92
MS 13304
TO IGNITION
AIR BAG 15 A
5204
SWITCH ~ 1 1 3 9 A Y E L ~ - - - - - - - - - - - - - - - - - - - - 1 1 3 9 C Y E L
.....---------1139BYEL_/ \
1139EYEL
.-----------------------------236YEUBLK
.----------------------------1400LTGRN
,--------------------------1401PNK
~--------------------1837LTGRN/WHT
.....-------14038 WHT/BLK-----,
_.__~--650AA BLK
DERM
IGNITION 1
IGNITION 1
DRIVER 36 VLR
DRIVER
SOURCE SENSE
PASS. 36 VLR
PASS. SOURCE
SENSE
REDUNDANT
INDICATOR
GROUND
PASS. SIDE HIGH
PASS. SIDE LOW
CRANK
SERIAL DATA
5225
'----------------326PPL
l'--------------------347AWHT
'--TO
_ _ _G_A_G_E~S~1~0-A_ _ _ _ _
S2_0_6-----348ADKGRN
3488 I G N I T I O N ~ 39A P N K - - - - - - - - - - - 3 9 H PNK
DK GRN SWITCH
39C PNK
c2oool
,:-- ,
I
02
DIAG. REQUEST
DRIVER SIDE
HIGH
DRIVER SIDE
LOW
REDUNDANT
INDICATOR
IGNITION 1
INSTRUMENT CLUSTER
L---.J
348F
-;fc200B
DK GRN L348G DK GRN
CA MARO
,-----------t B
FIREBIRD
8.45 KQ
17518 BLK/WHT --y-1751A BLK/WHT~r---,
-=-
AS
L
358
BRN
"AIRBAG"
WARNING
A7
__L~~_P- _ .J
1751E BLK/WHT
2
C200B/L.~~.J!(' C 00D
1751CBLK/WHT--------~
1751F BLK/WHT
SIR INDICATOR
SHORTING BAR
GROUND
GROUND
7-9-92
NS 11608
DTC61
SIR INDICATOR CIRCUIT FAILURE
When the ignition switch is first turned "ON" battery voltage is applied to the "AIR BAG" warning lamp and
to the "Ignition l" input terminals "A9" and "AlO". The DERM responds by flashing the "AIR BAG" warning
lamp seven times alternating between the primary and redundant lamp drivers. The DERM monitors the
primary lamp driver output by comparing the output state at "SIR Indicator" terminal "Bl" to the microprocessor
commanded state. When "Ignition 1" is above a specified value and the output state does not match the
commanded state of the primary lamp driver for 400 milliseconds DTC 61 is set.
Failure Conditions: DTC 61 will set when "Ignition l" voltage is above a specified value and the output state
at the "SIR Indicator" terminal "Bl" does not match the commanded state of the primary lamp driver for 400
milliseconds.
Action Taken: DERM attempts to turn "ON" the "AIR BAG" warning lamp using the redundant lamp driver
and sets a diagnostic trouble code.
DTC61
SIR INDICATOR CIRCUIT FAILURE
MALFUNCTIONS WITHIN THE" AIR BAG" WARNING LAMP

CIRCUITRY WILL SET THIS DIAGNOSTIC TROUBLE CODE. THESE
MALFUNCTIONS ARE ADDRESSED IN THE "SIR DIAGNOSTIC
SYSTEM CHECK" VIA CHART C AND CHART D. FAILURE TO
PROPERLY PERFORM THE "SIR DIAGNOSTIC SYSTEM CHECK" MAY
RESULT IN MISDIAGNOSIS OF A MALFUNCTIONING DERM.
IS DTC61 SET?

8-21-92
NS 13519
15
TO IGNITION
AIR BAG A
S204
SWITCH ~ 1 1 3 9 A Y E L - - - - - - - - - - - - - - - - - - 1 1 3 9 C YEL
.----------1139BYEL
1139EYEL
.-----------------------------236YEUBLK
,----------------------------1400LTGRN
.--------------------------1401PNK
.----------------------1837LTGRN/WHT
. - - - - - - - - 1 4 0 3 8 WHT/BLK----~
PASS.
_l_---650AA BLK
INFLATOR
PASS. INFLATOR
MODULE
MODULE JUMPER
~ 1403( WHT/BLK
l.:::::fi--0t
P----1403A WHT/BLK
348H DK GRN
SHORTING BARS
- - - - 3 4 8 ( DK GRN
_j
DERM
IGNITION 1
IGNITION 1
DRIVER 36 VLR
DRIVER
SOURCE SENSE
PASS. 36 "LR
PASS. SOURCE
SENSE
REDUNDANT
INDICATOR
GROUND
PASS. SIDE HIGH
PASS. SIDE LOW
CRANK
SERIAL DATA
5225
L----------------326PPL
l ' - - - - - - - - - - - - - - - - - - - - 3 4 7 A WHT
1-----1-,.:{:...,1
'---TO
_ _ _G_A_G_E_S_1_0_A_ _ _ _ _
S2_0_6-----348ADKGRN
3488 I G N I T I O N ~ 39A P N K - - - e - - - - - - - - 3 9 H PNK

SHORTING BARS
DK GRN SWITCH
PASSENGER
39C PNK
COMPARTMENT
C2000J
INSTRUMENT CLUSTER
DISCRIMINATING
I 02 I
r-------,
SENSOR
L---..J
I
I
348F
- Jrc2ooe
CAMARO
358
BRN
"AIR BAG"
FIREBIRD AS
WARNING
A7
8.45 Kil
LAMP
.- ,
<:
17518 BLK/WHT -y-1751A BLK/WHTv,,--,

_
(2008
01
,... __ _.
1751CBLK/WHT---------'
L-------.J
1751E BLK/WHT
(2000
1751F BLK/WHT
DIAG. REQUEST
DRIVER SIDE
HIGH
DRIVER SIDE
LOW
REDUNDANT
INDICATOR
IGNITION 1
SIR INDICATOR
SHORTING BAR
GROUND
GROUND
7-9-92
NS 11608
DTC62
REDUNDANT SIR INDICATOR CIRCUIT FAILURE
When the ignition switch is first turned "ON" battery voltage is applied to the "AIR BAG" warning lamp and
to the "Ignition l" input terminals "A9" and "AlO". The DERM responds by flashing the "AIR BAG" warning
lamp seven times alternating between the primary and redundant lamp drivers. The DERM monitors the
redundant lamp driver output by comparing the output state at "SIR Indicator" terminal "Bl" to the
microprocessor commanded state. When "Ignition 1" is above a specified value and the output state does not
match the commanded state of the redundant lamp driver for 400 milliseconds DTC 62 is set.
Failure Conditions: DTC 62 will set when "Ignition l" voltage is above a specified value and the output state
at the "SIR Indicator" terminal "Bl" does not match the commanded state of the redundant lamp driver for 400
milliseconds.
Action Taken: DERM attempts to turn "ON" the "AIR BAG" warning lamp using the primary lamp driver
and sets a diagnostic trouble code.

1. This test checks for an open in the "Redundant
Indicator Ground" circuit.
2.

due to an open in the "Redundant Indicator
Ignition 1" circuit or a malfunctioning DERM.
DTC62
REDUNDANT SIR INDICATOR CIRCUIT FAILURE
,--,.._~~~~~~~~~~~~~~~~~~~~~--,r-

"INTERMITTENTS AND POOR CONNECTIONS" IN SECTION SA-4. WHEN A
WIRE REPAIR IS REQUESTED USE J 38125-A AND REFER TO "SIR WIRE
REPAIR" IN SECTION 9J.
CD
----------,
'
GOTODTC61. '
L------------J

THE STEERING COLUMN ANO BEHIND THE VP COMPARTMENT
DOOR ASSEMBLY.
DISCONNECT DERM.
CHECK FOR PROPER CONNECTION TO DERM AT TERMINAL "A2"
AND AT TERMINAL "82".
IF OK THEN MEASURE RESISTANCE ON DERM HARNESS
CONNECTOR FROM TERMINAL" A2" (GROUND) TO TERMINAL
"A12" (GROUND).

TERMINAL"B2" TO TERMINAL" A 12" (GROUND).

REPLACE OERM, REFER TO SECTION 9J-B.

7-1-92
NS 15408
TO IGNITION
AIR BAG 1SA
5204
SWITCH ~ 1 1 3 9 A Y E L ~ - - - - - - - - - - - - - - - - - - - 1 1 3 9 C Y E L
--------1139BYEL__/ \
DERM
IGNITION 1
1139EYEL
.----------------------------236YEUBLK
..-------------------------~1400LTGRN
DUAL
POLE . . . - - - - - - - - - - - - - - - - - - , - - - - - - - 1 4 0 1 P N K
ARMING
SENSOR
14038 WHT/BLK
PASS. SIDE HIGH
PASS. SIDE LOW
DRIVER
INFLATOR
MODULE
347AWHT
DRIVER SIDE
HIGH
DRIVER SIDE
LOW
348F
DKGRN
1751C
PASSENGER
COMPARTMENT
DISCRIMINATING
SENSOR
BLKIWHTl
GROUND
6-30-92
NS11316
DTC 71 AND/OR 75
INTERNAL DERM FAULT
DTC 71 is an indication of an internal DERM malfunction and will set if any of the following conditions are
detected: 1) DERM energy reserve voltage discharge time failure for three consecutive ignition cycles ("TurnON" test), 2) DERM is unable to read from or write to EEPROM (tested during "EEPROM read/write cycle"), 3)
Either "36 VLR" power supply voltage is above a specified value for 500 milliseconds ("Continuous Monitoring"
test), 4) The DERM calculated number for the vehicle in which it is installed does not match the value stored in
EE PROM.
Test Conditions: The failure conditions are tested at different times: 1) At "Turn-ON," 2) Asynchronously, 3)
During "Continuous Monitoring," 4) At "Turn-On."
Failure Conditions: DTC 71 and/or DTC 75 will set when any of the indicated malfunctions are detected by
theDERM.
Conditions to Clear: DTC 71 and/or DTC 75 will clear when the indicated malfunctions are not detected by
theDERM.
DTC 71 AND/OR 75
INTERNAL DERM FAULT

------------,
GOTO THE "SIR

DIAGNOSTIC
SYSTEM CHECK."
:
:
~--------------~
1-9-92
MS 13304
TO IGNITION~ G ~
S204
SWITCH ........-----.. ~1139A Y E L ~ - - - - - - - - - - - - - - - - - - 1 1 3 9 C Y E L
r---------1139BYEL_/ \
DERM
IGNITION 1
1139EYEL
.---------------------------~236YEVBLK
,--------------------------~1400LTGRN
DUAL
POLE ~ - - - - - - - - - - - - - - - - - - - - - - - 1 4 0 1 P N K
ARMING
SENSOR
14038 WHT/BLK
PASS. INFLATOR
MODULE JUMPER
PASS.
~1403CWHT/BLK
INFLATOR
{
MODULE
~
348H DK GRN
1403A WHT/BLK
PASS. SIDE HIGH
ir----348C DK GRN
PASS. SIDE LOW
SHORTING BARS
347AWHT
DRIVER
INFLATOR
MODULE
DRIVER SIDE
HIGH
DRIVER SIDE
LOW
348E
DKGRN
348F
DKGRN
1751C
PASSENGER
COMPARTMENT
DISCRIMINATING
SENSOR
BLl<,WHTl
GROUND
6-30-92
NS 11316
DTC81
DRIVER IGNITION DIODE OPEN
VLR" power supplies indicates they are in a discharged state, the voltage measured at "Passenger Source Sense"
is within a specified range of"Ignition l" voltage and the voltage measured at "Driver Source Sense" is a specified
amount below "Ignition l" voltage DTC 81 is set.
active.
DERM detects "Ignition l" voltage at "Passenger Source Sense" terminal "A6" while simultaneously the DERM
does not detect "Ignition l" voltage at "Driver Source Sense" terminal "A5".
voltages measured at "Driver Source Sense" terminal "A5" and "Passenger Source Sense" terminal "A6" are
simultaneously within a specified range of"Ignition 1" voltage. When neither the failure nor clear conditions are

Source Sense" circuit to the "Passenger 36 VLR"
circuit.
Source Sense" circuit to the "Driver 36 VLR"
circuit.

due to an open within the dual pole arming sensor
DTC81
DRIVER IGNITION DIODE OPEN


YELLOW 2-WAY CONNECTORS LOCATED NEAR THE BASE OF THE
STEERING COLUMN AND BEHIND THE 1/P COMPARTMENT DOOR
ASSEMBLY.
HARNESS CONNECTOR FROM TERMINAL "D" TO TERMINAL "C".

HARNESS CONNECTOR FROM TERMINAL "D" TO TERMINAL "B".
RECONNECT DUAL POLE ARMING SENSOR.

DISCONNECT DERM.
MEASURE VOLTAGE FROM DUAL POLE ARMING SENSOR
HARNESS CONNECTOR TERMINAL "D" TO GROUND BY
BACKPROBING.
IS VOLTAGE 1 VOLTORLESS?
IGNITION SWITCH "Off."



7-1-92
NS 15409
TO IGNITION
AIR BAG 15A
5204
SWITCH ~ 1 1 3 9 A Y E L ~ - - . _ - - - - - - - - - - - - - - 1 1 3 9 C Y E L
r---------1139BYEL_/ \
DERM
IGNITION 1
1139EYEL
r---------------------------~236YEUBLK
.--------------------------~1400LTGRN
DUAL
POLE . - - - - - - - - - - - - - - - - - - - - - - - - 1 4 0 1 P N K
ARMING
SENSOR
14038 WHT/BLK
PASS. SIDE HIGH
PASS. SIDE LOW
347AWHT
DRIVER
INFLATOR
MODULE
DRIVER SIDE
HIGH
DRIVER SIDE
LOW
348F
DKGRN
1751C
PASSENGER
COMPARTMENT
DISCRIMINATING
SENSOR
BLK,WHTl
GROUND
6-30-92
NS 11316
DTC82
PASSENGER IGNITION DIODE OPEN
VLR" power supplies indicates they are in a discharged state, the voltage measured at "Driver Source Sense" is
within a specified range of "Ignition l" voltage and the voltage measured at "Passenger Source Sense" is a
specified amount below "Ignition l" voltage DTC 82 is set.
active.
DERM detects "Ignition l" voltage at "Driver Source Sense" terminal "A5" while simultaneously the DERM does
not detect "Ignition 1" voltage at "Passenger Source Sense" terminal "A6".
voltages measured at "Driver Source Sense" terminal "A5" and "Passenger Source Sense" terminal "A6" are
simultaneously within a specified range of "Ignition l" voltage. When neither the failure nor clear conditions are

1. This test checks for a short from the "Passenger
Source Sense" circuit to the "Passenger 36 VLR"
circuit.
2. This test check for a short from the "Passenger
Source Sense" circuit to the "Driver 36 VLR"
circuit.

due to an open within the dual pole arming sensor
DTC82
PASSENGER IGNITION DIODE OPEN
.........__~~~~~~~~~~~~~~~~~~~~~r- ----------------------------,
WHEN A WIRE REPAIR IS REQUESTED USE J 38125-A TERMINAL REPAIR
KIT AND REFER TO "SIR WIRE REPAIR" IN SECTION 9J.
~------------------------------J

DISCONNECT DRIVER AND PASSENGER INFLATOR MODULES, YELLOW 2WAY CONNECTORS LOCATED NEAR THE BASE OF THE STEERING COLUMN
AND BEHIND THE 1/P COMPARTMENT DOOR ASSEMBLY.
CONNECTOR FROM TERMINAL "F" TO TERMINAL "C".

HARNESS CONNECTOR FROM TERMINAL "F" TO TERMINAL "B".
REPAIR SHORT FROM CKT 1837

TO CKT 1401.
RECONNECT DUAL POLE ARMING SENSOR.

DISCONNECT DERM.
MEASURE VOLTAGE FROM DUAL POLE ARMING
SENSOR HARNESS CONNECTOR TERMINAL "F" TO
GROUND BY BACKPROBING.
REPAIR SHORT FROM CKT 1837

TOCKT236.


REPLACE DUAL POLE ARMING

7-1-92
NS 15410
TO IGNITION
AIR BAG 15 A
5204
SWITCH ~ 1 1 3 9 A YEL~-......- - - - - - - - - - - - - - - 1 1 3 9 C YEL
.---------1139BYEL_/ \
DERM
IGNITION 1
1139EYEL
.----------------------------236YELJBLK
.--------------------------~1400LTGRN
DUAL
POLE . - - - - - - - - - - - - - - - - - - - - - - - - - 1 4 0 1 P N K
ARMING
SENSOR
14038 WHT/BLK
DRIVER
SOURCE SENSE
PASS. 36 VLR
PASS. SOURCE
SENSE
PASS. SIDE HIGH
PASS. SIDE LOW
347AWHT
DRIVER
INFLATOR
MODULE
DRIVER SIDE
HIGH
DRIVER SIDE
LOW
348F
DKGRN
1751C
PASSENGER
COMPARTMENT
DISCRIMINATING
SENSOR
BLK,WHTl
GROUIIID
6-30-92
NS11316
HISTORY DTC 83
DRIVER RESERVE DIODE SHORTED
Sense" terminal "A5", and "Passenger Source Sense" terminal "A6". When the driver reserve diode is shorted
"Ignition 1" voltage is measured at "Driver 36 VLR" from the forward biased driver ignition diode. When the
voltage measured at "Driver 36 VLR" is within a specified range of "Ignition l" voltage for eight consecutive
"Turn-ON" tests History DTC 83 is set.
Test Conditions: Tested once each ignition during the "Turn-ON" test while the "36 VLR delay" is active.
Failure Conditions: History DTC 83 is set when the voltage measured at "Driver 36 VLR" terminal "A4" is
within a specified range of "Ignition 1" voltage for eight consecutive "Turn-ON" tests and no "higher priority
faults" are detected.
Action Taken: DERM sets a history diagnostic trouble code.
Conditions to Clear: History DTC 83 will clear when the voltage measured at "Driver 36 VLR" terminal
"A4" indicated that the power supply is in a discharged state during "Turn-ON" tests.

due to a shorted driver reserve diode within the
dual pole arming sensor or a malfunctioning
DERM.
1.
HISTORY DTC 83
DRIVER RESERVE DIODE SHORTED

"INTERMITTENTS AND POOR CONNECTIONS" IN SECTION SA-4. WHEN A
~--------------------------~
~-----------------------------~
: GO TO THE "SIR DIAGNOSTIC SYSTEM CHECK". :

DISCONNECT DRIVER AND PASSENGER INFLATOR MODULES, YELLOW 2-WAY CONNECTORS
LOCATED NEAR THE BASE OF THE STEERING COLUMN AND BEHIND THE 1/P COMPARTMENT
DOOR ASSEMBLY.
DISCONNECT DERM.
MEASURE VOLTAGE FROM DUAL POLE ARMING SENSOR HARNESS CONNECTOR TERMINAL "B"
TO GROUND BY BACKPROBING.


REPLACE DUAL POLE ARMING SENSOR, REFER
TO SECTION 9J-B.
MOUNTED.
7-9-92
NS 15411
AIRBAG 15A
TO IGNITION
S204
SWITCH ~ 1 1 3 9 A Y E L ~ - - - - - - - - - - - - - - - - - - 1 1 3 9 C Y E L
. - - - - - - - - - 1 1 3 9 8 YEL__/ \
DERM
IGNITION 1
1139E YEL
~--------------------------236YEUBLK
....-------------------------~1400LTGRN
DUAL
POLE ~ - - - - - - - - - - - - - - - - - - - - - - - 1 4 0 1 P N K
~::J~~
14038 WHT/BLK
1837 LT GRN/WHT
PASS. SIDE HIGH

PASS. SIDE LOW
DRIVER
INFLATOR
MODULE
347AWHT
DRIVER SIDE
HIGH
DRIVER SIDE
LOW
348F
DKGRN
1751C
PASSENGER
COMPARTMENT
DISCRIMINATING
SENSOR
BU<JWHTl
GROUND
6-30-92
NS 11316
HISTORY OTC 84
PASSENGER RESERVE DIODE SHORTED
During the "Turn-ON" tests, performed at the beginning of each ignition cycle, the DERM delays charging of
the "Driver 36 VLR" and "Passenger 36 VLR" power supplies. While the delay is active the DERM measures the
voltage at the "Driver 36 VLR" terminal "A4", "Passenger 36 VLR" terminal "A3", "Driver Source Sense"
terminal "A5" and "Passenger Source Sense" terminal "A6". When the passenger reserve diode is shorted
"Ignition 1" voltage is measured at "Passenger 36 VLR" from the forward biased passenger ignition diode. When
the voltage measured at "Passenger 36 VLR" is within a specified range of "Ignition l" voltage for eight
consecutive "Turn-ON" tests History DTC 84 is set.
Test Conditions: Tested once each ignition cycle during the "Turn-ON" test while the "36 VLR Delay" is
active.
Failure Conditions: History DTC 84 is set when the voltage measured at "Passenger 36 VLR" terminal "A3"
is within a specified range of "Ignition 1" voltage for eight consecutive "Turn-ON" tests and no "higher priority
faults" are detected.
Action Taken: DERM sets a history diagnostic trouble code.
Conditions to Clear: History DTC 84 will clear when the voltage measured at "Passenger 36 VLR" terminal
"A3" indicates that the power supply is in a discharged state during "Turn-ON" tests.

due to a shorted passenger reserve diode within
the dual pole arming sensor or a malfunctioning
DERM.
HISTORY OTC 84
PASSENGER RESERVE DIODE SHORTED
WAS THE "SIR DIAGNOSTIC SYSTEM CHECK" PERFORMED1
r
"INTERMITTENTS AND POOR CONNECTIONS" IN SECTION BA-4. WHEN A
LGO----------------------------,
TO THE "SIR DIAGNOSTIC SYSTEM CHECK." J

YELLOW 2-WAY CONNECTORS LOCATED NEAR THE BASE OF THE
STEERING COLUMN AND BEHIND THE 1/P COMPARTMENT DOOR
ASSEMBLY.
DISCONNECT DERM.
CONNECTOR TERMINAL "C" TO GROUND BY BACKPROBING.
IS VOLTAGE 1 VOLTORLESS1


7-1-92
NS15412
J 38125-A - TERMINAL REPAIR KIT
J 35616-A - CONNECTOR TEST ADAPTER KIT
J 38715 - SIR DRIVER/PASSENGER
SCAN TOOL
LOAD TOOL
3
J 39200 - DIGITAL MULTIMETER

4-8-92
MS 13511
SIR Special Tools
SIR SYSTEM REMOVAL & INSTALLATION 9J-B-1
SECTION 9J-B

(SIR) SYSTEM REMOVAL AND INSTALLATION
CAUTION: The procedures in this section must be followed in the order listed to
temporarily disable the Supplemental Inflatable Restraint (SIR) system and prevent
false diagnostic trouble codes from setting. Failure to follow procedures could result
in possible air bag deployment, personal injury, or otherwise unneeded SIR system
repairs.
the correct part number fastener is not available, a fastener of equal size and strength (or stronger) may
be used. Fasteners that are not reused, and those requiring thread-locking compound will be called out.
The correct torque value must be used when installing fasteners that require it. If the above conditions
are not followed, parts or system damage could result.
CONTENTS
On-Vehicle Service
Service Precautions
Enabling the SIR Sytem
Hand Ii ng/lnstal Iation/Diagnosis
after an Accident
Accident With Deployment Component Replacement
and Inspections
Accident With or Without Deployment
Component Inspections
9J-B-1
9J-B-1
9J-B-1
9J-B-2
9J-B-2
9J-B-2
9J-B-2
9J-B-3
9J-B-3
ON-VEHICLE SERVICE
SERVICE PRECAUTIONS
Wiring Repair 9J-B-3

9J-B-3
Dual Pole Arming Sensor 9J-B-4
Forward Discriminating Sensor 9J-B-5
Discriminating Sensor 9J-B-6
9J-B-7
Passenger lnflator Module
9J-B-7
Deployed lnflator Module 9J-B-7
Driver lnflator Module Section 3F
SIR Coil Assembly
Section 3F5B
"AIR BAG" Warning Lamp Section SC
Fastener Tightening Specifications 9J-B-8

or around SIR components or SIR wiring,
follow the procedures listed below to
temporarily disable the SIR system.
injury, or otherwise unneeded SIR system
repairs.
cause a deployment for up to two minutes after the
disconnection of the AIR BAG fuse and inflator module

circuits from the deployment loops to avoid an

key.
1. AIR BAG fuse from 1/P fuse block.
2. Lower sound insulator panel - left side, refer to
SECTION SC.
2-way connector located near the base of the
steering column.
SC.
5. CPA and yellow 2-way connector from passenger
inflator module.
9J-B-2 SIR SYSTEM REMOVAL & INSTALLATION
rn
Important
With the AIR BAG fuse removed and ignition

switch "ON" the "AIR BAG" warning lamp will be
"ON." This is normal operation and does not
indicate an SIR system malfunction.
REPAIRS AND INSPECTIONS REQUIRED AFTER

AN ACCIDENT
rn
1.

Yellow 2-way connector and CPA to passenger
inflator module.
8C.
3. Yellow 2-way connector and CPA near base of
steering column.
4. Lower sound insulator panel - left side, refer to
SECTION 8C.
5. AIR BAG fuse to 1/P fuse block.
Turn ignition switch to "RUN" and verify that the
"AIR BAG" warning lamp flashes seven times and
then turns "OFF." If it does not operate as
Handling/Installation/Diagnosis
1.
Driver and passenger inflator modules should not

be stored at temperatures above 65C (150F).
2. Discriminating sensors, dual pole arming sensors,
driver and passenger inflator modules, or DERMs
should not be used if they have been dropped from
a height of 91.4 centimeters (3 feet) or more.
3. When a discriminating sensor or a dual pole
arming sensor is replaced, it MUST be oriented
with the arrow on the sensor pointing toward the
front of the vehicle. It is very important for
discriminating sensors and dual pole arming
sensors to be located flat on the mounting surface,
parallel to the vehicle datum line, and that the
sensor mounting surface is free of any dirt or other
foreign material.
4. Do not apply power to the SIR system unless all
components are connected or a diagnostic chart
requests it, as this will set a diagnostic trouble
code.
5. The "SIR Diagnostic System Check" must be the
starting point of any SIR diagnostics~e "SIR
Diagnostic System Check" will lead you to the
correct chart to diagnose any SIR system
Important
If any SIR components are damaged, they must be

replaced. If SIR component mounting points are
damaged, they must be repaired or replaced.
Never use SIR parts from another vehicle. This
does not include remanufactured parts purchased
from an authorized GM dealer; they may be used
for SIR repairs.
Do not attempt to service dual pole arming
sensors, forward discriminating sensors, passenger
compartment discriminating sensors, SIR coil
assemblies, driver inflator modules, passenger
inflator modules or DERMs. Service of these items
is by replacement only.
Verify the part number of replacement inflator
modules. Some GM inflator modules look identical
but contain different internal components.

sensors and Supplemental Inflatable
Rest~aint (SIR) sys~em requires that any
repairs to the vehicle structure return it
to the original production configuration.
Deployment requires, at a minimum,
replacement of the sensors in the area of
accident damage, the inflator modules
and _dimensional inspection of the
steering column. Any visible damage to
the DERM mounting bracket requires
replacement, sensors in the area of
accident damage must be replaced and
the steering column must be
dimensionally inspected, whether
deployment has occurred or not.
Accident With Deployment - Component
Replacement and Inspections
Certain SIR components must be replaced or
inspected for damage after a frontal crash involving
air bag deployment. Those components are:
Driver inflator module.
Passenger inflator module.
[I] Important

replacement in both deployment and nondeployment crashes.
SIR coil assembly - Inspect wiring and

connector for any signs of scorching, melting,
or damage due to excessive heat. Replace if
damaged.

Certain SIR and restraint system components
must be inspected after any crash, whether the air bag
has deployed or not. Those components are:
Steering Column - Dimensionally inspect per
"Checking Steering Column for Accident
Damage" in SECTION 3F5B.
rn
Important

replacement in both deployment and nondeployment crashes.
Also, if a sensor is in an area of accident damage,

but the SIR system has not been deployed, replace the
sensor. The sensor bracket may be slightly bent,
wiring may be damaged, etc. In this case the sensor
might not work properly in another frontal crash.
Again, do not attempt to determine whether a sensor is
OK - ALWAYS replace it if it is in the area of accident
damage.
WIRING REPAIR
Special wiring repair procedures have been
developed for use on the Supplemental Inflatable
Restraint (SIR) system due to the sensitive nature of
the circuitry. These instructions must be followed
whenever servicing the SIR system wiring. Refer to
"Wiring Repair" in SECTION 9J.
DIAGNOSTIC ENERGY RESERVE MODULE

CAUTION: The following procedures
must be followed in the order listed to
temporarily disable the Supplemental
Inflatable Restraint (SIR) system and
prevent false diagnostic trouble codes
from setting.
Failure to follow
procedures could result in possible air
bag deployment, personal injury or
Knee Bolster and Mounting Points - Inspect for

any distortion, bending, or other damage.
I/P Steering Column Reinforcement Plate Inspect for any distortion, bending, cracking or
other damage.
1/P Braces - Inspect for any distortion, bending,
cracking or other damage.
Seat Belts and Mounting Points - Refer to
SECTION 10-11.
NOTICE: Do not open the DERM case for any

reason, touching the connector pins or soldered
components may cause electrostatic discharge
damage. Repair of a malfunctioning DERM is by
replacement only.

SIR sensor replacement policy requires
replacement of the sensors in the area of accident
damage only.
The "area of accident damage" is defined as that
area of the vehicle which is crushed, bent or damaged
in other ways. An example might be a significant
front end collision in which the forward portions of the
vehicle have contacted another vehicle, tree,
guardrail, etc. In this example, the sensor at the front
of the vehicle, on the front end tie bar, would require
replacement, since that portion of the vehicle was
damaged in the accident. Sensors in the passenger
compartment would not require mandatory
replacement. Of course, if the DERM sets a diagnostic
trouble code and the diagnostic chart leads to a
malfunctioning sensor that was not in the area of
accident damage, that sensor should also be replaced.
Sensors in the area of accident damage should be
replaced even if those sensors do not appear to be
damaged. Do not attempt to determine whether a
sensor is OK - ALWAYS replace it if it is in the area of
accident damage.
Disable SIR system. Refer to "Disabling the SIR

1. Lower sound insulator pad - right side, refer to
SECTION SC.
2. I/P compartment door assembly.
3. Connector Position Assurance (CPA) and electrical
connector.
4. DERM from vehicle.
!++j Install or Connect

1.
2.
3.
4.
DERM in vehicle.
Electrical connector and CPA.
I/P compartment door assembly.
Lower sound insulator pad - right side, refer to
SECTION 8C.
Enable SIR system, refer to "Enabling the SIR

HVACDUCT
FASTENERS
DERM
SIR WIRING HARNESS
SIR WIRING HARNESS
FLOOR TUNNEL
NS 16200
NS 16199
Figure 2 - Dual Pole Arming Sensor
Figure 1 - Diagnostic Energy Reserve Module

CAUTION: During service procedures,
be very careful when handling a sensor.
deployment.
from setting.
Failure to follow
Disable SIR system, refer to "Disabling the SIR

1. Center console, refer to SECTION 8C.
connector.
3. Sensor fasteners.
4. Sensor from vehicle.
[I] Important
The following procedures should be utilized in

the event that sensor mounting holes or
fasteners are damaged to the extent that the
sensor can no longer be properly mounted.
It is important that the fasteners do not have
any oil or other foreign material on them. Oil
will damage the plastic on the VP console.
First Repair
Install fastener (part# 11504352).
l~I Tighten
Fastener to 6.5 Nm (58 lb. in.).

Second Repair
2
l~I Tighten
j++j Install or Connect
Fastener to 3 Nm (27 lb. in.).
1. Sensor in vehicle.
l~I Tighten
Fasteners to 4.5 Nm (40 lb. in.).
3. Electrical connector and CPA.
4. Center console, refer to SECTION SC.
FASTENERS
Caution should be used to assure proper location of

sensors to the mounting brackets. The keying of the
sensors through the wiring harness connectors must
not be modified for any reason.

connector.
FRONT END TIE BAR ASSEMBLY
SIR WIRING HARNESS

NS 16201

deployment.
from setting.
Failure to follow
otnerwise unneeded SIR system repairs.
Figure 3 - Forward Discriminating Sensor

forward discriminating sensor requires
the sensor be rigidly attached to the
vehicle structure and that the arrow on
the sensor be pointing toward the front
of the vehicle.
[I] Important

First Repair
1.
2.
Drill 7.4 mm (19/64 inch) hole into clinch nut.

l~I Tighten
Second Repair
1.
2.
Drill 8.5 mm (21/64 inch) hole into clinch nut.

l~I Tighten
1-++I
Install or Connect

Sensor in vehicle.
Sensor fasteners.
1.
2.
3.
l~I Tighten
Fasteners to 10 N m (89 lb. ft.).
PASSENGER COMPARTMENT
deployment.
from setting.
Failure to follow

connector.

passenger compartment discriminating
sensor requires the sensor be rigidly
attached to the vehicle structure and that
the arrow on the sensor be pointing
toward the front of the vehicle.
(I] Important

BODY MOUNT STUDS

2
FASTENER
SIR WIRING HARNESS
PASSENGER COMPARTMENT
STEERING COLUMN SUPPORT BRACKET

NS 16202
Figure 4 Passenger Compartment Discriminating

Sensor

It is important that the fasteners do not have
any oil or other foreign material on them. Oil
will damage the plastic on the UP console.
First Repair
1.
2.
3.
Drill 3.5 mm (1/8 inch) hole through sensor and

cowl.
Enlarge sensor hole to 5 mm (3/16 inch).
l~I Tighten
Second Repair
1.
2.
3.
Grind off stud flush with panel.

Drill 5.6 mm (7/32 inch) hole in center of stud.
I~! Tighten
!-++!
1.
Install or Connect
Sensor in vehicle.

2.
Sensor fasteners.
l~I Tighten
Fasteners to 10 Nm (89 lb. in.).
3. Electrical connector and CPA.

from setting.
Failure to follow
1/P TRIM PAD
Special care is necessary when handling and

storing a live (undeployed) inflator module because the
rapid deployment of the bag could cause the inflator
module or an object placed in front of the module to be
thrown through the air in the unlikely event of an

1. I/P carrier assembly, refer to SECTION 8C.
connector.
3. Fasteners from inflator module.
4. Inflator module from vehicle.
SIR BRACKET ASSEMBLY
NS 11320
Figure 5 Passenger lnflator Module
CAUTION: When carrying a live inflator

module, make sure the bag is pointed
away from you. Never carry the inflator
module by the wires or connector on the
side of the module. In case of an
accidental deployment, the bag will then
deploy with minimal chance of injury.
When placing a live inflator module on a
bench or other surface, always face the
bag up, away from the surface. This is
to allow the air bag to expand in the
unlikely event of accidental deployment,
otherwise personal injury may result.
Deployed lnflator Module

After the inflator module has been deployed, the
present after deployment. As with many procedures,
you should wear gloves and safety glasses.
l++j Install or Connect

1.
2.
lnflator module in vehicle.

Fasteners on inflator module.
l~I Tighten
3.
4.
Fasteners to 2.8 Nm (25 lb. in.).

I/P carrier assembly, refer to SECTION 8C.
FASTENER TIGHTENING
SPECIFICATIONS
Driver Inflator Module
Fasteners
Dual Pole Arming Sensor
Fasteners
Forward Discriminating Sensor
Fasteners
Discriminating Sensor
Passenger Inflator Module
Fasteners
2.8 Nm (25 lb. in.)

4.5 Nm (40 lb. in.)
10 Nm (89 lb. in.)
10 Nm (89 lb. in.)
2.8 Nm (25 lb. in.)
REMOTE KEVLESS ENTRY 9K1
SECTION 9K
REMOTE KEYLESS ENTRY

result.
[I] Important
The Remote Keyless Entry System is intended to be used as a supplementary vehicle entry device. It is not intended to
replace, but rather should be used in conjunction with a door lock key. The system could be disabled due to radio
frequency interference or low transmitter battery power level. It is therefore necessary to always maintain access to a
door lock key.
CONTENTS
Functional Operation .......... , . . . . . . . . . .
Transmitter Assembly ....................
Battery Replacement . . . . . . . . . . . . . . . . . . .
_Recei~er Assembly ......................
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9K-1
9K-1
9K-1
9K-1
9K-2
9K-4
GENERAL DESCRIPTION
The remote keyless entry system (remote control
door lock system) is used to lock and unlock front side
doors and release the rear compartment lift window panel
assembly of the vehicle. The system will also turn on the
interior lights for about 40 seconds, or until the ignition
switch assembly is turned to "RUN," when the doors are
unlocked and for about two seconds when the doors are
locked. A small receiver assembly is installed in a pocket
on the right-hand hinge pillar. The receiver assembly
operates on a 315 MHz radio frequency at a low energy
level and complies with FCC rules Part 15. Operation is
subject to the following two conditions: (1) This device
may not cause harmful interference, and (2) This device
must accept any interference that may be received, including interference that may cause undesired operation.
The transmitter assembly is a hand-held item that is
attached to a key ring. It has three buttons that control the
functions of the system. If the remote lock control feature
fails to operate from a normal distance, check for two
conditions: weak batteries in remote lock control transmitter assembly (expected battery life is two years); or
close proximity to a radio transmitter, such as a radio
station tower, airport transmitter, and some mobile or CB
radios.
FUNCTIONAL OPERATION
Figure 1
To Unlock Doors
1. Press "UNLOCK" button once and release to
unlock driver's front side door only.

Receiver Assembly .....................
Programming Receiver Assembly ........
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fastener Tightening Specifications . . . . . . . . .
9K-17
9K-17
9K-17
9K-17
9K-17
2. Press "UNLOCK" button a second time (within 1 to

5 seconds of first depression) to unlock remaining
door.
To Release Rear Compartment Lift Window

Panel Assembly
Press bottom button marked with vehicle symbol on
top cover to release rear compartment lift window
panel assembly.
To Lock Doors
Press "DOOR" button marked with key symbol.
TRANSMITTER ASSEMBLY
The transmitter assembly will transmit a radio signal, which will control functions of the receiver assembly.
The range is approximately 7 to 10 m (22 to 33 feet).
Battery Replacement
Figure 1
!+-+I Remove or Disconnect

1. Key ring from transmitter assembly.
2. Screw from bottom cover, if equipped.
3. Top cover from bottom cover, using a flat-bladed
tool at eyelet end to unsnap, if necessary.
4. Batteries.
9K-2 REMOTE KEYLESS ENTRY
B
A
NOTICE: Use of wrong type of battery will cause

damage to the transmitter assembly.
(/)
... a:
1. Batteries.
-'O
<o
c
Use battery type DL2016, or equivalent.

2. Top cover by snapping into bottom cover.
DOOR
3. Screw to bottom cover, if equipped.

4. Key ring to transmitter assembly.
lll
1nspect
Transmitter assembly operation.
RECEIVER ASSEMBLY
The remote control door lock receiver assembly is
battery fed and is always monitoring the transmitter signal. When the correct transmitter signal is received to lock
the doors, a transistor driver will energize the correct lock
control relay coil. The receiver assembly will also control
which lock control relays will be energized to unlock the
doors, or release the rear compartment lift window panel
assembly.
A TOPCOVER
13 BOTTOM COVER
C SCREW
PC2001-9K-F-RP
Figure 1 - Remote Control Door Lock Transmitter Assembly

(Typical)
REMOTE KEVLESS ENTRY 9K-3
BLANK
ELECTRICAL DIAGNOSIS: AUO

HOT IS ACCY, RUN OR DURING
----,
rsE7PO-;:;E;;- DISTRIBUTION
PAGE SA-10-2
I
I
I
I
\
L----
.8 ORN
640
.SORN
----------..J
81! ........................................................."""640
.8 ORN 1640
,L C200D
&
9
.SORN
C200C
PSOO
.8 ORN
. . . . . . .640--...
.
,
-------------
ssoo
640
r-~------~""!11~------~--.. . PowER
r---------~.....,,....~----~~-.powER
DOOIILOCK
SWITCH.RH
DOORLOCK
SWITCH, LH
SEE GROUND
DISTRIBUTION
PAGE SA-14-7
.8 DK BLU
5220
-----1111(, -
245
BL;
.8 BLK
3 BLK
, ...
s_o_ _ __
750
_L~200
750
RELAY
,,.. '
,,.. '
!!
--LOCK
ALL
---
UNLOCK
DRIVER
295
RELAY
/!]
.8 TAN
294
GROUND
ILLUM
!NATION
OUTPUT
LOW
ILLUM!NATION
UNLOCK
ALL
KEY LESS
ENTRY
RECEIVER
.8 GRY
,,..,
,,.. '
BATIERY
UNLOCK
ALL
OUTPUT
LOW
.8GRY
295
DOORLOCKr""~----------:~-,
ACTUA TOR, LH
rn
l"'"""'..............
-,"'""IDOORLOCK
ACT~TOR, RH
IMPORTANT:
EACH MOTOR CONTAINS

BREAKER (ECB).

TERMINALS.
UNLOCK
DRIVER
OUTPUT
LOW
LOCK
ALL
OUTPUT
LOW
650
REMOTE KEYLESS ENTRY 9K-5
HOT AT ALL TIMES
~----
- -- -,u,
SEE POWER
DISTRIBUTION
\ PAGE8A-10-3
FUSE
I BLOCK
F
~I
15AMP
I
COURTESY
IGN
(NOTUSEO)
__ J
'-.SORN
640
.8 PNK
39
1 ORN
40
.5 ORN
r -
5206--,
.35PNK
A
---=--
39
SEE FUSE
BLOCK DETAILS
PAGE 8A-11-4
40
5210
SEE FUSE
BLOCK DETAILS
PAGE8A-11-7
.8 ORN
40
~~T.
E3
,.w .. - ..
...: : ,, ----- w~...
MIRROR
"111111
PAGE8A-114-0
C200D
SEE INTERIOR
LIGHTS
PAGE 8A-114-0
40
QOO<
tI
40
.5 ORN
5265
40
----
.5 ORN
.35 WHT
----411)- -
156
5262
.5 WHT
A ciooc
156
El
IGNITION
ON INPUT
r-+---+---"'I RELAY
8.5V
SOLID STATE
,...,
.5WHT
156
ta
LOGIC
HATCH
RELEASE
OUTPUT
LOW
.5WHT
C200Q
156
B
HATCH
RELEASE
5111/ITCH
.__
HATCH
RELEASE
.5 BLK
A
.5 BLK
SEE GROUND
DISTRIBUTION
PAGE 8A-14-8
1576
3 BLK
650
3 BLK
650
HATCH
RELEASE
ACTUATOR
A2y
.5BLK1WHT
--56----~8
.8 ORN1BLK 1434 {AUTOMATIC)
_
.15 TAN;WHT H (MANUAL)
II
GROUND PATH THROUGH

OR PARK BRAKE SWITCH
PAGE 8A 135-0_._
SEE GROUND
DISTRIBUTION
PAGE SA-14-11
1550
~ Ci:? 'i:? ct?
dJ~rlJc2]
12064998
12064766

BLU
BLK
12004680
BLKJWHT
SECTION
8A-201-PG
FIG.
COMPONENT
LOCATION
Mounted to I/P Tie Bar, below and right of

Steering Column ............................................... . 202-11
On roof, near hatch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 . . . . . . 6
Inside rear of left door .. .. .. .. .. .. .. .. .. .. .. .. .. .. 17
31
Inside rear of right door . . . . . . . . . . . . . . . . . . . . . . . . . . 17 .... . 31
Center of end panel, in Cargo Compartment . . . . . . . . 30 .... . 47
Mounted to right side of SIR Bracket, behind 1/P . . . . 45
66 .. 202-20
Left of Steering Column, in knee bolster pad . . . . . . . 38 .... . 57
Lower LH side ofl/P . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 .... . 57 .. 202-22
LH side of I/P Carrier, on the side . . . . . . . . . . . . . . . . . 8 ..... . 15 .. 202-22
Behind RH side kick panel, in molded pocket . . . . . . . 42
61 .. 202-22
Mounted in left door armrest . . . . . . . . . . . . . . . . . . . . . 18 .... . 33 .. 202-23
Mounted in right door armrest . . . . . . . . . . . . . . . . . . . . 18 .... . 33 .. 202-23
47
Center of end panel, in Cargo Compartment . . . . . . . . 30
72 .. 202-2
Steering Column . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Steering Column . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 . . . . . 72 .. 202-2
UnderRHsideofl/P,behindkickpanel ............ 46 ..... 67 .. 202-16
Dome Lamp ............ .

Door Lock Actuator, LH ..
Door Lock Actuator, RH ..
Hatch Release Actuator .. .
Hatch Release Relay .... .
Hatch Release Switc;h ... .
I/P Dimmer Switch ...... .
I/P Fuse Block .......... .
Key less Entry Receiver .. .
Rear Dome Light Switch ..
C200C (13 cavities)
C200D (48 cavities)
C240 (6 cavities) ........ .
CONN
COMPONENT
G200
G400
P500
P600
8206
8210
8211
8244
8262
8265
8500
8504
SECTION
8A-201-PG
LOCATION
Near base of LH "A" pillar, bolted to 1/P
Mounting Stud behind kick panel (2 rings, 2 wires)
9 ......
Bolted to Hatch Release Bracket in Rear
Compartment (2 rings, 3 wires) . . . . . . . . . . . . . . . . . . 30
Between LH door and "A" pillar . . . . . . . . . . . . . . . . . . . 32
Between RH door and "A" pillar . . . . . . . . . . . . . . . . . . . 32
breakout
Main Harn
1/P Harn, approx 7 cm from DERM Module breakout
breakout ..................................... . 32 .....
Mirror breakout
Cross Car Harn, approx 6 cm from Speaker breakout
17
Speaker breakout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
FIG.
CONN
16
47
49
49
49
31
31
Fora Service Part Cross Reference List and Information, refer to SECTION SA-200.
Diagnosis)
1. Check Fuses 7 and 8 in 1/P Fuse Block. If open,
refer to Chart #3.
2. Check for a poor connection at G200.
3. If the Transmitter fails to operate from a normal
distance, up to 7 to 10 meters (22 to 33 ft.), check
for two conditions: weak batteries in Transmitter
(expected life approximately 2 years depending on
use); or close proximity to a Radio Transmitter,
such as a Radio Station Tower, airport
Transmitter, and some mobile or CB Radios.
4. Try a second Transmitter if available. If the
second Transmitter works, remove the Battery and
install the Battery in the original Transmitter.
Try the original Transmitter again. If the original
Transmitter still does not work, it is defective.

SYSTEM DIAGNOSIS
procedures.

SYSTEM CHECK
NORMAL RESULTS
ACTION
[ 1]
Doors closed .
Vehicle in Park (Automatic) .
Parking Brake applied (Manual) .
Cycle Ignition to "RUN," then back to "OFF."
rn
Important:
Because of the Retained Accessory Power (RAP)
time out, Steps 1 through 4 must be done within
10 minutes after cycling Ignition and without
opening doors.
LH or RH Door Lock Switch to "LOCK."
Doors lock.
LH or RH Door Lock Switch to "UN LOCK."
Doors unlock.
Push Hatch Release Switch .
Hatch releases.
[2]
[3]
[4)
Open door .
LH or RH Door Lock Switch to "LOCK" (must be Doors lock.
done within 35 seconds of opening door because
of RAP).
[SJ
Exit vehicle, close door and hatch .

Press Door Unlock Button on Transmitter .
LH door unlocks and Interior Lights illuminate.
[6]
Press Door Unlock Button a second time within 5 RH door unlocks, Interior Lights will stay illuminated
for approximately 40 seconds from first press of
seconds of first press.
Unlock Button or until Ignition is turned "ON."
[7)
Wait for Interior Lights to go out .

Press Door Lock Button on Transmitter .
Doors lock and Interior Lights illuminate for

approximately 2 seconds to acknowledge locking of
doors.
Press Hatch Button on Transmitter .
Hatch Releases and Interior Lights illuminate for

approximately 40 seconds.
[8]
SYMPTOM TABLE
{Perform System Check to see what functions operate
before reading through Symptom Table)
SYMPTOM
PROCEDURE
PAGE NUMBER
All functions of Transmitter are inoperative.

Functions operate normally from switches.
Chart #1
9K-11
Keyless Entry Receiver/Transmitter will not program.
Chart #2
9K-11
Attempts to use Power Door Locks after replacing a

blown "PWR ACCY" Fuse 7 and/or "Courtesy" Fuse 8
continue to blow fuse.
Chart #3
9K-12
GENERAL
All functions of Transmitter and Power Door Locks Check for open in ground CKT 750 between 5220 and
G200, or poor connection at G200. If OK, replace
totally inoperative, Fuses 7 or 8 are not blown.
Keyless Entry Receiver.
POWER DOOR LOCKS

Power Door Locks totally inoperative from both
Power Door Lock Switches and from Transmitter.
Transmitter operates Dome Lamp and Hatch Release
normally.
Check CKT 295 for an open between 5504 and Keyless

Entry Receiver connector C2 terminal "C", or for poor
connection to Receiver. If OK, replace Receiver.
(Verify Actuator operation before replacing Receiver.
Apply B+ and ground momentarily across
disconnected connector C2 terminals "(" and "G",
then "C" and "H" .)
Power Door Locks inoperative from Transmitter only.

Locks operate normally from Power Door Lock
Switches (Hatch Release and Dome Lamp operate
normally from Transmitter).
Program a known good Transmitter (see procedure on

page 9K-16) and test the Keyless Entry System. If the
Door Lock Actuators operate normally, the original
Transmitter was defective. If the problem still exists,
replace the Keyless Entry Receiver.
Power Door Locks totally inoperative from both Check for open in CKT 640 between 5500 and Fuse 7,
Power Door Lock Switches. Locks operate normally or open in Fuse 7. If Fuse 7 is open, check for a short to
ground through CKT 640.
from Transmitter.
Power Door Locks operate from one Power Door Lock Check for open in CKT 640 between terminal "A" of
Switch only.
Locks operate normally from suspect switch and 5500, or for poor connection to
switch. If OK, replace suspect switch.
Transmitter.
Lock function inoperative from both Power Door Lock Check for open in CKT 750 between 5220 and RH
Switches and from Transmitter. Unlock function Power Door Lock Switch connector terminal "B". If
OK, replace RH Power Door Lock Switch.
operates normally.
Unlock function inoperative from both Power Door Check for open in CKT 750 between 5220 and RH
Lock Switches and from Transmitter. Lock function Power Door Lock Switch connector terminal "E". If
OK, replace RH Power Door Lock Switch.
operates normally.
Lock function operates from LH Power Door Lock
Switch and Transmitter only. Unlock function and RH
Power Door Lock Switch totally inoperative.
Chart #4
9K-12
Unlock function operates from LH Power Door Lock

Switch and Transmitter only. Lock function and RH
Power Door Lock Switch totally inoperative.
Chart #5
9K-1'2

SYMPTOM TABLE
SYMPTOM
PROCEDURE
PAGE NUMBER
Lock function operates from Transmitter only. Unlock

function and both Power Door Lock Switches totally
inoperative.
Chart #6
9K-13
Unlock function operates from Transmitter only. Lock

function and both Power Door Lock Switches totally
inoperative.
Chart #7
9K-13
LH Door Lock Actuator inoperative from Transmitter

and Door Lock Switches (RH Actuator OK).
Chart #8
9K-14
LH Door Lock Actuator inoperative from Transmitter Replace Keyless Entry Receiver.
only. Operates normally from Lock Switches (RH
Actuator operates normally from Transmitter).
RH Door Lock Actuator inoperative from Transmitter
and Door Lock Switches (LH Actuator OK).
Chart #9
9K-14
RH Door Lock Actuator inoperative from Transmitter Replace Keyless Entry Receiver.
only. Operates normally from Lock Switches (LH
Actuator operates normally from Transmitter).
DOME LAMP
Dome Lamp will not turn "ON" when Door Locks are Check for open in CKT 156 between Keyless Entry
locked or unlocked using Transmitter. Lamp operates Receiver and 5262, or for poor connection at
connector C2 terminal "D" of Receiver. If OK, replace
normally from switches.
Keyless Entry Receiver.
Dome Lamp will not turn "ON" using switches or See "Interior Lights," page SA-114-0.
Transmitter.
Dome Lamp does not turn off immediately after
Ignition is turned to "RUN," "BULB TEST" or "START."
(Dome Lamp should stay on for 40 seconds from first
press of Unlock Button on Transmitter or until Ignition
is turned "ON.")
Check for open in CKT 39 or poor connection at

connector Cl terminal "D". If OK and B+ is present at
connector C1 terminal "D" with Ignition "ON,"
replace Keyless Entry Receiver.
HATCH ACTUATOR
Hatch Release Actuator inoperative from Hatch See "Hatch Release," page SA-135-0.
Release Switch. Hatch Release operates normally
from Transmitter.
Hatch Release Actuator inoperative from Transmitter.
Hatch Release operates normally from Hatch Release
Switch (all other Transmitter functions normal).
Chart #10
Hatch Release Actuator inoperative from Hatch See "Hatch Release," page SA-135-0.
Release Switch and from Transmitter.
9K-15
CHART #1
ALL FUNCTIONS OF TRANSMITTER ARE INOPERATIVE.
FUNCTIONS OPERATE NORMALLY FROM SWITCHES.
PROGRAM A KNOWN GOOD TRANSMITTER (SEE PROCEDURE ON

PAGE 9K-16), AND TEST THE KEYLESS ENTRY SYSTEM.
DID THE KEYLESS ENTRY SYSTEM OPERATE NORMALLY?
DISCONNECT RECEIVER CONN C2.

CONNECT TEST LIGHT ACROSS CONN C2
TERMINALS "E" AND "F".
IS TEST LIGHT "ON"?
REPAIR OPEN OR BAD CONNECTION IN

CKT 40 TO FUSE 8, OR OPEN IN CKT 750
BETWEEN 5220 AND CONN C2 TERM ''E''.
THE ORIGINAL TRANSMITTER WAS

DEFECTIVE OR HAD A BAD BATTERY.
DISCONNECT RECEIVER CONN C1.

CHECK CKT 1455 TO THE DLC FOR AN OPEN OR
SHORT TO GROUND. (IFAN ATTEMPT WAS MADE TO
PROGRAM A NEW TRANSMITTER AND CKT 1455 WAS
LEFT GROUNDED, THE SYSTEM WILL NOT OPERA TE.)
IF CKT 1455 IS OK, CHECK FOR GOOD CONNECTIONS
TO THE KEYLESS ENTRY RECEIVER.
IF OK, REPLACE RECEIVER.
CHART #2
KEY LESS ENTRY RECEIVER/TRANSMITTER WILL NOT PROGRAM
(ASSUMES ORIGINAL TRANSMITTER WAS TRIED WITH A NEW BATTERY)
MEASURE THE VOLTAGE FROM DATA LINK CONNECTOR (DLC)

TERM "G" TO GROUND.
IS THE VOLTAGE APPROXIMATELY 8.5 VOLTS (7 TO 9 VOL TS)?
I
[$]
PROGRAM A KNOWN GOOD TRANSMITTER (SEE

PROCEDURE ON PAGE 9K-16) AND TEST THE KEYLESS
ENTRY SYSTEM.
IF THE KEYLESS ENTRY SYSTEM OPERATES NORMALLY,
THE ORIGINAL TRANSMITTER WAS DEFECTIVE.
IF THE KEYLESS ENTRY RECEIVER DOES NOT PROGRAM
USING A KNOWN GOOD TRANSMITTER, REPLACE THE
RECEIVER. (BE SURE TO UNGROUND CKT 1455 BEFORE
TESTING TRANSMITTER. THE SYSTEM WILL NOT
OPERATE WITH TERM "G" OF THE DLC GROUNDED.)
CHECK FOR AN OPEN, SHORT TO B + OR A SHORT TO

GROUND IN CKT 1455 TO THE DLC, OR FOR A POOR
CONNECTION TO THE KEYLESS ENTRY RECEIVER.
IF OK, REPLACE RECEIVER. (IF THE VOLTAGE AT THE
DLC TERM "G" WAS NOT 8.5 VOL TS BUT WAS
WITHIN A COUPLE OF VOL TS, TRY PROGRAMMING A
KNOWN GOOD TRANSMITTER BEFORE REPLACING
KEYLESS ENTRY MODULE.)

CHART #3
ATTEMPTS TO USE POWER DOOR LOCKS AFTER REPLACING A BLOWN "PWR ACCY" FUSE 7
AND/OR "COURTESY" FUSE 8 CONTINUE TO BLOW FUSE

DOES FUSE BLOW BEFORE ATTEMPTING TO OPERATE
POWER DOOR LOCK SWITCHES OR TRANSMITTER?
TEST POWER DOOR LOCK SYSTEM ONE FUNCTION AT A

TIME, INCLUDING TRANSMITTER, UNTIL FUSE BLOWS.
WHEN FUSE BLOWS, USE SCHEMATIC TO DETERMINE
WHAT CIRCUITS OR COMPONENTS COULD BE FAILING.
USE A TEST LIGHT OR DVM TO NARROW IN ON SHORT
TO GROUND POTENTIAL.
DISCONNECTING COMPONENTS IS HELPFUL WHEN
TRYING TO CHECK CIRCUITS THAT SHOULD NOT BE AT A
GROUND POTENTIAL.
CHART #4
CHART #5
UNLOCK FUNCTION OPERATES FROM LH POWER
DOOR LOCK SWITCH AND TRANSMITTER ONLY.
LOCK FUNCTION AND RH POWER DOOR
LOCK SWITCH TOTALLY INOPERATIVE.
DISCONNECT BOTH POWER DOOR LOCK SWITCHES.

CHECK FOR OPEN IN CKT 244 OR FOR POOR
CONNECTION AT EITHER SWITCH CONNECTOR.
ARE CIRCUIT AND CONNECTIONS OK?
CHECK BOTH POWER DOOR LOCK

SWITCHES FOR GOOD INTERNAL
CONTACTS.
EITHER TERM "E" OR TERM "C" OF
THE SWITCH. CONNECT THE OTHER
TERMINAL TO GROUND. MOVE
SWITCH FROM "REST" POSITION TO
"UNLOCK" POSITION.
TEST LIGHT SHOULD ILLUMINATE AT
"REST" AND "UNLOCK" POSITION.
IF NOT, REPLACE DEFECTIVE SWITCH.
USE SCHEMATICS AND DVM TO CHECK SUSPECT POWER CIRCUITS

FOR A SHORT TO GROUND POTENTIAL, EITHER THROUGH A
FAUL TY COMPONENT OR IN WIRING .
CONNECT A DVM SET TO VOLTAGE ACROSS FUSE TERMINALS.
START BY DISCONNECTING ONE COMPONENT AT A TIME.
IF All RELATED COMPONENTS ARE DISCONNECTED AND SHORT IS
STILL PRESENT, LOCATE AND REPAIR SHORT IN WIRING.
LOCK FUNCTION OPERA TES FROM LH POWER DOOR

LOCK SWITCH AND TRANSMITTER ONLY.
UNLOCK FUNCTION AND RH POWER DOOR
LOCK SWITCH TOTALLY INOPERATIVE.
REPAIR CIRCUIT OR
CONNECTION AS
NECESSARY.
DISCONNECT BOTH POWER DOOR LOCK SWITCHES.

CHECK FOR OPEN IN CKT 245 OR FOR POOR
CONNECTION AT EITHER SWITCH CONNECTOR.
CHECK BOTH POWER DOOR LOCK

SWITCHES FOR GOOD INTERNAL
CONTACTS.
EITHER TERM "B" OR TERM "D" OF
THE SWITCH. CONNECT THE OTHER
TERMINAL TO GROUND. MOVE
SWITCH FROM "REST" POSITION TO
"UNLOCK" POSITION.
TEST LIGHT SHOULD ILLUMINATE AT
"REST" AND "UNLOCK" POSITION.
IF NOT, REPLACE DEFECTIVE SWITCH.
REPAIR CIRCUIT
OR CONNECTION
AS NECESSARY.
CHART #6
LOCK FUNCTION OPERATES FROM TRANSMITTER ONLY.
UNLOCK FUNCTION AND BOTH POWER DOOR LOCK SWITCHES TOTALLY INOPERATIVE.
DISCONNECT LH POWER DOOR LOCK SWITCH.

DISCONNECT KEYLESS ENTRY RECEIVER CONN C2.
CHECK CKT 780 FOR AN OPEN OR POOR CONNECTION.
CONNECT A TEST LIGHT FROM B + TO LH POWER DOOR LOCK SWITCH TERM "E" OR
TERM"("'. CONNECT THE OTHER TERMINAL TO GROUND. TEST LIGHT SHOULD BE
"ON" WITH SWITCH IN "REST" POSITION.
MOVE SWITCH FROM "LOCK" TO "UNLOCK" A COUPLE OF TIMES.
IS TEST LIGHT ALWAYS "ON" WHENEVER SWITCH IS LEFT IN THE "REST" POSITION?
REPAIR CIRCUIT OR CONNECTION

AS NECESSARY.
CHECK FOR POOR CONNECTION TO KEYLESS

ENTRY RECEIVER AT CONN C2 TERM "B'".
IF OK, REPLACE KEYLESS ENTRY RECEIVER.
CHART #7
UNLOCK FUNCTION OPERATES FROM TRANSMITTER ONLY.
LOCK FUNCTION AND BOTH POWER DOOR LOCK SWITCHES TOTALLY INOPERATIVE.
DISCONNECT LH POWER DOOR LOCK SWITCH.

DISCONNECT KEYLESS ENTRY RECEIVER CONN C2.
CHECK CKT 781 FOR AN OPEN OR POOR CONNECTION.
CONNECT A TEST LIGHT FROM B + TO LH POWER DOOR LOCK SWITCH TERM "D" OR
TERM "B". CONNECT THE OTHER TERMINAL TO GROUND. TEST LIGHT SHOULD BE
"ON" WITH SWITCH IN "REST" POSITION.
MOVE SWITCH FROM "LOCK" TO "UNLOCK" A COUPLE OF TIMES.
IS TEST LIGHT ALWAYS "ON" WHENEVER SWITCH IS LEFT IN THE "REST" POSITION?
CHECK FOR POOR CONNECTION TO KEYLESS

ENTRY RECEIVER AT CONN C2 TERM "A".
REPAIR CIRCUIT OR CONNECTION

AS NECESSARY.

CHART #8
LH DOOR LOCK ACTUATOR INOPERATIVE FROM TRANSMITTER AND
DOOR LOCK SWITCHES (RH ACTUATOR OK)
IGNITION SWITCH TO "ACCY".

BACKPROBE WITH A TEST LIGHT ACROSS KEYLESS
ENTRY RECEIVER CONN C2 TERMINALS"(" AND "G".
LOCK AND UNLOCK DOORS FROM SWITCHES.
IS TEST LIGHT "ON" WHEN SWITCHES ARE OPERATED?
DISCONNECT LH DOOR LOCK ACTUATOR.

CONNECT TEST LIGHT ACROSS CONN TERMINALS "A" AND "B".
CHECK FOR POOR CONNECTION TO ACTUATOR.

IF OK, REPLACE ACTUATOR.
REPAIR OPEN IN EITHER CKT 694 BETWEEN

ACTUATOR AND RECEIVER, OR IN CKT 295
BETWEEN ACTUATOR AND 5504.

TO KEYLESS ENTRY RECEIVER.
CHART #9
RH DOOR LOCK ACTUATOR INOPERATIVE FROM TRANSMITTER AND
DOOR LOCK SWITCHES (LH ACTUATOR OK)
IGNITION SWITCH TO" ACCY".

BACKPROBE WITH A TEST LIGHT ACROSS KEYLESS
ENTRY RECEIVER CONN C2 TERMINALS "C" AND "H".
DISCONNECT RH DOOR LOCK ACTUATOR.

CONNECT TEST LIGHT ACROSS CONN TERMINALS" A" AND "B".

TO KEYLESS ENTRY RECEIVER.
CHECK FOR POOR CONNECTION TO ACTUATOR.

IF OK, REPLACE ACTUATOR.
REPAIR OPEN IN EITHER CKT 294 BETWEEN

ACTUATOR AND RECEIVER, OR IN CKT 295
BETWEEN ACTUATOR AND 5504.
CHART #10
HATCH RELEASE ACTUATOR I NOPE RA TIVE FROM TRANSMITTER. HATCH RELEASE OPERATES NORMALL y
FROM HATCH RELEASE SWITCH (ALL OTHER TRANSMITTER FUNCTIONS NORMAL).
PROGRAM A KNOWN GOOD TRANSMITTER (SEE PROCEDURE ON PAGE 9K-16),

AND CHECK THE HATCH RELEASE FUNCTION.
DOES HATCH RELEASE OPERATE NORMALLY FROM TRANSMITTER?

KEYLESS ENTRY RECEIVER AND S244, OR FOR
POOR CONNECTION TO RECEIVER OR AT C200.
CIRCUIT OPERATION
The Keyless Entry Receiver is designed with an
internal antenna. The Receiver picks up transmitted
Radio frequencies from a hand held Transmitter with
sufficient power to operate the system from up to 7 to
10 meters (22 to 33 ft.) from the Receiver.
TRANSMITTER FUNCTIONS
Lock
When the Lock Button is pressed, the Receiver

grounds the "Lock All" coil of Relay #1, causing both
Door Lock Actuators to lock. The Receiver also
grounds the "Illumination" coil of Relay #2 for two
seconds. This provides visual confirmation that a lock
function was performed.
Unlock
When the Unlock Button is pressed once, the

Receiver grounds the "Unlock Driver" coil of Relay #1,
causing the Left Hand Door Lock Actuator to unlock.
To provide an illuminated entry, the Receiver also
grounds the "Illumination" coil of Relay #2 for forty
seconds or until the Receiver sees an Ignition "ON"
input.
When the Unlock Button is pressed twice, the
second must be within five seconds of the first, the
Receiver grounds the "Unlock All" coil of Relay #2,
causing both actuators to receive unlock signals.
Hatch Release
When the Hatch Release Button is pressed, the

Receiver grounds the "Hatch Release" coil of Relay #3.
With Relay #3 closed, the Hatch Release Relay is
energized and applies battery voltage to the Hatch

Release Actuator, releasing the Hatch. To provide
hatch area illumination, the Receiver also grounds the
"Illumination" coil of Relay #2 for forty seconds or
until the Receiver sees an Ignition "ON" input. The
Hatch Release Function operates only when the
vehicle is in park or neutral (Automatic Transmission)
or the Parking Brake is applied (Manual
Transmission). The Hatch Release Function is
disabled as soon as the Keyless Entry Receiver sees an
Ignition "ON" input.
Illuminated Entry Operation
The Keyless Entry Receiver provides a ground to

turn on the Dome Lamp for illuminated entry
whenever a Transmitter request is received.
With a "Lock" request, the Dome Lamp is
turned on for two seconds to provide visual
confirmation that a lock function was
performed.
With an "Unlock'' or "Hatch Release" request,
the Dome Lamp is turned on for forty seconds
to provide illuminated entry and hatch area
illumination.
The illuminated entry time cannot be extended by
pressing the Lock, Unlock or Hatch Release Buttons
until it has timed out. Illuminated entry is disabled as
soon as the Keyless Entry Receiver sees an Ignition
"ON" input at terminal "D" of connector C 1.

Power Door Locks
The Door Lock Actuators always receive ground

through the Power Door Lock Switches from G200.
Battery voltage is applied to the actuators either from
the "PWR ACCY" Fuse 7 when the Power Door Lock
Switches are used (for the specific amount of time
allowed before the Power Door Lock Switches are
disabled, refer to "Retained Accessory Power," page
SA-15-0), or from the "Courtesy" Fuse 8 when the
Keyless Entry Receiver sees a request from the
Transmitter.
3.
4.
IT] Important:
PROGRAMMING THE KEYLESS

ENTRY RECEIVER
The Keyless Entry Receiver is capable of accepting
Vehicle Access Code (VAC) programming from any
two random Transmitters. One or two Transmitters
can be programmed. When two Transmitters are
programmed, they must be programmed during the
same program sequence, one after the other but not
simultaneously. The Transmitter is manufactured
with a permanent VAC combination (one of over 4
billion combinations) that cannot be changed for the
life of the Transmitter. The Receiver can only be
programmed by the Transmitter when it is powered at
the Battery input at connector C2 terminal "F" and the
program input line is grounded to connector Cl
terminal "A".
Press any button of the second Transmitter once.

In response, the Receiver will cycle the Door Lock
Actuators to acknowledge that a transmission has
been received.
Remove the fused jumper from the DLC and verify
system operation using all three transmitter
buttons.
Always program both Transmitters when

replacing a lost or damaged Transmitter. The
first Transmitter Code programmed will always
be in both memories until a second Transmitter
is programmed within the same sequence.
The Keyless Entry System will not be
operational if the program input line is left
grounded.
Program only one vehicle Key less Entry System
at a time. If multiple vehicles are being
programmed in close proximity simultaneously,
it is possible that the same Transmitter could be
trained to more than one Receiver.
Ci3J ~ ~ ct;:11:i9 ~
__.....- tlJ dJ OJ c2:i co clli ___....
Programming Procedure
1.
2.
Ground the program input line by connecting a

fused jumper at Data Link Connector (DLC) from
terminal "G" to terminal "A". The Receiver will
cycle the Door Lock Actuators within one to three
seconds to acknowledge that the Receiver is in the
"PROGRAM" mode.
Press any button on the Transmitter once. In
response, the Receiver will cycle the Door Lock
Actuators to acknowledge that a transmission has
been received.
12020043
BLK
ON-VEHICLE SERVICE
RECEIVER ASSEMBLY
Figure2

The remote control door lock receiver assembly (4)
is mounted in a pocket on the right-hand hinge pillar.
1. Body hinge pillar trim bolts/screws.
2. Right-hand body hinge pillar trim panel.
3. Receiver assembly (4) from pocket on hinge pillar.
4. Electrical connector secondary lock retainers from
electrical connectors.
5. Electrical connectors from receiver assembly (4).

1.
2.
3.
4.
5.
NOTICE: See "Notice" on page 9K-l of this section.

Electrical connectors to receiver assembly (4).
Connector should snap into place.
Check for positive connection by tugging on
connector, not wire.
Electrical connector secondary lock retainers to
electrical connectors.
Receiver assembly (4) to pocket on hinge pillar.
Right-hand body hinge pillar trim panel.
Body hinge pillar trim bolts/screws.
\
A RETAINER, ELECTRICAL CONNECTOR SECONDARY
LOCK
8 CONNECTOR, ELECTRICAL
C RETAINER, ELECTRICAL CONNECTOR SECONDARY
LOCK
D CONNECTOR, ELECTRICAL
E PILLAR, RIGHT-HAND HINGE
4 RECEIVER ASSEMBLY, REMOTE CONTROL DOOR LOCK
PC2002-9K-F-RP
Figure 2 - Remote Control Door Lock Receiver Assembly
B. Any transmitter code that was previously programmed has been erased.
l~I Tighten
Body hinge pillar trim bolts/screws to 1.3 Nm
(12 lb. in.).
6. If programming the system is necessary, refer to
"Programming Receiver Assembly" in this section.
Programming Receiver Assembly

1. Ground receiver program input line by connecting
fused jumper wire between terminal "G" on top far
right and terminal "A" on bottom far left of DLC
(data link connector).
Door lock assemblies and lift window lock
system will cycle indicating receiver assembly
is in program mode.
2. Press any button (only once) on transmitter assembly.
A. Door lock assemblies and lift window locksystem will cycle once confirming that transmitter
code is programmed.
C. Receiver assembly is now programmed to

transmitter assembly.
3. If programming a receiver assembly to match a
second transmitter assembly, press any button (only
once) on second transmitter assembly. This must be
done before fused jumper wire is disconnected.
When programming receiver assembly to match
transmitter assemblies, first transmitter code
matched will be stored in both receiver memories
unless second transmitter assembly is matched at the
same time.
Door lock assemblies and lift window lock
system will cycle once confirming that second
transmitter code is programmed.
4. Disconnect fused jumper wire from DLC.
System will not operate if ground connection is
not removed.
5. Verify operation of each transmitter assembly.
SPECIFICATIONS
Body Hinge Pillar Trim Bolt/Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3 Nm (12 lb. in.)
BODY SERVICE 10-1
SECTION 10
BODY SERVICE
CONTENTS
General Body Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section 10-1
Stationary Windows ...................................................... Section 10-2
Body Dimensions and Underbody ........................................... Section 10-3
Bumpers ............................................................... Section 10-4
Body Front End .......................................................... Section 10-5
Doors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section 10-6
Rear Quarters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section 10-7
Body Rear End .......................................................... Section 10-8
Roof . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section 10-9
Seats and Carpet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section 10-10
Seat Belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section 10-11
GENERAL BODY SERVICE 1011
SECTION 10-1
GENERAL BODY SERVICE

CAUTION: This vehicle is equipped with Supplemental Inflatable Restraint {SIR). Refer to
Location View in Section 9J before performing service on or around SIR components or
NOTICE: The theft deterrent label found on some major sheet metal, engines, and transmissions must be masked
prior to painting, rustproofing, undercoating, etc. The mask must be removed following the above operations.
Failure to keep the label clean and readable may result in liability for violation of Federal Vehicle Theft Prevention
Standard, and subject the vehicle owner to possible suspicion that the part was stolen.
CONTENTS
General Description . . . . . . . . . . . . . . . . . . . . . . . 10-1-1
On-Vehicle Service . . . . . . . . . . . . . . . . . . . . . . . 10-1-1
Fasteners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1-1
Weld Stud Replacement ................ 10-1-2
Lubrication ............................ 10-1-2
Federal Vehicle Theft Prevention
Standard . . . . . . . . . . . . . . . . Refer to Section OA
Stripes and Decals ...................... 10-1-2
Adhesive Nameplate/Emblem Assemblies ... 10-1-3
Adhesive Molding Assemblies ............ 10-1-3
Secure Loose Molding Assemblies ....... 10-1-3
Molding Assembly Completely
Removed (Method 1) ................ 10-1-3
Molding Assembly Completely
Removed (Method 2) . . . . . . . . . . . . . . . . 10-1-4
Molding Assembly Replacement . . . . . . . . . 10-1-4
Waterleak Diagnosis and Repair . . . . . . . . . . . 10-1-4
Generalized Testing ................... 10-1-5
Localized Testing (Spot Test) ........... 10-1-5
Water Hose Test ...................... 10-1-5
Air Hose Test ........................ 10-1-5
Waterleak Repair ..................... 10-1-5
Windnoise Diagnosis and Repair . . . . . . . . . . . 10-1-6
Squeak and Rattle Diagnosis and Repair . . . . . 10-1-7
Anticorrosion Treatment . . . . . . . . . . . . . . . . . 10-1-7
Corrosion Repair . . . . . . . . . . . . . . . . . . . . . . . 10-1-9
Metal Part Refinishing Basecoat/Clearcoat . . . . . . . . . . . . . . . . . . . . 10-1-9
GENERAL DESCRIPTION
The information in this section provides body service procedures that apply to the entire vehicle.
ON-VEHICLE SERVICE
FASTENERS
Many aluminum components are used on present
models. Aluminum in contact with steel may corrode
rapidly if not protected by special finishes or isolators.
Clearcoat Repair without Repainting . . . . . . 10-1-9

Basecoat/Clearcoat Preparation . . . . . . . . . . 10-1-9
Basecoat Application . . . . . . . . . . . . . . . . . . 10-1-9
Clearcoat Application . . . . . . . . . . . . . . . . 10-1-10
Industrial Fallout (Acid Rain) . . . . . . . . . . . . 10-1-10
Surface Level Contamination Repair . . . . . 10-1-10
Slight Clearcoat Damage - Wet Sanding,
Finesse Polishing . . . . . . . . . . . . . . . . . . 10-1-11
Clearcoat Thickness . . . . . . . . . . . . . . . . . . 10-1-11
Paint Gages ........................ 10-1-11
Rail Dust Damage Repair . . . . . . . . . . . . . 10-1-11
Preventing Industrial Fallout Damage .... 10-1-12
Plastic Part Identification ................ 10-1-12
How to Identify Plastic Parts ........... 10-1-12
Flexible Plastic Part Repair and
Refinishing ......................... 10-1-12
Repair Materials ..................... 10-1-12
Fabricating a Patch Panel .............. 10-1-12
Flexible Plastic Part Repair . . . . . . . . . . . . 10-1-16
Flexible Plastic Part Refinishing . . . . . . . . 10-1-17
Rigid Plastic Part Repair and Refinishing . . . 10-1-1 7
Repair Materials . . . . . . . . . . . . . . . . . . . . . 10-1-17
Rigid Plastic Part Repair . . . . . . . . . . . . . . 10-1-18
Rigid Plastic Part Refinishing . . . . . . . . . . 10-1-19
Carpet Insert Reattachment . . . . . . . . . . . . . . 10-1-19
Body Panel Assembly Adjustment and
Alignment . . . . . . . . . . . . . . . . . . . . . . . . . 10-1-19
Such fasteners have a special finish meeting GM

specifications, which provides adequate protection from
corrosion. These special fasteners, which are medium
blue, differ in color in order to more easily identify them
from the standard metric fasteners.
NOTICE: When replacing fasteners avoid substituting otherwise similar fasteners in locations which
require the use of special fasteners meeting GM
specifications 6111M, 6047, 6174M for aluminum
components. Failing to follow this precaution may
result in premature corrosion of the sheet metal in
the areas mentioned above.
10-1-2 GENERAL BODY SERVICE
Weld Stud Replacement

If during a repair procedure, a weld stud becomes
damaged, the following procedure may be used to replace
the weld stud.
1. Drill a hole into same location as damaged weld

stud.
2. Drive a screw into drilled hole.
3. Use screw to retain clips, molding assemblies, etc. in
same manner used with weld studs.
4. If surface becomes marred, repair and/or paint to
provide a smooth surface. Refer to "Metal Part
Refinishing - Basecoat/Clearcoat" in this section.
LUBRICATION
Mechanical parts having contacting surfaces in relative motion with any other body parts are lubricated
during assembly. To maintain ease of operation, it is
recommended that these parts be lubricated at the basic
service intervals shown in SECTION OB, using the
following lubricants:
Door hinge assemblies - oil (30 weight preferred).
Apply lubricant to roller and hinge pin bushings.
Important
Do not apply lubrication to hold-open link and

roller contacting surfaces as this could cause
improper roller operation.
Compartment lid assembly hinges and torque rod-to
-hinge surfaces - Lithium Lubricant (3M P/N 8915)
or equivalent.
Chrome key lock cylinder assemblies should be
lubricated with Multi-Purpose Lubricant (GM P/N
12345120 or equivalent) and black key lock cylinder
assemblies with Synthetic SAE 5W-30 engine oil.
Seat assembly mechanism and door assembly hardware are covered in their specific body sections in
this manual.
All weatherstrip assemblies should be periodically
lubricated with a silicone grease (GM PIN 12345579
or equivalent). A thin film of lubricant should be
applied using a clean cloth.
STRIPES AND DECALS

Stripes and decals adhere to a painted surface using
pressure sensitive adhesive.
The use of a wetting solution aids the technician in
lifting and positioning the stripe or decal during installation. A wetting solution also ensures a better bond
between stripe or decal and panel assembly.
Stripe or decal replacement involving collision
damage, or damage to underlying painted surface,
requires that metal repair and/or refinish operations be
completed before stripe or decal is installed.
NOTICE: Freshly painted surfaces must be allowed

to dry thoroughly before installing stripe or decal.
Residual solvents in fresh painted surfaces can lead
to subsequent blistering problems if stripe or decal is
applied before complete release of solvents. The
striping material highlights vehicle surface imperfection. All dings, rough metal, paint defects and
uneven two-tone paint break lines must be eliminated before stripe/decal application can take place.
Body surfaces and decals must be maintained
between 21 to 38C (70 to 100F) during installation.
Auxiliary heat sources to warm the body surfaces and
decals are required if the temperature is below 21 C
(70F), or the body surface must be allowed to cool if
above 38C (100F).
rn
Important
Never apply decals when body surface and

decal temperatures are below 21 C (70F).
Stripes and decals may be applied "dry." If this does
not result in a consistent bubble free application, the
"wet" method must be used as in the case of large
graphics packages.
rn
Important
Stripes or decals that are applied on flexible

surfaces (fascias, etc.) must be applied
using the "wet" method. This will reduce
the formation of bubbles under the decal due
to the outgassing potential of the flexible
materials.
The following equipment and materials are necessary when making a quality stripe or decal installation.
Equivalent products may be used.
Wetting solution - a foaming type window cleaner,
that does not contain ammonia.
Silicone, wax and grease remover.
Isopropyl alcohol.
Squeegee - 75 to 100 mm (3 to 4 inches) wide,
plastic or hard rubber. Deburr any sharp or rough
edges to prevent scratching of the stripe or decal.
Water bucket and sponge or spray bottle.
Sandpaper - 600 grit or finer, wet-or-dry type.
Heat gun or infrared heat lamp.
Clean, lint-free wiping rags.
Sharp knife or razor blade.
Scissors.
Fine pin or needle.
Marking pencil.

1. Necessary molding assemblies or trim panel assemblies.
2. Wash and clean repair surfaces, adjacent panel
assemblies and openings as required.
3. Molding assembly attaching clips, handles, sidemarker reflector assemblies and/or other stripe or
decal overlapping parts.
NOTICE: To avoid damaging underlying paint

finish, do not use pointed or sharp instruments for
removal of stripe or decal from panel assembly.
4. Stripe or decal by starting at one edge and peeling
stripe or decal from panel assembly surface.
Application of heat to stripe or decal at point of
removal aids removal operation.
5. All traces of adhesive residue from painted surfaces
with a silicone, wax and grease remover.

1. Prepare surface.
NOTICE: Always refer to manufacturer's packaged
instructions to avoid damage.
[I] Important
If area where stripe or decal is to be applied has
been refinished, remove any imperfections that

would show through stripe or decal.
l~I Clean
A. Painted surface with silicone, wax and grease
remover.
B. Area where stripe or decal will be applied with

a 50-50 mixture of isopropyl alcohol and water.
C. Wipe panel assembly surface with a clean cloth
while solvent is still wet and allow to dry.
2. Apply wetting solution to area where stripe or decal
is to be installed.
3. Put wetting solution on adhesive side of stripe or
decal.
Remove backing material of stripe or decal as
necessary.
. 4. Stripe or decal to panel assembly. Wetting solution
will allow movement of stripe or decal for proper
positioning.
A. Working from center where possible, squeegee
stripe or decal into position. Application of
additional wetting solution may be necessary
to ease installation of stripe or decal. Application of soapy wetting solution on top side of
stripe or decal will ease pull of squeegee on
stripe or decal and help to eliminate damage to
it.
B. Apply heat to stripe or decal at recessed areas.
Press stripe or decal into recess to obtain firm
bond.
ILl
1nspect
Stripe or decal from critical angle using

adequate light reflection to detect any
irregularities that may have developed
C. Remove all air bubbles by piercing with
a safety pin, needle or tool with same size
piercing tip. Never use razor blade or knife

edge.
Pierce bubble on its outer edge and force
air out from opposite edge with blade of
squeegee.
5. Previously removed parts and clean as required.
ADHESIVE NAMEPLATE/EMBLEM
ASSEMBLIES
For information on adhesive nameplate and emblem
assemblies, refer to the specific body sections in which
the nameplate and emblem assemblies are located.
ADHESIVE MOLDING ASSEMBLIES

The molding assemblies are attached to the body
panel assemblies with adhesive tape. To ensure a good
replacement of new or old molding assemblies, the panel
assembly surface should be warm, 21 to 32C (70 to
90F), clean and free of any wax or oily film. Methods are
listed to attach loose molding assembly ends, completely
removed molding assemblies, and replacement molding
assemblies.
Secure Loose Molding Assemblies

1. Wash affected area with soap and water and wipe
dry. Wipe panel assembly and adhesive side of
molding assembly with clean rag using oil-free
naphtha or alcohol.
If molding assembly has been pulled loose
from adhesive backing (tape remains on body
panel assembly), do not remove tape from
body panel assembly. Clean back of molding
assembly and tape on body panel assembly
with oil-free naphtha or alcohol and proceed
with step 3.
2. If needed, apply length of masking tape as molding
guide. Straight edge may also be used.
3. Apply adhesive to back of molding assembly and
press in place. If adhesive (GM PIN 1052621 or
equivalent), is used, apply constant pressure to
molding assembly for 30 seconds or until firm bond
has been made.
Molding Assembly Completely Removed

(Method 1)
Figure 1
rn
Important
Do not use this procedure if molding assembly

is dented or was pried from body panel assembly.
1. Wash affected area with soap and water and wipe
dry.
2. Remove all traces of adhesive from body panel
assembly and back of molding assembly using oilfree naphtha or isopropyl alcohol.
3. Mark proper position of molding assembly with
length of masking tape (Figure 1). Use adjacent
molding assemblies as guide.
1014 GENERAL BODY SERVICE

4. Warm body panel assembly with heat lamp or heat
gun to 21 C (70F).
5. Apply double-coated foam tape (3M P/N 06380 or
equivalent) to, the molding assembly.
6. Line up molding assembly to tape guideline on body
panel assembly or use straight edge to align molding
assembly to front or rear molding assemblies
already on vehicle.
7. Peel backing from end of molding.
8. Press firmly into place while continuing to remove
backing.
9. Hand roll molding assembly to body panel assembly
to ensure proper adhesion.
Molding Assembly Completely Removed

(Method 2)
Scotch-Brite Molding Adhesive and Stripe
Removal Discs (3M P/Ns 07501 and 07502) and the
Roloc + Holder (3M P/N 07500) can be used for quick
removal of adhesives from molding assemblies and panel
assemblies.
CAUTION: Approved safety glasses
should be worn when performing this
procedure to reduce the chance of personal injury.
1. Tighten holder in collet or chuck of any standard
tool.
2. Twist disc assembly securely into holder.
3. With tool running, bring outer edges of disc into
contact with material to be removed. Light contact is
all that is needed.
4. Guide tool so it works against the rotation of the
disc.
Molding Assembly Replacement

Figure 1

Molding assembly.
A. Hold hot air gun 152 mm (6 inches) from
surface of molding assembly to be removed.
B. Apply heat, using circular motion for about 30
seconds.
C. Place catgut or fishing line between molding
assembly and body panel assembly. Using
sawing motion, remove molding assembly
from panel assembly surface.
D. Discard molding.

Molding assembly.
A. Mark proper position of molding assembly
with length of masking tape or straight edge,
aligning to front or rear molding assemblies already on vehicle.
A TAPE GUIDELINE OR STRAIGHT EDGE

PCOOOM01-F-RP
Figure 1 - Adhesive Molding Assembly Repair
l~I Clean
B.
C.
D.
E.
F.
Area with soap and water and wipe dry.

Body panel assembly using oil-free
naphtha or isopropyl alcohol.
If needed, warm body panel assembly with
heat lamp or heat gun to 21 C (70F).
Peel backing from front end of molding assembly.
Do not touch adhesive backing.
Press molding assembly to body panel assembly while continuing to remove backing.
Hand roll molding assembly to body panel
assembly to ensure proper adhesion.
Molding assembly ends should not overlap
door assembly edge, door assembly edge
guard, lock cylinder assembly or body
openings.
IL'l'I Inspect
Molding assembly ends for bonding.
Hand roll loose ends.
WATERLEAK DIAGNOSIS AND REPAIR

GM vehicles are designed to operate under normal
environmental conditions. The design criteria for sealing
materials and components takes into consideration the
sealing forces required to withstand the natural elements.
These specifications do not, and cannot, take into consideration all artificial conditions . such as may be
encountered in some high-pressure car washes.
The watertest procedure has been correlated to the
natural elements and will determine the ability of a
vehicle to perform under normal operating conditions.
Repairing body waterleaks is a problem of proper
testing, diagnosis and repair through adjustment of misaligned components and/or application of proven repair
materials. The first step in waterleak diagnosis is finding
the condition under which the leak occurs. For example,
the leak is noticed only when parked on an inclined
GENERAL BODY SERVICE 10-1-5

drive, or when water is in the jack and spare tire stowage
assembly.
If the general leak area can be found, the exact entry
point can be quickly isolated by use of a localized test
such as a water hose or air hose. If the leak source is not
obvious, a testing method using watertest equipment
should be used. It may be necessary to remove some interior trim panel assemblies or components to locate areas
needing repairs.
Generalized Testing
The watertest stand must be constructed.
Watertest stand specifications:
- Volume of flow should be 14 liters (3.7
gallons) per minute.
- Water pressure, measured at nozzle - 155 kPa
(22 psi).
- Windshield assembly and front body pillar approximately 30 degrees down, 45 degrees
toward rear and aimed at corner of windshield
assembly.
- Doors - approximately 30 degrees down,
45 degrees toward rear and aimed at center of
rear door assembly or rear quarter panel
assembly.
- Rear window assembly and rear compartment
lid assembly or end gate assembly - approximately 30 degrees down, 30 degrees toward
front and aimed about 600 mm (24 inches)
from corner of rear window assembly.
If specified water pressure of 155 kPa (22 psi)
cannot be obtained because of local situation, both
test stands may be moved toward body until water
spray overlap can be obtained.
Localized Testing (Spot Test)

Localized testing may be made with either water or
air. Begin the test at the base of the suspected area and
continue up slowly until the leak is located.
[I] Important
Pinpoint the leak area before any repalf 1s
made. Random repair may only temporarily restrict water entry and make future diagnosis
and repair more difficult.
Continue localized testing in the same general area
to confirm that all leaks have been located.
Water Hose Test

Figures 2 and 3
1. Have helper inside vehicle to detect actual leak
point.
2. Use unrestricted water flow (no nozzle).
3. Begin at base of suspected leak area and move
upward slowly.
G93083-1-BG
Figure 2 - Water Hose Test of Windshield Pillar
G93080-1-BG
Figure 3 - Water Hose Test of Wheelhouse Assembly
Air Hose Test

Figures 4 and 5
1. Apply bubble solution (liquid soap) to suspected
leak area.
2. Apply air pressure with an air hose from inside
vehicle. Do not exceed 205 kPa (30 psi).
3. Observe for bubbles on outside at suspected leak
area.
Waterleak Repair
Figure 6
To locate the exact leak point or to repair the leak, it
may be necessary to remove some interior trim panel
assemblies or components. Waterleak repair is covered in
the section covering the component. For example, for the
repair procedure on stationary window assemblies, refer
to SECTION 10-2.
After completion of any waterleak repair, the general area should be retested using the watertest stand. Do
not use high-pressure air hose.
Material recommended for specific leak areas
include:
Urethane adhesive caulking kit (GM PIN
12345633 or equivalent) for windshield
assembly, rear window assembly, and stationary window assembly repair.
Brushable seam sealer which can be painted on
metal joints.

Bedding and glazing compound for ventilation
ducts and drip moldings.
Drip-check sealer for small cracks and pin
holes.
All-Around Autobody Sealant (3M P/N 08500
or equivalent) for large holes.
Weatherstrip adhesive (3M P/N 08011 or
equivalent) for weatherstrip assemblies.
Strip caulk for bolts, studs and screws.
WINDNOISE DIAGNOSIS AND REPAIR

G93084-1-BG
Figure 4 - Air Hose and Bubble Solution Test of Windshield

Assembly Glass Sealant
G93081-1-BG
Figure 5 - Air Hose and Bubble Solution Test of Panel Joints
Figures 4, 5 and 7
Many of the waterleak diagnosis tests are also used
for windnoise diagnosis.
Visual inspection.
- Misaligned components
- Loose fasteners
- Torn weatherstrip assemblies
- Broken weld joints
Sealer and/or adhesive skips
Tracing powder or chalk test.
A. Clean weatherstrip assemblies and contact surfaces with solvent.
B. Apply powder or chalk in an unbroken line to
contact surface of weatherstrip assembly
around perimeter of rear compartment lid
assembly, door assembly, side door window
assembly or hood assembly. Surrounding areas
must be free of chalk or powder.
C. Close panel assembly completely. Do not slam.
This presses weatherstrip assembly firmly
against mating surfaces.
fL'l'I
A
1
2
3
4
SEALER
PILLAR, WINDSHIELD
PANEL ASSEMBLY, DASH
REINFORCEMENT, WINDSHIELD LOWER FRAME
PILLAR INNER ASSEMBLY, BODY HINGE
PC0002-101-F-RP
Figure 6 - Sealing Front End to Prevent Water Leaks
Inspect
Applied chalk line on weatherstrip assembly

will be marred where contact is good. A corresponding imprint will be on mating surfaces.
Gaps or irregularities in powder or chalk line
on mating surfaces indicate areas with poor
seal.
Air pressure test.
A. Mask off pressure relief valves.
B. Turn on vehicle's ventilation fan.
C. Close all openings - windows, doors, etc. An
abnormal amount of high pressure will build
up in vehicle and will escape through poor
seals.
D. With stethoscope or length of heater hose,
listen for escaping air along door and window
seals.
Smoke or dusting powder test can be
used in same manner. Exact leak location
can be seen as smoke or powder travels
through poor seal.
Soap suds or bubble test.
A. Pressurize interior of vehicle as outlined in air
pressure test above.

Low uniform friction surfaces can be provided to
eliminate ''stick-slip'' motion.
ANTICORROSION TREATMENT
PC0003-101-F-RP
Figure 7 - Masking Tape Application to Identify Windnoise
B. Apply soapy solution to potential leak areas.

Escaping air pinpoints leak area. Air pressure
from air hose inside vehicle can be used
instead of pressurizing vehicle's interior. Do
not exceed 205 kPa (30 psi) when using air
hose. (Figures 4 and 5).
External windnoise.
A. Road-test vehicle to determine source of noise.
Wind roar is caused by outside air passing over an opening.
Wind whistle is caused by inside air seeping through a bad seal, or by outside air
passage over a protruding edge.
Wind rush is outside air passing over the
vehicle's body.
B. Tape various moldings and gaps until noise is
eliminated (Figure 7).
NOTICE: If masking the grille assembly and headlamp capsule assembly areas, care must be taken not
to restrict airflow and cause vehicle overheating.
Windnoise leak repairs are very similar to waterleak
repairs. The actual procedure depends on the type of seal
being repaired.
Leaks around door opening weatherstrip assemblies
do not always indicate a faulty weatherstrip assembly. A
door assembly or window adjustment may resolve the
condition. Refer to SECTION 10-6.
SQUEAK AND RATTLE DIAGNOSIS AND

REPAIR
Basically, squeaks and rattles are caused by improperly controlled relative motion between components.
There are three ways to prevent the squeak or rattle.
1. Attach component securely so there is no relative
motion during operation.
2. Separate components so there is no contact under
operating conditions.
3. Insulate components so that no squeaks or rattles
occur with relative motion between components.
Figures 8 and 9
CAUTION: When applying sound deadeners, due care and preventive measures must be exercised to prevent any
materials from being sprayed into
door assembly and quarter outer panel
mechanisms such as door lock cylinder assemblies, channel assemblies,
window regulators and seat belt retractors, as well as any moving or rotating
mechanical or suspension parts on the
underbody. After material application,
be sure all body drain holes are open.
Anticorrosion materials are used on interior and
exterior surfaces of metal panels to provide rust resistance. These materials include metals such as one-sided
and two-sided galvanized zincrometal and zinc-iron alloy
steels. These treated metals are used on components such
as quarter outer panels, wheelhouse assemblies and other
critical parts. These materials have multiple production
and field usages.
Metal conditioners and primers are used on interior
and exterior surfaces along with protective waxes on
interior surfaces in areas where moisture might accumulate. Sealers are applied along exposed joints and
moisture-repelling asphaltic sound deadeners are applied
inside the wheel wells and on some underbody components.
Any procedure that disturbs these special treatments, such as panel replacement or collision damage
repair operations, may leave the metal unprotected and
result in corrosion. Proper recoating of these surfaces with
service-type anticorrosion material is essential.
Metal conditioners and primer coatings are applied
to all metal panels at the time of vehicle manufacture.
After repair and/or replacement parts are installed, all
accessible bare metal surfaces must be treated with metal
conditioner and reprimed using an acrylic chromate material. This operation is to be performed prior to the application of sealers, waxes, deadeners and antirust compounds.
Sealers are applied to specific joints during
manufacture. These sealers are intended to prevent water
and dust from entering the vehicle and also are anticorrosion barriers. Sealers are applied to such areas as lid
hem flanges, wheelhouse panel assembly, quarter outer
panel, floor panel assembly, cowl assembly, roof module
assembly and various other panel-to-panel attaching
points. The originally sealed joints are obvious and any
damage to these sealed locations should be corrected by
resealing. Attaching points of new replacement panels
should be resealed. Replacement lid assemblies will also
require sealing in the hem flange areas.
Flanged joints, overlap joints and seams should be
sealed using a quality sealer of medium-bodied consistency. The sealer used must retain its flexible characteristics after curing and be paintable.
A SEALER
PC0004-101fRP
Figure 8 - Typical Joint Sealing, Rear End Area
A SEALER
<
\\ECTION AA
A
PC2001-101f-RP
Figure 9 - Typical Anticorrosion Treatment Around Perimeter

of Hood Assembly Outer-to-Inner Panel Flanges
Open joints which require bridging of the sealer to

close a gap should be sealed using a heavy-bodied caulking material. Follow the label directions for the material
selected.
Color application may be required to restore
repaired areas such as the hood assembly, quarter outer
panels, roof module assembly, engine compartment, underbody and inner panel assemblies to original appearance. When this is necessary, conventional refinishing
preparation, undercoat build-up and color application
techniques should be followed.
Deadener materials (spray-on type) are used on
various metal panels to provide corrosion resistance and
joint sealing. They control the general noise level inside

the passenger area of the vehicle. When deadeners are
disturbed because of damage, removed during repair
operations, or a new replacement panel is installed, the
deadener material must be replaced by a service equivalent material. The application pattern and location of
deadener materials can be determined by observing the
original production installation.
Anticorrosion compounds are light-bodied materials
designed to penetrate between metal-to-metal surfaces,
such as pinch-weld joints, hem flanges, and integral panel
assembly attaching points where metal surfaces are difficult to coat with conventional undercoating materials, and
are inaccessible for painting. Material suited for this type
application is a wax-type coating (GM PIN 12345489 or
equivalent).
Conventional undercoating is recommended to coat
large areas such as quarter outer panels, floor panel
assemblies, lid assemblies, hood assemblies, etc.
The sequence of steps for application of anticorrosion materials is as follows:
1. Clean and prepare metal.
2. Apply primer (acrylic chromate).
3. Apply sealers at all previously sealed joints.
4. Apply color in areas where color is required, such
as hem flanges, exposed joints and underbody components.
5. Apply deadeners as indicated by original application
pattern.
6. Apply anticorrosion compounds.
7. Apply underbody rustproofing material.
Cleaning of the interior and underbody panel assembly surfaces is necessary when original galvanized or
other anticorrosion materials have been burned off during
welding or heating operations. Removal of the residue
from burning will require additional care in such areas as
interior surfaces of box-type construction and when configurations of the metal panel assemblies limit access to
interior surfaces. One or more of the following methods
will remove the residue.
procedure to reduce the chance of
personal injury.
Where access is possible, scraping can be used. If a
standard putty knife or scraper will not fit into the
affected area, fabricate a small, flexible scraper from
a narrow piece of sheet metal.
A jet of compressed air will remove most residue
and could be effective in limited-access areas. Eye
protection is absolutely necessary in an operation of
this type.
Sandblasting is most effective and should be used
when the equipment is available and access to the
area is good. Sandblasting is an excellent method for
cleanup and preparation of open joints, underbody
components and hem flange areas.
Wire brushing (power and by hand).
When access is good, sandpaper and steel wool can
be used.
CORROSION REPAIR
Prior to replacing exterior body parts or assemblies,
check condition of paint on all covered or hidden interior
surfaces. If corrosion is found in these areas, proceed as
follows:
1. Remove corrosion with suitable wire brush and
abrasive or liquid corrosion-removing agent. Follow
label directions.
2. If necessary, wash with detergent, rinse and dry.
3. Apply a heavy coating of anticorrosion compound to
all cleaned hidden surfaces before installing exterior
body parts. Also, apply anticorrosion compound to
all inner surfaces of exterior body parts being
installed.
METAL PART REFINISHING BASECOAT/CLEARCOAT

CAUTION: Many paint repair systems
require additives containing isocyanates. It is essential that all recommendations and warnings listed on the
container label for materials selected
be followed. It is mandatory that adequate respiratory protection such as air
line respirators with a full hood be
worn. Such protection should be worn
during the entire painting process.
Persons with respiratory problems or
those allergic to isocyanates must not
be exposed to isocyanate vapors or
spray mist.
Basecoat/clearcoat is factory applied in four layers:
a cathodic immersion primer, a primer-surfacer, base
color of high-solids acrylic enamel (basecoat), and a clear
acrylic top coat (clearcoat) to give the finish a high-gloss
look.
pad. Adding small amount of liquid detergent to

water will improve wet-out and sanding performance.
7. Keep repair area wet while sanding. Sand lightly and
evenly in one direction only, using straight strokes.
rn
Frequently wipe or squeegee repair to determine when defect has been removed. Sand
only enough clearcoat to remove defect. Sanding below clearcoat requires repainting.
8. Using clean cloth, wipe repair area clean of water
and clearcoat residue.
9. Polish as necessary. Often, hand compounding and
polishing of a small repair area is all that is necessary to restore appearance.
Keep pad flat to panel assembly and allow
weight of polisher to do the work.
Use polish sparingly to achieve original shine.
Machine or hand polish repair area first, then
blend in with rest of panel assembly.
Basecoat/Clearcoat Preparation
1. Wash repair area with detergent and water.
2. Clean repair area with silicone, wax and grease
remover.
3. Repair and feather-edge damaged areas.
4. Treat metal surface with metal conditioner and conversion coating. Allow to dry.
5. Apply primer-surfacer. Dry 20 to 30 minutes.
6. Sand basecoat paint area with 400 grit or finer paper.
(For clearcoat only, wet sand with 600 grit or finer
paper or hand compound.)
7. Clean with silicone, wax and grease remover and
tack wipe.
rn
Clearcoat Repair without Repainting

Figure 10
If the damage or imperfection can be sanded or
polished without reaching the basecoat, you do not have
to repaint.
1. Thoroughly wash repair area with mild detergent
and water.
2. Apply small amount of medium to fine machine
rubbing compound to repair area and smear evenly
with compounding pad.
3. With polisher running at approximately 1,700 rpm,
polish repair area. Keep pad flat against panel
assembly while applying light pressure. Feature
lines and panel assembly edges should be done with
care.
4. Ifsanding is not required, proceed to step 9.
5. If repair is near adjacent panel assemblies, mask
adjacent panel assemblies to protect against sand
scratches and bum-through of panel assembly
edges.
6. Saturate piece of micro-fine sandpaper of 1,500 to
2,000 grit in container of water and attach to sanding
Important
Important
Do not do step 8 if the basecoat enamel used

for repair does not require it. Always refer to
manufacturer label directions.
8. Apply one or two coats of adhesion promoter:
A. Within moldings or breaklines.
B. Onto adjacent panel assembly 100 to 150 mm
(4 to 6 inches) if repair is not confined and
beyond area to be covered by clearcoat.
C. Allow to flash at least 30 minutes before applying clearcoat.
Basecoat Application
1.
2.
3.
4.
CAUTION: See "Caution" under "Metal

Part Refinishing - Basecoat/Clearcoat."
Activate enamel material per manufacturer instructions.
Mix thoroughly.
Reduce basecoat per manufacturer instructions.
Check viscosity with a Zahn number 2 viscosity cup
or equivalent.
CHEMICAL SPOTTING
'".,----=........
~
SAG
......... .-
CLEARCOAT
BASECOAT .....;~~,
PRIMER
-
.....;..
CLEARCOAT
BASECOAT~/' :-.
PRIMER
PRIMER
PRIMER
METAL
METAL
ORANGE PEEL
CLEARCOAT
--
--1.
--.-!
.,....
- BASECOAT
.-..!..-
PRIMER
PRIMER
METAL
SCRATCH
DIRT
CLEARCOAT
,,:..._,_ ...:_. BASECOAT ~ ..:-;
CLEARCOAT
, -._:--_ BASECOAT ;-:, ,- '
PRIMER
PRIMER
r"V
--
PRIMER
PRIMER
METAL
METAL
..
NC4005-101-B-RP
Figure 10 - Minor Paint Defects That Can Be Repaired without Repainting
5. Spray two or more medium-wet coats, 15 to 20 minutes apart, to achieve full-hiding and color match.
6. Cure per manufacturer instructions.
Clearcoat Application
CAUTION: See "Caution" under "Metal
Part Refinishing - Basecoat/Clearcoat."
1. Activate materials per manufacturer instructions.
2. Mix thoroughly.
3. Reduce clearcoat per manufacturer instructions.
4. Check viscosity with a Zahn number 2 viscosity cup
or equivalent.
5. Spray at 50 psi gun pressure. Apply two mediumwet coats, 15 to 20 minutes apart.
Cover entire panel assembly wherever possible.
When there are no breaklines, blend spray
within area prepared.
Important
Clean spray equipment immediately after use

with lacquer thinner.
INDUSTRIAL FALLOUT (ACID RAIN)
[I] Important
The following information regards the use of
finesse-type repairs to industrial fallout (acid
rain) and rail dust damage of basecoat/clearcoat paint finishes.
Since the severity of the condition varies from area
to area, proper diagnosis of the damage extent is critical to
the success of repairs. Diagnosis should be performed
under high-intensity fluorescent lighting, on horizontal
surfaces (hood assembly, roof panel assembly, rear
compartment lid assembly) after they have been properly
cleaned.
There are three basic types of acid rain damage:
Surface level contamination - may be repaired by
simply washing the vehicle, cleaning the surface
with a silicone, wax and grease remover, neutralizing acidic residue and finesse polishing.
Clearcoat etching - slight etching still noticeable
after the above washing and finesse polishing
procedure.
Basecoat etching - severe etching beyond the clearcoat into the basecoat.
Surface Level Contamination Repair

1. Wash vehicle with standard car detergent and water,
and dry thoroughly.

2. Clean affected area with silicone, wax and grease
remover.
3. Neutralize left over acidic residue by cleaning
damaged areas with mixture of baking soda and
water (one tablespoon per one quart of water), rinse
thoroughly and dry panel assemblies completely.
4. Apply finesse-type polish with foam pad.
If damage has been repaired, remove any swirl
marks with dual-action orbital polisher and
foam pad.
If some damage remains, proceed to "Slight
Clearcoat Damage - Wet Sanding, Finesse
Polishing" in following procedure.
Slight Cl~arcoat Damage -Wet Sanding,

Finesse Polishing
1. Select small test area on damaged panel assembly.
2. Wet sand damaged area with an American grade
ultra-fine sandpaper of 1,500 to 2,000 grit and rubber si:ronge sanding block. During wet sand process:
A. Use ample amounts of water.
B. Go slow to prevent removing too much cleartoat.
1
[I) i'ir,portant
:Se sure to use American sandpaper. European
s~ndpaper has a P before the grit number and
European grits do not align with American
grits the majority of the time.
3. Remo\je excess water with rubber squeegee and
inspect, area.
If,. wet sanding has repaired the damage, contiriue the sanding procedure on the entire panel
as~embly. Apply a finesse-type polish with a
foam pad and remove any swirl marks with a
dual-action orbital polisher and foam pad.
If (during the repair) it is suspected or observed
that etching has penetrated into the basecoat,
too much clearcoat has been removed during
sanding or base color is transferred to pad
during polishing, the affected areas may
require clearcoat/basecoat application or refinishing. Refer to "Metal Part Refinishing Basecoat/Clearcoat," "Flexible Plastic Part
Refinishing" and/or "Rigid Plastic Part
Refinishing" in this section.
4. Polish entire vehicle after all damage has been
repaired.
Clearcoat Thickness
The clearcoat on the vehicle is typically 0.059 to
0.078 mm (1.5 to 2 mils; 0.0015 to 0.0020 inch) thick.
Paint Gages
The best way to accurately measure how much
clearcoat has been removed is to use a paint gage before,
during and after the sanding process. Paint gages measure
the total thickness of the finish and when used, can determine how much clearcoat has been removed during the
repair process. Paint gages range from magnetic pull types

to sophisticated electronic types and are available from a
variety of sources.
The older magnetic type gages, at best have a 5
percent accuracy range and are not sensitive enough to
detect removal of 0.020 mm (0.5 mil; 0.0005 inch)
clearcoat. The newer type magnetic gages have improved
accuracy ranges. Most gages are confined to checking
either ferrous metal (steel) or non-ferrous metal (aluminum) panel assemblies. At this time, there are no viable
gages for reading film thickness on non-metallic panel
assemblies.
The more sophisticated digital type gages are able to
read film thickness on both ferrous and non-ferrous metal
panel assemblies. Digital gages can have an accuracy
range of 1 percent and include thickness standards for
recalibration.
Rail Dust Damage Repair

CAUTION: Rail dust remover (oxalic
acid) is an acidic substance containing
chemicals that will break down the iron
particles embedded in the finish. When
working with it, use the necessary
safety equipment, including gloves and
goggles. Follow the manufacturer's
directions closely because it may
require special handling and disposal.
Rail dust damage comes from the tiny iron particles
produced from the friction between the train wheels and
the track. It can also be deposited on vehicles if stored
near any operation producing iron dust (i.e., steel ore
yards). This dust can either lay on top of, or embed into
the paint surface. It is usually diagnosed as bumps in the
paint surface or rust colored spots in the paint.
1. Wash vehicle with soap and water, dry it and clean
affected area with silicone, wax and grease remover.
2. Rinse surface with cold water, keeping vehicle in
cool or shaded area.
3. Soak several terry cloth towels in container of rail
dust remover solution and, after damaged areas have
been rinsed with cold water, lay wet towels on
damaged areas.
4. Allow towels to remain in place for 20 minutes,
keeping them moist by spraying with water and not
allowing to dry on surface of vehicle.
5. After 20 minutes of applying towels, remove them
and rinse area thoroughly with cold water. Inspect
affected area to ensure dust has been removed. Use
both touch (feeling for bumpy surface) and sight
(magnifying glass for close inspection).
6. If, upon inspection, some particles are still present,
process of applying towels can be repeated three
times.
7. Select test area and hand wet sand with American
ultra fine 1,500 grit to 2,000 grit sandpaper to repair
damage (surface pitting from dust). Use ample
amounts of water and go slow to prevent removing
too much clearcoat.
NOTICE: Use a paint gage to determine the amount
of clearcoat removed. If too much has been

removed, additional clearcoat will have to be
applied.
[I] Important
If rail dust has penetrated into the basecoat, the
panel assembly requires refinishi.ng. Mak~ ~ure
all rail dust has been removed pnor to refm1shing or the rust spots will return, causing customer comebacks.
8. If damage has been repaired, complete repair to
entire panel assembly.
9. Polish the entire vehicle after all damage has been
repaired.
Preventing Industrial Fallout Damage

To prevent industrial fallout (acid rain) damage,
customers should be urged to wash and dry their vehicles
frequently and garage them, or at least cover them with a
quality car cover when not in use.
Vehicles in dealer inventories should be kept clean
and dry. A vehicle that sits unattended, espec~ally after the
sun has dried any water on the body surface, 1s a target for
acid rain damage.
3mm
HEIGHT
OF LETTERS
PREFERRED
SAE I PVC
ACCEPTABLE
SAE
PLASTIC PART IDENTIFICATION

How to Identify Plastic Parts
CAUTION: General Motors does NOT
recommend using a plastic "Burn Test"
to distinguish different types of plastics. This test produces vapors that can
be harmful to your health.
Specific plastics used on this vehicle ~re sh?wn ~n
Figures 12 and 13. The procedures provided. m this
section classify the plastics into two groups; flexible and
rigid. Refer to Figures 12 and 13 to identify the parts and
the repair/refinish procedure to use.
The following information can be used to specifically identify plastic parts when necessary.
1. Look on the back of the part for the International
Organization for Standardization (ISO) code marking as shown in Figure 11.
2. Refer to Figures 12 and 13. Match the ISO code
found on the parts with those on the charts.
3. Use the chart in Figure 14 to. iden.ti!y speci~l
handling procedures and the repa1r/refm1sh classification (rigid or flexible).
FLEXIBLE PLASTIC PART REPAIR AND

REFINISHING
Repair Materials
[I] Important
Use supplies and repair materials from th~ same
manufacturer for the best results. Do not mix systems.
t
i
3mm
HEIGHT
OF LETTERS
_L
3mm
HEIGHT
OF LETTERS
t
PC6011-101-D-RP
Figure 11 - Typical Plastic Parts Marking Symbol
These flexible plastic panel assembly repair procedures require the use of GM Goodwren~h Compoxy
Repair Material (GM P/N 12345744) or eqmvalent.
Fabricating a Patch Panel

Panel assemblies requiring slicing or sustaining
major damage may ne~d a .reinforcemen! panel. or patch
panel. If possible, obtam this part by cuttmg a piece from
the original damaged panel .asse!11bly. It shou~d be 7(:, to
102 mm (3 to 4 inches) in width 1f the damage 1s a spht or
break. If a part of the damaged panel assembly is missing,
the reinforcement panel or patch should extend 38 to 50
mm ( 1 1/2 to 2 inches) beyond the edges of the damaged
area.
An adequate part may be manufactured as follows:
1. Lay out a piece of wax paper larger than the damaged area on the panel assembly.
2. Apply a layer of repair material.
3. Cut a piece of reinforcement mat materi~l to desi~ed
size and shape and place over repa1r matenal.
Extend mat 38 to 50 mm (1 1/2 to 2 inches) beyond
repair area.
4. Apply a coat of repair material as necessary.
5. Place a piece of wax paper over the mat materi~l and
roll with the saturation roller to ensure saturation of
mat.
6. Remove wax paper from panel assembly.
7. Apply patch to inner side. of the damaged area, if
accessible. Work out any a1r pockets.
8. Allow to cure.
CHART OF PLASTIC PARTS IDENTIFICATION AND REFINISHING SYSTEMS

IDENTIFYING
OLD SYMBOL
IN(
)
CHEMICAL
COMPOSITION OR
PLASTIC "FAMILY" NAME
EXAMPLES OF
COMMON AND/OR
TRADE NAMES
TYPICAL AREA(S)
WHERE PART USED
TYPICAL PAINT
REPAIR SYSTEM
UP
Polyester/Thermoset
Fender Extensions, Hoods,

Roofs, Deck Lids,
Instrument Housings,
Ventilation Grids, Air
Scoops, Air Spoilers
SMC, Premi-glas,
Selectron, Vibrinmat,
"Fiberglass"
PE
Polyethylene
Inner Fender Panels,

Valances, Spoilers,
Interior Trim Panels,
Seat Belt Covers,
Gas Tank Shields
Dylan, Fortiflex, Marlex,

Alathon, Hi-fax, Hosalen,
Paxon
#7
PS
Polystyrene
Dash Panels
Door Panels
Lustrex. Dylan, Styron,

Durathon, Polystyrol
#7
Polyphenylene Ether
Chromed Plastic Parts

Headlamp Doors
Ornaments, Bezels
Noryl, Oleflo, Prevex
N/A
PP
Polypropylene
Door Panels, Load Floors,

Kick Panels, Deflector
Panels, Cowl Panels, Wheel
Covers, Interior Moldings,
Radiator Shrouds, Inner
Fenders, Bumper Fascia,
Prolax, Olello, Marlex,

Azdel, Novolen, Tenite,
Daplen, Escorene
#2,#3,#5
and #7
TPU ITPUR)
Polyurethane
Thermoplastic
Bumper Fascia, Soft Filler

Panels, Glass Moldings,
Gravel Deflectors
Pellethane; Estane, Roylar,

Toxin
#2,#3,#5
and #7
PUR
Polyurethane, Thermoset
(Unsaturated)
Bumper Fascia, Front and

Rear Body Panels, Filler
Panels
Castethane, Bayllex
!Commonly referred to as
RIM and RRIM)
#2 and #5
ABS
Acrylonitrile/Butadiene/
Styrene
Instrument Clusters, Trim

Moldings, Consoles,
Armrest Supports, Steering
Column, Brackets, Steering
Column Jackets
ABS, Cycolac, Abson,

Kralastic, Lustran, Absafil,
Dye!
#1, #4 and #6
ABS+ PC
Acrylonitrile/Butadiene
Styrene + Polycarbonate
Instrument Panels,
Instrument Clusters
Baybland, Proloy, Pulse

Cycoloy, KHA
#1,#4and#6
AB Vinyl-!Soft)
Head Restraint Covers,

Instrument Panel Pads,
Trim Moldings, Trim Panels
ABS Vinyl
#7 and #8
Ethylene/Propylene
(Rubber)
Bumper Fascia, Valance

Panels, Air Dams
TPO, TPR !Thermoplastic

Rubber), EPI, EPII
#3 and #5
EPDM
Ethylene Propylene Diene

Monomer
Bumper Impact Strips,

Body Panels
EPDM, Nordel
EVA
(EVAC)
Ethylene/Vinyl Acetate
Head Restraint Cover,

Miscellaneous Soft Trim
Components
Elvax, Microthane
Polyamide +
Polyphenylene Ether
Fenders, Exterior Trim
GTX
PPE(PPO)
ABS/PVC
TEO
(EP, EPM, TBO)
PA+ PPE
#1 and #4
#2, #3 and #5
#7 and #8
#2, #3 and #5
IMPORTANT: Follow selected paint manufacturer's product label directions. Observe all warnings on material container labels.
PC0012-101-B-RP
Figure 12 - Plastics Identification Chart (1 of 2)
CHART OF PLASTIC PARTS IDENTIFICATION AND REFINISHING SYSTEMS

IDENTIFYING
SYMBOL
OLD SYMBOL IN ( )
CHEMICAL
COMPOSITION OR
PLASTIC "FAMILY" NAME
TYPICAL AREA(S)
WHERE PART USED
EXAMPLES OF
COMMON AND/OR
TRADE NAMES
TYPICAL PAINT
REPAIR SYSTEM
PVC
Polyvinyl Chloride (Vinyl)
Interior Soft Trim,

Instrument Panel Skins,
Roof Covers
Geon, Vinylite, Pliovic,

"Vinyl", Vinoflex, Unichem
SAN
(SA)
Styrene-Acrylonitrite
Center Consoles, Glove Box

Doors, Interior Trim Panels
Lustran, Tyril, Forsacryl
#6 and #7
Polycarbonate +
Polybutylene Terephthalate
Bumper Covers
Xenoy, Valox, Macroblend
#1, #2, #4,

and #5
Polyamide
Headlamp bezels, Quarter

panel exits, Exterior Finish,
Trim Panels
Nylon, Capron, Zytel Rilsan,

Minion Vydyne, Wellamid
#1 and #4
Polybutylene Terephthalate
+ Ether Ester Block
Copolymer
Rocker Cover Mldgs.,

Fascias
Bexloy "M"
#1 and #4
PC
Polycarbonate
Interior Hard (Rigid) Trim

Panels, Valance Panels
Lexan, Merion, Calibre
PF
Phenol - Formaldehyde
Ashtrays
Phenolic, Bakelite, Durez,

Genal, Resinox, Amberol,
Plyophen
PC+ PETP
PA
PAG
PAGG
PBT + TEEE
(PBT + EEBC)
#8
#1,#4and#6
#6
FOR SYMBOLS NOT LISTED IN THIS CHART, CONTACT THE SOCIETY OF AUTOMOTIVE ENGINEERS, 400 COMMONWEAL TH DRIVE,
WARRENDALE, PA 15096-0001 FOR A COPY OF SAE-J 1344
( ) = OLD IDENTIFYING SYMBOLS IN ABOVE CHARTS
SAE
= TYPICAL ISO MARKING SYMBOL FOUND ON PLASTIC PARTS
I I
PVC
= TYPICAL NEW SAE MARKING SYMBOL FOUND ON PLASTIC PARTS
SUGGESTED PLASTIC PARTS PAINT REPAIR SYSTEMS
SYSTEM #1
(Exterior)
Conventional Lacquer Enamel * Acrylic Urethane
SYSTEM #2
(Exterior)
* Flexible Lacquer Enamel * Acrylic Urethane
SYSTEM #3
(Exterior)
Polypropylene Primer and * Special Topcoat
SYSTEM #4
(Exterior)
Base Color Coat with Acrylic Lacquer or * Acrylic Urethane Clear Coat
SYSTEM #5
(Exterior)
Base Color Coat with * Flexible Urethane Clear Coat
SYSTEM #6
(Interior)
Conventional (Standard) Interior Acrylic Lacquer
SYSTEM #7
(Interior)
Polypropylene Primer and Standard Interior Topcoat
SYSTEM #8
(Interior)
Vinyl Interior Color
* = Contains lsocyanates - Use recommended respiratory protection
PC6013-101-0-RP
Figure 13 - Plastics Identification Chart (2 of 2)
GENERAL BODY SERVICE 10~1-15
HANDLING PRECAUTIONS FOR PLASTICS

Abbreviation
PE
Resistance to gasoline and

solvents
Other cautions
80 (176)
Gasoline and most solvents are

harmless.
Flammable
Polyvinyl chloride
90 (194)

harmless if applied for a very
short time (wipe up quickly).
Poison gas is emitted when

burned.
Polypropylene
90(194)

harmless.
Flammable
ABS
Acrylonitrile butadiene
styrene resin
90(194)
Avoid gasoline and solvents.
Avoid brake fluid.
AES
Acrylonitrile ethylene
styrene
90 (194)
Avoid brake fluid.
Polymethyl methacrylate
90(194)
Avoid brake fluid.
PUR
Polyurethane
90 (194)

harmless.
Avoid brake fluid.
AAS
Acrylonitrile acrylic rubber

styrene
95 (203)
Avoid brake fluid.
PPE
Polyphenylene ether
110(230)
POM
Polyacetal
120 (248)
Gasoline and solvents are

harmless.
Polycarbonate
120 (248)
Polyamide (Nylon)
150 (302)

harmless.
FRP
Fiber reinforced plastics
170 (338)

harmless.
PPC
Polypropylene composite
115 (239)

harmless.
PBT
Polybutylene terephthalate
140 (284)

harmless.
TPR
Thermoplastic rubber
80 (176)
TPE
Thermoplastic elastomer
80 (176)
pp
PMMA
PC
PA, PAG
PAGG
2.
oc
Polyethylene
PVC
1.
Heat resisting
temperature
(OF)
Material name
Avoid battery acid.
Avoid immersing in water.
Flammable
When repairing and painting a portion of the body adjacent to plastic parts, consider their characteristics
(influence of heat and solvent) and remove them if necessary or take suitable measures to protect them.
Plastic parts should be repaired and painted using methods suiting the materials.
PC6014-101-D-RP
Figure 14 - Plastics Handling Precautions
rn
Important
Save leftover pieces of repair material. They can be

used later for reinforcing the back of small damaged
areas and puncture repairs.
When using mat reinforcement to repair inner or
outer surfaces of a panel assembly, be sure there are
no strands of the mat left uncovered or unsaturated
by repair material. If exposed, the mat may act as a
wick and draw moisture into the repaired area,
affecting the integrity and finish.
Flexible Plastic Part Repair

1. Clean and inspect damaged area as required (Figure 15).
2. Support and line up parts as necessary using tape and
a clamp for minor damage (Figure 16). Fabricate a
patch panel if necessary.
3. Abrade back side of damage by scuffing the area
with a 36 grit disc on a Roloc sander.
G93705-1-BG
Figure 15 - Inspect Damaged Area
G94062-1-BG
Figure 17 - Cutting Fiberglass Cloth to Size
rn
Important
Use only compressed air or a clean dry cloth to

remove residue.
4. If necessary, cut piece of reinforcement mat (porous
or uni-directional) to desired shape. Extend mat
38 to 50 mm (1 1/2 to 2 inches) beyond repair area
(Figure 17).
5. Mix and apply thin coat of GM Goodwrench
Compoxy Repair Material (GM PIN 12345744) or
equivalent to back side of damaged area.
6. Lay pre-cut piece of reinforcement mat into thin coat
of repair material using applicator to press mat so
it becomes saturated. Make sure all trapped air is
forced out.
7. If mat is not screen type, use saturation roller to
ensure mat is completely saturated and there are no
exposed fibers or trapped air.
8. Apply second coat of flexible repair material,
making sure mat is completely saturated and there
are no exposed fibers or trapped air (Figure 18).
9. Allow to cure per manufacturer instructions.
10. Remove tape or clamps used for maintaining

alignment and contours.
A TAPE
B CLAMP
PC6016-101-D-RP
Figure 16 - Aligning Damage with Tape and Clamp
11. At outer surface of panel assembly, bevel damaged

area with a 50 grit Roloc disc. This step extends
contact between repair material and substrate (Figure 19).
12. Using a 180 grit disc on a dual-action orbital sander,
feather out several inches beyond damaged area to
remove any paint or primer from substrate. This
provides proper surface for adhesion (Figure 20).
13. Apply light coat of repair material to front side of
damaged area, taking care to apply it smoothly. Repair material should be level and slightly above surrounding contour.
14. Allow to cure per manufacturer recommendations.
PC6020-101-D-RP
Figure 21 - Block Sanding for Accurate Contour
G94056-1-BG
Figure 18 - Applying Repair Material
15. Rough out surface with an 80 grit disc on a dualaction orbital sander.
16. Finish contour sanding with 220 to 320 grit (wet or
dry) sandpaper on a sanding block (Figure 21).
For further detailed information, refer to the STG
Composite Plastic Repair Book (P/N 22005.35-10).
Flexible Plastic Part Refinishing

Figures 12 and 13
To refinish repaired flexible parts, it is very important to follow the paint manufacturer's system regarding
preparation, priming, and refinishing. Because these parts
are flexible, they may require special additives in the
primers and topcoat to prevent cracking and poor adhesion. Always use manufacturer's recommended materials
and never mix with other systems.
RIGID PLASTIC PART REPAIR AND

REFINISHING
CAUTION: Many paint repair systems
require additives containing isocyanates. It is essential that all recommendations and warnings listed on the
container label for materials selected
be followed. It is mandatory that adequate respiratory protection such as air
line respirators with a full hood be
worn. Such protection should be worn
during the entire painting process.
Persons with respiratory problems or
those allergic to isocyanates must not
be exposed to isocyanate vapors or
spray mist.
PC6017-101-D-RP
Figure 19 - Panel Beveling
Repair Materials
rn
PC6018-101-D-RP
Figure 20 - Panel Feathering
Important
Use supplies and repair materials from the same

manufacturer for the best results. Do not mix systems.
These rigid plastic panel assembly repair procedures
require the use of GM Goodwrench Structural Bonding
Epoxy (GM PIN 12345726) or equivalent.
Rigid Plastic Part Repair

Figures 15, 19, 20 and 22 through 25
1. Clean and inspect damaged area as required (Figure 15).
2. Begin reinforcement repair to inner surface of panel
assembly by scuffing back side of area with an 80
grit disc on a dual-action orbital sander or by hand if
access is limited. Do not heavily rough out surface
of panel assembly.
rn
Important
Use only compressed air or a clean dry cloth to

remove residue.
3. Apply skim coat of GM Goodwrench Structural
Bonding Epoxy (GM PIN 12345726) or equivalent
(Figure 23) to bonding strip.
4. Position bonding strip in place and secure with
clamp (Figure 24).
A CLAMP
B BACKING PANEL
PC6023-101-D-RP
Figure 24 - Secure Bonding Strip

B
~-
__ ....-
..,....
-,
........ ......................
-----~~--:.
A
B
C
D
E
D
E
ROUND CORNERS
MATTING
BONDING MATERIAL
EXISTING PANEL
BONDING STRIP
PC0005101F-RP
~~~-}~->..r--~~~~~~-~~---~~~
Figure 25 - Cross Section of Splice

PC6021-101-D-RP
Figure 22 - Reinforcement Mat
PC6022-101-D-RP
Figure 23 - Bonding Epoxy
5. For best results, bonding epoxy should be force

dried.
A. After applying epoxy to panel assembly, allow
epoxy to air dry at room temperature for
twenty minutes.
B. Apply heat with uniform heat source to force
dry at surface temperature of 70 to 82C
(160 to 180F) for 45 minutes. Use surface
temperature gage to obtain proper surface temperature.
NOTICE: Exceeding 82C (180F) may cause
damage to interior components, weatherstrips or related trim in the heated area.
C. Allow panel assembly to return to room
temperature before sanding.
6. Remove tape or clamps used for maintaining alignment and contours.
7. At outer surface of panel assembly, bevel damaged
area with 50 grit disc on a Roloc sander or equivalent. This step extends contact between bonding
epoxy and substrate (Figure 19).

8. Using a 180 grit disc on a dual-action orbital sander,
feather out several inches beyond damaged area to
remove any paint or primer from substrate. This provides proper surface for bonding (Figure 20).
9. Apply light coat of GM Goodwrench Structural
Bonding Epoxy (GM PIN 12345726) or equivalent
(Figure 23).
10 Smooth out bonding epoxy. Bonding epoxy should
be level and slightly above surrounding area (Figure
25).
11. Lay pre-cut piece of reinforcement cloth into bonding epoxy. Use applicator to saturate and remove all
trapped air.
12. Apply second coat of bonding epoxy, making sure
reinforcement mat is fully enclosed and no air is
trapped. Smooth surface with applicator.
13. Place second layer of reinforcement cloth over
second coat of bonding epoxy, working it smooth
and removing all trapped air.
14. Apply final coat of bonding epoxy, and place sheet
of wax paper over it. Use saturation roller to ensure
full penetration of bonding epoxy into mat.
15. For best results, bonding epoxy should be force
dried.
A. After applying epoxy to panel assembly, allow
epoxy to air dry at room temperature for
twenty minutes.
B. Apply heat with uniform heat source to force
dry at surface temperature of 70 to 82 C
(160 to 180F) for 45 minutes. Use surface
temperature gage to obtain proper surface temperature.
NOTICE: Exceeding 82C (180F) may cause
damage to interior components, weatherstrips or related trim in the heated area.
C. Allow panel assembly to return to room
temperature before sanding.
16. Rough out surface with an 80 grit disc on a dualaction orbital sander.
17. Finish contour sanding with 220 to 320 grit (wet or

dry) sandpaper on a sanding block.
For further detailed information, refer to the STG
Composite Plastic Repair Book (PIN 22005.35-10).
Rigid Plastic Part Refinishing

To refinish repaired rigid parts, it is very important
to follow the paint manufacturer's directions regarding
preparation, priming, and refinishing. Some TEO (EP,
EPM, TPO) rigid parts require special polypropylene
primers for adhesion. Always use manufacturer's recommended materials and never mix with other systems.
CARPET INSERT REATTACHMENT

Carpet inserts attached to body side assemblies, door
assemblies and quarter trim panel assemblies which have
become loose may be reattached with general trim adhesive (3M PIN 08080 or equivalent).
Use the following procedure:
1. Remove trim panel assembly when necessary and
place on clean work surface. Mask off trim panel
assembly to prevent glue overspray.
2. Sand areas of trim panel assembly where carpet is to
be reglued using a coarse grit sandpaper. Polypropylene panel assemblies should have a rough surface
for best adhesion. Remove all sanding debris.
3. Spray general trim adhesive (3M PIN 08080 or
equivalent) on sanded surface and back side of
carpet following manufacturer instructions.
4. When both sprayed surfaces become tacky to the
touch, press carpet in place and smooth out any
irregularities.
5. Remove masking materials and reinstall panel
assembly.
BODY PANEL ASSEMBLY ADJUSTMENT

AND ALIGNMENT
Use Figures 26 and 27 as a maximum and minimum
gap reference.
LOCATION
CLEARANCE GAP*
(MILLIMETERS)
FLUSHNESS*
(MILLIMETERS)
A. HOOD ASSEMBLY TO
FRONT FASCIA
4.01 1.5)
+ 1.0/-0.5 (PARALLEL
WITHIN 1.5)
B. HOOD ASSEMBLY TO
FRONT FENDER ASSEMBLY
4.0 I 1.5) (PARALLEL WITHIN 1.5)
0.5
C. FRONT FENDER ASSEMBLY

TO FRONT FASCIA
0.5
D. FRONT FENDER ASSEMBLY

TO FRONT FASCIA
2.0 (0.5) (PARALLEL WITHIN 0.5)
0.5
E. FRONT SIDE DOOR

ASSEMBLY TO FRONT
FENDER ASSEMBLY
5.0 ( 1.5) (PARALLEL WITHIN 1.5)
2.01 2.0)
F. FRONT SIDE DOOR

ASSEMBLY TO FRONT
FENDER ASSEMBLY
7.5 to 4.0
+ 0.0 (OUTBOARD)
- 1.5 (INBOARD)
G. FRONT FENDER ASSEMBLY

TO OUTER ROCKER PANEL
2.0 (+ 3.0/-2.0)
+ 1.5/- 0.0
H. FRONT TURN SIGNAL LAMP

TO FRONT FASCIA
1.5 10.5) (PARALLEL WITHIN 0.5)
N/A
J. HOOD ASSEMBLY TO
4.0 ( 1.5)
+ 0.5/- 1.0
K. FRONT FENDER ASSEMBLY

TO HEADLAMP DOOR
4.0 ( 1.5)
0.5
L. FRONT FASCIA TO
HEADLAMP DOOR
4.0 ( 1.5)
+ 0.5/- 1.0
M. HOOD ASSEMBLY AIR

EXTRACTOR TO HOOD
OUTER PANEL
1.0 ( 0.5)
0.5 (0.5)
HEADLAMP DOOR
OPENINGS MUST BE PARALLEL WITHIN 1.0 mm UNLESS OTHERWISE NOTED.

PC2002-101-F-RP
Figure 26 - Body Panel Assembly Fit Requirements (1 of 2)
LOCATION
FLUSHNESS*
(MILLIMETERS)
CLEARANCE GAP*
(MILLIMETERS)
N. REARHATCHASSEMBLYTO
ROOF OUTER SAIL
8.0 ! 1.5) (PARALLEL WITHIN 2.0)
+ 3.0 (OUTBOARD)
- 1.0 (INBOARD)
0. REAR HATCH ASSEMBLY TO
1.5
P. REAR HATCH ASSEMBLY TO

ROOF
+ 3.0 (OUTBOARD)
Q. ROOF OUTER PANEL TO

QUARTER OUTER PANEL
N/A
R. REAR COMPARTMENT LIFT

WINDOW OUTER PANEL TO
OUTER LENS
N/A
R. OUTER LENS TO REAR FASCIA
1.0
S. ROCKER QUARTER OUTER

PANEL TO ROCKER OUTER
PANEL
N/A
+ 0.0/- 1.0
T. ROCKER QUARTER OUTER

PANEL TO FUEL FILLER
DOOR
3.01 1.0)
+ 1.5/- 0.0
V. QUARTER OUTER PANEL

TO REAR FASCIA
2.0
W. QUARTER OUTER PANEL

TO OUTER LENS
2.0
X. SPOILER TO TAIL LAMP
N/A
X. CENTER FILLER PANEL

TO REAR BUMPER FASCIA
1.0
Y. FRONT DOOR OUTER PANEL

TO QUARTER OUTER PANEL
2.0 ( 2.0)
z.
REAR FASCIA TO REAR

QUARTER PANEL
N/A
N/A
OPENINGS MUST BE PARALLEL WITHIN 1.0 mm UNLESS OTHERWISE NOTED.
QUARTER PANEL
- 1.0 (INBOARD)
Figure 27 - Body Panel Assembly Fit Requirements (2 of 2)
PC2003-101-F-RP
STATIONARY WINDOWS 10-2-1
SECTION 10-2
STATIONARY WINDOWS
CAUTION: When replacing a windshield, urethane adhesive kit GM P/N 12345633, or equivalent, which includes Essex Beta Seal 55802 with 43518 and 43520A primer, must be used to
maintain original installation integrity. Failure to use urethane adhesive kit GM P/N 12345633
will result in poor retention of the windshield which may allow unrestrained occupants to be
ejected from the vehicle with resulting personal injury.
result.
CONTENTS
Stationary Windows .....................
Adhesive Caulking Kit ...................
Windshield Reveal Molding Assembly ......
Windshield Reveal Molding Assembly ......
Windshield Assembly ...................
Short Method ........................
Extended Method . . . . . . . . . . . . . . . . . . . . .
Waterleak Correction ....................
10-2-1
10-2-1
10-2-1
10-2-1
10-2-1
10-2-1
10-2-2
10-2-2
10-2-4
10-2-5
GENERAL DESCRIPTION
Inside Rearview Mirror Assembly .......... 10-2-6

Courtesy Lamp Bulb Replacement ....... 10-2-6
Inside Rearview Mirror Support . . . . . . . . . 10-2-6
Rear Window Defogger . . . . . . . . . . . . . . . . . . 10-2-7
Testing Grid Lines .................... 10-2-8
Grid Line Repair ..................... 10-2-8
Braided Lead Wire Repair .............. 10-2-9
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2-10
Fastener Tightening Specifications ........ 10-2-10
Special Tools ........................... 10-2-10
molding assembly (2) is retained in place by a urethane

adhesive.
STATIONARY WINDOWS
ON-VEHICLE SERVICE
Figure 1
The windshield assembly (1) is installed from outside the body, using self-curing urethane. Replacement of
the windshield assembly ( 1) requires removal of components and cutting it away from the adhesive.
ADHESIVE CAULKING KIT

The urethane adhesive kit (GM PIN 12345633) is
used for windshield adhesive service operations and leak
repair. This kit includes urethane adhesive and primers.
Failure to use this kit, or an equivalent, when indicated,
will result in poor retention of the windshield assembly.
WINDSHIELD REVEAL MOLDING

ASSEMBLY
Figure 1
The one-piece windshield reveal molding assembly
(2) is vinyl and is hand-pressed into place. The reveal
WINDSHIELD REVEAL MOLDING

ASSEMBLY
Figure 1

1. Roof drip scalp molding assemblies, if equipped.
2. Carefully pry end of reveal molding assembly (2)
out about 76 mm (3 inches), using screwdriver.
3. Grasp with pliers and slowly pull reveal molding assembly (2) away from body.
IL'l'I Inspect
Reveal molding assembly (2).
- If original reveal molding assembly (2) cannot
be reused (due to damage, cut short, etc.),
1022 STATIONARY WINDOWS
A APPLY CLEAR AND BLACK PRIMER, THEN URETHANE ADHESIVE

TO REVEAL MOLDING GLASS EDGE CHANNEL BEFORE
ASSEMBLY
1 WINDSHIELD ASSEMBLY
2 MOLDING ASSEMBLY, WINDSHIELD REVEAL
3 STRIP, WINDSHIELD SEALING
4 SUPPORT, INSIDE REARVIEW MIRROR
5 MIRROR ASSEMBLY, INSIDE REARVIEW
6 ROOF
SECTION AA
PC2001-102-F-RP
Figure 1 - Windshield and Reveal Molding Assemblies
discard it and replace it with a new service

reveal molding assembly (2). Be sure to prefit
the service reveal molding assembly (2) by
locating it on the body prior to installation.
l~I Clean
Windshield assembly (1) of all traces of urethane,
using alcohol-dampened cloth.

1. Clear primer from urethane adhesive kit (GM PIN
12345633 or equivalent) in glass edge channel of
reveal molding assembly (2).
2. Black primer from urethane adhesive kit (GM PIN
12345633 or equivalent) over clear primer.
3. Urethane adhesive from kit (GM PIN 12345633 or
equivalent) evenly in glass edge channel of reveal
molding assembly (2) over black primer.
4. Reveal molding assembly (2).
A. Start from center and hand press reveal molding assembly (2) in place over edge of windshield assembly (1).
B. Tape can be applied to keep reveal molding
assembly (2) flush with body.
C. Flood reveal molding assembly (2) with warm
water to speed setup of adhesive.
WINDSHIELD ASSEMBLY
All windshield assemblies are installed from outside
the body using self-curing urethane adhesive. Replacing a
windshield assembly installed with urethane adhesive
requires either partial or complete replacement of the
adhesive. Partial replacement of the adhesive is known as

the short method. Complete replacement of the adhesive
is known as the extended method.
Windshield assembly removal is the same for both
the short and extended installation methods with one
exception. Use more care with the short method during
cutout to make certain that an even bead of adhesive
remains on the windshield opening to serve as a base for
the new windshield assembly.
Short Method
Figures 1 and 2
Tool Required:
J 24402-A Window Sealant Remover (Cold
Knife) or
J 24709-01 or J 24899-01 Urethane Window
Sealant Remover (Hot Knife) or
J 39032 Stationary Glass Removal Tool
and gloves should be worn when performing this procedure to reduce the
chance of personal injury.

1. Place protective coverings around area where windshield assembly (1) is being removed.
2. Inside rearview mirror assembly. Refer to "Inside
Rearview Mirror Assembly" in this section.
3. Windshield side garnish molding assemblies. Refer
to SECTION 10-9.
4. Wiper arm and wiper blade assemblies. Refer to
SECTION SE.
5. Air inlet screen assemblies. Refer to SECTION
10-5.
STATIONARY WINDOWS 1023

7. Windshield reveal molding assembly. Refer to
"Windshield Reveal Molding Assembly" in this
section.
8. Mask area around windshield opening to protect
painted surfaces and to aid in cleanup after installation.
Tape must not touch windshield sealant surface.
9. Using J 39032, make preliminary cut into urethane
adhesive around entire perimeter of windshield
assembly (1 ), staying as close to edge of windshield
assembly (1) as possible.
10. Pull away portion of reveal molding assembly (2)
between windshield assembly (1) and body.
11. Cut out windshield assembly (1), using J 24402-A,
J 24709-01 or J 24899-01, or J 39032.
Keep blade as close to edge of windshield
assembly (1) as possible.
Use care during cutout to make certain that
even bead of adhesive remains on windshield
opening to serve as base for new windshield
assembly (1).
12. Windshield assembly (1).
13. Windshield sealing strip (3) from windshield assembly (I).
l~I
Clean
Windshield opening of any loose material. If old
windshield assembly (1) is to be reinstalled, all old
urethane adhesive must be removed from it, using
alcohol-dampened cloth.

section.
2. Windshield assembly (1) in opening for fit.
A. With aid of helper, properly position windshield assembly (1) in opening and apply piece
of masking tape over each edge of windshield
assembly (1) and adjacent body pillars.
B. Slit tape vertically at edge of windshield
assembly (1).
C. During installation, tape on windshield assembly (1) can be aligned with tape on body to
guide windshield assembly (1) into desired
position.
3. Remove windshield assembly (1).
l~I
Clean
A. Surface of windshield assembly (1) to which
adhesive will be applied (around edge of inside
surface) by wiping with clean, alcohol-dampened cloth.
B. Allow to air dry.
SECTION A-A
8-9.5 mm
j_
B
(0.31-0.37")
14-15.Smm
~ I
(0.55-0.61")
:d ~~
(0.28-0.33")
SECTION B-8
A WINDSHIELD ADHESIVE PRIMER LOCATION

(CLEAR AND BLACK)
B URETHANE ADHESIVE MATERIAL
1 WINDSHIELD ASSEMBLY
2 MOLDING ASSEMBLY, WINDSHIELD REVEAL
4 SUPPORT, INSIDE REARVIEW MIRROR
PC0003-102-F-RP
Figure 2 - Windshield Assembly Primer and Adhesive

Locations
4. Windshield sealing strip (3).

Remove paper backing from new windshield
sealing strip (3) and position adjacent to lower
blackout line.
5. Clear and black primers from urethane adhesive kit
(GM PIN 12345633 or equivalent) around entire
perimeter of windshield inner surface as shown in
Figure 2.
Two primers are provided in urethane adhesive
kit (GM PIN 12345633 or equivalent). Clear
primer must be applied first, immediately followed by black primer. Allow black primer to
dry five minutes prior to application of urethane adhesive. Primer application is most
important because it acts as bonding agent for
urethane adhesive and windshield assembly
(1).
rn
6.
7.
8.
9.
Important
Maximum surface temperature must not

exceed 49C (120F) at time of primer application.
Urethane adhesive from kit (GM PIN 12345633 or
equivalent).
With household cartridge-type caulking gun
and nozzle, apply smooth continuous bead of
urethane adhesive, 7.0 to 8.5 mm (0.28 to 0.33
inch) wide and 14.0 to 15.5 mm (0.55 to 0.61
inch) high, around edge of windshield assembly where primed in previous step.
Windshield assembly (1) into windshield opening
with aid of helper.
Carry windshield assembly (1) with one hand
on inside and one hand on outside. Guide
windshield assembly (1) along rear edge of
front fender assembly to avoid smearing fresh
adhesive on instrument panel. At windshield
opening, put windshield assembly (1) in horizontal position. While one person holds windshield assembly (1) in this position, second
person can reach one arm around body pillar
and support it while first person assumes same
position.
Windshield assembly (1).
Center in opening.
Use tape guides previously applied to place
windshield assembly (1) in proper position.
Press windshield assembly (1) firmly to wet-out and
set adhesive.
Use care to avoid squeezing out excessive

amounts of adhesive that would cause appearance problem.
10. Using small disposable brush or flat, soft fiberglass
tool, paddle material around edge of windshield assembly (1) to ensure watertight seal.
If necessary, paddle additional material to fill
voids in seal.
11. Water test vehicle at once, using soft spray.
Use warm water.
Do not direct hard stream of water at fresh
adhesive material.
Water applied on top of urethane adhesive,
either during water test or as separate operation, will speed up cure of urethane adhesive.
ILl
1nspect
For leaks. Paddle in extra adhesive at leak

point, using small disposable brush or flat, soft
fiberglass tool.
13. Air inlet screen assemblies. Refer to SECTION
10-5.
14. Wiper arm and wiper blade assemblies. Refer to

SECTION 8E.
15. Windshield side garnish molding assemblies. Refer
to SECTION 10-9.
16. Inside rearview mirror assembly. Refer to "Inside
NOTICE: On windshield assembly installations, the
vehicle must remain at normal room temperature for
six hours or the adhesive will not cure properly.
Extended Method
Figures 1 and 2
The extended method requires that all old urethane
adhesive be completely removed from windshield opening. This method is used only for extreme cases such as:
When the old urethane adhesive can no longer serve
as a good base.
When there is damage to the windshield opening.
When there is a need for the windshield opening to
be repainted in a body shop.
!~I Clean
Windshield opening.
- Using sharp scraper or chisel, remove old
adhesive material from windshield opening
mounting surfaces.
- All traces of material need not be removed, but
there should not be any mounds or loose pieces
left.

and gloves should be worn when performing this procedure to reduce the
section.
2. Windshield assembly (1) in opening for fit.
A. With aid of helper, properly position windshield assembly (1) in opening.
B. Check relationship of new windshield assembly (1) to urethane adhesive of windshield
opening mounting surfaces. Excessive gaps
must be corrected by locating spacers or by
applying more adhesive than specified.
C. Apply piece of masking tape over each edge of
windshield assembly (1) and adjacent body pillars.
D. Slit tape vertically at edge of windshield
assembly (1).
E. During installation, tape on windshield assembly (1) can be aligned with tape on body to
guide windshield assembly (1) into desired
position.
3. Remove windshield assembly (1).
,.,, Clean
A. Surface of windshield assembly (1) to which

adhesive will be applied (around edge of inside
surface) by wiping with clean, alcohol-dampened cloth.
B. Allow to air dry.
4. Windshield sealing strip (3).
Remove paper backing from new windshield
sealing strip (3) and position adjacent to lower
blackout line.
5. Black primer from urethane adhesive kit (GM PIN
12345633 or equivalent) to windshield opening
mounting surfaces.
[I] Important
10. Press windshield assembly (1) firmly to wet-out and

set adhesive.
Use care to avoid squeezing out excessive
amounts of urethane adhesive that would cause
appearance problem.
tool, paddle material around edge of windshield
assembly (1) to ensure watertight seal.
If necessary, paddle additional material to fill
voids in seal.
12. Water test vehicle at once, using soft spray.
Use warm water.
Do not direct hard stream of water at fresh
adhesive material.
Water applied on top of urethane adhesive,
either during water test or as separate operation, will speed up cure of urethane adhesive.
Maximum surface temperature must not

exceed 49C ( 120F) at time of primer application.
6. Clear and black primers from urethane adhesive kit
(GM PIN 12345633 or equivalent) around entire
perimeter of windshield inner surface as shown in
Figure 2.
kit (GM PIN 12345633 or equivalent). Clear
primer must be applied first, immediately followed by black primer. Allow black primer to
dry five minutes prior to application of urethane adhesive. Primer application is most
important because it acts as bonding agent for
urethane adhesive and windshield assembly
(1).
7. Urethane adhesive from adhesive kit (GM PIN

12345633 or equivalent).
urethane adhesive, 7.0 to 8.5 mm (0.28 to 0.33
inch) wide and 14.0 to 15.5 mm (0.55 to 0.61
inch) high, around edge of windshield assembly (1) where primed in previous step.
8. Windshield assembly (1) into windshield opening
with aid of helper.
Carry windshield assembly (1) with one hand
on inside and one hand on outside. Guide
windshield assembly (1) along rear edge of
front fender assembly to avoid smearing fresh
adhesive on instrument panel. At windshield
opening, put windshield assembly (1) in horizontal position. While one person holds windshield assembly (1) in this position, second
person can reach one arm around body pillar
and support it while first person assumes same
position.
9. Windshield assembly (1) on supports.
Center in opening.
Use tape guides previously applied to place
windshield assembly (1) in proper position.
ll'l'I
13.
14.
15.
16.
17.
Inspect
For leaks. Paddle in extra adhesive at leak

point, using small disposable brush or flat, soft
fiberglass tool.
Roof drip scalp molding assemblies, if equipped.
Air inlet screen assemblies. Refer to SECTION
10-5.
Wiper arm and wiper blade assemblies. Refer to
SECTION 8E.
Windshield side garnish molding assemblies. Refer
to SECTION 10-9.
Inside rearview mirror assembly. Refer to "Inside
NOTICE: On windshield assembly installations, the
vehicle must remain at normal room temperature for
six hours or the adhesive will not cure properly.
WATERLEAK CORRECTION
Where accessible, waterleaks can be corrected without removing and reinstalling the windshield assembly.
This method applies only to urethane-installed windshield
assemblies and use of windshield urethane adhesive furnished in urethane adhesive kit (GM PIN 12345633 or
equivalent).
1. Remove reveal molding assembly in area of leak.
In some cases, it may become necessary to
remove interior moldings to locate source of
leak.
2. Mark location of leak.
A. Carefully push outward on windshield assembly in area of leak to determine extent of leak.
Operation should be performed while
water is being applied to leak area.
B. Mark extent of leak area.
3. Using sharp knife, trim off uneven edge of adhesive
at leak point and 76 mm to 102 mm (3 inches to 4
inches) on both sides of leak point or beyond limits
of leak area.

4. Clean dirt or foreign material from leak area with
water (outside body). Dry area with air hose.
5. Prime affected area with black primer supplied in
adhesive kit GM PIN 12345633 or equivalent.
Allow primer to dry five minutes.
6. Apply urethane adhesive from urethane adhesive kit
(GM PIN 12345633 or equivalent) at leak point and
76 mm to 102 mm (3 inches to 4 inches) on both
sides of leak point or beyond limits of leak area.
7. Right after performing previous step, use flat stick
or other suitable flat, soft fiberglass tool to work
adhesive material well into leak point and into joint
of original material and body. This will ensure
watertight seal along entire length of material
application.
8. Using warm water, spray test to ensure leak has been
corrected.
Do not run heavy stream of water directly on
freshly applied urethane adhesive.
9. If leak still exists, use flat, soft fiberglass tool and
paddle additional adhesive material into leak point.
10. Replace all previously removed parts.
INSIDE REARVIEW MIRROR ASSEMBLY

Figure3
The inside rearview mirror assembly (5) is fastened
to an inside rearview mirror support (4) that is secured to
the windshield assembly (1). The rearview mirror assembly (5) is equipped with dual courtesy lamps.

2. Loosen bolt/screw (9).
3. Rearview mirror assembly (5) from rearview mirror
support (4).

NOTICE: See "Notice" on page 10-2-1 of this
section.
1. Rearview mirror assembly (5) to rearview mirror
support (4).
2. Bolt/screw (9).
l~I Tighten
Courtesy Lamp Bulb Replacement

There are two inside rearview mirror lamps (left and
right) on the inside rearview mirror assembly. These
lamps have replaceable bulbs.

1. Pry off courtesy lamp lens assembly.
2. Courtesy lamp bulb.
10
1
4
5
8
WINDSHIELD ASSEMBLY
SUPPORT, INSIDE REARVIEW MIRROR
MIRROR ASSEMBLY, INSIDE REARVIEW
CONNECTOR, INSIDE REARVIEW MIRROR
COURTESY LAMP ELECTRICAL
9 BOLT/SCREW, INSIDE REARVIEW MIRROR
10 LENS ASSEMBLY, COURTESY LAMP
PC000&-102-F-RP
Figure 3 - Inside Rearview Mirror Assembly

1. Courtesy lamp bulb.
2. Courtesy lamp lens assembly.
Inside Rearview Mirror Support

Figure 4
The inside rearview mirror assembly is attached to
an inside rearview mirror support (4) that is secured to the
windshield assembly (1). The rearview mirror support (4)
is installed by the window supplier, using a plastic-polyvinyl butyral adhesive.
Service replacement windshield assemblies have the
rearview mirror support (4) bonded to the windshield
assembly (1). To install a detached rearview mirror support (4) or install a new part, the following items are
needed.
GM PIN 1052369, Loctite 312 Adhesive kit, twocomponent pack or equivalent.
Mirror support (4).
Wax marking pencil or crayon.
Window cleaning solution or window polishing
compound.
Rubbing alcohol.
Clean paper towels.
Fine grit emery cloth or sandpaper, number 320 or
number 360.
Clean toothpick.
l@I Measure
Distance from bottom of windshield assembly (1) to
determine location of rearview mirror support (4).
A. Rearview mirror support (4) should be located
at center of windshield assembly (1), 689 mm

If original rearview mirror support (4) is to be
reused, all traces of old adhesive must be

removed prior to installation.
3. Wipe sanded rearview mirror support (4) with clean
paper towel saturated with alcohol and allow to dry.

Rearview mirror support (4) to windshield assembly
(1).
A. Follow directions on adhesive kit (GM PIN

1052369 or equivalent) to prepare rearview
mirror support (4) prior to installation on windshield assembly (1).
B. Lightly apply adhesive accelerator to bonding
surfaces of rearview mirror support (4) and
windshield assembly (1) and allow to dry completely.
\
A
B
C
D
E
1
4
rn
C.
D.
D
LOCATING CIRCLE
CLEANING AREA CIRCLE
BASE OF SUPPORT LINE
OUTSIDE GLASS
CENTERLINE
WINDSHIELD ASSEMBLY
SUPPORT, INSIDE REARVIEW MIRROR
E.
F.
PC0007-102-FRP
Figure 4 - Inside Rearview Mirror Support Placement
(27 1/8 inches) from base of windshield assembly (1) to base of rearview mirror support (4 ).
B. Mark location on outside of windshield assembly (1) with wax pencil or crayon.
C. Make larger diameter circle around marked
location on outside windshield surface.
15!1 Clean
1. Area of large circle on inside windshield surface
with paper towel and window cleaning solution or
window polishing compound.
A. Rub area until completely clean and dry.
B. When dry, clean area with alcohol-saturated
paper towel to remove any traces of cleaning
solution or polishing compound.
2. Sand bonding surface of new or detached original
rearview mirror support (4) with piece of fine grit
emery cloth or sandpaper, number 320 or number
360.
G.
Important
Due to rapid bonding of adhesive, the following steps must be performed without
hesitation.
Apply two drops of adhesive to rearview mirror support (4).
Use toothpick to evenly distribute adhesive
over entire bonding surface of rearview mirror
support (4).
Properly position rearview mirror support (4)
to pre-marked location with rounded end
pointed upward.
Press rearview mirror support (4) against
windshield assembly (1) for 30 to 60 seconds,
exerting steady pressure against windshield
assembly (1).
After five minutes, remove excess adhesive
with alcohol-moistened paper towel or window cleaning solution.
REAR WINDOW DEFOGGER

The optional rear window defogger system consists
of tinted windows with a number of horizontal ceramic
silver compound element lines and two vertical bus bars
baked into the inside surface during the glass forming
operation. The feed wire or terminal is soldered to the feed
bus bar on the left side. The ground wire or terminal is
soldered to the ground bus bar on the right side.
The system operates on 12 volts. Under some conditions, heat from the window may not be detected by finger
touch. The length of time required to remove interior fog
from the rear window will vary with such conditions as
vehicle speed, outside window temperature, atmospheric
pressure and number of passengers.
The system uses an instrument panel mounted
switch with an integral indicator lamp and will operate for
five or ten minutes, automatically turning off through the
use of a timer. The system can be turned off during this
operation period by turning either the instrument panel
mounted switch or ignition switch to "OFF."
10-28 STATIONARY WINDOWS
Testing Grid Lines

Figures 5 and 6
To locate inoperative grid lines, start the engine and

tum on the rear window defogger system. Ground one test
lamp lead and lightly touch other probe to each grid line.
Figure 5 illustrates pattern of test lamp brilliance to be
expected with a properly functioning grid.
If test lamp bulb shows full brilliance at both ends of
grid lines, check for loose ground wire contact to body
metal.
Range of zones of bulb brilliance may vary slightly
from one window to another. Bulb brilliance will decrease
proportionately to increased resistance in grid line as
probe is moved from feed bus bar to ground bus bar.
All grid lines must be tested in at least two places to
eliminate the possibility of bridging a break. For best
results, contact each grid line a few centimeters (inches)
either side of window centerline. If an abnormal lamp
reading is apparent on a specific grid line, place test lamp
probe on that grid at the feed bus bar and move probe
toward ground bus bar until lamp goes out. This will indicate a break in continuity of grid line (Figure 6).
If no break in continuity is found and braided lead
wire repairs are not needed but system is still inoperative,
refer to SECTION 8A for electrical diagnosis.
Grid Line Repair
A
B
C
D
E
F
NO BULB BRILLIANCE
BROKEN GRID LINE
FULL BULB BRILLIANCE
INSIDE OF GLASS
FEED BUS BAR
GROUND BUS BAR
PC6015 1020-RP
Figure 6 - Test Lamp Bulb Brilliance with Broken Grid Lines
lll 1nspect
Rear window defogger grid lines.
2. Mark grid line breaks on outside of window with
grease pencil.
Clean
Grid line area to be repaired.

3. Buff with fine steel wool and wipe clean, using alcohol-dampened cloth.
4. Buff and clean about 6 mm (1/4 inch) beyond each
side of break in grid line.
Figures 7 and 8

1. Battery negative cable assembly. Refer to SECTION
601.

REPAIR MATERIAL
ONE-HALF BULB BRILLIANCE
TWO STRIPS OF TAPE
THREE-QUARTER BULB BRILLIANCE
WOOD SPATULA
FULL BULB BRILLIANCE
KC0140102B-RP
Figure 5 - Normal Test Lamp Bulb Brilliance Zones
KC0160 102BRP
Figure 7 - Applying Repair Material to Broken Grid Line
STATIONARY WINDOWS 10-2-9
Braided Lead Wire Repair

Figures 8 and 9
The rear defogger bus bar lead wire or terminal can
be reattached by resoldering, using a solder containing 3
percent silver and a rosin flux paste.
0I
0
[]

REPAIR AREA
HEATGUN
25 mm (1 ") BETWEEN REPAIR
AREA AND HEAT GUN NOZZLE
KC0170-102-B-RP
Figure 8 - Applying Heat to Grid Line Repair
1. Grid line repair decal or two strips of tape positioned

above and below repair area.
Repair decal or tape must be used to control
width of repair area.
If decal is used, be sure die-cut metering slot is
same width as grid line.
2. Mix grid repair material according to manufacturer
instructions.
3. Grid repair material, at room temperature, to repair
area, using small wood stick or spatula.
4. Carefully remove decal or tape.
NOTICE: Grid line repair material must be cured
with heat. To avoid heat damage to interior trim, protect trim near repair area where heat is to be applied.
5. Apply heat to repair area for one to two minutes with
heat gun capable of reaching 260C (500F).
Hold heat gun nozzle 25 mm (1 inch) from
surface.
Minimum temperature of 149C (300F) is
required.
6Dl.
!ll

6Dl.
l~I
Clean
Buff repair area with fine steel wool to remove

oxide coating formed during window
manufacturing.
NOTICE: To prevent burning bus bar, soldering iron
tip temperature should be just enough to melt solder
and allow it to run freely. Iron should be in contact
with bus bar as short a time as possible.

1. Paste-type rosin flux in small quantities to wire lead
and bus bar repair, using brush.
Soldering iron tip should be coated with solder
beforehand.
2. Solder to feed bus bar or ground bus bar.
Draw soldering iron tip across fluxed area,
thinly coating bus bar with solder.
3. Small amount of flux to underside of lead wire braid.
Align spots with fluxed and tinned spots on
feed bus bar or ground bus bar.
1nspect
Grid line repair area.

A. If repair appears discolored, apply coating of tincture of iodine to repair area, using pipe cleaner or fine brush.
B. Allow iodine to dry for about 30 seconds
and carefully wipe off excess with lintfree cloth.
7. Test rear window defogger operation to verify grid
line repair. Refer to "Testing Grid Lines" in this section.
NOTICE: At least 24 hours are required for complete curing of repair materials. Unit should not be
physically disturbed until after that time, or repair
may not hold.
A SOLDERING IRON
B FLUX
C FEED BUS BAR
PC6018-102-D-RP
Figure 9 - Bus Bar Repair
10-2-10 STATIONARY WINDOWS

4. Coat tip of soldering iron with solder.
5. Solder to underside of lead wire braid.
Draw iron across fluxed spot, thinly coating
spot with solder.
6. Solder spot on braid against spot on feed bus bar or
ground bus bar.
A. Apply heat to top of lead wire braid, causing

solder spots to melt and fuse together.
B. Holding force should not be removed until solder has solidified.
7. Wipe off excess flux with solvent.
601.
SPECIFICATIONS
Inside Rearview Mirror Bolt/Screw .................................... 2 Nm (18 lb. in.)
SPECIAL TOOLS
1.
2.
J 24709-01
OR
J 24899-01
J24402-A
3.
J39032
~
1. URETHANE GLASS SEALANT REMOVER (HOT KNIFE)
2. GLASS SEALANT REMOVER (COLD KNIFE)
3. STATIONARY GLASS REMOVAL TOOL
PCOOOB-102-F-RP
BODY DIMENSIONS AND UNDERBODY 1031
SECTION 10-3
BODY DIMENSIONS AND UNDERBODY

Standard and subject the vehicle owner to possible suspicion that the part was stolen.
result.
CONTENTS
General Description ....................... 10-3-1
General Body Construction ............... 10-3-1
On-Vehicle Service ....................... 10-3-1
Alignment Checking .................... 10-3-1
Frame and Underbody ................. 10-3-1
Underbody Dimensions . . . Refer to SECTION 11
Frame Dimensions . . . . . . . Refer to SECTION 11
Underhood Dimensions . . . Refer to SECTION 11
Upper Body Dimensions . . Refer to SECTION 11
Body Side Dimensions . . . . Refer to SECTION 11
Cradle-to-Body Fastener Repair ........... 10-3-1

Frame ................................ 10-3-2
Underbody Flush ....................... 10-3-2
Steering Unit Rack and Pinion
Support Mount Plates .................. 10-3-2
Steering Unit Mounting .................. 10-3-2
Floor Pan Insulator ....... Refer to SECTION 10-10
Front Side Door Sill Trim Plate ............ 10-3-2
Specifications ............................ 10-3-2
Fastener Tightening Specifications ......... 10-3-2
GENERAL DESCRIPTION
ON-VEHICLE SERVICE
GENERAL BODY CONSTRUCTION

Information in this section pertains to unitized body
construction which incorporates integral front and rear
frame side rails.
The front suspension lower control arms are supported by a crossmember. The crossmember is bolted to
the body at six locations - three on each side of the engine
front compartment lower rails. Mounting provisions for
the front suspension system are shared by chassis components (suspension lower control arms and crossmember)
and body components (engine compartment side panels).
The suspension strut towers must be dimensionally correct in relation to the remainder of the underbody in order
to maintain specified suspension strut and caster/camber
angles.
Since the individual underbody components contribute directly to the overall strength of the body, proper
welding techniques must be observed during service
repair operations. The underbody components should be
properly sealed and rustproofed whenever body repair
operations destroy or damage the original sealing and
rustproofing. When rustproofing critical underbody components, use a good quality air dry primer such as corrosion-resistant chromate or equivalent material.
Combination type primer-surfacers are not recommended.
ALIGNMENT CHECKING
Frame and Underbody
Use a tram gage to accurately measure underbody
alignment. Make sure the tram gage set has a vertical
pointer that can reach 914 mm (36 inches).
Two types of measurements can be made with a tram
gage: direct point-to-point measurements and measurements calculated on a horizontal plane, or datum line, parallel to the underbody. To calculate measurements on a
horizontal plane, the vertical pointers must be set as specified for each point to be measured.
Point-to-point measurements are generally taken
only on engine compartment components and simply
require the vertical pointers to be equally set. Dimensionsto-gage holes are measured to dead center of the holes and
flush to the adjacent surface metal unless otherwise specified.
CRADLE-TO-BODY FASTENER REPAIR

1. Drill out center of drive train and front suspension
nut in rear mount.
2. Insert drive train and front suspension nut.
3. Insert front crossmember bolt/screw through drive
train and front suspension n11t.
10-32 BODY DIMENSIONS AND UNDERBODY
l~I
4. Brake pipe assemblies to engine cradle assembly.

Refer to SECTION 5.
Tighten
Front crossmember bolt/screw to 125 Nm

(92 lb. ft.).
5. Brake hose brackets to engine cradle assembly.

Refer to SECTION 5.
6. Engine mount. Refer to SECTION 6A2A or SECTION 6A3A.
FRAME
l++I
7. Steering gear bolts/screws. Refer to SECTION 3B.

3E.
3. Front upper control arm pivot shaft. Refer to SECTION 3C.
8. Lower control arm assemblies. Refer to SECTION

3C.
9. Front lower control arm bolts/screws to frame
10. Lower control arm assembly to steering knuckle
11. Front shock absorber bolt/screw. Refer to SECTION
3C.
4. Front shock absorber bolt/screw. Refer to SECTION

3C.
12. Front upper control arm pivot shaft. Refer to SECTION 3C.
5. Lower control arm assembly from steering knuckle

assembly (including cotter pin). Refer to SECTION
3C.

3E.
6. Front lower control arm bolts/screws from frame

7. Lower control arm assemblies. Refer to SECTION
3C.
8. Steering gear bolts/screws. Refer to SECTION 3B.
9. Engine mount. Refer to SECTION 6A2A or SECTION 6A3A.
Support engine assembly with jacking fixtures
in front and rear.
10. Brake hose brackets from engine cradle assembly.
Refer to SECTION 5.
11. Brake pipe assemblies from engine cradle assembly.
Refer to SECTION 5.
14. Lower vehicle.
UNDERBODY FLUSH
Due to buildup of road salts and corrosives on the
vehicle underbody, the underbody (including suspension,
exhaust and fuel line areas) should be flushed with clean
water annually, preferably each spring. This will increase
the life and strength of the underbody components.
STEERING UNIT RACK AND PINION

SUPPORT MOUNT PLATES
The fore and aft and side-to-side dimension reference
points for the rack and pinion steering mount plates are
measured point to point. The vertical dimensions for the
reference points are measured on a vertical plane from the
datum line to the center of the steering unit attaching holes.
12. Wheel speed sensor assembly from engine cradle

13. Engine cradle mount bolt/screw. Refer to SECTION
6A2A or SECTION 6A3A.
14. Engine cradle assembly.
l++I
Install or Connect
STEERING UNIT MOUNTING

Vehicles involved in accidents resulting in frame
damage, major body or sheet metal damage, or where the
steering column has been impacted, may also have a misaligned steering column.
1. Engine cradle assembly.
For the procedure to check capsules on the steering

column bracket assembly, refer to SECTION 3F.
2. Engine cradle mount bolt/screw. Refer to SECTION

6A2A or SECTION 6A3A.
FRONT SIDE DOOR SILL TRIM PLATE
3. Wheel speed sensor assembly to engine cradle

To remove, pull up on front side door sill trim plate.

Snap into place to install.
SPECIFICATIONS
Front Crossmember Bolt/Screw ....................................... 125 Nm (92 lb. ft.)
BUMPERS 1041
SECTION 10-4
BUMPERS
number is not available, a fastener of equal size and strength (or stronger) may be used. Fasteners that are not
result.
CONTENTS
Bumper Assemblies . . . . . . . . . . . . . . . . . . . . .
Energy Absorbing Units . . . . . . . . . . . . . . . . .
Front Bumper Assembly .................
Front Bumper Fascia . . . . . . . . . . . . . . . . . .
Front License Plate Bracket .............
Front Bumper Energy Absorber .........
Front Bumper Impact Bar Assembly ......
10-4-1
10-4-1
10-4-1
10-4-1
10-4-1
10-4-1
10-4-3
10-4-3
10-4-3
GENERAL DESCRIPTION
BUMPER ASSEMBLIES
The front bumper design includes a full-width
energy absorber of a styrofoam material. The rear bumper
design is a full-width honeycomb energy absorber of
guide flex (or equivalent) material. Both bumpers are
backed up by rigidly mounted impact bars. The front
bumper fascia is polyurea painted body color. The rear
bumper fascia is polyurethane painted body color.
For repair of the front and rear bumper fascias, refer
to SECTION 10-1.
ENERGY ABSORBING UNITS

General Motors passenger car bumper systems are
designed to take a collision into a fixed barrier at 8 km/h
(5 mph) without damage. After absorbing the energy of a
collision, these bumper systems restore themselves to
their miginal position.
ON-VEHICLE SERVICE
FRONT BUMPER ASSEMBLY
Front Bumper Fascia
Figures 1 and 2

Front Bumper Fascia Emblem Assemblies

Front Fog Lamp Opening Cover ........ .
Front Bumper Fascia Lower Deflectors ... .
Rear Bumper Assembly ................. .
Rear Bumper Fascia .................. .
Rear Bumper Energy Absorber ......... .
Rear Bumper Impact Bar .............. .
Specifications ........................... .
Fastener Tightening Specifications ........ .
10-4-4
10-4-4
10-4-4
10-4-5
10-4-5
10-4-6
10-4-6
10-4-8
10-4-8
2. Front bumper fascia lower deflectors. Refer to

"Front Bumper Fascia Lower Deflectors" in this
section.
3. Retainers (21).
4. Nuts (3 and 10), bolts/screws (4 and 11) and lower
supports (7 and 9).
5. Lower vehicle.
7. Manually raise headlamp assemblies.
8. Retainers (6).
10. Front bumper fascia (1 or 35).
11. Electrical connectors from front bumper fascia
(1 or 35).

section.
1. Electrical connectors to front bumper fascia (1 or 35).
2. Front bumper fascia (1 or 35).
l~I Tighten
Bolts/screws (2 and 8) to 1.7 Nm (15 lb. in.).
4. Retainers (6).
5. Manually retract headlamp assemblies.
13
24
25
37
~~-----F,gure 1 - Front Bumper Assembly
BUMPERS 10-4-3
A COLLAR, RAIL
B BRACKET, OUTER SUPPORT
STUD FRONT BUMPER PLATE ASSEMBLY
D BASE FIREBIRD AND FORMULA
E TRANS AM
1 FASCIA, FRONT BUMPER
2 BOLT/SCREW, FRONT BUMPER FASCIA BRACE
3 NUT, FRONT BUMPER FASCIA LOWER SUPPORT
4 BOLT/SCREW, FRONT BUMPER FASCIA LOWER
SUPPORT
6 RETAINER, FRONT BUMPER FASCIA (PUSH-IN)
7 SUPPORT, FRONT BUMPER FASCIA LOWER
8 BOLT/SCREW, FRONT BUMPER FASCIA BRACE
9 SUPPORT, FRONT BUMPER FASCIA LOWER
10 NUT, FRONT BUMPER FASCIA LOWER SUPPORT
SUPPORT
13 ABSORBER, FRONT BUMPER FASCIA ENERGY
14 PLATE ASSEMBLY, FRONT BUMPER IMPACT
15 PLATE ASSEMBLY, FRONT BUMPER IMPACT
16 RETAINER, FRONT BUMPER IMPACT BAR STUD
17 RETAINER, FRONT BUMPER IMPACT BAR STUD
18 BAR ASSEMBLY, FRONT BUMPER IMPACT
19 NUT, FRONT BUMPER IMPACT BAR
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
NUT, FRONT BUMPER IMPACT BAR

RETAINER, FRONT BUMPER FASCIA (PUSH-IN)
RETAINER, FRONT BUMPER FASCIA ENERGY
RETAINER, FRONT BUMPER FASCIA LOWER
DEFLECTOR
BOLT/SCREW, FRONT BUMPER FASCIA LOWER
DEFLECTOR
BOLT/SCREW, RADIATOR AIR LOWER DEFLECTOR
DEFLECTOR, FRONT BUMPER FASCIA LOWER
RETAINER, FRONT BUMPER FASCIA LOWER
DEFLECTOR
BOLT/SCREW, FRONT BUMPER FASCIA LOWER
DEFLECTOR
BOLT/SCREW, RADIATOR AIR LOWER DEFLECTOR
COVER, FRONT FOG LAMP OPENING
NUT, FRONT FOG LAMP OPENING COVER
FASCIA, FRONT BUMPER
BOLT/SCREW, FRONT FOG LAMP OPENING COVER
PC2006-104-F-RP
Figure 2 - Front Bumper Assembly - Legend
8. Lower supports (7 and 9), nuts (3 and 10) and bolts/

screws (4 and 11).
l~I Tighten
Nuts (3 and 10) to 10 Nm (89 lb. in.).
Bolts/screws (4 and 11) to 10 Nm (89 lb. in.).
9. Retainers (21).
10. Front bumper fascia lower deflectors. Refer to
"Front Bumper Fascia Lower Deflectors" in this
section.
11. Lower vehicle.
2. Retainers (22).
3. Front bumper energy absorber (13).

1. Front bumper energy absorber (13).
2. Retainers (22).
Install retainers (22) starting at center of front
bumper energy absorber (13) and working
outboard.
3. Front bumper fascia. Refer to "Front Bumper
Fascia" in this section.
Front License Plate Bracket
Front Bumper Impact Bar Assembly
Figures 1 and 2
1. Bolts/screws attaching front license plate bracket to

front bumper fascia.
2. License plate bracket from front bumper fascia.

License plate bracket to front bumper fascia.
A. Align holes in license plate bracket with holes
in front bumper fascia.
B. Install bolts/screws attaching license plate
bracket to front bumper fascia.
Front Bumper Energy Absorber

Figures 1 and 2

1. Front bumper fascia. Refer to "Front Bumper
Fascia" in this section.

1. Front bumper energy absorber. Refer to "Front
Bumper Energy Absorber" in this section.
2. Nuts (19 and 20) from plate assembly studs.
3. Front bumper impact bar assembly (18).

section.
1. Front bumper impact bar assembly (18).
2. Nuts (19 and 20) to plate assembly studs.
l~I Tighten
3. Front bumper energy absorber. Refer to "Front
Bumper Energy Aborber" in this section.
10-4-4 BUMPERS
Front Bumper Fascia Emblem Assemblies

Figure 3

Emblem assembly (45).
A. Apply heat using heat gun, making sure heat
gun is moved in circular motion and is held at
least 152 mm (6 inches) from emblem assembly (45) for about 30 seconds.
B. Peel emblem assembly (45) from front bumper
fascia (1) with flat-bladed tool, making sure
not to damage paint.
155
mm
(6.1")
lt:fl Clean
Area with suitable solvent of isopropyl alcohol
50-50 mixture by volume with water or high-flash
naphtha.

Emblem assembly (45).
A. Body and part temperature must be 26C
(80F) minimum or 6C (10F) above ambient air temperature, whichever is higher, but
not to exceed 40C (105F) during installation.
B. Peel protective paper from emblem assembly
adhesive.
[I] Important
Position emblem assembly (45) carefully
on front bumper fascia (1). Emblem
assembly (45) cannot be easily removed
after contact with vehicle. Refer to Figure 3.
C. Press emblem assembly (45) into place and
apply constant pressure for 30 seconds.
SECTION A-A
1 FASCIA, FRONT BUMPER

45 EMBLEM ASSEMBLY, FRONT BUMPER FASCIA
PC2002-104-F-RP
Figure 3 - Front Bumper Fascia Emblem Assembly (Typical)

section.
1. Front fog lamp opening cover (31 or 37).
2. Nuts (32) to front fog lamp opening cover (31) or
bolts/screws (36) to front fog lamp opening cover
(37).
l~I Tighten
Nuts (32) to 2.3 Nm (20 lb. in.).
D. Remove pre-mask from emblem assembly

(45).
Front Bumper Fascia Lower Deflectors

Front Fog Lamp Opening Cover
Figure 4

2. Retainers (2 I).
Remove enough retainers (21) so that lower
portion of front bumper fascia (1 or 35) can be
pulled down to gain access to nuts (32) or
bolts/screws (36).
3. Nuts (32) from front fog lamp opening cover (31) or
bolts/screws (36) from front fog lamp opening cover
(37).
4. Front fog lamp opening cover (31 or 37).
Figures

1. Retainers (23).
2. Bolts/screws (24 and 50) from front lower deflector
(26) and wheelhouse panel liner (51).
3. Bolts/screws (25) from front lower deflector (26)
and radiator air lower deflector (49).
4. Retainers (47) from front lower deflector (26) and
radiator air lower baffle (48).
5. Front lower deflector (26).
Slide front lower deflector (26) outward from
radiator air lower deflector (49) and wheelhouse panel liner (51 ).
BUMPERS 1045
I
~21
37
A
A
B
1
21
31
BASE FIREBIRD AND FORMULA

TRANSAM
RETAINER, FRONT BUMPER FASCIA (PUSH-IN)
32
35
36
37

PC2003104-F-RP
Figure 4 - Front Fog Lamp Opening Covers (Left Side Shown, Right Side Similar)
l++I
Install or Connect

section.
1. Front lower deflector (26).
Slide front lower deflector (26) inward and
over radiator air lower deflector (49) and
wheelhouse panel liner (51).
2. Retainer (47) to radiator air lower baffle (48) and
front lower deflector (26).
3. Bolts/screws (25) to radiator air lower deflector (49)
and front lower deflector (26).
l~I
Tighten

4. Bolts/screws (24 and 50) to wheelhouse panel liner
(51) and front lower deflector (26).
5. Retainers (23).
REAR BUMPER ASSEMBLY

Rear Bumper Fascia
Figure 6
l++I
7.
8.
9.
10.
11.
l++I
Install or Connect

section.
1. Rear body wiring harness connector to rear fascia
wiring harness connector.
2. Rear bumper fascia (68).
3. Nuts (54 and 55).
l~I
4.
5.
6.
7.

2. Retainers (69 and 70).
4. Nuts (53).
5. Lower vehicle.
6. Rear end finish panel assembly. Refer to SECTION
10-8.
Compact spare tire and jack assembly.

Retainers (67).
Nuts (54 and 55).
Rear bumper fascia (68).
Rear body wiring harness connector from rear fascia
wiring harness connector.
8.
Tighten
Nuts (54 and 55) to 10 Nm (89 lb. in.).

Retainers (67).
Compact spare tire and jack assembly.
Rear end finish panel assembly. Refer to SECTION
10-8.
Nuts (53).
l~I
Tighten
Nuts (53) to 10 Nm (89 lb. in.).

l~I
Tighten
1046 BUMPERS
26
26
51
48
47
50
26
23 RETAINER, FRONT BUMPER FASCIA LOWER

DEFLECTOR
DEFLECTOR
25 BOLT/SCREW, RADIATOR AIR LOWER DEFLECTOR
26 DEFLECTOR, FRONT BUMPER FASCIA LOWER
47 RETAINER, FRONT BUMPER FASCIA LOWER
DEFLECTOR
48 BAFFLE, RADIATOR AIR LOWER

49 DEFLECTOR, RADIATOR AIR LOWER
DEFLECTOR
51 LINER, FRONT WHEELHOUSE PANEL
PC2004-104-F-RP
Figure 5 - Front Bumper Fascia Lower Deflector (Left Side Shown, Right Side Similar)
10. Retainers (69 and 70).

11. Lower vehicle.
Rear Bumper Energy Absorber

Figure 6
l++I
3. Rivets (64).
4. Rear bumper fascia. Refer to "Rear Bumper Fascia"
in this section.
Rear Bumper Impact Bar

Figure 6
1. Rear bumper fascia. Refer to "Rear Bumper Fascia"

in this section.
2. Rivets (64) using 1/4-inch drill bit.
4. Rear bumper energy absorber (65).

section.
1. Rear bumper energy absorber (65).
Position hole at center of rear bumper energy
absorber (65) over locating boss at center of
rear bumper impact bar (61).
Install bolts/screws (66) starting at center of
rear bumper energy absorber (65) and working
outboard.
l~I
Tighten
l++I
1. Rear bumper energy absorber. Refer to "Rear

2. Nuts (56 and 72) from plate assembly studs.
3. Rear bumper impact bar (61).
Note number and placement of shims (57 and
60).

section.
1. Rear bumper impact bar (61) and shims (57 and 60).
Place shims (57 and 60) in location from which
they were removed.
2. Nuts (56 and 72) to plate assembly studs.
l~I
Tighten

3. Rear bumper energy absorber. Refer to "Rear
BUMPERS 1047
61
65
A
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70
71
72
BOSS, LOCATING
NUT, REAR BUMPER FASCIA
NUT, REAR BUMPER IMPACT BAR
SHIM, REAR BUMPER IMPACT BAR
RETAINER, REAR BUMPER IMPACT BAR BOLT
(PUSH-ON)
RETAINER, REAR BUMPER IMPACT BAR BOLT
(PUSH-ON)
SHIM, REAR BUMPER IMPACT BAR
BAR, REAR BUMPER IMPACT
PLATE ASSEMBLY, REAR BUMPER IMPACT BAR STUD
PLATE ASSEMBLY, REAR BUMPER IMPACT BAR STUD
RIVET, REAR-END FASCIA ENERGY ABSORBER
ABSORBER, REAR BUMPER FASCIA ENERGY
BOLT/SCREW, REAR END FASCIA ENERGY ABSORBER
RETAINER, REAR BUMPER FASCIA (PUSH-IN)
FASCIA. REAR BUMPER
BOLT/SCREW, REAR BUMPER FASCIA
NUT, REAR BUMPER IMPACT BAR
69
70
PC2005-104-F-RP
Figure 6 - Rear Bumper Assembly
10-48 BUMPERS
SPECIFICATIONS
Front Bmnper Fascia Brace Bolt/Screw ................................. 1.7 Nm (15 lb. in.)
Front Bumper Fascia Lower Support Bolt/Screw ........................... 10 Nm (89 lb. in.)
Front Bumper Fascia Lower Support Nut ................................. 10 Nm (89 lb. in.)
Front Bumper Impact Bar Nut ......................................... 25 Nm (18 lb. ft.)
Front Fog Lamp Opening Cover Bolt/Screw ............................. 1.7 Nm (15 lb. in.)
Front Fog Lamp Opening Cover Nut ................................... 2.3 Nm (20 lb. in.)
Radiator Air Lower Deflector Bolt/Screw ............................... 5.5 Nm (49 lb. in.)
Rear Bumper Fascia Bolt/Screw ......................................... 2 Nm (18 lb. in.)
Rear Bumper Fascia Nut .............................................. 10 Nm (89 lb. in.)
Rear Bumper Impact Bar Nut .......................................... 15 Nm (11 lb. ft.)
Rear End Fascia Energy Absorber Bolt/Screw ............................ 5.5 Nm (49 lb. in.)
BODY FRONT END 1051
SECTION 10-5
BODY FRONT END

result.
CONTENTS
Body Front End ........................ 10-5-1
Lubrication ............................ 10-5-3
Fasteners ............................. 10-5-3
Anticorrosion Protection ................. 10-5-3
Front End Panels ....................... 10-5-3
Radiator Air Baffle Assemblies
and Deflectors . . . . . . . . . . Refer to Section 6B
Radiator Air Lower Deflector ........... 10-5-3
Radiator Support Assembly ... Refer to Section 11
Headlamp Housing
Panel Assembly and Brackets ......... 10-5-3
Battery Tray and Coolant Recovery
Reservoir Assembly . . . . . . Refer to Section 6B
SIR Forward
Discriminating Sensor ..... Refer to Section 9J
Front Fender Assembly .................. 10-5-4
Front Wheelhouse Panel Liner .......... 10-5-4
Front Fender Assembly and Brackets ..... 10-5-5
Hood Panel Assembly . . . . . . . . . . . . . . . . . . . 10-5-6
Hood Insulator ....................... 10-5-9
Hood Closeout Filler .................. 10-5-9
Hood Hinge Assembly ................ 10-5-10
Hood Primary Latch Assembly . . . . . . . . . 10-5-11
Hood Secondary Latch Assembly ....... 10-5-12
GENERAL DESCRIPTION
BODY FRONT END
Figures 1 and 2
The hood panel assembly (1) is composed of galvanized metal. Further rigidity is obtained by the use of rein-
Hood Primary Latch Release

Cable Assembly ...................
Hood Open Assist Rod Assembly .......
Hood Open Assist Rod Bracket Assembly
Hood Rear Seal Assembly .............
Hood Adjust Front Bumper ............
Hood Air Extractors ..................
Plenum Chamber ......................
Front End Sealing .....................
Air Inlet Screen Assemblies . . . . . . . . . . . . .
Body Hinge Pillar Trim Panel Assembly ....
Dash Sound Barrier Assembly ............
Body Hinge Pillar
Inner Panel Sound Barriers . . . . . . . . . . . .
Front Door Jamb Switch Assemblies .......
Exterior Moldings and Decal . . . . . . . . . . . . .
Rocker Panel Molding Assembly .......
Front Fender Center Rear Molding
Assembly ........................
Headlamp Opening Door Decal .........
Roof Side Rail Weatherstrip Retainer ......
Body Panel Adjustment and Alignment ....
Hood Panel Assembly Adjustment ......
Specifications ...........................
Fastener Tightening Specifications ........
10-5-12
10-5-14
10-5-14
10-5-15
10-5-15
10-5-15
10-5-16
10-5-16
10-5-16
10-5-17
10-5-17
10-5-18
10-5-19
10-5-19
10-5-19
10-5-20
10-5-20
10-5-20
10-5-21
10-5-21
10-5-24
10-5-24
forcement braces and brackets located so as not to

interfere with adjustments or service repair. The hood primary latch assembly (27) is attached to the hood primary
latch support assembly (26).
Front fender assemblies (13) are composed of reinforced reaction injection molded (RRIM) urethane. The
1052 BODY FRONT END
17
PC2001-105-F-RP
Figure 1 - 8 ody Front End C
omponents
---~c200
- -
BODY FRONT END 1053
1
2
3
4
5
6
7
8
9
11
12
13
14
15
16
17
18
19
PANEL ASSEMBLY, HOOD

BRACKET, HOOD HINGE
HINGE ASSEMBLY, HOOD
MOLDING ASSEMBLY, HOOD REAR
PLATE ASSEMBLY, HOOD HINGE MOUNT
SHIM, HOOD
BRACKET, HOOD OPEN ASSIST ROD
ROD ASSEMBLY, HOOD OPEN ASSIST
STUD, HOOD STRUT BALL
BRACKET, FRONT FENDER REAR UPPER
BRACKET, FRONT FENDER REAR CENTER
FENDER ASSEMBLY, FRONT
MOLDING, FRONT FENDER CENTER REAR
LINER, FRONT WHEELHOUSE PANEL
BRACKET ASSEMBLY, FRONT BUMPER FASCIA OUTER
FILLER, HOOD CLOSEOUT
20 CABLE ASSEMBLY, HOOD PRIMARY LATCH RELEASE

21 BRACKET ASSEMBLY, HEADLAMP HOUSING
PANEL UPPER
22 SUPPORT ASSEMBLY, HEADLAMP HOUSING PANEL
23 BRACKET, HEADLAMP HOUSING PANEL
24 PANEL ASSEMBLY, HEADLAMP HOUSING
25 CLIP, HOOD PRIMARY LATCH RELEASE CABLE
26 SUPPORT ASSEMBLY, HOOD PRIMARY LATCH
27 LATCH ASSEMBLY, HOOD PRIMARY
30 BUMPER ASSEMBLY, HOOD ADJUST FRONT
31 CAP, HOOD ADJUST FRONT BUMPER
32 LATCH ASSEMBLY, HOOD SECONDARY
33 STRIKER, HOOD PRIMARY LATCH
34 INSULATOR, HOOD
35 SEAL, HOOD REAR
37 EXTRACTOR, HOOD AIR
38 SCREEN, HOOD AIR EXTRACTOR
PC2002-105-F-RP
Figure 2 - Body Front End Components - Legend
front fender assemblies (13) attach to the front wheelhouse panel liner (15).
LUBRICATION
For lubrication of hood hinges, hood latch assembly
release pawl, hood latch assembly and pivots, headlamp
door assembly, etc., refer to SECTION OB.
FASTENERS
NOTICE: When replacing fasteners avoid substituting otherwise similar fasteners in locations which
require the use of GM 6174 or GM 604 7 type special
fasteners for aluminum components, if used. Failing
to follow this precaution may result in premature
corrosion of the sheet metal in the areas mentioned
above.
ANTICORROSION PROTECTION
Anticorrosion materials are part of the coating on
most metal panels to provide rust resistance. When servicing these panels, use only GM replacement parts and
recoat with specified service primers and paints.
ON-VEHICLE SERVICE
FRONT END PANELS
Radiator Air Lower Deflector
Figure3

1. Bolts/screws (40) attaching radiator air lower
deflector (17) to front bumper fascia lower deflectors (16).

NOTICE: See "Notice" on page 10-5-1 of this section.
2. Bolts/screws (40 and 41 ).
l~I Tighten
Bolts/screws (40 and 41) to 5.5 Nm (49 lb.
in.).
Headlamp Housing Panel Assembly and

Brackets
Figure 4

1. Front bumper fascia. Refer to SECTION 10-4.
2. Bolts/screws (48) from pivot support brackets and
panel brackets (23).
3. Bolts/screws (44, 45 and 46) from headlamp housing panel assembly (24).
Slide headlamp housing panel assembly (24)
slightly out to gain access to headlamp assembly electrical connectors.
5. Headlamp housing panel assembiy (24).
6. Panel support bolts/screws (49) and panel support
assemblies (22), if necessary.
7. Panel bracket bolts/screws (47) and panel brackets
(23), if necessary.
8. Upper bracket bolts/screws (50) and upper bracket
assembly (21), if necessary.
1054 BODY FRONT END
A
16
17
40
SUPPORT ASSEMBLY, RADIATOR

BOLT/SCREW, RADIATOR AIR LOWER DEFLECTOR,
5.5 Nm (49 LB. IN.)
41 BOLT/SCREW, RADIATOR AIR LOWER DEFLECTOR,
5.5 Nm (49 LB. IN.)
41
PC0001105-F-RP
Figure 3 - Radiator Air Lower Deflector
l++I
l~I
Install or Connect

1. Panel support assemblies (22) and panel support
bolts/screws (49), if removed.
l~I
Tighten
Panel support bolts/screws (49) to 10 Nm (89

lb. in.).
2. Panel bracket (23) and panel bracket bolts/screws
(4 7), if removed.
l~I
Tighten
Panel bracket bolts/screws (47) to 5.5 Nm (49

lb. in.).
3. Upper bracket assemblies (21) and upper bracket
l~I
Tighten
Upper bracket bolts/screws (50) to 10 Nm (89

lb. in.).
4. Headlamp housing panel assembly (24).
6. Bolts/screws (44, 45 and 46) to headlamp housing
l~I
Tighten
Bolts/screws (44, 45 and 46) to 8 Nm (71 lb.

in.).
7. Panel bracket bolts/screws (48) to panel brackets
(23) and pivot support brackets.
Tighten
Panel bracket bolts/screws (48) to 1.7 Nm (15

lb. in.).
8. Front bumper fascia. Refer to SECTION 10-4.
FRONT FENDER ASSEMBLY

Front Wheelhouse Panel Liner
Figures
l++I
1. Front wheelhouse bolt/screw caps (53).

3. Front tire and wheel assembly. Refer to SECTION
3E.
4. Bolts/screws (54) from wheelhouse panel liner (15)
and lower deflector (16).
5. Bolts/screws (55) from wheelhouse panel liner (15).
6. Retainers (56).
7. Wheelhouse panel liner (15).
l++I
Install or Connect

1. Wheelhouse panel liner (15).
2. Retainers (56).
3. Bolts/screws (55) to wheelhouse panel liner (15).
l~I
Tighten
BODY FRONT END 10-55
24
A BRACKET, PIVOT SUPPORT
21 BRACKET ASSEMBLY, HEADLAMP HOUSING PANEL
UPPER
22 SUPPORT ASSEMBLY, HEADLAMP HOUSING PANEL
23 BRACKET, HEADLAMP HOUSING PANEL
44 BOLT/SCREW, HEADLAMP HOUSING PANEL,
8 Nm (71 LB. IN.)
45 BOLT/SCREW, HEADLAMP HOUSING PANEL,
8 Nm (71 LB. IN.)
46 BOLT/SCREW HEADLAMP HOUSING PANEL,

8 Nm (71 LB. IN.)
47 BOLT/SCREW, HEADLAMP HOUSING PANEL BRACKET,
5.5 Nm (49 LB. IN.)
48 BOLT/SCREW, HEADLAMP HOUSING PANEL BRACKET
1.7 Nm (15 LB. IN.)
49 BOLT/SCREW, HEADLAMP HOUSING PANEL
SUPPORT, 10 Nm (89 LB. IN.)
50 BOLT/SCREW, HEADLAMP HOUSING PANEL UPPER
BRACKET, 10 Nm (89 LB. IN.)
Pc2003-105-F-RP
Figure 4 - Headlamp Housing Panel Assembly and Brackets
4. Bolts/screws (54) to wheelhouse panel liner (15) and

lower deflector (16).
l~I Tighten
5. Front tire and wheel assembly. Refer to SECTION
3E.
6. Lower vehicle.
Front Fender Assembly and Brackets

Figure6
NOTICE: Tape front fender assembly and door
edges to prevent vehicle damage during front fender
assembly removal and installation.

1. Front fender bolts/screws (60 and 61).

3. Front wheelhouse panel liner enough to gain access
to front fender bolt/screw (63). Refer to "Front
Wheelhouse Panel Liner" in this section.
5. Front fender assembly (13).
6. Outer bracket bolts/screws (64) and fascia outer
bracket assembly ( 18), if necessary.
7. Rear upper bracket bolts/screws (65) and rear upper
bracket (11 ), if necessary.
8. Rear center bracket bolts/screws (66) and rear center
bracket ( 12 ), if necessary.

1056 BODY FRONT END
~53
55
16
15
56
LINER, FRONT WHEELHOUSE PANEL
CAP, FRONT WHEELHOUSE PANEL LINER
BOLT/SCREW
54 BOLT/SCREW, FRONT WHEELHOUSE PANEL LINER,
5.5 Nm (49 LB. IN .. )
55 BOLT/SCREW, FRONT WHEELHOUSE PANEL LINER,
1.3 Nm (12 LB. IN.)
56 RETAINER, FRONT WHEELHOUSE PANEL LINER
13
15
16
53
54
PC2004-105-F-RP
Figure 5 - Front Wheelhouse Panel Liner
L Rear center bracket (12) and rear center bracket

l~I
Tighten
Rear center bracket bolts/screws (66) to 5.5

Nm (49 lb. in.).
2. Rear upper bracket ( 11) and rear upper bracket bolts/
screws (65).
l~I
Tighten
Rear upper bracket bolts/screws (65) to 5.5

Nm (49 lb. in.).
3. Outer bracket assembly (18) and outer bracket bolts/
screws (64 ), if removed.
l~I
Tighten
Outer bracket bolts/screws (64) to 5.5 Nm (49

lb. in.).
4. Front fender assembly (13).
l~I
Tighten
Front fender bolts/screws (62 and 63) to 5.5

Nm (49 lb. in.).
6. Front wheelhouse panel liner. Refer to "Front
Wheelhouse Panel Liner" in this section.
7. Lower vehicle.
l~I
Tighten
Front fender bolts/screws (60 and 61) to 5.5

Nm (49 lb. in.).
HOOD PANEL ASSEMBLY

Figures 7 and 8
NOTICE: Raise hood panel assembly and install
protective coverings over fender assembly areas to
BODY FRONT END 10-5-7
62
11
12
13
18
60
61
62
63
64
BRACKET, FRONT FENDER REAR UPPER

BRACKET, FRONT FENDER REAR CENTER
BRACKET ASSEMBLV, FRONT BUMPER FASCIA OUTER
BOLT/SCREW, FRONT FENDER, 5.5 Nm (49 LB. IN.)
BOLT/SCREW, FRONT FENDER, 5.5 Nm (49 LB.IN.)
BOLT/SCREW, FRONT FENDER, 5.5 Nm (49 LB IN.)
BOLT/SCREW, FRONT FENDER 5.5 Nm (49 LB. IN.)
BOLT/SCREW, FRONT BUMPER FASCIA OUTER
BRACKET, 10 Nm (89 LB. IN.)
65 BOLT/SCREW, FRONT FENDER REAR UPPER BRACKET,
5.5 Nm (49 LB. IN.)
66 BOLT/SCREW, FRONT FENDER REAR CENTER
BRACKET, 5.5 Nm (49 LB. IN.)
PC2005-105-F-RP
Figure 6 - Front Fender Assembly and Brackets
1058 BODY FRONT END
A BRACKET, WHEELHOUSE
B CLIP
7 BRACKET, HOOD OPEN ASSIST ROD
8 ROD ASSEMBLY, HOOD OPEN ASSIST
9 STUD, HOOD STRUT BALL
69 NUT, HOOD STRUT
71 STUD, HOOD STRUT
PC0002-105-F-RP
Figure 7 - Hood Open Assist Rod Assembly
1 PANEL ASSEMBLY, HOOD

72 BOLT/SCREW, HOOD BODY SIDE HINGE,
27 Nm (20 LB. FT.)
73 NUT, HOOD HINGE BRACKET, 27 Nm (20 LB. FT.)
PC0003-105-FFP
Figure 8 - Hood Panel Assembly
BODY FRONT END 1059

prevent damage to paint and moldings when
removing or installing the hood panel assembly.
11
Adjust
Hood panel assembly, if necessary. Refer to "Hood

Panel Assembly Adjustment" in this section.
1. With aid of a helper, support hood panel assembly

(1).
Hood Insulator
2. Rod assembly (8) from strut stud (71).

3. Hood hinge bolts/screws (72) and nuts (73).
4. Hood panel assembly (1).
Figures 1, 2 and 9
l+,.I Remove or Disconnect

1. Raise hood panel assembly (1) to full open position.
2. Retainers (74) from hood panel assembly (1) and

1. Hood panel assembly (1), with aid of a helper.

l~I Tighten
Hood hinge bolts/screws (72) or nuts (73) to 27
Nm (20 lb. ft.).
3. Rod assembly (8) to strut stud (71).
ll'l'I Inspect
1. Close hood panel assembly (1) slowly, checking
clearance between hood panel assembly ( 1) and
front fender assemblies (13) and headlamp opening
doors.
2. With hood panel assembly (1) closed, check alignment of hood panel assembly (1 ). For hood assembly alignment specifications, refer to "Body Panel
Adjustment and Alignment" in this section.
hood insulator (34).

3. Hood insulator (34).
l,.+I Install or Connect

1. Hood insulator (34).
2. Retainers (74) to hood panel assembly (1) and hood
insulator (34).
Start installing retainers (74) at front of hood
insulator (34) and work rearward.
3. Close hood panel assembly (1).
Hood Closeout Filler

Figure 10

1. Retainers (79).
2. Hood closeout filler (80).
35 INSULATOR, HOOD
74 RETAINER, HOOD INSULATOR
PC2006-105-FRP
Figure 9 - Hood Insulator
10-5-10 BODY FRONT END

79 RETAINER, HOOD CLOSEOUT FILLER
80 FILLER, HOOD CLOSEOUT
PC2007-105F-RP
Figure 10 - Hood Closeout Filler
l++I
Install or Connect

1. Hood closeout filler (80).
2. Retainers (79).
l++I
Install or Connect

1. Hood hinge mount plate assembly (5), if removed.
A. Install retainers (78).
Hold hood hinge plate assembly (5) in

position and press retainers (78) over
plate assembly studs.
Hood Hinge Assembly

Figures 8 and 11
NOTICE: Raise hood panel assembly and install
protective coverings over the fender assembly areas
to prevent damage to paint when removing or installing hood hinge assemblies.
l++I
1. Safely support hood panel assembly (1) in full open

position.
2. Hood hinge bolt/screw (76) and shim (75).
4. Hood hinge nuts (77) from lower attachment of hood
hinge assembly (3).
5. Hood hinge assembly (3).
6. Hood hinge mount plate assembly (5), if necessary.
A. Remove front wheelhouse panel liner. Refer to
"Front Wheelhouse Panel Liner" in this section.
B. Remove retainers (78).
Use a flat-bladed tool to pry off retainers
(78) from plate assembly studs.
C. Remove hood hinge mount plate assembly (5).
B. Install front wheelhouse panel liner. Refer to

"Front Wheelhouse Panel Liner" in this section.
2. Hood hinge assembly (3).
3. Hood hinge nuts (77) to lower attachment of hood
hinge assembly (3).
l~I
Tighten
Nuts (77) to 25 Nm (18 lb. ft.).

l~I
Tighten
Bolts/screws (72) or nuts (73) to 27 Nm (20

lb. ft.).
5. Shim (75) and bolt/screw (76) to lower attachment
of hood hinge assembly (3).
l~I
Tighten

6. Hood support from hood panel assembly (1).
A
3
5
75
76
77
78
STUD, HOOD HINGE MOUNT PLATE ASSEMBLY

HINGE ASSEMBLY, HOOD
PLATE ASSEMBLY, HOOD HINGE MOUNT
SHIM, HOOD HINGE
BOLT/SCREW, HOOD HINGE, 10 Nm (89 LB. IN.)
NUT, HOOD HINGE, 25 Nm (18 LB. FT.)
RETAINER, HOOD HINGE MOUNT PLATE
PC0004-105-F-RP
Figure 11 - Hood Hinge Assembly
ILl 1nspect
Hood panel assembly (1) for alignment. Refer
to "Hood Panel Assembly Adjustment" in this
section.
Hood Primary Latch Assembly

Figures 12 and 13

1. Mark position of hood primary latch bolts/screws
(82) on latch support assembly (26).
2. Hood primary latch bolts/screws (82).
3. Hood latch release cable assembly (20) from hood
primary latch assembly (27).
Insert screwdriver into latch clip and lift hood
latch release cable assembly (20) from hood
4. Latch support assembly (26), if necessary.
A. Mark location of hood primary latch assembly
(27) on upper radiator support.
B. Remove headlamp housing panel assembly

and headlamp housing panel upper bracket
assembly. Refer to "Headlamp Housing Panel
Assembly and Brackets" in this section.
C. Remove windshield washer solvent container
assembly. Refer to SECTION 8E.
D. Latch support bolts/screws (83) and latch support assembly (26).

1. Latch support assembly (26), ifremoved.
A. Position latch support assembly (26) with
marks made during removal.
B. Install latch support assembly (26) and latch
support bolts/screws (83), if removed.
l~I Tighten
Latch support bolts/screws (83) to 18
Nm (13 lb. ft.).
C. Install windshield washer solvent container
assembly. Refer to SECTION 8E.
D. Install headlamp housing panel assembly and
headlamp housing panel upper bracket assembly. Refer to "Headlamp Housing Panel
Assembly and Brackets" in this section.
2. Hood latch release cable assembly (20) to hood primary latch assembly (27).
A. Connect hood latch release cable assembly
(20) by inserting end of hood latch release
cable assembly (20) to hood primary latch
assembly (27).
B. Connect latch clip to hood primary latch
assembly (27).
3. Hood primary latch assembly (27) to latch support
assembly (26).
4. Hood primary latch bolts/screws (82).
Position hood primary latch assembly (27) so
that hood primary latch bolts/screws (82) line
up with marks on latch support assembly (26).
26
26 SUPPORT ASSEMBLY, HOOD PRIMARY LATCH

27 LATCH ASSEMBLY, HOOD PRIMARY
82 BOLT/SCREW, HOOD PRIMARY LATCH,
18 Nm (13 LB. FT.)
83 BOLT/SCREW, HOOD PRIMARY LATCH SUPPORT,
18 Nm (13 LB. FT.)
PC0005 105-F-RP
Figure 12 - Hood Primary Latch Assembly
l~I
Tighten
Hood primary latch bolts/screws (82) to 18

Nm (13 lb. ft.).
ILl
1nspect
Hood panel assembly alignment. Refer to "Hood

Panel Assembly Adjustment" in this section.
11
2. Hood secondary latch assembly (32) from hood

panel assembly (1).
!++I

1. Hood secondary latch assembly (32) to hood panel
assembly (1 ).
2. Hood secondary latch bolts/screws (81 ).
l~I
Adjust
Hood primary latch assembly (27), if necessary.
l~I
Tighten
Hood primary latch bolts/screws (82) to 18

Nm (13 lb. ft.).
Hood Secondary Latch Assembly

Figure 14
l++I
1. Hood secondary latch bolts/screws (81 ).
Tighten
Hood secondary latch bolts/screws (81) to 12

Nm (106 lb. in.).
A. Loosen hood primary latch bolts/screws (82).
B. Adjust hood primary latch assembly (27) up or

down to specifications noted during inspection.
Install or Connect
Hood Primary Latch Release Cable

Assembly
Figures 12 and 13
l++I
1. Hood primary latch release cable assembly (20)

from primary latch assembly (27) and radiator support.
A. Disconnect cable assembly (20) by inserting a
screwdriver into latch clip and lifting cable
assembly (20) from primary latch assembly
(27).
B. Pry cable grommet from primary latch assembly (27).
~~~,
20
j
A
!VIEWA!
A
20
25
29
HANDLE, HOOD PRIMARY LATCH RELEASE CABLE

CABLE ASSEMBLY, HOOD PRIMARY LATCH RELEASE
CLIP, HOOD PRIMARY LATCH RELEASE CABLE
BOLT/SCREW, HOOD PRIMARY LATCH RELEASE
CABLE, 1.9 Nm (17 LB. IN.)
PC000&-105-F-RP
Figure 13 - Hood Primary Latch Release Cable Assembly
2.
3.
4.
5.
l++I
C. Pull primary latch release cable assembly (20)

out through hole in radiator support.
Driver side body hinge pillar trim panel. Refer to
"Body Hinge Pillar Trim Panel" in this section.
Hood primary latch release cable bolts/screws (29)
and hood primary latch release cable handle.
Cowl grommet by prying with a screwdriver.
Hood primary latch release cable assembly (20).
Note where hood primary latch release cable
assembly (20) is routed before removing so it
can be installed correctly.
Install or Connect

1. Hood primary latch release cable assembly (20)
through cowl.
Route hood primary latch release cable assembly (20) where previously noted.
2. Cowl grommet.
3. Hood primary latch release cable handle and hood
primary latch release cable bolts/screws (29).
1 PANEL ASSEMBLY, HOOD

32 LATCH ASSEMBLY, HOOD SECONDARY
81 BOLT/SCREW, HOOD SECONDARY LATCH,
12 Nm (106 LB. IN.)
l~I
PC0007-105-F-RP
Figure 14 - Hood Secondary Latch Assembly
Tighten
Hood primary latch release cable bolts/screws

(29) to 1.9 Nm (17 lb. in.).
4. Driver side body hinge pillar trim panel. Refer to
"Body Hinge Pillar Trim Panel" in this section.
10514 BODY FRONT END

5. Hood primary latch release cable assembly (20) to
A. Connect hood primary latch release cable
assembly (20) to cable clip.
B. Route hood primary latch release cable assembly (20) through hole in radiator support.
C. Insert end of hood primary latch release cable
assembly (20) into latch clip and attach cable
grommet.
Hood Open Assist Rod Assembly

Figure 7
If both rod assemblies are being replaced, replace
only one at a time.
CAUTION: Hood open assist rod
assemblies hold the hood assembly in
the up position. Insure the hood assembly is safely supported when hood
open assist rod assemblies are
removed or installed to avoid the possibility of damage to the vehicle or personal injury.

1. Hood open assist rod assembly (8) to hood strut ball
stud (9).
Snap rod assembly (8) to ball stud (9).
2. Hood open assist rod assembly (8) to hood strut stud
(71).
Snap rod assembly (8) onto strut stud (71).
3. Remove hood support.
Hood Open Assist Rod Bracket Assembly

Figure 15

1. Safely support hood panel assembly (1) in the full
open position.
2. Hood open assist rod assembly (8) from hood strut
stud (71).
Use a small flat-bladed tool to pry clip out
while pulling assist rod assembly (8) from
hood strut stud (71).
3. Hood open assist rod assembly (8) from hood strut
ball stud (9).
Use a small flat-bladed tool to pry clip out
while pulling assist rod assembly (8) away
from hood strut ball stud (9).
1.
2.
3.
4.
CAUTION: Hood open assist rod

assemblies hold the hood assembly in
the up position. Insure the hood assembly is safely supported when hood
open assist rod assemblies are
removed or installed to avoid the possi
bility of damage to the vehicle or personal injury.
Safely support hood panel assembly (1) in full open
position.
Upper hood open assist rod attachment.
Hood open assist rod bracket bolts/screws (87).
Hood open assist rod bracket assembly (85).

1
84
85
86

BRACKET ASEMBLY, HOOD OPEN ASSIST ROD
BRACKET ASSEMBLY, HOOD OPEN ASSIST ROD
BOLT/SCREW, HOOD OPEN ASSIST ROD,
10 Nm (89 LB. IN.)
87 BOLT/SCREW, HOOD OPEN ASSIST ROD,
10 Nm (89 LB. IN.)
PCOOOB-105-F-RP
Figure 15 - Hood Open Assist Rod Bracket Assembly

1. Hood open assist rod bracket assembly (85).
2. Hood open assist rod bracket bolts/screws (87).
l~I

Hood adjust front bumper (30).
- Rotate counterclockwise.
Tighten
Hood open assist rod bracket bolts/screws (87)

to 10 Nm (89 lb. in.).
3. Upper hood open assist rod attachment.
4. Remove hood support.
Hood Rear Seal Assembly

Figure 16

1. Hood adjust front bumper (30).
Rotate clockwise until hood adjust front bumper (30) is at the same height as measured
before removal.
2. Check hood panel assembly alignment. Refer to
"Hood Panel Assembly Adjustment" in this section.
Hood Air Extractors
1. Hood rear seal assembly fasteners.
2. Hood rear seal assembly (90).
Figure 18
1. Hood rear seal assembly (90).

2. Hood rear seal assembly fasteners.
Hood Adjust Front Bumper

Figure 17
To aid in adjustment, measure hood adjust front
bumper height and record before removing.
1.
2.
3.
4.
5.
6.
Hood insulator front attachments.

Hood air extractor push-on r\.ut (92).
Hood air extractor nuts (91).
Hood air extractor (37).
Hood air extractor screen bolts/screws (98).
Hood air extractor screen (38).
90
A FASTENER, HOOD REAR SEAL

90 SEAL ASSEMBLY, HOOD REAR
PC0009-105-F-RP
Figure 16 - Hood Rear Seal Assembly
30
31~
30

30 BUMPER, HOOD ADJUST FRONT
31 CAP, HOOD ADJUST FRONT BUMPER
PC2008-105F-RP
Figure 17 - Hood Adjust Front Bumper Assemblies

1. Hood air extractor screen (38) to hood air extractor
(37).
2. Hood air extractor screen bolts/screws (98).
f~I
Tighten
Hood air extractor screen bolts/screws (98) to

1.7 Nm (15 lb. in.)
3. Hood air extractor (37) to hood panel assembly (1).
4. Hood air extractor nuts (91).
f~I
Tighten
Hood air extractor nuts (91) to 3 Nm (27 lb.

in.).
5. Hood air extractor push-on nut (92).
6. Hood insulator front attachments.
PLENUM CHAMBER
Air enters the front plenum chamber through air
inlet screen assemblies. The air is drawn through the plenum chamber to the heater and air conditioning evaporator module assembly by the blower motor assembly. Air is
distributed in the vehicle through the air distribution system. For air distribution information, refer to SECTION
IA or lBl. Water entering the plenum chamber is drained
through openings provided for that purpose.
FRONT END SEALING

All potential waterleak locations are sealed in production with high quality durable sealers. To reseal spe-
cific areas, a high quality medium-bodied sealer that will

remain flexible after curing and can be painted should be
used. Refer to SECTION 10-1.
AIR INLET SCREEN ASSEMBLIES

Figure 19

1. Hood rear seal assembly. Refer to "Hood Rear Seal
2. Retainers (95) from driver side screen assembly.
3. Windshield wiper arm assemblies. Refer to SECTION 8E.
4. Driver side screen assembly (94).
5. Windshield washer nozzle hose clips to driver side
screen assembly (94).
6. Retainers (95) from passenger side screen assemblies (93).
7. Passenger side screen assemblies (93).
8. Windshield washer nozzle hose clips from passenger
side screen assembly (93).

NOTICE: Install air inlet screen assemblies prior to
water testing or the windshield wiper motor could be
damaged.
1. Route windshield washer nozzle hose clips to passenger side screen assembly (93).
2. Passenger side screen assembly (93).
3. Retainers (95) to passenger side screen assembly
(93).
1
37
38
91
92
98

EXTRACTOR, HOOD AIR
SCREEN, HOOD AIR EXTRACTOR
NUT, HOOD AIR EXTRACTOR, 3 Nm (27 LB. IN.)
NUT, HOOD AIR EXTRACTOR (PUSH-ON)
BOLT/SCREW, HOOD AIR EXTRACTOR SCREEN,
1.7 Nm (15 LB. IN.)
93 SCREEN ASSEMBLY, AIR INLET (PASSENGER SIDE)

94 SCREEN ASSEMBLY, AIR INLET (DRIVER SIDE)
95 RETAINER, AIR INLET SCREEN
PC2009-105-F-RP
PC0010-105-F-RP
Figure 18 - Hood Air Extractor
Figure 19 - Air Inlet Screen Assemblies
4. Windshield washer nozzle hose clips to driver side

screen assembly (94).
5. Driver side screen assembly (94).
6. Retainers (95) to driver side screen assembly (94).
7. Windshield wiper arm assemblies. Refer to SECTION 8E.
8. Check for proper operation of windshield wiper and
washer system.
9. Hood rear seal assembly. Refer to "Hood Rear Seal
BODY HINGE PILLAR TRIM PANEL

ASSEMBLY
Figure20

2. Body hinge pillar trim panel assembly (96).
Slide upward and rearward.

1. Body hinge pillar trim panel assembly (96).
Slide forward and downward into position.
l~I Tighten
97
96 PANEL ASSEMBLY, BODY HINGE PILLAR TRIM
97 BOLT/SCREW, BODY HINGE PILLAR TRIM PANEL
1.3 Nm (12 LB. IN.)
PC0011-105-F-RP
Figure 20 - Body Hinge Pillar Trim Panel Assembly

(Right Side Shown, Left Side Similar)
DASH SOUND BARRIER ASSEMBLY

Figure21

to SECTION 8C.
100
100 BARRIER ASSEMBLY, DASH SOUND

PC2010-105-F-RP
Figure 21 - Dash Sound Barrier Assembly
BODY HINGE PILLAR INNER PANEL SOUND

BARRIERS
2. Dash sound barrier assembly (100).
Figure22
1. Dash sound barrier assembly (100).

to SECTION 8C.
1. Body hinge pillar trim panel assembly. Refer to

"Body Hinge Pillar Trim Panel Assembly" in this
section.
A DRIVER SIDE
B PASSENGER SIDE
102 BARRIER, BODY HINGE PILLAR INNER PANEL
SOUND (LEFT)
SOUND (LEFT)
SOUND (LEFT)

SOUND (RIGHT)
SOUND (RIGHT)
SOUND (RIGHT)
Figure 22 - Body Hinge Pillar Inner Panel Sound Barriers
PC0012-105-F-RP
BODY FRONT END 10519

2. Body hinge pillar inner panel sound barriers ( 102,
103 and 104 or 105, 106 and 107).

1. Paper backing from body hinge pillar inner panel
sound barrier (102, 103 and 104 or 105, 106 and
107).
2. Body hinge pillar inner panel sound barriers (102,
103 and 104 or 105, 106 and 107).
3. Body hinge pillar trim panel assembly. Refer to
"Body Hinge Pillar Trim Panel Assembly" in this
section.
FRONT DOOR JAMB SWITCH ASSEMBLIES

Figure23
Door jamb switch assemblies (108 or 110) consist of
a plunger, plunger collar, threaded retainer and terminals.
They are installed in the door hinge pillars. When the door
of the vehicle is closed, the plunger is depressed, which
creates an open in the ground circuit. When the door is
opened, the plunger is released and completes the circuit
to ground.
When a new door jamb switch assembly (108 or
110) is installed and the door is closed the first time, the
plunger is forced into the sleeve and automatically adjusts
the door jamb switch assembly (108 or 110) for that particular door. If a door jamb switch assembly (108 or 110)
fails, it should not be readjusted by hand. A new door
jamb switch assembly (108 or 110) should be installed.


2. Double or single terminal door jamb switch assembly (108 or 110).
4. Seal (109 or 111 ).

1. Seal (109 or 111) to door jamb switch assembly (108
or 110) until fully seated.
3. Double or single terminal door jamb switch assembly (108 or 110).
l~I Tighten
Door jamb switch assembly (108 or 110) to
6 Nm (53 lb. in.).
EXTERIOR MOLDINGS AND DECAL

Rocker Panel Molding Assembly
Figure24

1. Rear wheelhouse panel liner attachments. Pull rear
portion of liner away from fender assembly.
2. Rocker panel molding retainer nuts (116).
3. Rocker panel molding retainers ( 115 and 119).
4. Rocker panel molding bolts/screws ( 117).
5. Rocker panel molding assembly (118).
A
B
C
108
DRIVER SIDE
PASSENGER SIDE
SWITCH ASSEMBLY, DRIVER SIDE DOOR JAMB,
6 Nm (53 LB. IN.)
109 SEAL, DOOR JAMB SWITCH

110 SWITCH ASSEMBLY, PASSENGER SIDE DOOR JAMB,
6 Nm (53 LB. IN.)
111 SEAL, DOOR JAMB SWITCH
Figure 23 - Door Jamb Switch Assemblies
PC0013-105-F-RP
116
13
115
116
117

RETAINER, ROCKER MOLDING
NUT, ROCKER PANEL MOLDING RETAINER
BOLT/SCREW, ROCKER PANEL MOLDING
1.5 Nm (13 LB. IN.)
118 MOLDING ASSEMBLY, ROCKER PANEL
119 RETAINER, ROCKER MOLDING
120 RETAINER, ROCKER MOLDING
,,.;.
117
lVIEWB
I
PC2011-105-F-~P
Figure 24 - Rocker Panel Molding Assembly

1. Rocker panel molding assembly (118).
2. Rocker panel molding bolts/screws ( 11 7).
l~I Tighten
Rocker panel molding bolts/screws ( 117) to
1.5 Nm (13 lb. in.).
3. Rocker panel molding retainers (115 and 119).
4. Rocker panel molding retainer nuts ( 116).
5. Rear wheelhouse panel liner attachments.
Front Fender Center Rear Molding Assembly

Figure25
For information and procedures on replacing adhesive molding assemblies, refer to SECTION 10-1. Refer
to Figure 25 for correct placement of the molding assembly (14).
Headlamp Opening Door Decal

Figure26
For information and procedures on replacing decals,
refer to SECTION 10-1. Refer to Figure 26 for correct
placement of the decal (68).
ROOF SIDE RAIL WEATHERSTRIP

RETAINER
Figure27

1. Lower the upper front portion of front side door
weatherstrip assembly. Refer to SECTION 10-6.
2. Roof side rail weatherstrip retainer bolts/screws
(121 or 123).
3. Roof side rail weatherstrip retainer (122 or 124).

1. Roof side rail weatherstrip retainer (122 or 124).
2. Roof side rail weatherstrip retainer bolts/screws
(121 or 123).
13
14
SECTION A-A
13 FENDER ASSEMBLY, FRONT

14 MOLDING, FRONT FENDER CENTER REAR
SECTION BB
PC2012-105-F-RP
Figure 25 - Installing Front Fender Center Rear Molding Assembly
l~I
Tighten
Bolts/screws (121 or 123) to 1.3 Nm (12 lb.

in.).
3. Front side door weatherstrip assembly. Refer to
SECTION 10-6.
BODY PANEL ADJUSTMENT AND

ALIGNMENT
Figures 11 and 28
Hood Panel Assembly Adjustment

The hood panel assembly, front fender assemblies
and hood hinges are "net build," therefore minimum
adjustment can be made. If the door panel assembly can
not be brought into specifications shown in Figure 28 by
loosening hood hinge bolts/screws and/or adjusting the
hood adjust front bumper assemblies, the structural body
should be checked for damage or misalignment.
68
A ALIGN INBOARD EDGE OF DECAL WITH INBOARD
EDGE OF HEADLAMP OPENING DOOR AND ALIGN
LOWER EDGE OF DECAL WITH FORWARD EDGE OF
HEADLAMP OPENING DOOR
68 DECAL, HEADLAMP OPENING DOOR (FORMULA VS)
PC2013-105-F-RP
Figure 26 - Headlamp Opening Door Decal
Raising or Lowering Rear Corners of Hood

Panel Assembly
[el Adjust
Hood adjust front bumper assembly.
A. Close hood panel assembly (1) firmly.
B. Determine amount of adjustment needed.
Refer to Figure 28 for hood panel assembly
alignment specifications.
B
A
A STANDARD ROOF
B T-TOP ROOF
121 BOLT/SCREW, ROOF SIDE RAIL WEATHERSTRIP
RETAINER, 1.3 Nm (12 LB.IN.)
122 RETAINER, ROOF SIDE RAIL WEATHERSTRIP

123 BOLT/SCREW, ROOF SIDE RAIL WEATHERSTRIP
RETAINER, 1.3 Nm (12 LB. IN.)
124 RETAINER, ROOF SIDE RAIL WEATHERSTRIP
PC0014-105-F-RP
Figure 27 - Roof Side Rail Weatherstrip Retainer
C. Open hood panel assembly (1).

D. Change height by turning the hood bumper
assemblies up or down.
E. Repeat above steps until hood panel assembly
(1) is properly aligned.
Fore and Aft Adjustment

A minimum adjustment can be obtained by loosening the hood hinge bolts/screws (76) and nuts (77), then
sliding forward or rearward. For best appearance, adjust
one side at a time.
Adjust

section.
Hood panel assembly (1).

A. Loosen hood hinge to body bolts/screws (76)
and nuts (77).
B. Move hood panel assembly (1) forward or
rearward. Refer to Figure 28 for hood panel
assembly alignment specifications.
l~I
Tighten
Hood hinge nuts (77) to 25 Nm (18 lb. ft.).

Hood hinge bolts/screws (76) to 10 Nm (89
lb. in.).
BODY FRONT END 10523
GAP 4.0 mm 1.5 mm

(0.16 0.06")
GAP PARALLEL WITHIN 1.5 mm (0.06")
51
SECTION AA
51
~ ' FL~:H 0.5 mm (0.02")
--=--- . --H--
/C_
_ / .,,,,_
711" t
GAP 4.0 mm 1.5 mm

(0.16" .04")
PARALLEL WITHIN 1.5 mm (0.06")
~ . O mm0.05 mm
(0.08" 0.02")
SECTION C-C
52
13
GAP
0.5 mm 0.5 mm
(0.02" 0.02")
13
SECTION B-B
v13
GAP 5.0 mm 1.5 mm I0.20" 0 . 0 6 " J
DOOR ASSEMBLY FLUSH

GAP 2.0 mm 0.5 mm 1 ,
TO FENDER ASSEMBLY 25.4 mm (1.0") FROM
(0.08" + 0.02") L
BOTTOM OF DOOR ASSEMBLY 2.0 mm 2.0 mm
PARALLEL WITHIN 0.5 mm-(0.02") T
(0.08" + 0.08")
- ~ - - FLUSH + 0.5 mm (0.02")
SECTION E-E
52
SECTION D-D
57
GAP 4.0 mm to 7.5 mm ~ (0.16" to 0.30")

DOOR ASSEMBLY FLUSH TO
FENDER ASSEMBLY
OUTBOARD 0.0 mm (0.00")
INBOARD 1.5 mm (0.06")
13
~
52
:51
l-- GAP 2.0 mm (0.08")
+ 3.0 mm (0.12")
- 2.0 mm (0.08")
FENDER ASSEMBLY FLUSH TO
ROCKER PANEL ASSEMBLY
+1.5 mm (0.06") - 0.0 mm (0.00")
13
SECTION F-F
SECTION G-G
FLUSH +0.5 mm (0.02")
GAP 4.0 mm 1.5 m m _ - \ ~ ~ ,,,--------
(0.16" + 0.06")
PARALLEL WITHIN
1.0 mm (0.04")
'L--/
jl
j
GAP 4.0 mm+ 1.5 mm
~
(0.16"0.06")
~ L L E L WITHIN 1.0 mm I0.04"1
36
ir
36
SECTION J-J
j\
13
SECTION K-K
FRONT BUMPER FASCIA
ASSEMBLY 0.5 mm (0.02")
DOWN FROM HEADLAMP OPENING
DOOR +0.5 mm (0.02") -1.0 mm (0.04")
1
13
36
37
51
52
57
58

DOOR, HEADLAMP OPENING
EXTRACTOR, HOOD AIR
DOOR ASSEMBLY, FRONT SIDE
PANEL ASSEMBLY, ROCKER
HEADLAMP ASSEMBLY
GAP 1.0 mm 0.5 mm (0.04" 0.02")

51
58
SECTION L-L
Figure 28 --- Front End Body Panel Alignment Specifications
--11-
1-
37
SECTIONM-M
PC2014-105 F-RP
10524 BODY FRONT END
SPECIFICATIONS
Body Hinge Pillar Trim Panel Bolt/Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3 Nm (12 lb. in.)
Driver Side Door Jamb Switch Assembly ................................. 6 Nm (53 lb. in.)
Front Bumper Fascia Outer Bracket Bolt/Screw ........................... 10 Nm (89 lb. in.)
Front Fender Bolt/Screw ......................./ ...................... 5.5 Nm (49 lb. in.)
Front Fender Rear Center Bracket Bolt/Screw ............................ 5.5 Nm (49 lb. in.)
Front Fender Rear Upper Bracket Bolt/Screw ............................ 5.5 Nm (49 lb. in.)
Front Wheelhouse Panel Liner Bolt/Screw ............................... 1.3 Nm (12 lb. in.)
Front Wheelhouse Panel Liner Bolt/Screw (Lower) ....................... 5.5 Nm (49 lb. in.)
Headlamp Housing Panel Bracket and Pivot Support Bracket Bolt/Screw ...... 1.7 Nm (15 lb. in.)
Headlamp Housing Panel Bolt/Screw ..................................... 8 Nm (71 lb. in.)
Headlamp Housing Panel Bracket Bolt/Screw ............................ 5.5 Nm (49 lb. in.)
Headlamp Housing Panel Support Bolt/Screw ............................. 10 Nm (89 lb. in.)
Headlamp Housing Panel Upper Bracket Bolt/Screw ....................... 10 Nm (89 lb. in.)
Hood Air Extractor Nut ............................................... 3 Nm (27 lb. in.)
Hood Air Extractor Screen Bolt/Screw .................................. 1.7 Nm (15 lb. in.)
Hood Body Side Hinge Bolt/Screw ..................................... 27 Nm (20 lb. ft.)
Hood Hinge Bolt/Screw .............................................. 10 Nm (89 lb. in.)
Hood Hinge Nut .................................................... 25 Nm (18 lb. ft.)
Hood Open Assist Rod Bolt/Screw ...................................... 10 Nm (89 lb. in.)
Hood Primary Latch Bolt/Screw ........................................ 18 Nm (13 lb. ft.)
Hood Primary Latch Release Cable Bolt/Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.9 Nm (17 lb. in.)
Hood Primary Latch Support Bolt/Screw ................................. 18 Nm (13 lb. ft.)
Hood Secondary Latch Bolt/Screw ..................................... 12 Nm (106 lb. in.)
Passenger Side Door Jamb Switch Assembly ............................... 6 Nm (53 lb. in.)
Radiator Air Lower Deflector Bolt/Screw ............................... 5.5 Nm (49 lb. in.)
Rocker Panel Molding Bolt/Screw ..................................... 1.5 Nm (13 lb. in.)
Roof Side Rail Weatherstrip Retainer Bolt/Screw ......................... 1.3 Nm (12 lb. in.)
DOORS 10-6-1
SECTION 10-6
DOORS
CAUTION: Make sure to disconnect the front side door window switch when working inside
the driver's door. When operated, the Express Down feature allows the front side door window to drop very quickly which could cause personal injury.
Failure to keep the label clean and reaqable may result in liability for violation of Federal Vehicle Theft Prevention
result.
CONTENTS
Theft Deterrent Labels . . . . . . . . Refer to Section OA
Hardware Lubrication . . . . . . . . Refer to Section OB
Thread Locking Fasteners ................ 10-6-2
Front Side Door Water Deflectors .......... 10-6-2
Front Side Door Lock Striker Assemblies .... 10-6-2
Front Side Door Lock Assemblies . . . . . . . . . . 10-6-2
Front Side Door Outside Handle
Assemblies .......................... 10-6-2
Express Down ......................... 10-6-2
Front Side Door Upper and Lower
Hinge Assemblies .................... 10-6-2
Outside Rearview Mirror Assemblies ....... 10-6-2
Front Side Door Interior Trim ............. 10-6-2
Front Side Door Right and Left Trim
Assemblies ........................ 10-6-2
Front Side Door Armrest and Map
Pocket and Radio Front Side Door
Speaker Grilles . . . . . . . . . . . . . . . . . . . 10-6-3
Accessory Switch Panel Assembly
and Accessory Switch Opening
Cover Assembly .................. 10-6-3
Front Side Door Inside Handle Bezel . . . . . 10-6-7
Front Side Door Locking Rod Knob . . . . . . 10-6-7
Front Side Door Exterior Trim . . . . . . . . . . . . 10-6-8
Front Side Door Center Molding
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 10-6-8
Front Side Door Emblem Assembly . . . . . . 10-6-8
Door Edge Protector . . . . . . . . . . . . . . . . . . 10-6-9
Front Side Door Hardware and Front
Side Door Window . . . . . . . . . . . . . . . . . . . . 10-6-9
Front Side Door Weatherstrip Assembly . . . 10-6-9
Front Side Door Window Outer
Sealing Strip Assembly . . . . . . . . . . . . . 10-6-10
Front Side Door Window Inner
Sealing Strip . . . . . . . . . . . . . . . . . . . . . . 10-6-11
Front Side Door Front and Rear
Belt Seals . . . . . . . . . . . . . . . . . . . . . . . . 10-6-11
Front Side Door Bottom Auxiliary

Sealing Strip ......................
Front Side Door Trim Panel
Retainer Seals . . . . . . . . . . . . . . . . . . . .
Front Side Door Inside Handle Seal
Front Side Door Window Regulator
Counterbalance Arm Channel
Assembly ......................
Front Side Door Window Channel
Assembly and Front Side Door
Window Rear Guide Channel
Assembly ....................
Side Window, Outside Remote
Control Rearview Mirror Selector
and Door Lock Switches ..........
Front Side Door Water Deflector ........
Outside Rearview Mirror Assembly . . . . .
Outside Rearview Mirror
Reflective Glass ...................
Outside Rearview Mirror Applique
Assembly ........................
Radio Front Side Door Speaker
Assembly . . . . . . . . . . . . . . . . . . . . . . . .
Radio Front Side Door (Tweeter)
Speaker Assembly .................
Front Side Door Outside Handle
Assembly ........................
Front Side Door Inside Handle Assembly .
Handle Assembly ..................
Front Side Door Lock Assembly ........
Front Side Door Outside Handle Rod ....
Front Side Door Inside Handle
Rod Assembly ....................
Front Side Door Locking Rod ..........
Front Side Door Lock Cylinder Rod .....
Front Side Door Lock Striker Assembly ..
Front Side Door Lock Striker
Adjustment .......................
10-6-12
10-6-13
10-6-13
10-6-14
10-6-14
10-6-15
10-6-15
10-6-17
10-6-18
10-6-19
10-6-19
10-6-20
10-6-20
10-6-20
10-6-22
10-6-22
10-6-23
10-6-24
10-6-24
10-6-25
10-6-25
10-6-25
10-6-2 DOORS
Front Side Door Lock Striker
Anchor Plate .....................
Front Side Door Interlock Striker
Assembly ........................
Front Side Door Bumper ..............
Front Side Door Lock Actuator .........
Lock Cylinder Unit ..................
Front Side Door Upper Hinge Assembly ..
Front Side Door Lower Hinge Assembly .
Front Side Door Assembly ............
Front Side Door Window . . . . . . . . . . . . . .
Front Side Door Window Adjustment ....
10-6-26
10-6-27
10-6-27
10-6-27
10-6-28
10-6-28
10-6-28
10-6-29
10-6-32
10-6-33
GENERAL DESCRIPTION
This section contains the service operations necessary for the removal, installation, adjustment and sealing
of door assemblies, hardware and trim (Figures 1 through
4).
THREAD LOCKING FASTENERS

All factory installed door hardware attaching bolts/
screws contain an epoxy thread-locking compound to
ensure the torque will be maintained.
Service replacement bolts/screws may not contain a
thread-locking compound. Such bolts/screws may be
treated with GM P/N 1052279, Loctite 75, or equivalent. The adhesive is placed on the fastener prior to installation. After the fastener is installed and tightened, the
adhesive will cure, preventing the fastener from becoming
loose.
FRONT SIDE DOOR WATER DEFLECTORS

Water deflectors are used to seal the door inner panels, preventing water entry.
FRONT SIDE DOOR LOCK STRIKER

ASSEMBLIES
Each lock striker assembly is a dual-pin type that
attaches to an anchor plate in the body lock pillar. The
door assembly is held in the closed position when the lock
assembly snaps over and engages the striker assembly.
An interlock striker assembly is also installed to the
body lock pillar. It engages into a slot in the door assembly.
FRONT SIDE DOOR LOCK ASSEMBLIES

The lock assemblies use the fork bolt lock design
which includes a safety interlock feature. The door assembly is secured in the closed position when the fork bolt
engages the striker assembly. Door assemblies can be
locked from the inside by moving the knob rearward and
from the outside using the oval-headed key.
FRONT SIDE DOOR OUTSIDE HANDLE

ASSEMBLIES
The outside handle assemblies actuate the lock
assemblies through rods.
Front Side Door Window Front

Up Stop Support Assembly ..........
Front Side Door Window Stabilizer
Assembly ........................
Front Side Door Window Front and
Rear Bumpers ....................
Assembly ........................
Motor Assembly ..................
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . .
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . .
10-6-35
10-6-35
10-6-36
10-6-36
10-6-37
10-6-38
10-6-38
10-6-39
EXPRESS DOWN
Express Down fully lowers the driver's front side
door window when the side window switch is pressed
quickly and released.
FRONT SIDE DOOR UPPER AND LOWER

HINGE ASSEMBLIES
The hinge assemblies are steel and are fastened with
bolts/screws and nuts. The hinge assemblies are directly
accessable.
OUTSIDE REARVIEW MIRROR ASSEMBLIES

The left-hand mirror assembly is remote control and
the right-hand mirror assembly is direct control. Electric
control is optional.
ON-VEHICLE SERVICE
FRONT SIDE DOOR INTERIOR TRIM
Front Side Door Right and Left Trim
Assemblies
Figure5

1. Accessory switch panel assembly or accessory
switch opening cover assembly, as equipped. Refer
to "Accessory Switch Panel Assembly and Accessory Switch Opening Cover Assembly" in this section.
2. Front side door inside handle bezel. Refer to "Front
Side Door Inside Handle Bezel" in this section.
3. Front side door window regulator handle assembly
and front side door window regulator handle spacer.
Refer to "Front Side Door Window Regulator Handle Assembly" in this section.
4. Outside rearview mirror bezel assembly. Refer to
"Outside Rearview Mirror Assembly" in this section.
NOTICE: Do not try to pull trim assembly straight
off door assembly, or hooks in trim assembly will
break. To disengage hooks, trim assembly must be
lifted up and then pulled away from door assembly.
6. Trim assembly (100).
DOORS 10-6-3
A. Pull slightly on rear of trim assembly (100) to
release tab.
Front Side Door Armrest and Map Pocket

and Radio Front Side Door Speaker Grilles
B. Lift up on trim assembly (100).
Figures 3 and 4
These components of the trim assembly (89 or 100)
are held in position with heat stakes. These components
are included with the replacement part trim assembly, but
they can also be serviced separately.
C. Pull trim assembly (100) away from door

assembly (152), making sure that hooks
release from holes in door inner panel.
D. Disconnect radio front side door (tweeter)
speaker electrical connector, if equipped.
E. Remove courtesy lamp socket assembly from

trim assembly (100).
[I] Important
If trim assembly is being replaced, radio front side
door (tweeter) speaker, if equipped, must be
removed from trim assembly and transferred to new
trim assembly. Refer to "Radio Front Side Door
(Tweeter) Speaker Assembly" in this section.

1. Trim assembly (100) to door inner panel.
A. Insert hooks along bottom of trim assembly

(100) part way into holes in door inner panel.
B. Route electrical connectors through opening in
trim assembly (100), if equipped.
c.
Install courtesy lamp socket assembly to trim

assembly (100).
D. Connect radio front side door (tweeter) speaker

E. Align upper edge of trim assembly (100) over

door inner panel flange and insert remaining
hooks into holes.
F. Push downward to engage hooks.
G. Push rear of trim assembly (100) into door
assembly (152) to engage tab.
l~I Tighten
3. Outside rearview mirror bezel assembly. Refer to
4. Front side door window regulator handle assembly
and front side door window regulator handle spacer.
Refer to "Front Side Door Window Regulator Handle Assembly" in this section.
switch opening cover assembly, as equipped. Refer
to "Accessory Switch Panel Assembly and Accessory Switch Opening Cover Assembly" in this section.

1. Front side door trim assembly. Refer to "Front Side
Door Right and Left Trim Assemblies" in this section.
2. Armrest (95), pocket (110 or 120) or grille (98 or
99).
A. Peel back the sound deadener.
B. Using a soldering iron, melt heat stakes retaining armrest (95), pocket (110 or 120) or grille
(98 or 99).
C. Pull armrest (95), pocket (110 or 120) or grille
(98 or 99) from trim assembly (89 or 100).

1. Armrest (95), pocket (110 or 120) or grille (98 or
99).
A. Insert heat stakes through holes in trim assembly (89 or 100).
B. Melt heat stakes using a soldering iron.
C. Press melted heat stakes flat using suitable surface.
D. Apply adhesive to sound deadener.
E. Reposition sound deadener.
Accessory Switch Panel Assembly and

Accessory Switch Opening Cover Assembly
Figure 6
If the vehicle is equipped with side window, mirror
selector or door lock switches (111, 114 or 93), it will have
a panel assembly (112). If the vehicle is not equipped
with any of these switches, then it will have a cover
assembly. Both parts are removed in the same way.
NOTICE: When removing the panel assembly, the
ignition switch must be in the "OFF" position and
retained accessory power (RAP) must not be present. This will eliminate the possibility of shorting
out the switch if a screwdriver, awl or metal object is
used.

Panel assembly (112) or cover assembly.
A. Pry at front and rear of panel assembly (112) or
cover assembly with a flat-bladed tool to
release metal clips.
B. Disconnect electrical connectors, if equipped.
10-64 DOORS
10
10
30
20
A
- ------,;~;-;--=:
Figure - Froornt Side Door Assembly (1 of 2)
PC0001-106-F-RP
DOORS 10-6-5
A
B
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
WITH ELECTRIC-OPERATED SIDE WINDOW

WITHOUT ELECTRIC-OPERATED SIDE WINDOW
WINDOW, FRONT SIDE DOOR
RETAINER, FRONT SIDE DOOR WINDOW BUSHING
PIN, FRONT SIDE DOOR WINDOW STABILIZER
BOLT/SCREW, FRONT SIDE DOOR WINDOW STABILIZER
PIN
RETAINER, FRONT SIDE DOOR FRONT BELT SEAL
SEAL, FRONT SIDE DOOR REAR BELT
BOLT/SCREW, FRONT SIDE DOOR LOCK ACTUATOR
ACTUATOR, FRONT SIDE DOOR LOCK
LOCK ASSEMBLY, FRONT SIDE DOOR
BOLT/SCREW, FRONT SIDE DOOR LOCK
CLIP, FRONT SIDE DOOR LOCKING ROD
RETAINER, FRONT SIDE DOOR OUTSIDE HANDLE ROD
ROD, FRONT SIDE DOOR OUTSIDE HANDLE
ROD, FRONT SIDE DOOR LOCK CYLINDER
BUMPER, FRONT SIDE DOOR
CHANNEL ASSEMBLY, FRONT SIDE DOOR WINDOW
RIVET, FRONT SIDE DOOR WINDOW
REGULATOR ASSEMBLY, FRONT SIDE DOOR WINDOW
REGULATOR COUNTERBALANCE ARM
NUT, FRONT SIDE DOOR WINDOW REGULATOR
COUNTERBALANCE ARM CHANNEL
RIVET, FRONT SIDE DOOR WINDOW REGULATOR
SPACER, FRONT SIDE DOOR WINDOW REGULATOR
HANDLE
SPRING, DOOR WINDOW REGULATOR HANDLE
HANDLE ASSEMBLY, FRONT SIDE DOOR WINDOW
REGULATOR
NUT, FRONT SIDE DOOR WINDOW REAR GUIDE
CHANNEL
REAR GUIDE
NUT, FRONT SIDE DOOR WINDOW REAR GUIDE
CHANNEL
SEALING STRIP, FRONT SIDE DOOR BOTTOM
AUXILIARY
BUMPER, FRONT SIDE DOOR WINDOW REAR
KNOB, FRONT SIDE DOOR LOCKING ROD
BUMPER, FRONT SIDE DOOR WINDOW FRONT
RIVET, FRONT SIDE DOOR INSIDE HANDLE
HANDLE ASSEMBLY, FRONT SIDE DOOR INSIDE
BOLT/SCREW, OUTSIDE REARVIEW MIRROR APPLIOUE
NUT, OUTSIDE REARVIEW MIRROR OPENING
APPLIOUE
HINGE ASSEMBLY, FRONT SIDE DOOR LOWER
NUT, FRONT SIDE DOOR LOWER HINGE
GROMMET, DOOR WIRING HARNESS
NUT, FRONT SIDE DOOR UPPER HINGE
42 HINGE ASSEMBLY, FRONT SIDE DOOR UPPER

43 WASHER, OUTSIDE REARVIEW MIRROR APPLIOUE
44 SUPPORT ASSEMBLY, FRONT SIDE DOOR WINDOW
FRONT UP STOP
45 NUT, FRONT SIDE DOOR WINDOW FRONT UP STOP
SUPPORT
46 CLIP, FRONT SIDE DOOR INSIDE HANDLE ROD
47 ROD ASSEMBLY, FRONT SIDE DOOR INSIDE HANDLE
48 CLIP, FRONT SIDE DOOR LOCKING ROD
49 ROD, FRONT SIDE DOOR LOCKING
50 SEAL, FRONT SIDE DOOR INSDE HANDLE
51 STABILIZER ASSEMBLY, FRONT SIDE DOOR WINDOW
52 BOLT/SCREW, FRONT SIDE DOOR WINDOW STABILIZER
53 BOLT/SCREW, FRONT SIDE DOOR WINDOW FRONT UP
STOP
54 STOP, FRONT SIDE DOOR WINDOW FRONT UP
55 APPLIQUE ASSEMBLY, OUTSIDE REARVIEW MIRROR
56 SEAL, FRONT SIDE DOOR FRONT BELT
58 WASHER, FRONT SIDE DOOR WINDOW FRONT UP
STOP
59 BUSHING ASSEMBLY, FRONT SIDE DOOR WINDOW
60 WEDGE, FRONT SIDE DOOR WINDOW
61 NUT, FRONT SIDE DOOR WINDOW STABILIZER PIN
62 SEALING STR!P ASSEMBLY, FRONT SIDE DOOR
WINDOW OUTER
63 STRIKER ASSEMBLY, FRONT SIDE DOOR INTERLOCK
64 SPACER, FRONT SIDE DOOR INTERLOCK STRIKER
65 PLATE, FRONT SIDE DOOR LOCK STRIKER ANCHOR
66 WASHER, FRONT SIDE DOOR LOCK STRIKER
67 SPACER, FRONT SIDE DOOR LOCK STRIKER
68 STRIKER ASSEMBLY, FRONT SIDE DOOR LOCK
69 BOLT/SCREW, FRONT SIDE DOOR LOCK STRIKER
70 NUT, FRONT SIDE DOOR OUTSIDE HANDLE
71 CLIP, FRONT SIDE DOOR LOCK CYLINDER PAWL
72 RETAINER, FRONT SIDE DOOR LOCK CYLINDER
73 GASKET, FRONT SIDE DOOR LOCK CYLINDER
74 CYLINDER UNIT, LOCK
75 CLIP, FRONT SIDE DOOR OUTSIDE HANDLE
76 HANDLE ASSEMBLY, FRONT SIDE DOOR OUTSIDE
77 FILLER, FRONT SIDE DOOR OUTSIDE HANDLE
78 PROTECTOR, DOOR EDGE
79 BOLT/SCREW, FRONT SIDE DOOR UPPER HINGE
80 BOLT/SCREW, FRONT SIDE DOOR LOWER HINGE
81 WASHER, FRONT SIDE DOOR INTERLOCK STRIKER
82 REGULATOR ASSEMBLY, FRONT SIDE DOOR WINDOW
83 MOTOR ASSEMBLY, FRONT SIDE DOOR WINDOW
REGULATOR
116 DOOR ASSEMBLY, FRONT SIDE
125 RETAINER, FRONT SIDE DOOR REAR BELT SEAL
136 ROD, FRONT SIDE DOOR LOCK CYLINDER
PC0002-106F-RP
Figure 2 - Front Side Door Assembly - Legend (1 of 2)
10.5.5 DOORS
86
88
92
re-_94
93
89
100
109
jVIEWA
106
105
L-----------~;;33-Figure
PC2003-106-F-RP
FFront Side
. Door Assembly (2 of 2)
DOORS 10-6-7
Front Side Door Inside Handle Bezel

Figure 7
A
B
C
D
E
F
32
55
84
85
86
87
88
89
90
91
92
93
94
95
96
97
98
99
100
101
103
104
105
106
107
108
109
110
120
152
WITH QUAD FRONT DOOR-MOUNTED SPEAKERS

WITH DUAL FRONT DOOR-MOUNTED SPEAKERS
DRIVER'S SIDE MANUAL REMOTE CONTROL
DRIVER'S SIDE ELECTRIC CONTROL
JACKSCREW
TRUNNION, OUTSIDE REARVIEW MIRROR
KNOB, FRONT SIDE DOOR LOCKING ROD
APPLIQUE ASSEMBLY, OUTSIDE REARVIEW MIRROR
BEZEL ASSEMBLY, OUTSIDE REARVIEW MIRROR
BOLT/SCREW, OUTSIDE REARVIEW MIRROR BEZEL
DEFLECTOR, FRONT SIDE DOOR WATER
NUT, FRONT SIDE DOOR ARMREST
SEALING STRIP, FRONT SIDE DOOR WINDOW INNER
TRIM ASSEMBLY, FRONT SIDE DOOR
BOLT/SCREW, FRONT SIDE DOOR ARMREST
BEZEL, FRONT SIDE DOOR INSIDE HANDLE
PANEL ASSEMBLY, ACCESSORY SWITCH
SWITCH, DOOR LOCK
SWITCH, SIDE WINDOW
ARMREST, FRONT SIDE DOOR
BOLT/SCREW, FRONT SIDE DOOR ARMREST
BOLT/SCREW, FRONT SIDE DOOR INSIDE HANDLE
BEZEL
GRILLE, RADIO FRONT SIDE DOOR SPEAKER
GRILLE, RADIO FRONT SIDE DOOR (TWEETER)
SPEAKER
TRIM ASSEMBLY, FRONT SIDE DOOR
NUT, OUTSIDE REARVIEW MIRROR
GLASS, OUTSIDE REARVIEW MIRROR REFLECTIVE
MIRROR ASSEMBLY, OUTSIDE REARVIEW
BEZEL ASSEMBLY, OUTSIDE REARVIEW MIRROR
APPLIQUE ASSEMBLY, OUTSIDE REARVIEW MIRROR
GLASS, OUTSIDE REARVIEW MIRROR REFLECTIVE
POCKET, FRONT SIDE DOOR MAP
POCKET, FRONT SIDE DOOR MAP
PC2004-106-FRP
Figure 4 - Front Side Door Assembly - Legend (2 of 2)

switch opening cover assembly. Refer to "Accessory Switch Panel Assembly and Accessory Switch
Opening Cover Assembly" in this section.
2. Front side door locking rod knob. Refer to "Front
Side Door Locking Rod Knob" in the following procedure.
3. Bolt/screw (97).
4. Bezel (91).
Slide bezel (91) forward to release from trim
assembly.

1. Bezel(91).
Route inside handle assembly (35) and locking
rod through appropriate openings in bezel (91).
Position bezel (91) and slide rearward.
2. Bolt/screw (97).
l~I Tighten
3. Front side door locking rod knob. Refer to "Front
Side Door Locking Rod Knob" in the following procedure.
switch opening cover assembly. Refer to "Accessory Switch Panel Assembly and Accessory Switch
Opening Cover Assembly" in this section.
Front Side Door Locking Rod Knob

FigureB
C. Remove switches, if equipped and panel

assembly is being replaced. Refer to "Side
Window, Outside Remote Control Rearview
Mirror Selector and Door Lock Switches" in
this section.

Panel assembly (112) or cover assembly.
A. Install switches if removed. Refer to "Side
Window, Outside Remote Control Rearview
Mirror Selector and Door Lock Switches" in
this section.
B. Connect electrical connectors, if equipped.
C. Position panel assembly (112) or cover assembly and press to secure clips.

Knob (32).
A. Slide knob (32) forward.
B. Insert a small flat-bladed tool behind end of
knob (32) and pry it away from locking rod
(49).

Knob (32).
A. Position knob (32) over locking rod (49) and
insert end of knob (32) through hole in handle
bezel.
B. Slide knob (32) rearward over locking rod (49)
until end of locking rod (49) fits into depression in knob (32).
10-6-8 DOORS
90
A CONNECTOR, RADIO FRONT SIDE DOOR SPEAKER
(TWEETER) ELECTRICAL
90 BOLT/SCREW, FRONT SIDE DOOR ARMREST
100 TRIM ASSEMBLY, FRONT SIDE DOOR
PC2005 106-F-RP
Figure 5 - Front Side Door Trim Assembly (Typical Right Shown, Left Similar)
C. Snap knob (32) over locking rod (49).

114
FRONT SIDE DOOR EXTERIOR TRIM

Front Side Door Center Molding Assembly
Figure 9
For information and procedures on replacing adhesive molding assemblies, refer to SECTION 10-1. Refer
to Figure 9 for correct placement of the molding assembly
(117).
Front Side Door Emblem Assembly

Figure 10
l++I
Tool Required:
J 25070 Heat Gun
Emblem assembly (118 or 119).

A. Hold J 25070 at least 152 mm (6 inches) from
emblem assembly (118 or 119). Apply heat in
an even and circular motion.
B. Pull emblem assembly (118 or 119) from door
assembly (116) with flat-bladed tool, making
sure not to damage paint.
IOI
Clean
1. Area with suitable solution of isopropyl alcohol

50/50 mixture by volume with water or high-flash
naphtha.
2. Area with clean, dry cloth.
c
A CONNECTOR, DOOR LOCK SWITCH ELECTRICAL
B CONNECTOR, OUTSIDE REMOTE CONTROL REARVIEW
MIRROR SELECTOR SWITCH ELECTRICAL
C CONNECTOR, SIDE WINDOW SWITCH ELECTRICAL
93 SWITCH, DOOR LOCK
111 SWITCH, SIDE WINDOW
112 PANEL ASSEMBLY, ACCESSORY SWITCH
114 SWITCH, OUTSIDE REMOTE CONTROL REARVIEW
MIRROR SELECTOR
115 HARNESS ASSEMBLY, CROSSBODY AND FRONT SIDE
DOOR WIRING
PC2006106-F-RP
Figure 6 - Accessory Switch Panel Assembly (Typical)
l++I
Install or Connect
New emblem assembly (118 or 119).

A. Heat door assembly surface and adhesive side
of new emblem assembly (118 or 119). Temperature must be 26C (80F) or 6C (10F)
DOORS 10-6-9
above air temperature in area, whichever is
higher, but not exceeding 40C (105F).
B. Remove liner from adhesive strip.
rn
Important
Position emblem assembly (118 or 119)

carefully. Emblem assembly (118 or 119)
cannot be removed without reapplying
adhesive after contact with vehicle.
C. Press emblem assembly (118 or 119) into place
and apply pressure.
Door Edge Protector

Figure 11

Tool Required:
J 25070 Heat Gun
Protector (78).
protector (78). Apply heat in an even and circular motion.
B. Peel protector (78) from door assembly (116)
with flat-bladed tool, making sure not to damage paint.
32 KNOB, FRONT SIDE DOOR LOCKING ROD

PC2008-106-F-RP
Figure 8 - Installing Front Side Door Locking Rod Knob
li,I Clean
naphtha.

Protector (78).
A. Remove liner from protector (78).
B. Line up top of protector (78) to bottom of handle assembly at outer edge of door assembly
(116).
rn
Important
Be sure that inside corner of protector is

against edge of door assembly.
C. Press entire length of tape area to secure.
35 HANDLE ASSEMBLY, FRONT SIDE DOOR INSIDE
91 BEZEL, FRONT SIDE DOOR INSIDE HANDLE
97 BOLT/SCREW, FRONT SIDE DOOR INSIDE HANDLE
BEZEL
DOOR WIRING
PC2007-106-F-RP
Figure 7 - Front Side Door Inside Handle Bezel (Right

Shown, Left Similar)
FRONT SIDE DOOR HARDWARE AND

FRONT SIDE DOOR WINDOW
Front Side Door Weatherstrip Assembly
Figures 12 and 13

Tool Required:
J 21104-B Universal Weatherstrip Remover
10-6-10 DOORS
116
SECTION A-A
116
117
117
117 MOLDING ASSEMBLY, FRONT SIDE DOOR CENTER
5.0 mm ( 0 . 2 0 " ~
.FRT'
3.5 mm 10.14"1
SECTION 8-8
PC2009 106-F-RP
Figure 9 - Installing Front Side Door Center Molding Assembly
1. Body hinge pillar trim panel. Refer to SECTION

10-5.
2. Windshield pillar trim panel. Refer to SECTION
10-5.
3. Rear quarter trim panel. Refer to SECTION 10-7.
4. Bolts/screws (124), if equipped.
5. Retainers (121) using J 21104-B.
6. Weatherstrip assembly (122 or 123).
A. Pull weatherstrip assembly (122 or 123) from
flange and weatherstrip retainer assemblies.
B. Break adhesive bond at front belt with a flatbladed tool.

1.
2.
3.
4.

Remove protective liner from adhesive strip on weatherstip assembly (122 or 123).
Position weatherstrip assembly (122 or 123) at front
belt.
Retainer (121) at front belt.
Weatherstrip assembly (122 or 123).
A. Insert weatherstrip assembly (122 or 123) into
retainer assembly up hinge pillar.
B. Install retainer (121) at lock pillar belt.
C. Insert weatherstrip assembly (122 or 123) into
retainer assemblies up lock pillar and across
roof assembly.
D. Roll weatherstrip assembly (122 or 123) into
retainer assembly.
a. Starting at lock pillar belt, roll up to corner and back down to belt.
b. Starting at lock pillar top corner, roll forward to front belt and back to lock pillar
top corner.
E. Insert weatherstrip assembly (122 or 123) into
flange below belt at front, bottom and back.
F. Roll entire length to seat.
5. Bolts/screws (124), if equipped.

6. Rear quarter trim panel. Refer to SECTION 10-7.
7. Windshield pillar trim panel. Refer to SECTION
10-5.
8. Body hinge pillar trim panel. Refer to SECTION
10-5.
Front Side Door Window Outer Sealing Strip

Assembly
Figure 14

1. Lower window.
2. Sealing strip assembly (62) by pulling to release the
spring clips.

Sealing strip assembly (62).
A. Align spring clips to slots in door outer panel
reinforcement and insert clips.
B. Tap to secure clips.

C. Ensure that sealing strip assembly (62) 1s
seated flush to the door outer panel.
DOORS 10-6-11
116
14.0 mm (0.55")
[
/B
_jl'
~,, >
I.
-.,
2fE:
'
78
mm (1.6")
116
78
SECTION A-A
A LINER, TAPE
78 PROTECTOR,DOOREDGE
118
PC0011106-F-R
Figure 11 - Installing Door Edge Protector
Front Side Door Window Inner Sealing Strip

Figures 3 and 4

20.0 mm ~.79")
Uc

2. Inner sealing strip (88) by removing staples.
W-~58.0 mm (2.3")
l,.+I Install or Connect
116
1. Inner sealing strip (88) to trim assembly (89 or 100).

2. Staples to secure inner sealing strip (88) to trim
Front Side Door Front and Rear Belt Seals

Figure 15

A LINER, PROTECTIVE
B LOWER EDGE OF FRONT SIDE DOOR CENTER MOLDING
ASSEMBLY
118 EMBLEM ASSEMBLY, FRONT SIDE DOOR
119 EMBLEM ASSEMBLY, FRONT SIDE DOOR
PC2010106-F-RP
Figure 10 - Installing Front Side Door Emblem Assembly

2. Retainers (5 or 125) by prying out with a flat-bladed
tool.
Discard retainers (5 or 125).
3. Seal (6 or 56).

1. Seal (6 or 56).
2. New retainers (5 or 125).
10-6-12 DOORS
116
62
SECTION A-A
A DOOR INNER PANEL

62 SEALING STRIP ASSEMBLY, FRONT SIDE DOOR
WINDOW OUTER
PC0014106-F-RP
Figure 14 - Front Side Door Window Outer Sealing Strip

Assembly
SECTION A-A
121 RETAINER, FRONT SIDE DOOR WEATHERSTRIP

122 WEATHERSTRIP ASSEMBLY, FRONT SIDE DOOR

Front Side Door Bottom Auxiliary Sealing

Strip
Figure 16
PC0012106-F-RP
Figure 12 - Front Side Door Weatherstrip Assembly

Tool Required:
J 25070 Heat Gun
125
w1
121
152
121 RETAINER, FRONT SIDE DOOR WEATHERSTRIP
123 WEATHERSTRIP ASSEMBLY, FRONT SIDE DOOR
124 BOLT/SCREW, ROOF LIFT-OFF WINDOW BODY SIDE
WEATHERSTRIP
5
6
56
125
152
RETAINER, FRONT SIDE DOOR FRONT BELT SEAL

SEAL, FRONT SIDE DOOR REAR BELT
SEAL, FRONT SIDE DOOR FRONT BELT
RETAINER, FRONT SIDE DOOR REAR BELT SEAL
PC0013-106-F-RP
Figure 13 - Front Side Door Weatherstrip Assembly (With

Roof Lift-Off Window Assemblies)
PC00151~6-F-RP
Figure 15 - Front Side Door Front and Rear Belt Seals
DOORS 10-6-13
152
30
[VIEWA
30
A LOCATING FEATURE
30 SEALING STRIP, FRONT SIDE DOOR BOTTOM
AUXILIARY
SECTION A-A
PC0016-106-F-RP
Figure 16 - Installing Front Side Door Bottom Auxiliary Sealing Strip
Sealing strip (30).

sealing strip (30). Apply heat in an even and
circular motion.
B. Pull sealing strip (30) from door assembly
(152) with flat-bladed tool, making sure not to
damage paint.
1.,1
Clean

naphtha.

New sealing strip (30).
A. Heat door surface and adhesive side of new
sealing strip (30). Temperature must be 35C
3C (95F 5F).
B. Remove protective liner from adhesive strip.
rn
Important
Position sealing strip carefully. Sealing

strip cannot be removed without reapplying adhesive after contact with vehicle.
C. Align sealing strip (30) to locating feature
starting at rear edge of door inner panel.
D. Press sealing strip (30) into place and apply

pressure along entire surface.
Front Side Door Trim Panel Retainer Seals

Figure 17

2. Seals (126).

1. Seals (126).
Front Side Door Inside Handle Seal

Figure 18

2. Seal (50).
10-6-14 DOORS
126
22 NUT, FRONT SIDE DOOR WINDOW REGULATOR

152
PC0019-106-F-RP
126 SEAL, FRONT SIDE DOOR TRIM PANEL RETAINER

Figure 19 - Removing Front Side Door Window Regulator

Counterbalance Arm Channel Nuts
PC2017-106-F-RP
Figure 17 - Front Side Door Trim Panel Retainer Seals
3. Front side door water deflector as needed. Refer to

"Front Side Door Water Deflector" in this section.
4. Nuts (22) attaching channel assembly (21) to door
inner panel.
5. Channel assembly (21) from window regulator balance arm roller.
6. Channel assembly (21) through access hole.

35 HANDLE ASSEMBLY, FRONT SIDE DOOR INSIDE
50 SEAL, FRONT SIDE DOOR INSIDE HANDLE
PC0018-106-F-RP
Figure 18 - Front Side Door Inside Handle Seal

1. Seal (50) and press down to base of handle assembly
(35).
Install seal (50) with smooth side toward door
inner panel.
Side Door Inside Handle Bezel'' in this section.

Counterbalance Arm Channel Assembly
Figures 19 and 20

1. Raise window.

1. Channel assembly (21) through access hole to window regulator balance arm roller.
2. Channel assembly (21) to door inner panel.
3. Nuts (22).
l~I Tighten
Nuts (22) to 10 Nm (89 lb. in.).
4. Front side door water deflector. Refer to "Front Side
Door Water Deflector" in this section.
Front Side Door Window Channel Assembly

and Front Side Door Window Rear Guide
Channel Assembly
Figures 21 and 22

1. Front side door window. Refer to "Front Side Door
Window" in this section.
2. Nuts (27 and 29).
3. Channel assembly (18) with rear guide channel
assembly (28) attached from regulator rollers.
4. Channel assembly (18) through access hole.
DOORS 10615
20
152
A ROLLER, REGULATOR BALANCE ARM

21 CHANNEL ASSEMBLY, FRONT SIDE DOOR WINDOW
PC0020-106-F-RP
Figure 20 - Removing Front Side Door Window Regulator Counterbalance Arm Channel Assembly (Typical)
5. Rear guide channel assembly (28) from channel

roller.
29
LJ.11...
m~'
/f,r=,
~ ...F ,
t="\
"fr~'
1. Rear guide channel assembly (28) to channel roller.
/~'~'
11 I
2. Channel assembly (18) with rear guide channel

assembly (28) through access hole, allowing rear
guide channel assembly (28) to drop.
,,,'~''
ef---,
L'
3. Channel assembly (18) to regulator rollers.

A. Insert front of channel assembly (18) onto
front regulator roller.
B. Push forward until rear edge of channel assembly (18) lines up with rear roller.
C. Insert rear roller onto channel assembly (18)
by pushing rearward.
4. Align studs on rear guide channel assembly (28) to
slots in door inner panel.
5. Nuts (27 and 29).
l~I Tighten
Nut (27) to 10 Nm (89 lb. in.).
Nuts (29) to 27 Nm (20 lb. ft.).
6. Front side door window. Refer to "Front Side Door
Window" in this section.
Side Window, Outside Remote Control

Rearview Mirror Selector and Door Lock
Switches
Figure23

1. Accessory switch panel assembly. Refer to "Accessory Switch Panel Assembly" in this section.
27 NUT, FRONT SIDE DOOR WINDOW REAR GUIDE

CHANNEL
CHANNEL
PC0021-106-F-RP
Figure 21 - Removing Front Side Door Window Rear Guide

Channel Nuts
2. Switch (93, 111 or 114) by prying with a flat-bladed

tool to release switch (93, 111 or 114) from panel
assembly (112).

1. Switch(93, 111 or 114)intopanelassembly(ll2).
2. Accessory switch panel assembly. Refer to "Accessory Switch Panel Assembly" in this section.
Front Side Door Water Deflector

Figure24
Whenever work is performed where the deflector
(86) is disturbed, the deflector (86) must be properly
sealed and taped to the door inner panel to prevent waterleaks. For service sealing, strip caulking is recommended
if additional sealing material is required.
10-6-16 DOORS
18

REAR GUIDE
PC0022-106-F-RP
Figure 22 - Removing Front Side Door Window Channel Assembly and Front Side Door Window Rear Guide Channel Assembly
When access to the door inner panel is required to

perform service operations, the deflector (86) may be
completely or partially detached from the door inner
panel. If the existing deflector (86) is damaged so that it
will not properly seal the door assembly, replace the
deflector (86).
If only partial removal of the deflector (86) is
required, perform only the steps that are necessary to
expose the required area of the door inner panel.

2. Deflector (86).
A. Break the sealer bond with a flat-bladed tool.
B. Peel tape from door inner panel.

C. Disconnect tabs on lower edge of deflector
(86) from slots in door inner panel.
IL'l'I Inspect
Deflector (86) for tears or holes. Repair using waterproof body tape on both sides of deflector (86) or
replace deflector (86).

1. Deflector (86).
A. Apply continuous bead of string sealer to guide
water to drain slots.
B. Align arrows on deflector (86) at upper outer
comers to front and rear of door inner panel.
112
w~oo
\~S
~-qi
114
A CONNECTOR, DOOR LOCK SWITCH ELECTRICAL

B CONNECTOR, OUTSIDE REMOTE CONTROL REARVIEW
MIRROR SELECTOR SWITCH ELECTRICAL
C CONNECTOR, SIDE WINDOW SWITCH ELECTRICAL
93 SWITCH, DOOR LOCK
111 SWITCH, SIDE WINDOW
112 PANEL ASSEMBLY, ACCESSORY SWITCH
114 SWITCH, OUTSIDE REMOTE CONTROL REARVIEW
MIRROR SELECTOR
PC2023-106-F-RP
Figure 23 - Removing Switches (Typical)
C. Slick down top of deflector (86).
D. Pull electrical connectors through appropriate

holes or slots in deflector (86).
E. Slick outer edge of deflector (86) to door inner
panel working downward to bottom edge.
F. Insert tabs into retaining slots and slick.
DOORS 10-6-17
152
86
C\"'
!VIEWA
86
A PANEL, DOOR INNER

86 DEFLECTOR, FRONT SIDE DOOR WATER
DOOR WIRING
PC2024-106-F-RP
Figure 24 - Front Side Door Water Deflector
Outside Rearview Mirror Assembly

Figures 25 and 26

1. Bolt/screw (85).
2. Bezel assembly (105).
3. Remote handle from bezel assembly (105), if
equipped.
4. Front side door trim assembly, if equipped with electric control mirror assemblies. Refer to "Front Side
5. Electrical connector, if equipped.
A. Pull rosebud clip on electrical connector from
mirror assembly (127).
B. Pull apart connection.
6. Nuts (101).
7. Mirror assembly (109 or 127).

1. Mirror assembly (109 or 127).
2. Nuts (101).
l~I Tighten
Nuts (101) to 6 Nm (53 lb. in.).
3. Electrical connector, if equipped.
A. Connect electrical connector.
B. Push rosebud clip on electrical connector into
hole in mirror assembly (127).
A HANDLE, OUTSIDE REARVIEW MIRROR REMOTE

85 BOLT/SCREW, OUTSIDE REARVIEW MIRROR BEZEL
105 BEZEL ASSEMBLY, OUTSIDE REARVIEW MIRROR
PC0025106-F-RP
Figure 25 - Removing Outside Rearview Mirror Bezel

Assembly (Typical)
4. Front side door trim assembly, if removed. Refer to

''Front Side Door Right and Left Trim Assemblies''
in this section.
5. Remote handle to bezel assembly (105), if equipped.
A. Align slot in remote handle to tab on bezel
assembly (105).
B. Push remote handle into bezel assembly (105)

to engage threads on remote handle onto metal
clip in bezel assembly (105).
6. Bezel assembly (105).
Align retainers in bezel assembly (105) to
holes in applique assembly.
7. Bolt/screw (85).
l~I Tighten
10-6-18 DOORS
127
101
108
101
109
101
101 NUT, OUTSIDE REARVIEW MIRROR
109 MIRROR ASSEMBLY, OUTSIDE REARVIEW (ELECTRIC)
127 MIRROR ASSEMBLY, OUTSIDE REARVIEW (MANUAL
REMOTE)
B
PC0026-106-FRP
Figure 26 - Removing Outside Rearview Mirror Assembly

(Typical)
Outside Rearview Mirror Reflective Glass

Electric
c
A
B
C
D
TRUNNION, OUTSIDE REARVIEW MIRROR

RECEPTOR, OUTSIDE REARVIEW MIRROR TRUNNION
RECEPTOR, JACKSCREW
JACKSCREW
108 GLASS, OUTSIDE REARVIEW MIRROR REFLECTIVE
Figure27
PC0027-106-F-RP

CAUTION: To minimize the chance of
personal injury, gloves and safety
glasses should be worn when removing broken glass.
1. Move mirror assembly to extreme outboard travel
position.
2. Glass (108) by inserting finger at slot on inboard
side of mirror assembly and pulling out.
3. Jackscrews and trunnion bar from motor pack unit.
ll"'I
Inspect
Motor pack unit. If damaged, replace mirror assembly. Refer to "Outside Rearview Mirror Assembly"
in this section.

1. Jackscrews and trunnion bar to new glass (108).
2. New glass (108).
A. Align jacks crews perpendicular to glass (108).
B. Align trunnion bar parallel to glass (108).
Figure 27 - Outside Rearview Mirror Reflective Glass

(Electric)
C. Position end of jackscrews at opening approximately 13 mm (1/2 inch) into motor pack unit.
D. Visually align trunnion bar with receptor by
lifting inboard corner of glass (108).
E. Apply pressure with palm of hand until glass
(108) is seated firmly to receptor.
F. Manually rotate glass (108) to check for proper
installation.
Manual

CAUTION: To minimize the chance of
personal injury, gloves and safety
glasses should be worn when removing broken glass.
NOTICE: When breaking glass, cover door area
surrounding glass to avoid damage to paint.
Glass.
A. Place tape over glass.
B. Break glass.
DOORS 10-6-19
C. Remove broken pieces from mirror assembly.
IS,I Clean
Inside of mirror assembly with clean cloth.
152

Glass.
A. Remove protective liner to expose adhesive.

B. Press glass firmly onto center of mirror assembly.
Manual Remote Control

The reflective glass on the outside rearview mirror
assembly with manual remote control is not serviceable. If
the glass is broken, replace the mirror assembly. Refer to
36 BOLT/SCREW, OUTSIDE REARVIEW MIRROR APPLIQUE

37 NUT, OUTSIDE REARVIEW MIRROR OPENING
APPLIOUE
43 WASHER, OUTSIDE REARVIEW MIRROR APPLIOUE
55 APPLIOUE ASSEMBLY, OUTSIDE REARVIEW MIRROR
Outside Rearview Mirror Applique Assembly

Figure28

1. Lower window.
"Right Front Side Door Water Deflector" in this
section.
4. Outside rearview mirror assembly. Refer to "Outside Rearview Mirror Assembly" in this section.
5. Nut (37).
7. Washer (43).
8. Applique assembly (55).

1. Applique assembly (55) through opening between
door inner panel and door outer panel.
2. Washer (43) and bolts/screws (36).
!~I Tighten
3. Nut (37).
!~I Tighten
Nut (37) to 6 Nm (53 lb. in.).
4. Outside rearview mirror assembly. Refer to "Outside Rearview Mirror Assembly" in this section.
PC0028-106-F-RP
Figure 28 - Removing Outside Rearview Mirror Applique

Assembly

Door Water Deflector'' in this section.
Radio Front Side Door Speaker Assembly

Figure29

4. Speaker assembly (128 or 130).

2. Speaker assembly (128 or 130).
10-6-20 DOORS
Front Side Door Outside Handle Assembly

Figure30

1. Raise window.
4. Handle rod (13) from fastener on clip (135).
5. Handle rod (13) from clip (135).
6. Nuts (70).
7. Handle assembly (134) from door outer panel.
8. Filler (133) from handle assembly (134).
VFRr
152.....,_~.
131~~
130~'A
132
129~
B
A WITH DUAL FRONT DOOR-MOUNTED SPEAKERS
B WITH QUAD FRONT DOOR-MOUNTED SPEAKERS
C CONNECTOR, RADIO FRONT SIDE DOOR SPEAKER
ELECTRICAL
D CONNECTOR, RADIO FRONT SIDE DOOR (TWEETER)
SPEAKER ELECTRICAL
128 SPEAKER ASSEMBLY, RADIO FRONT SIDE DOOR
129 BOLT/SCREW, RADIO FRONT SIDE DOOR SPEAKER
130 SPEAKER ASSEMBLY, RADIO FRONT SIDE DOOR
131 SPEAKER ASSEBMLY, RADIO FRONT SIDE DOOR
(TWEETER)
132 NUT, RADIO FRONT SIDE DOOR (TWEETER) SPEAKER

1. Filler (133) to handle assembly (134).
2. Handle assembly (134) to door outer panel.
A. Hold handle assembly (134) in open position
and insert studs through holes in door outer
panel.
B. Move handle assembly (134) rearward into
slots and press.
3. Nuts (70).
l~I Tighten
4.
PC2029-106-F-RP
Figure 29 - Removing Radio Front Side Door Speaker

Assemblies
Radio Front Side Door (Tweeter) Speaker

Assembly
Figure29

2. Nuts (132).
3. Speaker assembly (131)_

NOTICE: See "Notice" on page 10-6-1 of this section_
1. Speaker assembly (131).
2. Nuts (132).
Door Right and Left Trim Assemblies" in this section_
5.
6.
7.
Nuts (70) to 7 Nm (62 lb. in.).

Handle rod (13) into clip (135) on handle assembly
(134).
Handle rod (13) onto fastener on clip (135).
Front side door water deflector. Refer to "Front Side
Front side door trim assembly. Refer to "Front Side
Door Right and Left Trim Assemblies" in this seC'tion.
Front Side Door Inside Handle Assembly

Figure31

1. Raise window.
3. Front side door inside handle seal. Refer to "Front
Side Door Inside Handle Seal" in this section.
5. Rivet (34).
A. Tap rivet mandrel until it falls out of rivet (34).
B. Drill out rivet (34) with 3/16-inch drill bit.
DOORS 10-6-21
152
152
133
@)~~134
13
13
70
133
134
135
152

NUT, FRONT SIDE DOOR OUTSIDE HANDLE
FILLER, FRONT SIDE DOOR OUTSIDE HANDLE
HANDLE ASSEMBLY, FRONT SIDE DOOR OUTSIDE
CLIP, FRONT SIDE DOOR OUTSIDE HANDLE
PC0030-106-F-RP
Figure 30 - Front Side Door Outside Handle Assembly
6.
7.
8.
9.
10.
C. Remove rivet fragments from hole.

Handle assembly tab from door inner panel slot by
sliding handle assembly (35) rearward.
Rod assembly (47) from fastener on clip (46).
Rod assembly (47) from clip (46).
Handle assembly (35) from door inner panel.
Clip (46) from handle assembly (35).
Use needlenose pliers to squeeze clip (46) and
push from handle assembly (35).
!Ll 1nspect
Clip (46).
rn
Important
If clip (46) is damaged, it must be replaced.

Use GM PIN 16627328 (left-hand) or GM PIN
9835133 (right-hand).

1. Clip (46) into handle assembly (35).
2. Handle assembly (35) to door inner panel.
Rotate front of handle assembly (35) into slot.
3. Rod assembly (4 7) into clip (46) on handle assembly
(35).
4. Rod assembly (47) onto fastener on clip (46).
5. Tab on handle assembly (35) into slot on door inner
panel by rotating and sliding forward.
A
B
34
35
46
47
OUTSIDE VEHICLE
DOOR INNER PANEL
RIVET, FRONT SIDE DOOR INSIDE HANDLE
HANDLE ASSEMBLY, FRONT SIDE DOOR INSIDE
CLIP, FRONT SIDE DOOR INSIDE HANDLE ROD
ROD ASSEMBLY, FRONT SIDE DOOR INSIDE HANDLE
PC0031-106-F-RP
Figure 31 - Installing Front Side Door Inside Handle

Assembly
10-6-22 DOORS
6. Align hole in handle assembly (35) with hole in door
inner panel.
7. Rivet (34).
9. Front side door inside handle seal. Refer to "Front
Side Door Handle Inside Handle Seal" in this section.
Front Side Door Window Regulator Handle

Assembly
Figure 32

Tool Required:
J 9886-01 Door Handle Clip Remover
1. Handle assembly (26) by pushing J 9886-01
between handle assembly (26) and spacer (24) to
release clip.
2. Spacer (24) from spindle.

1. Spacer (24) to spindle.
NOTICE: Strike handle assembly with mallet at hub
when installing to avoid damage.
A. Position handle assembly (26) to spindle pointing forward if window assembly is up, or rearward if window assembly is down.
B. Tap handle assembly (26) with mallet until
snap ring in handle assembly (26) engages
groove in spindle.
Front Side Door Lock Assembly

Figure 33
CAUTION: Do not attempt to repair a
broken lock assembly. A lock malfunction may result in serious bodily injury.
A broken lock assembly must be
replaced.

1. Raise window.
4. Electrical connector from lock assembly (9), if
equipped.
5. Inside handle rod assembly (47) from clip (15).
6. Clip (15) using needlenose pliers.
~fl)c~~
;-~
A/9
,Jfj,
-----,jt1_.
;,::'L,
"'-c
24
26
A
B
C
24
SPINDLE, REGULATOR
FRONT SIDE DOOR WINDOW UP
FRONT SIDE DOOR WINDOW DOWN
SPACER, FRONT SIDE DOOR WINDOW REGULATOR
HANDLE
26 HANDLE ASSEMBLY, FRONT SIDE DOOR WINDOW
REGULATOR
PC00321~6fRP
Figure 32 - Front Side Door Window Regulator Handle

Assembly
Discard clip (15).

7. Locking rod (49) from clip (17).
8. Clip ( 17) using needlenose pliers.
Discard clip (17).
9. Outside handle rod (13) from retainer (12).
A. Use right-angle needlenose pliers to squeeze
retainer tabs and pull retainer (12) through
hole.
B. Unscrew retainer (12) from outside handle rod
(13).
10. Lock cylinder rod (14) from clip (11).
11. Clip (11) from lock assembly (9) using needlenose
pliers.
Discard clip (11).
13. Lock assembly (9) through access hole.

1. Lock assembly (9) through access hole.
l~I Tighten
3. New clip (11) into lock assembly.
Use GM PIN 16606936.
4. Lock cylinder rod (14) into clip (11).
5. New retainer (12) to lock assembly (9).
6. Outside handle rod (13) to retainer (12).
A. Line up lower end of outside handle rod (13) to
retainer (12).
DOORS 10-6-23
152
152
jv1EWB
9
10
11
12
13
14
15
17
47
49
152

BOLT/SCREW, FRONT SIDE DOOR LOCK
RETAINER, FRONT SIDE DOOR OUTSIDE HANDLE ROD
ROD ASSEMBLY, FRONT SIDE DOOR INSIDE HANDLE
ROD, FRONT SIDE DOOR LOCKING
PC0033-106-F-RP
Figure 33 - Front Side Door Lock Assembly
B. Snap outside handle rod (13) into back half of

retainer (12).
C. Snap retainer cover closed over threaded part
of outside handle rod (13).
7. New clip (17) to lock assembly (9).

Use GM P/N 16606936.
8. Locking rod ( 49) to clip (17).

Use GM P/N 16606936.
10. Inside handle rod assembly (47) to clip (15).
11. Electrical connector to lock assembly (9), if
equipped.

Front Side Door Outside Handle Rod

Figures 30 and 33

1. Raise window.

4. Outside handle rod (13) from fastener on clip (135).
5. Outside handle rod (13) from clip (135).
6. Outside handle rod (13) from retainer (12).
A. Use right-angle needlenose pliers to squeeze
retainer tabs and pull retainer (12) through
hole.
B. Unscrew retainer (12) from outside handle rod
(13).
10624 DOORS
7. Outside handle rod (13) from door assembly.
47

1. New retainer (12) to lock assembly (9).
2. Outside handle rod (13) to retainer (12).
A. Line up lower end of outside handle rod ( 13) to
retainer (12).
B. Snap outside handle rod (13) into back half of
retainer (12).
C. Snap retainer cover closed over threaded part
of outside handle rod (13).
3. Outside handle rod (13) into clip (135).
4. Outside handle rod (13) onto fastener on clip (135).
49
48
Front Side Door Inside Handle Rod

Assembly

1. Raise window.
4. Rod assembly (4 7) from fastener on clip (46).
5. Rod assembly (47) from clip (46).
6. Clip (46) from handle assembly (35).
Use needlenose pliers to squeeze clip (46) and
push from handle assembly (35).
Discard clip ( 15).
ILl
1nspect
Clip (46).
rn
Important
If clip (46) is damaged, it must be replaced.

Use GM PIN 16627328 (left-hand) or GM PIN
9835133 (right-hand).

Line up black band on inside handle rod
assembly (47) with slot in clip (48) and snap
inside handle rod assembly (47) into clip (48).
SECTION A-A
A PANEL, DOOR INNER

47 ROD ASSEMBLY, FRONT SIDE DOOR INSIDE HANDLE
48 CLIP, FRONT SIDE DOOR LOCKING ROD
PC0034-106-F-RP
Figure 34 - Front Side Door Inside Handle Rod Assembly

and Front Side Door Locking Rod

4. Clip (46) to handle assembly (35).
6. Inside handle rod assembly (47) to fastener on clip
(46).
Front Side Door Locking Rod

Figures 33 and 34

1. Raise window.
DOORS 10-6-25
Discard clip ( 17).

1. Locking rod (49) to clip (48).
Line up black band on locking rod (49) with
slot in clip (48) and snap locking rod (49) into
clip (48).
Use GM P/N 16606936.
3. Locking rod (49) to clip (17).
Front Side Door Lock Cylinder Rod

Figures 33 and 35

1. Raise window.
Discard clip (11).
6. Lock cylinder rod (14) from fastener on clip (137).

2. Lock cylinder rod (14) onto fastener on clip (137).
3. New clip ( 11) into lock assembly (9).
Use GM P/N 16606936.
14 ROD, FRONT SIDE DOOR LOCK CYLINDER

137 CLIP, FRONT SIDE DOOR LOCK CYLINDER PAWL
PC0035-106-F-RP
Figure 35 - Front Side Door Lock Cylinder Rod
Front Side Door Lock Striker Assembly

Figure 36

1.
2.
3.
4.
5.
Mark position of striker assembly (68).

Bolts/screws (69).
Striker assembly (68).
Spacers (67), as equipped.
Washer (66).

1.
2.
3.
4.

Washer (66).
Any spacers (67) that were removed.
Striker assembly (68) to location marked.
Bolts/screws (69).
l~I Tighten
ll'l'I Inspect
Striker assembly-to-lock assembly engagement. If
adjustment is needed, refer to "Front Side Door
Lock Striker Adjustment" in the following procedure.
Front Side Door Lock Striker Adjustment

With J 39346
Figure 37
Tool Required:
J 39346 "Mini-Wedge" Door Striker Aligner
10626 DOORS
66
67
68
69
WASHER, FRONT SIDE DOOR LOCK STRIKER

SPACER, FRONT SIDE DOOR LOCK STRIKER
STRIKER ASSEMBLY, FRONT SIDE DOOR LOCK
BOLT/SCREW, FRONT SIDE DOOR LOCK STRIKER
PC0036-106-F-RP
68 STRIKER ASSEMBLY, FRONT SIDE DOOR LOCK

69 BOLT/SCREW, FRONT SIDE DOOR LOCK STRIKER
Figure 36 - Front Side Door Lock Striker Assembly
11
PC0037 1Oo-F-RP
Adjust
Figure 37 - Adjusting Front Side Door Lock Striker Assembly

with J 39346
[I] Important
Door assembly must be properly aligned
before adjusting the striker assembly.
Striker assembly (68).
A. Loosen bolts/screws (69) just enough to allow
movement of the striker assembly (68).
B. Install J 39346 to striker assembly (68).
C. Close door assembly while holding outside
handle assembly in open position.
Do not slam door assembly.
D. Open door assembly.
l~I
Tighten

E. Remove J 39346.
Without J 39346
11
Adjust
[I] Important
Door assembly must be properly aligned
before adjusting the striker assembly.
1. Striker assembly up or down and inboard or outboard.
A. Loosen striker assembly bolts/screws.

B. Move striker assembly up or down and inboard
or outboard, as required.
l~I
Tighten
Striker assembly bolts/screws to 24 Nm (18

lb. ft.).
2. Striker assembly forward or rearward.
A. Apply modeling clay or body caulking compound to door lock assembly opening.
B. Close door assembly far enough for striker
assembly to make impression in clay or caulking compound.
Closing the door assembly all the way
will make removing the clay or caulking
compound difficult.
C. Open door assembly and check that striker
assembly impression is centered forward and
rearward in the lock assembly opening.
D. If adjustment is needed:
a. Remove striker assembly. Refer to
"Front Side Door Lock Striker Assembly" in this section.
b. Add or remove spacers as needed.
c. Install striker assembly. Refer to "Front
Side Door Lock Striker Assembly" in
this section.
3. After adjusting striker assembly, touch up any
exposed, unpainted areas.
Front Side Door Lock Striker Anchor Plate

Figure38
l++I
1. Radio rear quarter trim panel speaker assembly.

DOORS 10-6-27
65 PLATE, FRONT SIDE DOOR LOCK STRIKER ANCHOR

PC0038 106-F-RP
Figure 38 - Front Side Door Lock Striker Anchor Plate
2. Front side door lock striker assembly. Refer to

"Front Side Door Lock Striker Assembly" in this
section.
3. Anchor plate (65) through speaker access hole.

1. Anchor plate (65).
2. Front side door lock striker assembly. Refer to
"Front Side Door Lock Striker Assembly" in this
section.
3. Radio rear quarter trim panel speaker assembly.
63 STRIKER ASSEMBLY, FRONT SIDE DOOR INTERLOCK

64 SPACKER, FRONT SIDE DOOR INTERLOCK STRIKER
81 WASHER, FRONT SIDE DOOR INTERLOCK STRIKER
PC0039-106-F-RP
Figure 39 - Front Side Door Interlock Striker Assembly
Front Side Door Bumper

Figure 40

Bumper (146) by prying with a flat-bladed tool.

Bumper (146) by pressing into holes.
Front Side Door Interlock Striker Assembly

Figure 39
Tool Required:
J 29843-9 Door Lock Striker and Seat Belt
Torx Wrench

1. Striker assembly (63) using J 29843-9.
2. Spacers (64 ), as equipped.
3. Washer (81).

1. Spacers (64) to stud end of striker assembly (63).
Install the same number of spacers (64) as are
installed with the front side door lock striker
assembly.
2. Washer (81).
3. Striker assembly (63).
!~I Tighten
Striker assembly (63) to 45 Nm (33 lb. ft.).
Front Side Door Lock Actuator

Figures 41 and 42

1. Front side door lock assembly. Refer to "Front Side
Door Lock Assembly" in this section.
2. Bolts/screws.
3. Actuator (147).

rn
Important
Before installing new actuator ( 147), make

sure the lock assembly (148) is in full open
position.
1. Release lock assembly (148) to be sure it is in full
open position.
A. Push up on lock cylinder rod lever.
B. Pull on inside handle rod lever.
2. Make sure actuating arm bumper is on actuating
arm.
10-6-28 DOORS
8. Gasket (73).

1.
2.
3.
4.
5.
Gasket (73) to cylinder unit (74).

Cylinder unit (74).
Retainer (72) to shoulder of cylinder unit (74).
Lock cylinder rod (14) into clip (137).
Lock cylinder rod (14) onto fastener on clip (137).
116

146 BUMPER, FRONT SIDE DOOR
PC0040-106-F-RP
Figure 40 - Front Side Door Bumper
3. Actuating arm with bumper into actuating arm

receiver.
4. Align bolt/screw holes.
5. Bolts/screws.
ILl
1nspect
Lock assembly operation by pushing inward
on fork bolt until it clicks into full closed position.
- Lock assembly (148) must operate to full
closed position without interference.
6. Electrical connector to lock assembly.
7. Electrical connector to door lock switch.
ILl
1nspect
Actuator operation by pressing door lock
switch to ensure that actuator locks and
unlocks lock assembly (148).
8. Front side door lock assembly. Refer to "Front Side
Door Lock Assembly" in this section.
Lock Cylinder Unit

Figure 43

1. Raise window.
4. Lock cylinder rod (14) from fastener on clip (137).
6. Retainer (72) using a screwdriver to slide upward.
7. Cylinder unit (74).
Front Side Door Upper Hinge Assembly

Figures 44 and 45

1. Support door assembly (116) in full open position.
2. Mark position of upper hinge assembly (149) on
door assembly (116) and hinge pillar.
4. Nuts (41).
5. Upper hinge assembly (149).

1. Upper hinge assembly (149) to position marked.
2. Nuts (41).
A. Install nuts (41 ), but do not tighten.
B. Loosen nuts (39).
l~I Tighten
Nuts (41 and 39) to 50 Nm (37 lb. ft.) in
sequence.
A. Install bolts/screws (79), but do not tighten.
B. Loosen bolts/screws (80).
l~I Tighten
Bolts/screws (79 and 80) to 50 Nm (37
lb. ft.) in sequence.
Front Side Door Lower Hinge Assembly

Figures 44 and 45
Tool Required:
J 36604 Door Hinge Spring Compressor

1. Support door assembly (116) in full open position.
2. Mark position of lower hinge assembly (150) on
door assembly (116) and hinge pillar.
DOORS 10-6-29
147
c
A
B
C
D
E
147
148
LEVER, INSIDE HANDLE ROD

LEVER, LOCK CYLINDER ROD
RECEIVER, ACTUATING ARM
BUMPER, ACTUATING ARM
ARM, ACTUATING
ACTUATOR, FRONT SIDE DOOR LOCK
PC0041106-F-RP
Figure 41 - Front Side Door Lock Actuator
CAUTION: Before removing spring,

cover with shop cloth to prevent spring
from flying off and causing personal
injury or damage.
3. Spring using J 36604.
5. Nuts (39).
6. Lower hinge assembly (150).
l++I
Install or Connect
l~I
Tighten

sequence.
A. Install bolts/screws (80), but do not tighten.
l~I
Tighten
Bolts/screws (80 and 79) to 50 Nm (37

lb. ft.) in sequence.
4. Spring from J 36604.
1. Lower hinge assembly (150) to position marked.
Front Side Door Assembly
2. Nuts (39).
Figures 44 and 45
A. Install nuts (39), but do not tighten.

Tool Required:
J 36604 Door Hinge Spring Compressor
10-6-30 DOORS
72
152
c
A
137
74
152
c
B
A PARTIALLY CLOSED POSITION

B FULL CLOSED POSITION
C BOLT, FORK
PC0042106-F-RP
Figure 42 - Front Side Door Lock Positions
14
72
73
74
137
152

RETAINER, FRONT SIDE DOOR LOCK CYLINDER
GASKET, FRONT SIDE DOOR LOCK CYLINDER
CYLINDER UNIT, LOCK
CLIP, FRONT SIDE DOOR LOCK CYLINDER PAWL
[I) Important
PC0043-106-F-RP
Figure 43 - Removing Lock Cylinder Unit
Steps 1 through 5 apply only to door assemblies equipped with power accessories.
3. Electrical connectors from all components in door
assembly.
4. Grommet (40) from door assembly.
5. Crossbody and front side door wiring harness
assembly from door assembly.
CAUTION: Before removing spring,

cover with shop cloth to prevent spring
from flying off and causing personal
injury or damage.
6. Spring using J 36604.
7. Support door assembly.
8. Nuts (39 and 41).
9. Door assembly.

1. Door assembly to upper and lower hinge assemblies
(149 and 150).
2. Nuts (39 and 41).
l.I Tighten
sequence.
3. Spring from J 36604.
rn
Important
Steps 4 through 8 apply only to door assemblies equipped with power accessories.
4. Crossbody and front side door wiring harness
assembly to door assembly.
5. Grommet (40) to door assembly.
DOORS 10-6-31
116
jv1EWA
I
116
150
80
39 NUT, FRONT SIDE DOOR LOWER HINGE

40
41
79
80
116
149
150
GROMMET, DOOR WIRING HARNESS

NUT, FRONT SIDE DOOR UPPER HINGE
BOLT/SCREW, FRONT SIDE DOOR UPPER HINGE
BOLT/SCREW, FRONT SIDE DOOR LOWER HINGE
HINGE ASSEMBLY, FRONT SIDE DOOR UPPER
HINGE ASSEMBLY, FRONT SIDE DOOR LOWER
I~~~
PC0044-106F-RP
Figure 44 - Front Side Door Upper and Lower Hinge Assemblies
B
A FRONT SIDE DOOR HINGE BOLT/SCREW-TO-HINGE
PILLAR TIGHTENING SEQUENCE
B FRONT SIDE DOOR HINGE NUT-TO-FRONT SIDE DOOR
ASSEMBLY TIGHTENING SEQUENCE
PC0045106FRP
Figure 45 - Front Side Door Hinge Fastener Tightening Sequences
10-6-32 DOORS
6. Electrical connectors to components in door assembly.
152
Front Side Door Window

and gloves should be worn when performing these procedures to reduce the
chance of personal injury should window breakage occur.
l++I
1. Lower window about halfway.

CAUTION: Support front side door window. If window drops into door, personal injury or window damage may
result.
4. Support window (1) in position needed to access rivets (19) by inserting rubber wedge door stops at
front and rear of window (1) between window (1)
and door inner panel.
5. Rivets (19).
Drill out rivets (19) with 1/4-inch drill bit.
6. Window (1) by raising out of door assembly (116 or
152).
ILl
1nspect
Bushing assemblies (59), retainers (2), up stop

(54), pins (3) and wedges (60) on the window
(1) for damage.
7. Bushing assemblies (59) and retainers (2), if necessary, using a flat-bladed tool covered with cloth
body tape.
8. Bolt/screw (53), if necessary.
9. Up stop (54), nut (57) and washer (58), if necessary.
IO.Bolts/screws (4), if necessary.
II.Pins (3), nuts (61) and wedges (60), if necessary.
l++I
Install or Connect

1. Wedges (60) and pins (3), ifremoved.
2. Bolts/screws (4 ), if removed.
A STOP, RUBBER WEDGE DOOR

PC0046 106F-RP
Figure 46 - Supporting Front Side Door Window
l~I
Tighten

3. Nuts (61), if removed.
l~I
Tighten
Nuts (61) to 8 Nm (71 lb. in.).

4. Up stop (54) and washer (58), if removed.
5. Bolt/screw (53), if removed.
l~I
Tighten

6. Nut (57), if removed.
l~I
Tighten
Nuts (57) to 8 Nm (71 lb. in.).

7. Bushing assemblies (59) and retainers (2), if
removed.
8. Window (1) into door assembly (116 or 152) so that
holes in bushing assemblies (59) line up with holes
in channel assembly.
9. Rivets (19) in sequence.
[!I Adjust
Window ( 1), if necessary. Refer to '' Front Side
Door Window Adjustment" in this section.
DOORS 10-6-33
1 WINDOW, FRONT SIDE DOOR

19 RIVET, FRONT SIDE DOOR WINDOW
PC0047-106-F-RP
Figure 47 - Front Side Door Window Rivets
4
2
1
2
3
4
53
54
57
58
57
59
60
61
WINDOW, FRONT SIDE DOOR

RETAINER, FRONT SIDE DOOR WINDOW BUSHING
PIN, FRONT SIDE DOOR WINDOW STABILIZER
BOLT/SCREW, FRONT SIDE DOOR WINDOW STABILIZER
PIN
BOLT/SCREW, FRONT SIDE DOOR WINDOW FRONT UP
STOP
STOP, FRONT SIDE DOOR WINDOW FRONT UP
NUT, FRONT SIDE DOOR WINDOW FRONT UP STOP
WASHER, FRONT SIDE DOOR WINDOW FRONT UP
STOP
BUSHING ASSEMBLY, FRONT SIDE DOOR WINDOW
WEDGE, FRONT SIDE DOOR WINDOW
NUT, FRONT SIDE DOOR WINDOW STABILIZER PIN
61
PC0048 106-F-RP
Figure 48 - Front Side Door Window
Front Side Door Window Adjustment

Figure 49
lg) Adjust
1. Window up or down at front.
A. Loosen nut (45).
B. Adjust up stop support (44 ).
l~I
Tighten
Nut (45) to 10 Nm (89 lb. in.).

2. Window up or down at rear.
A. Loosen bolt/screw ( 151 ).
B. Adjust rear up stop and tighten bolt/screw
(151).
3. Window parallel to weatherstrip assembly.
A. Lower window part way and raise back to
within 25 mm (1 inch) of weatherstrip assembly.
10-6-34 DOORS
45
152
21
152~
152
l~tfJ
,.~~"
. v/'<?4' I'
22
!views
151
!VIEWC
152
~52
51
~
!VIEWD
2a-/iq i
I

22 NUT, FRONT SIDE DOOR WINDOW REGULATOR
CHANNEL
REAR GUIDE
CHANNEL
FRONT UP STOP
SUPPORT
151 BOLT/SCREW, FRONT SIDE DOOR WINDOW REAR
CHANNEL EXTENSION
L/
Figure 49 - Adjusting Front Side Door Window
!VIEWE
152
PC0049-106-F-RP
DOORS 10-6-35
C. Adjust channel assembly (21).
l~I
Tighten
Nut (27) to 10 Nm (89 lb. in.).

Nuts (29) to 27 Nm (20 lb. ft.).
5. Upper edge of window inboard or outboard.
A. Loosen nuts (29).
B. Move jackstuds in or out using an allen
wrench.
l~I
Tighten
Nuts (29) to 27 Nm (20 lb. ft.).

6. Stabilizer assemblies (51).
A. Raise window to full closed position.
C. Apply slight pressure outboard on window at
belt.
D. Move stabilizer assemblies (51).
l~I
//
Tighten
Nuts (22) to 10 Nm (89 lb. in.).

4. Window forward or rearward.
A. Loosen nuts (27 and 29).
B. Move window forward or rearward.
l~I
152
Tighten
ll"'I Inspect
Window operation and stability.
- If window binds, move stabilizer assemblies (51) inboard slightly.
- If window is unstable, move stabilizer
assemblies (51) outboard.
Front Side Door Window Front Up Stop

Support Assembly
Figure SO

1. Lower window.
3. Nut (45).
4. Support assembly (44).

1. Support assembly (44).
44

FRONT UP STOP
SUPPORT
PC0050 106-F-RP
Figure 50 - Front Side Door Window Front Up Stop Support

Assembly
2. Nut (45).
1ll
1nspect
Window alignment. Adjust if necessary. Refer

to "Front Side Door Window Adjustment" in
this section.
l~I
Tighten
Nut (45) to 10 Nm (89 lb. in.).

Front Side Door Window Stabilizer Assembly

Figure 51

2. Bolt/screw (52).
3. Stabilizer assembly (51).

1. Stabilizer assembly (51 ).
2. Bolt/screw (52).
ll"l'I Inspect
Window stability. Adjust if necessary. Refer to
"Front Side Door Window Adjustment" in
this section.
l~I
Tighten
10636 DOORS

PC0051-106-F-RP
Figure 51 - Front Side Door Window Stabilizer Assembly

Front Side Door Window Front and Rear

Bumpers
Figure 52

1. Raise window.
3. Radio front side door speaker assembly, if removing
front bumper (33). Refer to "Radio Front Side Door
Speaker Assembly" in this section.
4. Front or rear bumper (33 or 31) using a flat-bladed
tool to release adhesive strip from door outer panel.

1. Front or rear bumper (33 or 31 ).
A. Remove protective liner from adhesive strip.
B. Insert front or rear bumper (33 or 31) through
access hole.
C. Press front or rear bumper (33 or 31) into position on door outer panel.
2. Radio front side door speaker assembly, if removed.
Refer to "Radio Front Side Door Speaker Assembly" in this section.
~FAT
A
31
33
152
LINER, PROTECTIVE
BUMPER, FRONT SIDE DOOR WINDOW REAR
BUMPER, FRONT SIDE DOOR WINDOW FRONT
PC0052-106-F-RP
Figure 52 - Front Side Door Window Front and Rear

Bumpers

Assembly
Figures 53 and 54

and gloves should be worn when performing these procedures to reduce the
chance of personal injury should window breakage occur.
DOORS 10-6.-37

1. Raise window about halfway.
CAUTION: Support front side door win
dow. If window drops into door, personal injuiry or window damage may
result.
4. Support window in position by inserting rubber
wedge door stops at front and rear of window
between window and door inner panel.
5. Front side door window rear guide channel nuts so
rear guide channel assembly can be moved. Refer to
''Front Side Door Window Channel Assembly and
Front Side Door Window Rear Guide Channel
6. Rivets (23).
A. Push rivet mandrel out of rivet (23) with a
punch.
B. Drill out rivet (23).
7. Electrical connector from motor assembly (83) by
sliding motor assembly (83) and regulator assembly
(82) rearward, if equipped.
8. Regulator assembly (20 or 82) from channel assemblies.
9. Regulator assembly (20 or 82), with motor assembly
(83) attached if equipped, through rear access hole.

1. Regulator assembly (20 or 82), with motor assembly
(83) attached if equipped, through rear access hole.
2. Regulator assembly (20 or 82) to channel assemblies.
3. Electrical connector to motor assembly (83), if
equipped.
4. Rivets (23) in sequence shown in Figure 53.
5. Front side door window rear guide channel nuts.
Refer to "Front Side Door Window Channel Assembly and Front Side Door Window Rear Guide Channel Assembly" in this section.
!Ll 1nspect
Window alignment. Adjust if necessary. Refer
to "Front Side Door Window Adjustment" in
this section.
152
152
B
A MANUAL SHOWN, POWER SIMILAR
B POWER
C CONNECTOR, FRONT SIDE DOOR WINDOW
REGULATOR MOTOR ELECTRICAL
23 RIVET, FRONT SIDE DOOR WINDOW REGULATOR
REGULATOR
PC0053106FRP
Figure 53 - Front Side Door Window Regulator Assembly
Front Side Door Window Regulator Motor

Assembly
Figure54

CAUTION: If electric motor removal
from the regulator assembly is
required, the sector gear must be
locl<ed in position. The regulator lift
arm is under tension from the counterbalance spring and could cause personal injury if the sector gear is not
locked in position.
1. Front side door window regulator assembly with
motor assembly. Refer to "Front Side Door Window
Regulator Assembly" in this section.
2. Drill hole through window regulator sector gear and
backplate.
10638 DOORS
3. Install bolt and nut to lock sector gear into position.
4. Rivets.
A. Push rivet mandrel out of rivet with a punch.
B. Drill out rivet.

5. Motor assembly (83).
83
A DRILLED HOLE
REGULATOR
1. Motor assembly (83).

2. Rivets.
3. Remove bolt and nut used to secure sector gear.
4. Front side door window regulator assembly and
motor. Refer to "Front Side Door Window Regulator Assembly" in this section.
PC0054-106-F-RP
Figure 54 - Locking Sector Gear
SPECIFICATIONS
Front Side Door Armrest Bolt/Screw ................................... 4.5 Nm (40 lb. in.)
Front Side Door Inside Handle Bezel Bolt/Screw ......................... 1.4 Nm (12 lb. in.)
Front Side Door Interlock Striker Assembly .............................. 45 Nm (33 lb. ft.)
Front Side Door Lock Bolt/Screw ...................................... 10 Nm (89 lb. in.)
Front Side Door Lock Striker Bolt/Screw ................................ 24 Nm (18 lb. ft.)
Front Side Door Lower Hinge Bolt/Screw ................................ 50 Nm (37 lb. ft.)
Front Side Door Lower Hinge Nut ...................................... 50 Nm (37 lb. ft.)
Front Side Door Outside Handle Nut ..................................... 7 Nm (62 lb. in.)
Front Side Door Upper Hinge Bolt/Screw ................................ 50 Nm (37 lb. ft.)
Front Side Door Upper Hinge Nut ...................................... 50 Nm (37 lb. ft.)
Front Side Door Window Front Up Stop Bolt/Screw ......................... 7 Nm (62 lb. in.)
Front Side Door Window Front Up Stop Nut ............................... 8 Nm (71 lb. in.)
Front Side Door Window Front Up Stop Support Nut ....................... 10 Nm (89 lb. in.)
Front Side Door Window Rear Guide Channel Nut (Lower) .................. 10 Nm (89 lb. in.)
Front Side Door Window Rear Guide Channel Nut (Upper) .................. 27 Nm (20 lb. ft.)
Front Side Door Window Regulator Counterbalance Arm Channel Nut ......... 10 Nm (89 lb. in.)
Front Side Door Window Stabilizer Bolt/Screw ............................ 10 Nm (89 lb. in.)
Front Side Door Window Stabilizer Pin Bolt/Screw ......................... 7 Nm (62 lb. in.)
Front Side Door Window Stabilizer Pin Nut ............................... 8 Nm (71 lb. in.)
Outside Rearview Mirror Applique Bolt/Screw ............................. 6 Nm (53 lb. in.)
Outside Rearview Mirror Bezel Bolt/Screw ................................ 4 Nm (35 lb. in.)
Outside Rearview Mirror Nut ........................................... 6 Nm (53 lb. in.)
Outside Rearview Mirror Opening Applique Nut ........................... 6 Nm (53 lb. in.)
DOORS 10-6-39
SPECIAL TOOLS
1.
2.
\)-e-~. ., I ?:;:
(.
J 9886-01
J 21104-B
4.
5.
J 25070
J39346
6.
J 29843-9
3.
J 36604
1.
2.
3.
4.
5.
6.
DOOR HANDLE CLIP REMOVER

UNIVERSAL WEATHERSTRIP REMOVER
DOOR LOCK STRIKER AND SEAT BELT TORX WRENCH
HEAT GUN
"MINI-WEDGE" DOOR STRIKER ALIGNER
DOOR HINGE SPRING COMPRESSOR
PC0055106-F-RP
REAR QUARTERS 10-7-1
SECTION 10-7
REAR QUARTERS
result.
CONTENTS
Rear Quarters . . . . . . . . . . . . . . . . . . . . . . . . . .
Interior Trim . . . . . . . . . . . . . . . . . . . . . . . . . . .
Front Quarter Trim
Finishing Panel Assembly . . . . . . . . . . . .
Quarter Inner Rear Trim
Finishing Panel Assembly . . . . . . . . . . . .
Quarter Trim Finishing Panel Extension
(With Lift-Off Roof Assemblies) .......
Radio Rear Sail Panel
Speaker Grille Assembly .............
Rear Quarter Rear Radio
Speaker Grille Assembly .............
10-7-1
10-7-1
10-7-1
10-7-1
10-7-1
10-7-1
10-7-4
10-7-4
10-7-4
GENERAL DESCRIPTION
REAR QUARTERS
Figure 1
The information in this section provides service
procedures that apply to all rear quarter components, as
shown in Figure 1.
ON-VEHICLE SERVICE
INTERIOR TRIM
Front Quarter Trim Finishing Panel
Assembly
Figure2

1. Lower the folding seatback.
2. Left or right shroud side trim finishing panel. Refer
to SECTION 10-5.
3. Coat hook assembly (1).
Release retainer with a screwdriver and pull
out.
4. Striker bolt/screw (2), and washer (3).
5. Front quarter trim finishing panel assembly (4).
Push lap belt through slot in front quarter trim
finishing panel assembly (4).
Radio Rear Sail Panel Speaker

Assembly ......................... 10-7-5
Radio Rear Speaker Assembly .......... 10-7-5
Low Frequency Audio Amplifier
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 10-7-7
Quarter Outer Panel Pressure Relief
Valve Assembly .................... 10-7-8
Exterior Trim . . . . . . . . . . . . . . . . . . . . . . . . . . 10-7-8
Rear Quarter Center Molding Assembly ... 10-7-8
Fuel Tank Filler Door Assembly ........... 10-7-9
Fuel Tank Filler Pocket Assembly .......... 10-7-9
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-7-11
Fastener Tightening Specifications . . . . . . . . 10-7-11
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-7-11
6. Speaker grille assembly (5), if necessary.

section.
1. Speaker grille assembly (5), if removed.
2. Front quarter trim finishing panel assembly (4).
Thread lap belt through front quarter trim
finishing panel (4 ).
3. Striker bolt/screw (2) and washer (3).
l~I Tighten
Striker bolt/screw (2) to 48 Nm (35 lb. ft.).
4. Coat hook assembly (1).
Slide into position and press retainer to lock.
5. Left or right shroud side trim finishing panel. Refer
to SECTION 10-5.
6. Raise the folding seatback.
Quarter Inner Rear Trim Finishing Panel

Assembly
Figures 3 and 4
Tool Required:
J 24595-C Trim Pad Remover

1. Raise rear compartment lift window.
10-7-2 REAR QUARTERS
25
~I
14
26
30
28
19
4 PANEL ASSEMBLY, FRONT QUARTER TRIM FINISHING
5 GRILLE ASSEMBLY, RADIO SPEAKER
7 PANEL ASSEMBLY, RIGHT QUARTER INNER REAR TRIM
FINISHING
8 PANEL ASSEMBLY, LEFT QUARTER INNER REAR TRIM
FINISHING
14 EXTENSION, QUARTER TRIM FINISHING PANEL
16 SPEAKER ASSEMBLY, RADIO REAR SAIL PANEL
18 SPEAKER ASSEMBLY, RADIO REAR
19 SPEAKER ASSEMBLY, RADIO REAR

22 SPEAKER ASSEMBLY, REAR
25 VALVE ASSEMBLY, QUARTER OUTER PANEL
PRESSURE RELIEF
26 MOLDING ASSEMBLY, REAR QUARTER CENTER
28 DOOR ASSEMBLY, FUEL TANK FILLER
30 POCKET ASSEMBLY, FUEL TANK FILLER
PC0001-107-F-RP
Figure 1 - Rear Quarter Components
A
B
ck3
A
B
1
2
RETAINER
HOLE IN FRONT QUARTER TRIM FINISHING PANEL
HOOK ASSEMBLY, COAT
BOLT/SCREW, SECOND SEATBACK CUSHION LOCK
STRIKER, 48 Nm (35 LB. FT.)
3 WASHER, SECOND SEATBACK CUSHION LOCK
STRIKER
4 PANEL ASSEMBLY, FRONT QUARTER TRIM FINISHING
PC0002-107-F-RP
Figure 2 - Front Quarter Trim Finishing Panel Assembly
2. Sunshade
Snap out.
3. Three retainers (6), if removing right side.
4. Quarter inner rear trim finishing panel assembly (7
OJ 8).
5. If removing left side, use J 24595-C to unsnap three
retainers (11).
6. Radio speaker electrical connector.
7. Radio speaker grille assembly (10), if necessary.
Squeeze outer edges with fingertips and pull
out.
8. Radio rear speaker assemblies. Refer to " Radio
Rear Speaker Assembly" in this section.
9. Three retainers ( 11) on left side, if necessary.

1. Three retainers ( 11 ), if removed from left side.
2. Radio rear speaker assemblies. Refer to "Radio
Rear Speaker Assembly" in this section.
3. Radio speaker grille assembly (10), if removed.
Squeeze outer edges with fingertips, place in
position and release pressure.
4. Radio speaker electrical connector.
5. Quarter inner rear trim finishing panel assembly (7
or 8).
On left quarter inner rear trim finishing panel
assembly (8), align three retainers (11) with
holes in quarter panel assembly (12) and press
down to lock in position.
6. Three retainers (6), if installing right quarter inner
rear trim finishing panel assembly (7).
1074 REAR QUARTERS
SECTION BB
6 RETAINER, QUARTER INNER REAR TRIM FINISHING
PANEL
7 PANEL ASSEMBLY, RIGHT QUARTER INNER REAR TRIM
FINISHING
PC0003-107-F-RP
Figure 3 - Right Quarter Inner Rear Trim Finishing Panel Assembly
7. Sunshade.
Snap into position.
8. Lower rear compartment lift window.
Quarter Trim Finishing Panel Extension

(With Lift-Off Roof Assemblies)
Figures

2. Quarter trim finishing panel extension (14).

1. Quarter trim finishing panel extension ( 14).
,~, Tight~n
Radio Rear Sail Panel Speaker Grille

Assembly
Figure2

Speaker grille assembly (5).
- Squeeze outer edges with fingertips and pull
out.

- Squeeze outer edges, place in position and
release pressure.
Rear Quarter Rear Radio Speaker Grille

Assembly
Figures 3 and 4

- Squeeze outer edges with fingertips and pull
out.

REAR QUARTERS 1075
8 PANEL ASSEMBLY, LEFT QUARTER INNER REAR TRIM
FINISHING
11 RETAINER, QUARTER INNER REAR TRIM FINISHING
PANEL
12 PANEL ASSEMBLY, QUARTER OUTER
SECTION B-B
PC0004-107-F-RP
Figure 4 - Left Quarter Inner Rear Trim Finishing Panel Assembly
- Squeeze outer edge with fingertips, place in

position and release pressure.
Radio Rear Sail Panel Speaker Assembly

Figure 6

1. Front quarter trim finishing panel assembly. Refer to
"Front Quarter Trim Finishing Panel Assembly" in
this section.
3. Radio speaker assembly (16).

2. Radio speaker assembly (16).

l~I Tighten
Four bolts/screws (15) to 1.9 Nm (17 lb. in.).
4. Front quarter trim finishing panel assembly. Refer to
"Front Quarter Trim Finishing Panel Assembly" in
this section.
Radio Rear Speaker Assembly

Figure 7

1. Quarter inner rear trim finishing panel assembly.
Refer to "Quarter Inner Rear Trim Finishing Panel
2. Radio speaker assembly (18 or 19).
Rotate counterclockwise and pull out.
14
13 BOLT/SCREW, QUARTER TRIM FINISHING PANEL,
2.5 Nm (22 LB. IN.)
14 EXTENSION, QUARTER TRIM FINISHING PANEL
PCOOOS-107-F-RP
Figure 5 - Quarter Trim Finishing Panel Extension
16
15
15 BOLT/SCREW, RADIO REAR SPEAKER,
1.9 Nm (17 LB. IN.)
16 SPEAKER ASSEMBLY, RADIO REAR SAIL PANEL
PC0006-107FRP
Figure 6 - Radio Rear Sail Panel Speaker Assembly
A
I
20
A
B
18
19
20
DRILL 1/16-INCH HOLES AS SHOWN

SPEAKER ASSEMBLY, RADIO REAR
SPEAKER ASSEMBLY, RADIO REAR
BOLT/SCREW, RADIO REAR SPEAKER,
1.9 Nm (17 LB. IN.)
19
18
PC0007-107-F-RP
Figure 7 - Radio Rear Speaker Assembly
If replacing only one speaker assembly ( 18 or

19), pull wire out of electrical connector.

1. Plug speaker wire into electrical connector, if
removed.
2. Radio speaker assembly (18 or 19).
A. Drill two 1/16-inch holes in rear quarter trim
finishing panel speaker mounting bosses as
shown in Figure 7.
B. Place radio speaker assembly (18 or 19) in
position and rotate clockwise until holes in
radio speaker assembly (18 or 19) align with
drilled holes.
C. Install two self-tapping bolts/screws (20), GM

PIN 11505169, into drilled holes.
l~I Tighten
Two bolts/screws (20) to 1.9 Nm (17 lb. in.).
Refer to "Quarter Inner Rear Trim Finishing Panel
Low Frequency Audio Amplifier Assembly

Figure 8
Tool Required:
J 24595-C Trim Pad Remover

1. Right front quarter trim finishing panel assembly.
Refer to "Front Quarter Trim Finishing Panel
2. Two retainers (31) using J 24595-C trim pad
remover.
3. Amplifier assembly (32).

2. Amplifier assembly (32).
4. Right front quarter trim finishing panel assembly.
Refer to "Front Quarter Trim Finishing Panel
32
31 RETAINER, LOW FREQUENCY AUDIO AMPLIFIER
BRACKET
32 AMPLIFIER ASSEMBLY, LOW FREQUENCY AUDIO
PC2008-107-F-RP
Figure 8 - Low Frequency Audio Amplifier Assembly
Quarter Outer Panel Pressure Relief Valve

Assembly
Figure 9

1. Rear bumper fascia. Refer to SECTION 10-4.
3. Quarter outer panel pressure relief valve assembly
(25).

1. Quarter outer panel pressure relief valve assembly
(25).
l~I Tighten
/ Four bolts/screws (24) to 1.4 Nm (13 lb. in.).
3. Rear bumper fascia. Refer to SECTION 10-4.
EXTERIOR TRIM
NOTICE: When removing or installing any outside
molding, cover adjacent finishes with masking tape
to prevent damage to the finish. Use proper tools and
take care to prevent damage to the molding.
Rear Quarter Center Molding Assembly

Figure 10

Molding assembly (26) from body surface.
A. Hold hot air gun 304 mm (12 inches) from surface of molding assembly (26).
26 MOLDING ASSEMBLY, REAR QUARTER CENTER
PC0010-107-F-RP
24 BOLT/SCREW, QUARTER OUTER PANEL PRESSURE

RELIEF VALVE, 1.4 Nm (13 LB. IN.)
25 VALVE ASSEMBLY, QUARTER OUTER PANEL PRESSURE RELIEF
PC0009107-F-RP
Figure 9 - Quarter Outer Panel Pressure Relief Valve

Assembly
B. Apply heat, using circular motion for about 30

seconds.
C. Using care, peel molding assembly (26) from
body surface.

Molding assembly (26) to body surface.
A. Body surface must be warm, 21 C (70F),
clean and wax free.
B. ~f installing a new part, remove adhesive backmg.
C. When installing a previously removed part, or
a partially loosened part, apply a thin, even
film of GM PIN 1052621 adhesive to adhesive
portion of molding assembly (26).
D. Align and press molding assembly (26) into
position.
FUEL TANK FILLER DOOR

Figure 11

1. Fuel tank filler pocket assembly. Refer to "Fuel
Tank Filler Pocket Assembly" in the following procedure.
2. Install fuel tank filler cap.
3. Drill out four rivets (27).
4. Fuel tank filler door assembly (28).
Figure 10 - Rear Quarter Center Molding Assembly
It may be necessary to gently pry back sound

insulating material around filler door hinge.

1. Fuel tank filler door assembly (28).
2. Four rivets (27).
Install rivets alternately top to bottom.
3. Remove fuel tank filler cap.
4. Fuel tank filler pocket assembly. Refer to "Fuel
Tank Filler Pocket Assembly" in the following procedure.
FUEL TANK FILLER POCKET ASSEMBLY

Figure 12

1. Open fuel tank filler door assembly (28) and remove
cap.
3. Fuel tank filler pocket assembly (30).

1. Fuel tank filler pocket assembly (30).
l~I Tighten
Two bolts/screws (29) to 1.9 Nm (17 lb. in.).
3. Install cap and close fuel tank filler door assembly
(28).
"~_/
28
27 RIVET, FUEL TANK FILLER DOOR

PC0011107-F-RP
Figure 11 - Fuel Tank Filler Door Assembly
f0
30
28
29

29 BOLT/SCREW, FUEL TANK FILLER POCKET,
1.9 Nm (17 LB. IN.)
30 POCKET ASSEMBLY, FUEL TANK FILLER
PC0012-107FRP
Figure 12 - Fuel Tank Filler Pocket Assembly
SPECIFICATIONS
Fuel Tank Filler Pocket Bolt/Screw .................................... 1.9 Nm (17 lb. in.)
Quarter Outer Panel Pressure Relief Valve Bolt/Screw . . . . . . . . . . . . . . . . . . . . . 1.4 N m ( 13 lb. in.)
Quarter Trim Finishing Panel Bolt/Screw ............................... 2.5 Nm (22 lb. in.)
Radio Rear Speaker Mounting Bolt/Screw ............................... 1.9 Nm (17 lb. in.)
Second Seatback Striker Bolt/Screw .................................... 48 Nm (35 lb. ft.)
SPECIAL TOOLS
J 24595-C
TRIM PAD REMOVER

MC0012-106-FRP
BODY REAR END 10-8-1
SECTION 10-8
BODY REAR END

CAUTION: When replacing a lift window, urethane adhesive GM P/N 12345633 must be used
to maintain original installation integrity. Failure to use urethane adhesive GM P/N 12345633
will result in poor retention of the lift window which may allow unrestrained occupants to be
ejected from the vehicle with resulting personal injury.
part number fastener is not available, a fastener of equal size and strength (or stronger) may be used. Fasteners that
are not reused, and those requiring thread locking compound will be called out. The correct torque value must be
used when installing fasteners that require it. If the above conditions are not followed, parts or system damage
could result.
CONTENTS
General Description . . . . . . . . . . . . . . . . . . . . . . . 10-8-1
Body Rear End . . . . . . . . . . . . . . . . . . . . . . . . . 10-8-1
On-Vehicle Service . . . . . . . . . . . . . . . . . . . . . . . 10-8-1
Rear Compartment Lock System . . . . . . . . . . . 10-8-1
Rear Compartment Lid Lock Cylinder
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 10-8-1
Endgate Latch Assembly ............... 10-8-3
Rear Compartment Lift Window Lock
Striker Assembly ................... 10-8-4
Rear Compartment Lid Lock Release
Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . 10-8-5
Rear Compartment Lid Lock Switch
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 10-8-5
Rear Compartment Lift Window
Weatherstrip . . . . . . . . . . . . . . . . . . . . . . . . . 10-8-6
Rear Compartment Exterior Trim . . . . . . . . . . 10-8-6
Taillamp Filler . . . . . . . . . . . . . . . . . . . . . . . 10-8-6
Rear End Lamp Assemblies . . . . Refer to Section 8B
Rear Compartment Interior Trim ........... 10-8-6
Taillamp Closeout Filler . . . . . . . . . . . . . . . 10-8-6
Closeout Panel Assembly ............ 10-8-7
Rear Compartment Side Trim Assembly ... 10-8-7
GENERAL DESCRIPTION
BODY REAR END
Figures 1 and 2
This section contains the service operations necessary for the removal, installation, adjustment and sealing
of body rear end hardware and trim components.
ON-VEHICLE SERVICE
REAR COMPARTMENT LOCK SYSTEM
Rear Compartment Lid Lock Cylinder
Assembly
Figure 3

1. Open window panel assembly.
Roof Lift-Off Window Stowage

Retainer Assemblies . . . . . . . . . . . . . . . . . 10-8-7
Rear Compartment Trim Assembly . . . . . . . 10-8-8
Rear Compartment Lift Window Panel
Assembly and Components . . . . . . . . . . . . . 10-8-8
Hinge Assemblies . . . . . . . . . . . . . . . . . . 10-8-8
Rear Compartment Lift Window Strut
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 10-8-9
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 10-8-9
Adjustment . . . . . . . . . . . . . . . . . . . . . . . 10-8-11
Rear End Spoiler Assembly . . . . . . . . . . . . 10-8-11
Liftgate Window Opening Finish Lace . . . 10-8-11
Rear Compartment Lift Window Inner
Panel Cover Assembly . . . . . . . . . . . . . . 10-8-11
Side Molding Assemblies ........... 10-8-12
Rear Compartment Lift Window ........ 10-8-12
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-8-16
Fastener Tightening Specifications . . . . . . . . 10-8-16
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-8-16
2. Taillamp filler. Refer to "Taillamp Filler" in this

section.
3. Rivets (14).
4. Lock cylinder assembly (13).
rn
Important
Tan dot on lock cylinder assembly (13) must

face upward when installing lock cylinder
assembly (13).
1. Lock cylinder assembly (13), guiding lock cylinder
shaft through hole in rear end panel into hole in lock
support.
2. Align lock cylinder assembly (13).
3. Right rivet (14)
1082 BODY REAR END
4
OR
30
~5
'
!VIEWB
16
PC2001-108-F-RP
Figure 1 - Body Rear End

A
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
18
19
20
21
TRANSAM
WINDOW, REAR COMPARTMENT LIFT
LACE, LIFTGATE WINDOW OPENING FINISH
SPOILER ASSEMBLY, REAR END
PANEL ASSEMBLY, REAR COMPARTMENT LIFT WINDOW
(TRANS AM)
STRIKER ASSEMBLY, REAR COMPARTMENT LIFT WINDOW
LOCK
NUT, REAR COMPARTMENT LIFT WINDOW LOCK STRIKER
WEATHERSTRIP, REAR COMPARTMENT LIFT WINDOW
BOLT/SCREW, ENDGATE LATCH
LATCH ASSEMBLY, ENDGATE
BOLT/SCREW, REAR COMPARTMENT LID LOCK RELEASE
ACTUATOR
SWITCH ASSEMBLY, REAR COMPARTMENT LID LOCK
BOLT/SCREW, REAR COMPARTMENT LID LOCK SWITCH
CYLINDER ASSEMBLY, REAR COMPARTMENT LID LOCK
RIVET, REAR COMPARTMENT LID LOCK CYLINDER
FILLER, TAILLAMP
PANEL ASSEMBLY, REAR COMPARTMENT LIFT WINDOW
CLOSEOUT
ACTUATOR, REAR COMPARTMENT LID RELEASE
NUT, REAR COMPARTMENT LIFT WINDOW
BODY SIDE HINGE
GASKE:T, REAR COMPARTMENT LID BODY SIDE HINGE
HINGE ASSEMBLY, REAR COMPARTMENT LIFT WINDOW
22 NUT, REAR COMPARTMENT LIFT WINDOW

WINDOW SIDE HINGE
23 NUT, ROOF LIFT-OFF WINDOW STOWAGE
RETAINER BRACKET
24 BUMPER ASSEMBLY, REAR COMPARTMENT LIFT WINDOW
25 NUT, REAR END SPOILER
26 WASHER, REAR END SPOILER
27 STUD, REAR COMPARTMENT LIFT WINDOW
28 STRUT ASSEMBLY, REAR COMPARTMENT LIFT WINDOW
29 STUD, LIFTGATE STRUT BODY SIDE
30 PANEL ASSEMBLY, REAR COMPARTMENT LIFT WINDOW
(EXCEPT TRANS AM)
31 COVER ASSEMBLY, REAR COMPARTMENT LIFT WINDOW
INNER PANEL
32 MOLDING ASSEMBLY, REAR COMPARTMENT LIFT WINDOW
SIDE (RIGHT)
33 MOLDING ASSEMBLY, REAR COMPARTMENT LIFT WINDOW
SIDE (LEFT)
34 TRIM ASSEMBLY, REAR COMPARTMENT SIDE
35 RETAINER, REAR COMPARTMENT TRIM
36 TRIM ASSEMBLY, REAR COMPARTMENT
37 RETAINER ASSEMBLY, ROOF LIFT-OFF WINDOW
STOWAGE (RIGHT)
STOWAGE (LEFT)
39 FILLER, TAILLAMP CLOSEOUT
40 RETAINER, TAILLAMP CLOSEOUT FILLER
PC2002-1os-F-RP
Figure 2 - Body Rear End - Legend
4. Left rivet (14).

5. Taillamp filler. Refer to "Taillamp Filler" in this
section.
Endgate Latch Assembly

Figure 4

2. Rear compartment trim assembly as needed. Refer

to "Rear Compartment Trim Assembly" in this
section.
3. Rear compartment lid lock switch electrical connector. Refer to "Rear Compartment Lid Lock
Switch Assembly" in this section.
4. Rear compartment lid lock release actuator secondary lock retainer and electrical connector. Refer to
"Rear Compartment Lid Lock Release Actuator" in
this section.
6. Latch assembly (9).

section.
1. Latch assembly (9).

Align holes in latch assembly (9) with holes in
support.
SECTION A-A
A SUPPORT,ENDGATELATCH
B PANEL, REAR END
13 CYLINDER ASSEMBLY, REAR COMPARTMENT
LID LOCK
14 RIVET, REAR COMPARTMENT LID LOCK CYLINDER
l~I Tighten
PCOOOJ-108-F-RP
Figure 3 - Rear Compartment Lid Lock Cylinder Assembly
10-8-4 BODY REAR END
A SUPPORT,ENDGATELATCH
8 BOLT/SCREW, ENDGATE LATCH
9 LATCH ASSEMBLY, ENDGATE
PC0004-108-F-RP
Figure 4 - Endgate Latch Assembly
3. Rear compartment lid lock release actuator electrical

connector and secondary lock retainer. Refer to
"Rear Compartment Lid Lock Release Actuator" in
this section.
4. Rear compartment lid lock switch electrical connector. Refer to "Rear Compartment Lid Lock
Switch Assembly" in this section.
5. Rear compartment trim assembly. Refer to "Rear
Compartment Trim Assembly" in this section.
Rear Compartment Lift Window Lock Striker

Assembly
Figures

2. Rear compartment lift window inner panel cover
assembly. Refer to "Rear Compartment Lift Window Inner Panel Cover Assembly" in this section.
3. Nuts (6).
4 PANEL ASSEMBLY, REAR COMPARTMENT LIFT

WINDOW
5 STRIKER ASSEMBLY, REAR COMPARTMENT LIFT
WINDOW LOCK
6 NUT, REAR COMPARTMENT LIFT WINDOW LOCK
STRIKER
PCOOOS-108-F-RP
Figure 5 - Rear Compartment Lift Window Lock Striker

Assembly

section.
2. Nuts (6).
l~I Tighten
Nuts (6) to 10 Nm (89 lb. in.).

IL'l'I Inspect
Window panel operation. Adjust if necessary. Refer
to "Rear Compartment Lift Window Panel Adjustment" in this section.
BODY REAR END 1085
Rear Compartment Lid Lock Release

Actuator

Rear Compartment Lid Lock Switch

Assembly
Figure 6
Figure 6

section.
3. Secondary lock retainer from actuator (18).
4. Electrical connector from actuator (18).
6. Actuator (18) from latch assembly (9).

section.
1. Actuator (18) to latch assembly (9).

section.
3. Electrical connector from switch assembly (11).
4. Secondary lock retainer and electrical connector
from actuator (18).
5. Endgate latch assembly. Refer to "Endgate Latch
6. Bolt/screw (12).
7. Switch assembly (11) from latch assembly (9).

section.
1. Switch assembly (11) to latch assembly (9).
3. Electrical connector to actuator (18).

4. Secondary lock retainer.
10
18
A CONNECTOR, REAR COMPARTMENT LID LOCK

RELEASE ACTUATOR ELECTRICAL
B RETAINER, SECONDARY LOCK,
C CONNECTOR, REAR COMPARTMENT LID LOCK
SWITCH ELECTRICAL
10 BOLT/SCREW, REAR COMPARTMENT LID LOCK
RELEASE ACTUATOR
11 SWITCH ASSEMBLY, REAR COMPARTMENT LID LOCK
12 BOLT/SCREW, REAR COMPARTMENT LID
LOCK SWITCH
18 ACTUATOR, REAR COMPARTMENT LID LOCK RELEASE
PC000&-108-F-RP
Figure 6 - Rear Compartment Lid Lock Release Actuator and Switch Assembly
1086 BODY REAR END

2. Bolt/screw (12).
3. Endgate latch assembly. Refer to "Endgate Latch
4. Electrical connector and secondary lock retainer to
actuator (18).
5. Electrical connector to switch assembly (11).
REAR COMPARTMENT LIFT WINDOW

WEATHERSTRIP
A
Figure 7

1. Weatherstrip (7) by peeling from flange.
lr,I Clean
Weatherstrip sealer from flange.
2. Support window panel assembly.
3. Strut assemblies at quarter inner roof panel. Refer to
"Rear Compartment Lift Window Strut Assembly"
in this section.
4. Weatherstrip (7) from opening.
SECTION A-A
A FLANGE
7 WEATHERSTRIP, REAR COMPARTMENT LIFT WINDOW
PC0007-108-F-RP
Figure 7 - Rear Compartment Lift Window Weatherstrip
1. Weatherstrip (7) into opening.

2. Strut assemblies at quarter inner roof panel. Refer to
in this section.
3. Weatherstrip (7).
A. Position weatherstrip (7) to top center of
flange.
B. Attach upper corners, then work from corners
to center across top.
C. Attach elbow areas, then work from elbows to
upper corners.
D. Attach rear corners, then work from rear corners to elbows.
E. Work from rear corners to center across rear.
F. Roll entire weatherstrip (7) to seat.
15 FILLER, TAILLAMP
REAR COMPARTMENT EXTERIOR TRIM
PC2008 108-F-RP
Figure 8 - Removing Taillamp Filler
Taillamp Filler
Figures
1+1 Remove or Disconnect

1. Taillamp assemblies. Refer to SECTION 8B.
2. Filler (15).

1. Filler (15).
2. Taillamp assemblies. Refer to SECTION 8B.
REAR COMPARTMENT INTERIOR TRIM

Taillamp Closeout Filler
Figure9

1. Retainer (40).
2. Filler (39).

WINDOW CLOSEOUT
PC0010-108-F-RP
39 FILLER, TAILLAMP CLOSEOUT

40 RETAINER, TAILLAMP CLOSEOUT FILLER
Figure 10 - Rear Compartment Lift Window Closeout

Panel Assembly
PC2009-108-F-RP
Figure 9 - Taillamp Closeout Filler
Rear Compartment Side Trim Assembly

Figure 11

1. Filler (39).
Tab on filler (39) is fitted under flange on taillamp housing.
2. Retainer (40).
Rear Compartment Lift Window Closeout

Panel Assembly
Figure 10
1. Left quarter inner rear trim finish panel assembly.

2. Side trim assembly (34).
Reposition left side of rear compartment trim
assembly and lift out side trim assembly (34).

1. Side trim assembly (34).
Position side trim assembly (34) in rear
compartment with inboard edge under rear
compartment trim assembly.
2. Left quarter inner rear trim finish panel assembly.
Roof Lift-Off Window Stowage Retainer

Assemblies
1. Close panel assembly (16).

Panel assembly (16) must be resting on rear
quarter trim panel assembly to be removed.
2. Panel assembly (16).
Slide panel assembly (16) rearward to unsnap
it from retainers on rear quarter trim panel
assembly.

Panel assembly (16).
- Slide panel assembly (16) along groove of rear
quarter trim panel assembly and snap into
retainers.
Figure 12
Retainer assemblies (37 and 38) are provided in the
rear compartment for vehicles equipped with roof lift-off
window assemblies.

1. Nuts (23).
2. Retainer assembly (37 or 38).

section.
1. Retainer assembly (37 or 38).
34 TRIM ASSEMBLY, REAR COMPARTMENT SIDE

PC2011-108-F-RP
23 NUT, ROOF LIFT-OFF WINDOW STOWAGE RETAINER

BRACKET
STOWAGE (RIGHT)
STOWAGE (LEFT)
Figure 11 - Rear Compartment Side Trim Assembly
2. Nuts (23).
PC0012108-F-RP
Hold retainer assembly (37 or 38) outboard,

down and forward when installing nuts (23).
l~I
Figure 12 - Roof Lift-Off Window Stowage Retainer

Assemblies
Tighten
Nuts (23) to 6 Nm (53 lb. in.).
3. Quarter inner rear trim finish panel assemblies.

4. Roof lift-off window stowage retainer assemblies, if
equipped. Refer to "Roof Lift-Off Window Stowage
Retainer Assemblies" in this section.
Rear Compartment Trim Assembly

Figure 13

1. Roof lift-off window stowage retainer assemblies, if
equipped. Refer to "Roof Lift-Off Window Stowage
Retainer Assemblies" in this section.
2. Quarter inner rear trim finish panel assemblies.
3. Retainer (35) from rear compartment latch support.
Separate hook-and-loop retainers on trim
assembly (36) from floor carpet assembly.
l++l
lnstall or Connect

Position in rear compartment and under trim
line of floor carpet assembly. Connect hookand-loop retainers.
2. Retainer (35) by pushing into rear compartment
latch support.
REAR COMPARTMENT LIFT WINDOW

PANEL ASSEMBLY AND COMPONENTS
Rear Compartment Lift Window Hinge
Assemblies
Figure 14
1. Rear compartment lift window panel assembly.

Refer to "Rear Compartment Lift Window Panel
2. Nuts (22).
3. Hinge assemblies (21).

section.
1. Hinge assemblies (21).
22
21
21 HINGE ASSSEMBLY, REAR COMPARTMENT LIFT

WINDOW
22 NUT, REAR COMPARTMENT LIFT WINDOW WINDOW
SIDE HINGE
PCOO 14 108-F-RP
35 RETAINER, REAR COMPARTMENT TRIM ASSEMBLY

36 TRIM ASSEMBLY, REAR COMPARTMENT
Figure 14 - Removing Rear Compartment Lift Window Hinge

Assembly
PC2013-108F-RP
Figure 13 - Rear Compartment Trim Assembly
2. Stud (29) through strut assembly (28) to quarter

inner roof panel.
l~I
2. Nuts (22).
l~I
Tighten
Stud (29) to 27 Nm (20 lb. ft.).
Tighten
Nuts (22) to 25 Nm (18 lb. ft.).

Rear Compartment Lift Window Strut

Assembly
3. Strut assembly (28) to stud (27).

4. Quarter trim finish panel assembly. Refer to SECTION 10-7.

Assembly
Figures 16 and 17
CAUTION: The steps must be performed with the assistance of a helper

to reduce the possibility of glass breakage or personal injury. Approved safety
glasses and gloves should be worn to
reduce the chance of personal injury
should glass breakage occur.
Figure 15

CAUTION: Do not attempt to remove or
loosen the strut assemblies without the
window panel assembly fully open. A
strut assembly removed under pressure may result in personal injury.
1. Raise and support window panel assembly.
l++I
1. Raise and support window panel assembly.

2. Headlining trim finishing panel. Refer to SECTION
10-9.
3. Strut assembly (28) from stud (27) on window panel

assembly (4) by unsnapping.
3. Grommet.
4. Stud (29) from strut assembly (28).
5. Strut assembly (28).
5. Strut assemblies at window panel assembly. Refer to

in this section.
l++l 111stall or Connect

section.
1. Strut assembly (28) to quarter inner roof panel.
6. Nuts (19).
7. Window panel assembly (4).
8. Gaskets (20) from hinge assemblies (21).

WINDOW
27 STUD, REAR COMPARTMENT LIFT WINDOW STRUT
WINDOW SIDE
28 STRUT ASSEMBLY, REAR COMPARTMENT LIFT
WINDOW
29 STUD, REAR COMPARTMENT LIFT WINDOW STRUT
BODY SIDE
PC0015-108-F-RP
Figure 15 - Rear Compartment Lift Window Strut Assembly
[I] Important
If window panel assembly is being replaced, remove

the hinge assemblies, spoiler assembly if equipped,
window and harness assemblies. Refer to "Rear
Compartment Lift Window Hinge Assembly,"
"Rear End Panel Spoiler Assembly" and "Rear
Compartment Lift Window" in this section.
l++I
Install or Connect

section.
1. Gaskets (20) to hinge assemblies (21).
2. Window panel assembly (4) aligning studs on hinge
assemblies (21) to holes.
3. Nuts (19).
l~I
Tighten
Nuts (19) to 25 Nm (18 lb. ft.).

4. Strut assemblies at window panel assembly. Refer to
in this section.
6. Grommet.
A. Route harness assembly.
B. Apply soap solution to grommet.
A GROMMET, REAR HATCH WIRING HARNESS

B FRAME, ROOF
WINDOW
PC0016108-F-RP
Figure 16 - Disconnecting Rear Hatch Wiring Harness

Grommet
C. Seat grommet at window panel assembly and

roof frame.
7. Headlining trim finishing panel. Refer to SECTION
10-9.
BODY REAR END 10811
20
3. High-mounted stoplamp. Refer to SECTION 8B.

4. Wiring extension from spoiler assembly (3).
A. Disconnect electrical connector.
B. Remove tape.
C. From outside vehicle, pull wiring extension
from spoiler assembly (3).
5. Nuts (25).
6. Spoiler assembly (3).
7. Washers (26).
l++I
A FRAME, ROOF
WINDOW
19 NUT, REAR COMPARTMENT LIFT WINDOW BODY SIDE
HINGE
20 GASKET, REAR COMPARTMENT LID BODY SIDE HINGE
21 HINGE ASSEMBLY, REAR COMPARTMENT LIFT
WINDOW
PC0017-108-F-RP
Figure 17 - Removing Rear Compartment Lift Window

Panel Assembly

Adjustment
Figure 18
[el Adjust
1. Window panel assembly (4) so it is flush to quarter
outer panel and centered in opening.
A. Open window panel assembly (4).
B. Move rear compartment trim assembly as
needed. Refer to "Rear Compartment Trim
C. Loosen bolts/screws (8).
D. Close window panel assembly (4).
E. Move window panel assembly (4) as required.
l~I
Tighten

2. Window panel assembly (4) so it is flush to quarter
trim finish panel assembly.
Loosen or tighten bumper assemblies (24) as
needed.
Rear End Spoiler Assembly

Figure 19
2. Rear compartment lift window side molding assemblies. Refer to "Rear Compartment Lift Window
Side Molding Assemblies" in this section.
1.
2.
3.
4.
Install or Connect
NOTICE: See "Notice" on page 10-8-1 in this

section.
Washers (26) to studs on spoiler assembly (3).
Spoiler assembly (3).
Push spoiler assembly (3) forward.
Nuts (25).
l~I
Tighten
Nuts (25) in sequence to 6 Nm (53 lb. in.).

5. Harness assembly into spoiler assembly (3).
A. Route wiring extension through spoiler assembly (3).
B. Pull on wiring extension to seat grommet.
C. Connect electrical connector.
D. Tape wiring extension to window panel assembly.
6. High-mounted stoplamp. Refer to SECTION 8B.
Liftgate Window Opening Finish Lace

Figure20
l++I
Lace (2) by pulling from window (1).
l++I
Install or Connect
1. Remove rear compartment lift window. Refer to

''Rear Compartment Lift Window'' in this section.
2. Lace (2) to window (1).
3. Rear compartment lift window. Refer to "Rear
Compartment Lift Window" in this section.
Rear Compartment Lift Window Inner Panel

Cover Assembly
Figure 21
!++I
Cover assembly (31) by pulling to release retainers

(42) from window panel assembly.
10812 BODY REAR END
)
1
4 PANEL ASSEMBLY, REAR COMPARTMENT

LIFT WINDOW
8 BOLT/SCREW, ENDGATE LATCH
24 BUMPER ASSEMBLY, REAR COMPARTMENT LIFT-----._
WINDOW
~--,z,--..___---J-~~-~======11
8
PC0018108-F-RP
Figure 18 - Rear Compartment Lift Window Panel Adjustment

Cover assembly (31) by aligning retainers (42) to
window panel assembly and pushing to secure.
Rear Compartment Lift Window Side

Molding Assemblies
Figure21

1. Cover assembly (31) by pulling to release retainers
(42) from window panel assembly.
2. Molding assembly (32 or 33) by pulling to release
retainers (42) and clips (43) from window panel
assembly.

1. Molding assembly (32 or 33) by aligning retainers
(42) and clips (43) to window panel assembly and
pushing to secure.
2. Cover assembly (31) by aligning retainers (42) to
window panel assembly and pushing to secure.

Figures 20 and 22
Tool Required:
J 24402-A Glass Sealant Remover (Cold
Knife) or J 24709-01 or J 24899-01 Urethane
Glass Sealant Remover (Hot Knife)
and gloves should be worn when per
forming this procedure to reduce the
BODY REAR END 10813
3
3
26
A EXTENSION, CENTER HIGH-MOUNTED STOPLAMP WIRING

B GROMMET, CENTER HIGH-MOUNTED STOPLAMP WIRING
EXTENSION
C TAPE
D CONNECTOR, CENTER HIGH-MOUNTED STOPLAMP WIRING
EXTENSION ELECTRICAL
3 SPOILER ASSEMBLY, REAR END

4 PANEL ASSEMBLY, REAR COMPARTMENT LIFT WINDOW
25 NUT, REAR END SPOILER
26 WASHER, REAR END SPOILER
PC2019108-FRP
Figure 19 - Rear End Spoiler Assembly

1. Lace (2) by pulling off of window (1).
SECTION A-A
5. Place window panel assembly (4) on a protected

work surface.
6. Rear window defogger electrical connector, if
equipped.
1 WINDOW, REAR COMPARTMENT LIFT

2 LACE, LIFTGATE WINDOW OPENING FINISH
7. Mask area around window (1) to protect painted

surfaces and to aid in cleanup after installation.
Tape must not touch window sealant surface.
8. Window (1) using J 24402-A, J 24709-01 or
J24899-01 to cut through adhesive.
Keep blade as close to edge of window ( 1) as
possible.
Make sure that an even bead of adhesive
remains on window panel assembly (4) to
serve as base for new window (1 ).
PC0020108FRP
Figure 20 - Installing Liftgate Window Opening Finish Lace
l~I Clean
Window panel assembly (4) of any loose material.
Adhesive from window (1), if window (1) is not
being replaced.
- Use an alcohol-dampened cloth.
10814 BODY REAR END
4
SECTION 8-8
SECTION A-A
31
32
I
e:
ej
?:t
SECTION C-C
32
33
I
SECTION D-D
33

WINDOW
31 COVER ASSEMBLY, REAR COMPARTMENT LIFT
WINDOW INNER PANEL
32 MOLDING ASSEMBL V, REAR COMPARTMENT LIFT
WINDOW SIDE (RIGHT)
33 MOLDING ASSEMBLV, REAR COMPARTMENT LIFT
WINDOW SIDE (LEFT)
42 RETAINER, REAR COMPARTMENT LIFT WINDOW
INNER PANEL COVER
43 CLIP, REAR COMPARTMENT LIFT WINDOW SIDE TRIM
FINISH PANEL COVER
PC0021-108-F-RP
Figure 21 - Rear Compartment Lift Window Inner Panel Cover Assembly and Rear Compartment Lift Window Side
Molding Assembly

I. Primers from urethane adhesive kit, GM PIN
12345633, to window (1) and window panel assembly (4).

kit. Clear primer must be applied first, immediately followed by black primer. Allow black
primer to dry five minutes prior to application
of urethane adhesive. Application of primers is
important because primers cause urethane
adhesive to bond to window (1) and window
panel assembly (4).
2. Urethane adhesive from kit to window (1).
urethane adhesive around window (1) where
primed.
3. Lace (2) to window (1).

A. Starting at one side, press lace (2) onto window
( 1) for about 400 mm ( 16 inches), being careful not to stretch lace (2).
B. Roll lace (2) from inboard to outboard.
C. Repeat for other side of lace (2).
D. Press on remaining lace (2) and roll.
4. Window (1) to window panel assembly (4) with aid
of helper.
Use vacuum cups to position window (1).
Position upper corners of window ( 1) to upper
corners of window panel assembly (4 ), then lay
window (1) onto window panel assembly (4)
and press firmly on rear of window (1) to
ensure proper lace fit.
5. Press window (1) firmly to wet-out and set adhesive.
Avoid squeezing out excess adhesive that
would cause appearance problem.
25 mm-1
i(1.D"l -------iEI==::=:I-
-.j
'-- 25 mm
r-
i\c===::::::~
(1 O")
SECTION A-A
4
--,
~25 mm (1.0")
c:=:=::=, (
SECTION 8-8
--------A
':::,.._
~~(0.5"1
SECTION C-C
7mml03"11
I_J
'- - ~
n1
1
~!JiF
SECTION C-C
A
B
C
1
2
4
14mm(0.6")
PRIMER PATH
PRIME AND BEAD PATH
CENTERLINE
WINDOW, REAR COMPARTMENT LIFT
LACE, LIFTGATE WINDOW OPENING FINISH
PANEL ASEMBLY, REAR COMPARTMENT LIFT
WINDOW
PC0022-108-F-RP
Figure 22 - Installing Rear Compartment Lift Window Adhesive Primers and Adhesive

tool, paddle adhesive around edge of window (1) to
ensure a watertight seal.
Paddle additional adhesive to fill voids in seal,
if necessary.
7. Rear window defogger electrical connector, if
equipped.

SPECIFICATIONS
Endgate Latch Bolt/Screw ............................................ 10 Nm (89 lb. in.)
Rear Compartment Lift Window Body Side Hinge Nut ...................... 25 Nm (18 lb. ft.)
Rear Compartment Lift Window Lock Striker Nut ......................... 10 Nm (89 lb. in.)
Rear Compartment Lift Window Strut Body Side Stud ...................... 27 Nm (20 lb. ft.)
Rear Compartment Lift Window Window Side Hinge Nut ................... 25 Nm (18 lb. ft.)
Rear End Spoiler Nut ................................................. 6 Nm (53 lb. in.)
Roof Lift-Off Window Stowage Retainer Bracket Nut ....................... 6 Nm (53 lb. in.)
SPECIAL TOOLS
J 24402-A
J 24709-01
OR
J 24899-01
1 URETHANE GLASS SEALANT REMOVER (HOT KNIFE)

2 GLASS SEALANT REMOVER (COLD KNIFE)
NC1010-102-B-RP
ROOF 10-9-1
SECTION 10-9
ROOF
result.
CONTENTS
Roof . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Headlining Panel Assembly . . . . . . . . . . . . . . .
Sunshade Assembly .....................
Interior Lighting ........................
Dome Lamp . . . . . . . . . . . . . . . . . . . . . . . . .
Interior Moldings . . . . . . . . . . . . . . . . . . . . . . .
Windshield Side Upper Garnish Molding
Assembly (Without Lift-Off Window
Assemblies) . . . . . . . . . . . . . . . . . . . . .
Assembly (With Lift-Off Window
Assemblies) .....................
Roof Drip Scalp Molding Assembly ........
10-9-1
10-9-1
10-9-1
10-9-1
10-9-3
10-9-3
10-9-3
10-9-4
10-9-4
10-9-4
10-9-5
Roof Outer Panel ............. Refer to Section 11

Roof Rear Panel .............. Refer to Section 11
Roof Lift-Off Window Assembly .......... 10-9-5
Roof Lift-Off Window Assembly
Removal and Installation ............. 10-9-5
Roof Lift-Off Window Assembly
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . 10-9-5
Roof Lift-Off Window Assembly Repair .. 10-9-6
Roof Panel Longitudinal Bow Finish
Molding Assembly .................. 10-9-7
Roof Lift-Off Window Lock Cylinder
Assembly ......................... 10-9-8
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-9-8
Fastener Tightening Specifications . . . . . . . . . 10-9-8
GENERAL DESCRIPTION
ROOF
5.
Figure 1
The information in this section provides service procedures that apply to all roof components.
6.
ON-VEHICLE SERVICE
7.
8.
HEADLINING PANEL ASSEMBLY

Figure2
The headlining panel assembly (3) is partially held
in place with headlining panel tape (1) and a retainer (2).
When the interior moldings, sunshade assemblies and
dome lamp housing assembly are installed, the headlining
panel assembly (3) is completely held in place.

1. Open rear compartment lift window.
2. Sunshade assemblies. Refer to "Sunshade Assembly" in this section.
3. Dome lamp housing assembly. Refer to "Dome
Lamp" in this section.
4. Windshield side upper garnish molding assemblies.
Refer to "Windshield Side Upper Garnish Molding
Assembly (Without Lift-Off Window Assemblies)"
or "Windshield Side Upper Garnish Molding

Assembly (With Lift-Off Window Assemblies)" in
this section.
Quarter trim finish panel assemblies. Refer to SECTION 10-7.
Loosen seat belt escutcheons and slide down seat
belt assemblies.
Retainer (2) from headlining panel assembly (3).
Headlining panel assembly (3).
A. Pull carefully on headlining panel assembly (3)
to remove from roof panel assembly.
B. Slide seat belt assemblies through seat belt
slots.
C. Remove headlining panel assembly (3) from
vehicle through rear compartment lift window
opening.

1. Peel backing from new headlining panel tape ( 1) and
apply to depressions in roof panel assembly.
2. Headlining panel assembly (3).
A. Place headlining panel assembly (3) in vehicle
through rear compartment lift window
opening.
B. Insert seat belt assemblies into seat belt slots.
C. Pull dome lamp electrical connector through
opening.
1092 ROOF
!VIEWA
-----:',.,- I -------
!VIEWC
IVIEWE I
17
A
B
2
3
4
5
6
7
8
9
10
11
12
17
WITHOUT LIFT-OFF WINDOW ASSEMBLIES

WITH LIFT-OFF WINDOW ASSEMBLIES
RETAINER, HEADLINING TRIM FINISH PANEL
PANEL ASSEMBLY, HEADLINING TRIM FINISH
BOLT/SCREW, SUNSHADE, 1.7 Nm (15 LB. IN.)
SUNSHADE ASSEMBLY
BULB, DOME LAMP
MOLDING ASSEMBLY, WINDSHIELD SIDE UPPER
GARNISH
BOLT/SCREW, WINDSHIELD GARNISH MOLDING,
1.7 Nm (15 LB. IN.)
MOLDING ASSEMBLY, WINDSHIELD SIDE UPPER
GARNISH
MOLDING ASSEMBLY, ROOF DRIP SCALP
WINDOW ASSEMBLY, ROOF LIFT-OFF
PC2001 109-F-RP
Figure 1 - Roof Components
ROOF 10-9-3
~A
"1~J
- - - - - ,_.-1 /
A
1
2
3
SLOT, SEAT BELT

TAPE, HEADLINING TRIM FINISH PANEL
RETAINER, HEADLINING TRIM FINISH PANEL
PANEL ASSEMBLY, HEADLINING TRIM FINISH
A SUPPORT.SUNSHADE
4 BOLT/SCREW, SUNSHADE, 1.7 Nm (15 LB. IN.)
5 SUNSHADE ASSEMBLY
PC0003-109FRP
Figure 3 - Sunshade Assembly
PC0002109-F-RP
Figure 2 - Headlining Panel Assembly (Typical)
3.
4.
5.
6.
7.
8.
9.
D. Apply pressure at centerline of headlining

panel assembly (3) to engage headlining panel
tape (1).
Retainer (2) to headlining panel assembly (3).
Slide seat belt escutcheons up seat belt assemblies
and snap into retractor.
Quarter trim finish panel assemblies. Refer to SECTION 10-7.
Windshield side upper garnish molding assemblies.
Assembly (Without Roof Lift-Off Window Assemblies)" or "Windshield Side Upper Garnish Molding Assemblies (With Roof Lift-Off Window
Assemblies)" in this section.
Dome lamp housing assembly. Refer to "Dome
Lamp" in this section.
Sunshade assemblies. Refer to "Sunshade Assembly" in this section.
Close rear compartment lift window.
SUNSHADE ASSEMBLY
Figure3

2. Sunshade assembly (5).

1. Sunshade assembly (5).
Position sunshade support to headlining panel
assembly.
l~I Tighten
INTERIOR LIGHTING
Dome Lamp
Figure4

Loosen enough to pull dome lamp housing
assembly (6) from headlining panel assembly.
2. Dome lamp housing assembly (6) by pulling from
headlining panel assembly.

2. Dome lamp housing assembly (6).
Use locating pins to position dome lamp housing assembly (6) to headlining panel assembly.
l~I Tighten
1094 ROOF
8
B
jv1EwA
PIN, LOCATING
8 BULB, DOME LAMP
A
B
6
7
A TAB
B S-CLIP
9 MOLDING ASSEMBLY, WINDSHIELD SIDE UPPER
GARNISH
PC0005-109-F-RP
Figure 5 - Windshield Side Upper Garnish Molding Assembly

(Without Lift-Off Window Assemblies)
PC2004-109-F-RP
Figure 4 - Dome Lamp Housing Assembly

INTERIOR MOLDINGS
Assembly (Without Lift-Off Window
Assemblies)
Figures

Windshield side upper garnish molding assembly (9)
by pulling away from windshield inner side frame.
1. Windshield side upper garnish molding assembly

(11).
Align clips to holes on windshield inner side
frame.
l~I Tighten

Windshield side upper garnish molding assembly
(9).
A. Align tabs on windshield side upper garnish

molding assembly (9) to holes in windshield
inner side frame and apply pressure to secure.
B. Align S-clips on windshield side upper garnish
molding assembly (9) to door opening flange
and apply pressure to secure.

Assembly (With Lift-Off Window Assemblies)
Figure 6

2. Windshield side upper garnish molding assembly

(11) by pulling away from windshield inner side
frame.
A CLIP
10 BOLT/SCREW, WINDSHIELD GARNISH MOLDING,
1.7 Nm (15 LB. IN.)
11 MOLDING ASSEMBLY, WINDSHIELD SIDE UPPER
GARNISH
PC000&-109-F-RP
Figure 6 - Windshield Side Upper Garnish Molding Assembly

(With Lift-Off Window Assemblies)
ROOF 10-9-5
ROOF DRIP SCALP MOLDING ASSEMBLY

17
Figure 7

Roof drip scalp molding assembly (12) by pulling
away from door opening.

Roof drip scalp molding assembly (12) beginning at
rear of door opening and pressing entire length to
secure.
ROOF LIFT-OFF WINDOW ASSEMBLY

The roof lift-off window assemblies are manually
operated. The window assemblies are curved to match the
contour of the roof and are made of tinted, tempered glass.
The front side door weatherstrip assemblies are one piece
and molded to the shape of the roof opening. The weatherstrip assemblies are held on by retainer assemblies. For
information on service of weatherstrip and retainer
assemblies, refer to SECTION 10-6.
Roof Lift-Off Window Assembly Removal

and Installation
SECTION A-A
17 WINDOW ASSEMBLY, ROOF LIFT-OFF
20 MOLDING ASSEMBLY, ROOF PANEL LONGITUDINAL
BOW FINISH
PC0008-109F-RP
FigureB
Figure 8 - Installing Roof Lift-Off Window Assembly
The roof lift-off window assemblies (17) can be

removed and stored in the roof lift-off window stowage
retainer assembly.
C. Repeat for other roof lift-off window assembly

(17).
Roof lift-off window assemblies (17).

A. Turn window latch handle assembly.
B. Pivot roof lift-off window assembly (17)
upward slightly and pull outward to release
from under longitudinal bow finish molding
assembly (20).

Roof lift-off window assemblies (17).
A. Carefully insert inside edge of roof lift-off
window assembly (17) under longitudinal bow
finish molding assembly (20).
B. Lower roof lift-off window assembly (17) and
latch into place.
C. Repeat for other roof lift-off window assembly

(17).
D. Check for proper fit and adjust if necessary.
Refer to "Roof Lift-Off Window Assembly
Adjustment" in the following procedure.
Roof Lift-Off Window Assembly Adjustment

Figure 9
12 MOLDING ASSEMBLY, ROOF DRIP SCALP

PCOOOM09FRP
Figure 7 - Roof Drip Scalp Molding Assembly
The roof lift-off window assembly is adjustable

within the lift-off window opening. The roof lift-off window assemblies are adjusted up and down by adding or
removing backing plates (26). In-and-out and fore-and-aft
travel is adjusted by loosening bolts/screws (23) and
repositioning front and rear striker assemblies (25 and 24)
as necessary. Adjustments should be made to get a flush
fit of the roof lift-off window assemblies to the roof.
10-9-6 ROOF
l~I Tighten
ILl
1nspect
1. Install roof lift-off window assemblies and inspect

for proper fit.
2. Remove roof lift-off window assemblies.

1. Quarter inner trim finish panel extension.
2. Quarter trim finish panel bolts/screws.
23
!VIEWA
!VIEWS!
23
A SLOT CUT-OUT
23 BOLT/SCREW, ROOF REAR PANEL LATCH STRIKER,
10 Nm (89 LB. IN.)
24 STRIKER ASSEMBLY, ROOF LIFT-OFF WINDOW REAR
25 STRIKER ASSEMBLY, ROOF LIFT-OFF WINDOW FRONT
26 PLATE, ROOF LIFT-OFF WINDOW FRONT STRIKER
BRACKET BACKING
27 RETAINER ASSEMBLY, ROOF LIFT-OFF PANELJWINDOW
FRONT NUT PLATE
PCOOOS-109-F-RP
Figure 9 - Roof Lift-Off Window Striker Assemblies
l~I Tighten
Quarter trim finish panel bolts/screws to 1. 7
Nm (15 lb. in.).
3. Windshield side upper garnish molding assembly.
this section.
4. Roof lift-off window assemblies. Refer to "Roof
Lift-Off Window Assembly Removal and Installation" in this section.
Roof Lift-Off Window Assembly Repair

Figure 10

2. Windshield side upper garnish molding assembly.
this section.
3. Quarter trim finish panel bolts/screws.
4. Quarter inner trim finish panel extension to access
rear striker assemblies (24).
5. Loosen bolts/screws (23).
11 Adjust
Front and rear striker assemblies (25 and 24).
A. Up and down.
Add or remove backing plates (26).
B. In and out.
Move front or rear striker assembly (25
or 24) in or out as required.
C. Fore and aft.
Move front or rear striker assembly (25
or 24) fore or aft as required.
If a new roof lift-off window assembly (17) is being

installed, transfer the hardware from the original roof liftoff window assembly (17) to the new one as a bench procedure.

2. Place on a clean, protected surface.
l+!+I Disassemble
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
Handle bolt/screw (30).

Handle assembly (16).
Trim cover bolts/screws (18).
Trim cover assembly (15).
Weatherstrip bolts/screws (14).
Weatherstrip assembly (13) by pulling from weatherstrip retainer assembly (28).
Weatherstrip retainer bolts/screws (29).
Weatherstrip retainer assembly (28).
Roof lift-off window latch bolts/screws.
Latch (31).
l+!+I Assemble
ROOF 10-9-7
Install handle in open position.
10. Handle bolt/screw (30).
l++I
Install or Connect
Roof lift-off window assemblies. Refer to "Roof

Roof Panel Longitudinal Bow Finish Molding

Assembly
Figure 11
13 WEATHERSTRIP ASSEMBLY, ROOF SIDE RAIL
WEATHERSTRIP, 1.3 Nm (12 LB. IN.)
15 COVER ASSEMBLY, ROOF LIFT-OFF WINDOW LATCH
TRIM
16 HANDLE ASSEMBLY, ROOF LIFT-OFF WINDOW LATCH
18 BOLT/SCREW, ROOF LIFT-OFF WINDOW LATCH TRIM
COVER, 1.7 Nm (15 LB. IN.)
28 RETAINER ASSEMBLY, ROOF LIFT-OFF WINDOW BODY
SIDE WEATHERSTRIP WINDSHIELD FRAME
WEATHERSTRIP WINDSHIELD FRAME RETAINER,
1.3Nm (12 LB. IN.)
30 BOLT/SCREW, ROOF LIFT-OFF WINDOW LATCH HANDLE
31 LATCH, ROOF LIFT-OFF WINDOW
PC0010-109-F-RP
l++I

3. Longitudinal bow finish molding assembly (20).
!++I
Install or Connect

1. Longitudinal bow finish molding assembly (20).
Figure 10 - Roof Lift-Off Window Assembly
A. Position molding so "FRT" marked on protective paper is forward.

B. Remove protective paper.
1. Latch (31).
2. Bolts/screws (19), in order, to positions 1, 2 and 3.
2. Roof lift-off window latch bolts/screws.

3. Weatherstrip retainer assembly (28).
4. Weatherstrip retainer bolts/screws (29).
l~I
Tighten
Weatherstrip retainer bolts/screws (29) to 1.3

Nm (12 lb. in.).
5. Weatherstrip assembly (13) to weatherstrip retainer
assembly (28).
Insert outboard lip of weatherstrip assembly
(13) into weatherstrip retainer assembly (28)
and roll inboard lip into weatherstrip retainer
assembly (28).
6. Weatherstrip bolts/screws (14).
l~I
20
Tighten
Weatherstrip bolts/screws (14) to 1.3 Nm (12

lb. in.).
7. Trim cover assembly (15).
8. Trim cover bolts/screws (18).
l~I
19
Tighten
Trim cover bolts/screws (18) to 1.7 Nm (15

lb. in.).
A
B
C
19
POSITION 1
POSITION 2
POSITION 3
BOLT/SCREW, ROOF PANEL LONGITUDINAL BOW
FINISH HOLDING, 1.7 Nm (15 LB. IN.)
20 MOLDING ASSEMBLY, ROOF PANEL LONGITUDINAL
BOW FINISH
PC0011-109-F-RP
Figure 11 - Roof Panel Longitudinal Bow Finish Molding

Assembly
1098 ROOF
l~I

Tighten
Bolts/screws (19) as they are installed in positions 1, 2 and 3 to 1.7 Nm (15 lb. in.).
Roof Lift-Off Window Lock Cylinder

Assembly
!~I Tighten
Trim cover bolts/screws (18) to 1.7 Nm (15
lb. in.).
7. Rooflift-off window assembly. Refer to "Roof LiftOff Window Assembly Removal and Installation"
in this section.
Figures 10 and 12
l++I
1. Roof lift-off window assembly. Refer to "Roof LiftOff Window Assembly Removal and Installation"
in this section.
6. Lock cylinder retainer (21).
l++I
Install or Connect

Align tabs of lock cylinder assembly (22) with
notches in latch support.
2. Lock cylinder retainer (21).

21 RETAINER, ROOF LIFT-OFF WINDOW LOCK CYLINDER
22 CYLINDER ASSEMBLY, ROOF LIFT-OFF WINDOW LOCK
PC0012-109-FRP
Figure 12 - Roof Lift-Off Window Lock Cylinder Assembly

(Left Side Shown)
SPECIFICATIONS
Dome Lamp Bolt/Screw ............................................. 1.7 Nm (15 lb.
Quarter Trim Finish Panel Bolt/Screw .................................. 1.7 Nm (15 lb.
Roof Lift-Off Window Body Side Weatherstrip Bolt/Screw . . . . . . . . . . . . . . . . . 1.3 Nm (12 lb.
Roof Lift-Off Window Body Side Weatherstrip Windshield Frame Retainer
Bolt/Screw ...................................................... 1.3 Nm (12 lb.
Roof Lift-Off Window Latch Trim Cover Bolt/Screw ...................... 1.7 Nm (15 lb.
Roof Panel Longitudinal Bow Finish Molding Bolt/Screw .................. 1.7 Nm (15 lb.
Roof Rear Panel Latch Striker Bolt/Screw ................................ 10 Nm (89 lb.
Sunshade Bolt/Screw ............................................... 1.7 Nm (15 lb.
Windshield Garnish Molding Bolt/Screw ................................ 1.7 Nm (15 lb.
in.)
in.)
in.)
in.)
in.)
in.)
in.)
in.)
in.)
SEATS AND CARPET 10-10-1
SECTION 10-10
SEATS AND CARPET

result.
CONTENTS
General Description . . . . . . . . . . . . . . . . . . . . . . 10-10-1
Front Seat Assembly . . . . . . . . . . . . . . . . . . . . 10-10-1
Front Seatback . . . . . . . . . . . . . . . . . . . . . . . 10-10-1
Rear Seat Assembly . . . . . . . . . . . . . . . . . . . . 10-10-1
~loor ~arpet Assembly . . . . . . . . . . . . . . . . . . 10-10-1
Diagnosis .............................. 10-10-2
Front Seat Assembly .................... 10-10-2
Manual Front Seat Adjuster Assembly ..... 10-10-2
Power Front Seat Adjuster Assembly ...... 10-10-2
Pneumatic Comfort Controls ............ 10-10-2
On-Vehicle Service ...................... 10-10-2
Front Seat Assembly .................... 10-10-2
Front Seatback . . . . . . . . . . . . . . . . . . . . . . . 10-10-3
Trim Covers ......................... 10-10-5
Front Seat Cushion Assemblies . . . . . . . . . . 10-10-9
Lumbar and Lateral Support Bladders . . . . . 10-10-9
Head Restraint Assembly .............. 10-10-11
GENERAL DESCRIPTION
FRONT SEAT ASSEMBLY
Front Seat Recliner Assembly ..........

Manual Front Seat Adjuster Assembly ....
Driver Seat Adjuster and Drive Motor
Assemblies . . . . . . . . . . . . . . . . . . . . . . . .
Passenger Seat Adjuster Assemblies .....
Power Front Seat Adjuster Assembly .....
Front Seat Adjuster Actuator Lever Knob .
Rear Seat Assembly ...................
Rear Seat Cushion Assembly ...........
Rear Seatback Cushion Assembly .......
Shoulder Restraint Guide ..............
Rear Trim and Covers .................
Seatback Lock Assembly and Striker .....
Floor Carpet Assembly .................
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . .
Special Tools ..........................
10-10-12
10-10-14
10-10-15
10-10-17
10-10-17
10-10-19
10-10-20
10-10-20
10-10-21
10-10-21
10-10-22
10-10-22
10-10-25
10-10-26
10-10-26
10-10-26
The recliner control is mounted on the outboard side of

the seat assembly and controls the seatback angle. The
inner hinge arm bolt/screw acts as a pivot point for the
seatback. The recliner control has an inertia seatback lock
that lets the occupant move the seatback without the lever.
If the vehicle stops or slows suddenly, or is declined 20
degrees or more, the inertia seatback lock locks the seatback and the emergency release lever must be used to
move the seatback.
The seatback angle can be changed by lifting the
reclining control handle. Lifting the recliner control handle releases the lock bars and lets the seatback pivot
forward and rearward. Releasing the recliner control handle lets the cam plate move counterclockwise, causing the
lock bar teeth to lock the seatback in a new position. The
recliner control handle should return automatically to its
original position.
The front seat assemblies are bucket seats. Both seat

assemblies have inertia seatback locks, manual seatback
recliners and manual seatback adjuster assemblies. A
4-way manual or a power 6-way seat adjuster assembly is
available on the driver's seat as an option.
Also, both front seats can be ordered with pneumatic
seats that have an adjustable thigh support, and inflatable
lumbar and lateral support bladders.
The seatback and cushion assemblies have formed
foam pads that fit the contours of the seatback and seat
cushion frames.
CAUTION: Do not try to change the
designed seat position by changing the
seat adjuster-to-floor pan anchor
placement or the seat adjuster-to-seat
frame anchor placement. Changing the
designed seat position could affect the
safe performance of the seat and cause
personal injury.
The rear seat assembly is of the solid, folding bench

type. It is fastened onto the vehicle with studs and nuts
and bolts/screws.
Front Seatback
FLOOR CARPET ASSEMBLY
Bucket seat assemblies have a tubular frame seatback and a standard manual seatback recliner assembly.
All floor carpet assemblies consist of a molded onepiece carpet over both front and rear floor pan assemblies.
REAR SEAT ASSEMBLY
10-10-2 SEATS AND CARPET
DIAGNOSIS
FRONT SEAT ASSEMBLY
Manual Front Seat Adjuster Assembly
All passenger seats and some driver seats have
manual seat adjuster assemblies attached to the seat cushion frame. An adjuster actuator lever is located at the lower front edge of the seat cushion. When the lever is moved
to the left, the seat adjuster assemblies unlock. The seat
can then be moved forward and rearward. The seat locks
in place when the lever is released.
The seat adjuster assemblies are held onto the seat
cushion frame with bolts/screws and to the floor pan with
nuts installed over studs. Adjuster channel covers are
installed between the seat cushion frame and the seat
adjuster assemblies.
1. Adjuster assemblies will not lock or will not unlock.
Linking wire may be too loose, too tight or
disconnected.
Return spring may be disconnected or
damaged.
Lock bar may be stuck or damaged.
2. One adjuster assembly locks and other adjuster
assembly does not lock.
One adjuster assembly may be forward or rearward of another adjuster assembly. Make
adjustments at floor pan attachments.
3. Seat is hard to move forward or rearward.
Adjuster assemblies may be new. Move seat
forward and rearward several times to work
tightness out of channels.
Adjuster assemblies may not be lubricated
properly.
Adjuster channels may be damaged.
Adjuster assemblies may not be parallel. Make
adjustments at floor pan attachments.
4. One adjuster assembly will not move up or down.

Vertical drive cable assembly may be disconnected or damaged.
Vertical actuator may be damaged.
Pneumatic Comfort Controls

These seats have inflatable lumbar and lateral support bladders in the seatback. The lumbar support bladder
is located in the lower middle section of the seatback, and
the lateral support bladders are located in the sides of the
seatback. The control switch to inflate or deflate the support bladders is located on the lower outboard side of the
seat cushion. A pump, valve and relay are attached to the
bottom of the driver's seat cushion. The pump operates
both front seats.
1. Driver and passenger seats will not function at the
same time.
Operate one seat at a time. Although each seat
has a switch, one pump runs both seats; so the
two seats cannot be run at the same time.
2. Switch button is pushed, but no electrical "click" is
heard.
Seat may not be plugged into vehicle electrical
system.
Wiring harness fuse may be blown.
3. Wiring harness fuse blows often.
Grommet that prevents the switch from contacting the trim support panel may be damaged
or missing. Repair kits are available to correct
this condition.
4. Pump runs and does not shut off.
Hose may be disconnected or damaged.
5. When switch button is pushed, the pump clicks and
shuts off.
Hose may be pinched.
6. Driver seat operates, but passenger seat does not.
Hose crossover may be pinched.
ON-VEHICLE SERVICE
Power Front Seat Adjuster Assembly

Six-way power seat adjuster assemblies are available on the driver's seat. The adjuster assemblies use three
12 volt reversible, permanent-magnet motors controlled
by a switch on the forward outboard side of the seat.
1. One adjuster assembly reaches maximum horizontal
or vertical position before other adjuster assembly.
Adjuster assemblies may be out of phase.
2. Seat assembly does not move smoothly.
Adjuster shoes and channels may not be properly lubricated.
Horizontal actuator gear may be too tight.
3. One adjuster assembly will not move forward and
backward.
Horizontal drive cable assembly may be
damaged.
Horizontal actuator may be damaged.
FRONT SEAT ASSEMBLY

Figure 1

1. Caps (5) covering nuts (3) and studs (4).
2. Nuts (3) from studs (4).
3. Body wiring harness electrical connector, if necessary.
4. Seat air supply hose, if necessary.
NOTICE: Failure to place a protective shield over
nearby trim and paint may cause damage to the
vehicle.
5. Place protective shield over nearby trim and paint.
6. Seat assembly (I or 2) from floor pan assembly.
7. Seat assembly (I or 2) from vehicle.
4
A
1
2
3
4
5
CONNECTOR, BODY WIRING HARNESS ELECTRICAL

SEAT ASSEMBLY, DRIVER
SEAT ASSEMBLY, PASSENGER
NUT, DRIVER/PASSENGER SEAT ADJUSTER, 24 Nm (18 LB. FT.)
STUD, DRIVER/PASSENGER SEAT ADJUSTER
CAP, DRIVER/PASSENGER SEAT ADJUSTER STUD
PC2001-1010-F-RP
Figure 1 - Removing Seat Assemblies from Floor Pan Assembly

CAUTION: Replace belts, retractors,
and hardware in use during all but a
minor collision. Also, restraint systems
should be replaced and anchorages
properly repaired if they were in areas
damaged by a collision, whether the
belt was in use or not. If there is any
question, replace the belt system. Damage, whether visible or not, could result
in serious personal injury in the event
of an accident.
section.
1. Seat assembly (1 or 2) to vehicle.
2. Seat assembly (1 or 2) over studs (4) to floor pan

assembly.
3. Remove protective shield.

4. Nuts (3) to studs (4).
l~I
Tighten
Nuts (3) to 24 Nm (18 lb. ft.).

5. Body wiring harness electrical connector, if
disconnected.
6. Seat air supply hose, if removed.
7. Caps (5) covering nuts (3) and studs (4).
Front Seatback
Figure2

1. Front seat assembly. Refer to "Front Seat Assem-
bly" in this section.

2. Hinge arm trim covers. Refer to "Trim Covers" in
this section.

3. Bolts/screws (6 and 7) attaching hinge arm assembly
(8) to cushion assembly (9).
4. Seatback (10) from cushion assembly (9) by unsnapping from front seatback pivot bushing (11 ).
5. Front seatback pivot bushing (11).

section.
NOTICE: Anytime the front seatback is removed, a
new seatback pivot bushing must be installed.
1. Front seatback pivot bushing (11).
2. Seatback (10) to cushion assembly (9).
Align pivot shaft on seatback with hole in
cushion assembly (9).
10
l~I Tighten
4. Hinge arm trim covers. Refer to "Trim Covers" in
this section.
5. Front seat assembly. Refer to "Front Seat Assembly" in this section.
Inertia Seatback Lock Check

In-Vehicle
IL'S'I Inspect
1. Inertia seatback lock.
CAUTION: Perform the check in an area
clear of other vehicles or obstructions.
The driver must be buckled into the
restraint system, and a helper must be
buckled into the rear seat restraint system. The helper should hold the sides
of the passenger seatback near the top
with arms still and body relaxed. Failure to perform these precautions may
cause damage to the vehicle and possible personal injury.
A. Drive vehicle forward between 16 and 24 km/h
(10 and 15 mph).
When performing check on driver's seatback, driver should lean forward slightly.
Helper must not push forward on seatback before driver applies brakes.
B. Quickly apply brakes to stop vehicle as fast as
possible without skidding tires.
C. Inertia seatback lock should lock and top of
seatback should only move forward about
100 mm (4 inches).
2. If either inertia seatback lock does not lock, perform
out-of-vehicle check.
jv1ewAj
A SHAFT, PIVOT
6 BOLT/SCREW, FRONT SEATBACK HINGE ARM,
24 Nm (18 LB. FT.)
7 BOLT/SCREW, FRONT SEATBACK HINGE ARM,
24 Nm (18 LB. FT.)
8 ARM ASSEMBLY, FRONT SEATBACK HINGE
9 CUSHION ASSEMBLY, FRONT SEAT
10 SEATBACK, FRONT
11 BUSHING, FRONT SEATBACK PIVOT
PC2002-1010-F-RP
Figure 2 - Removing Front Seatback (Typical)
SEATS AND CARPET 10-105

Out-of-Vehicle
Trim Covers
Figure 3
Front Trim Covers
ll'l'I
Figure 4
Inspect
1. Inertia seatback lock.

A. Remove seat assembly from vehicle. Refer to
"Front Seat Assembly" in this section.
B. Place seat assembly right side up on clean

surface.
C. Raise rear of seat assembly until seatback is
6 degrees forward of vertical.
D. Place blocks under rear of seat assembly to
hold seat assembly in position.
E. Check that seatback is locked in position.
F. Install seat assembly into vehicle if inertia
seatback lock works properly. Refer to "Front
Seat Assembly" in this section.
2. If inertia seatback lock does not work properly,

entire recliner control must be replaced. Refer to
"Front Seat Recliner Assembly" in this section.

1. Bolts/screws (13 and 16) attaching covers (15 and
17) to driver seat adjuster track assemblies.
2. Covers (15 and 17) from driver seat adjuster track
assemblies.

section.
1. Covers (15 and 17) to driver seat adjuster track

assemblies.
2. Bolts/screws (13 and 16) to covers (15 and 17).
l~I
Tighten
Bolts/screws (13 and 16) to 1.7 Nm (15 lb. in.).
14
A-----r-t
I
17
A
B
C
D
1 SEAT ASSEMBLY, DRIVER

12 BOLT/SCREW, DRIVER SEAT OUTER ADJUSTER LOWER,
1.7 Nm (15 LB. IN.)
13 BOLT/SCREW, DRIVER SEAT ADJUSTER FRONT TRIM
14 COVER, DRIVER SEAT OUTER ADJUSTER LOWER
15 COVER, DRIVER SEAT INNER ADJUSTER FRONT TRIM
16 BOLT/SCREW, DRIVER SEAT ADJUSTER FRONT TRIM
17 COVER, DRIVER SEAT OUTER ADJUSTER FRONT TRIM
SIX DEGREES FORWARD OF VERTICAL

METER, ANGLE
LEVER, EMERGENCY RELEASE
BLOCK
PC0003-1010-F-RP
Figure 3 - Checking Inertia Seatback Lock (Typical)
PC2004-1010-F-RP
Figure 4 - Driver Seat Adjuster and Trim Covers
10106 SEATS AND CARPET

Outer Adjuster Lower Cover
Figure 4

1. Bolt/screw (12) attaching cover (14) to driver seat
adjuster track assembly.

2. Cover (14) from driver seat adjuster track assembly.

section.
1. Cover (14) to driver seat adjuster track assembly.
2. Bolt/screw (12) to cover (14).
l~I Tighten
Hinge Arm Trim Covers
4.
5.
6.
7.
Cushion inner finish panel bolts/screws (27).

Cushion inner finish panel (26).
Front seatback hinge arm bolts/screws (6 and 7).
Cushion finish panel outer support bolts/screws
(28).
8. Cushion finish panel outer support (29).
9. Cushion finish panel inner support bolts/screws
(30).
10. Cushion finish panel inner support (31).

1.
2.
3.
4.
5.
Figures
6.
l~I Tighten
1. Bolts/screws (21 and 22) attaching cover (18 or 19)
to seat assembly (1 or 2).

2. Cover (18 or 19).
3. Bolts/screws (23 or 27) attaching panel (20 or 26) to
seat assembly (1 or 2).
4. Panel (20 or 26).

1.
2.
3.
4.

section.
Panel (20 or 26).
Bolts/screws (23 or 27) attaching panel (20 or 26) to
seat assembly (1 or 2).
Cover (18 or 19) to seat assembly (1 or 2).
Bolts/screws (21 and 22).
l~I Tighten
5. Secure bolts/screws (22, 23 and 27).
Uplevel Seat Trim
Figure 6
Seat Cushion Trim

1. Cushion outer finish panel bolts/screws (23).
2. Cushion outer finish panel (20).

3. Pneumatic pump and valve switch. Refer to "Seat
Pneumatic Pump and Valve Switch" under "Lumbar and Lateral Support Bladders" in this section.

section.
Cushion finish panel inner support (31).
Cushion finish panel inner support bolts/screws
(30).
Secure bolts/screws (30).
Cushion finish panel outer support (29).
Cushion finish panel outer support bolts/screws
(28).
Front seatback hinge arm bolts/screws (6 and 7).

7. Cushion inner finish panel (26).
8. Cushion inner finish panel bolts/screws (27).
9. Cushion outer finish panel (20).
10. Pneumatic pump and valve switch (25). Refer to
"Seat Pneumatic Pump and Valve Switch" under
"Lumbar and Lateral Support Bladders" in this
section.
11. Cushion outer finish panel bolts/screws (23).
Seatback Trim

1. Seatback finish panel bolt/screw caps (32).
2.
3.
4.
5.
6.
7.
Bolts/screws (33) and retainer (34).

Seatback finish panel bolts/screws (35).
Seatback finish panel (36).
Seatback map pocket net (37).
Seatback inner trim panel bolts/screws (38).
Seatback inner trim panel (39).

section.
1. Seatback inner trim panel (39).
2. Seatback inner trim panel bolts/screws (38).
3. Seatback map pocket net (37).
24
19
21
A
B
1
2
18
19
20
21
22
23
24
25
26
27
DRIVER AND PASSENGER SEAT

DRIVERSEATONLY
SEAT ASSEMBLY, DRIVER
SEAT ASSEMBLY, PASSENGER
COVER, FRONT SEATBACK FRAME HINGE ARM TRIM
COVER, FRONT SEATBACK FRAME HINGE ARM TRIM
PANEL, DRIVER SEAT CUSHION OUTER FINISH
BOLT/SCREW, DRIVER SEAT ADJUSTER
BOLT/SCREW, FRONT SEATBACK FRAME HINGE
BOLT/SCREW, DRIVER SEAT CUSHION OUTER FINISH PANEL
ADJUSTER ASSEMBLY, FRONT SEAT
SWITCH, DRIVER SEAT PNEUMATIC PUMP AND VALVE
PANEL, DRIVER SEAT CUSHION INNER FINISH
BOLT/SCREW, DRIVER SEAT CUSHION INNER FINISH PANEL
PC2005 1010-F-RP
Figure 5 - Hinge Arm Trim Covers
26
20
23
36
39
,,
37 " ~ , . ,
'1
32
33
34
6 BOLT/SCREW, FRONT SEATBACK HINGE ARM

7
8
9
10
20
23
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
BOLT/SCREW, FRONT SEATBACK HINGE ARM

ARM ASSEMBLY, FRONT SEATBACK HINGE
CUSHION ASSEMBLY, FRONT SEAT
SEATBACK, FRONT
PANEL, DRIVER SEAT CUSHION OUTER FINISH
BOLT/SCREW, DRIVER SEAT CUSHION OUTER FINISH PANEL
SWITCH, DRIVER SEAT PNEUMATIC PUMP AND VALVE
PANEL, DRIVER SEAT CUSHION INNER FINISH
BOLT/SCREW, DRIVER SEAT CUSHION INNER FINISH PANEL
BOLT/SCREW, DRIVER SEAT CUSHION FINISH PANEL
OUTER SUPPORT
SUPPORT, DRIVER SEAT CUSHION FINISH PANEL OUTER
BOLT/SCREW, DRIVER SEAT CUSHION FINISH PANEL
INNER SUPPORT
SUPPORT, DRIVER SEAT CUSHION FINISH PANEL INNER
CAP, DRIVER SEATBACK FINISH PANEL BOLT/SCREW
BOLT/SCREW, DRIVER SEATBACK FINISH PANEL
RETAINER, DRIVER SEAT TRIM FINISH PANEL
BOLT/SCREW, DRIVER SEATBACK FINISH PANEL
PANEL, DRIVER SEATBACK FINISH
NET, DRIVER SEATBACK MAP POCKET
BOLT/SCREW, DRIVER SEATBACK INNER TRIM PANEL
PANEL, DRIVER SEATBACK INNER TRIM
PC2006-1010-FRP
Figure 6- Uplevel Seat Trim

4. Seatback finish panel (36).
5. Seatback finish panel bolts/screws (35).
6. Bolts/screws (33) with retainers (34).
7. Seatback finish panel bolt/screw caps (32).
Front Seat Cushion Assemblies

Seat Cushion Cover Assembly
Figure 7

2. J-retainers from seat cushion frame assembly.

1. Cover assembly (40) over seat cushion frame
assembly.
Cap front and rear corners of cover assembly
(40) over cushion assembly (9) and regulate to
desired appearance.
2. J-retainers to seat cushion frame assembly.
Seatback Cover Assemblies (Base Level)

Figures

1. Seatback. Refer to "Front Seatback" in this section.
2. Head restraint. Refer to "Base Level" under "Head
Restraint Assembly" in this section.
3. Seatback lock release knob (42).

1. Cover assembly (41) to seat cushion pad assembly.
2. Head restraint. Refer to "Base Level" under "Head
3. Seatback lock release knob (42).
Seatback Cover Assemblies (Uplevel)

Figure 9

1. Seat trim. Refer to "Uplevel Seat Trim" under
"Trim Covers" in this section.
A J-RETAINER
9 CUSHION ASSEMBLY, FRONT SEAT
40 COVER ASSEMBLY, FRONT SEAT CUSHION
PC2007-1010-F-RP
Figure 7 - Front Seat Cushion Cover Assembly
2. Head restraint. Refer to "Uplevel" under "Head

4. Rings (43) attaching cover assembly (41) to seat
cushion pad assembly and wire assembly (44).
5. Wire assembly (44).

1. Cover assembly (41) to seat cushion pad assembly.
2. Wire assembly (44) attaching cover assembly (41) to
seat cushion pad assembly.
3. Rings (43).
5. Head restraint. Refer to "Uplevel" under "Head
6. Seat trim. Refer to "Uplevel Seat Trim" under
Lumbar and Lateral Support Bladders

Bladder Replacement
Figure 10

1. Seatback cover. Refer to "Seatback Cover Assemblies (Uplevel)" under "Front Seat Cushion Assemblies" in this section.
2. Seatback pad (45) from frame (46).
3. Seatback lumbar bladder (47) and hose.
4. Seat lateral support bladder retainer (48).
5. Seat lateral support bladders (49) and hose.

1. Seat lateral support bladders (49) and hose.
2. Seat lateral support bladder retainer (48).
41
~42
A
9
41
42
J-RETAINERS
SEATBACK,FRONT
COVER ASSEMBLY, FRONT SEATBACK
KNOB, SEATBACK LOCK RELEASE
PC2008-1010-F-RP
Figure 8 - Front Seatback Cover Assemblies (Base Level)
43
A
B
C
41
43
44
OPEN POSITION
CLOSED POSITION
HOSE ASSEMBLIES, BLADDER
COVER ASSEMBLY, FRONT SEATBACK
RING, FRONT SEATBACK COVER RETAINER
WIRE ASSEMBLY, FRONT SEATBACK BOLSTER
PC2009 1010-F-RP
Figure 9 - Front Seatback Cover Assemblies (Uplevel)
3. Seatback lumbar bladder (47) and hose.

4. Seatback pad (45) to frame (46).
5. Seatback cover. Refer to "Seatback Cover Assemblies (Uplevel)" under "Front Seat Cushion Assemblies" in this section.
Pump, Valve and Module
Figure 11

2. Adjuster. Refer to "Manual Front Seat Adjuster

3. Air supply hoses.
4. Electrical connectors
5. Seat pneumatic control module bolts/screws (50).
Driver side only.
6. Seat pneumatic control module (51). Driver side
only.
7. Seat inflator pump bolts/screws (52).
8. Seat inflator pump (53).
9. Seat pneumatic valve bolts/screws (54).

11. Adjuster. Refer to "Manual Front Seat Adjuster
49
Seat Pneumatic Pump and Valve Switch

Figure 12

1. Cushion outer finish panel. Refer to "Hinge Arm
Trim Covers" under "Trim Covers" in this section.
2. Electrical connector from switch (25).
3. Switch (25) by unsnapping from outer finish panel
(20).

45
46
47
48
49
PAD, DRIVER SEATBACK

FRAME, DRIVER SEAT
BLADDER, DRIVER SEATBACK LUMBAR
RETAINER, SEAT LATERAL SUPPORT BLADDER
BLADDER, SEAT LATERAL SUPPORT
1. Switch (25).
2. Electrical connector to switch (25).
3. Cushion outer finish panel. Refer to "Hinge Arm
Trim Covers" under "Trim Covers" in this section.
Head Restraint Assembly

Base Level
PC2010-1010-F-RP
Figure 1O- Bladder Replacement
10. Seat pneumatic valve (55).

11. Seat cushion pneumatic mounting plate bolts/screws
(56), if necessary.
12. Seat cushion pneumatic mounting plate (57), if
necessary.

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.

section.
Seat cushion pneumatic mounting plate (57), if
necessary.
Seat cushion pneumatic mounting plate bolts/screws
(56), if necessary.
Seat pneumatic valve (55).
Seat pneumatic valve bolts/screws (54).
Seat inflator pump (53).
Seat inflator pump bolts/screws (52).
Seat pneumatic control module (51). Driver side
only.
Seat pneumatic control module bolts/screws (50).
Driver side only.
Electrical connectors.
Air supply hoses.
Figure 13
Tool Required:
J 39641 Headrest Removal Tool

1. Seatback release knob.
2. Separate I-retainers at bottom of seat and pull seat
cover past head restraint posts.
3. Slide J 39641 up head restraint posts with tool tabs
fitting into open slots between head restraint guide
tabs.
4. With headrest removal tools in place, rotate each
tool so head restraint guide tabs expand outward.
5. Head restraint (58).

2. Pull down on seat cover firmly to enable I-retainers
at the bottom of seat to lock together.
3. Seatback release knob.
Uplevel
Figure 13
Tool Required:
J 39641 Headrest Removal Tool

1. Seatback trim. Refer to "Uplevel Seat Trim" under
2. Cover retainer rings (43) and raise cover to access
guides (62).
50
51
52
53
54
55
56
57
BOLT/SCREW, DRIVER SEAT PNEUMATIC CONTROL MODULE

MODULE, DRIVER SEAT PNEUMATIC CONTROL
BOLT/SCREW, SEAT INFLATOR PUMP
PUMP, SEAT INFLATOR
BOLT/SCREW, SEAT PNEUMATIC VALVE
VALVE, SEAT PNEUMATIC
BOLT/SCREW, SEAT CUSHION PNEUMATIC MOUNTING PLATE
PLATE, SEAT CUSHION PNEUMATIC MOUNTING
PC2011-1010-F-RP
Figure 11 - Pump, Valve and Module
20
1.
2.
3.
4.
5.
20 PANEL, DRIVER SEAT CUSHION OUTER FINISH
25 SWITCH, DRIVER SEAT PNEUMATIC PUMP AND VALVE

section.
Head restrainer post retaining rings (64) to bottom of
posts.
Head restraint (61).
Cover retainer rings (43).
Seatback trim. Refer to "Uplevel Seat Trim" under
Seat shoulder belt guide (65 and 66) and bolts/
screws (60 and 63), if necessary.
Secure bolts/screws (60 and 63).
Front Seat Recliner Assembly

PC2012-1010-F-RP
Figure 12 - Seat Pneumatic Pump and Valve Switch
3. Head restraint post retaining rings (64) from bottom

of posts.
4. Slide J 39641 up head restraint posts with tool tabs
fitting into open slots between head restraint guide
tabs.
5. With headrest removal tools in place, rotate each
tool so head restraint guide tabs expand outward.
7. Bolts/screws (60 and 63) and seat shoulder belt
guide (65 and 66), if necessary.
Figure 14

1. Bolts/screws (23) attaching panel (20) to front seat
assembly.
2. Panel (20).
3. Seat cushion trim. Refer to "Seat Cushion Trim"
under "Trim Covers" in this section.
4. Pull seatback cover far enough forward to access
bolts/screws (68).
5. Bolts/screws (68) attaching recliner assembly (67)
to front seat assembly.
6. Recliner assembly (67).
65
60
=1:r~
61
66
f"59
59~
58
62
62
r7o/f:;_;
(TI:::,
I
\
I
1
I
I
I
I
I
I
'
62
J 39641
A BASE LEVEL
B UP LEVEL
43 RING, FRONT SEATBACK COVER RETAINER
58 RESTRAINT, SEAT HEAD
59 GUIDE, SEAT HEAD RESTRAINT
60 BOLT/SCREW, SEAT SHOULDER BELT GUIDE
61 RESTRAINT, SEAT HEAD
62 GUIDE, SEAT HEAD RESTRAINT
63 BOLT/SCREW, SEAT SHOULDER BELT GUIDE
64 RETAINING RINGS, HEAD RESTRAINT POST
65 GUIDE, SEAT SHOULDER BELT
66 GUIDE, SEAT SHOULDER BELT
PC2013-1010-F-RP
Figure 13 - Head Restraint Assemblies
70
A COVER ASSEMBLY, FRONT SEATBACK
20 PANEL, DRIVER SEAT CUSHION OUTER FINISH
23 BOLT/SCREW, DRIVER SEAT CUSHION OUTER FINISH PANEL
67 RECLINER ASSEMBLY, DRIVER/PASSENGER SEAT
68 BOLT/SCREW, DRIVER/PASSENGER SEAT RECLINER, 24 Nm
(18 LB. FT.)
69 FASTENER, DRIVER SEAT RECLINER HANDLE
70 HANDLE, DRIVER SEAT RECLINER
PC2014-1010-F-RP
Figure 14 - Removing Recliner Assembly (Typical)

section.
1. Recliner assembly (67) to front seat assembly.

2. Bolts/screws (68) attaching recliner assembly (67)
to front seat assembly.
l~I Tighten
3. Seatback cover to original position.
4. Seat cushion trim. Refer to "Seat Cushion Trim"
under "Trim Covers" in this section.
5. Panel (20) over recliner assembly (67).
6. Secure bolts/screws (23) through panel (20) to front
seat assembly.
B. Release recliner control handle, checking that

it returns to its original position and that seatback remains fully reclined.
C. Lift recliner control handle and pull seatback
forward to an intermediate reclined position.
D. Release recliner control handle.
E. Press seatback rearward to check that seatback
is locked and stays in position.
F. Lift recliner control handle and move seatback
to normal position, checking ease of recliner
control handle operation and seatback return.
G. Release recliner control handle.
H. Press seatback rearward to check that seatback
is locked and stays in position.
2. If recliner control does not operate correctly, remove
or replace. Refer to "Front Seat Recliner Assembly" in this section.
Manual Front Seat Adjuster Assembly
Recliner Assembly Control Check
Figure 15
ll'l'I Inspect
1. Recliner control
A. Lift recliner control handle and press seatback
rearward into fully-reclined position, checking
ease of recliner control handle operation and
seatback movement.

2. Bolts/screws (71 and 78) attaching adjuster assembly (75) to front seat assembly.
75
78
.f'
79
_.(
76

71 BOLT/SCREW, DRIVER SEAT OUTER ADJUSTER UPPER,
24 Nm (18 LB. FT.)
72 BOLT/SCREW, DRIVER SEAT INNER ADJUSTER UPPER,
24 Nm (18 LB. FT.)
73 SPACER, DRIVER SEAT OUTER ADJU~TER
74 FASTENER, DRIVER SEAT OUTER ADJUSTER SPACER
75 ADJUSTER ASSEMBLY, DRIVER SEAT 01.)TER
76 ADJUSTER ASSEMBLY, DRIVER SEAT INNER
77 SILENCER, DRIVER SEAT ADJUSTER RETURN SPRING
78 BOLT/SCREW, DRIVER SEAT OUTER ADJUSTER LOWER,
24 Nm (18 LB. FT.)
79 BOLT/SCREW, DRIVER SEAT INNER ADJUSTER LOWER,
24 Nm (18 LB. FT.)
PC20151010-F-RP
Figure 15 - Driver Seat Adjuster Assemblies (Manual)
4. Bolts/screws (72 and 79) attaching adjuster assembly (76) to front seat assembly.

section.
1. Adjuster assembly (76) to front seat assembly.
l~I Tighten
3. Adjuster assembly (75) to front seat assembly.
l~I Tighten
Driver Seat Adjuster and Drive Motor

Assemblies
Figures 16 and 17

2. Drive cables (86).
3. Nut (83) securing motor support (84) with motor
assemblies (85) attached.
4. Motor support (84) with motor assemblies (85)
attached.
7. Adjuster cover bolts/screws, if necessary.
8. Adjuster covers, if necessary.

A
83
89
B CONNECTOR, DRIVE CABLE
80 BOLT/SCREW, DRIVER SEAT ADJUSTER-TO-SEAT
FRAME, 24 Nm (18 LB. FT.)
81 ACTUATOR, DRIVER SEAT ADJUSTER HORIZONTAL
82 ADJUSTER ASSEMBLY, DRIVER SEAT
83 NUT, DRIVER SEAT ADJUSTER
84 SUPPORT, DRIVER SEAT ADJUSTER MOTOR
85 MOTOR ASSEMBLY, DRIVER SEAT ADJUSTER
86 CABLE, DRIVER SEAT ADJUSTER DRIVE
87 ACTUATOR, DRIVER SEAT ADJUSTER FRONT VERTICAL
88 SPRING, DRIVER SEAT VERTICAL ASSIST
89 ACTUATOR, DRIVER SEAT ADJUSTER REAR VERTICAL
PC2016-1010F-RP
Figure 16 - Driver Seat Adjuster Drive Motor Assembly
l+!+I Disassemble
CAUTION: Failure to place the power
adjuster assembly in a bench vise
before removing the rear vertical actuator will cause ejection of the compressed assist spring and possible
personal injury.
1. Rear adjuster nut (92).
A. Place adjuster assembly (82) in a bench vise
and remove rear adjuster nut (92).
B. Open vise slowly to relieve assist spring compression and remove adjuster assembly (82)
from vise.
2. Vertical assist spring (88).
3. Front adjuster nut (91 ).
4. Bolts/screws (90) from adjuster horizontal actuator
(81).
5. Adjuster horizontal actuator (81 ).
6. Adjuster bolts/screws (93).
7. Rear vertical actuator (89).
8. Front vertical actuator (87).
l+!+I Assemble
1. Front vertical actuator (87).
2. Rear vertical actuator (89).
3. Adjuster bolts/screws (93).
4. Adjuster horizontal actuator (81).

5. Bolts/screws (90) to adjuster horizontal actuator
(81).
6. Front adjuster nut (91).
7. Vertical assist spring (88).
8. Rear adjuster nut (92).
A. Place adjuster assembly (82) into a bench vise.
B. Carefully compress vertical assist spring (88)
and install rear adjuster nut (92).
C. Remove power adjuster assembly (45) from
bench vise.

section.
1. Adjuster covers, if removed.
2. Adjuster cover bolts/screws, if removed.
l~I Tighten
Adjuster cover bolts/screws to 1.7 Nm
(15 lb. in.).
l~I Tighten
attached.

6. Nut (83) securing motor support (84).
o---92
I
Motor Assemblies Replacement

3. Nut (83).
attached.
5. Electrical connectors from motor assemblies (85).
6. Motor assemblies (85) from motor support (84).
Grind off ends of grommet to separate motor
assemblies (85) from motor support (84).

1.
2.
3.
4.
5.
6.

section.
Motor assemblies (85) to motor support (84 ).
A. Drill out top end of grommet, using a 3/16-inch
drill bit.
B. Secure motor assemblies (85) to motor support
(84) with 3/16-inch rivets.
Electrical connectors to motor assemblies (85).
Motor support (84) with motor assemblies (85)
attached.
Nut (83).
Drive cables (86).
Front seat assembly. Refer to "Front Seat Assembly" in this section.
Passenger Seat Adjuster Assemblies

Figure 18

1. Seat assembly. Refer to "Front Seat Assembly" in
this section.
2. Bolts/screws (96 and 98) attaching adjuster assemblies (97 and 99) and covers (94 and 95) to seat
assembly (2).
3. Adjuster assemblies (97 and 99).
4. Covers (94 and 95).

section.
1. Covers (94 and 95).
2. Adjuster assemblies (97 and 99).
1
93
88
~93
81
87
88
89
90
91
92
93
ACTUATOR, DRIVER SEAT ADJUSTER HORIZONTAL

ACTUATOR, DRIVER SEAT ADJUSTER FRONT VERTICAL
SPRING, DRIVER SEAT VERTICAL ASSIST
ACTUATOR, DRIVER SEAT ADJUSTER REAR VERTICAL
NUT, DRIVER SEAT FRONT ADJUSTER
NUT, DRIVER SEAT REAR ADJUSTER
PC20171010FRP
Figure 17 - Adjuster Horizontal and Vertical Actuator
l~I Tighten
4. Seat assembly. Refer to "Front Seat Assembly" in
this section.

Figure 19

1. Driver seat assembly. Refer to "Front Seat Assembly" in this section.
2. Hinge arm trim cover. Refer to "Hinge Arm Trim
Cover" under "Trim Covers" in this section.
3. Connector (101) from adjuster assembly (24) by
releasing retainers (102).

1. Connector (101) to adjuster assembly (24) by reengaging retainers (102).
2. Hinge arm trim cover. Refer to "Hinge Arm Trim
Cover" under "Trim Covers" in this section.
3. Driver seat assembly. Refer to "Front Seat Assembly" in this section.
94
2 SEAT ASSEMBLY, PASSENGER

94 COVER, PASSENGER SEAT OUTER ADJUSTER
REAR TRIM
95 COVER, PASSENGER SEAT INNER ADJUSTER
REAR TRIM
96 BOLT/SCREW, PASSENGER SEAT OUTER ADJUSTER,
24 Nm (18 LB. FT.)
97 ADJUSJ"ER ASSEMBLY, PASSENGER SEAT OUTER
98 BOLT/SCREW, PASSENGER SEAT INNER ADJUSTER,
24 Nm (18 LB. FT.)
99 ADJUSTER ASSEMBLY, PASSENGER SEAT INNER
100 SPRING, PASSENGER SEAT ADJUSTER RETURN
PC2018-1010-F-RP
Figure 18 - Passenger Seat Adjuster Assemblies (Typical)

Adjustments
Figure20
With seat adjuster assembly installed, chucking or
jerking can be corrected by tightening or loosening the
horizontal actuator and pinion gear to the adjuster lower
track rack gear.
C. Using large screwdriver, apply 67 to 111 N

( 15 to 25 pounds) of outward pressure on
actuator (104). At same time, use horizontal
adjuster switch to move seat forward and backward to help seat horizontal actuator pinion
gear teeth tight to lower track rack gear teeth
and eliminate any free play.
D. While keeping pressure on actuator (104),
tighten bolt/screw (103) to 28 Nm (20 lb. ft.).
Adjust

section.
Actuator (104).
A. Operate seat assembly to full-up position and
about 3/4-forward position.
B. Loosen bolt/screw (103).
Power Front Seat Adjuster Assembly Phase
When one adjuster assembly reaches either maximum horizontal or maximum vertical travel before the
other, the adjuster assemblies are out of phase. Out-ofphase adjuster assemblies can occur over time or when the
seat assemblies are serviced.
ll'l'I Inspect
Horizontal travel.
2. Vertical phase.
A. Operate vertical adjuster switch until one
adjuster assembly reaches full-up position at
both front and rear.
B. Disconnect both front and rear vertical drive
cable assemblies from full-up adjuster
assemblies.
C. Operate vertical adjuster switch until other
adjuster assembly reaches full-up position at
both front and rear.
D. Connect vertical drive cable assemblies.
ll'l'I Inspect
Vertical travel.
Front Seat Adjuster Actuator Lever Knob

24
17 COVER, FRONT SEATBACK FRAME HINGE ARM TRIM
24 ADJUSTER ASSEMBLY, FRONT SEAT
101 CONNECTOR, FRONT SEAT ADJUSTER ELECTRICAL
102 RETAINER, FRONT SEAT ADJUSTER
PC20191010FRP
Figure 19 - Front Seat Adjuster Assembly (Power)
Figure21
The adjuster actuator lever knob fits over the end of
the adjuster actuator lever assembly that comes out from
the lower seat cushion assembly. The knob can generally
be removed and installed several times without becoming
too loose.

Knob ( 105) from adjuster actuator lever assembly.
A. Place protective covering over nearby trim.
B. Clamp locking pliers onto adjuster actuator
lever assembly.
C. Using body spoon, pry downward to remove
knob (105).
A SCREWDRIVER
103 BOLT/SCREW, DRIVER SEAT ADJUSTER ACTUATOR,
28 Nm (20 LB. FT.)
104 ACTUATOR, DRIVER SEAT ADJUSTER
PC20201010FRP
Figure 20 - Adjusting Seat Adjuster Actuator
l:eJ
Adjust
1. Horizontal phase.
A. Operate horizontal adjuster switch until one
adjuster reaches full-forward position.
B. Detach horizontal drive cable assembly from
full-forward adjuster assembly.
C. Operate horizontal adjuster switch until other
adjuster assembly reaches full-forward
position.
D. Connect horizontal drive cable assembly.
A
B
C
D
105
SPOON, BODY
COVERING, PROTECTIVE
PLIERS, LOCKING
LEVER ASSEMBLY, ADJUSTER ACTUATOR
KNOB, DRIVER/PASSENGER SEAT ADJUSTER
ACTUATOR LEVER
PC2021-1010fRP
Figure 21 - Adjuster Actuator Lever Knob

2. Seat cushion assembly (106) by pulling upward and
forward.

Knob (105) to adjuster actuator lever assembly.
A. Place protective covering over nearby trim.
B. Draw pencil line on adjuster actuator lever
assembly 25 mm (1 inch) from end as guide for
full-depth fit of knob (105).
C. Secure locking pliers to adjuster actuator lever
assembly and seat.
NOTICE: While installing the adjuster actuator
lever knob, take care not to bend the adjuster actuator lever assembly.
D. Insert knob (105) onto adjuster actuator lever
assembly.
Gate marks on knob ( 105) must face to
rear.
E. Press knob (105) firmly onto adjuster actuator
lever assembly.

vehicle.
4. Seat cushion assembly (106) from vehicle.
A. Remove seat cushion assembly (106) through
rear compartment lift window, being careful
not to damage rear seatback.
B. Remove protective shield.

section.
vehicle.
REAR SEAT ASSEMBLY
2. Seat cushion assembly (106) into vehicle.
Rear Seat Cushion Assembly
A. Load seat cushion assembly (106) through rear

compartment lift window, being careful not to
dent rear seatback.
Figure22

3. Seat cushion assembly (106) by pushing rearward.
A ANCHOR WIRE LOOP

106 CUSHION ASSEMBLY, REAR SEAT
107 BOLT/SCREW, REAR SEAT CUSHION
7v-
Figure 22 - Rear Seat Cushion Assembly
PC20221010F-RP
SEATS AND CARPET 101021

4. Bolt/screw ( 107) through anchor wire loop in hole in
floor pan assembly.
l~I
l++l
Tighten
Rear Seatback Cushion Assembly

Figure23
l++I
1.
2.
1. Rear seat cushion assembly. Refer to "Rear Seat

Cushion Assembly" in this section.
2. Shoulder restraint guide. Refer to "Shoulder
Restraint Guide" in this section.
3. Lock assembly (109) from striker (108).
4. Nuts (111) from rear seatback cushion studs.
5. Seat studs from outer pivot supports by lifting
upward on outboard side of cushion assembly (110).
NOTICE: Failure to place protective shield over
nearby trim and paint may cause damage to vehicle.
7. Cushion assembly (110) from vehicle.
A. Remove cushion assembly (110) through rear
compartment lift window, being careful not to
damage front seat assemblies.
3.
4.
5.
6.
lnstall or Connect

section.
NOTICE: Failure to place protective shield over
nearby trim and paint may cause damage to vehicle.
Protective shield over nearby trim and paint.
Cushion assembly ( 110) into vehicle.
Load cushion assembly (110) through rear
compartment window.
Remove protective shield.
Seat studs into outer pivot supports.
Nuts (111) to seat studs loosely.
Lock assembly (109) to striker (108).
l~I
Tighten
Nuts (111) to 24 Nm (18 lb. ft.).

Restraint Guide" in the following procedure.
Shoulder Restraint Guide

Figure24

1. Bolts/screws (113) attaching guide (112) to rear
seatback cushion assembly.
2. Guide (112).

section.
L Guide (112) to rear seatback cushion assembly.
l~I
Tighten
A SUPPORT, OUTER PIVOT

B
108
109
110
111
STUD, REAR SEATBACK CUSHION

STRIKER, REAR SEATBACK
LOCK ASSEMBLY, REAR SEATBACK
CUSHION ASSEMBLY, REAR SEATBACK
NUT, FOLDING REAR SEATBACK CUSHION PIVOT,
24 Nm (18 LB. FT.)
112 GUIDE, REAR SEAT BELT SHOULDER RESTRAINT
113 BOLT/SCREW, REAR SEAT BELT SHOULDER RESTRAINT
GUIDE, 10 Nm (89 LB. IN.)
PC2023-1010FRP
Figure 23 - Rear Seatback Cushion Assembly
PC2024-1010-F-RP
Figure 24 - Shoulder Restraint Guide
Rear Trim and Covers

The rear seat cushion and seatback cushion assemblies have formed foam pads that fit the contour of the seat
frames. The seat covers are either cloth or leather. They
are held on to the seat assembly with trim retainer rings,
bolster wires and zippers. A shoulder restraint guide is
attached to the outboard sides of the seat assemblies with
bolts/screws.
Seat Cushion Cover
Figure25

1. Rear seat cushion assembly from vehicle. Refer to
"Rear Seat Cushion Assembly" in this section.
2. Rings ( 116) on bottom of seat cushion assembly.
A. Note position ofrings (116).
B. Pull cushion cover (114) away from foam pad

to expose wire assemblies (115).
3. Remaining rings (116).
Note position ofrings (116).
4. Wire assemblies (115) from pad wires.
5. Cushion cover (114).
A
B
114
115
116

1. Turn cushion cover (114) inside out.
WIRE, PAD
POCKET
COVER,REARSEATCUSHION
WIRE ASSEMBLY, REAR SEAT CUSHION BOLSTER
RING, REAR SEAT CUSHION TRIM RETAINER
2. If installing replacement cushion cover ( 114),

remove wire assemblies ( 115) from old seat cushion
cover pockets and slide wire assemblies (115) into
replacement seat cushion cover pockets.
PC2025-1010f-RP
3. Wire assemblies (115) to pad wires.

4. Rings (116) where old rings (116) were removed.
Figure 25 - Rear Seat Cushion Cover
5. Cushion cover (114) over pad by turning cushion

cover ( 114) right side out.
6. Rings (116) where old rings (116) were removed
from bottom of seat cushion assembly.
7. Rear seat cushion assembly to vehicle. Refer to
"Rear Seat Cushion Assembly" in this section.

1. Rear seatback cover (117).
Rear Seatback Cover

Figures 26 and 27
3. Seatback lock assemblies. Refer to "Seatback Lock

Assembly and Striker" in this section.

1. Rear seatback from vehicle. Refer to "Rear Seatback Cushion Assembly" in this section.
2. Seatback lock assemblies. Refer to "Seatback Lock
Assembly and Striker" in this section.
3. Shoulder restraint guide. Refer to
4. Rear seatback cover ( 117).
"Shoulder
4. Rear seatback to the vehicle. Refer to "Rear Seatback Cushion Assembly" in this section.
Seatback Lock Assembly and Striker

The rear seat assembly folds down to provide additional storage space in the rear of the vehicle. The seatback lock assemblies are located on the outboard sides of
the seat assembly. The strikers are located on the wheelhouse panel assemblies.
A J-RETAINERS
117 COVER, REAR SEATBACK
118 PAD, REAR SEATBACK
PC2026-1010-F-RP
Figure 26 - Rear Seatback Cover Bottom Attachment
119
117
110 CUSHION ASSEMBLY, REAR SEATBACK
120 LOCK ASSEMBLY, REAR SEATBACK
121 BOLT/SCREW, REAR SEATBACK LOCK, 27 Nm
(20 LB. FT.)
122 WASHER, REAR SEATBACK LOCK
PC20281010-F-RP
Figure 28 - Rear Seatback Lock Assembly
117 COVER, REAR SEATBACK

118 PAD, REAR SEATBACK
119 PANEL, FOLDING REAR SEATBACK
PC2027 -1010-F-RP
Figure 27 - Rear Seatback Cover
l~I Tighten
3. Rear seatback cushion assembly. Refer to "Rear
Seatback Cushion Assembly" in this section.
Seatback Lock Assembly

Rear Seatback Lock Striker
Figure28

2. Rear seatback cushion assembly. Refer to "Rear
Seatback Cushion Assembly" in this section.
4. Lock assembly (120) and washer (122).

section.
1. Washer (122) and lock assembly (120).
Figure29

Bolt/screw (125), sleeve (124) and washer (123).

section.
1. Washer (123) and sleeve (124) over bolt/screw
(125).
l~I Tighten
A CONNECTOR, SEAT BELT ALARM ELECTRICAL

B CONNECTOR, DRIVER/PASSENGER SEAT WIRING
ELECTRICAL
C CONNECTOR, POWER SEAT ADJUSTER ELECTRICAL
126 CARPET ASSEMBLY, FLOOR
PC2030-1010-F-RP
Figure 30 - Floor Carpet Assembly

123 WASHER, FOLDING SEATBACK LOCK STRIKER
124 SLEEVE, FOLDING REAR SEATBACK CUSHION
LOCK STRIKER
125 BOLT/SCREW, FOLDING REAR SEATBACK CUSHION
LOCK STRIKER, 48 Nm (35 LB. FT.)
PC2029-1010F-RP
Figure 29 - Folding Rear Seatback Lock Assembly
FLOOR CARPET ASSEMBLY

Figure30
Floor carpet assemblies have been designed for the
high floor pan temperatures caused by the catalytic converter in the exhaust system. When servicing a vehicle in
the field, it is essential that any floor pan carpet assemblies that have been disturbed or removed be reinstalled in
the original sequence and location.
CAUTION: Any carpet service repair or
replacement should be the same thickness, size and location as the original
installation in the vehicle or vehicle
damage and personal injury could
result.
When servicing or replacing interior carpets, the
following instructions must be observed
Carpets must be installed in the original position and
sequence. Pieces should be butted together to avoid
gapping or overlapping.
If it is necessary to replace a carpet, specified material must be used.
Use original part to determine the amount of
replacement material and as a template for cutting
and fitting new piece to floor pan assembly.
When installing a carpet, do not enlarge cutouts or
holes used for attachment of interior components
such as seat assemblies or seat belt assemblies.
Spray-on deadeners and trim adhesives should not

be applied to the top of the floor pan assembly at the
area directly over the Three Way+ Oxidation catalytic converter or muffler assembly.

2. Rear seat assembly. Refer to "Rear Seat Assembly"
in this section.
3. Front seatbelt assemblies. Refer to SECTION 10-11.
4. Rear seatbelt assemblies. Refer to SECTION 10-11.
5. Body hinge pillar trim panels. Refer to SECTION
10-5.
8C.
8. Floor carpet assembly (126).

1. Floor carpet assembly (126).
8C.
4. Body hinge pillar trim panels. Refer to SECTION
10-5.
5. Rear seatbelt assemblies. Refer to SECTION 10-11.
6. Front seatbelt assemblies. Refer to SECTION 10-11.
7. Rear seat assembly. Refer to "Rear Seat Assembly"
in this section.
SPECIFICATIONS
Driver Seat Adjuster Bolt/Screw .......................................
Driver Seat Inner Adjuster Lower Bolt/Screw .............................
Driver Seat Inner Adjuster Upper Bolt/Screw .............................
Driver Seat Outer Adjuster Lower Bol.t/Screw .............................
Driver Seat Outer Adjuster Upper Bolt/Screw .............................
Driver/Passenger Seat Adjuster Actuator Bolt/Screw .......................
Driver/Passenger Seat Adjuster Nut .....................................
Driver/Passenger Seat Recliner Bolt/Screw ...............................
Folding Rear Seatback Cushion Lock Striker Bolt/Screw ....................
Folding Rear Seatback Cushion Pivot Nut ................................
Front Seatback Hinge Arm Bolt/Screw (Front) ............................
Front Seatback Hinge Arm Bolt/Screw (Rear) .............................
Passenger Seat Inner Adjuster Bolt/Screw ................................
Passenger Seat Outer Adjuster Bolt/Screw ................................
Rear Seatback Lock Bolt/Screw ........................................
Rear Seat Belt Shoulder Restraint Guide Bolt/Screw ........................
Rear Seat Cushion Bolt/Screw .........................................
24 Nm (18 lb. ft.)

24 Nm (18 lb. ft.)
24 Nm (18 lb. ft.)
24 Nm (18 lb. ft.)
24 Nm (18 lb. ft.)
28 Nm (20 lb. ft.)
24 Nm (18 lb. ft.)
24 Nm (18 lb. ft.)
48 Nm (35 lb. ft.)
24 Nm (18 lb. ft.)
24 Nm (18 lb. ft.)
24 Nm (18 lb. ft.)
24 Nm (18 lb. ft.)
24 Nm (18 lb. ft.)
27 Nm (20 lb. ft.)
10 Nm (89 lb. in.)
24 Nm (18 lb. ft.)
SPECIAL TOOLS
1.
1. HEADREST REMOVAL TOOL
J 39641
PC2031-1010-F-RP
SEAT BELTS 10-111
SECTION 10-11
SEAT BELTS
CAUTION: Replace belts, retractors, and hardware in use during all but a minor collision.
Also, restraint systems should be replaced and anchorages properly repaired if they were in
areas damaged by a collision, whether the belt was in use or not. If there is any question,
replace the belt system. Damage, whether visible or not, could result in serious personal
injury in the event of an accident.
result.
CONTENTS
General Description . . . . . . . . . . . . . . . . . . . . . .
Front Seat Belt Assemblies . . . . . . . . . . . . . .
Rear Seat Belt Assemblies . . . . . . . . . . . . . . .
On-Vehicle Service . . . . . . . . . . . . . . . . . . . . . .
Operational and Functional Checks . . . . . . . .
Service Precautions . . . . . . . . . . . . . . . . . .
Front Seat Belt Assemblies . . . . . . . . . . . . . .
Front Driver and Passenger Seat
Buckle-Side Belt Assemblies . . . . . . . . .
Retractor-Side Belt Assemblies . . . . . . .
10-11-1
10-11-1
10-11-1
10-11-1
10-11-1
10-11-2
10-11-2
10-11-2
Rear Seat Belt Assemblies . . . . . . . . . . . . . . .

Rear Seat Outer-Side Belt Assemblies . . .
Center Belt Assemblies . . . . . . . . . . . . . . .
Child Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Child Seat Top-Tether
Anchor Bracket (U.S. Vehicles) .......
Child Seat Top-Tether
Anchor Bracket (Canadian Vehicles) ...
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fastener Tightening Specifications . . . . . . . .
10-11-3
10-11-3
10-11-4
10-11-4
10-11-4
10-11-6
10-11-7
10-11-7
10-11-2
GENERAL DESCRIPTION
FRONT SEAT BELT ASSEMBLIES
The front seat belt system includes front seat retractor-side belt assemblies. The front seat belt assemblies are
attached to the floor. The shoulder retractors are attached
near the rear window panel assembly.
Special care must be taken when servicing the front
seat belt assemblies. Front seat belt assemblies must be
serviced as complete sets. The driver and passenger
retractor-side belt assemblies may be serviced individually. Do not attempt to make repairs to these units. The
entire seat belt assembly must be replaced with a new service replacement part.
The driver's seat belt assembly includes a reminder
lamp and tone alarm to warn the driver that the driver seat
belt assembly is not buckled when the ignition switch is
turned "ON." If the driver's seat belt assembly is
buckled, the tone alarm 'Nill not operate, but the reminder
lamp will stay on for 4 to 8 seconds.
If the driver's seat belt assembly is not buckled, both
the tone alarm and the reminder lamp will operate and
stay on for 4 to 8 seconds. To diagnose a system failure for
the seat belt and ignition key and lamps and turn signal
alarm assembly (tone alarm) or the seat belt indicator
assembly (reminder lamp) refer to SECTION 8A.
REAR SEAT BELT ASSEMBLIES

The rear seat belt system includes rear seat retractorside belt assemblies. Special care must be taken when
servicing the rear seat belt assemblies. Rear seat belt
assemblies must be serviced as complete sets. The rear
seat retractor-side belt assemblies may be serviced individually. Do not attempt to make repairs to these units.
The entire seat belt assembly must be replaced with a new
service replacement part.
ON-VEHICLE SERVICE
OPERATIONAL AND FUNCTIONAL CHECKS
1. Grasp seat belt floor attachments and manually
check that attachments are secure.
2. Visually check that shoulder belt buckles face
inboard and are accessible.
3. Grasp retractor units and manually check that
attachments are secure.
4. Fully extend shoulder belt and visually check that no
twists are in it.
5. Allow shoulder belt to retract.
6. Grasp shoulder belt latch and extend completely,
checking that it extends easily.
7. Snap shoulder belt latch into buckle.
8. Tug sharply on buckle, checking that it remains
locked.
10112 SEAT BELTS

9. Push button on buckle. Latch must release from
buckle easily and button return to its original position.
Service Precautions

section.
Keep sharp edges and damaging objects away from
seat belt assemblies.
Avoid bending or damaging any part of the belt
buckle or latch plate.
Do not bleach or dye seat belt webbing. Clean only
with a mild soap solution and water.
Use correct seat belt anchor bolts/screws and tighten
to the correct torque value.
FRONT SEAT BELT ASSEMBLIES

Buckle-Side Belt Assemblies
3. Plug (2) from bolt/screw (3).

4. Bolt/screw (3) attaching belt assembly (1) to floor
pan assembly.
5. Belt assembly ( 1).

section.
1. Belt assembly (1 ).
2. Bolt/screw (3) attaching belt assembly (1) to floor
pan assembly.
l~I Tighten
3. Plug (2) to bolt/screw (3).
4. Driver side seat belt warning electrical connector.
5. Front seat cushion assembly. Refer to SECTION
10-10.
Figure 1
Driver seat buckle-side belt assembly is shown, passenger seat buckle-side belt assembly is similar.

Retractor-Side Belt Assemblies
Figures 2 and 3
1. Front seat cushion assembly, if necessary. Refer to

SECTION 10-10.
2. Driver side seat belt warning electrical connector.

1. Plug (4) from bolt/screw (5)
2. Bolt/screw (5) attaching plate to rocker panel assembly.
3. Plate.
4. Pull webbing and plate out of shoulder belt guide.
5. Lower rear portion of headliner finishing trim panel.
-...... ~.
.,.:
........
,.-
A
,,,
,,,
,
,,'
.:.:-"'",...
r' . .
..
..,.
\,
A CONNECTOR, DRIVER SIDE SEATBELT WARNING

ELECTRICAL
1 BELT ASSEMBLY, DRIVER SEAT BUCKLE-SIDE
2 PLUG, DRIVER SEAT BUCKLE-SIDE BELT SLEEVE
3 BOLT/SCREW, DRIVER SEAT BUCKLE-SIDE BELT
PC0001-1011-F-RP
Figure 1 - Front Driver and Passenger Seat

Buckle-Side Belt Assemblies
. A PLATE, FRONT SEATBELT ANCHOR

4 PLUG, PASSENGER SEAT RETRACTOR-SIDE BELT
SLEEVE
5 BOLT/SCREW, FRONT SEAT BELT ANCHOR PLATE
7 BELT ASSEMBLY, FRONT SEAT RETRACTOR-SIDE
PC0002-1011fRP
Figure 2 - Front Seat Belt Anchor Plate

(Passenger Side Shown - Driver Side Similar)
SEAT BELTS 10-113

5. Plate to rocker panel assembly.
6. Bolt/screw (5).
l~I
Tighten

7. Plug (4) to bolt/screw (5).
REAR SEAT BELT ASSEMBLIES

Rear Seat Outer-Side Belt Assemblies
Figure 4
l++I
1. Quarter inner rear trim finish panel assembly. Refer
2.
3.
4.
8
5.
6.
7 BELT ASSEMBLY, PASSENGER SEAT RETRACTOR-SIDE

8 BOLT/SCREW, PASSENGER SEAT SHOULDER BELT
PC0003 1011-FRP
Figure 3 - Front Seat Retractor Side Belt Assembly

(Passenger Side Shown - Driver Side Similar)
l++I
to SECTION 10-7.
Rear seat cushion assembly. Refer to SECTION
10-10.
Nut ( 16) attaching rear seat shoulder belt retractor to
inner wheelhouse panel assembly (28).
Bolts/screws (14) attaching rear seat shoulder belt
guide (13) to rear seatback cushion assembly (17).
Bolt/screw (9) and spacer (11) attaching belt assembly (10) to floor panel assembly (19).
Belt assembly (10) from vehicle.
Install or Connect

section.
1. Belt assembly anchor plate to floor panel assembly
(19).
2. Bolt/screw (9) through belt assembly anchor plate
and spacer (11) to floor panel assembly (19).
l~I
6. Bolts/screws (8) attaching belt assembly (7) to rear
roof panel assembly.
7. Belt assembly (7) from rear roof panel assembly.
l++l
111stall or Connect

section.
1. Belt assembly (7) to rear roof panel assembly.
l~I
Tighten

3. Raise rear portion of headliner finishing trim panel
back into position. Refer to SECTION 10-9.
4. Route webbing and plate through shoulder belt
guide.
Tighten

3. Shoulder belt guide (13) to rear seatback cushion
assembly (17).
l~I
Tighten

5. Belt retractor assembly to inner wheelhouse panel
assembly (28).
6. Nut (16).
l~I
Tighten
Nut (16) to 55 Nm (41 lb. ft.).

7. Rear seat cushion assembly. Refer to SECTION
10-10.
10-11-4 SEAT BELTS
14

10-10.
15
CHILD SEAT
If a child seat that requires a top strap is to be used in
a rear seat position, a special dealer-installed anchor
bracket must be used to anchor the child seat top-tether to
the rear compartment front panel on Canadian vehicles, or
the rear compartment rear panel on U.S. vehicles. To
ensure the correct child seat top-tether angle, the child
seat must only be used in the seating position for which
the anchor bracket is installed.
Child Seat Top-Tether Anchor Bracket (U.S.

Vehicles)
12
Figure 5
If an anchor bracket (21) is being installed for the
first time, use the following procedure.
Top-Tether Anchor Bracket Initial Installation

section.
9 BOLT/SCREW, REAR SEAT SHOULDER BELT

10 BELT ASSEMBLY, REAR SEAT OUTER SIDE
11 SPACER, REAR SEAT BELT ANCHOR PLATE
12 CUSHION ASSEMBLY, REAR SEAT
13 GUIDE, REAR SEAT SHOULDER BELT
14 BOLT/SCREW, REAR SEAT SHOULDER BELT GUIDE
15 ESCUTCHEON, QUARTER LOWER TRIM FINISH PANEL
REAR SEAT BELT
16 NUT, REAR SEAT SHOULDER BELT RETRACTOR
17 CUSHION ASSEMBLY, REAR SEATBACK
18 BELT ASSEMBLY, CENTER
19 PANEL ASSEMBLY, FLOOR
27 BOLT/SCREW, CENTER BELT
28 PANEL ASSEMBLY, INNER WHEELHOUSE
PC0004-1011-F-RP
Important
1.
2.
3.
Figure 4 - Rear Seat Outer-Side and Center Belt Assemblies
Center Belt Assemblies

Figure 4

10-10.
2. Bolt/screw (27) attaching belt assembly ( 18) to floor
3. Belt assembly (18).

section.
1. Belt assembly (18).
2. Bolt/screw (27).
l~I Tighten
4.
5.
This procedure is not to be used for Canadian

vehicles.
Depending on whether or not vehicle has roof liftoff window assemblies or not, make proper paper or
cardboard template as shown in Figure 5.
Center template on rear compartment rear panel. If it
does not fit exactly, make certain that proper end is
facing front of vehicle.
Using one of two hole-position marks on template,
depending on which side of vehicle child restraint is
to be installed, make a dimple in rear compartment
rear panel sheet metal using a center punch.
From underneath vehicle, make sure there is clearance for washer (23) to be installed at this location.
From inside vehicle, make sure there is clearance to
install anchor bracket (21 ).
[el Adjust
Location as needed to provide clearance for
parts and mark new location using center
punch.
6. Using 9 mm (3/8-inch) drill bit, drill hole at centerpunched location through floor carpet assembly and
rear compartment rear panel.
CAUTION: All bolt/screw holes to the
exterior of the vehicle must be sealed
completely to prevent carbon monoxide from entering the vehicle. Breathing
carbon monoxide can cause carbon
monoxide poisoning and may be fatal.
7. Install anchor bracket (21), bolt/screw (20), gasket
sealer (22), washer (23), and nut (24).
SEAT BELTS 10115
104mm
(4.1")
A LOCALLY F
B LIFT-OFF p~RICATED TEMPL
20 ~OOCALLY FAB~~tASSEMBLIES ATE, WITH ROOF
LT/SCREW
TED TEMP
:; ~NC HOR BRA!K~P-TETHER Al:'~ HARDTOP
23 WASKET SEALER T, TOP-TETHER OR BRACKET
24
ASHER TOP , TOP-TETHER

NUT, TOP-TETH~E:1ER ANCH0:~~10R BRACKET
NCHOR BRAC KETCKET
_ _ _P_COOOS-1011-F-RP
.
Figure 5 - Child Seat Top-Tether Anchor Bracket (U S Vehicles)
10-11-6 SEAT BELTS
rn
Important
Do not use a nut driver to tighten this hardware, or fasteners will not be properly seated.
l~I
Tighten
Bolt/screw (20) and nut (24) until fully seated,

but not stripped.
Top-Tether Anchor Bracket Replacement

CAUTION: All bolt/screw holes to the
exterior of the vehicle must be sealed
completely to prevent carbon monoxide from entering the vehicle. Breathing
carbon monoxide can cause carbon
monoxide poisoning and may be fatal.
If the anchor bracket (21) becomes damaged, it must
be replaced.
l++I
.,,,,.,.....,...
260mm
(10.2")
/::_}];{
--- .............I I_
140 mm (5.5")
R.H. SIDE
85 mm (3.3")
L.H. SIDE
17 mm
(0.67")
1. Nut (24), washer (23), gasket sealer (22), bolt/screw

(20), and anchor bracket (21 ).
2. Seal hole in rear compartment rear panel if permanently removing anchor bracket (21).
l++I
Install or Connect

section.
Anchor bracket (21 ), bolt/screw (20), gasket sealer
(22), washer (23), and nut (24).
rn
Important
l~I
Tighten
Bolt/screw (20) and nut (24) until fully seated,

but not stripped.
Child Seat Top-Tether Anchor Bracket

(Canadian Vehicles)
Figure 6
All Canadian vehicles are equipped with drilled and
tapped plates welded to the rear compartment front panel.
These plates serve as mounting points for child seat toptether anchor brackets (25).
If an anchor bracket (21) is being installed for the
first time, use the following procedure.
A CUT "H" PATTERN ONLY WHERE INDICATED BY

DOTTED LINE
B MOUNTING PLATE, ANCHOR BRACKET
25 BRACKET, TOP-TETHER ANCHOR
26 BOLT/SCREW, TOP-TETHER ANCHOR BRACKET
Top-Tether Anchor Bracket Initial Installation
l++I
Install or Connect

section.
PCOOOS-1011-F-RP
Figure 6 - Child Seat Top-Tether Anchor Bracket (Canadian

Vehicles)
SEAT BELTS 10-11-7
l~I
[I] Important
Tighten
This procedure is not to be used for U.S.

vehicles.
Bolts/screws (26) until fully seated, but not

stripped.
If the child seat is to be installed in the driver

side rear seat, be sure to use the proper locating
dimensions.
Top-Tether Anchor Bracket Replacement

If the anchor bracket (25) becomes damaged, it must
be replaced.
1. Behind the rear seatback cushion assembly, measure

about 260 mm (10.2 inches) rearward from edge of
rear compartment front panel and 140 mm (5.5
inches) inward from right side quarter trim finishing
panel, or 85 mm (3.3 inches) from left side quarter
trim finishing panel, to locate a depression under the
floor carpet assembly in this area.
2. Use this depression as a guide to make an "H" pattern cut in the floor carpet assembly, as shown in
Figure 6.
3. Peel back floor carpet assembly to expose anchor
bracket mounting plate.
4. Position anchor bracket (25) to anchor bracket
mounting plate.

2. Anchor bracket (25).

section.
1. Anchor bracket (25) to anchor bracket mounting
plate.
Important
l~I
[I] Important
Tighten
Bolts/screws (26) until fully seated, but not

stripped.
SPECIFICATIONS
Driver/Passenger Seat Buckle-Side Belt Sleeve Bolt/Screw ..................
Driver/Passenger Seat Shoulder Belt Bolt/Screw ...........................
Front Seat Belt Anchor Plate Bolt/Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rear Seat Center Belt Bolt/Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rear Seat Shoulder Belt Bolt/Screw .....................................
Rear Seat Shoulder Belt Guide Bolt/Screw ...............................
Rear Seat Shoulder Belt Retractor Nut ...................................
42 Nm (31 lb. ft.)

24 Nm (18 lb. ft.)
42 N m (31 lb. ft.)
42 N m (31 lb. ft.)
42 Nm (31 lb. ft.)
10 Nm (89 lb. in.)
55 Nm (41 lb. ft.)
STRUCTURAL BODY REPAIR AND DIMENSIONS 11-1
SECTION 11
STRUCTURAL BODY REPAIR

AND DIMENSIONS
CONTENTS
Panel Identification (1) . . . . . . . . . . . . . . . . . . . . . . 11-2
Radiator Support Assembly (2) ................ 11-4
Upper Rail (3) ............................. 11-5
Engine Compartment
Front Outer Side Rail .................... 11-5
Front Wheelhouse Panel
Upper Side Rail Assembly ................ 11-8
LowerRail(4) ............................ 11-12
Front Wheelhouse Assembly (5) .............. 11-13
Side Door Opening Frame (6) ................

Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Sectioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Door Service (7) . . . . . . . . . . . . . . . . . . . . . . . . . . .
Door Outer Panel Replacement .............
Roof Outer Panel (8) .......................
Windshield Replacement (9) .................
Quarter Panel Assembly (10) .................
Body Dimensions (11) ......................
11~16
11-16
11-18
11-21
11-21
11-23
11-25
11-26
11-30
112 STRUCTURAL BODY REPAIR AND DIMENSIONS
PANEL IDENTIFICATION
RRIM URETHANE
INTEGRATED STEEL PARTS
GALVANIZED METAL
~-----------~
RADIATOR SUPPORT ASSEMBLY

The radiator support
assembly consists of
eight pieces:
four upper, two sides
(left and right) and two
lower (Figure 2-1 ).
Relacement of the
radiator support assembly has been noticably
improved over past
vehicle models. Virtually
all attaching surfaces are
easily accessible for
service, which makes
replacment much less
complicated, as well as
economical.
The radiator support is
available as an entire unit
including all brackets and
reinforcements. Note:
the lower outer support
is serviced separately
(Figure 2-2). In addition,
the lower left , right and
inner support are also
available separately
(Figure 2-1 ).
Figure 2-1.
Radiator
SuPf)ort
Assembly
(Exploded View)
Figure 2-2.
Radiator
SuPf>ort
Assembly and
Lower Outer
SuPf>ort
STRUCTURAL BODY REPAIR AND DIMENSIONS 115
ENGINE COMPARTMENT FRONT OUTER SIDE RAIL

Before attempting to remove the engine compartment front outer side rail, visually inspect
the damage and restore as much of the damage as possible to factory specifications. The
engine compartment front outer side rail is attached to the front wheelhouse panel upper
side rail assembly with spot welds.To remove the outer side rail, the spot welds must be
drilled out. On the service part outer side rail, plug weld holes are not included. They must be
drilled in the same location as the original spot welds.
Remove front fender
assembly, hood
assembly and hood
hinge assembly.
Figure 3-1.
Note number and

location of welds for
installation of new
outer side rail.
Drilling Plug
Welds
Drill out all related

factory welds
(Figure 3-1 ).
Remove outer
side rail.
Remove air baffle
material from side
rail assembly
(Figure 3-2).
Remove sealant from
side rail assembly, as
necessary.
Figure 3-2.
Removing Air
Baffle Material
A AIR BAFFLE
Install or Connect
Position the new outer
side rail to side rail
assembly and clamp
in place.
(Continued)
Mark seven formed
and pierced locations
from the side rail
assembly to the new
outer side rail.
Figure 3-3.
Marking Hole
Locations
Mark the hood hinge

hole locations
(Figure 3-3).
Remove clamps and
outer side rail.
Drill I /8-inch holes in
marked locations on the
new outer side rail at
formed and pierced
locations (Figure 3-4).
Drill two 3/8-inch holes
at hood hinge hole
Figure 3-4.
Hole Size
and Locations
Drill 5/ 16-inch holes

3/4-inch fore and aft of
seven formed and
pierced locations
(Figure 3-4).
HOOD HINGE HOLES
Drill 5/ I 6-inch holes on

remaining locations as
noted from old outer
side rail (Figure 3-4).
If the angina/ outer side rail is
damaged beyond recognition,
place holes for welding 1-112
inches apart.
Install J-clips included

with rail, GM P/N
I 0079 I 70, at five
formed and pierced
Two formed and pierced locations
at hood hinge mounting panel do
not require )-Clips.
~
I
~-o
o o o~!.,_=:::::="::::::::==-:=:::::::::
Figure 3-5.
Installing }-Clips
ENGINE COMPARTMENT FRONT OUTER SIDE RAIL
Install or Connect (Continued)

Position the new outer
-.. . . . .~
.::::::,,.,__
side rail in place,
~ ~--::::::-,....., - - ~
0
0
insert locating tab
o -~ 0
'B,....-1
through slot (Figure 3-6).~------=-o-.-.-;o,~on-"cioiiJfVr--,:,,.-o~c Figure 3-6.
~_;;__.
c--:-:--- .. ..._ Installing Outer
Install fender mounting
Side Rail
(~
I'
bolts/screws included
0
0
0
0
......11
with rail, GM P/N
~
)Jr)'"=
<....o
.--~
I I 505023, at five J-clips
\ I
.
.Jl:~-.'-... - - ~ / \/ )
-~I
I
to secure outer side

rail in place.
FRl
.,,\\/\
/
) \
fir
---=:::::::.::.-..
_A,
MEASURE
Refer to service manual for
proper dimensions.
Discard original two

spacers on hood hinge
bracket bolt/screw
replace with four washers provided, one on
each side of rail for each
stud. Install hood hinge
bracket upside down,
washers and bolts/
screws to outer side rail
at hood hinge mounting
panel (Figure 3-7).
Figure 3-7.
Installing Hood
Hinge Bracket
A SERVICE KIT WASHERS
Using MIG welder,

randomly plug weld
new outer side rail in
place (Figure 3-8).
IMPORTANT
Be sure to measure continually
throughout welding process to
maintain correct dimensions.
Clean and prepare

welded surfaces. Apply
3M Brushable Seam
Sealer, part number
08655 or equivalent,
as necessary.
Figure 3-8.
Welding Outer
Side Rail
11-8 STRUCTURAL BODY REPAIR AND DIMENSIONS

Apply Convenience
Products ozone safe
Reddy Insulation
foam or equivalant
to replace air
baffle material.
Refinish according to
paint manufacturer's
recommendations.
Apply anticorrosion
material, as necessary.
Install hood hinge
assembly, hood
assembly and front
fender assembly.
FRONT WHEELHOUSE PANEL

UPPER SIDE RAIL ASSEMBLY
When replacing the upper side rail assembly, it will be necessary to cut a section of the
damaged side rail assembly away and section a new side rail assembly in its' place. Removal
of the side rail assembly requires the use of a template to help in determining the location
of the cut to be made.
Outer side rail. Refer to
''Engine Compartment
Front Outer Side Rail".
Position template
included with rail to
side rail assembly at
forward edge where
indicated by arrows and
scribe line onto side rail
assembly where shown
(Figure 3-9).
Figure 3-9.
Scribing Line
on Inner
Side Rail

Remove or Disconnect (Continued)

cowl panel.
Drill out welds at cowl
panel only. Remaining welds will
hold side rail assembly in
place while cutting.
Figure 3-10.
Separating
Inner Side
Rail Assembly
from Cowl
Separate side rail

assembly away from
cowl panel (Figure 3-10).
Cut side rail assembly
at scribed lines, being
careful not to cut
adjacent panels
(Figure 3-1 I).
Figure 3-11.
Cutting Inner
Side Rail
Assembly
Note number and

location of remaining
welds for installation of
new side rail assembly.
Remove side rail

assembly (Figure 3-12).
Figure 3-12.
Removing
Inner Side Rail
Assembly
Install or Connect
Prepare mating surfaces
for proper fit of new side
rail assembly.
Clean sealer away from
mating surfaces, as
necessary (Figure 3-1 3).
Figure 3-13.
Preparing
Mating Surface
(Continued)
On new side rail
assembly, drill 5/ I 6-inch
holes in remaining
locations as noted
from original side
rail assembly.
If original side rail assembly is
damaged beyond recognition,
place holes for welding I I/2
inches apart.
Clean inboard surface of

seven pierced locations
on side rail assembly
with mild soap and
water and wipe dry.
Clean with wax and
grease remover.
Remove backing from
washers included with
Figure 3-14.
Installing
Adhesive
Washers
~@
rail and carefully apply to

motor compartment
{
side of new side rail
/
assembly at five pierced
NOTICE:
Use only service kit washers
provided with rail, GM PIN
I 2520407. Use of any other
washer could cause improper
positioning of side rail assembly.
Position new side rail

assembly to overlap
remainder of original
side rail assembly by 35
mm. Align to arrows on
remainder of original
side rail assembly and
clamp.
MEASURE
Refer to service manual for proper
dimensions.
OJ
1~~


Using MIG welder at
overlap, plug weld all 8
mm pre-drilled holes in
new side rail assembly in
sequence shown.
Using MIG welder, make
I -inch stitch welds along ~
seam leaving I-inch gaps. 'o"o--4
~~~;:;:;:J""'
Using MIG welder,

randomly plug weld all
remaining holes in new
side rail assembly.
IMPORTANT
Complete stitch
welding along seam
(Figure 3-15).
Remove clamps.
Clean and prepare
welded surfaces. Prime
with two-part catalyzed
primer. Do not combine
paint systems. Refer to
recommendations.
Install outer side rail.
Refer to "Engine
Compartment Front
Outer Side Rail".
----..L_/
Figure 3-15.
Welding Inner
LOWER RAIL
Replacement of the
engine compartment
inner and outer side rail
assemblies has been
noticeably improved
over past vehicle
models. Virtually all
attaching surfaces are
easily accessible from
underneath for
service, which makes
replacement much less
complicated.
Engine Com-
partment Side
Rail Assemblies
The service part comes

as an entire unit, including all brackets and
reinforcements as shown
in Figure 4- I . The outer
side rail extension is also
available as shown in
Figure 4-2.
NOTICE:
At this time, sectioning
of the engine compartment inner and outer
side rail assemblies is
not recommended,
as doing so could
compromise the
structural integrity
of the vehicle.
Engine
Compartment
Side Rail with
Extension
Removed
FRONT WHEELHOUSE ASSEMBLY

This service part is available as an entire part including all brackets and reinforcements,
as shown in Figure 5-1. The Front Wheelhouse Apron is also available separately as
shown in Figure 5-2.
Remove outer body
panels and related
components.
Restore as much of the

damage as possible to
factory specifications.
Figure 5-1.
Front Wheelhouse Available
as Complete
Assembly
Remove sealants and

corrosion materials
as necessary.

installation of the
new front wheelhouse
assembly.
Drill out all related
factory welds.
Remove front
wheelhouse assembly.
Prepare mating surfaces
for proper fit of new
front wheelhouse
assembly.
FigureS-2.
Front Wheelhouse Apron
Available
Separately
Set the new front

wheelhouse assembly on
a work surface with
underside up.
Position template
(included in service kit)
in the front wheelhouse
assembly as shown
(Figure 5-3).
Figure 5-3.
Positioning
Temf>late to
Wheelhouse
Assembly
LEFT HAND
With a center punch,

locate four strut attaching holes (Figure 5-4).
Remove template. Drill
12-mm ( 15/32-inch)
holes in marked
locations on new front
wheelhouse assembly
(Figure 5-5).
Figure 5-4.
Punching Strut
Attaching Holes
Drill 8-mm (5/ 16-inch)

holes in remaining locations I I /2 inches apart.
Position new front
wheelhouse assembly in
place, align and clamp.
8-
MEASURE
Refer to the appropriate service
manual for proper dimensions or
see Body Dimensions Section in
this publication.
-~-0
Figure 5-5.
Drilling Strut
Attaching Holes
(fjJ
(:)-
FRONT WHEELHOUSE ASSEMBLY

Using a MIG welder,
randomly plug weld
the new front wheelhouse assembly in place
(Figure 5-6).
IMPORTANT
Remove clamps. Clean

and prepare welded
surfaces. Apply 3M
Brushable Seam Sealer,
part number 08655 or
equivalent, as necessary.
recommendations.
Apply anticorrosion
figure 5-6.
Welding Wheelhouse Assembly
The side door opening frame on the Camaro/Firebird can be either replaced as a unit or
sectioned, following the proper techniques. The service part frame will come as a complete
unit and will need to be trimmed to fit each application such as coupe, T-Tops, etc.
Templates are provided with the service part as a guide for trimming.
The following items may need to be removed or protected before replacing or sectioning
the frame, the Door hinges, outer rocker panel, upper outer side rail, windshield,
weatherstripping, roof outer panel and T-Tops (if applicable), quarter panel assembly
and rear end deck lid assembly.
REPLACEMENT
Remove all applicable
panels and components.
Remove appropriate
sealer.
Drill out factory welds
around the frame
perimeter with a
5/ 16-inch drill bit.
NOTICE.:
When drilling out welds, use
caution so that inner panels are
not damaged.
Figure 6-1.
Recommended
Locations for
Sectioning
Note number and

installation of new
door frame.
Prepare mating
surfaces for installation
of new frame.
The recommended locations for sectioning are shown in Figure 6-1. A sectioning
procedure may be performed at these locations by overlapping the original panel by 20mm.
Use the MIG welding procedures previously discussed.
REPLACEMENT
On the new frame, drill

5/ I 6-inch holes in
locations as noted from
the original frame.
NOTICE:
If the original frame is damaged
beyond recognition, place holes for
welding I I /2 inches apart
Align frame and clamp to

hold in place.
Using a MIG welder, plug
weld at same locations
as original.
Clean and prepare
welded surfaces. Apply
Brushable Seam Sealer
3M P/N 08655 or
equivalent, as necessary.
recommendations.
Apply anticorrosion
Install all panels and
components that were
removed.
SECTIONING
When sectioning the door opening frame, note that there are five locations where sectioning
should not take place (Figure 6-2). Sectioning in these areas would jeopardize the structural
integrity of the vehicle. When sectioning in an area with no reinforcement, a backing plate or
sleeve must be used.
Remove all applicable
panels and components.
Measure, mark, cut and
remove the damaged
panel, being careful in
areas where there are
multiple layers of steel.
Measure, mark, cut and
install the new panel to
check for a proper fit
(Figure 6-3).
Figure 6-2.
Areas Where
Sectioning
Should Not
Take Place
A gap of I 1/2 times the thickness
of the metal must be maintained

at the joint between the old panel
and the replacement panel. Trim
as required.
When the replacement

panel fits properly,
remove it from the
vehicle and set aside.
Figure 6-3.
Fitting the
New Panel
In areas having no inner

reinforcements, cut
pieces to serve as
backing plates of the
same configuration
(approximately 3 inches
long) from the areas
where the splices are to
be made. Use the
damaged panel or the
excess portions of the
replacement panel
(Figure 6-4).
Modify the pieces
so they fit snugly to
the backside of the
splice joints.
Pre-drill 5/ 16-inch plug
weld holes indicated on
the following illustrations
for installation of new
panel (Figure 6-5).
Figure 6-4.
Fitting the
Backing Plate
Figure 6-5.
Pre-drilling Plug
Weld Holes
Figure 6-6.
Fitting the
Backing Plate
for Welding
When all the backing

plates are welded in
place, reinstall the new
part and check the fit.
When the replacement
panel is properly fit and
aligned, clamp and MIG
weld it to the backing
plates (Figure 6-7).
An alternating weld
sequence 1s recommended to reduce heat
and metal distortion.
Figure 6-7.
Welding the
Joint Gap
Complete the splice joint

(Figure 6-7) by welding the
joint gap closed using an
alternating stitch MIG weld.
This will minimize heat build
up and distortion. MIG
weld the remaining weld
holes to attach the panel
permanently (Figure 6-8).
Figure 6-8.
-............
Grind excess weld off joints
and inspect.
When satisfied that the
weld and splice joints are
structurally sound, proceed
with the recommended
finishing procedures.
Clean and prepare welded
surfaces. Apply Brushable
Seam Sealer 3M P/N 08655,
as necessary.
Paint and refinish according
to paint manufacturer's
recommendations.
Apply anticorrosion material,
as necessary.
Install all panels and
components that were
removed.
----
Welding the
Remaining
Holes
DOOR SERVICE
The inner and outer door panels on the new Camaro/Firebird are composed of
sheet molded compound (SMC). (Figure 7-1) Repair of the door assembly can be
performed using conventional procedures. Detailed information and instructions are
available by obtaining General Motors Corporation STG Composite (plastic) Panel Repair
publication No. 22005.35-1.
The steps listed below are provided as a reference for removal and replacement
of the door outer panel.
Door Outer Panel Replacement

Door outer panels
are available through
General Motors Service
Parts Operations
(GMSPO). When a door
outer panel requires
replacement, remove it
from the vehicle and
place it on a suitable
surface, door outer
panel facing up, being
careful not to damage
the door assembly.
Figure 7-1.
Complete Door
Assembly
Using the Chicago
Pneumatic Pneu-nife CP
838, cut an access hole
into the bottom of the
door panel. Cut through
the outer panel, being
careful not to cut into
the inner panel, as
shown in Figure 7-2.
Figure 7-2.
Door Outer
Panel Replacement
(Continued)
Using a heat gun, apply heat
to the door outer panel
while prying with a putty
knife. When the adhesive
reaches approximately
400F, the bond will begin
to break. (Figure 7-3)
NOTICE:
Do not heat the door inner panel more
than necessary as this will soften the
panel and cause damage.
Continue applying heat and

prying with the putty knife
until the entire panel is
removed. (Figure 7-4)
Figure 7-3.
Door Outer
Panel Removal
After the door panel has

been removed, clean
off any excess adhesive left
on the inner panel.
Install or Connect
Check the fit of the new
outer panel. Apply adhesive
to the door inner panel.
NOTE:
GM Goodwrench Strucural Bonding
Epoxy Part No. 12345726 material is
recommended.
Set the outer panel in place

and clamp until the
adhesive is cured.
NOTICE:
To avoid unnecessary work, be sure
the clamps do not distort the outer
door panel.
Clean up excess adhesive.

Reinstall door to vehicle.
Figure 7-4.
Entire Door
Outer Panel
Removed
ROOF OUTER PANEL

The roof outer panel assembly is composed of sheet molded compound (SMC).
It attaches to the steel roof structure with urethane adhesive. Repair of the roof outer
panel assembly can be performed using conventional procedures. Detailed information and
instructions are available by obtaining General Motors Corporation STG Composite
(plastic) Panel Repair publication No. 22005.35-1.
The steps listed below are provided as a reference for removal and replacement of the
roof outer panel assembly. Refer to Figure 8-1 for illustrations of the T-top and coupe
outer roof panels.
NOTICE:
When cutting, use care to protect

adjacent panels, gloss,
weatherstrips and moldings.
Using a Chicago pneumatic knife with a panel

blade, cut roof outer
panel 3 inches from all
edges and lift off.
With a Chicago
pneumatic knife with
a urethane blade or
service wire or Equalizer
Magnum, cut urethane
adhesive and remove
remaining roof
outer panel.
Figure 8-1.
Re-placing the
Roof Outer
Panel
1'
I
,.
I I
I:
I
I
I
I I
I I
I I
I
I
\
I
I
I I
I
I
I
I
I I
I
I I
I
I I
L _____
J L ______
Remove all loose or

damaged urethane as
necessary.
- - - CUT LINES
-URETHANE
ROOF OUTER PANEL (CONTINUED)
Install or Connect
Temporarily set
new roof outer panel
into place and check
alignment.
Remove roof outer
panel and set aside.
Use appropriate body
primer supplied in
Adhesive Caulking Kit
GM P/N I 2345633, on
both inner structure
and new roof outer
panel as required.
NOTICE:
Do not prime over remaining

urethane adhesive.
Apply urethane adhesive,

GM P/N I 2345633,
approximately IO mm in
diameter, around the
perimeter of the roof
outer panel.
With the aid of a helper,
install new roof outer
panel and press firmly to
set adhesive.
Install surrounding
weatherstrips and
moldings while the roof
outer panel cures.
WINDSHIELD REPLACEMENT
CAUTION:
When replacing a windshield or hatch
roof glass, urethane adhesive GM PIN
I 2345633, or equivalent Essex Beta
Seal 55802 with 435 I8 and 43520A
primer must be used to maintain
original installation integrity. Failure to
use the urethane adhesive GM PIN
I 2345633, or equivalent will result in
poor retention of the windshield which
may allow unrestrained occupants to be
eJected from the vehicle with resulting
personal injury.
Proper installation of the

windshield is extremely
important so that occupant
protection provided by the
supplemental inflatable restraint
(SIR) system is maintained.
GM material is available in kit
form, GM P/N 12345633,
through your local GM Dealer.
Essex materials may be ordered
through your local PT/ jobber or
call: 1-800-453-3779 for
additional information.
The tools listed below are approved and recommended for GM automotive glass replacement. T oo/s may be ordered through Kent-Moore. Specify part number when ordering glass.
J 24852
J 28628
J 36020
Hot Knife Blade
Windshield Remover
J 24402-A
J 39032
Stationary Glass
Removal Tool
"'~ J2'' "'/ "'/

Urethane Glass
Sealant Remover
Handle
Windshield Remover Blade
Side Garnish
Molding Remover
Glass Sealant Remover
J 25070
Heat Gun
QUARTER PANEL ASSEMBLY

The quarter panel assembly has been specially designed for improved serviceability. Additional
panels have been added allowing for easier and faster service. The quarter panel assembly is
attached to the structure with plug welds. To remove the quarter panel assembly, the welds
must be drilled out using a 5/ 16-inch drill bit. The roof outer panel covers a section of the
quarter panel assembly at the top and must be positioned out of the way to provide access
to the welds. At the bottom of the quarter panel assembly at the rocker panel, there are four
hidden welds. They can only be accessed after all the other welds have been drilled out. The
quarter panel assembly can be pulled forward and the welds drilled from inside.
NOTICE:
Care must be taken when working

around the roof outer panel. Failure to
use care may result in damage to the
roof outer panel. In this case, additional
time will be needed in repairing it. Refer
to "Rigid Plastic Repair" procedures.
NOTICE:
Service of the quarter panel assembly by
splicing a joint just below the roof panel
is not recommended. The panel is
structural in this area, and splicing will
reduce the integrity of the vehicle.
Make a cut at the top
of the quarter panel
assembly, as close to the
roof panel overlap as
possible without damaging it (Figure I 0-1 ).
Drill out visible plug
welds around the
quarter panel assembly.
Be sure to note the
number and location of
welds for the new
Figure I 0-1.
Cutting the
Top and
Bottom of the
Quarter Panel
(Continued)
Cut inboard flanges fore
and aft of the lower
quarter panel assembly
at the rocker panel
assembly (Figure I 0-1 ).
Figure I0-2.
Separating the
Quarter Panel
from the Vehicle
Pull upper portion of

the quarter panel
assembly away from the
vehicle and drill out the
four inner plug welds at
the rocker panel
assembly (Figure I 0-2).
Remove the quarter
panel assembly.
With a hammer and
flat punch, flatten the
quarter panel flange
remaining at the roof
line (Figure I 0-3).
Figure I0-3.
Cutting the
Roof Outer
Panel
With a chicago
pneumatic knife using
the 3 I /2-inch offset
blade, part number
KF- 140665 or the
Equalizer Magnum, cut
the bottom edge of the
roof outer panel
(Figure I 0-3).
With a service wire,
using upward movements, saw urethane
from the roof panel
away from the "B" pillar
area. Cut to the top of
the roof outer panel,
using caution to avoid
damage (Figure I 0-4).
NOTICE:
When working around the roof
outer panel, care must be taken
to avoid causing damage.
Figure I0-4.
Cutting the
Urethane from
the Roof Panel
QUARTER PANEL ASSEMBLY
Remove or Disconnect (Continued)

To reveal welds, pull the
roof outer panel outward and support it out
of the way, being careful
not to lift too far as
damage to the roof
outer panel may occur.
Drill out exposed welds
to remove flange
(Figure I 0-5).
Stress areas when li~ed
Install or Connect
Prepare mating
surfaces for installation
of the new quarter
panel assembly.
Drill holes in locations as
noted from the original
IMPORTANT
ff original is beyond recognition,
place holes for welding I I /2
inches apart.
Align the new

quarter panel assembly
and measure.
_/ _/
J
Figure I0-5.
Plug Welds
at Roof Outer
Panel
(Continued)
With the upper quarter
panel assembly pulled
away from the vehicle,
use a MIG welder to
repalce the welds in the
bottom at the rocker
panel (Figure I 0-6).
Align the remainder
of the quarter panel
assembly and clamp
in place.
Plug weld remaining
locations (Figure I 0-5).
At the roof outer panel,
remove loose adhesive
and clean all surfaces for
refinishing, as necessary.
Prime with an
anti corrosion-type
primer to restore
damaged ELPO
surface. If additional
primer for adhesive
area is required,
see package for
appropriate primer.
NOTICE:
Be careful not to prime over
existing or remaining urethane.
Rebond roof outer

panel using GM Urethane P/N I 2345633,
or equivalent.
Figure I0-6.
Welding the
Quarter
Panel at the
Bottom of the
Rocker Panel
FRONT
HEIGHT
557
690
557
862
557
690
557
DATUM LINE
~ - 358----- 358-~
WIDTH
~ - - - 426--t--- 426----
- - . . . - - - - 494--i--- 494--+--...--
I
I
I
I
LENGTH
1613--J
1613
FORM AND PIERCE
trufil!I
TO DATUM LINE
WillII:!
TO<t_
ALL MEASUREMENTS ARE READ

FROM (FORMED SURFACES) AND
CENTER OF HOLE
!-1613
975
1613---J
I L1613
1613
UNDER BODY
DRIVER SIDE
WIDTH
<t.
I~ I
I I)
I II
)I I
II I
II
<t.
446.5
0
:ti
c:
c:
:ti
HEIGHT
430
561
540
413
350
333
375
785
470
>
rm
598
470
601
:ti
DATUM LINE
:a
,--------1188.5-------1
>
z
517
76
LENGTH
670----l
'-----950-----t
.....- - - - - - 1 4 5 0 - - - - - - - - - - !
492
1-----730-----'
i------780-----
1--------1275--------'
WHEELBASE 2566
-<
....-------1275-------~
0
0
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......
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ROOF
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:a
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HEIGHT
WIDTH
884- -
LENGTH
LENGTH
WIDTH
HEIGHT
873
912----
:a
: : __r _-1--= =
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HEIGHT
--::::_j_ --+_ --
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-1390
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WIDTH
LENGTH
LENGTH
WIDTH
HEIGHT
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LENGTH
WIDTH
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- - -822
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---914
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---957
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---990
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---999
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769
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---862
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---862
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754
750
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764
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WIDTH
771
508
---1005
597
---1003
686
- - -999
796
---990
1006
---957
1186
---914
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---822
LENGTH
HEIGHT
.....
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RIGHT SIDE
0
772
132
WIDTH
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782
WIDTH
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LENGTH
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HEIGHT
HEIGHT
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WIDTH
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681
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WIDTH
488
385
608
505
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PONT. 732
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1463
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1381 PONT.
INDEX 1
A
A/C Clutch Circuit Diagnosis ......... 5.7L (VIN P) 6E3-C10-1
A/C Compressor Clutch Control . . . . . . 3.4L (VIN S) 6E3-C10-1
A/C System (Engine Off), Charging the ................ 18-14
A/C System Oil Change Replenishing ................. 18-13
Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OA-16
ABS Enable Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5E 1-7
ABS Operation, Tires and ........................... 5E1 -6
ABS Service Precautions ......................... 5E1 -160
ABS System - Self Test (Initialization) ................. 5E1 -5
ABS Warning/Indicator Lamp Operation ............... 5E1 -6
ABS Warning/Indicator Lamps ....................... 5E1 -8
ABS Wiring Harness ............................... 5E1 -8
Absorber Assembly, Shock, Rear Suspension ........... 30-9
(3.4L VIN S) .................................... 6C-18
(5.7L VIN P) .................................... 6C-18
Accelerator Controls, Engine Fuel ..................... 6C-6
Accelerator Pedal Replacement ...................... 6C-19
Access Door Assembly, Instrument Panel
Fuse Block ..................................... 8C-23
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
Accessory Switch Opening Cover Assembly,
Accessory Switch Panel Assembly and . . . . . . . . . . . . 10-6-3
Accessory Switch Panel Assembly and Accessory
Switch Opening Cover Assembly . . . . . . . . . . . . . . . . . 10-6-3
Accumulator Assembly, Automatic Trans
On-Vehicle Service .............................. 7A-23
Accumulator Valve Body Assembly, Auxiliary,
4L60 Trans Unit Repair ...................... 7A-15B-51
Acid Rain, Industrial Fallout, General
Body Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1-1 0
ACR 4 Setup and Maintenance, Station, HVAC .......... 18-9
Actuator Control Module Assembly, Headlamp
Opening Door ................................... 88-7
Actuator Cylinder Assembly, Clutch Master and ......... 7C-7
Actuator Lever Knob, Front Seat Adjuster . . . . . . . . . . 10-10-19
Actuator, Rear Compartment Lid Lock Release . . . . . . . . 10-8-5
Actuators, Vacuum, Heater and Ventilation
Adapter Plate, Transmission, 6-Speed Manual
Trans Repair and Inspection .................. 78-108-21
Adhesive Caulking Kit, Stationary Windows . . . . . . . . . . . 10-2-1
Adhesive Molding Assemblies . . . . . . . . . . . . . . . . . . . . . . 10-1-3
Adhesive Nameplate/Emblem Assemblies . . . . . . . . . . . . 10-1-3
Adjust Front Bumper, Hood . . . . . . . . . . . . . . . . . . . . . . . . 10-5-15
Adjuster and Drive Motor Assemblies, Driver Seat . . . 10-10-15
Adjuster Assemblies, Passenger Seat . . . . . . . . . . . . . 10-10-17
Adjuster Assembly, Manual Front Seat . . . . . . . . . . . . . . 10-10-2
Adjuster Assembly, Manual Front Seat,
On-Vehicle Service . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-10-14
Adjuster Assembly, Power Front Seat . . . . . . . . . . . . . . . 10-10-2
Adjuster Assembly, Power Front Seat,
On-Vehicle Service . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-10-17
Adjustment and Alignment, Body Panel . . . . . . . . . . . . . 10-5-21
Adjustment, Hood Panel Assembly . . . . . . . . . . . . . . . . . 10-5-21
Aiming After a Collision, Headlamp,
On-Vehicle Service ............................... 88-9
Aiming Alternate Procedure, Headlamp,
Aiming by Screen Method, Headlamp,
Aiming Procedure, Front fog Lamp,

Air Baffle Assemblies and Deflectors, Radiator . . . . . . . . . 68-20
"AIR BAG" Warning Lamp, SIR . . . . . . . . . . . . . . . . . . . . . . . 9J-4
Air Bleed Pipe Assembly, Coolant . . . . . . . . . . . . . . . . . . . . 68-22
Air Check, Clutch, 4L60 Trans Unit Repair ......... ?A-158-34
Air Cleaner and Crankcase Ventilation Filter
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 08-5
Air Conditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-23
Air Conditioning Compressor and Condenser
Hose Assembly, On-Vehicle Service ............... 1B-16
Air Conditioning Compressor Assembly . . . . . . . . . . . . . . . . 1B-4
Air Conditioning Compressor Assembly,
On-Vehicle Service .............................. 18-20
Air Conditioning Compressor Bracket Assembly
(3.4L L32 Engine), Generator and ................. 1B-23
Air Conditioning Compressor Low Pressure Cutoff
Switch Assembly, Manual Control ................. 181 -17
Air Conditioning Compressor Relay . . . . . . . . . . . . . . . . . . . . 18-5
Air Conditioning Compressor Relay,
Manual Control ................................ 181 -15
Air Conditioning Compressor Service or
Unit Repair, HD6/HR6 - HE ...................... 102-1
Air Conditioning Condenser Assembly . . . . . . . . . . . . . . . . . 1B-4
Air Conditioning Condenser Assembly,
Air Conditioning Control Assembly, Heater and .......... 8C-9
Air Conditioning Control Lamp, Heater and . . . . . . . . . . . . . 88-3
Air Conditioning Control Lamp, Heater and,
Air Conditioning Ducts, Heat, Ventilation and ........... 8C-13
Air Conditioning Evaporator . . . . . . . . . . . . . . . . . . . . . . . . . . 18-5
Air Conditioning Evaporator and Blower
Module Assembly, Heater and .................... 8C-15
Air Conditioning Evaporator, On-Vehicle Service ....... 181-17
Sensor Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18-5
Sensor Assembly, Manual Control ................ 181 -15
Air Conditioning Evaporator Tube,
On-Vehicle Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18-18
Air Conditioning, Heater, Ventilation and . . . . . . . . . . . . . . . . 1B-1
Air Conditioning, Heating and . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Air Conditioning Low Pressure Cutoff Switch
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-5
Air Conditioning, Manual Control ..................... 181 -1
Air Conditioning Odor, Eliminating ..................... 18-7
Air Conditioning Overview, Manual Control . . . . . . . . . . . . . 1B1-1
Air Conditioning Performance Test ................... 181-11
Air Conditioning Receiver and Dehydrator Assembly . . . . . 18-4
Air Conditioning Receiver and Dehydrator Assembly,
Air Conditioning Receiver Dehydrator Tube,
Sensor Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-5
Air Conditioning Refrigerant Pressure Sensor
Assembly, Manual Control . . . . . . . . . . . . . . . . . . . . . . . 181 -17
Air Conditioning Refrigerant Service Valve,
Air Conditioning System Operation, Heater,
Ventilation and . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18-3
Air Conditioning Thermostatic Expansion
Valve Assembly, On-Vehicle Service ............... 18-18
2 INDEX
Air Deflectors, Heater and Ventilation
Air Delivery, Improper, Manual Control A/C ........... 181 -1 O
Air Distribution System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-5
Air Distribution System, Manual Control A/C ........... 181-3
Air Distributor Assembly ............................ 8C-13
Air Extractors, Hood . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-515
Air Hose Test, Waterleak . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1-5
Air Injection (AIR) System,
Secondary ...................... 5.7L (VIN P) 6E3-C6-1
Air Injection (AIR) System,
Secondary ...................... 3.4L (VIN S) 6E3-C6-1
Air Inlet Screen Assemblies . . . . . . . . . . . . . . . . . . . . . . . 10-5-16
Air Inlet Valve, Manual Control A/C ................... 181-4
Air Intake System .................. 5.7L (VIN P) 6E3-C14-1
Air Intake System .................. 3.4L (VIN S) 6E3-C14-1
Air Lower Baffle Assembly and Deflector,
Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68-20
Air Lower Deflector, Radiator . . . . . . . . . . . . . . . . . . . . . . . 10-5-3
Air Outlet Duct Assemblies, Outer .................... 8C-15
Air Outlet Duct Assembly, Floor ...................... 8C-14
Air Outlets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-5
Air Upper Baffle Assembly, Radiator .................. 68-21
Alarm Assembly, On-Vehicle Service .................. 8C-25
Alignment Angles, Measuring Front .................... 3A-3
Alignment Angles, Measuring Rear . . . . . . . . . . . . . . . . . . . . 3A-5
Alignment Checking, Body Dimensions and
Underbody . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-3-1
Alignment Preliminary Inspection, Wheel ............... 3A-2
Alignment, Wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-1
All Season Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3E-2
Aluminum Radiator Service Diagnosis . . . . . . . . . . . . . . . . . 68-9
Aluminum Radiator Service, On-Vehicle Service ......... 68-8
Aluminum Radiator Service Precautions ................ 68-8
Aluminum Radiator Service Repair Methods . . . . . . . . . . . 68-10
Aluminum Radiator Service Repairable Leaks .......... 68-1 O
Aluminum Wheel Assemblies ........................ 3E-11
Aluminum Wheel Assembly Hub Cap . . . . . . . . . . . . . . . . . 3E-11
Aluminum Wheel Assembly Porosity Repair ........... 3E-11
Aluminum Wheel Assembly Refinishing . . . . . . . . . . . . . . . 3E-11
AM/FM Stereo and Clock Radio Assembly,
On-Vehicle Service ............................... 8C-7
AM/FM Stereo/Cassette (UM6), ETR .................. 9A-2
AM/FM Stereo/Cassette/Equalizer (UX1 ), ETR .......... 9A-3
AM/FM Stereo/Compact Disc Player/Equalizer
(U1 A), ETR ..................................... 9A-5
AMAX Stereo Certification . . . . . . . . . . . . . . . . . . . . . . . . . . . 9A-2
Ambient Light Sensor Assembly,
Daytime Running Lamp .......................... 8C-1 O
Ambient Light Sensor, Daytime Running Lamp (DRL)
(Canadian Only) ................................. 8C-4
Ambient Light Sensor Module Assembly,
Daytime Running Lamp .......................... 8C-1 O
Amplifier Assembly, Low Frequency Audio . . . . . . . . . . . . 10-7-7
Amps, Cold Cranking, Battery Assembly .............. 601 -2
Anchor Bracket (Canadian Vehicles),
Child SeatTop-Tether ........................... 10-11-6
Anchor Bracket (U.S. Vehicles), Child Seat
Top-Tether .................................... 10-11-4
Anchor Bracket and Mounting Plate,
Rear Brake Caliper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 582-8
Anchor Plate, Front Side Door Lock Striker . . . . . . . . . . 10-6-26
Angle Adjustment, Rear Thrust . . . . . . . . . . . . . . . . . . . . . . . 3A-6
Angle, Thrust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-1
Angles, Measuring Front Alignment .................... 3A-3

Angles, Measuring Rear Alignment . . . . . . . . . . . . . . . . . . . . 3A-5
Antenna Assembly Diagnosis, Radio Fixed . . . . . . . . . . . . . 9A-6
Antenna Assembly, Radio Fixed . . . . . . . . . . . . . . . . . . . . . . 9A-1
Antenna Assembly, Radio Fixed, On-Vehicle Service ..... 9A-7
Anti-Theft Feature, Setting Delco-Loe II . . . . . . . . . . . . . . . . 9A-6
Anticipate Switch Assembly, Clutch .................... 7C~7
Anticorrosion Protection, Body Front End . . . . . . . . . . . . . 10-5-3
Anticorrosion Treatment . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1-7
Antilock Brake System .............................. 5E1-1
Antilock, Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Antilock Braking Mode Operation ..................... 5E1-4
Applique Assembly, Outside Rearview Mirror . . . . . . . . . 10-6-19
Arm Assembly, Lower Control, Rear Suspension . . . . . . . . 30-5
Arm Channel Assembly, Front Side Door Window
Regulator Counterbalance . . . . . . . . . . . . . . . . . . . . . . 10-6-14
Arm Replacement, Wiper . . . . . . . . . . . . . . . . . . . . . . . . . . . 8E-10
Arm, Torque, Rear Suspension ....................... 30-6
Arming Sensor, Dual Pole, SIR ....................... 9J-4
Arming Sensor, Dual Pole, SIR Removal and
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9J-B-4
Armrest and Map Pocket and Radio Front Side
Door Speaker Grilles, Front Side Door . . . . . . . . . . . . 10-6-3
Ashtray Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88-3
Ashtray Lamp, On-Vehicle Service ................... 88-12
Assist Rod Bracket Assembly, Hood Open . . . . . . . . . . . 10-5-14
Audio Amplifier Assembly, Low Frequency . . . . . . . . . . . . 10-7-7
Audio Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9A-1
Automatic and Manual Transmission .................... 7-1
Automatic Transmission Assembly Removal and
Installation ..................................... 7A-30
Automatic Transmission Case Extension,
Speedometer Drive Gear and . . . . . . . . . . . . . . . . . . . . . 7A-22
Automatic Transmission Control Assembly .............. 7A-9
Automatic Transmission Control Lever Solenoid ........ 7A-12
Automatic Transmission Diagnosis, 4L60 ........... 7A-15A-1
Automatic Transmission Indicator Lamp ................ 88-3
Automatic Transmission Indicator Lamp,
Automatic Transmission Oil Cooler Upper Pipe
and Upper and Lower Hose Assemblies . . . . . . . . . . . . 7A-18
Automatic Transmission Oil Filter Assembly,
Changing Transmission Fluid and .................. 7A-17
Automatic Transmission On-Vehicle Service ............ 7A-1
Automatic Transmission On-Vehicle Service
Preliminary Checking Procedure . . . . . . . . . . . . . . . . . . . . 7A-3
Automatic Transmission Park Lock Cable Assembly ..... 7A-1 O
Automatic Transmission Range Selector Lever
Cable Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A-9
Automatic Transmission TV Cable Assembly,
Automatic Transmission TV Cable Assembly,
Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7A-17
Automatic Transmission TV Cable Assembly
System ........................................ 7A-13
System Diagnosis ............................... 7A-14
System Parts, Inspection of ....................... 7A-16
Automatic Transmission Unit Repair, 4L60 .......... 7A-15B-1
Automatic Transmission Unit Repair 4L60
Disassembled Views ........................ 7A-158-62
Auxiliary Accumulator Valve Body Assembly,
INDEX 3
Auxiliary Fuse Block ................................ 8C-2
Auxiliary Fuse Block, On-Vehicle Service .............. BC-20
Auxiliary Sealing Strip, Front Side Door Bottom . . . . . . . 10-6-12
Auxiliary Valve Body Assembly, Automatic Trans . . . . . . . 7A-25
Axle Assembly Identification, Rear ..................... 48-4
Axle Assembly, Rear, On-Vehicle Service .............. 48-14
Axle Assembly, Standard Rear . . . . . . . . . . . . . . . . . . . . . . . . 48-1
Axle Assembly Usage, Rear ......................... 48-27
Axle Housing Replacement, Rear .................... 48-24
Axle Inspection and Diagnosis, Rear ................... 48-7
Axle Limits for Fitting and Adjusting, Rear ............. 48-27
Axle Noises, Rear, Diagnosis ......................... 48-5
Axle, Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48-1
Axle Shaft Bearing Noise, Rear ....................... 48-5
Axle Shaft, Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48-11
Axle Suspension, Rear .............................. 30-1
B
Backing Plate, Duo-Servo Drum Brakes,
On-Vehicle Service .............................. 5C2-6
Backlash Clunk, Rear Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . 48-5
Backlash, Differential Ring Gear-to-Differential
Drive Pinion Gear ............................... 48-18
Backup Lamp Switch Assembly, Manual Trans
Backup Lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88-2
Backup Lamps, On-Vehicle Service .................... 88-4
Baffle Assemblies and Deflectors, Radiator Air ......... 68-20
Baffle Assemblies and Deflectors, Radiator Air .......... 68-3
Baffle Assembly and Deflector, Radiator Air Lower ...... 68-20
Baffle Assembly, Radiator Air Upper .................. 68-21
Balance Check, Propeller Shaft Assembly .............. 4A-7
Balance, Duo-Servo Drum Brakes, Diagnosis .......... 5C2-2
Balance, Duo-Servo Drum Brakes Unit Repair ......... 5C2-7
Balance Precautions, General, Tire and Wheel
Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3E-9
Balance, Tire and Wheel Assembly . . . . . . . . . . . . . . . . . . . . 3-22
Balance Weights, Wheel ............................ 3E-1 O
Balancer Assembly and Hub, Crankshaft,
5.7L Engine On-Vehicle Service ................. 6A3A-11
5.7L Engine Unit Repair Assembly ............... 6A3B-36
5. 7L Engine Unit Repair Disassembly ............ 6A3B-13
Balancer Assembly, Crankshaft, 3.4L L32 Engine
On-Vehicle Service ............................ 6A2A-14
Balancing, Off-Vehicle, Tire and Wheel Assemblies ...... 3E-9
Balancing, On-Vehicle, Tire and Wheel Assemblies ..... 3E-10
Balancing, Propeller Shaft Assembly . . . . . . . . . . . . . . . . . . . 4A-7
Balancing Tire and Wheel Assembly . . . . . . . . . . . . . . . . . . . 3E-8
Ball Assembly Leak Check Procedure,
Retainer and, 4L60 Trans Unit Repair .......... 7A-15B-14
Ball Assembly, Third Accumulator Retainer and,
Ball Stud Assembly Inspection, Control Arm,
Front Suspension ................................ 3C-1
Ball Stud Assembly, Lower Control Arm,
Ball Stud Assembly Replacement, Control Arm,
Ball Stud Assembly Replacement, Lower Control Arm,
Ball Stud Assembly Replacement, Upper Control Arm,

Ball Stud Assembly, Upper Control Arm,
Front Suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3C-4
Ball Studs, Valve Rocker Arm, 5.7L Engine
Unit Repair Assembly .......................... 6A3B-37
Band Assembly, 2-4, 4L60 Trans Unit Repair ....... ?A-158-40
Band Servo Assembly, 2-4 . . . . . . . . . . . . . . . . . . . . . . . . . . 7A-23
Base Auto System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9A-1
Base Braking Mode Operation, ABS .................. 5E1-3
Base Heater System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1A-1
Basecoat/Clearcoat, Metal Part Refinishing . . . . . . . . . . . 10-1-9
Battery ........................................... 601-1
Battery Assembly Charging ......................... 601 -6
Battery Assembly, Charging a Very Low or
Completely Discharged .......................... 601 -7
Battery Assembly Electrical Drain .................... 601 -4
Battery Assembly Protection During Vehicle
Storage ........................................ 601 -3
Battery Assembly Ratings ........................... 601 -2
Battery Assembly Replacement ...................... 601 -8
Battery Assembly Testing ........................... 601 -3
Battery Assembly Usage ........................... 601 -13
Battery Cable Assembly Replacement and
Routing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 601 -9
Battery Negative Cable Assembly,
Disconnecting the ................................ OA-1
Battery Replacement, Remote Keyless Entry ............ 9K-1
Battery Tray and Coolant Recovery Reservoir
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68-19
Battery Tray Assembly and Hold-Down Retainer ........ 601 -2
Battery Tray Assembly Replacement .................. 601 -8
Beam Control Switch Assembly,
Headlamp Automatic . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8C-12
Bearing Assembly and/or Bearing Seal,
Rear Axle Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48-12
Bearing Assembly, Differential Drive Pinion
Gear Inner ..................................... 48-22
Bearing Assembly, Differential Drive Pinion
Gear Outer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48-21
Bearing Assembly Preload Adjustment,
Differential ..................................... 48-19
Bearing Assembly Repack, Front Wheel . . . . . . . . . . . . . . . 08-4
Bearing Assembly, Wheel, Front Suspension ........... 3C-16
Bearing, Center Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-1
Bearing Diagnosis, Tapered Roller . . . . . . . . . . . . . . . . . . . . . 3-23
Bearing Locations, Seal and, 4L60 Trans
Unit Repair ................................. 7A-15B-68
Bearing Noise, Connecting Rod . . . . . . . . . . . . . . . . . . . . . . . . 6-4
Bearing Noise, Main . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
Bearing Noise, Rear Axle Shaft ....................... 48-5
Bearing Preload, Rack, Power Steering Gear
Unit Repair .................................... 381 A-4
Bearing Replacement, Center Support . . . . . . . . . . . . . . . . 4A-12
Bearing Rollers and Spacers, 5-Speed Manual
Trans Cleaning and Inspection .................. 78-68-8
Bearing Seal, Rear Axle Shaft Bearing
Assembly and/or . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48-12
Bearings, Camshaft, 3.4L L32 Engine Assembly ...... 6A2B-41
Bearings, Camshaft, 3.4L L32 Engine
Disassembly ................................. 6A2B-22
Bearings, Crankshaft, 3.4L L32 Engine
4 INDEX
Bearings, Crankshaft, 5.7L Engine
Bearings, Front and Rear, 5-Speed Manual Trans
Cleaning and Inspection ........................ 78-68-8
Belt (Serpentine Belt), Power Steering Pump ............ 38-5
Belt Assemblies, Center ........................... 10-11-4
Belt Assemblies, Front Driver and Passenger
Seat Buckle-Side .............................. 10-11-2
Belt Assemblies, Front Driver and Passenger Seat
Retractor-Side ................................. 10-11-2
Belt Assemblies, Front Seat ........................ 10-11-1
Belt Assemblies, Front Seat, On-Vehicle Service ...... 10-11-2
Belt Assemblies, Rear Seat ........................ 10-11-1
Belt Assemblies, Rear Seat, On-Vehicle Service ....... 10-11-3
Belt Assemblies, Rear Seat Outer-Side .............. 10-11-3
Belt Inspection, Serpentine Drive ...................... 08-4
Belt Seals, Front Side Door Front and Rear ........... 10-6-11
Belt Tension Specifications, Maintenance and
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 08-9
Belts, Seat ....................................... 10-11-1
Bench-Check Procedures, A/C Compressor .......... 102-11
Bi-Level Valve, Manual Control A/C ................... 181-5
Bladders, Lumbar and Lateral Support,
On-Vehicle Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-10-9
Blade Assembly Replacement, Wiper . . . . . . . . . . . . . . . . . 8E-11
Blade Element Cleaning, Windshield,
Off-Vehicle Service .............................. 8E-16
Blade Element Replacement, Wiper . . . . . . . . . . . . . . . . . . 8E-13
Blade Element Set Check, Windshield,
Bleed Pipe Assembly, Coolant Air .................... 68-22
Bleeder Valves, Hydraulic Modulator ................ 5E1 -167
Bleeding Hydraulic System ........................... 7C-4
Bleeding Procedure, ABS ......................... 5E1 -164
Bleeding the Power Steering System . . . . . . . . . . . . . . . . . . 38-4
Blocker Rings, First/Second, 5-Speed Manual Trans
Blocker Rings, Synchronizer, 5-Speed Manual Trans
Blocker Rings, Third/Fourth, 5-Speed Manual Trans
Blower Module Assembly, Heater and Air
Conditioning Evaporator and ...................... 8C-15
Blower Motor Assembly and Blower Motor Fan . . . . . . . . . 1A-16
Blower Motor Assembly and Evaporator,
Manual Control A/C ............................. 181 -5
Blower Motor Assembly Noise . . . . . . . . . . . . . . . . . . . . . . . . 1A-8
Blower Motor Assembly Relay . . . . . . . . . . . . . . . . . . . . . . . . 1B-5
Blower Motor Assembly Relay, Manual Control A/C .... 181 -15
Blower Motor Assembly Speed Control Knob . . . . . . . . . . . 1A-3
Blower Motor Assembly Switch, Control Assembly
and Vacuum Selector Valve and/or . . . . . . . . . . . . . . . . . . 1A-8
Blower Motor Fan, Blower Motor Assembly and . . . . . . . . 1A-16
Blower Motor Resistor Assembly . . . . . . . . . . . . . . . . . . . . . 1A-16
Blower Motor Speed Control, Manual Control A/C ....... 181-3
Body and Associated Parts, Valve, 4L60 Trans
Unit Repair ................................. 7A-158-48
Body and Chassis, Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
Body Construction, General . . . . . . . . . . . . . . . . . . . . . . . . 10-3-1
Body Dimensions (11 ), Structural Body Repair and . . . . . . 11-30
Body Dimensions and Underbody . . . . . . . . . . . . . . . . . . . 10-3-1
Body Front End . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-5-1
Body Hinge Pillar Inner Panel Sound Barriers . . . . . . . . 10-5-18
Body Hinge Pillar Trim Panel Assembly ............. 10-5-17
Body Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OA-2

Body, Oil Pump Cover and, 4L60 Trans
Unit Repair ................................. 7A-15B-44
Body Panel Adjustment and Alignment . . . . . . . . . . . . . . 10-5-21
Body Panel Assembly Adjustment and Alignment . . . . . 10-1-19
Body Rear End . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-8-1
Body Repair and Dimensions, Structural . . . . . . . . . . . . . . . 11-1
Body Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1
Body Service, General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1-1
Bolster, Knee, SIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9J-6
Bolt Replacement, Wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3E-4
Bolts, Metric Wheel Nuts and . . . . . . . . . . . . . . . . . . . . . . . . . 3E-4
Booster Assembly, Power Brake ..................... 501 -1
Booster Assembly, Power Brake,
Booster System, Vacuum ........................... 501-1
Booster Vacuum Hose and Routing,
Power Brake ................................... 501 -4
Boot Assembly, Manual Transmission
Control Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78-4
Bore Repair Procedure, Governor, 4L60 Trans
Unit Repair ................................. 7A-15B-73
Borg-Warner (T5) 5-Speed Manual Trans
Borg-Warner (T5) 5-Speed Manual Transmission
Unit Repair ................................... 78-68-1
Borg-Warner (T56) 6-Speed Manual Transmission
Unit Repair .................................. 78-1 OB-1
Bracket and Link Assembly, Stabilizer Shaft ............. 30-8
Bracket, Brake Pedal Assembly with . . . . . . . . . . . . . . . . . . . . 5-5
Bracket, Front License Plate . . . . . . . . . . . . . . . . . . . . . . . . 10-4-3
Brackets, Engine Mount Assemblies and,
3.4L L32 Engine On-Vehicle Service .............. 6A2A-4
Brackets, Engine Mount Assemblies and,
5.7L Engine On-Vehicle Service .................. 6A3A-3
Brackets, Front Fender Assembly and . . . . . . . . . . . . . . . 10-5-5
Brackets, Headlamp Housing Panel Assembly and . . . . . 10-5-3
Braided Lead Wire Repair . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2-9
Brake (Center) Hose Assembly, Rear .................. 5-19
Brake Adjustment, Parking ........................... 5F-7
Brake Adjustment, Rear Drum, On-Vehicle Service ..... 5C2-7
Brake Booster Assembly, Power ..................... 501 -1
Brake Booster Assembly, Power,
Brake Caliper Anchor Bracket and Mounting Plate,
Rear .......................................... 582-8
Brake Caliper Assembly, Front, Unit Repair ............ 581 -8
Brake Caliper Assembly Inspection, Rear . . . . . . . . . . . . . . 582-3
Brake Caliper Assembly, Rear, On-Vehicle Service ...... 582-3
Brake Caliper Assembly, Rear, Unit Repair . . . . . . . . . . . 582-11
Brake Combination Valve, ABS ...................... 5E1-8
Brake Combination Valve, ABS,
On-Vehicle Service ............................ 5E1-172
Brake Combination Valve Assembly . . . . . . . . . . . . . . . . . . . . 5-2
Brake Control Module (EBCM), Electronic, ABS ........ 5E1 -6
Brake Control Module (EBCM), Electronic, ABS,
On-Vehicle Service ............................ 5E1 -169
Brake Fluid and Fluid Handling . . . . . . . . . . . . . . . . . . . 5-2, 5A-2
Brake Fluid, Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Brake Fluid Leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Brake Fluid, Substandard or Contaminated ......... 5-2, 5A-2
Brake Free-Travel Adjustment, Parking ................ 582-9
Brake Hose and Pipe Assembly Inspection . . . . . . . . . . . . . . 5-5
Brake Hose Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18
INDEX 5
Brake Hose Assembly, Front . . . . . . . . . . . . . . . . . . . . . . . . . 5-18
Brake Hose Assembly, Rear . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19
Brake Hydraulic System, Flushing . . . . . . . . . . . . . . . . . . . . . . 5-2
Brake Hydraulic System, Flushing,
"BRAKE" Indicator Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5F-1
Brake Inner and Outer Pad Assemblies Inspection,
Rear Disc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 582-2
Brake Inner and Outer Pad Assemblies,
Rear Disc, On-Vehicle Service .................... 582-6
Brake Lever Assembly, Parking . . . . . . . . . . . . . . . . . . . . . . . 5F-1
Brake Lever Assembly, Parking, On-Vehicle Service ..... 5F-3
Brake, Parking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5F-1
Brake Pedal Assembly, On-Vehicle Service .............. 5-8
Brake Pedal Assembly Travel . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Brake Pedal Assembly with Bracket . . . . . . . . . . . . . . . . . . . . 5-5
Brake Performance, External Conditions
That Affect . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 5-4
Brake Pipe Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11
Brake Pipe Assembly, Double Lap Flare . . . . . . . . . . . . . . . . 5-15
Brake Pipe Assembly ISO Flare . . . . . . . . . . . . . . . . . . . . . . . 5-16
Brake Pressure Differential Warning Switch . . . . . . . . . . . . . . 5-2
Brake Proportion Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Brake Rotor Assemblies, Burnishing Rear . . . . . . . . . . . . 582-11
Brake Rotor Assemblies, Refinishing Rear ............. 582-9
Brake Rotor Assembly Inspection, Front ............... 581-2
Brake Rotor Assembly Inspection, Rear ............... 582-2
Brake Rotor Assembly, Rear, On-Vehicle Service ....... 582-8
Brake Rotor Assembly Tolerance and Surface
Finish, Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 582-2
Brake Rotor, Non-Directional Finishing, Front .......... 581 -7
Brake System, Antilock ............................. 5E1-1
Brake System, Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Brake System, Parking .............................. 5F-1
Brake System Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Brake Transmission Shift Interlock (BTSI) .............. 3F-3
Brakes ............................................. 5-1
Brakes Diagnosis, Rear Disc . . . . . . . . . . . . . . . . . . . . . . . . 582-2
Brakes, Duo-Servo Drum ........................... 5C2-1
Brakes, Front Disc ................................. 581-1
Brakes, Rear Disc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 582-1
Braking Mode Operation Anti lock ..................... 5E1 -4
Braking Mode Operation, Base, ABS ................. 5E1 -3
Buckle-Side Belt Assemblies, Front Driver and
Passenger Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-11-2
Buffer, Vehicle Speed Sensor (VSS) ................... 8C-4
Built-In Hydrometer ................................ 601-3
Bulb Replacement, Courtesy Lamp . . . . . . . . . . . . . . . . . . 10-2-6
Bulb Usage Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88-16
Bulbs, Halogen ........... -.......................... 88-2
Bumper Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-4-1
Bumper Assembly, Front . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-4-1
Bumper Assembly, Jounce, Rear Suspension ........... 30-1
Bumper Assembly, Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-4-6
Bumper Energy Absorber, Front . . . . . . . . . . . . . . . . . . . . . 10-4-3
Bumper Energy Absorber, Rear . . . . . . . . . . . . . . . . . . . . . 10-4-6
Bumper Fascia Emblem Assemblies, Front . . . . . . . . . . . 10-4-4
Bumper Fascia, Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-4-1
Bumper Fascia Lower Deflectors, Front . . . . . . . . . . . . . . 10-4-5
Bumper Fascia, Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-4-6
Bumper, Front Side Door . . . . . . . . . . . . . . . . . . . . . . . . . 10-6-27
Bumper, Hood Adjust Front . . . . . . . . . . . . . . . . . . . . . . . . 10-5-15
Bumper Impact Bar Assembly, Front . . . . . . . . . . . . . . . . . 10-4-3
Bumper Impact Bar, Rear . . . . . . . . . . . . . . . . . . . . . . . . . . 10-4-6
Bumpers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-4-1
Bumpers, Front Side Door Window Front
and Rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-6-36
Burnishing Front Brake Rotor Assemblies ............. 581 -8
Burnishing Rear Brake Rotor Assemblies ............. 582-11
Bushing Assembly, Lower Control Arm,
Bushing Assembly, Lower Control Arm,
Rear Suspension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30-1
Bushing Replacement Procedure, 4L60 Trans
Unit Repair ................................. 7A-158-70
Bushing, Upper Control Arm, Front Suspension ........ 3C-16
c
Cable Assemblies, Parking Brake . . . . . . . . . . . . . . . . . . . . . 5F-1
Cable Assembly (Disc Brakes), Rear,
Parking Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5F-6
Cable Assembly (Drum Brakes), Rear,
Parking Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5F-5
Cable Assembly Adjustment, Cruise Control . . . . . . . . . . . 98-17
Cable Assembly Adjustment, Temperature Control . . . . . . . 1A-8
Cable Assembly, Automatic Transmission TV,
Cable Assembly, Cruise Control,
Cable Assembly, Front, Parking Brake . . . . . . . . . . . . . . . . . 5F-3
Cable Assembly, Hood Primary Latch Release . . . . . . . 10-5-12
Cable Assembly Replacement, Cruise Control . . . . . . . . . 98-16
Cable Assembly, Setting Automatic
Transmission TV ................................ 7A-17
Cable Assembly System, Automatic
Transmission TV ................................ 7A-13
Cable Assembly System Diagnosis,
Automatic Transmission TV ....................... 7A-14
Cable Assembly System Parts, Inspection of
Automatic Transmission TV ....................... 7A-16
Cable Assembly, Temperature Control ................ 1A-15
Cables Assemblies, Parking Brake,
On-Vehicle Service ............................... 5F-3
Caliper Assembly, Front Brake ....................... 581 -1
Caliper Assembly, Front Brake, On-Vehicle Service ..... 581 -4
Caliper Assembly, Front Brake, Unit Repair ............ 581 -8
Caliper Assembly Inspection, Front Brake ............. 581 -4
Caliper Assembly Inspection, Rear Brake .............. 582-3
Caliper Assembly, Rear Brake, On-Vehicle Service ...... 582-3
Caliper Assembly, Rear Brake, Unit Repair . . . . . . . . . . . 582-11
Camber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-1
Camber Adjustment, Front Caster and ................. 3A-4
Camshaft, 3.4L L32 Engine Assembly .............. 6A2B-46
Camshaft, 3.4L L32 Engine Disassembly ............ 6A2B-18
Camshaft Assembly, 3.4L L32 Engine
Camshaft Assembly, 5.7L Engine
Unit Repair Assembly .......................... 6A38-34
Unit Repair Cleaning, Inspection and Repair ...... 6A3B-29
Unit Repair Disassembly ....................... 6A3B-14
Camshaft Bearings, 3.4L L32 Engine Assembly ...... 6A2B-41
Camshaft Bearings, 3.4L L32 Engine
Disassembly ................................. 6A2B-22
6 INDEX
Camshaft Bearings, 5.7L Engine Unit Repair
Assembly .................................... 6A3B-31
Camshaft Bearings, 5. 7L Engine Unit Repair
Disassembly ................................. 6A3B-16
Camshaft Inspection, 3.4L L32 Engine .............. 6A28-38
(3.4L L32 Engine) ............................... 604-2
(3.4L L32 Engine), On-Vehicle Service ............. 604-9
Driveshaft Assembly, Timing Chain Assembly ..... 6A3B-30
Camshaft Sprockets, Timing Chain Assembly,
and Crankshaft and, 3.4L L32 Engine
Cap and Lines Inspection, Fuel Tank ................... 08-5
Cap Assembly, Radiator Filler . . . . . . . . . . . . . . . . . . . . . . . . 68-2
Cap Assembly, Radiator Filler, Diagnosis . . . . . . . . . . . . . . . 68-4
Capacity, Reserve, Battery Assembly ................. 601 -2
Care, Cleanliness and, Engine . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Carpet Assembly, Floor . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-10-1
Carpet Assembly, Floor, On-Vehicle Service ........ 10-10-25
Carpet Insert Reattachment . . . . . . . . . . . . . . . . . . . . . . . 10-1-19
Carpet, Seats and . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1 0-1
Carrier and Sun Gear, Input, 4L60 Trans
Unit Repair ................................. 7A-15B-23
Carrier Assembly, Reaction Internal Gear and,
Carrier, Instrument Panel, On-Vehicle Service .......... 8C-17
Case, 4L60 Trans Unit Repair ................... 7A-15B-13
Case Assembly, 4L60 Trans Unit Repair .......... 7A-158-13
Case Extension Oil Seal Assembly ................... 7A-30
Case Extension, Speed Sensor/Speedometer and,
4L60 Trans Unit Repair ....................... 7A-158-4
Case Extension, Speed Sensor/Speedometer and,
Case Extension, Speedometer Drive Gear and
Automatic Transmission .......................... 7A-22
Case Porosity Repair, Transmission ................... 7A-8
Case, Transmission, 6-Speed Manual Trans
Assembly .................................. 78-108-27
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78-108-8
Repair and Inspection ....................... 78-108-21
Cassette Care, Tape Player and ...................... 9A-7
Cassette Tape Player, ETR AM/FM
Stereo/Cassette (UM6) ............................ 9A-3
Cassette Tape Player, ETR AM/FM
Stereo/Cassette/Equalizer (UX1) ................... 9A-4
Caster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3A-1
Caster and Camber Adjustment, Front ................. 3A-4
Catalytic Converter Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 6F-1
Catalytic Converter Assembly, On-Vehicle Service ....... 6F-4
Catalytic Converter Hanger Assembly,
Catalytic Converter Heat Shield,
On-Vehicle Service .............................. 6F-11
Caulking Kit, Adhesive, Stationary Windows . . . . . . . . . . 10-2-1
Center Belt Assemblies ............................ 10-11-4
Center, Convenience, Instrument Panel and Gages ...... 8C-2
Center Support Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-1
Center Support Bearing Replacement . . . . . . . . . . . . . . . . . 4A-12
Chain and Sprocket Noises, Timing Gear or . . . . . . . . . . . . . 6-4
Chain Usage, Tire .................................. 3E-2
Channel Assembly, Front Side Door Window . . . . . . . . . 10-6-14

Charging a Very Low or Completely Discharged
Battery Assembly ............................... 601 -7
Charging, Battery Assembly ......................... 601-6
Charging Equipment, Battery ....................... 601-10
Charging Procedure, Battery Assembly ............... 601-7
Charging System .................................. 603-1
Charging the A/C System (Engine Off) . . . . . . . . . . . . . . . . 18-14
Charging Time Required, Battery Assembly ............ 601-7
Chassis, Electrical Body and . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
Chassis Fuel Feed and Return Pipes ................. 6C-14
Chassis Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 08-4
Chatter Repair, Wiper .............................. 8E-16
Check Ball "Fail Safe" System, Checking Lifter and,
Automatic Trans ................................ 7A-16
Check Valve, Vacuum .............................. 501 -4
Chemical Stability in the Refrigeration System,
Maintaining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18-9
Child Seat, Seat Belts ............................. 10-11-4
(Canadian Vehicles) ............................ 10-11-6
(U.S. Vehicles) ................................. 10-11-4
Chimes, Warning/Reminder .......................... 8C-6
Chimes, Warning/Reminder, On-Vehicle Service ........ BC-25
Circuit, Cranking ................................... 602-1
Circuit Description, Fluid Flow and,
4L60 Trans Diagnosis ........................ 7A-15A-18
Circuit Diagnosis, A/C Clutch . . . . . . . . 5. 7L (VIN P) 6E3-C10-1
Clamps and Welded Connections,
Exhaust System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6F-2
Clamps Inspection, Hose Assemblies and,
Cooling and Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68-3
Cleaning, Inspection and Testing
(PG-250 and 80210 Starter Motor Assemblies) ..... 602-10
Cleanliness and Care, Engine . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Clearance Dimensions, Exhaust System . . . . . . . . . . . . . . 6F-13
Clearcoat Application, Metal Part Refinishing . . . . . . . . . 10-1-10
Clearcoat Damage, Wet Sanding,
Finesse Polishing, Slight .. .- ..................... 10-1-11
Clearcoat Repair without Repainting,
Metal Part Refinishing . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1-9
ClearcoatThickness .............................. 10-1-11
Clock Radio Assembly, AM/FM Stereo and,
On-Vehicle Service ............................... BC-7
Closeout Filler, Hood . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-5-9
Closeout Filler, Taillamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-8-6
Closeout Panel Assembly, Rear Compartment
Lift Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-8-7
Cluster Assembly, Instrument, On-Vehicle Service ...... 8C-16
Cluster Bezel Assembly, Upper Trim Panel
Assembly and Compartments, Trim Panel .......... 8C-22
Cluster Trim Plate Bezel Assembly,
Instrument Panel ................................ 8C-22
Cluster Warning Lamps .............................. 8C-5
Clutch ............................................. 7C-1
Clutch (TCC) System (A/T), Torque
Converter ....................... 5.7L (VIN P) 6E3-C8-1
Clutch (TCC) System, Torque
Converter . . . . . . . . . . . . . . . . . . . . . . . 3.4L (VIN S) 6E3-C8-1
Clutch Air Check, 4L60 Trans Unit Repair ......... 7A-158-34
Clutch Anticipate Switch Assembly .................... 7C-7
Clutch Application Chart, 4L60 Trans Diagnosis ..... 7A-15A-7
Clutch Assembly, 3-4, 4L60 Trans Unit Repair ...... 7A-158-34
INDEX 7
Clutch Assembly, Input, 4L60 Trans
Unit Repair ................................. 7A-158-24
Clutch Assembly, Reverse Input, 4L60 Trans
Unit Repair ................................. 7A-15B-36
Clutch Backing Plate Selection, Reverse Input,
4L60 Trans Unit Repair ...................... 7A-158-38
Clutch Coil, Compressor ............................ 102-7
Clutch Diagnosis, Torque Converter ................... 7A-9
Clutch Driven Plate Assembly (5-Speed) ............... 7C-8
Clutch Driven Plate Assembly (6-Speed) ............... 7G-9
Bearing Assembly (5-Speed) ...................... 7C-12
Bearing Assembly (6-Speed) ...................... 7C-12
Clutch, Hydraulic ................................... 7C-2
Clutch Master and Actuator Cylinder Assembly .......... 7C-7
Clutch Parts, Lo and Reverse, 4L60 Trans
Unit Repair ................................. 7A-158-11
Clutch Pedal Assembly ............................. 7C-7
Clutch Pedal Position Switch Assembly
(Clutch Start Switch Assembly) ..................... 7C-8
Clutch Pilot Bearing ................................. 7C-2
Clutch Pilot Bearing, On-Vehicle Service .............. 7C-13
Clutch Piston Travel Check, 3-4, 4L60 Trans
Unit Repair ................................. 7A-158-34
Clutch Piston Travel Check, Forward,
Clutch Plate and Hub Assembly, Compressor .......... 102-3
Clutch Preliminary Checks ........................... 7C-2
Clutch Release Bearing Assembly (5-Speed),
Clutch Fork Assembly and ........................ 7C-12
Clutch Release Bearing Assembly (6-Speed),
Clutch Fork Assembly and ........................ 7C-12
Clutch Rotor and/or Bearing, Compressor ............. 102-4
Clutch Spacer Plate Selection, Lo and Reverse,
4L60Trans Unit Repair ...................... 7A-15B-17
Clutch Sprag Assembly, Forward, 4L60 Trans
Unit Repair ................................. 7A-158-31
Clutch Support Assembly, Lo and Reverse,
Clutch System Diagnosis ............................ 7C-2
Clutches, Reverse Input and Input, 4L60 Trans
Unit Repair ................................. 7A-158-39
Coast Test, Propeller Shaft ........................... 4A-3
Codes, Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OA-19
Codes, Option and Process ......................... OA-21
Coding, Lock Cylinder ............................... OA-6
Coding Lock Cylinders, Assembling and ................ OA-8
Coil Assembly (3.4L L32 Engine), Ignition,
On-\Jehicle Service .............................. 604-8
Coil Assembly (3.4L L32 Engine), Ignition,
Unit Repair .................................... 604-10
Coil Assembly (5.7L LT1 Engine), Ignition,
On-\Jehicle Service .............................. 604-6
Coil Assembly, SIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9J-6
Cold Cranking Amps, Battery Assembly ............... 601 -2
Column Assembly Removal, Steering . . . . . . . . . . . . . . . . . 3F-11
Column Assembly, Steering . . . . . . . . . . . . . . . . . . . . . . . . . . 3F-3
Column, Lower, SIR Tilt Steering Floor Shift
Unit Repair ................................... 3F5B-15
Column, Mid, SIR Tilt Steering Floor Shift
Unit Repair ................................... 3F5B-11
Column On-Vehicle Service, Steering Wheel and ........ 3F-1
Column, Steering, SIR ............................... 9J-6
Column, Upper, SIR Tilt Steering Floor Shift

Unit Repair .................................... 3F5B-4
Column-Mounted Dimmer Switch, Steering
Column Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
Combination Valve Assembly, Brake . . . . . . . . . . . . . . . . . . . . 5-2
Combination Valve Assembly, Brake,
Common Causes of Failure, Battery Assembly ......... 601 -2
Compact Disc Care ................................. 9A-7
Compact Disc Player, ETR AM/FM
Stereo/Compact Disc Player/Equalizer (U1A) ......... 9A-5
Compact Spare Tire Assembly . . . . . . . . . . . . . . . . . . . . . . . . 3E-8
Compartment, Instrument Panel,
On-Vehicle Service .............................. 8C-23
Compartment Lamp, Instrument Panel ................. 88-4
Compartment Lamp, Instrument Panel,
Compartment Lamp Switch .......................... 8C-12
Compartments, Trim Panel Cluster Bezel
Assembly, Upper Trim Panel Assembly and ......... 8C-22
Component Repair and Transmission Reassembly,
Component Replacement, Exhaust System . . . . . . . . . . . . . 6F-3
Components, Daytime Running Lamp (DRL)
(Canadian Only) ................................ 8C-10
Components, Other, Manual Control A/C .............. 181-4
Compression Test, Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
Compressor and Condenser Hose Assembly,
Air Conditioning, On-Vehicle Service ............... 18-16
Compressor Assembly, Air Conditioning . . . . . . . . . . . . . . . . 1B-4
Compressor Assembly, Air Conditioning,
On-Vehicle Service .............................. 1B-20
Compressor Assembly, Manual Control A/C ............ 181-8
Component Replacement . . . . . . . . . . . . . . . . . . . . . . . . 1B-24
Compressor Bracket Assembly (3.4L L32 Engine),
Generator and Air Conditioning . . . . . . . . . . . . . . . . . . . . 1B-23
Compressor Clutch Coil ............................ 102-7
Compressor Clutch Control, A/C . . . . . 3.4L (VIN S) 6E3-C10-1
Compressor Clutch Plate and Hub Assembly .......... 102-3
Compressor Clutch Rotor and/or Bearing . . . . . . . . . . . . . . 102-4
Compressor Leak Testing .......................... 102-11
Compressor Low Pressure Cutoff Switch Assembly,
Air Conditioning, Manual Control ................. 181 -17
Compressor Pressure Relief Valve .................. 102-10
Compressor Relay, Air Conditioning . . . . . . . . . . . . . . . . . . . 1B-5
Compressor Relay, Air Conditioning,
Manual Control ................................ 181-15
Compressor Repair Procedures, Major . . . . . . . . . . . . . . . . 102-8
Compressor Repair Procedures, Minor ................ 102-3
Compressor Service or Unit Repair,
HD6/HR6- HE Air Conditioning ................... 102-1
Compressor Shaft Seal Replacement . . . . . . . . . . . . . . . . . 102-8
Compressor System, On-Vehicle Service .............. 18-14
Condenser Assembly, Air Conditioning . . . . . . . . . . . . . . . . . 1B-4
Condenser Assembly, Air Conditioning,
Condenser Assembly, Manual Control A/C ............. 181 -9
Condenser Hose Assembly, Air Conditioning
Compressor and, On-Vehicle Service . . . . . . . . . . . . . . 18-16
Connecting Rod Assemblies, Piston and,
3.4L L32 Engine On-Vehicle Service ............. 6A2A-26
Connecting Rod Assemblies, Piston and,
8 INDEX
Connecting Rod Assembly, Piston and,
Connecting Rod Bearing Noise . . . . . . . . . . . . . . . . . . . . . . . . 6-4
Connecting Rod Bearings, 3.4L L32 Engine
Connecting Rod Bearings, 5. 7L Engine
Connecting Rod Bearings, 5.7L Engine
Connecting Rod Bearings, 5.7L Engine
Connecting Rod, Piston and, 3.4L L32 Engine
Disassembly ................................. 6A2B-21
Connecting Rods, Pistons and, 3.4L L32 Engine
Assembly .................................... 6A2B-44
Connecting Rods, Pistons and, 3.4L L32 Engine
Cleaning, Inspection and Repair ................. 6A2B-26
Connector and Seal, Electrical . . . . . . . . . . . . . . . . . . . . . . . 7A-30
Connector, Data Link (DLC) .......................... 8C-9
Connectors, Electrical, ABS ....................... 5E1 -173
Console Assembly, Front Floor . . . . . . . . . . . . . . . . 8C-2, 8C-10
Console Lamp ..................................... 88-3
Console Lamp, On-Vehicle Service ................... 88-13
Construction, 5.7L Engine Unit Repair ............... 6A3B-6
Contact Pattern Test, Tooth, Rear Axle ................. 48-7
Contact Plate Assembly, Steering Wheel
Horn Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3F-8
Contaminated Brake Fluid, Substandard or . . . . . . . . . 5-2, 5A-2
Control Arm Assembly, Lower, Front Suspension ........ 3C-7
Control Arm Assembly, Lower, Rear Suspension . . . . . . . . . 30-5
Control Arm Assembly, Upper, Front Suspension ....... 3C-15
Control Arm Ball Stud Assembly Inspection,
Control Arm Ball Stud Assembly, Lower,
Control Arm Ball Stud Assembly Replacement,
Lower, Front Suspension .......................... 3C-4
Upper, Front Suspension .......................... 3C-6
Control Arm Ball Stud Assembly, Upper,
Control Arm Bushing Assembly, Lower,
Control Arm Bushing Assembly, Lower,
Rear Suspension ................................ 30-1
Control Arm Bushing, Upper, Front Suspension ........ 3C-16
Control Assembly (5-Speed), Manual Transmission .. , ... 78-6
Control Assembly (6-Speed), Manual Transmission ...... 78-8
Control Assembly and Vacuum Selector Valve
and/or Blower Motor Assembly Switch . . . . . . . . . . . . . . . 1A-8
Control Assembly, Heater and Air Conditioning . . . . . . . . . . 8C-9
Control Assembly, Heater and Ventilation ............... 1A-1
Control Assembly Lamp Bulb . . . . . . . . . . . . . . . . . . . . . . . . 1A-14
Control Assembly, Manual Control NC ................ 181-2
Control Cable Replacement (3.4L VIN S),
Accelerator ..................................... 6C-18
Control Cable Replacement (5.7L VIN P),
Accelerator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6C-18
Control Lamp, Heater and Air Conditioning . . . . . . . . . . . . . 88-3
Control Lamp, Heater and Air Conditioning,
Control Lever Boot Assembly, Manual Transmission ...... 78-4
Control Lever Handle Assembly (6-Speed),

Manual Transmission ............................. 78-8
Control Lever Solenoid, Automatic Transmission ........ 7A-12
Control, Mode, Manual Control NC ................... 181 -2
Control Switch Assembly, Headlamp Automatic
Beam ......................................... 8C-12
Control Switch Assembly, Radio . . . . . . . . . . . . . . . . . . . . . . 3F-8
Control Switches, NC Compressor .................. 102-11
Control Switches, Functional, Cruise Control ............ 98-2
Control, Temperature, Manual Control NC ............. 181 -2
Control Valve Assembly, 4L60 Trans
Unit Repair ................................. 7A-158-49
Control Valve Assembly, Automatic Trans .............. 7A-26
Control Valve Assembly, Power Steering Pump
Unit Repair .................................... 381 B-6
Controls, Instrument Panel, Gages and Console
On-Vehicle Service ............................... 8C-7
Controls, Pneumatic Comfort, Diagnosis . . . . . . . . . . . . 10-10-2
Controls, Radio Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9A-2
Convenience Center, Instrument Panel, Gages and
Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8C-2
Convenience Center, On-Vehicle Service .............. 8C-20
Conversions, English-Metric . . . . . . . . . . . . . . . . . . . . . . . . . OA-11
Converter Assembly, Catalytic . . . . . . . . . . . . . . . . . . . . . . . . 6F-1
Converter Assembly, Catalytic, On-Vehicle Service . . . . . . . 6F-4
Converter Clutch Diagnosis, Torque ................... 7A-9
Converter Cover, Transmission ...................... 7A-24
Converter Evaluation, Torque, 4L60 Trans
Diagnosis ................................... 7A-15A-4
Coolant Air Bleed Pipe Assembly .................... 68-22
Coolant, Checking Engine ............................ 68-3
Coolant Concentration, Engine ........................ 68-3
Coolant Drain Hole Plug, Engine Block . . . . . . . . . . . . . . . . . 68-3
Coolant Fan Assembly, Electric Engine . . . . . . . . . . . . 1B-4, 68-2
Coolant Fan Assembly, Electric Engine,
Coolant Heater Assembly Replacement, Engine . . . . . . . . . 9E-1
Coolant Heater Cord Assembly Replacement,
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9E-2
Coolant Heater, Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9E-1
Coolant Hose Assemblies, Engine .................... 68-21
Coolant Level Sensor, On-Vehicle Service ............. 68-19
Coolant Pump, 3.4L L32 Engine Assembly .......... 6A2B-48
Coolant Pump, 3.4L L32 Engine Cleaning,
Inspection and Repair ......................... 6A2B-39
Coolant Pump, 3.4L L32 Engine Disassembly ........ 6A2B-17
Coolant Recovery Reservoir Assembly,
Battery Tray and ................................ 68-19
Coolant Recovery System . . . . . . . . . . . . . . . . . . . . . . . . . . . 68-3
Coolant Temperature (ECT) Sensor, Engine ............ 68-3
Coolant Temperature Gage Sensor, Engine ............. 68-3
Coolant Testing, Engine ............................. 68-22
Coolant Thermostat Assembly, Engine . . . . . . . . . . . . . . . . . 68-3
Cooler Assembly, Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . 68-2
Cooler Flushing Procedure, Oil, Automatic Trans ....... 7A-19
Cooling and Radiato . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68-1
Cooling Check, Insufficient, Manual Control NC ....... 181-10
Cooling Fan Control . . . . . . . . . . . . . . . . 3.4L (VIN S) 6E3-C12-1
Cooling Fin Removal, Aluminum Radiator
Cooling System Diagnosis Chart . . . . . . . . . . . . . . . . . . . . . . 68-5
Cooling System, Draining and Refilling the .............. 68-6
Cooling System Overheating, Diagnosis ................ 68-4
Cooling System Service ............................. OB-4
INDEX 9
Core Repair, General, Aluminum Radiator
Correcting Non-Uniform Tires . . . . . . . . . . . . . . . . . . . . . . . . 3E-11
Corrosion Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1-9
Countershaft, 6-Speed Manual Trans Repair and
Inspection .................................. 78-108-13
Countershaft Bearing, Front, 5-Speed Manual
Trans Cleaning and Inspection ................. 78-68-12
Countershaft Extension, 6-Speed Manual Trans .... 78-108-32
Countershaft Extension Assembly, 6-Speed
Manual Trans Assembly ...................... 78-1 OB-28
Manual Trans Disassembly .................... 78-108-7
Manual Trans Repair and Inspection ........... 78-1 OB-13
Countershaft, Input Shaft/Mainshaft and,
6-Speed Manual Trans ....................... 78-1 OB-32
Coupling Shaft Assembly, Steering Gear . . . . . . . . . . . . . . 3F-1 O
Courtesy Lamp Bulb Replacement . . . . . . . . . . . . . . . . . . 10-2-6
Courtesy Lamps, Front Side Door . . . . . . . . . . . . . . . . . . . . . 88-3
Courtesy Lamps, Front Side Door,
Cover (Assemble), Oil Pump, 4L60 Trans
Unit Repair ................................. 7A-15B-43
Cover (Disassemble), Oil Pump, 4L60 Trans
Unit Repair ................................. 7A-158-41
Cover and Body, Oil Pump, 4L60 Trans
Unit Repair ................................. 7A-15B-44
Cover Assemblies, Valve Rocker Arm,
5.7L Engine Unit Repair Disassembly ............ 6A3B-11
Cover Assembly, Engine Front, 3.4L L32 Engine
Cover Assembly, Engine Front, 5.7L Engine
Cover Assembly, Engine Front, 5.7L Engine
Cover Assembly, Rear Compartment Lift Window
Inner Panel ................................... 10-8-11
Cover Assembly Replacement, Wiper Motor . . . . . . . . . . . 8E-15
Cover, Engine Front, 3.4L L32 Engine Assembly ..... 6A2B-48
Cover, Front Fog Lamp Opening . . . . . . . . . . . . . . . . . . . . 10-4-4
Cover, Transmission Converter ...................... 7A-24
Covers, Rear Trim and, On-Vehicle Service ......... 10-10-22
Covers, Trim, On-Vehicle Service . . . . . . . . . . . . . . . . . . 10-10-5
Cracked, Scored or Grooved, Duo-Servo
Drum Brakes ................................... 5C2-7
Cradle-to-Body Fastener Repair . . . . . . . . . . . . . . . . . . . . . 10-3-1
Crankcase Ventilation Filter Replacement,
Air Cleaner and . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OB-5
Crankcase Ventilation System . . . . . . . 3.4L (VIN S) 6E3-C14-1
Crankcase Ventilation System ....... 5.7L (VIN P) 6E3-C14-1
Cranking Circuit ................................... 602-1
Cranking System .................................. 602-1
Crankshaft, 3.4L L32 Engine Assembly ............. 6A2B-42
Crankshaft, 3.4L L32 Engine Cleaning,
Crankshaft, 3.4L L32 Engine Disassembly ........... 6A2B-21
Crankshaft and Camshaft Sprockets,
Timing Chain Assembly, and, 3.4L L32 Engine
Crankshaft Assembly, 5.7L Engine Unit Repair

Assembly .............................. : ..... 6A3B-32
Crankshaft Assembly, 5.7L Engine Unit Repair
Crankshaft Balancer Assembly, 3.4L L32 Engine
Crankshaft Balancer Assembly and Hub,
5. 7L Engine Unit Repair Assembly ............... 6A3B-36
Crankshaft Bearing Fitting, 5.7L Engine
Crankshaft Bearings, 3.4L L32 Engine
Crankshaft Bearings, 5.7L Engine
Crankshaft Position Sensor Assembly
(3.4L L32 Engine), 24X Signal .................... 604-2
(3.4L L32 Engine), 3X Signal ...................... 604-2
(3.4L L32 Engine), 3X Signal,
Crankshaft Rear Oil Seal, 5.7L Engine
Crankshaft Rear Oil Seal Assembly,
Crankshaft Rear Oil Seal Assembly,
Crankshaft Rear Oil Seal Housing,
5. 7L Engine Unit Repair Assembly ............... 6A3B-33
Crankshaft Rear Oil Seal Housing Assembly
and Gasket, 5.7L Engine On-Vehicle Service ...... 6A3A-28
Cross-Flow Radiator Core and Outlet and
Inlet Tanks ...................................... 68-2
Crossmember Assembly, Front Suspension ............ 3C-16
Crossover Pipe Assembly, Exhaust . . . . . . . . . . . . . . . . . . . . 6F-1
Crossover Pipe Assembly, Exhaust,
Cruise Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98-1
Cruise Control Cable Assembly,
Cruise Control Module Assembly . . . . . . . . . . . . . . . . . . . . . . 98-1
Cruise Control Module Assembly,
Cruise Control Switch Assemblies . . . . . . . . . . . . . . . . . . . . . 98-1
Cruise Control Switch Assemblies,
Cruise Control Switch Assemblies, Stoplamp and . . . . . . . . . 5-8
"CRUISE" (Cruise Control) Indicator Lamp .............. 8C-5
CS Generator Assembly Bench Check ................ 603-2
CS Generator Assembly On-Vehicle Check ............ 603-2
(3.4L L32 Engine), On-Vehicle Service ............. 603-3
(3.4L L32 Engine), Unit Repair .................... 603-6
CS-130 and CS-144 Generator Assemblies ............ 603-1
(5.7L LT1 Engine), On-Vehicle Service ............. 603-6
CS-144 124-Amp Generator Disassembly,
Test and Reassembly (5.7L LT1 Engine) ............ 603-6
CS-144 Generator Assemblies, CS-130 and ........... 603-1
10 INDEX
Cushion Assemblies, Front Seat,
On-Vehicle Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-10-9
Cutoff Switch Assembly, Air Conditioning
Compressor Low Pressure, Manual Control ........ 181 -17
Cutoff Switch Assembly, Air Conditioning Low
Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-5
Cylinder Block, 3.4L L32 Engine Assembly .......... 6A2B-41
Cylinder Block, 3.4L L32 Engine Cleaning,
Cylinder Head, 3.4L L32 Engine Assembly .......... 6A2B-45
Cylinder Head, 3.4L L32 Engine Disassembly ........ 6A2B-20
Cylinder Head Assembly, 5.7L Engine
Cylinder Head Assembly, 5.7L Engine
Cylinder Head Assembly, 5. 7L Engine
Unit Repair Disassembly ....................... 6A38-14
Cylinder Head Assembly and Gasket,
Cylinder Head Assembly and Gasket,
Cylinder Head Reconditioning, 3.4L L32 Engine ...... 6A2B-33
Cylinder Line Assembly and 0-Ring Seals,
Power Steering Gear Unit Repair ................. 381 A-5
Cylinder Unit, Lock, Doors . . . . . . . . . . . . . . . . . . . . . . . . 10-6-28
Cylinders, Replacement Lock . . . . . . . . . . . . . . . . . . . . . . . . . OA-6
D
Damage Repair, Rail Dust .......................... 10-1-11
Damper, Torsional, 3.4L L32 Engine Assembly ....... 6A2B-49
Dash Sound Barrier Assembly . . . . . . . . . . . . . . . . . . . . . 10-5-17
Data Link Connector (DLC) ........................... 8C-9
Daytime Running Lamp Ambient Light Sensor
(Canadian Only) ................................. 8C-4
Sensor Assembly ............................... 8C-1 O
Sensor Module Assembly ........................ 8C-1 O
Daytime Running Lamp Components
(Canadian Only) ................................ 8C-10
Daytime Running Lamps (Canadian Only) ......... 88-2, 8C-2
Decal, Exterior Moldings and, Body Front End . . . . . . . . 10-5-19
Decal, Headlamp Opening Door . . . . . . . . . . . . . . . . . . . 10-5-20
Decals, Stripes and . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1-2
Decimal and Metric Equivalents . . . . . . . . . . . . . . . . . . . . . . OA-11
Definitions, Transmission Assembly ................... 7A-2
Deflector, Driver Knee Bolster Assembly and ........... 8C-1 O
Deflector, Radiator Air Lower . . . . . . . . . . . . . . . . . . . . . . . 10-5-3
Deflector, Radiator Air Lower Baffle Assembly and . . . . . . 68-20
Deflectors, Air, Heater and Ventilation
Deflectors, Front Bumper Fascia Lower . . . . . . . . . . . . . . 10-4-5
Deflectors, Radiator Air Baffle Assemblies and .... 68-3, 68-20
Defogger Outlet Duct Assembly ...................... 8C-14
Defogger, Rear Window . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2-7
Defrost Valve, Heater and, Manual Control A/C ......... 181-5
Defrosting, Insufficient Heating or ..................... 1A-8
Dehydrator Assembly, Air Conditioning Receiver and ..... 18-4
Dehydrator Assembly, Air Conditioning Receiver and,
Dehydrator Assembly, Receiver, Manual Control A/C .... 181 -9
Dehydrator Tube, Air Conditioning Receiver,
Delco-Loe II Anti-Theft Feature, Setting ................ 9A-6

Deployed Inflatable Restraint Steering Wheel
Module Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3F-4
Deployed lnflator Module, SIR Removal and
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9J-B-7
Deployment-Component Inspections, Accident
With or Without . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . 9J-22
Deployment-Component Replacement and
Inspections, Accident With . . . . . . . . . . . . . . . . . . . . . . . 9J-22
DERM ............................................ 9J-4
Diagnostic Energy Reserve Module,
SIR Removal and Installation . . . . . . . . . . . . . . . . . . . 9J-B-3
Diagnostic System Check, SIR . . . . . . . . . . . . . . . . . . . . . 9J-A-4
Diagnostic Trouble Codes, SIR ..................... 9J-A-2
Differential Bearing Assembly Preload Adjustment ...... 48-19
Differential Case (Limited Slip) ....................... 48-24
Differential Case, Rear Axle, Unit Repair .............. 48-16
Differential Drive Pinion Gear . . . . . . . . . . . . . . . . . . . . . . . . 48-20
Differential Drive Pinion Gear Depth .................. 48-22
Differential Drive Pinion Gear Inner Bearing
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . .. 48-22
Differential Drive Pinion Gear Outer Bearing
Assembly ...................................... 48-21
Differential Drive Pinion Gear Position on
Tooth Pattern, Effects of ........................... 48-8
Differential Drive Pinion Gear Yoke and Seal ........... 48-13
Differential Drive Pinion Gear Yoke Runout
Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4A-5
Differential Ratios and Tire Information ................. OA-6
Differential Ring Gear Tooth Nomenclature . . . . . . . . . . . . . 48-7
Differential Ring Gear-to-Differential Drive Pinion
Gear Backlash . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48-18
Differential Warning Switch, Brake Pressure . . . . . . . . . . . . . 5-2
Dimensions ........................................ 11-8
Dimensions, Structural Body Repair and . . . . . . . . . . . . . . . 11-1
Dimmer Switch Assembly, Headlamp and
Instrument Panel Lamp ........................... 8C-4
Dimmer Switch Assembly, Headlamp and
Instrument Panel Lamp, On-Vehicle Service ......... 8C-18
Dimmer Switch Assembly, Ignition Switch and . . . . . . . . . . . 3F-5
Dimmer Switch, Column-Mounted,
Steering Column Diagnosis . . . . . . . . . . . . . . . . . . . . . .. . 3-14
Disabling the SIR System . . . . . . . . . . . . . . . . . . . . . . . 3F-4, 9J-8
Disabling the SIR System, Instrument Panel,
Gages and Console .............................. 8C-7
Disc Brakes, Front ................................. 581-1
Disc Brakes, Rear Axle Assembly with ................ 48-25
Disc Care, Compact . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9A-7
Discriminating Sensor, Forward, SIR Removal
and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9J-B-5
Discriminating Sensor, Passenger Compartment,
SIR Removal and Installation .................... 9J-B-6
Discriminating Sensors, SIR . . . . . . . . . . . . . . . . . . . . . . . .. . 9J-5
Dismounting, Tire Mounting and . . . . . . . . . . . . . . . . . . . . . . . 3E-6
Distributor (5.7L LT1 Engine), On-Vehicle Service ....... 604-6
Distributor Assembly, 5. 7L Engine
Distributor Assembly, 5.7L Engine
Unit Repair Assembly .......................... 6A38-36
Distributor Assembly, 5.7L Engine
Distributor Assembly, Air ............................ 8C-13
Distributor Ignition (DI) System ........ 5.7L (VIN P) 6E3-C4-1
Dome and Reading Lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . 88-3
INDEX 11
Dome Lamp, On-Vehicle Service ..................... 88-13
Dome Lamp, Roof . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-9-3
Door Assembly, Front Side . . . . . . . . . . . . . . . . . . . . . . . . 10-6-29
Door Decal, Headlamp Opening . . . . . . . . . . . . . . . . . . . 10-5-20
Door Edge Protector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-6-9
Door Jamb Switch Assemblies, Front . . . . . . . . . . . . . . . 10-5-19
Door Lock Switches, Side Window,
Outside Remote Control Rearview Mirror
Selector and . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-6-15
Door Opening Frame (6), Side, Structural
Body Repair and Dimensions . . . . . . . . . . . . . . . . . . . . . 11-16
Door Opening Frame Replacement, Side,
Structural Body Repair and Dimensions . . . . . . . . . . . . 11-16
Door Opening Frame Sectioning, Side,
Structural Body Repair and Dimensions . . . . . . . . . . . . 11-18
Door Outer Panel Replacement, Structural Body
Repair and Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . 11-21
Door Service (7), Structural Body Repair and
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-21
Door Sill Trim Plate, Front Side . . . . . . . . . . . . . . . . . . . . . 10-3-2
Doors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-6-1
Double Lap Flare, Brake Pipe Assembly . . . . . . . . . . . . . . . 5-15
Drain, Battery Assembly Electrical .................... 601 -4
Drain Cock Assembly, Radiator . . . . . . . . . . . . . . . . . . . . . . . 68-2
Drain Cock Assembly, Radiator, On-Vehicle Service ..... 68-14
Drain Hole Plug, Engine Block Coolant ................. 68-3
Draining and Refilling the Cooling System .............. 68-6
Draining the Engine Assembly, 5.7L Engine
Drip Scalp Molding Assembly, Roof . . . . . . . . . . . . . . . . . . 10-9-4
Drive Belt and Tensioner Assembly, Serpentine,
Drive Belt and Tensioner Assembly, Serpentine,
Drive Belt, Serpentine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68-3
Drive Belt, Serpentine, Cooling and Radiator
Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68-6
Drive Gear and Automatic Transmission
Case Extension, Speedometer .................... 7A-22
Drive Gear Assembly, 5-Speed Manual Trans
Cleaning and Inspection . . . . . . . . . . . . . . . . . . . . . . . 78-68-12
Drive Gear Bearing Retainer Oil Seal, 5-Speed
Manual Trans Cleaning and Inspection .......... 78-68-1 O
Drive Gear Disassembly, 5-Speed Manual Trans ..... 78-68-8
Drive Motor Assemblies, Driver Seat Adjuster and . . . 10-10-15
Drive Pinion Gear Yoke and Seal, Differential .......... 48-13
Drive Shaft Seal, Power Steering Pump
Unit Repair .................................... 381 B-6
Drive Shaft Seal Replacement, Power Steering
Pump Unit Repair .............................. 381 B-3
Driveability and Emissions
Fuel Injection ........................ 3.4L (VIN S) 6E3-1
Driveability and Emissions
Fuel Injection ........................ 5.7L (VIN P) 6E3-1
Driveability and Emissions General Information .......... 6E-1
Driven Gear, 5th/6th, 6-Speed Manual
Trans Assembly ............................ 78-1 OB-29
Driven Gear, 5th/6th, 6-Speed Manual
Trans Disassembly ........................... 78-1 OB-6
Driven Member, Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7C-1
Driven Plate Assembly (5-Speed), Clutch ............... 7C-8
Driven Plate Assembly (6-Speed), Clutch ............... 7C-9
Driver and Passenger Seat Buckle-Side Belt
Assemblies, Front .............................. 10-11-2
Driver and Passenger Seat Retractor-Side

Belt Assemblies, Front .......................... 10-11-2
Driver Knee Bolster Assembly and Deflector ........... 8C-10
Driver Seat Adjuster and Drive Motor Assemblies . . . . 10-10-15
Driving Members, Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7C-1
Drum Assembly Inspection .......................... 5C2-1
Drum Assembly, On-Vehicle Service .................. 5C2-2
Drum Assembly, Unit Repair ......................... 5C2-7
Drum Brake Adjustment, Rear, On-Ve)1icle Service ...... 5C2-7
Drum Brakes, Duo-Servo ........................... 5C2-1
Dual Pole Arming Sensor, SIR ........................ 9J-4
Dual Pole Arming Sensor, SIR Removal and
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9J-B-4
Duct Assemblies, Outer Air Outlet .................... 8C-15
Duct Assembly, Defogger Outlet ..................... 8C-14
Duct Assembly, Floor Air Outlet ...................... 8C-14
Ducts and Outlets, Manual Control A/C ............... 181 -5
Duo-Servo Drum Brakes ............................ 5C2-1
Dust Seal and Bearing Annulus Assembly, Pinion
Seal, Power Steering Gear Unit Repair ............ 381 A-6
E
Electric Cooling Fan(s) ............. 5.7L (VIN P) 6E3-C12-1
Electric Engine Coolant Fan Assembly ............ 1B-4, 68-2
Electric Engine Coolant Fan Assembly,
Electric Halogen Leak Detector, HVAC ................. 1B-6
Electrical Body and Chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
Electrical Connector and Seal,
Automatic Transmission .......................... 7A-30
Electrical Connectors, ABS ........................ 5E1 -173
Electrical Controls, Torque Converter Clutch ............ 7A-9
Electrical Diagnosis Index . . . . . . . . . . . . . . . . . . . . . . . . . . 8A-1-0
Electrical/Electronic Components and Systems,
Standard Nomenclature for . . . . . . . . . . . . . . . . . . . . . . . OA-11
Electrical, Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60-1
Electrical Wiring Diagrams, 4L60 Trans Diagnosis .. 7A-1 SA-42
Electrolyte Freezing ................................ 601-2
Electronic Brake Control Module (EBCM), ABS ......... 5E1 -6
Electronic Brake Control Module (EBCM), ABS,
On-Vehicle Service ............................ 5E1 -169
Electronic Ignition (El) System . . . . . . . . 3.4L (VIN S) 6E3-C4-1
Electronic Ignition Module,
3.4L L32 Engine Assembly ..................... 6A2B-49
Electronic Ignition Module,
3.4L L32 Engine Disassembly ................... 6A2B-16
Electronic Speed Sensor (6-Speed),
Manual Trans On-Vehicle Service ................. 78-11
Electrostatic Discharge (ESD) Sensitive Parts,
Handling ....................................... 8C-7
Electrostatic Discharge (ESD) Sensitive Parts,
Handling ........................................ OA-1
Electrostatic Discharge Damage . . . . . . . . . . . . . . . . . . . . . . 6E-3
Element Cleaning, Windshield Blade,
Element Set Check, Windshield Blade,
Emblem Assemblies, Front Bumper Fascia . . . . . . . . . . . 10-4-4
Emblem Assembly, Front Side Door . . . . . . . . . . . . . . . . . 10-6-8
Emission (EVAP) Control System,
Evaporative . . . . . . . . . . . . . . . . . . . . . 3.4L (VIN S) 6E3-C3-1
Emission (EVAP) Control System,
Evaporative . . . . . . . . . . . . . . . . . . . . . 5.7L (VIN P) 6E3-C3-1
12 INDEX
Emissions Fuel Injection,
Driveability and ...................... 3.4L (VIN S) 6E3-1
Emissions Fuel Injection,
Driveability and ...................... 5.7L (VIN P) 6E3-1
Emissions General Information, Driveability and ......... 6E-1
Enable Relay, ABS ................................. 5E1-7
Enable Relay, ABS, On-Vehicle Service ............. 5E1-172
Enabling the SIR System . . . . . . . . . . . . . . . . . . . . . . . 3F-4, 9J-8
Enabling the SIR System, Instrument Panel,
Gages and Console .............................. BC- 7
End Plate and Rotating Group Replacement,
Power Steering Pump Unit Repair ................ 381 B-4
End Play Check, Transmission,
4L60 Trans Unit Repair ............. ?A-158-8, 7A-15B-45
Endgate Latch Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 10-8-3
Energy Absorber, Front Bumper . . . . . . . . . . . . . . . . . . . . . 10-4-3
Energy Absorber, Rear Bumper . . . . . . . . . . . . . . . . . . . . . 10-4-6
Energy Absorbing Units, Bumpers . . . . . . . . . . . . . . . . . . . 10-4-1
Energy Reserve Module, Diagnostic,
SIR Removal and Installation . . . . . . . . . . . . . . . . . . . . 9J-B-3
Engagement Switch, Cruise Control,
Engine ............................................. 6-1
Engine, 3.4L L32 Disassembly ...................... 6A2B-6
Engine Assembly, 3.4L L32 Engine
Engine Assembly, 5. 7L Engine
Engine Assembly, Draining the, 5.7L Engine
Unit Repair Disassembly ....................... 6A3B-1 O
Engine Block, 5.7L Engine Unit Repair
Assembly .................................... 6A3B-31
Engine Block, 5.7L Engine Unit Repair
Engine Block Coolant Drain Hole Plug . . . . . . . . . . . . . . . . . 68-3
Engine Compartment Connecting Fuel Pipes
(Chassis to Engine) ............................. 6C-15
Engine Compartment Front Outer Side Rail,
Structural Body Repair and Dimensions ............. 11-5
Engine Compression Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
Engine Construction, 3.4L L32 Engine ............... 6A28-6
Engine Control Module (ECM) and
Sensors . . . . . . . . . . . . . . . . . . . . . . . . 3.4L (VIN S) 6E3-C2-1
Engine Control Module (ECM) and
Sensors . . . . . . . . . . . . . . . . . . . . . . . . 5.7L (VIN P) 6E3-C1-1
Engine Control Module (ECM),
Theft Deterrent Systems . . . . . . . . . . . . . . . . . . . . . . . . . . 9D-3
Engine Coolant, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68-3
Engine Coolant Concentration . . . . . . . . . . . . . . . . . . . . . . . . 68-3
Engine Coolant Fan Assembly, Electric ............ 1B-4, 68-2
Engine Coolant Fan Assembly, Electric,
Engine Coolant Heater .............................. 9E-1
Engine Coolant Heater Assembly Replacement . . . . . . . . . 9E-1
Engine Coolant Heater Cord Assembly
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9E-2
Engine Coolant Hose Assemblies . . . . . . . . . . . . . . . . . . . . 68-21
Engine Coolant Temperature (ECT) Sensor ............. 68-3
Engine Coolant Temperature Gage Sensor ............. 68-3
Engine Coolant Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68-22
Engine Coolant Thermostat Assembly . . . . . . . . . . . . . . . . . 68-3
Engine Coolant Thermostat Assembly,
Engine Coolant Thermostat Assembly Test ............. 68-4
Engine, Draining the, 3.4L L32 Engine

Disassembly .................................. 6A2B-6
Engine Electrical .................................... 6D-1
Engine Front Cover, 3.4L L32 Engine Assembly ..... :' M2B-48
Engine Front Cover, 3.4L L32 Engine Cleaning,
Engine Front Cover, 3.4L L32 Engine Disassembly ... 6A2B-18
Engine Front Cover Assembly, 3.4L L32 Engine
On-Vehicle Service .......................... :. 6A2,l\-14
Engine Front Cover Assembly, 5.7L Engine

Engine Front Cover Assembly, 5. 7L Engine
Engine Fuel ....................................... 6C~ 1
Engine General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Engine Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . oA.. 4
Engine Knock Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
Engine Lubrication, 3.4L L32 Engine ................. 6A2B-6
Engine Mechanical Diagnosis ....................... : . . 6-3
Engine Mount Assemblies and Brackets,
Engine Mount Assemblies and Brackets,
' .. ,
5.7L Engine On-Vehicle Service .................. 6ApA-3
Engine Noise Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
Engine Oil and Oil Filter Change . . . . . . . . . . . . . . . . . . . . . . 08-1
Engine Oil Cooler and Hose Assembly,
5. 7L Engine On-Vehicle Service ................. 6A3A-19
Engine Oil Cooler Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 68-2
Engine Oil Cooler Inlet and Outlet
Hose Assemblies ............................... 68-19
Engine On-Vehicle Service, 3.4 Liter
V6 RPO L32 -VIN S ........................... 6A2A-1
Engine On-Vehicle Service RPO LT1 -VIN P,
5.7 Liter V8 ................................... 6A3A-1
Engine Performance Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Engine Service, General Information on . . . . . . . . . . . . . . . . . 6-2
Engine Unit Repair, 3.4 Liter V-6 VIN Code S ......... 6A2B-1
Engine Unit Repair RPO LT1 -VIN P, 5.7 Liter V8 ..... 6A3B-1
Engine Wiring ..................................... 6D5-1
Engine Wiring Harness Assembly (3.4L L32),
Left-Hand Side ................................. 6D5-3
Rear View ..................................... 6D5-4
Right-Hand Side ................................ 605-2
Engine Wiring Harness Assembly (5.7L LT1 ),
Left-Hand Side ................................. 6D5-6
Engine Wiring Harness Assembly (5. 7L LT1 ),
Right-Hand Side ................................ 605-5
Engine Wiring Harness Assembly (All),
Transmission ................................... 6D5-7
English-Metric Conversions . . . . . . . . . . . . . . . . . . . . . . . . . OA-11
Equipment, Charging, Battery Assembly .............. 6D1 -1 O
Equivalents, Decimal and Metric . . . . . . . . . . . . . . . . . . . . . OA-11
ETR AM/FM Stereo/Cassette (UM6) ................... 9A-2
ETR AM/FM Stereo/Cassette/Equalizer (UX1) ........... 9A-3
ETR AM/FM Stereo/Compact Disc Player/Equalizer
(U1 A) .......................................... 9A-5
Evacuating and Recharging Procedures,
Refrigerant Recovery and Recycling, Adding Oil ...... 1B-9
INDEX 13
Evaporative Emission (EVAP)
Control System .................. 5.7L (VIN P) 6E3-C3-1
Evaporative Emission (EVAP)
Control System .................. 3.4L (VIN S) 6E3-C3-1
Evaporator, Air Conditioning . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-5
Evaporator, Air Conditioning, On-Vehicle Service ...... 181-17
Evaporator and Blower Module Assembly,
Heater and Air Conditioning ....................... BC-15
Evaporator, Blower Motor Assembly and,
Manual Control NC ............................. 181 -5
Evaporator, Manual Control NC ...................... 181 -9
Evaporator Temperature Sensor Assembly,
Air Conditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1B-5
Evaporator Temperature Sensor Assembly,
Air Conditioning, Manual Control ................. 181 -15
Evaporator Tube, Air Conditioning,
On-Vehicle Service .............................. 1B-18
Exhaust Crossover Pipe Assembly .................... 6F-1
Exhaust Crossover Pipe Assembly,
, On-Vehicle Service .............................. '. 6F-3
System . . . . . . . . . . . . . . .. .. . . . .. . . 3.4L (VIN S) 6E3-C7-1
System . . . . . . . . . . . .. . . . . . . . . . . . . 5.7L (VIN P) 6E3-C7-1
Exhaust Heat Shield, On-Vehicle Service .............. 6F-11
; ,Exha'usJ Manifold, 3.4L L32 Engine Assembly ........ 6A2B-50
Exhaust Manifold, 3.4L L32 Engine Disassembly ..... 6A2B-14
Exhaust Manifold Assemblies, 3.4L L32 Engine
Exhaust Manifold Assemblies, 5.7L Engine
On-Vehicle Service ............................. 6A3A-7
Exhaust Manifold Assemblies, 5. 7L Engine
Exhaust Manifold Assemblies, 5.7L Engine
Unit Repair Disassembly ....................... 6A3B-1 O
Exhaust Muffler Assembly ............................ 6F-2
Exhaust Muffler Assembly, On-Vehicle Service .......... 6F-6
Exhaust Muffler Hanger Assemblies,
Exhaust Muffler Heat Shield, Exhaust Pipe
Heat Shield Assembly and . . . . . . . . . . . . . . . . . . . . . . . . 6F-12
Exhaust Muffler Interior Bracket Assembly,
On-Vehicle Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6F-1 O
Exhaust Pipe Assembly, On-Vehicle Service ............ 6F-5
Exhaust Pipe Heat Shield Assembly and
Exhaust Muffler Heat Shield . . . . . . . . . . . . . . . . . . . . . . 6F-12
Exhaust System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6F-1
Exhaust System Clearance Dimensions . . . . . . . . . . . . . . . 6F-13
Exhaust System Component Replacement ............. 6F-3
Exhaust Tailpipe Extension Assembly
(5.7L LT1 Engine) ................................ 6F-6
Expansion Valve Assembly, Air Conditioning
Thermostatic, On-Vehicle Service . . . . . . . . . . . . . . . . . . 18-18
Expansion Valve Assembly, Thermostatic . . . . . . . . . . . . . . . 1B-4
Express Down, Doors . . . . . . . . . . . . . . . . . ... . . . . . . . . . . 10-6-2
Extension (With Lift-Off Roof Assemblies),
Quarter Trim Finishing Panel ..................... 10-7-4
Extension Assembly (5.7L LT1 Engine),
Exhaust Tailpipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6F-6
Extension Assembly, Countershaft, 6-Speed
Manual Trans Assembly ...................... 78-1 OB-28
Extension Assembly, Countershaft, 6-Speed
Manual Trans Repair and Inspection ........... 78-1 OB-13
Extension, Countershaft, 6-Speed Manual Trans .... 78-1 OB-32
Extension Housing, 6-Speed Manual Trans

Assembly .................................. 78-108-31
Disassembly ................................ 78-1 OB-4
Repair and Inspection ....................... 78-108-23
Extension Housing Bushing, 5-Speed
Manual Trans Cleaning and Inspection .......... 78-68-10
Extension Housing Oil Seal, 5-Speed
Manual Trans Cleaning and Inspection .......... 78-68-10
Exterior Lighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88-2
Exterior Lighting, On-Vehicle Service .................. 88-4
Exterior Moldings and Decal, Body Front End . . . . . . . . 10-5-19
Exterior Trim, Front Side Door . . . . . . . . . . . . . . . . . . . . . . 10-6-8
Exterior Trim, On-Vehicle Service . . . . . . . . . . . . . . . . . . . 10-7-8
Exterior Trim Taillamp Filler, Rear Compartment . . . . . . . 10-8-6
External Conditions That Affect Brake Performance . . . . . . . 5-4
External Leakage Check, Power Steering
Gear and Pump Assemblies . . . . . . . . . . . . . . . . . . . . . . . 3-15
F
Fan Assembly, Electric Engine Coolant . . . . . . . . . . . . . . . . . 1B-4
Fan, Blower Motor Assembly and Blower Motor . . . . . . . . 1A-16
Fan Control, Cooling . . . . . . . . . . . . . . . 3.4L (VIN S) 6E3-C12-1
Fans, Electric Cooling .............. 5.7L (VIN P) 6E3-C12-1
Fascia Emblem Assemblies, Front Bumper . . . . . . . . . . . 10-4-4
Fascia, Front Bumper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-4-1
Fascia Lower Deflectors, Front Bumper . . . . . . . . . . . . . . 10-4-5
Fascia, Rear Bumper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-4-6
"FASTEN SAFETY BELTS" Indicator Lamp ............. 8C-5
Fasten Seat Belt Assembly Warning ................... 8C-6
Fastener Repair, Cradle-to-Body . . . . . . . . . . . . . . . . . . . . 10-3-1
Fastener Strength Identification . . . . . . . . . . . . . . . . . . . . . . OA-10
Fasteners, Body Front End . . . . . . . . . . . . . . . . . . . . . . . . . 10-5-3
Fasteners, General Body Service . . . . . . . . . . . . . . . . . . . 10-1-1
Fasteners, Metric . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OA-9
Fasteners, Prevailing Torque ........................ OA-10
Fasteners, Thread Locking, Doors . . . . . . . . . . . . . . . . . . . 10-6-2
Federal Vehicle Theft Prevention Standard . . . . . . . . . . . . . OA-2
Feed Pipe/Hose Assembly (Fuel Tank), Rear Feed ...... 6C-14
Fender Assembly and Brackets, Front . . . . . . . . . . . . . . . 10-5-5
Fender Assembly, Front . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-5-4
Fender Center Rear Molding Assembly, Front . . . . . . . . 10-5-20
Filler Cap Assembly, Radiator, Diagnosis . . . . . . . . . . . . . . . 68-4
Filler Cap, Fuel .................................... 6C-2
Filler Door Assembly, Fuel Tank . . . . . . . . . . . . . . . . . . . . . 10-7-9
Filler Neck, Fuel Tank ............................... 6C-2
Filler Pocket Assembly, Fuel Tank . . . . . . . . . . . . . . . . . . . 10-7-9
Filler Tube Assembly, Transmission Fluid .............. 7A-20
Filter Assembly, Pan and, 4L60 Trans
Unit Repair .................................. 7A-15B-5
Finesse Polishing, Slight Clearcoat Damage,
Wet Sanding .................................. 10-1-11
Finish Lace, Liftgate Window Opening ............... 10-8-11
Finish Molding Assembly, Roof Panel
Longitudinal Bow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-9-7
Finishing Panel Assembly, Front Quarter Trim ......... 10-7-1
Finishing Panel Assembly, Quarter Inner Rear Trim . . . . 10-7-1
Finishing Panel Extension
(With Lift-Off Roof Assemblies), Quarter Trim . . . . . . . 10-7-4
First/Second Blocker Rings, 5-Speed
Manual Trans Cleaning and Inspection ........... 78-68-9
Fittings, Handling Refrigerant Lines and . . . . . . . . . . . . . . . . 1B-8
14 INDEX
Fixed Antenna Assembly Diagnosis, Radio . . . . . . . . . . . . . 9A-6
Fixed Antenna Assembly, Radio . . . . . . . . . . . . . . . . . . . . . . 9A-1
Fixed Antenna Assembly, Radio,
On-Vehicle Service ............................... 9A-7
Flare, Double Lap, Brake Pipe Assembly . . . . . . . . . . . . . . . 5-15
Flare, ISO, Brake Pipe Assembly . . . . . . . . . . . . . . . . . . . . . . 5-16
Flasher Assembly, Hazard Lamp . . . . . . . . . . . . . . . . . . . . . . 88-2
Flasher Assembly, Hazard Lamp,
Flasher Assembly, Turn Signal Lamp .................. 88-3
Flasher Assembly, Turn Signal Lamp,
Floor Air Outlet Duct Assembly ...................... 8C-14
Floor Carpet Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1 0-1
Floor Carpet Assembly, On-Vehicle Service ......... 10-10-25
Floor Console Assembly, Front . . . . . . . . . . . . . . . . 8C-2, 8C-10
Flow Control Valve, Hydraulic Pump ................... 38-8
Fluid and Automatic Transmission Oil Filter
Assembly, Changing Transmission ................. 7A-17
Fluid and Fluid Handling, Brake ....................... 5A-2
Fluid, Brake, Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Fluid Capacities, Approximate ........................ 08-9
Fluid, Checking and Adding, ABS .................. 5E1 -160
Fluid, Checking and Adding Power Steering . . . . . . . . . . . . 38-4
Fluid Checking Procedure, Transmission ............... 7A-4
Fluid Filler Tube Assembly, Transmission .............. 7A-20
Fluid Flow and Circuit Description, 4L60 Trans
Diagnosis .................................. 7A-15A-18
Fluid Handling, Brake Fluid and . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Fluid, Hydraulic Clutch ............................... 7C-2
Fluid Leak Diagnosis, Automatic Trans ................. 7A-6
Fluid Leaks, Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Fluid Leaks, Possible Points of, Automa

1993 Pontiac Firebird Service Manual

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1993 Pontiac Firebird Service Manual

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TABLE OF CONTENTS

Heater and Ventilation

ELECTRICAL - BODY AND CHASSIS

Engine General Description

Automatic and Manual Transmission

Driveability and Emissions Fuel Injection (Port) (3.4L)

STEERING, SUSPENSION, TIRES

Steering, Suspension, Tires and

General Body Service

Structural Body Repair and

1993 SERVICE MANUAL COMMENT FORM

From: Dealer Firm Name _ _ _ _ _ _ _ _ _ _ _ _ Dealer Code _ _ _ _ __

Warren, Mi. 48090

GENERAL INFORMATION OA1

Lock Cylinder Coding ...................... OA-6

SUPPLEMENTAL INFLATABLE RESTRAINT

HANDLING ELECTROSTATIC DISCHARGE

Refer to CAUTIONS and the SIR Component and

"INFLATABLE RESTRAINT" indicator lamp in

DISCONNECTING THE BATTERY NEGATIVE

NOTICE: When handling an electronic part that has

OA2 GENERAL INFORMATION

SPECIAL TOOL ORDERING INFORMATION

Figure 1 - ESD Sensitive Parts Label

Sun Electric Corporation

FEDERAL VEHICLE THEFT PREVENTION

VEHICLE IDENTIFICATION NUMBER

GENERAL INFORMATION OA-3

Vehicle Identification Number

G.M. MAKE IDENTIFIERS

G.M. PLANT CODES

MODEL YEAR CODES

SERIES AND MODEL TABLE

TWO DOOR COUPE/SEDAN

TWO DOOR HATCHBACK

TWO DOOR CONVERTIBLE

MANUAL BELTS WITH DRIVER

MANUAL BELTS WITH DRIVER INFLATABLE

AUTOMATIC BELTS WTH DRIVER

Figure 2 -VIN Codes

OA-4 GENERAL INFORMATION

VIN NUMBER PLATE

Figure 3 - VIN Plate Location

Vehicle Identification Number

Figures 2 and 4 through 6

Figure 4 - VIN Derivative

Figure 5 - Engine Identification Locations (Typical)

GENERAL INFORMATION OAS

transmission identification number gives the transmission

Engine Identification Number

Figure 6 - Engine Identification Number

M49-Borg-Warner Manual 5-speed

M49-Borg-Warner Manual 5-Speed

Figure 7 - Transmission Usage Chart

Figure 8 - Automatic Transmission Identification

OA6 GENERAL INFORMATION

DIFFERENTIAL RATIOS AND TIRE

GENERAL VEHICLE LIFTING AND JACKING

When a vehicle is lifted with a vehicle jack or floor

LOCK CYLINDER CODING

Key Identification and Usage

Replacement Lock Cylinders

Figure 9 - Manual Transmission Identification

Lock cylinders (3) are available from service parts