2000 SvcMan Bookmarked

2000 Chevrolet Camaro
and Pontiac Firebird

Service anual
Volume 1
This manual provides information on the diagnosis, the service procedures, the adjustments,
and the specifications for the 2000 Chevrolet Camaro and Pontiac Firebird.
Information on transmission unit repair (overhaul) can be found in the 2000 Transmission/
Transaxle/Transfer Case Unit Repair Manual (TURM) available separately. The TURM manual
contains information on automatic and manual transmissions, including the fluid flow and circuit
description information.
The technicians who understand the material in this manual and in the appropriate Dealer Service
Bulletins better serve the vehicle owners.
When this manual refers to a brand name, a part number, or a specific tool, you may use an
equivalent product in place of the recommended item. All information, illustrations, an.d
specifications in this manual are based on the latest product information available at the time of
publication approval. General Motors reserves the right to make changes at any time without
notice.
TABLE OF CONTENTS
Volume 1 Volume 3
Preface ................................................................ 1 Preface ................................................................ 1
Cautions and Notices .... .. .. ....... ... ... .... ... ... .. .... .. .. 3 Cautions and Notices . ... .... .... ... ... ... ... ... .. .. .. .. .... .. 3
General Information ....................................... 0-1 Transmissionrrransaxle ................................ 7-1
General Information ......................................... 0-3 Manual Transmission - M49 ............................ 7-5
Maintenance and Lubrication ......................... 0-34 Manual Transmission - MM6 ......................... 7-32
Vibration Diagnosis and Correction .. ... ... .. . .. ... 0-42 Automatic Transmission - 4L60-E .................. 7-63
HVAC ................................................................ 1-1 Clutch ......................................................... 7-382
Heating, Ventilation and Air Conditioning ......... 1-3 Body and Accessories ................... ... ............ 8-1
HVAC Systems - Manual ............................. 1-101 Data Link Communications ............................ 8-15
Steering ............................................................ 2-1 Lighting Systems .. .... .. .. .... ..... .. .. .... .... .. ..... .. .. . 8-35
Power Steering System . .. ... .. .. .. ... ... ... .... .. .. ... .. . 2-3 Wipers/Washer Systems .............................. 8-239
Steering Wheel and Column - Tilt ................. 2-50 Entertainment .............................................. 8-272
Suspension .... .... ...... ......... ..... ................ ..... ..... 3-1 Wiring Systems ........................................... 8-376
Suspension General Diagnosis ... ... .... ... ... ... .. .. . 3-3 Body Control System . .. ..... .. .. . .. .. .. .. ... .. . .. ... .. . 8-520
Wheel Alignment ........................................... 3-10 Instrument Panel, Gauges and Console ....... 8-545
Front Suspension .......................................... 3-15 Keyless Entry .... .... ..... .. . .. . ... .. .. .. .... ... ... ... .. ... 8-646
Rear Suspension .. .. .. . .... .. .... ...... .. .... .... .. ... .. ... 3-43 Horns ... ... ... ... .. .. .... ... .. .. . .. .. .. .. ... .. .... . .. .. .. ... . .. 8-665
( Cl Tires and Wheels .......................................... 3-61 Theft Deterrent .. .. .. .. .. .. ... ..... .. . .. . .. . .. . .. .. ... .. ... 8-675
Driveline/Axle .................................................. 4-1 Cruise Control ............................................. 8-713
Propeller Shaft .. .. . ... .... ... ... ...... ... ... .... .... .. .... ... . 4-3 Retained Accessory Power .......................... 8-754
Rear Drive Axle ............................................ 4-21 Exterior Trim ............................................... 8-764
Brakes ............................................. .-. ............... 5-1 Waterleaks .................................................. 8-776
Hydraulic Brakes ............................................. 5-5 Air/Wind Noise ............................................ 8-783
Disc Brakes . .. ..... ... ... . .... .. ...... ... ... ... ..... .. ... . .. . 5-56 Squeaks and Rattles ... .... .... .. .. .. ... .. . ... .... .. ... 8-785
Park Brake . .. ... ..... ... . ... .. .. .. ..... . ... ... .... .... .. .... .. 5-84 Stationary Windows ..................................... 8-801
Anti lock Brake System .................................. 5-97 Bumpers . .. ..... .. .... ..... ... ... .. .... ... .. ... .... .. ..... ... 8-829
INDEX ....................................................... INDEX-1 Body Front End ........................................... 8-849
Doors . ... ... ... .... ... ..... .... ... ..... ... ... .. ... ... .... .... .. 8-878
Roof ............................................................ 8-937
Volume 2
Seats ... ... ... ... . ... .... .... .... ... .. ... ... .. ... .... .. ..... . 8-1020
Preface ................................................................ 1 Interior Trim .............................................. 8-1061
Cautions and Notices .. ... ... ...... .. .... ..... ... ... ... .... .. . 3
Body Rear End .. .. .. .. .. . .. . .. .... ... .. .... .. .. . .. .. .. . 8-1075
Engine .............................................................. 6-1 Plastic Panel Information and Repair ......... 8-1112
Engine Mechanical - 3.8L .............................. 6-15 Paint/Coatings ........................................... 8-1133
Engine Mechanical - 5.7L ............................ 6-249 Frame and Underbody ............................... 8-1141
Engine Cooling ............................................ 6-594 Collision Repair ......................................... 8-1188
Engine Electrical ......................................... 6-674
Engine Controls - 3.8L ................................ 6-786 Restraints ......................................................... 9-1
Engine Controls - 5.7L .............................. 6-1325 Seat Belts .. .... .... .. ...... . .... . .. . .... .. ... .. ... ... ..... ... ... 9-3
Engine Exhaust ......................................... 6-1972 SIR ............................................................... 9-29
INDEX ....................................................... INDEX-1 INDEX ....................................................... INDEX-1
Preface Table of Contents - 1
Cautions and Notices
Cau1ions and Notices ........................................ 3 SIR Special Tool Caution .................................. 6

Definition of Caution, Notice, and Vehicle Lifting Caution ...................................... 6
Important .......................................................3 Window Removal Caution ................................. 6
ABS Handling Caution ...................................... 3 Window Retention Caution ................................ 6
Batteries Produce Explosive Gases Work Stall Test Caution .................................... 6
Caution ......................................................... 3
Air in the Power Steering System
Battery Disconnect Caution ............................... 3
Notice ........................................................... 6
Brake Dust Caution ......................................... .4
Anti-Corrosion Materials Notice ......................... 6
Brake Fluid Irritant Caution .............................. .4
Brake Pipe Replacement Caution .................... .4 Belt Dressing Notice ......................................... 7
Breathing R-134a Caution ................................ .4 Component Fastener Tightening Notice ............. 7
Clutch Dust Caution ......................................... .4 Defective Scan Tool Notice ...............................7
Electric Coolant Fan Caution ........................... .4 Engine Emission Notice .................................... 7
Express Window Down Caution ....................... .4 Fastener Notice ................................................ 7
Fuel and EV AP Pipe Caution ........................... .4 Fuel Pressure Notice ........................................ 7
Fuel Gauge Leak Caution ................................ .4 Fuel Tank Strap Fastener Notice ...................... 7
Fuel Pipe Fitting Caution ................................. .4 Handling ESD Sensitive Parts Notice ................ 7
Fuel Storage Caution ........................................ 5 Handling IAC Valve Notice ...............................7
) Gasoline/Gasoline Vapors Caution .................... 5
Lower 0-Ring Removal Caution ........................ 5
Heated Oxygen and Oxygen Sensor
Notice ...........................................................7
Moving Parts and Hot Surfaces Caution ........... 5 Ignition OFF When Disconnecting
Radiator Cap Removal Caution ......................... 5 Battery Notice ............................................... 8
Relieving Fuel Pressure Caution ....................... 5 Installing Hoses without Twists or
Road Test Caution ........................................... 5 Bends Notice .................................................8
Safety Glasses and Compressed Air Nylon Fuel Lines Notice .................................... 8
Caution .........................................................5
08011 System Description Notice ...................... 8
Safety Goggles and Fuel Caution ..................... 5
Seat Belt Replacement Caution ........................ 5 PCM and ESD Notice ....................................... 8
SIR Caution ......................................................5 Servicing and Replacing Seat Belts
SIR Handling Caution ....................................... 5 Notice ...........................................................8
SIR lnflator Module Disposal Caution ................ 5 Test Probe Notice ............................................. 8
SIR lnflator Module Handling and Using Proper Power Steering Fluid
Storage Caution ............................................ 6 Notice ...........................................................8
)
2 - Table of Contents Preface
\
(
BLANK
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Preface Cautions and Notices - 3
Cautions and Notices

) Definition of Caution, Notice, and IMPORTANT Defined
Important IMPORTANT statements emphasize a necessary
characteristic of a diagnostic or repair procedure.
The diagnosis and repair procedures in the GM
IMPORTANT statements are designed to do
Service Manual contain both general and specific
the following:
Cautions, Notices, and lmportants. GM is dedicated to
the presentation of service information that helps • Clarify a procedure
the technician to diagnose and repair the systems • Present additional information for accomplishing a
necessary for the proper operation of the vehicle, procedure
however, certain procedures may present a hazard to
• Give insight into the reason or reasons for
the technician if they are not followed in the
performing a procedure in the manner
recommended manner. Cautions; Notices; and
recommended
lmportants are elements designed to prevent these
hazards, however, not all hazards can be foreseen. • Present information that will help to accomplish a
This information is placed at strategic locations within procedure in a more effective manner
the service manual. This information is designed to • Present information that gives the technician the
preventthe following from occurring: benefit of past experience in accomplishing a
O Serious bodily injury to the technician procedure with greater ease
0 Damage to the vehicle
ABS Handling Caution
.. Unnecessary vehicle repairs
" Unnecessary component replacement Caution: Certain components in the Antilock Brake
System (ABS) are not intended to be serviced·
" Improper repair or replacement of vehicle individually. Attempting to remove or disconnect
components. Any caution or notice that appears in certain system components may result in personal
general information is referenced from the injury and/or improper system· operation. Only
individual service categories. those components with approved removal
CAUTION Defined and installation procedures should be serviced.
) When encountering a CAUTION, you will be asked to
take a necessary action or not to take a prohibited Batteries Produce Explosive Gases
action. If a CAUTION is not heeded, the following Caution
consequences may occur:
Caution: Batteries produce explosive gasses.
" Serious bodily injury to the technician Batteries contain corrosive acid. Batteries supply
• Serious bodily injury to other technicians in the levels of electrical current high enough to
workplace area cause bums. Therefore, to reduce the risk of
• Serious bodily injury to the driver and/or personal injury while working near a battery:
passenger(s) of the vehicle, if the vehicle has • Always shield your eyes.
been improperly repaired
• A void leaning over the battery whenever
NOTICE Defined possible.
Notices call special attention to a necessary action or • Do. not expose the battery to open flames or
to a prohibited action. If a NOTICE is not heeded, sparks.
the following consequences may occur: • Do not allow battery acid to contact the eyes
• Damage to the vehicle or the skin.
• Unnecessary vehicle repairs - Flush any contacted areas with water
immediately and thoroughly.
• Unnecessary component replacement
- Get medfoal help.
• Improper operation or performance of the system
or component under repair
Battery Disconnect Caution
" Damage to any systems or components which are
dependent upon the proper operation of the. Caution: Before servicing any electrical
system or component under repair component, the ignition key must be in the OFF or
• Improper operation or performance of any LOCK position and all electrical loads must be
systems or components which are dependent OFF, unless instructed otherwise in these
upon the proper operation or performance of the procedures. If a tool or equipment could easily
) system or component under repair come in contact with a live exposed electrical
terminal, also disconnect the. negative battery
• Damage to fasteners, basic tools, or special tools cable. Failure to follow these precautions
• The leakage of coolant, lubricant, or other vital may cause personal injury and/or damage to the
11uids vehicle or its components.
4 - Cautions and Notices Preface
Brake Dust Caution Electric Coolant Fan Caution
Caution: Avoid taking the following actions when Caution: An electric fan under the hood can start (
you service wheel brake parts: up even when the engine is not running and
.. Do not grind brake linings. can injure you. Keep hands, clothing and tools
• Do not sand brake linings. away from any underhood electric fan.
• Do not clean wheel brake parts with a dry
brush or with compressed air. Express Window Down Caution
Some models or aftermarket brake parts may Caution: Disconnect the power window switch
contain asbestos fibers which can become when working inside the driver's door. When
airborne in dust. Breathing dust with asbestos operated, the Express Down Feature allows the
fibers may cause serious bodily harm. Use a door window to drop very quickly, without
water-dampened cloth in order to remove any dust stopping, which could cause personal injury.
on brake parts. Equipment is available
commercially in order to perform this washing
function. These wet methods prevent fibers from Fuel and EVAP Pipe Caution
becoming airborne. Caution: In order to reduce the risk of fire and
personal injury observe the following items:
Brake Fluid Irritant Caution
.. Replace all nylon fuel pipes that are nicked,
Caution: Brake fluid may irritate eyes and skin. In scratched or damaged during installation,
case of contact, take the following actions: do not attempt to repair the sections of
" Eye contact-rinse thoroughly with water. the nylon fuel pipes
• Skin contact-wash with soap and water. • Do not hammer directly on the fuel harness
• If ingested-consult a physician immediately. body clips when installing new fuel pipes.
Damage to the nylon pipes may result in
Brake Pipe Replacement Caution a fuel leak.
Caution: Always use double-walled steel brake " Always cover nylon vapor pipes with a wet
pipe when replacing brake pipes. The use of any towel before using a torch near them. Also,
other pipe is not recommended and may cause never expose the vehicle to temperatures (
brake system failure. Carefully route and retain higher than 1.15°C (239°F) for more.than
replacement brake pipes. Always use the correct one hour, or more than.. 90°C (194°F) for any
fasteners and in the original location for extended period.
replacement brake pipes. Failure to properly route " Apply a few drops of clean engine oil to the
and retain brake pipes may cause damage to. male pipe ends before connecting fuel pipe
the brake pipes and brake system resulting fittings. This will ensure proper reconnection
in personal injury. and prevent a possible fuel leak. (During
normal operation, the 0-rings located in the
Breathing R-134a Caution female connector will swell and may prevent
Caution: Avoid breathing the A/C Refrigerant 134a proper reconnection if.not lubricated.)
(R-134a) and the lubricant vapor or the mist.
Exposure may irritate the eyes, nose, and throat. Fuel Gauge Leak Caution
Work in a well ventilated area. In order to remove
Caution: Wrap a shop towel around the fuel
R-134a from the A/C system, use service
pressure connection in order to. reduce the risk of
equipment that is certified to meet the
fire and personal injury. The towel will absorb
requirements of SAE J 2210 (R-134a recycling
any fuel leakage that occurs during the connection
equipment). If an accidental system discharge
of the fuel pressure gauge. Place the towel in an
occurs, ventilate the work area· before continuing
approved container 1111hen the connection of
service. Additional health and safety information
the fuel pressure gauge is complete.
may be obtained from the refrigerant and lubricant
manufacturers.
Fuel Pipe Fitting Caution
Clutch Dust Caution Caution: Always apply a few drops of clean engine
Caution: When servicing clutch parts, do not oil to the male pipe ends before connecting fuel
create dust by grinding or sanding the clutch disc pipe fittings in order to reduce the risk of fire and
or by cleaning parts with a dry brush or with personal injury.
compressed air. A water-dampened cloth-NOT
SOAKED---should be used. The clutch disc This will ensure proper reconnection and prevent (
contains asbestos fibers which can become a possible fuel leak.
airborne if dust·is created during servicing. During normal operation, the 0-rings located in
Breathing dust containing asbestos fibers may the female connector will swell and may prevent
cause serious bodily harm. proper reconnection if not lubricated.
Fuel Storage Caution Safety Glasses and Compressed Air
Caution: Do not drain the fuel into an open Caution
) container. Never store the fuel in an open Caution: Wear safety glasses when using
container due to the possibility of a fire or an compressed air in order to prevent eye injury.
explosion.
Gasoline/Gasoline Vapors Caution Safety Goggles and Fuel Caution

Caution: Gasoline or gasoline vapors are highly Caution: Always wear safety goggles when
flammable. A fire could occur if an ignition source working with fuel in order to protect the eyes from
is present. Never. drain or store gasoline or fuel splash.
diesel fuel in an open container, due to the
possibility of fire or explosion. Have a dry chemical
(Class BJ fire extinguisher nearby. Seat Belt Replacement Caution
Caution: To help avoid personal injury from
Lower 0-Ring Removal Caution unrepaired crash damage to a restraint system:
Caution: Verify that the lower(small) 0-ring of O Replace each seat belt system worn during
each injector does not remain in the lower a crash unless the crash was minor.
manifold in order to reduce the risk of fire and
personal injury. • Perform the seat belt check for each seat belt
system. Replace the seat belt system if there
If tt,e 0-ring is not removed with the injector, the is any doubt about the condition of system
replacement injector with new 0-rings will not seat components.
properly in the injector socket. Improper seating
could cause a fuel leak. SIR Caution
Moving Parts and Hot Surfaces Caution Caution: This vehicle has a Supplemental Inflatable
Restraint (SIR) System. Failure to follow the
Caution: While working around a running engine, correct procedure could cause air bag deployment,
) avoid contact with moving parts and hot surfaces
to prevent possible bodily injury.
personal injury, or unnecessary SIR system
repairs. To help avoid that: (1) Refer to SIR
Component Views to determine if you are
performing service on or near the SIR components
Radiator Cap Removal Caution or the SIR wiring. (2) If you are [performing
Caution: To avoid being burned, do not remove service on or near SIR components or the SIR
the radiator cap or surge tank cap while the engine wiring], you must disable the SIR system, refer to
is hot. The cooling system will release scalding Disabling the SIR System.
fluid and steam under pressure if radiator cap
or surge tank cap is removed while the engine and
radiator are still hot. SIR Handling Caution
Caution: When you are performing service on or
Relieving Fuel Pressure Caution near the SIR components or the SIR wiring,
you must disable the SIR system. ·Refer to
Caution: ReHeve the fuel system pressure before Disabling the SIR System. Failure to follow the
servicing fuel system components in order to correct procedure could cause air bag deployment,
reduce the risk of fire and personal injury. personal injury, or unnecessary SIR system
repairs.
After relieving the system pressure, a small
amount of fuel may be released when servicing
the fuel lines or connections. In order to redLf.Ce the SIR lnfla.tor Module Disposal Caution
chance of personal injury, cover the regulator
and the fuel line fittings with a shop towel before Caution: In order to prevent accidental deployment
disconnecting. This will catch any fuel that . ofthe air bag which could cause personal injury,
may leak out. Place the towel in an approved do not dispose of an undeployed inflator module
container when the disconnection is complete. as normal shop waste. The undeployed inflator
module. contains substances that could cause
Road Test· Caution severe·illness or personal injury if the sealed
container is damaged during disposal. Use the
) Caution: Road test a vehicle under safe conditions following deployment procedures to safely dispose
and while obeying all traffic laws. Do not attempt of an 1.mdeployed inflator module. Failure to
any maneuvers that could jeopardize vehicle dispose of an inflator module as instructed may
control. Failure to adhere to these precautions be a violation of federal, state, province, or
could lead to serious personal injury. local laws.
SIR lnflator Module Handling and Storage Work Stall Test Caution
Caution Caution: One or more of the following guidelines
may apply when performing specific required tests (
Caution: When you are carrying an undeployed
in the work stall:
inflator module:
• When a test requires spinning the drive
• Do not carry the inflator module by the wires wheels with the vehicle jacked up, adhere to
or connector on the inflator module the following precautions:
O Make sure the bag opening points away - Do not exceed 56 km/h (35 mph) when
.from you · spinning one drive wheel with the
other drive wheel stopped. This .limit ;s
When you are storing an undeployed inflator · necessary because the speedometer
module, make sure the bag opening points away indicates only one-half the actual vehicle
from the surface on which the inflator module speed under these conditions. Personal
rests. When you are storing a steering column, do injury may result from excessive
not rest the column with the bag opening facing wheel spinning.
down and the column vertical. Provide free --' If all of the drive wheels are spinning at
space for the air bag to expand in case of an the same speed, do not exceed 112 km/h
accidental deployment. Otherwise, personal injury (70 mph). Personal injury may result
may result. from excessive wheel spinning.
- All persons should stay clear of the
SIR Special Tool Caution rotating components and the balance
weight areas in order to avoid possible
Caution: In order to avoid deploying the air bag personal injury.
when troubleshooting the SIR system, use only the
equipment specified in this manual and the - When running an engine in the repair stall
for an extended period of time, use care
instructions given in this manual. Failure to use
not to overheat the engine and the
the specified equipment as instructed could cause transmission.
air bag deployment, personal injury to you or
someone else, or unnecessary SIR system repairs. • When a test requires jacking up the vehicle
and running with the wheels and brake (
rotors removed, adhere to the following
Vehicle lifting Caution precautions:
- Support the suspension of all drive
Caution: To avoid any vehicle damage, serious wheels at normal ride height.
personal injury or death when major components
are removed from the vehicle and the vehicle - Do not apply the brake with the brake
is supported by a hoist, support the vehicle with rotors removed.
jack stands at the opposite end from which - Do not place the transmission in PARK
the components are being removed. with the drive wheels still spinning.
- Tum Off the ignition in order to stop the
powertrain components from spinning.
Window Removal Caution
Caution: When working with any type of glass, use Air in the Power Steering System Notice
approved safety glasses and gloves to reduce Notice: If the power steering system has been
the chance of personal injury. serviced, an accurate fluid level reading cannot be
obtained unless air is bled from the steering system.
The air in the fluid may cause pump cavitation
Window Retention Caution noise and may cause pump damage over a period
Caution: When replacing stationary windows, of time.
Urethane Adhesive Kit GM PIN 12346392, or
a urethane adhesive system meeting GM Anti-Corrosion Materials Notice
Specification GM3651 M, must be used to maintain Notice: Anti-corrosion compounds have been applied
original installation integrity. Failure to use the to the interior surfaces of some metal panels to
urethane adhesive· kit will result in poor retention provide rust resistance. W.hen servicing these panels
of the window which may allow unrestrained in areas on which this material has been disturbed,
occupants to be ejected from the vehicle resulting or when installing new panels, avoid corrosion damage
in personal injury. by coating with anti-corrosion compound.
(
Belt Dressing Notice Handling ESD Sensitive Parts Notice
) Notice: Do not use belt dressing on the drive belt. Notice: Electrostatic discharge (ESD) can da,,age
Belt dressing causes the breakdown of the composition many solid-state electri.cal components. ESD
of the drive belt. Failure to follow this recommendation susceptible components may or may not be l~beled
will damage the drive belt. with the ESD symbol. Handle all electrical cornponents
carefully. Use the following precautions in ord6 r to
Component Fastener Tightening Notice avoid ESD damage:
Notice: Replacement components must be the correct " Touch a metal ground point in order to renove
part number for the application. Components your body's static charge before servicingany
requiring the use of the thread locking compound, electronic component; especially after slidhg
lubricants, corrosion inhibitors, or sealants are across the vehicle seat.
identified in the service procedure. Some replacement
components may come with these coatings already • Do not touch 1exposed terminals. Terminah may
applied. Do not use these coatings on components connect to circuits susceptible the ESD danage.
unless specified. These coatings can affect the O Do not allow tools to contact exposed
final torque, which may affect the operation of the terminals when servicing connectors.
component. Use the correct torque specification when
• Do not remove components from their proective
installing components in order to avoid damage.
packaging until required to do so.
Defective Scan Tool Notice • Avoid the following actions unless requirecby the
diagnostic procedure:
Notice: Do not use a scan tool that displays faulty
data. Report the scan tool problem to the - Jumpering or grounding of the compcients
manufacturer. Use of a faulty scan tool can result in or connectors.
misdiagnosis and unnecessary parts replacement. - Connecting test equipment probes to
components or connectors. Connect
Engine Emission Notice the ground lead first when using test robes.
Notice: Modifications made to the engine or its • Ground the protective packaging of any
individual components can effect the vehicle's component before opening. Do not rest soli-state
emission controls and may cause the Malfunction components on metal workbenches, or on Ip
Indicator Lamp (MIL), Check Engine, or Service Engine of TVs, radios, or other electrical devices.
Soon lamp to illuminate. Modifications may also
cause the vehicl.e to fail a required Emission Handling IAC Valve Notice
Inspection/Maintenance test.
Notice: If the IAC valve has been in service: D(f\lOT
Fastener Notice push or pull on the IAC valve pintle. The force
required to move the pintle may damage the thnds
Notice: Use the correct fastener in the correct on the worm drive. Also, DO NOT soak the IAC
location. Replacement fasteners must be the correct
valve in any liquid cleaner or solvent, as damag1naY
part number for that application. Fasteners requiring result.
replacement or fasteners requiring the use of '
thread locking compound or sealant are identified in
the service procedure. Do not use paints, lubricants, or Heated Oxygen and Oxygen Sensor
corrosion inhibitors on fasteners or fastener joint Notice
surfaces unless specified. These coatings affect
fastener torque and joint clamping force and may Notice: Do not remove this pigtail from either the
damage the fastener. Use the correct tightening heated oxygen sensor (H02S) or the oxygen
sequence and specifications when installing fasteners sensor (028). Removing the pigtail or the conne~
in order to avoid damage to parts and systems. - will affect sensor operation.
Fuel Pressure Notice Handle the oxygen sensor carefully. Do not drop l
H02S. Keep the in-line electrical conne9tor and
Notice: Do not allow the fuel pressure to exceed the the louvered end free of grease, dirt, or other
specified value because damage to the fuel pressure contaminants. Do not use cleaning solvents of
regulator or the fuel pressure gauge may result. any type.
Fuel Tank: Strap Fastener Notice Do not repair the wiring, connector or terminals.
Replace the oxygen sensor if the pigtail wiring,
Notice: Tighten the strap fasteners by steps, connector, or terminal is damaged.
alternating between the fasteners, until the specified
torque is reached. A failure to tighten th.e strap This external clean air reference is obtained by w,1
fasteners as specified will cause the bottom of the the oxygen sensor signal and heater wires. Any
tank to flex upward. This will result in the fuel gauge attempt to repair the wires, connectors, or termina
indicating that there is fuel remaining in the tank when could result in the obstruction of the air reference I
the tank runs dry. degraded sensor performance.
The following guidelines should be used when PCM and ESD Notice
servicing the heated oxygen sensor:
Notice: Do not touch the connector pins or soldered
" Do not apply contact cleaner or other materials to components on the circuit board in order to prevent
the sensor or vehicle harness connectors. These possible electrostatic discharge (ESD) damage
materials may get into the sensor causing to the PCM.
poor performance. ·
" Do not damage the sensor pigtail and harness Servicing and Replacing Seat Belts Notice
wires in such a way that the wires inside are
exposed. This could provide a path for foreign Notice: To prevent possible seat belt damage, refer
materials to enter the sensor and cause to the following items before servicing or replacing lap
performance problems. and shoulder belts, including single loop belt
systems: ·
" Ensure the sensor or vehicle lead wires should
not be bent sharply or kinked. Sharp bends or " Lap and shoulder belts will be serviced as follows:
kinks could block the reference air path through - Replace only the part in question.
the lead wire. - All belts need to be serviced as a set to
• Do not remove or defeat the oxygen sensor assure the belt components are from
ground wire (where applicable). Vehicles the same supplier.
that utilize the ground wired sensor may rely on - Do not intermix standard and deluxe belts on
this ground as the only ground contact to the front or rear seats.
sensor. Removal of the ground wire will cause - All attachment hardware must be replaced,
poor engine performance.
not reused.
• Ensure that the peripheral seal remains intact on • Keep sharp edges and damaging objects away
the vehicle harness connector in order to prevent from belts.
damage due to water intrusion. The engine
harness may. be repaired using Packard's Crimp • Avoid bending or damaging any portion of the belt
and Splice Seals Terminal Repair Kit. Under buckle or latch plate.
no circumstances should repairs be soldered since " Do not bleach or dye belt or strap webbing. Clean
this could result in the air reference being with a mild soap solution and water.
obstructed. " When installing lap or shoulder belt anchor bolts,
start the bolts by hand to ensure that the bolts
(
Ignition OFF When Disconnecting Battery are threaded straight.
Notice • Do not attempt repairs on lap or shoulder belt
retractor mechanisms to lap belt retractor
Notice: Always turn the ignition OFF when connecting covers. Replace defective assemblies with new
or disconnecting battery cables, battery chargers, or service replacement parts.
jumper cables. Failing to do so may damage the
Powertrain Control Module (PCM) or other electronic • Do not attempt to remove the seat belt retractor
components. cover. The cover and the long rivet securing
the cover to the retractor are not available
as service replacement parts.
Installing Hoses without Twists or Bends
Notice Test Probe Notice
Notice: The inlet and outlet hoses must not be twisted Notice: Do not insert test equipment probes into any
during installation. Do not bend or distort the inlet or connector or fuse block terminal. The diameter of
outlet hoses to make installation easier. Failure to the test probes will deform most terminals. A deformed
follow these procedures could result in component terminal can cause a poor connection, which can
damage. result in system failures. Always use the J 35616-A
Connector Test Adapter Kit or the J 42675 Flat
Nylon Fuel Lines Notice Wire Probe Adapter Kit in order to frontprobe
terminals. Do not use paper clips or other substitutes
Notice: Do not attempt to straighten any kinked nylon as they can damage terminals and cause incorrect
fuel lines. Replace any kinked nylon fuel feed or measurements.
return pipes in order to prevent damage to the vehicle.
Using Proper Power Steering Fluid Notice
OBDII System Description Notice Notice: When adding fluid or making a complete
Notice: The OBD II symbol is used on the circuit fluid change, always use the proper power steering
diagrams in order to alert the technician that the circuit fluid. Failure to use the proper fluid will cause
is essential for proper OBD 11 emission control hose and seal damage and fluid leaks.
circuit operation. Any circuit which, if it fails causes the
Malfunction Indicator Lamp (MIL) to turn on, is
identified as an OBDII circuit.
General Information Table of Contents 0-1
)
Section O
General Information
General Information ........................................ 0-3 Maintenance .................................................. 0-35

Conversion - English/Metric ............................ 0-3 Maintenance Schedule .................................0-35
Equivalents - Decimal and Metric ................... 0-3 Explanation of Scheduled Services .............. 0-37
Arrows and Symbols ...................................... 0-4 Oil Life Monitor - Resetting .......................... 0-39
Special Tools Ordering Information ................ 0-5 Owner Checks and Services ........................ 0-39
Diagnostic Work Sheets ................................. 0-5 Periodic Maintenance Inspection .................. 0-41
Training .........................................................0-5 Vibration Diagnosis and Correction ........... 0-42
Vehicle Identification ......................................0-5 Specifications ................................................0-42
VIN Derivative ...............................................0-7 Tire and Wheel Runout Specifications .......... 0-42
Label - Vehicle Certification ........................... 0-8 Propeller Shaft Runout Specifications ........... 0-42
Tire Placard ...................................................0-9
Propeller Shaft Balancing Weight Amounts ..... 0-42
Engine ID and VIN Derivative
Diagnostic Information and Procedures ....... 0-43
Location (RPO L36} ...................................0-9
Systematic Approach ...................................0-43
Engine ID and VIN Derivative
Location (RPO LS1) .................................0-10 Diagnostic Information and Procedures ........ 0-43
Transmission ID and VIN Derivative Tire and Wheel Inspection ........................... 0-44
Location ...................................................0-12 Road Test ................................................... 0-45
Types of Road Test Procedures .................. 0-45
) Transmission Usage ....................................0-13
Labeling - Anti-Theft ....................................0-14 Classifying the Vibration ............................... 0-47
Label - Service Parts ID ..............................0-14 Vibrations That Can Be Felt ......................... 0-47
RPO Code List ............................................0-15 Vibrations That Make Noise ......................... 0-48
Labels - How to Obtain Replacement ........... 0-17 Matching Frequency to Component RPM ..... 0-48
Fasteners ....................................................0-17 Rotor/Drum Imbalance ................................. 0-50
Thread Inserts .............................................0-21 Driveline Vibration Analysis .......................... 0-51
Abbreviations and Meanings ........................ 0-22 Diagnosing First-Order Driveline Vibration .... 0-51
Key and Lock Cylinder Coding ..................... 0-27 Diagnosing Second-Order Driveline
Lifting and Jacking the Vehicle .................... 0-30 Vibration ................................................... 0-61
Strategy Based Diagnosis ............................ 0-32 Engine Related Vibration ..............................0-67
Special Tools and Equipment ....................... 0-33 Tire and Wheel Vibration ............................. 0-70
Repair Instructions ........................................ 0-71
Maintenance and Lubrication ......................0-34
Balancing Tires and Wheels ........................ 0-71
Specifications ................................................0-34
Description and Operation ............................0-73
Capacities - Approximate Fluid ..................... 0-34
Fluid and Lubricant Recommendations .........0-34 Basic Terms ................................................0-73
Tire Inflation Pressure Specifications Reed Tachometer ........................................ 0-81
(Tire Inflation Specifications) .....................0-35 Electronic Vibration Analyzer (EVA) .............. 0-81
Maintenance Items .......................................0-35 Special Tools and Equipment ....................... 0-86
)
\
0-2 Table of Contents General Information
(
BLANK
(
General Information General Information 0-3
General Information
Conversion - English/Metric Conversion - English/Metric (cont'd)
English
Multiply/
Divide by
Length
Metric English I Multiply/
Divide by
Temperature
I Metric
in 25.4 mm (°F-32) I 1.8 I = I ~c

ft 0.3048 OF I = I (°C X 1.8) + 32
m
yd 0.9144 Fuel Performance
mi 1.609 km 235.215/mpg I = I U100 km
Area
645.2 sq mm
Equivalents - Decimal and Metric
sq in Fraction (in) Decimal (in) Metric (mm)
6.45 sq cm
1/64 0.015625 0.39688
sq ft 0.0929
sq m 1/32 0.03125 0.79375
sq yd 0.8361
3/64 0.046875 1.19062
Volume
1/16 0.0625 1.5875
16,387.0 cu mm
. 5/64 0.078125 1.98437
cu in 16.397 cu cm
3/32 0.09375 2.38125
O.Q164
7/64 0.109375 2.77812
qt 0.9464 L
1/8 0.125 3.175
gal 3.7854 9/64 0.140625 3.57187
cu yd 0.746 cum 5/32 0.15625 3.96875
Mass 11/64 0.171875 4.36562
lb 0.4536
) 907.18
kg
3/16 0.1875 4.7625
13/64 0.203125 5.15937
ton
0.907 tonne (t) 7/32 0.21875 5.55625
Force 15/64 0.234375 5.95312
kg 9.807 1/4 0.25 6.35
oz 0.2780 newtons (N) 17/64 0.265625 6.74687
lb 4.448 9/32 0.28125 7.14375
Acceleration 19/64 0.296875 7.54062
ft/s2 0.3048 5/16 0.3125 7.9375
m/s2
in/s2 0.0254 21/64 0.328125 8.33437
Torque 11/32 0.34375 8.73125
lb in 0.11296 23/64 0.359375 9.12812
N-m 3/8 0.375
lb ft 1.3558 9.525
Power 25/64 0.390625 9.92187
hp 0.745 kW 13/32 0.40625 10.31875

27/64 0.421875 10.71562
Pressure (Stress)
7/16 0.4375 11.1125
inches of H20 0.2491
kPa 29/64 0.453125 11.50937
lb/sq in 6.895
15/32 0.46875 11.90625
Energy (Work)
31/64 0.484375 12.30312
Btu 1055.0
1/2 0.5 12.7
lb ft 1.3558 J (J= one Ws)
33/64 0.515625 13.09687
kW hour 3,600,000.0 17/32 0.53125 13.49375
Light 35/64 0.546875 13.89062
Foot Candle 10.764 lm/m 2 9/16 0.5625 14.2875
Velocity 37/64 0.578125 14.68437
mph 1.6093 km/h 19/32 0.59375 15.08125
0-4 General Information General Information
Equivalents - Decimal and Metric (cont'd) Arrows and Symbols
Fraction (in) Decimal (in) Metric (mm) This service manual uses various symbols in order to
39/64 0.609375 15.47812 describe different service operations.
;o
5/8 0.625 15.875
41/64 0.640625 16.27187 i
21/32 0.65625 16.66875
3~
43/64 0.671875 17.06562
~i::'~.?
11/16 0.6875 17.4625
~~<P~
45/64 0.703125 17.85937
23/32 0.71875 18.25625
4
h >.
47/64 0.734375 18.65312 5 6
3/4
49/64
0.75
0.765625
19.05
19.44687 \_.
25/32 0.78125 19.84375
51/64 0.796875 20.24062
13/16 0.8125 20.6375 9
8
\+
53/64 0.828125 21.03437
7~
27/32 0.84375 21.43125 \6+,
55/64 0.859375 21.82812
7/8 0.875 22.225
57/64 0.890625 22.62187 10 11 12
29/32
59/64
15/16
0.90625
0.921875
0.9375
23.01875
23.41562
23.8125
\._ )4 \.,.. (
61/64 0.953125 24.20937
31/32 0.96875 24.60625 196216
63/64 0.984375 25.00312 legend
1 1.0 25.4 (1) Front of Vehicle
(2) View Detail
(3) Ambient Air Mixed With Another Gas or
Indicate Temperature Change
(4) Motion or Direction
(5) View Angle
(6) Dimension (1 :2)
(7) Ambient/Clean Air Flow or Cool Air Flow
(8) Lubrication Point-Oil or Fluid
(9) Task Related
(10) Sectioning (1 :3)
(11) Gas Other Than Ambient Air or Hot Air Flow
(12) Lubrication Point-Grease or Jelly
(
Special Tools Ordering Information United States
The special service tools shown in this service manual Dealers
that have product numbers beginning with J or BT
are available for worldwide distribution from: All US Dealers enroll through the GM Enrollment
Calling Center (EEC). Each GM Dealer has an
OE Tool and Equipment Group assigned consultant that calls the Service Manager
Kent-Moore
each month. During this consultation call, the
28635 Mound Road
Warren, Ml, U.S.A. 48092-3499 EEC proCf3SSes enrollments requested by the Dealer
Phone: 1-800-345-2233or810-574-2332 Service Manager. Technicians should advise their
Monday through Friday Service Manager of the training they need, course
8:00 a.m.-7:00 p.m. Eastern Standard Time names, and course numbers for the classes the want
Fax: 1-800-578-7375 or810-578-7321 to attend.
The TECH 2® scan tool and accessories can be Fleets
purchased through:
Fleets are to call their GM Training Center.
Dealer Equipment and Services
5775 Enterprise Dr. Non-GM Dealer Technician
Warren, Ml, U.S.A. 48092-3463 Technician training for non-GM dealers is available
Phone: 1-800-GM-TOOLS or 810-574-2332 through ACDelco. This training is for ACDelco
Monday through Friday
customers employed in the automotive or truck service
8:00 a.m.-6:00 p.m. EST
industry.
Fax: 1-810-578-7205
GM Training Center course availability and schedules
Diagn-ostic~Wol'l{-Sheets-- --------can-be-ebtained by calling 1-800-825-5886.
The GM Diagnostic Worksheet has been designed to Clinics are offered through ACDelco Warehouse
improve communications between the service Distributors. Contact yours directly.
customer and the technician. The diagnostic worksheet Correspondence courses are available on batteries,
can provide the technician with more information spark plugs and filters. These courses can be obtained
than the conventional repair order, since it is filled out through any ACDelco Representative or ACDelco
) by the service customer. The GM Diagnostic Warehouse Distributor.
Worksheets are available to you at no cost. GM
Service Bulletin 58-01-01 has information on how to
order this diagnostic worksheet. Vehicle Identification
Training
General Motors makes available automotive classroom 1
training through the GM Training Centers and colleges.
GMCL (General Motors of Canada Ltd)
Dealers
Course scheduling for GMCL Training Centres, remote
and college locations is determined by Dealer
Training Needs requested in TAMS (Technician
Activity Monitoring System). Dealers register their
Training Needs electronically via DCS. Training is then
scheduled when sufficient Needs are received to
support minimum classroom attendance. Dealers who
have entered Needs will receive invitations via
DCS (Dealer Communication System) to attend the
requested training. Dealers having questions
concerning the GMCL training process can directly
contact GMCL Training Co-ordinators via toll free
numbers 1-800-263-9555 (English) or 1-800-263-9770
65474
(French).
Fleets Legend
(1) Vehicle Identification Number Plate Location
GMCL Fleet Training is accomplished through a
separate training organization in Canada. Fleets can
request training by faxing a document contained The vehicle identification number (VIN) plate is the
in a GMCL brochure (Fleet Training - Your Competitive legal identifier of the vehicle. The VIN plate is located
Advantage) distributed to fleets (FAX# 905-831-1598). on the upper LH corner of the instrument panel (IP)
Further information concerning Fleet training can be and can be seen through the windshield from the
obtained by calling toll free to ·1-888-456-6660. outside of the vehicle.
The last five digits of the assembly plant sequential
number are stamped onto the rear side of the front sill
(tie bar). This number is the same as the last
five digits on the VIN plate. The VIN plate also has bar
code characteristics.
Vehicle Identification Number (VIN) System
Position Definition Character Description
1 Country of Origin 2 Canada
2 Manufacturer G General Motors
3 Division 1 Chevrolet
- 2 Pontiac
4-5 Carline/Series FP Camaro Sport Coupe
- FS Firebird
Formula/
- FV
Trans Am
6 Body Type 2 Two Door
Two Door
- 3
Convertible
Active (Manual) Belts with Driver and Passenger
7 Restraint System 2
Inflatable Restraint System
RPO LS1, V8, 5.7L, SFI, United States Production,
8 Engine G
Mid/Lux Division
RPO L36, V6,
3.8L, SFI,
United States
- K
Production,
Mid/Lux
Division
(
9 Check Digit 0 -
10 Model Year y 2000
11 Assembly Plant 2 St Therese, Quebec
12-17 Plant Sequence Number - -
(
VIN Derivative
) All engines and transmissions are stamped or laser
etched with a partial vehicle identification
number (VIN), which was derived from the complete
VIN. A VIN derivative contains the following
nine positions:
Position Definition Character Description

1 GM Division Identifier 1 Chevrolet
- - 2 Pontiac
2 Model Year y 2000
3 Assembly Plant 2 St. Therese
4-9 Plant Sequence Number - -
A VIN derivative can be used to determine if a vehicle

contains the original engine or transmission by
matching the VIN derivative positions to their
accompanying positions in the complete VIN:
VIN Derivative Position Equivalent VIN Position

1 3
2 10
3 11
4-9 12-17
)
)
label - Vehicle Certification
(
MFD. BY GENERAL MOTORS CORP.
GVWR GAWR FRT GAWR RR

PNBV PNBE AV PNBE AR
11
THIS VEHICLE CONFORMS TO ALL
THIS VEHICLE CONFORMS TO ALL APPLICABLE U.S. APPLICABLE CANADA MOTOR
FEDERAL MOTOR VEHICLE SAFETY, BUMPER AND VEHICLE SAFETY, BUMPER AND
THEFT PREVENTION STANDARDS IN EFFECT ON THEFT PREVENTION STANDARDS
THE DATE OF MANUFACTURE SHOWN ABOVE. IN EFFECT ON THE DATE OF
MANUFACTURE SHOWN ABOVE.
7 \ 6 5 4
(
65484
The vehicle certification label displays the following The front gross axle weight (GAW) is the weight
assessments: exerted on the front axle. The rear gross axle
" The name of the manufacturer (1) weight (GAW) is the weight exerted on the rear axle.
O
The Gross Vehicle Weight Rating (GVWR) (2) The front and rear gross axle weights must not
exceed the front and rear gross axle weight ratings.
" The Gross Axle Weight Rating (GAWR) (3)
The payload rating defines the vehicle's maximum
" The vehicle payload rating
allowable cargo load. The cargo load includes
" The vehicle class type (Pass Car, etc) (6) the driver and the passengers. The payload rating is
" The vehicle identification number (7) based on the vehicle's factory installed equipment.
" The date of manufacture (Mo/Yr) (8) Deduct the weight of accessories added to the vehicle
.. The original equipment tire sizes and the after the final date of manufacture from the payload
recommended tire pressures rating.
Gross vehicle weight (GVW) is the weight of the The vehicle may have a Gross Combination Weight
vehicle and everything it carries. Include the following Rating (GCWR). The Gross Combination Weight
items when figuring the GVW: Rating refers to the total maximum weight of
" The base vehicle weight (factory weight) the loaded tow vehicle (including driver and
passengers) and a loaded trailer.
" The weight of the vehicle accessories
.. The weight of the driver and the passengers The vehicle's tires must be the proper size and
properly inflated for the load the vehicle is carrying .
.. The weight of the cargo For more information on tires refer to Tire Placard.
The gross vehicle weight must not exceed the Gross
Vehicle Weight Rating.
Tire Placard Engine ID and VIN Derivative
) location (RPO l36)
The eighth character in the Vehicle Identification
Number (VIN) identifies the engine. Adhesive-backed
labels attached to the engine, laser etching, or
stampings on the engine block indicate the engine unit.
number/date code. All engines are stamped with a
VIN derivative. For added information on VIN
derivative, refer to VIN Derivative.
7 5
446246
The primary location of the VIN derivative for the

65541 3.8 L engine is above the starter motor on the engine
Legend block (1).
(1) Specified Occupant Seating Positions
(2) Total Occupant Seating
(3) Maximum Vehicle Capacity Weight
(4) Tire Pressures, Front, Rear, and Spare
(5) Tire Speed Rating, Front, Rear, and Spare
(6) Tire Label Code
(7) Engineering Model Minus First Character
(8) Tire Sizes, Front, Rear, and Spare
(9) Vehicle Identification Number
The Tire Placard is permanently located on the edge

of the driver's door. Refer to the placard to obtain:
• The maximum vehicle capacity weight
• The cold tire inflation pressures
• The tire sizes (original equipment tires)
• The tire speed ratings (original equipment tires)
182099
The secondary location of the VIN derivative for the

3.8 L engine is below the water pump on the
engine block (1 ).
Engine ID and VIN Derivative The eighth digit of the vehicle identification
location (RPO lS1) number (VIN) is the engine code letter, which identifies
the engine as a 5.7 L V8.
Engine ID Number locations
Stick-on labels attached to the engine, laser etching,
or stampings on the engine block indicate the
engine unit number/build date code.
The engine ID number will be located at either the
primary or the secondary location, as shown.
63234
legend
(1) Engine ID Number, Primary Location
(2) Engine ID Number, Secondary Location
(
Engine VIN Derivative Locations
)
171897
Legend
(1) VIN Derivative, Primary Location (2) VIN Derivative, Secondary Location
The engine is also stamped with a VIN derivative

which will be located at either the primary or secondary
location, as shown.
)
Transmission ID and VIN Derivative
Location
Automatic Transmission ID location
1
486303
The transmission ID and the VIN derivative for the

M30 transmission are located on the left side of
the transmission just above the transmission pan.
(
VIN Derivative Breakdown
9 YD D 9 -187 A
-
SHIFT BUILT
'--~9-=~19_9_9~---'~ A, B OR J = FIRST SHIFT
C, H OR W = SECOND SH IFT
MODEL
JULIAN DATE
(OR DAY OF THE YEAR)
HYDRA- MATIC 4L60- E
CALENDAR YEAR
174101
The transmission identification (ID) number indicates

the transmission model year, type and when the
unit was built.
(
Manual Transmission ID location
)
486305
The transmission model identification is located on a. ·

label or tag on the transmission case. If this label
is missing or unreadable, use the service parts
identification label in order to identify the vehicle's
transmission.
) Transmission Usage
Body Fuel Engine Automatic Manual
Type Car Line (Division) Engine Size System RPO Transmission Used Transmis$ion Used
CAMARO
F 5.7L V8 SFI LS1 4L60-E (M30) T56 (MM6)
(CHEVROLET)
CAMARO
F ·. 3.8L V6 SFI L36 4L60-E (M30) T-5 (M49)
(CHEVROLET)
F FIREBIRD (PONTIAC) 5.7L V8 SFI LS1 4L60-E (M30) T56 (MM6)
F FIREBIRD (PONTIAC) ,.,.-. 3.8L V6 SFI L36 4L60-E (M30) T-5 (M49)
)
Labeling - Anti-Theft Label - Service Parts ID
(
sEv1cE PARTS 10ENT1FicZ'i,6t1 £' "';oc,/r:.r0,;;,~;;·rt;0;i1)

";,J:l i.~'1;:pc1,i~
1'i:----- ~NlEve}:12 :·
0
usTE oEs oPTloNs 0
·-
=
====
=
=== === 7~ ·.·.·
I
6~-~-1
5 4 3
175291 65485
Federal law requires that General Motors label certain Legend

body parts on every vehicle with the VIN. The (1) Vehicle ldentific~tion Numb~r
purpose of the law is to reduce the number of motor (2) Engineering Model Number (Vehicle Division,
vehicle thefts by helping in the tracing and recovery of Vehicle Line. and Body Style)
parts from stolen vehicles. (3) Interior Trim and Decor Level
The labels are permanently affixed to an interior (4) Exterior (Paint Color) WA Number
surface of the part. The label on a replacement part (5) Paint Technology (
contains the letter R, the manufacturer's logo, and the (6) Special Order Paint Colors and Numbers
DOT symbol. (7) Vehicle Option Content
The Service Parts Identification Label aids the seNice

personnel in identifying the parts and options
originally installed on the vehicle.
(
RPO Code List RPO Table (cont'd)
RPO Description
) The production/process codes provide a description of
the Regular Production Options (RPOs) used on the G80 Axle Positraction
Camara and Firebird. The RPO list is printed on the IL2 Trim, Interior Leather (W/AQ9) Pontiac
Service Parts Identification Label. The following is a list
IL4 Trim, Interior European Camaro
of the RPO abbreviations and the description of each:
IL5 Trim, Interior (w/AQ9) Pontiac
RPO Table IPB
Trim, Interior Cloth Camaro and
Firebird
RPO Description
Trim, Interior (w/AR9) European
A26 Window Glazing, European IPD
Camaro
AG1 Driver Front Seat, Power Adjuster
IP2 Trim, Interior Leather Camaro
AH3 Front Seat, Manual 4-Way Adjuster
IP3 Trim, Interior Leather Pontiac
Inflatable Restraint System, Driver and
AK5 JAF Brake Provisions, European
Passenger
AN4 Restraint Provisions, Child Brake System, PWR Front and
J65
Rear Disc
Front Seat, Driver and Passenger
AQ9
Recline K05 Heater, Engine Block
Front Bucket Seat, Deluxe K29 Module Powertrain Control, Export
AR9
European Style
K34 Cruise Control, Automatic
AUO Remote Entry Lock Control
K68 Generator, 105 Amp
AU3 Side Door Elec Lock Control
LS1 Engine, Gas V8 5.7L SFI Aluminum
Restr.aint Conversion Seat, Manual
AX4 L36 Engine, Gas V6 3.8L MFI HO
European
A31 Window, Power Operated Side M49 Transmission, Manual 5 Speed OD
.
Lock Control, Rear Compt Lid Remote MM6 Transmission, Manual 6 Speed OD
A90
Elec Release
M30 Transmission, Auto 4 Speed Electronic
835 Covering Rear Floor Mats
Steering Wheel, Sport Soft Rim
B4C Sales Special Service Pkg (Police) NK3
Simulated Leather
884 Molding, 8/S Exterior Leaded. Fuel System Compatible,
NM8
CC1 Roof Hatch Removable Panels, Glass European
C49 Rear Window Defogger, Electric NP5 Steering Wheel, Leather Wrapped
C60 HVAC System AC Man Controls NP? Steering Column, EEC Approved
Mirror, 0/S LH & RH Remote Control NW9 Traction Control, Electronic
DD9
Electric Color
N36 Steering Wheel, 4 Spoke Sport
DE4 Sunshade, Removable Hatch Roof
N60 Wheel, Aluminum Painted
Mirror, 0/S LH & RH Remote Control
DG7 Wheel, Styled Aluminum 17" 5 Spoke
Electric Color N66
Polished
021 Sunshade, Windshield
Wheel, Custom Sport Var4 17"
Mirror, 0/S LH Remote Control, RH N73
035 (Restricted to Camaro SS)
Manual Color
N92 Cover, Wheel Bolt-on
082 Paint Special
Suspension System, Ride and N96 Wheel, 16 X 8 Cast Aluminum
FE2
Handling N98 Wheel, 16 X 8 Cast Aluminum Chrome
Suspension System, Special Ride and PA6 Wheel, Styled Painted 16"
FE4
Handling
P05 Wheel, Styled Chrome 16"
Suspension System, Front and Rear
FE? Wheel, 17 X 9 Aluminum Painted
Heavy Duty QA9
(Blue Tint)
FE9 Certification Emission-Federal
083 Wheel, 16 X 7.5 Steel
Suspension System, Front and Rear
F41 QCB Tire, All P235/55R16 BW
Firm Ride and Handling
) GU2 Axle Ratio 2.73 QEA Tire, All P215/60R16 BW
GU4 Axle Ratio 3.08 QFK Tire, All P275/40R17 BW
GUS Axle Ratio 3.23 QFZ Tire, All P245/50R16 BW
GU6 Axle Ratio 3.42 QLC Tire, All P245/50R16 BW
RPO Table (cont'd) RPO Table (cont'd)
RPO Description RPO Description (
Headlamps, Control Leveling System W59 Entertainment System Option I
TR7
Automatic W66 Merchandised Pkg, Formula
T1G Vehicle, Military Personnel W68 Sales Package, Firebird Upfitter .
T37 Lamp, Fog Deluxe W73 Entertainment System Option J
T39 Lamp, Turn Signal Aux X10 Entertainment System, Option I
T43 Spoiler, Rear X20 Entertainment System, Option J
T62 Lighting, Daytime Running Delete Y3F Sales Package, RS Camara
T65 Lighting, Daytime Running Export Y8.1 Merchandised Pkg, Firebird
T78 Headlamp Control, Delete
Y82 Merchandised Pkg, Trans Am
T79 Lamp, Fog Rear Y84 Merchandised Pkg, Trans Am GTA
T82 Headlamp Control, Automatic ON-OFF Merchandised Pkg, Performance
Y87
T84 Headlamps, RH Rule of Road Enhancement
T85 Headlamps, LH Rule of the Road Z5X Mirror Provisions, Arabic Language
T89 Lamp, Tail & Stop Export 01U Primary Color, Exterior Special
T96 Lamp, Fog Performance Package,
1LE
UA6 Theft Deterrent System Component Special
Cluster, Inst Oil Cool Temp Volts Trip 101 Interior Trim; Arctic White
UB3
Odom Tach 100 Molding Color, Arctic White
UC2 Speedometer, Inst Kilo Positive Bias 10T Top Color, Arctic White
Electronic System Steering Wheel Ace 10U Primary Color, Exterior Arctic White
UK3
Controls
i 10 Molding Color, Pewter Metallic
Radio, AM/FM Stereo Auto Rev Music
ULO 11 U Exterior Color, Pewter Metallic
Srch Cass Clock ETR
Radio, AM/FM Stereo Auto Rev Cass 102
Trim Combination, Leather Arctic (
UM6 White Camara and Firebird
Clock ETR
Radio, AM/FM Stereo Compact Disc Trim Combination, .
UNO 103
Auto Tone Clock Leather Arctic White Pontiac
Speaker Sys, 4 Dual Frt Dr Mtd Dual Trim Combination,
uoo STD RGE Otr/Shelf
105
Leather Arctic White Pontiac
Radio, AM/FM Stereo Auto Rev Music 148 Trim Combination, Cloth Dark Gray
UW3
Search Cass Data Sys 140 Trim Combination, Cloth Dark Gray
Speaker System, 8 Ouat Frt Dr Mtd 141 Interior Trim, Very Dark Gray
UZ7
Dual RR Hatch Amplifier
Trim Combination, Leather Very Dark
U1S Player, Multiple Compact Disc 142
Gray Camara and Firebird
Speaker System, 4 Dual Coax Frt Trim Combination,
U62
Dual Coax PKG Shelf 143
Leather Very Dark Gray Firebird
U73 Antenna, Fixed Radio
Trim Combination,
144
U75 Antenna, Power Radio Leather Very Dark Gray Camara
VK3 License Plate, Front Mounting Pkg 200 Molding Color, Blue Metallic
VL4 License Plate, Rear Mounting Pkg 20U Exterior Color, Blue Metallic
V12 Cooling System, Power Steering 280 Molding Color, Navy Blue Met
V76 Hook, Tow Primary Color,
28U
WS6 Performance Package Special Exterior Navy Blue Metallic
310 Molding Color, Bright Green
WS9 Model Conversion, Formula
WU6 31U Primary Color, Exterior Bright Green
Sales Package, Firehawk Upfitter
WU8 Sales Package, Z28 SS 360 Molding Color, Fern Green
W52 36U Exterior Color, Fern Green

Entertainment System Option B
W53 Entertainment System Option C
4i0 Molding Color, Black (
W54 41T Top Color, Black
Entertainment System Option D -· 4iU
Entertainment System Option E Primary Color, Exterior Black
W55 -·-----
(MONSOON) 528 Trim Combination, Cloth Light Neutral
-
General Information General Information Oa17
RPO Table (cont'd) labels - How to Obtain Replacement
) RPO Description Obtain replacements for the following labels through
the GM Service Parts Operations:
520 Trim Combination, Cloth Light Neutral
• The vehicle emission control information
521 Interior Trim, Medium Neutral (exhaust emission tune-up) label
Trim Combination, • The spare wheel caution label
522
Leather Light Neutral • The jacking label
Trim Combination, • The serpentine belt routing label
523
Leather Medium Neutral II " The engine fan caution label
Trim Combination, • The spare tire storage label
524 The following labels are not available as service parts:
Leather Medium Neutral
56T Top Color, Medium Dark Neutral
" The vehicle certification label
• The tire pressure placard
630 Molding Color, Sport Gold • The service parts identification label
63U Exterior Color, Sport Gold
Fasteners
738 Trim Combination, Cloth Flame Red
Metric Fasteners
731 Interior Trim, Flame Red This vehicle is dimensioned in the metric system. Most
790 Molding Color, Mystic Teal metric fasteners are very close in diameter to well
known fasteners in the English (inch) system. Replace
79U Primary Color, Exterior Mystic Teal
fasteners with those of the same nominal diameter,
810 Molding Color, Bright Red thread pitch, and strength.
81U Primary Color, Exterior Bright Red A number marking identifies the OE metric fasteners
(except cross-recess head screws). The number
880 Molding Color, Bright Purple also indicates the strength of the fastener material. A
88U Primary Color, Exterior Bright Purple Posidrive® or Type 1A cross-recess identifies a
metric cross-recess screw. For best results, use a
Trim Combination, Type 1A cross-recess screwdriver, or equivalent, in
928
) Cloth Medium Pewter Posidrive® recess head screws.
921 Interior Trim, Pewter GM Engineering Standards and North American
960 Molding Color, Cayenne Red
Industries have adopted a portion of the ISO-defined
standard metric fastener sizes. The purpose of this was
Primary Color, to reduce the number of fastener sizes used while
96U
Exterior Cayenne Red Metallic retaining the best thread qualities in each thread size.
990 Molding Color,Hugger Orange For example, the metric M6.0 X 1 screw, with nearly the
same diameter and 25.4 threads per inch replaced the
99U Exterior Color, Hugger Orange English 1/4-20 and 1/4-28 screws. The thread pitch is
midway between the English coarse and fine thread
pitches.
Fastener Strength Identification
4 5
1 2 3
6
(
171891
Legend
(1) English Bolt, Grade 2 (Strength Class) (5) Metric Nut, Strength Class 9
(2) English Bolt, Grade 5 (Strength Class) (6) Metric Bolts, Strength Class Increases as
(3) English Bolt, Grade 7 (Strength Class) Numbers Increase
(4) English Bolt, Grade 8 (Strength Class)
The most commonly used metric fastener strength Prevailing Torque Fasteners
property classes are 9.8 and 10.9. The class
) identification is embossed on the.head of each bolt.
The English (inch) strength classes range from grade 2
to grade 8. Radial lines are embossed on the head
of each bolt to identify the strength class. The number
of lines on the head of the Qolt is two lines less
than the actual grade. For example, a grade 8 bolt will
have 6 radial lines on the. bolt head. Some metric
nuts are marked with a single-digit strength 2 3 4 .5
identification number on the nut face.
The correct fasteners are available through GM SPO.
Many metric fasteners available in the aftermarket
parts channels were designed to meet the metric
standards of countries other than the United States,
and may exhibit the following defects: ·
e Reduced strength 6 7 8 9
c No numbered head marking system
e Wrong thread pitch
The metric fasteners on GM products are designed to 171892
new, international standards. The following are the legend

most common sizes and pitches, except for special (1) Prevailing Torque Nut, Center Lock Type
applications: (2) Prevailing Torque Nut, Top Lock Type
e M6.0X i (3) Prevailing Torque Nut, Nylon Patch Type
0 MS X 1.25 (4) Prevailing Torque Nut, Nylon Washer
Insert Type
®· MiO X 1.5
(5) Prevailing Torque Nut, Nylon Insert Type
) o M12 X i.75 (6) Prevailing Torque Bolt, Dry Adhesive
Coating Type
(7) Prevailing Torque Bolt, Thread Profile
Deformed Type
(8) Prevailing Torque Bolt, Nylon Strip Type
(9) Prevailing Torque Bolt, Out-of-Round Thread
Area Type
A prevailing torque nut is designed to develop an

interface between the nut and bolt threads. Distortion
of the top of a metal nut or the use of a nylon
patch on the threads in the middle of the hex flat
provides the interface.
)
A prevailing torque bolt/nut that is clean and free of 3. Hand start the fastener at the original location.
rust can be reused as follows: 4. Inspect the fastener for torque development,
1. Clean away all dirt or foreign material. referring to the following table. (
2. Inspect the fastener for signs of overtightening. 5. Tighten the fastener within specifications.
Prevailing Torque Specifications (Metric-Size Fasteners)
Specification
Application Metric .English
Nuts and All Metal Bolts/Screws
6mm 0.4 N-m 41bin
6.3mm 0.4 N·m 41bin
Bmm 0.6 N·m 71bin
10mm 1.4 N-m 121bin
12mm 2.2N·m 181bin
14mm 3.0 N-m 271bin
16mm 4.2 N-m 371bin
20mm 7.0 N-m 621bin
Adhesive or Nylon Coated Bolts/Screws
6mm 0.4 N-m 41bin
6.3mm 0.4 N-m 41bin
Bmm 0.6N·m 71bin
10mm 1.2 N-m 11 lb in
12mm 1.6 N-m 14 lb in
14mm 2.4 N-m 21 lb in (
16mm 3.4 N-m 301bin
20mm 5.6 N·m 501bin
Prevailing Torque Specifications (English-Size Fasteners)

Specification
Application Metric English
Nuts and All Metal Bolts/Screws
0.250 in 0.4 N-m 41bin
0.312 in 0.6 N-m 51bin
0.375 in 1.4 N-m 121bin
0.437 in 1.6 N-m 161bin
0.500 in 2.4 N-m 21 lbin
0.562 in 3.2 N-m 281bin
0.625 in 4.2N·m 371bin
0.750 in 7.0 N-m 621bin
Adhesive or Nylon Coated Bolts/Screws
0.250 in 0.4 N·m 41bin
0.312 in 0.6 N·m Sib in
0.375 in 1.0 N-m 91b in
0.437 in 1.4 N-m 121bin
0.500 in 1.8 N-m 161bin
(
0.562 in 2.6 N-m 231bin
0.625 in 3.4 N-m 301bin
0.750 in 5.2 N·m 491b in
Thread Inserts
) Repair Procedure
Tools Required
General purpose thread repair kits. These kits are
available commercially.
Caution: Wear safety glasses in order to avoid eye
damage.
Important: Refer to the thread repair kit

manu1acturer's instructions regarding the size of the
drill and tap to use.
Avoid any buildup of chips. Back out the tap every few
turns and remove the chips.
4963
4. Thread the thread insert onto the mandrel of the.

installer. Engage the tang of the insert onto the
end of the mandrel.
Important: The insert should be flush to one turn
below the surface.
5. Lubricate the insert with light engine oil (except
when installing in aluminum) and install the
) insert.
6. If the tang of the insert does not break off when
backing out the installer, break the tang off with
a drift.
4962
1. Determine the size, the pitch, and the depth of the

damaged thread. If necessary, adjust the stop
collars on the cutting tool and tap to the
required depth.
2. Drill out the damaged threads. Clean out
any chips.
3. Lubricate the tap with light engine oil. Tap the
hole. Clean the threads.
)
0-22 General Information General information
Abbreviations and Meanings
Abbreviation Meaning
Btu British thermal units
Abbreviation Meaning
c
A oc Degrees Celsius
A Ampere(s)
CAC Charge Air Cooler
ABS Antilock Brake System
CAFE Corporate Average Fuel Economy
A/C Air Conditioning
Cal Calibration
AC Alternating Current
ACC Accessory, Automatic Climate Control Cam Camshaft
·-
AGL Air Cleaner CARB California Air Resources Board
Air Conditioning Refrigerant, cc cubic centimeters
ACR4
Recovery, Recycling, Recharging CCM Central Control Module
AID Analog to Digital CCOT Cycling Clutch Orifice Tube
g
AOL Automatic Door Lock ' "
CCP Climate Control Panel

A/F Air/Fuel (Ratio) ·--·-----
CD Compact Disc
AIR Secondary Air Injection --------, I
CE Comm,tatoc Eod
ALC Automatic Level Control
CEA.B Cold Engine Air Bleed ·
Amplitude Modulation/Frequency
AM/FM Counter Electromotive Force . .
Modulation CEMF
j
Ant Antenna cfm cubic feet per minute ·
AP Accelerator Pedal cg center of gravity
API American Petroleum Institute CID Cubic Inch Displacement
APP
APT
Accelerator Pedal Position
Adjustable Part Throttle
CKP Crankshaft Position _____]
ARS Automatic Restraint System
CKT Circuit
---·· (
CL Closed Loop
ASR Acceleration Slip Regulation -
C/Ltr Cigar Lighter
A/T Automatic Transmission/Transaxle
CMP Camshaft Position
ATC Automatic Temperature Control ---------·-·----
CNG Compressed Natural Gas
ATDC After Top Dead Center
Auto Automatic
co Carbon Monoxide
avg average C02 Carbon Dioxide
AWD All Wheel Drive Coax Coaxial -~

AWG American Wire Gage COMM Communication ,_J
B Conn Connector
·-
B+ Battery Positive Voltage CPA Connector Position Assurance
·-
B- Battery Negative Voltage CPP Clutch Pedal Position
BARO Barometric (pressure) CPS Central Power Supply
batt battery
--
CPU Central Processing Unit
BBV Brake Booster Vacuum CRT Cathode Ray Tube
BCM Body Control Module
CRTC Cathode Ray Tube Controiler
-=3
BHP Brake Horsepower
cs Charging System I
BLK Black
CTP Closed Throttle Positio_n__
BLU Blue
cu ft cubic foot/feet
BP Back Pressure
~
cu in cubic inch/inches
BPM Brake Pressure Modulator
CV Contant Velocity (joint)
BPMV Brake Pressure Modulator Valve --
BPP Brake Pedal Position CVR SS
Continuously Variable Road Sensing (
Suspension
BRN Brown ·------
Cy! Cylinder(s)
BTDC Before Top Dead Center
BTSI Brake Transmission Shift Interlock
Abbreviation Meaning Abbreviation Meaning

) D Erasable Programmable Read Only
EPROM
DAB Delayed Accessory Bus Memory
dB decibels ESC Electronic Suspension Control
dBA decibels on A-weighted scale ESD Electrostatic Discharge
DC Direct Current Electronic Throttle Control,
ETC
DCM Door Control Module Electronic Temperature Control
DE Drive End ETCC Electronic Touch Climate Control
DEC Digital Electronic Controller ETR Electronically Tuned Receiver
DERM Diagnostic Energy Reserve Module EVAP Evaporative Emission
DI Distributor Ignition EVO Electronic Variable Orifice
dia diameter Exh Exhaust
DIC Driver Information Center F
Diff Differential OF Degrees Fahrenheit
DK Dark
FC Fan Control
DLC Data Link Connector
FDC Fuel Data Center
DMM Digital Multimeter
Federal (all United States except
DOHC Dual Overhead Camshafts FED
California)
DR Driver FEDS Fuel Enable Data Stream
DRL Daytime Running Lamps
FF Flexible Fuel
OTC Diagnostic Trouble Code
Fl Fuel Injection
E
Federal Motor Vehicle Safety
EBCM Electronic Brake Control Module FMVSS
Standards
Electronic Brake and Traction Control F/P Fuel Pump
EBTCM
Module
ft foot/feet
EC .· Electrical Center
ECC Electronic Climate Control FT Fuel Trim
ECI Extended Compressor at Idle F4WD Full Time Four Wheel Drive
ECL Engine Coolant Level 4WAL Four Wheel Antilock
ECM Engine Control Module 4WD Four Wheel Drive
ECS Emission Control System FW Flat Wire
ECT Engine Coolant Temperature FWD Front Wheel Drive
Electronically Erasable Programmable G
EEPROM
Read Only Memory
g grams, gravitational accelaration
Evaporator Equalized Values in
EEVIR GA Gage
Receiver
EFE Early Fuel Evaporation gal gallon
EGR Exhaust Gas Recirculation gas gasoline
Exhaust Gas Recirculation Thermal GCW Gross Combination Weight
EGR TVV
Vacuum Valve
Gen Generator
El Electronic Ignition
GL Gear Lubricant
ELAP Elapsed
GM General Motors
ELC Electronic Level Control
General Motors Service Parts
E/M English I Metric GMSPO
Operations
EMF Electromotive Force
gnd ground
Eng Engine
gpm gallons per minute
EOP Engine Oil Pressure
GRN Green
EOT Engine Oil Temperature
GRY Gray ..
EPA Environmental Protection Agency
GVWR Gross Vehicle Weight Rating
EPR Exhaust Pressure Regulator

(
H km/I kilometers per liter
H Hydrogen kPa kilopascals
H20 Water KS Knock Sensor
Harn Harness kV kilovolts
HC Hydrocarbons L
H/CMPR High Compression L Liter
HD Heavy Duty L4 Four Cylinder Engine, In-line
HOC Heavy Duty Cooling L6 Six Cylinder Engine, In-Line
hex hexagon lb pound
Hg Mercury lb ft pound feet (torque)
Hi Alt High Altitude lb in pound inch (torque)
H02S Heated Oxygen Sensor LCD Liquid Crystal Display
hp horsepower LDCL Left Door Closed Locking
HPL High Pressure Liquid LDCM Left Door Control Module
HPS High Performance System LED Light Emitting Diode
HPV High Pressure Vapor LF Left Front
Htd Heated LH Left Hand
HTR Heater Im lumens
HUD Head-up Display LR Left Rear
.·
HVAC Heater-Vent-Air Conditioning It left
HVACM Heater-Vent-Air Conditioning Module LT Light
HVM Heater Vent Module M
Hz Hertz MAF Mass Air Flow (
I .. Man Manual
IAC Idle Air Control MAP Manifold Absolute Pressure
IAT Intake Air Temperature MAT Manifold Absolute Temperature
IC Integrated Circuit, Ignition Control max maximum
ICM Ignition Control Module M/C Mixture Control
ID Identification, Inside Diameter MOP Manifold Differential Pressure
IOI Integrated Direct Ignition MFI Multiport Fuel Injection
ign ignition mi miles
ILC Idle Load Compensator MIL Malfunction Indicator Lamp
in inch/inches min minimum
INJ Injection ml milliliter
inst instantaneous mm millimeter
1/P Instrument Panel mpg miles per gallon
IPC Instrument Panel Cluster mph miles per hour
1/PEC Instrument Panel Electrical Center ms millisecond
ISC Idle Speed Control MST Manifold Surface Temperature
ISO International Standards Organization MIT Manual Transmission/Transaxle
ISS Input Speed Shaft MV Megavolt
K mV millivolt
KAM Keep Alive Memory N
KDD Keyboard Display Driver NAES North American Export Sales
kg kilogram NC Normally Closed (
kHz kilohertz NEG Negative
km kilometer Neu Neutral
km/h kilometers per hour NLGI National Lubricating Grease Institute
General Information General Information «J:·25
) Abbreviation Meaning Abbreviation Meaning

N-m Newton-meter (torque) pt pint
NO Normally Open PWM Pulse Width Modulated
NOx. Oxides of Nitrogen Q
NPTC National Pip~ Thread Coarse qt quart(s)
NPTF National Pipe Th.read Fine R
NV RAM Non Volatile Random Access Memory R-12 Refrigerant-12
0 R-134a Refrigerant-134a
02 Oxygen Random Access Memory
028 Oxygen Sensor (non permanent memory devise,
RAM
memory contents are lost when power
OBD II On-Board Diagnostics II is removed)
oc Oxidation Converter (Catalytic) RAP Retained Accessory Power
OD Outside Diameter RAV Remote Activation Verification
ODO Odometer RC DLR Remote Control Door Lock Receiver
OE Original Equipment RDCM Right Door Control Module
OEM Original Equipment Manufacturer Ref Reference
OHC Overhead Camshaft Rev Reverse
OL Open Loop RF Right Front, Radio Frequency
ORN Orange RFA Remote Function Actuation
oss Output Shaft Speed RFI Radio Frequency Interference
oz ounce(s) RH Right Hand
p RKE Remote Keyless Entry
PAG Polyalkylene Glycol Rly Relay
) PASS Passenger . Read Only Memory (permanent
PASS-Key®
Personalized Automotive Security . ROM memory devise, memory conten.ts are
System retained when power is removed)
P/B Power Brakes Engine Speed
RPM
(Revolutions Per Minute)
PC Pressure Control
RPO Regular Production Option
PCB Printed Circuit Board
RR Right Rear
PCM Powertrain Control Module
. rt right
. PCS Pressure Control Solenoid
PCV Positive Crankcase Ventilation ' RTD Real Time Damping
Room Temperature Vulcanizing
PM Permanent Magnet (Generator) RTV
:
(sealer)
P/N Part Number RWAL Rear Wheel Antilock
PNK Pink
RWD Rear Wheel Drive
PNP Park/Neutral Position
s
PRNDL Park,. Reverse, Neutral, Drive, Low
s second(s)
POA Pilqt Operat!3d Absol.ute (Valve) SAE Society of Automotive Engineers
. .POS Positive
. SC Supercharger
POT Potentiometer (Variable Resistor)
SCB · Supercharger Bypass
PPL Purple . . SCM Seat Control Module
ppm parts per million SDM Sensing and Diagnostic Module
.. PROM Programmable Read Only Memory
SEO Special Equipment Option .
PIS Power Steering
SFI Sequential Multiport Fuel Injection
... PSD Power Sliding Door
System International
SI
PSP Power Steering Pressure (modern version of metric system)
psi pounds per square inch SIR Supplemental Inflatable Restraint
psi a pounds per square inch absolute SLA Short/Long Arm (suspension)
pounds per square inch gage sol solenoid
·-
psig

(
802 Sulfur Dioxide v
SP Splice Pack v Volt(s), Voltage
SPO Service Parts Operations V6 Six Cylinder Engine, V-Type
sq ft square foot/feet
V8 Eight Cylinder Engine, V-Type
sq in square inch/inches
Vac Vacuum
SRC Service Ride Control
VAC Vehicle Access 'code
SRI Service Reminder Indicator
VATS Vehicle Anti-Theft System
ST Scan Tool
VCM Vehicle Control Module
S4WD Selectable Four Wheel Drive
Sw Switch VDOT Variable Displacement Orifice Tube
syn synchronizer VDV Vacuum Delay Valve

T vel velocity
Tach Tachometer VES Variable Effort Steering
TBI Throttle Body Fuel Injection VF Vacuum Fluorescent
TC Turbocharger VIO Violet
TCC Torque Converter. Clutch VIN Vehicle Identification Number
TCS Traction Control System VMV Vacuum Modulator,Valve
TDC Top Dead Center Voltage Regulator
VR
TEMP Temperature
V ref Voltage Reference
Term Terminal
vss Vehicle Speed .Sensor
TFP Transmission Fluid Pressure
w
TFT Transmission Fluid Temperature
TOG Transmission Oil Cooler
w/ with (
W/B Wheel Base
TP Throttle Position
TPA Terminal Positive Assurance WHL Wheel
TPM Tire Pressure Monitoring WHT White

TR Transmission Range w/o without
TRANS Transmission/Transaxle WOT Wide Open Throttle
TV Throttle Valve W/P Water Pump
TVRS Television and Radio Suppression · WIS Windshield
TVV Thermal Vacuum Valve wss Wheel Speed Sensor
TWC Three Way Converter (Catalytic) Warm Up Oxidation Converter
WU-OC
Three Way + Oxidation Converter (Catalytic)
TWC+OC
(Catalytic) Warm Up Three Way Converter
WU-TWC
TXV Thermal Expansion Valve (Catalytic)
u x
Universal Asynchronous Receive and X-valve Expansion valve
UART
Transmit
y
U/H Underhood
yd yard(s)
U/HEC Underhood Electrical Center ..
YEL Yellow
U-joint Universal Joint
UTD Universal Theft Deterrent
UV Ultraviolet
(
Key and lock Cylinder Coding Replacement Lock Cylinders
) Key Identification and Usage
New lock cylinders (except ignition lock cylinders) are
available from the service parts warehouse with new
lock cylinder locking bars. The tumblers are also
The lock cylinder keyway is designed so that other
available and must be assembled into the cylinder as
model keys will not enter a current model lock cylinder. recommended. For additional information, refer to the
A single key is used for all locks on the vehicle. following.
The key identification is obtained from the Lock Cylinder Tumbler Operation
four-character key code stamped on the knockout All lock tumblers are shaped alike with the exception of
portion of the key head. Knock the plugs out of the key the notched position on one side. As the key is inserted
head after the code numbers have been recorded. into the lock cylinder, the tumblers are lowered to the
The code list, available to owners of key cutting correct height so that the notches on each tumbler are
equipment from equipment suppliers, determines the at the same level. When the notches on all six tumblers
lock combinations from the code numbers. line up, two small springs push the side bar into the
notches, allowing the cylinder to turn in the cylinder
If the code numbers are not available from the records bore. Five types of tumblers are used in making the lock
or from the knockout plug, lay the key on the key code combinations, and each tumbler is coded and stamped
diagram in order to determine the lock combinations with a number between 1 and 5.
(the tumbler numbers and the position arrangement). Assembling and Coding ignition Lock
Cylinders
Cutting Keys
Tools Required
J 41340 Lock Cylinder Staking and Holding Fixture
--
J
J -
1--' '-
.lJ 1!..1..1 .1-,._11
.,,.._ .,_,. ,,..,,..,,.,

I
]
4
1 3 5 7 9 3
~ 2 4 6 8 10 2
,__ 1
__y
-
b ::::i:::::;;;;;;;;!!~~
1
r
1
2 '.
-
65495
After the code has been .determined from the code list 65496
or the key code diagram, perform the following steps: 1. Determine the tumbler numbers/arrangement: .
1. Cut a blank key to the proper level (1) of each 1.1. Place the tip of the key directly over the
of the tumbler positions (2). tip of the illustrated key.
1.2. Inspect that the diagram outlines the key.
2. Inspect the key operation in the lock cylinder. 1.3. Starting with position 1 (open end of
cylinder), find and record the lowest
level (tumbler number) that is visible.
1.4. Repeat the previous step for positions 2-:-10.
65498 65501
2. Starting with position 1, insert the tumblers (4) 8. Inspect for proper tumbler installation:
into their corresponding slots in the coded order. 8.1. Hold the spring retainer (2) in position.
3. Using your fingers, pull out the side bar (3) until 8.2. Insert the key (1) into the cylinder.
the tumblers fall completely into place.
8.3. The side bar (3) should drop down flush
4. Insert one tumbler spring (2) above each with the cylinder diameter if properly
tumbler (4). installed.
5. Lubricate the tumblers using Superlube® 8.4. Disassemble and assemble properly as
GM P/N 12346241 or equivalent. needed. (
6. Insert the spring retainer (1) prongs into the slots 9. Remove the key.
at the end of each cylinder.
65502
65499
1O. Secure the cylinder in the J 41340.
7. Press down the retainer (1) until fully seated in
the depression. 10.1. Inspect that the spring retainer is facing up
and positioned directly under the
punch slots.
10.2. Push the cylinder into the J 41340 until
butted with the cylinder bezel.
10.3. Tighten the holding screw.
J 41340
65503 65505
11. Stake the bezel end of the retainer in place: 13. Loosen the holding screw.
11.1. Hold the flat side of the punch, part of 14. Remove the cylinder from the J 41340.
J 41340, squarely against the face of the 15. Inspect that the retainer is properly staked.
cylinder bezel. Restake as needed.
11.2. Stake the lock cylinder metal over the .. 16. Lubricate the cylinder retainer slot.
retainer corners.
17. Insert the following parts into the cylinder
retainer slot:
J 41340 • The retainer spring (2)
• The retainer (3)
Important: Use a paste type grease, not a spray, for
the following step.
18. Lubricate the following parts with
GM P/N 12345996 or equivalent as needed:
• The detent pins (1)
• The cylinder retainer (3)
Side Door lock Cylinder Coding
The side door lock cyHnder has five snap-in tumblers.
The number 1-5 positions (beginning closest to the
cylinder head) are a brass retainer tumbler. The
6-1 Opositions are standard tumbler positions.
Therefore, only the 6-10 positions are required.
65504
12. Stake the other end of the retainer:

12.1 . Remove the punch, part of J 41340.
12.2. Rotate the punch, part of J 41340,
180 degrees. ·
12.3. Hold the punch, part of J 41340, squarely
against the end of the punch slot on
J 41340.
12.4. Stake the metal over the other end of the
retainer.
Lifting and Jacking the Vehicle Rear Hoist Pads
Caution: To help avoid personal injury, always use
jack stands when you are working on or under
any vehicle that is supported only by a jack.
Caution: To avoid any vehicle damage, serious

personal injury or death when major components
are removed from the vehicle and the vehicle
is supported by a hoist, support the vehicle with
jack stands at the opposite end from which
the components are being removed.
Notice: When you are jacking or lifting a vehicle at

the frame side rails or other prescribed lift points,
be certain that the lift pads do not contact the catalytic
converter, the brake pipes or the fuel lines. If such
contact occurs, vehicle damage or unsatisfactory
vehicle performance may result.
For lifting the vehicle, various lift points are

recommended. Before you begin any lifting procedure, 255757
be sure the vehicle is on a clean, hard, level surface. Be
sure all the lifting equipment meets weight standards Important: The rear hoist pads must not contact the
and is in good working order. Be sure all the vehicle body rocker panels or the floor pan.
loads are equally distributed and secure. If you are only Position the rear hoist pads (body/frame contact)
supporting the vehicle at the frame side rails, make sure as shown.
the lifting equipment does not put too much stress on,
or weaken, the frame side rails. Suspension Contact Hoist
If you use any other hoisting methods than those Front Lift
(
called out, take special care not to damage the fuel
tanks, the exhaust system or the underbody.
Frame Contact Hoist
Front Hoist Pads
255761
Position the front lift (suspension contact) as follows: ·

under the outer edge of the front suspension lower
control arms.
255759
Important: The front hoist pads must not contact the (

rocker panels, the front fenders, or the floor pan.
Position the front hoist pads (frame contact) as shown.
Rear Lift Under the Rear Differential
)
255755 175241
Position the rear lift (suspension contact) as shown. Important: When Hfting the vehicle with a floor jack,
Vehicle Jacking block the wheels at the opposite end from which
you are raising.
Under the Front Crossmember Position the floor jack pad under the center of the rear
axle differential.
Jack Stands
)
Important: When supporting the vehicle with jack
stands, the jack stands should be placed under
the frame, the front crossmember, or the rear axle.
175243
Important: When lifting the vehicle with a floor jack,

block the wheels at the opposite end from which
you are raising.
Position the floor jack pad under the center of the
front crossmember. ·
)
Strategy Based Diagnosis is numbered, you are not required to complete every
box in order to successfully diagnose a customer
The goal of Strategy Based Diagnostics is to provide
concern. The first step of your diagnostic process
guidance when you create a plan of action for each
specific diagnostic situation. Following a similar plan for should always be, Verify the Customer Concern (box 1).
each diagnostic situation, you will achieve maximum The final step of your diagnostic process should be,
efficiency when you diagnose and repair vehicles. Repair and Verify the Fix (box 7). Refer to the following
Although each of the Strategy Based Diagnostics boxes chart for the correct strategy based diagnostics.
VERIFY CUSTOMER CONCERN
PRELIMINARY CHECKS
2
Visual and Operational
Perform Published
3
DIAGNOSTIC SYSTEM CHECKS
CHECK FOR BULLETINS

4
(Printed/lDCS/ESI)
5.1 5.2 5.3 5.4

STORED SYMPTOM NO PUBLISHED
INTERMITTENT
DTC(S) NO DTC(S) DIAGNOSTICS
Follow Follow Analyze and See
Published Published Develop Diagnostic
DTC SYMPTOM Diagnostics Details
or call
Diagnostics Diagnostics
Technical
(
Assistance
5.5
OPERATING AS DESIGNED
o Check Identical Vehicle
o Customer Misunderstanding of System:
Explain Operation to Customer or refer
to Owner or Service Manual
o Product Problem:
Cali Technical Assistance
7 REPAIR AND VERIFY FIX
6508
Legend
(1) Verify the customer concern: The first part of (2) Preliminary Checks: Conduct a thorough
this step is to obtain as much information visual inspection. Review the service history. ·
as possible from the customer such as: Are Detect unusual sounds or odors. Gather
there aftermarket accessories on the diagnostic trouble code information in order
vehicle? When does the condition occur? to achieve an effective repair.
Where does the condition occur? How long (3) Perform Published Diagnostic System (
and how often does the condition occur? Checks: One or more DTCs may not support
In order to verify the concern the technician a system. System checks verify the proper
should know the normal operation of the operation of the system. This will lead
system and refer to the owner or service the technician in an organized approach to
manual for any information needed. diagnostics.
(4) Check Bulletins and Other Service (5.5) Vehicle Operates as Designed: This
Information: Such as videos, newsletters, condition exists when the vehicle is found to
) and the Pulsat programs. operate normally. The condition described
(5.1) Stored DTCs: Follow the designated DTC by the customer may be normal. Verify
table exactly in order to make an effective against another like vehicle that is. operating
repair. normally under the same conditions
(5.2) Symptom No DTC: Select the symptom from described by the customer. Explain your
the symptom tables. Follow the diagnostic findings and the operation of that system to
steps or suggestions in order to complete the the customer.
repair, or refer to the applicable (6) Re-examine the Concern: If a technician
component/system check. cannot successfully find or isolate the
(5.3) No Published Diagnostics: Analyze the. concern, a reevaluation is necessary.
concern. Develop a plan for the diagnostics. Re-verify the concern. The concern could be
The service manual schematics will help you an intermittent or normal.
to see system power, ground; input and
(7) Repair and Verify Fix: After isolating the
output circuits. You can also identify splices
cause, make the repairs and validate
and other areas where multiple circuits are
for proper operation. Verify that the symptom
tied together. Look at component locations to
see if components, connectors or harnesses has been corrected which may involve
may be exposed to extreme temperature, road testing the vehicle.
moisture, road salt or other corrosives
(battery acid, oil or other fluids). Utilize the
wiring diagrams, system description and
operation, and system circuit description.
(5.4) lntermittents: An intermittent condition is
one that does not occur continuously and will
occur when certain conditions are met.
Generally, intermittents are caused by: Faulty
electrical connections and wiring,
) malfunctioning components, electromagnetic/
radio frequency interference, and aftermarket
equipment.. Com.bine the technician
knowledge with efficient use of the available
service information. Evaluate the symptoms
and conditions described by the customer.
Use a check sheet or other method in order to
identify the component. Follow the
suggestions for intermittent diagnosis found in
the service manual. The Tech 1, Tech 2
scan tools, and the J39200 (Fluke 87) have
data capturing capabilities that can assist in
detection of intermittents.
Special Tools and Equipment

Tool Illustration Tool Number/Description
J 41340
Lock Cylinder Staking and
Holding F.ixture
65540
)
0-34 Maintenance and lubrication General Information
Maintenance and Lubrication

Specifications
Capacities - Approximate Fluid
Approximate Fluid Capacities
Specification
Description Metric I English
Engine Cooling System
3.8 L With Manual Transmission 11.0 liters 11.6 quarts
3.8 L With Automatic Transmission 10.8 liters 11.4 quarts
5. 7 L With Manual Transmission 11.3 liters 11.9 quarts
5.7 L With Automatic Transmission 11.2 liters 11.8 quarts
Engine Crankcase
3.8 L With Filter 4.2 liters 4.5 quarts
5. 7 L With Filter 5.2 liters 5.5 quarts
Transmission
4L60-E 4.7 liters 5.0 quarts
After Complete Overhaul (L36) 8.3 liters 8.8 quarts
After Complete Overhaul (LSi) 10.2 liters 10.8 quarts
M49 5-Speed Manual Transmission 3.2 liters 3.4 quarts
MM6 6-Speed Manaual Transmission 3.8 liters 4.0 quarts
Approximate Fuel Capacities (All Vehicles) 63.6 liters 16.8 quarts
Fluid and lubricant Recommendations

Component Fluid or Lubricant Recommended
Automatic Transmission DEXRON®-111 Automatic Transmission Fluid. , ..
Chassis Lubrication Chassis lubricant (GM P/N 12377985 or equivalent) or lubricant meeting requjrernents of
NLGI Grade 2, Category GC or GC-LB. . .
Differential, Locking Axle Lubricant (GM P/N 12378261) Synthetic 75W-90 GL-5 Gear Lubricant with Limited
Slip Differential Additive (GM P/N 1052358) .
Differential, Non-Locking Axle Lubricant (GM P/N 12378261) Synthetic 75W-90 GL-5 Gear Lubricant.
Engine Coolant 50/50 mixture of clean water (preferably distilled) and GM Goodwrench® DEX-COOL® or
Havoline® DEX-COOL® coolant (only).
Engine Oil Engine oil with the American Petroleum Institute Certified For Gasoline Engines
"Starburst" symbol of the proper viscosity. To determine the preferred viscosity for your
vehicle's engine, refer to the Explanation of Scheduled Services.
Hinges, Hood and Door Multi-Purpose lubricant, Superlube® (GM P/N 12346241 or equivalent).
Hood Latch Lubriplate lubricant aerosol (GM P/N 12346293 or equivalent) or lubricant meeting
• Pivots and Spring Anchor requirements of NLGI Grade 2, Category LB or GC-LB. ·
• Release Pawl
Hydraulic Brake System Delco Supreme 11® Brake Fluid (GM P/N 12377967 or equivalent DOT-3 brake fluid).
Hydraulic Clutch System Hydraulic Clutch Fluid (GM P/N 12345347 7 or equivalent DOT-3 brake fluid).
Lock Cylinders Multi-Purpose Lubricant, Superlube® (GM P/N 12346241 or equivalent).
Manual Transmission DEXRON®-111 Automatic Transmission Fluid.
Parking Brake Cable Guides Chassis lubricant (GM P/N 12377985 or equivalent) meeting requirements of
NLGI Grade 2, Category GC or GC-LB.
Power Steering System GM Hydraulic Power Steering Fluid (GM P/N 1052884 (pt), 1050017 (qt), or equivalent).
Weatherstrip Conditioning Dielectric Silicone Grease (GM P/N 12345579 or equivalent). (
Windshield Washer Solvent GM Optikleen® Washer Solvent (GM P/N 1051515) or equivalent.
General Information Maintenance and Lubrication 0-35
Tire Inflation Pressure Specifications (Tire Inflation Specifications)
) Specification
Compact spare tire 420 kPa 60 psi
Tires under normal driving conditions 2"10 kPa 30 psi
Tires under sustained high speed driving of 160 km/h (100 mph) or
265 kPa 38 psi
higher
Maintenance Items
Usage Type
Air Cleaner/Filter
3.8 Land 5.7 L AC Type A917C
Engine Oil Filter
3.8L (L36) AC Type PF-47
5.7L(LS1) AC Type PF-44
Fuel Filter
3.8 L (L36) AC Type G627
5.7L(LS1) AC Type GF-578
PCVValve
3.8 L (L36) AC Type CV892C
5.7L (LS1) AC Type CV948C
Radiator Cap
3.8 L (L36) and 5.7 L (LS1) AC Type RC-24
Spark Plugs and Gaps
3.8 L (L36) AC Type 41-921
.· (GAP 1.52 mm, 0.060 in)
) 5.7 L (LS1) AC Type 41-952
(GAP 1.52 mm, 0.060 in)
Maintenance
Maintenance Schedule Maintenance Schedule Engine Oil Change
Intervals
Normal Vehicle Use
This vehicle is equipped with an engine oil life monitor.
The maintenance instructions contained in this
The engine oil life monitor will indicate when to change
Maintenance Schedule are based on the assumption
the engine oil - usually between 5 000 km (3,000 miles)
that the vehicle will be used as designed:
and 16 000 km (10,000 miles) since the last oil change .
.. To carry passengers and cargo within the Under severe conditions, the CHANGE OIL message
recommended limitations as indicated on the Tire may be displayed before 5 000 .km (3,000 miles).
Placard located on the edge of the driver's door.
The vehicle MUST NOT be driven more than 16 000 km
• On reasonable road surfaces within legal driving
(10,000 miles) or 12 months without an oil change.
limits.
The engine oil life monitor will not detect dust in the
e On unleaded gasoline of the recommended type.
oil. If the vehicle is driven in a dusty area, be sure
For information on the proper type of fuel to
to change the oil every 5 000 km (3,000 miles)
use, refer to the Owner's Manual.
or sooner if the CHANGE OIL message is displayed.
Maintenance Schedule intervals
The services shown in this schedule up to 166 000 km
Footnotes
(100,000 miles) should be performed after 166000 km :j: The U.S. Environmental Protection Agency or the
(100,000 miles) at the same intervals. The services California Air Resources Board has determined
shown in this schedule to be performed at 240 000 km that the failure to perform this maintenance. item will
(150,000 miles) should be performed after 240 000 km not nullify the emission warranty or limit recall
(150,000 miles) at the same intervals. liability prior to the completion of the vehicle's useful
life. We, however, urge that all recommended
) For explanations of the maintenance inspections and
services included in this Maintenance Schedule, maintenance services be performed at the indicated
refer to Explanation of Scheduled Services. intervals and the maintenance be recorded.
For additional maintenance inspecUons and services * This vehicle is equipped with an oil life monitor. For ·
which are not included in this Maintenance Schedule, description and resetting information, refer to Oil
refer to Periodic Maintenance Inspection. Life Monitor - Resetting.
0-36 Maintenance and lubrication General Information
16 000 km (10,000 Miles) 96 000 km (60,000 Miles)
" Check the engine oil life monitor. If the engine oil • Check the engine oil life monitor. If the engine oil \
and filter are changed, reset the engine oil life and filter are changed, reset the engine oil life
monitor. Refer to Oil Life Monitor - Resetting. monitor. Refer to Oil Life Monitor - Resetting.
This is an emission control service. * This is an emission control service. *
.. Inspect the air cleaner filter if the vehicle is driven • Replace the air cleaner filter.
in dusty conditions. Replace the filter if necessary.
This is an emission control service.
This is an emission control service. + O Inspect the fuel tanks, cap and lines for damage
32 000 km (20,000 Miles) or leaks. Inspect the fuel cap gasket for any
" Check the engine oil life monitor. If the engine oil damage. Replace parts as needed.
and filter are changed, reset the engine oil life This .is an emission control service. +
monitor. Refer to Oil Life Monitor - Resetting. • Inspect the accessory drive belts.
This is an emission control service. * This is an emission control service.
" Inspect the air cleaner filter if the vehicle is driven
in dusty conditions. Replace the filter if necessary. 112 000 km (70,000 Miles)
This is an emission control service. + • Check the engine oil life monitor. If the engine oil
and filter are changed, reset the engine oil life
48 000 km (30,000 Miles) monitor. Refer to Oil Life Monitor - Resetting.
• Check the engine oil life monitor. If the engine oil This is an emission control service. *
monitor. Refer to Oil Life Monitor - Resetting. • Inspect the air cleaner filter if the vehicle is driven
This is an emission control service. *
" Replace the air cleaner filter.
This is an emission control service. +
This is an emission control service. 128 000 km (80,000 Miles)
.. Inspect the fuel tanks, cap and lines for damage • Check the engine oil life monitor. If the engine oil
or leaks. Inspect the fuel cap gasket for any and filter are changed, reset the engine oil life
damage. Replace parts as needed. monitor. Refer to Oil Life Monitor - Resetting.
(
This is an emission control service. + This is an emission control service. *
0 Inspect the air cleaner filter if the vehicle. is driven
64 000 km (40,000 Miles)
" Check the engine oil life monitor. If the engine oil
monitor. Refer to Oil Life Monitor - Resetting. 144 000 km (90,000 Miles)
This is an emission control service. * • Check the engine oil life monitor. If the engine oil
O
Inspect the air cleaner filter if the vehicle is driven and filter are changed, reset the engine oil life
in dusty conditions. Replace the filter if necessary. monitor. Refer to Oil Life Monitor - Resetting.
This is an emission control service. + This is an emission control service. *
.. Replace the air cleaner filter.
80 000 km (50,000 Miles)
.. Check the engine oil life monitor. If the engine oil
and filter are changed, reset the engine oil life • Inspect the fuel tanks, cap and lines for damage
monitor. Refer to Oil Life Monitor - Resetting. or leaks. Inspect the fuel cap gaskeffor any
damage. Replace parts as needed.
This is an emission control service. *
.. Inspect the air cleaner filter if the vehicle is driven
in dusty conditions. Replace the filter if necessary. 160 000 km (100,000 Miles)
This is an emission control service. + • Check the engine oil life monitor. If the engine oil
• Change the automatic transmission fluid and filter and filter are changed, reset the engine oil life
if the vehicle is mainly driven under one or more monitor. Refer to Oil Life Monitor - Resetting.
of these conditions: An emission control service. *
- In heavy traffic where the outside • Inspect the air cleaner filter if the vehicle is driven
temperature regularly reaches 32°C (90°F) or in dusty conditions. Replace the filter if necessary.
higher.
- In hilly or mountainous terrain.
• Replace the spark plugs. (
- Uses such as high performance operation.
If the vehicle is not used under any of these
conditions, change the fluid and filter at " Inspect the spark plug wires.
166 000 km (100,000 miles). This is an emission control service.
General Information Maintenance and lubrication 0-37
• Change the automatic transmission fluid and filter Engine Oil Viscosity
if the vehicle is mainly driven under one or more
) of these conditions:
- In heavy traffic where the outside temperature RECOMMENDED SAE VISCOSITY GRADE ENGINE OILS
regularly reaches 32°C (90°F) or higher.
FOR BEST FUEL ECONOMY AND COLD STARTING, SELECT THE LOWEST
- In hilly or mountainous terrain. SAE VISCOSITY GRADE OIL FOR THE EXPECTED TEMPERATURE RANGE.
- Uses such as high performance operation.
If the vehicle has not been used under any of the
severe conditions listed previously and, therefore, has
not had the automatic transmission fluid and filter WOK
changed, change both the fluid and filter. r:011 nus
240 000 km (150,000 Miles)
HOT SYMBOL
WEATHER
Drain, flush and refill the cooling system (or every
'F 'C
60 months since the last cooling system service,
whichever occurs first). For information on the proper + 100 +38
coolant to use, refer to Fluid and Lubricant
+8E +27
Recommendations.
+60 +16
Explanation of Scheduled Services 140 +4

The following text and illustrations describe the details
,20 -7
of the scheduled required maintenance services.
· 18
For information on the proper fluids and lubricants to SAE10W-30
use refer to Fluid and Lubricant Recommendations. PREFERRED
abovaO'F
Engine Oil and Oil Filter Change SAESW-30 (-jS'C)
For the engine oil and oil filter changing procedure

refer to the following: COLD
• Engine Oil and Oil Filter Replacement in Engine WEATHER
Mechanical - 3.8 L. ·
) • Engine Oil and Oil Filter Change in Engine
DO NOT USE SAE 20W-50 OR ANY
OTHER GRADE OIL NOT RECOMMENDED
Mechanical - 5.7 L. 196359
Engine Oil Quality Notice: Using engine oils of any viscosity other than
those viscosities recommended could result in
engine damage.
Motor oil viscosity has an effect on fuel economy and
cold-weather operation (starting and oil flow). Lower
viscosity motor oils can provide better fuel economy
and cold-weather performance.
When choosing an motor oil, consider the range of
outdoor temperatures the vehicle will be operated in
before the next oil change. Then select the
recommended oil viscosity.
The recommended SAE motor oil viscosity is 5W-30.
However, if outdoor temperatures will remain above
-18°C (0°F), , OW-30 may be used.
65538
Important: DO NOT use engine oil additives in

Camaro and Firebird engines.
) When changing or adding to the motor oil, use ONLY
motor oils of the proper quality. The engines in the
Camara and Firebird require motor oils of the proper
viscosity (thickness) and marked by the American
Petroleum Institute (API) Certified For Gasoline
Engines STARBURST symbol.
0-38 Maintenance and Lubrication General Information
Engine Oil Quality and Viscosity (Export)
(
SAE 5W- 30 API service SJ, ACEA A3-96
SAE 10W-30 API service SJ, ACEAA3-96
.SAE 5W-40 API service SJ, ACEA A3-96
SAE 10W-40 API service SJ, ACEAA3-96
OF -22 -4 14 32 50 68 86 104 122

oc -30 -20 -10 0 10 20 30 40 50
191050
In areas of the world other than North America, it may Transmission Service
be difficult to find oils that display the API
STARBURST symbol. Manual Transmission
If you cannot find oils displaying the API STARBURST, No fluid service is required. For fluid level inspection
look for oils that meet the API Service SJ and refer to Manual Transmission Fluid Level Check
ACEA A3-96 requirements. in Manual Transmission - M49 or Manual Transmission
Fluid Level Check in Manual Transmission - MM6.
The recommended SAE engine oil viscosity is 5W-30,
Automatic Transmission
(
however, additional engine oil viscosities meeting
the API Service SJ and ACEA A3-96 requirements Change both the fluid and the filter according to the
may be used in accordance with the temperature maintenance interval schedule.
ranges shown. For the fluid and filter changing procedure refer to
Accessory Drive Belt Inspection Automatic Transmission Fluid/Filter Changing in
Automatic Transmission - 4L60-E.
Inspect the accessory drive belts for the following:
• Cracks Spark Plug Replacement
• Fraying Replace the spark plugs according to the maintenance
interval schedule.
• Wear
For information on the correct type of spark plug refer
• Proper te.nsion
to Spark Plug Usage.
Replace as needed. (A belt can develop many small For the spark plug replacement procedure refer to
cracks in individual ribs without affecting the belt's Spark Plug Replacement.
performance.) Refer to the following:
• Drive Belt Replacement in Engine Spark Plug Wire Inspection
Mechanical - 3.8 L. Clean the spark plug wires and inspect for burns,
• Drive Belt Replacement - AccesSOJY' or Drive Belt cracks, or other damage. Inspect the wire's boot fit at
Replacement - A/C in Engine Mechanical - 5.7 L. the coil and at the spark plugs. Replace the wires
as needed. Refer to the following:
Cooling System Service • Spark Plug Wire Harness Replacement (3.8 L Right
Important: If silicate coolant is added to the cooling Bank) in Engine Electrical.
system, premature engine, heater core, or radiator • Spark Plug Wire Harness Replacement (3.8 L Left
corrosion may result. In addition, the coolant will Bank) in Engine Electrical.
require replacement much more frequently (every O Spark Plug Wire Harness Replacement (5. 7 L) in
50 000 km (30,000 miles) or 24 months.) Engine Electrical.

Drain, flush, and refill the system with a 50/50 mixture
of clean water (preferably distilled) and ONLY GM
Air Cleaner Filter Replacement (
Goodwrench® DEX-COOL® or Havoline® DEX-COOL® Replace the air cleaner filter according to the
(silicate-free) coolant. Refer to Draining and Filling maintenance schedule intervals with the correct type.
Cooling System (3.8 L) or Draining and Filling Cooling For information on the correct type of air cleaner
System (5. 7 L) in Engine Cooling. filter refer to Maintenance Items.
General Information Maintenance and Lubrication 0-39
Oil Life Monitor a Resetting At Least Once a Month
) DescriptlC>n Inspect the tire inflation. Make certain that the tires are
inflated to the pressures specified on the
The engine oil life monitor will indicate when to Certification/Tire label located on the driver's door lock
change the engine oil - usually between 5 000 km
pillar. Refer to Tire Placard.
(3,000 miles) and 12 500 km (7,500 miles) since the
last oil change. Under severe conditions, the CHANGE Clean the playback heads and the capstan of the
OIL message may be displayed before 5 000 km cassette deck. Cleaning should be done after every
(3,000 miles). The vehicle must not be driven more 50 hours of tape playing time. Refer to Cleaning Tape
than 12 500 km (7,500 miles) or 12 months without an Head and Capstan, Cassette Cleaning in Body and
oil change. Accessories.
The engine oil life monitor will not detect dust in the
oil. If the vehicle is driven. in a dusty area, be sure ,
At Least Twice A Year
to change the oil every 5 000 kni (3,000 miles) Restraint System Check
or sooner if the CHANGE OIL message is displayed.
Make sure the safety belt reminder light and all of
Reset the oil life monitor when the oil has been your belts, buckles, latch plates, retractors, and
changed, use the following procedure.
anchorages are working properly. Look for any other
Resetting Procedure loose or damaged safety belt system parts. If you
Follow this procedure to reset the engine oil life see anything that might keep am safety belt system
monitor: from doing its job, have it repaired. Have any torn
or frayed safety belts replaced.
1. Turn the ignition to RUN (engine off) ..
2. Press the TRIP/OIL RESET button on the Also look for any opened or broken air bag coverings,
instrument panel for 12 seconds. and have them repaired or replaced. (The SIR
system does not need regular maintenance).
The OIL CHANGE light will start to flash to
confirm that the system is reset. Wiper Blade Check
The reset is complete when the OIL CHANGE Inspect wiper blades for wear or cracking. Replace the
light goes out. blade inserts that appear worn or damaged or that
) 3. Turn the ignition OFF. streak or miss areas. of the windshield.
Air Cleaner Filter Restriction Indicator Check
Owner Checks and Services
Your vehicle has an indicator on the engine that lets·
Th.e following information covers the tests, inspections,
and services required to maintain the safety, you know when the air cleaner filter is dirty and needs
to be changed. Inspect indicator at least twice a
dependability, and emission control performance of
year or when your oil is changed, whichever occurs
the vehicle.
first. Inspect your air cleaner filter restriction indicator
Make certain that any necessary repairs are completed more often if the vehicle is used in dusty areas.
on time. Whenever any fluids and/or lubricants.are
added to the vehicle, be certain to use the proper fluids Weatherstrip lubrication
and/or lubricants. Refer to Fluid and Lubricant Silicone grease on weatherstrips will make them last
Recommendations. longer, seal better, and not stick or squeak. Apply
At Each Fuel Fm silicone grease with a clean cloth. During very cold,
damp weather more frequent application may be
Perform the following underhood inspections at each required.
fuel fill.
Automatic Transmission Check
Engine Oil level
Inspect the automatic transmission fluid level; add if
Inspect the engine oil level and add the proper oil
needed. A fluid loss may indicate a problem.
when necessary. Refer to Fluid and Lubricant
Inspect the system and repair as needed.
Recommendations.
Engine Coolant level At Least Once a Year
Inspect the engine coolant level and add the proper Key lock Cylinders
coolant mixture when necessary. Refer to Fluid Lubricate the lock cylinders with the recommended
and Lubricant Recommendations. lubricant. Refer to Fluid and Lubricant
Windshield Washer Fluid level Recommendations.
J Inspect the windshield washer fluid level in the Important: More frequent lubrication may be required
windshield washer reservoir and add the proper fluid when any of the listed parts are exposed to a corrosive
when necessary. Refer to Fluid and Lubricant environment. In order to locate the proper lubricant,
Recommendations. refer to Fluid and Lubricant Recommendations.
0-40 Maintenance and Lubrication General Information
Body lubrications Park Brake and Automatic Transmission PARK (P)
Lubricate all of the following areas: Mechanism Test
(
.. Body door hinges Test the parking brake and automatic transmission
PARK (P) mechanism:
• Body hood, safety lever, and prop rod pivot
Caution: When performing this check, the vehicle
• Fuel door could begin to move. You or others could be
• Rear compartment hinges injured and property could be damaged. Make sure
• Rear compartment latches and locks there is room in front of the vehicle in case the
vehicle begins to roll. Be ready to apply the regular
• Instrument panel compartment hinges, latch, and brake at once, should the vehicle begin to move.
lock cylinder
• Console cover hinges and latch Follow this procedure to test the parking brake
and automatic transmission PARK mechanism:
• Seat hardware
1. Park on a fairly steep hill, with the vehicle facing
Starter Switch downhill.
Test the starter switch: 2. Keep your foot on the brake pedal.
• Before you start, make sure you have enough 3. Set the parking brake.
room around the vehicle in case the vehicle moves
4. In order to test the parking brake:
suddenly.
4.1. Start the engine.
• Firmly apply both the parking brake and the
regular (hydraulic) brake. DO NOT use the 4.2. Place the shift lever in the NEUTRAL (N)
accelerator pedal, and be ready to turn off the position
engine immediately if it starts. 4.3. Slowly remove foot pressure from the
• For vehicles equipped with an automatic brake pedal
transmission try to start the engine in each gear. 5. In order to test the PARK (P) mechanism follow
The starter should work ONLY in PARK (P) or steps 1-3 above. and then do the following:
NEUTRAL (N). If the starter activates in any other
gear position the vehicle requires immediate
5.1. Place the shift lever in the PARK (P) (
position
service.
For vehicles equipped with the manual transmission, 5.2. Release all of the brakes
place the shift lever in the NEUTRAL (N) position, push Lap and Shoulder Belts Condition and Operation
the dutch pedal in halfway, and try to start the
Inspect all of the following seat belt system
engine. The starter should work only when the clutch
components:
pedal is pushed all the way to the floor. If the
starter works when the clutch pedal is not pushed all • Webbing
the way in, the vehicle requires immediate service. • Buckles
Steering Column lock • Latch plates
Test the steering column lock: • Retractors
While the vehicle is parked and with the parking brake • Guide loops
set, try to turn the key to LOCK in each of the shift • Anchors
lever positions.
Replace the belt if the webbing is cut or otherwise
For an automatic transmission, the key should turn to damaged.
LOCK onlywhen the shift lever is in the PARK (P)
position.
For vehicles with a key release button, try to turn the
key to lock without the button. The key should turn
to LOCK only with the key button depressed.
(
General• Information Maintenance and Lubrication 0-41
Periodic Maintenance Inspection • If compressed air is not available, use a water
hose to force water through the radiator from
) Steering and Suspension Inspection the rear surface of the radiator toward the front of
Inspect the front and the rear suspension for the the vehicle.
following: To help ensure proper cooling system pressure, a
• Damaged parts pressure test of the cooling system and pressure cap
• Loose or missing parts is recommended at least once a year.
• Signs of wear or lack of lubrication Throttle System Inspection
Inspect the power steering lines and the hoses for the
The throttle system (including the accelerator and the
following:
cruise control) should operate freely and without
• Proper hookup hesitation between full closed and wide open throttle.
O Binding
Important: The accelerator and the cruise control

.• Leaks
cables should NOT be lubricated under any
~ Cracks
circumstance. Any throttle system components
• Chafing, etc .. causing hesitation or sticking should be replaced.
Tire and Wheel Inspection Inspect for the following:
Inspect the tires for uneven wear or damage. If there .. Missing parts such as retainers or clips.
is irregular or premature wear, test the wheel
• Interference of the linkage or the cable conduit to
alignment. Inspect for damaged wheels. For tire
critical components such as fuel lines, brake
diagnosis information, refer to Abnormal or Excessive
Tire Wear in Suspension General Diagnosis. lines, harness leads, etc.
Forwheel alignment diagnosis information, refer to " Proximity of the cable to the exhaust system and
Preliminary Alignment Inspection in Wheel Alignment. other heat sources. Inspect for melting and/or
discoloration.
Exhaust System Inspection
.. Cable kinking. Avoid sharp bends in cables.
lnspectthe complete system. Inspect the body near
) the exhaust system. Look for broken, damaged, " Clearance of the throttle system's moving parts
· missing or out-of-position parts as well as open seams, throughout their travel from other stationary
holes, loose connections or other conditions which components.
could cause a heat build-up in the floor pan or could let ., Damage of any components due to cable kinking,
exhaust fumes into the .vehicle. For exhaust system severe abrasion, misalignment, etc. If any of the
inspection diagnosis refer to Exhaust System above conditions exist, see your dealer for a
Inspection in Engine Exhaust. rerouting, adjustment, or replacement
Engine Cooling System Inspection recommendation.
Caution: NEVER spray water on a hot radiator. The Brake System inspection
resulting steam could cause personal injury.
Inspect the entire brake system.
Notice: Compressed air or water. can be used to clean
the radiator fins. Do not exceed 138 kPa (20 psi). Notice: A low brake fluid level can indicate worn disc
Pressure over 138 kPa (20 psi) will damage the brake pads which may need to be serviced. Also,
radiator. if the brake system warning light stays on or comes
Inspect and replace the radiator hoses if they are on, something may be wrong with the brake system. If
cracked, swollen, or deteriorated. the anti-lock brake system warning light stays on or
comes on, something may be wrong with the anti-lock
Inspect all of the pipes, the fittings, and the clamps brake system.
and replace as needed.
Important: The radiator and the A/C condenser should Inspect the brake lines and the hoses for the following:
be kept clean to ensure proper system performance. " Proper hookup
Cleaning is recommended at least once a year.
" Binding
Inspect the front surface of the radiator and the A/C
condenser. Insects, leaves, debris, etc. can affect the "Leaks
performance of the radiator and the A/C condenser. " Cracks
If the front surface of either or both of these • Chafing, etc.
components requires cleaning, the unwanted material
) can be removed by performing the following: Inspect the disc brake pads for wear. Inspect the
surface condition of the rotors. Inspect all other brake
" Ensure that the engine is off and cool.
parts including the calipers, the parking brake, etc.
• Blow compressed air through the radiator from the
rear surface of the radiator toward the front of the The brakes may need to be inspected more often
vehicle. if driving habits or conditions result in frequent braking.
0-42 Vibration Diagnosis and Correction General Information
Vibration Diagnosis and Correction

Specifications
Tire and Wheel Runout Specifications
Specification
Aluminum Wheel
Lateral 0.762 mm 0.030 in
Radial 0.762 mm 0.030 in
Steel Wheel
Lateral 1.143 mm 0.045 in
Radial 1.015 mm 0.040 in
Tire and Wheel (Radial and Lateral)
Off-Vehicle 1.27 mm '• 0.05 in
On-Vehicle 1.52 mm • ·. 0.06in
Wheel Stud · 0.25 mm O.Q1 in
Wheel Hub 0 ..132 mm 0.0052 in
Propeller Shaft Runout Specifications Propeller Shaft Balancing. Weight Amounts

Application Metric English Correction, .Total Weight Clamp Spread, Degrees
One-Piece Propeller Shaft Runout 0.0 180
• Front 1.016 mm 0.040 in 0.1 . 174
• Center 1.27 mm 0.050 in 0.2 . 169
(
• Rear 0.3 163
1.40 mm 0.055 in ·..
0.4 157
Two-Piece Propeller Shaft Runout
. 0.5 151
• Front 0.762 mm 0.030 in
0.6 145
• Center 0.762 mm 0.030 in
0.7 139
• Rear 0.889 mm 0.035 in
0.8 . 133
Pinion Runout 0.076 mm 0.003 in 0.9 127
.
1.0 120
1.1 113
1.2
. . ·· ..
106
. 1.3 99
1.4 91
1.5 8:3
1.6 74
1.7 64
1.8 52
'
t.9 36
··2.0 .. 0
(
General Information Vibration Diagnosis and Correction 0-43
Diagnostic Information and Procedures
) Systematic Approach " Can the customer hear the vibration?
During the last 10-15 years, vehicle design and .. Does the engine or the vehicle load affect the
engineering have dramatically changed due to the vibration?
following factors: • Does the vibration occur in more than
.. Increased fuel costs one gear range?
" Decreased fuel supplies • When did the vibration first appear?
~ Corporate Average Fuel Economy requirements The answers to these questions will help in duplicating
~ Clean air legislation and diagnosing the vibration.
.. Foreign competition If you suspect that the vibration is normal, compare
" Ability to withstand collision the vibraiion with a vehicle that is equipped in the
" Rising customer expectations same way, including the following factors:
Vehicle designs have evolved from full-frame • Body style
construction to lighter unibody designs. These designs • Engine option
transfer noise and vibration much more readily. " Engine driven accessories
General Motors has greatly reduced the use of heavier • Transmission type
and smoother running V8 engines, replacing these • Tire size
engines with lighter, more fuel-efficient 4-cylinder and " Suspension performance type
6-cylinder engines. During this same time period, the • Axle ratio
following options have become increasingly popular: Important: Do NOT attempt to repair a normal
.. Air conditioning condition, or the customer will probably be convinced
., Power steering that the vehicle has a problem. Customer satisfaction
., All-wheel drive becomes extremely difficult after this point.
Such options increase engine load and can also If necessary, ride with the customer. Make the
generate unwanted noise and vibration. comparison with the customer present and explain the
Customer perception of quality can be directly linked to situation.
the presence or absence of unwanted noise and
Duplicate the Condition
\ vibration. The technician's ability to quickly diagnose
) and repair a noise or vibration concern directly affects All vehicles produce vibrations. Some vibrations are
that customer's loyalty to the dealership. The technician normal, while others are not. Some vibrations can
who is capable of satisfying this need will be highly be repaired, some cannot. Duplicate or experience the
regarded and in great demand. customer's complaint. Evaluate the vibration and
The intentions of this section of the service manual the cause of the vibration under changing conditions.
are to provide systematic approaches to vehicle Otherwise, you cannot know for certain that you
vibration diagnosis and correction. By using the are fixing what the customer would like fixed.
Strategy Based Diagnosis and the troubleshooting The. symptoms and characteristics of a noise or
philosophies covered in this section, the technician will vibration are also important information. Ask yourself
be able to provide effective and timely repairs. the following questions before you begin:
" What does the vibration feel like?
Diagnostic information and Procedures 0 . Does the vibration make noise? If so, what does
This section describes the techniques and procedures the vibration sound like?
for correcting the following types of vibrations: Different types of noise and vibration have particular
" Tire and wheel shake characteristics. These characteristics will help
., S1eering/suspension shimmy and shake determine the cause of the condition, and the best
" Launch shudder way to correct the condition.
.. Exhaust moan A Process of Elimination
0 Engine firing frequency You must understand a few basic concepts before
attempting to diagnose a vibration. As in any
Identifying the Complaint
diagnostic process, you must perform the
The first step in diagnosing a vibration complaint is to following steps:
identify the exact vibration that concerns the customer.
• Gather the information
Sometimes the v.ibration can be duplicated at a given O Decipher the information
speed. Other vibrations may not be as evident

• Make your correction based on the results
and may require questioning the customer carefully.
Perform a road test with the customer in the vehicle in Road test the vehicle and inspect the vehicle in a
order to determine the specific vibration complaint. manner which systematically eliminates different
) Ask the following questions when attempting to identify
components. This process supplements the
information which you have received from the
a vibration complaint: customer concerning the complaint. Concentrating
" At what speed is the vibration the worst? efforts on the areas that have not been eliminated will
" Can the customer feel the vibration? If so, where? make repairs faster and more effective.
Tire and Wheel Inspection
(
182126
The tires on all new GM models have a tire

performance criteria (TPC) rating number molded on
the sidewall. The TPC. rating will appear as a
4-digit number preceded by the letters TPC SPEC on
the tire wall near the tire size. A replacement tire
should have the same TPC rating.
(
1 2 2 3
95607
Legend
(1) Hard Cornering, Under Inflation (3) Heavy Acceleration on Drive Axle, Excessive
(2) Excessive Toe on Non~Drive Axle Toe on Drive Axle, Over Inflation
(
Inspect the tire and wheel assemblies for the following Types of Road Test Procedures
conditions:
) • Unusual wear such as cupping, flat spots, and
Caution: Refer to Road Test Caution in Cautions
and Notices.
heel-and-toe wear
Important: Before performing any road test, inspect
(These conditions can cause tire growl, howl,
the tires and wheels. Refer to Tire and Wheel
slapping noises, and vibrations throughout
the vehicle.)
Inspection
• Proper inflation The following road test procedures are the most
informative and the most used:
• Bulges in the sidewalls
• Slow acceleration test
(Do not confuse bulges with normal ply splices,
• Neutral coast-down test
commonly seen as indentations in the sidewall).
• Downshift test
• Bent rim flanges
• Neutral run-up test
By inspecting these characteristics of the tire and
wheel assemblies, you may discover the cause of the • Brake torque test
vibration. The inspection will also provide assurance " Steering input test
that the vehicle is safe for road testing. O Standing start acceleration test (launch shudder)
These tests will help to pinpoint the vibration. Perform

Road Test all of the tests on a smooth and level road.
Purpose of Road Testing Slow Acceleration Test
The purpose of road testing is to duplicate the vibration This test will identify those conditions which are
complaint and to find any operating conditions that related to the engine-speed or to the vehicle-speed.
change or eliminate the vibration. Most importantly, Additional tests may be necessary in order to
road testing will determine whether the vibration is determine the exact cause of the vibration.
related to the engine speed or to the road speed.
In order to complete a quick and accurate road test,
and Notices.
install an engine tachometer (such as a scan tool) and
1. On a smooth, level road, slowly accelerate up to
) the EVA in the vehicle. Place the EVA vibration sensor
in a location where the customer's concern can be felt. highway speed. ·
2. Look for disturbances that match the customer's
Which Component Group is Causing the description.
Vibration
3. Observe. the following readings where the
After you have related a vibration to either the engine disturbance occurs:
or to the vehicle~speed, break the vibration down
further in order to fit into one of the following groups of " The vehicle speed, km/h (mph)
rotating components: " The engine speed (RPM)
• The engine, the clutch disc (manual transmission), • The frequency (if possible)
the propeller shaft (within the driveline support Now perform the neutral coast-down test and the
assembly), the transmission flexplate (automatic downshift test.
transmission), and the transmission torque
converter Neutral Coast~Down Test
• The transmission output shaft and the rear axle Caution: Refer io Road Test Caution in Cautions
differential pinion (mounted in the rear of the. and No.tices.
differential) 1. On a smo.oth level road, accelerate to a speed
• The tires, the wheels, the hubs, and the rotors slightly higher than the speed at which the
vibration occurs.
These 3 groups represent the major areas that can
produce vibration complaints. The components in each 2. Shift the vehicle into NEUTRAL gear and coast
group are related to each other because the down through the vibration range.
components are either bolted or splined together. This Observe whether the vibration is present in
means that each group of components rotates at · NEUTRAL gear.
the exact same speed.
If the vibration still occurs in NEUTRAL gear, then the
These categories can be broken down further in order vibration is definitely sensitive to vehicle-speed. At
to identify the exact component responsible for the this point, the following components have been
disturbance. The emphasis is on testing (and eliminated as a cause of the vibration:
) more testing) in order to pinpoint the source and to
" The engine
eliminate unnecessary parts replacement.
• The clutch disc (manual transmission)
Perform a road test for ALL vibration complaints
unless the disturbance occurs only with the vehicle at • The transmission flywheel (automatic transmission)
a standstill. • The torque converter
Depending on the symptoms or the frequency, the Brake Torque Test
repair will concentrate on one of the following
This test is designed to identify engine-related (
components: vibrations that were not uncovered with the neutral
.. The tire and wheel assemblies run-up test. This test also works for vibrations that are
" The transmission output shaft sensitive to the engine load or to the torque. This
test will probably not apply to vibrations which
.. The propeller shaft are related only to the speed of the vehicle.
• The rear. axle differential pinion
" The rear drive axle or the rear drive axle shafts and Notices.
Downshift Test i. Apply the park brake.
Caution: Refer to Road Test Caution in Cautions 2. Block the front wheels.
and Notices.
3. Step firmly on the brake pedal.
1. On a smooth, level road, accelerate to the speed 4. Place the vehicle in DRIVE.
at which the concern vibration occurs. 5. Slowly increase the engine speed while looking
Observe the engine RPM. for vibrations that match the customer's
2. Decelerate and safely downshift to the next description.
lower gear. 6. Observe the engine speed (RPM) and the
3. Operate the vehicle at the previous engine RPM. frequency (if possible) at which the disturbance
occurs.
If the vibration returns at the same engine RPM,
the following conditions are the most probable causes 7. If necessary, place the vehicle in REVERSE gear
of the vibration: and repeat steps 5 and 6.
.. The engine Steering Input Test
" The clutch disc (manual transmission) This test is intended to determine how much the ·
• The propeller shaft wheel bearings and other suspension components
contribute to the vibration, especially a vibration · (.
• The transmission flywheel (automatic relating to noise, such as growl, grinding, and roaring.
transmission)
.. The torque converter
and Notices.
Repeat this test in lower gears, and in NEUTRAL, in
order to confirm the results. 1. With the vehicle at the vibration speed (mph),
drive through slow sweeping turns, first in
In some cases, a vibration may also be sensitive to
one direction and then in the other direction.
torque or engine load, as well as being related to
a specific engine speed or vehicle speed. These 2. If the vibration gets worse or if the vibration goes
vibrations can be most difficult to diagnose, and require away, inspect the following components as
additional testing. A systematic approach usually possible causes of the vibration:
leads to isolating the problem. • The wheel bearings
Neutral Run-Up Test O The hubs
This test is designed to identify vibrations which are • The tire tread
related to the speed of the engine. Use this test when 3. The CV joint angle increases when the vehicle is
the customer has a concern with vibration at idle, turning. On front wheel drive (FWD) and
or as a follow-up to the downshifttest. This test four wheel drive (4WD) vehicles, CV joint condition
probably doesn't apply when the complaint is related systems may appear when the angle increases.
to vehicle speed only (appearing at the same Putting a load on the CV joint may increase ·
vehicle speed regardless of the engine speed). the vibration amplitude. The third order, tire speed
Caution: Refer to Road Test Caution in Cautions related amplitude would remain the same. ·
and Notices.
1. Slowly increase the engine speed while looking

for disturbances that match the customer's
complaint.
2. Observe the engine speed (RPM) and the
(
frequency (if possible) where the vibration occurs.
Standing Start Acceleration Vibrations That Can Be Feit
) (launch Shudder) Test
Shake
The purpose· of this test is to duplicate a vibration
called launch shudder. In some cases, a powertrain
mount or an exhaust ground-out may also be the
cause of the vibration, depending on the symptoms.
Caution: Refer to Road Test Caution in Cautio.ns
and Notices.
1. With the vehicle at a complete stop and in gear,

remove your foot from the brake pedal.
2. Accelerate to 48-64 km/h (30-40 mph) while
looking for vibrations that match the customer's
description.
Other possible causes of launch shudder include the
following conditions:
• Incorrect trim height. Refer to Trim Height
Specifications in Suspension General Diagnosis.
• A worn or damaged drive axle CV joint
• Aground-out through the engine or transmission
mounts 95608
• Faulty exhaust hangers and mounts The shake is a low frequency vibration, typically
5-20 Hz. The shake is sometimes seen in the steering
Classifying the Vibration wheel, the seat, or the console. The best description is
the feeling from an out-of-round or unbalanced tire.
The next step after road testing the vehicle is to Customers may refer to a shake in one of the
) identify the frequency of the duplicated and abnormal following terms:
vibration .. Use the EVA in order to measure the
frequenct If the EVA is not available, observe how .. Shimmy
the vibration feels or sounds. The majority of vibrations • Wobble
will fit into one of the following categories. • Shudder
• Vibrations that can be felt: "Waddle
- Shake • Hop
- Roughness In most cases, shake is caused by damage or wear to
- Buzz the following components:
- Tingling .. The tires
• Vibrations that make noise: "The wheels
- Boom • The brake rotors (vehicle-speed sensitive)
- Moan and groan e The steering tie rod ends
- Howl • The suspension ball joints
- Whine • The engine (engine-speed sensitive)
Roughness
Roughness is a vibration with a slightly higher
frequency than the shake, usually 20-50 Hz.
Roughness is similar to the feeling you get from
holding a jigsaw.
)
0:-48 Vibration Diagnosis and Correction General Information
Buzz Howl
Buzz is slightly higher in frequency: 50-100 Hz. A Howl is a noise at mid-range frequency of
buzz is similar to the feel of an electric razor. You may 120-300 Hz. This so.unds like the wind howling.
feel it in your hands through the steering wheel, in
your feet through the floor, or in the seat. Inspect the Whine
following components for a possible cause: Whine is a prolonged, high-pitched sound in the
" The exhaust system 300-500 Hz range. Whine is usually related to the
" The A/C compressor meshing gears or gear noise. Similar sounds include
" The engine mosquitoes, turbine engines, and vacuum cleaners.
Tingling Matching Frequency to Component RPM

This is the highest vibration frequency that you can
feel. Tingling may sometimes produce a pins and At this point in the diagnosis, the vibration has
needles sensation. Customers may say the vibration gone through the following analysis:
creates numbness in their hands or feet. • The vibration has been duplicated.
• The vibration has been designated as abnormal.
Vibrations That Make Noise
• The vibration has been related either to engine
Boom speed or to vehicle speed.
Boom is a low frequency interior noise of 20-60 Hz. • The vibration has been assigned a frequency from
Sometimes the customers complain of a pressure the EV A or identified based on its feel or its sound.
in their ears. Examples of similar noises include
a bowling ball rolling down an alley, deep thunder, or Automotive vibrations are usually related to the rotating
a bass drum. speed of a component. Calculate the speed of these
components using either an engine speed method or a
A customer may use the following words to
vehicle speed method. Use the engine RPM readings
describe boom:
taken during the road test in order to diagnose the
" Droning vibrations that are sensitive to engine speed.
" Growling If the vibration is sensitive to vehicle speed, determine
" Moaning I
the rotational speed of the tires. As long as you \
" Roaring operate the vehicle at a constant speed, the tires will
e Rumbling operate at a constant speed. This speed is measured
in rotations, or cycles per second. The reading is
O Humming
then compared to the frequency of the vibration, which
Boom may be accompanied by a perceptible vibration is also measured in cycles per second.
(roughness).
Moan or Drone
Moan or dron'e is a sustained tone at a low frequency
of 60-120 Hz, somewhat higher than boom.
Examples of similar noises include a bumble bee or
blowing air across the top of a soda bottle. A customer
may use the following words to describe moan
or drone:
" Humming
e Buzzing
" Resonance
Moan or drone may be accompanied by a perceptible
buzzing vibration. Inspect the following systems:
" The powertrain mounts
., The exhaust system
(
Calculating Tire Rotation
TIRE/WHEEL AND PROPSHAFr ROTATION
Vehicle Information
km/h
Complaint Speed: _ _ _ _ _ _ _ _ _ _ _ _ (mph) Year: _ _ _ _ _ Model: _ _ _ __
Symptom: VIN:-------------
Frequency: Engine: _ _ _ _ _Trans: - - - - - -
Engine Speed: _ _ _ _ _ _ _ _ _ _ _ _ rpm Tire Size: _ _ _ _ Axle Ratio: _ _ __
Gear: TPC Spec: _ _ _ _ _ _ _ _ _ _ __
Tire/Wheel Speed
Vibration km/h f S(km/h) Increments of
Occurs at: mph f 5(mph) 8 km/h (5mph)
Tire/Wheel Speed,
8 km/h (5mph)
increments
I x
tire RPS'
at 8 km/h RPS (Hz)
1st order
~--~ (5mph)
(from chart)
1st order x2 2nd order
1st order x3 3rd order
Propeller Shaft Speed

Propeller Shaft Speed
1st order
tire x 1st order
(axle ratio)
1st order
propshaft x2 2nd order
"'RPS=revolutions per second; equates to cycles per second (Hz}.
6509
Determine the rotational speed of the tires in 3. Determine the vehicle tire size.
revolutions per second, or Hertz (Hz), based on the 4. Locate on the table below, the Hertz value at
vehicle speed at which the vibration occurs. In order to
8 km/h (5 mph) for that tire size.
determine the rotational speed, use the following
procedure: 5. Multiply the Hertz value by the number of 8 km/h
1. Determine the speed at which the vibration (5 mph) increments.
occurs. 6. The result is the rotational speed of the tires in
2. Determine the number of 8 km/h (5 mph) Hertz at the complaint speed. If this figure
increments: matches the vibration frequency, a first-order
• Divide the complaint speed by eight when vibration is present in the tire and wheel assembly.
using kilometers.
• Divide the complaint speed by five when
· using miles.
)
For example, if the complaint speed is 60 mph, the " Perform the following calculation:
number of increments is 12. According to the following 2.1. Make a mark on the tires and the
table, a tire with size of P235/75R15 has a value of propeller shaft.
1.00 Hz. You can calculate the rotational speed
2.2. Rotate the tires for one complete
at 60 mph:
revolution, counting the number of
12 increments x 1 Hz = 12 Hz propeller shaft rotations.
For example, the propeller shaft
Tire/Speed rotates approximately 31/~ times for
Revs/Sec (Hz) every tire revolution. The axle
Tire Size Tread at 5 MPH ratio is 3.5:1
P235/55R16 AL2 1.11 3. In order to find the propeller shaft rotation speed,
P215/60R16 AL2 1.10 multiply the tire speed by the rear axle ratio.
P275/40ZR17 HW4 1.12 In the earlier example, at a 60 mph complaint speed:
P245/50ZR 16 AL3 1.13 12 Hz x 3.5 = 42 Hz
P215/60R16 AL3 1.10 Match the frequency of the vibration from the EVA
P245/50ZR16 HW4 1.13 with the rotational speed of a component (either a tire
Tread Types: AL2: Touring AL3: Export HW4: or a wheel). !f none of the frequencies match, do
Performance Tire one of the following actions.:
Sometimes, the tire/wheel vibration may be of a • Recheck the data.
higher-order. in order to compute possible higher-order • Attempt to match the figures again, allowing for
vibrations, multiply the rotational speed of the tires, i-5 mph of speedometer error.
in Hertz, at the complaint speed by the order number. When you have matched the speed ofthe component
If any of these matches the vibration frequency, a with the frequency of the vibration, refer to the
vibration of that particular order is present in one of the service information that outlines the repair procedures
tire/wheel assemblies. for that particular component.
Steering and Suspension Assembly Vibrations
Steering and suspension assembly vibrations are Rotor/Drum Imbalance
the first level of testing for low-frequency vibrations that Rotors and drums do not have a set tolerance. (
are sensitive to vehicle speed. The symptoms of a However, rotors or drums with more than 21 g
steering/suspension first-order vibration are a shimmy (0.75 ounce) imbalance have the potential to cause
or a shake. This is usually felt in the steering wheel vibration. Inspect the rotors and the drums for
or in the seat. Inspect the following components imbalance using either the on-vehicle or the off-vehicle
for wear or damage: method.
" The steering tie rod ends Checking Rotor/Drum Imbalance (On-Vehicle)
.. The suspension ball joints 1. Raise and suitably support the vehicle. Refer
to Lifting and Jacking the Vehicle in General
Calculating Propeller Shaft Rotation Information.
The propeller shaft drives the tires through the rear
2. Remove the rear tire and wheel. Refer to Tire and
axle. Knowing the rotational speed of the tires enables
Wheel Removal and Installation in Tires and
you to easily calculate the speed of the propeller shaft.
Wheels.
Therefore, you can determine the rotational speed of
the propeller shaft by multiplying the rotational speed of Caution: Refer to Work Stall Test Caution in
the tires by the ratio of the rear axle. Cautions and Notices.
3. Reinstall the wheel nuts in order to retain the
Ratio
rotors/drums.
RPO Description
GU2 Ratio, Rear Axle 2.73 4. Run the vehicle at the complaint speed while
inspecting for the vibration.
GU4 Ratio, Rear Axle 3.08
Ratio, Rear Axle 3.23
5. If the vibration still exists, perform the
GU5
following steps:
GU6 Ratio., Rear Axle 3.42
5.1. Remove the rotors/drums.
1. Obtain the tire speed by performing the tire speed 5.2. Run the vehicle back to speed. ·
calculation, described earlier in this section. 6. If the vibration is eliminated, perform the
2. Determine the axle ratio using one of the following following steps:
methods: 6.1. Remove the rotors/drums one at a time.
~ Cross reference the axle information from the
6.2. Perform the vibration test for each (
service information part label to the parts book. rotor/drum.
.. Cross reference the axle identification 6.3. Replace the rotor/drum that is causing the
code that is stamped on the axle to the imbalance.
parts book. 6.4. Inspect the balance of the new rotor/drum.
Checking Rotor/Drum imbalance (Off-Vehicle) The above components are either bolted or splined
1. Measure the diameter and the width of the together. Therefore, all .of the components rotate at the
rotor/drum. same speed, vibrate at the same frequency, and
have the same symptoms.
Driveline vibrations may relate either to the first order.
or to the second order of driveline rotation. Driveline
vibrations are always related to the speed of the
vehicle. The vibration is often related to torque. If the
vibration is worse or only noticeable when
accelerating, decelerating, or crowding the throttle, the
vibration is related to the torque. In this case, the
vibration will always occur at the same speed.
If a vibration is sensitive both to torque and to speed,
the driveline is the probable cause. Tire/wheel
vibrations are speed-sensitive, but not torque-sensitive.
First-Order Driveline Vibration Symptoms
The following symptoms may indicate first-order
driveline vibration:
• The vibration is related to vehicle speed.
" The vibration is torque sensitive.
• A boom or moan noise is present.
• The vibration occurs commonly above 72 km/h
182237
(45 mph), but possibly at speeds as low as
2. Mount th.e rotor/drum on a balancer in the same 48 km/h (30 mph).
manner as a wheel.
• The roughness or buzz vibration is felt in the seat,
Important: You can only inspect the rotors/drums for the floor or the steering wheel.
static imbalance. Ignore the dynamic imbalance
reading. • The corresponding frequency on the EVA equals
first-order driveline rotation (25-60 Hz), depending
) 3. Inspect for static imbalance.
4. If the rotor/drum shows imbalance, replace the
on the speed of the vehicle and the ratio of the
axle. Refer to Matching Frequency to Component
rotor/drum.
RPM in order to obtain the rotation speed of
5. Inspect the balance of the new rotor/drum before the· propeller shaft.
you install the rotor/drum on the vehicle.
Driveline Vibration Analysis Diagnosing First-Order Driveline Vibration
Diagnosis will be much easier once you have
identified a vibration as first-order of driveline rotation
during the road test. Next identify the exact area of
the vibration and take proper action.
In most cases, vibration may be reproduced in the
stall. In the stall the vibration may be better or worse
than that experienced during the road test.
The objective is to reduce the vibration to the lowest
point possible in the stall, then evaluate the results
during a road test. Many times, a vibration you were
only able to reduce drastically in the stall will be ·
completely eliminated on the road.
The cause of first-order driveline vibration is usually
excessive runout or an imbalanced component.
The following procedure offers a systematic process of
elimination in order to determine which component
is at fault:
1. Raise the vehicle to curb height. Support the
vehicle on a hoist or heavy stands. Refer to
95589 Lifting and Jacking the Vehicle in General
The following components are possible sources of Information.
) driveline vibration: 2. Remove the rear tires/wheels. Refer to Tire and
.. The transmission output shaft Wheel Removal and Installation in Tires and
0 The propeller shatt(s)/driveshaft(s) Wheels.
e The pinion yoke/flange (2) 3. Inspect the propeller shaft. The propeller shaft
"' The pinion gear should be free of undercoating before continuing.
4. Inspect the propeller shaft and the U-joint for any Measuring Propeller Shaft Runout
obvious dents or damage. Dents or damage will
contribute to first-order driveline vibrations. Tools Required
5. Start the engine. • J 8001 Dial Indicator Set
• J 7872 Magnetic Base Dial Indicator Set
6. Place the transmission in gear.
7. Run the vehicle up to the speed at which the
vibration was most severe.
8. Record whether the vibration was present, and at
what speed.
9. If the vibration is not present do a complete
road test.
10. If the vibration is present, determine which end of
the driveshaft is vibrating the most. Hold your 1 2
hand against the pinion nose and the transmission
tailshaft, or hold an EVA vibration sensor up to
each component.
11. If the vehicle is equipped with a two-piece
propeller shaft, inspect the center support bearing
6 5 4 3
for vibration.
12. If the transmission tail is vibrating, touch the
transmission crossmember under the transmission
mount. If there is no vibration on the crossmember,
then the transmission mount is working properly.
182256
13. Remember which end of the driveshaft is the
worst, and how severe the vibration is. The Legend
inspection will be a reference by which to judge (1) Slip Yoke
future progress. (2) Tube
Do not fill the propeller shaft with foam, oil, or any (3) Rear Runout Check (
other substance in order to correct a vibration. Filling (4) Center Runout Check
the propeller shaft is only effective in reducing an (5) Front Runout Check
unrelated condition called Torsional Rattle. Filling the
propeller shaft should only be done in strict (6) Damper
adherence to the procedure outlined in corporate
bulletins that address Torsional Rattle. Failure to follow 1. Raise the vehicle on a suitable hoist. Refer to
the correct procedure will induce a vibration and/or Lifting and Jacking the Vehicle in General
affect the structural integrity of the propeller shaft. The Information.
propeller shaft will then have to be replaced. 2. Allow the wheels to spin freely.
Propeller Shaft Runout
A propeller shaft or pinion (companion) flange with
excessive runout causes first-order driveline vibrations.
Use the following procedure in order to measure the
runout of the propeller shaft:
" Remove excess corrosion of the propeller shaft
surface before inspecting the runout.
" Inspect for damage and dents.
e Replace dented propeller shafts .
., Remove any undercoating from the propeller shaft

before proceeding .
.. Refer to Measuring Propeller Shaft Runout, below,
for the measurement procedure that applies to the
following shaft assemblies:
- One-piece
- Two-piece (
The splined end of a propeller shaft is critical to the 182270
smooth operation of a two-piece propeller shaft. When
inspecting stub-shaft runout, ensure that the dial 3. Attach a J 8001 and a J 7872.
indicator readings are accurate. 4. Place the transmission in NEUTRAL.
5. Rotate the pinion flange or the transmission yoke Important: The runout of the rear splines on the front
by hand while taking the measurements for the propeller shaft affects the runout of the front
run out. measurement on the rear propeller shaft.
Important: The propeller shaft turns easier in 7.1. Measure the rear propeller shaft.
one direction than in the other. Removing the wheels 7.2. Mark the position of the rear shaft in the
will also help. Do not include fluctuations on the pinion flange.
dial indicator due to welds or surface irregularities.
7.3. Remove the rear shaft.
6. Perform the following steps for one-piece propeller
shafts if the runout exceeds the tolerances at 7.4. Measure the front propeller shaft runout on
one or more points: the tube and the stub shaft.
6.1. Rotate the propeller shaft 180 degrees in 7.5. Replace the propeller shaft if either
the pinion flange. measurement is out of tolerance. Refer
6.2. Reinstall the propeller shaft. to Propeller Shaft Runout Specifications.
6.3. Measure the propeller shaft runout. important: When you replace a propeller shaft,
6.4. If the runout still exceeds the tolerance, inspect the new shaft for runout. Inspect the pinion
inspect the pinion flange runout before flange runout if the replacement shaft runout is also out
replacing the propeller shaft. of tolerance.
7. Perform the following steps for two-piece propeller
shafts if the runout exceeds the tolerances at
one or more points:
Propeller Shaft Measurement Points

Propshaft Front Runout Center Runout Rear Runout Stub Shaft Runout
One-Piece Measure Measure Measure -
Aluminum Graphite Measure - Measure -
Two-Piece Front
Measure - - Measure
Slip Yoke
) Measuring Pinion Flange Runout

Tools Required
• J 8001 Dial Indicator Set
• J 2340$ Dial Indicator Extension
• J 35819 Flange Runout Gauge
1. Place the vehicle on a suitable hoist. Refer to
Lifting and Jacking the Vehicle in General
Information.
2. Allow the wheels to rotate freely.
3. Remove the propeller shaft from the pinion flange.
J 35819
176029
4. Install the J 35819.

If a J 35819 is not available, measure the pinion
runout as close as possible to the pinion flange.
Important: The dial indicator will have inverted
readings. You are measuring the inside diameter of
the flange; you are not measuring the outside
diameter. The highest reading on the dial indicator is
the low spot. The lowest reading is the high spot.
5. Rotate the pinion shaft 360 degrees and zero the
dial indicator on the low spot.
0-54. Vibration Diagnosis and Correction General Information
6. Rotate the pinion flange again and record the total .. Do not remove any weights on the outboard edge
runout. of the dust slinger. These weights are present in
I
7. If the pinion flange runout is 0.15 mm (0.006 in) or order to balance internal axle components. The \
less, remove the pinion flange balance weight. weights are not related to the pinion flange runout.
8. If the pinion flange runout is greater than 0.15 mm .. If a J 35819 is not available, inspect the propeller
(0.006 in) but not less than 0.28 mm (0.011 in), shaft runout as near as possible to the flange.
and the runout compensation weight is at or near Rotate the shaft 180 degrees in the pinion flange.
the low spot, no further action is necessary. If Reinstall the shaft. Inspect the measurement at the
the runout compensation weight is not at or near same location.
the low spot, remove the weight.
A large difference in the runout, greater than
9. If the pinion flange runout is greater than 0.28 mm 0.38 mm (0.015 in), may indicate that the flange is
(0.011 in) but not greater than 0.38 mm (0.015 in), out of tolerance. If the runout does not change at
and the balance weight is at or near the low point,
all, the flange is OK.
no further action is necessary. If the runout
compensation weight is. not at or near the low spot, Balanced Axles
remove the weight and re-index the pinion flange
until the runout is 0.25 mm (0.010 in) or less. Beginning in the early i 990's, the manufacturer began
system balancing rear axles. During the build
10. Replace the pinion flange/yolk when the runout process, these axle assemblies were spun with a
cannot be reduced to 0.25 mm (O.Oi O in) or less.
slave fixture. A balance weight was attached to the
Then, recheck the runout. Service replacement
outboard edge of the companion flange dust slinger. A
flanges do not have balance weights.
system-balanced rear axle companion flange differs
from a non-balanced flange. You must diagnose
and service this flange in a unique way.
,.
I
-- -- .
I
182274
• If necessary, add compensation weights on the

face of the pinion flange dust slinger. These 386770
weights are tack-welded onto the slinger. You may
remove the weights with a die-grinder. Some pinion flange assemblies have a U-shaped
• Carefully remove the spot weld at either end of deflector designed to hold a system balance weight on
the weight. the outside diameter.
• Do not remove the weight unless you have
inspected the pinion flange runout and the
procedure requires weight removal.
(
5. Reinspect the propeller shaft runout if the vibration
is present after the pinion flange runout is
corrected. If the propeller shaft runout is still
excessive, correct the runout before doing a
driveline system balance. Either replace the shaft
with a shaft that is within tolerance or sublet the
shaft to a reputable independent for straightening
and re-balance. Ensure that the new or rebuilt shaft
is within runout tolerance before continuing.
6. Once the propeller shaft and pinion flange are
within runout tolerances, inspect to see if the
vibration is still present. If the level of the vibration
is still unacceptable, perform a driveline system
balance procedure.
Correcting Vibration at the Transmission
Tailshaft
First-order driveline vibrations that originate at the
transmission end of the propeller shaft are rare. If the
tailshaft of the transmission is vibrating, inspect the
386772
tailshaft housing bushing for wear or damage. A leaky
Other pinion flange assemblies have a runout transmission tailshaft oil seal indicates bushing
compensation weight on the face of the deflector. The problems.
pinion flange assemblies that are system balanced Feel for vibration at the crossmember underneath the
do not use runout compensation weights. transmission mount. If there is no vibration, the
Measuring the runout on a system-balanced transmission mount is functioning properly by isolating
companion flange is very straight-forward. A balanced the vibration from the structure of the vehicle. The
flange that is good will have a measured runout transmission mount is therefore probably not the cause
between 0.00-0.38 mm (0.00-0.015 in). If a balanced of the vibration.
) flange has more than 0.38 mm (0.015 in) runout,
replace the flange or reindex the flange 180 degrees
Use the following procedure if you can feel vibration
on the crossmember and the tailshaft bushing,
on the pinion. If you replace or reindex a balanced and if the transmission output is normal:
flange, you must system balance the rear axle again.
Correcting Vibration at the Pinion Nose
Most first-order driveline vibrations originate at the
pinion nose end of the driveshaft. Ensure that
the vibrations are at a minimum at this location in
order to achieve acceptable results. Reduce the runout
of the components to a minimum. Balance the
driveline as a system when necessary.
1. Measure the runout of the propeller shaft and
inspect the tolerance.
2. If the tolerance is excessive, mark the position of
the shaft for future reference and rotate the shaft
180 degrees,
3. Reinstall the shaft and reinspect the runout.
Inspect the level of vibration in order to determine
if the vibration is lower or corrected.
4. If the runout is still excessive, or if the vibration is
still present, refer to Measuring Pinion Flange
Runout. Replace the pinion flange or re-index the 182281
flange 180 degrees if the pinion flange runout
exceeds the tolerance. 1. Measure the propeller shaft runout. If the runout is
Remove and reinstall the pinion flange only once excessive, replace the shaft with one that has
on axles utilizing a.crush type sleeve. Replace acceptable runout. Alternatively, sublet the shaft
the sleeve with a new sleeve if the sleeve is to a reputable independent service shop in
crushed. Removing the sleeve requires rem.oval of order to have the shaft rebalanced and the runout
the ring and pinion set. Replace flanges with corrected.
excessive runout. Regardless of the method used, 2. Test drive the vehicle. If the vibration is still
measure the pinion flange runout in order to unacceptable, balance the shaft on the vehicle.
ensure that the flange is within tolerance. Refer to Rear Driveline System Balance.
0-56 Vibration Diagnosis and Correction General information
Correcting Vibration at the Center Support Driveline System Balance without the
Bearing Electronic Vibration Analyzer (EVA)
The following procedure is designed to fine-tune the
balance of the propeller shaft while it is mounted in the
vehicle. This procedure will also correct residual
imbalance of the remaining driveline components.
Prior to balancing the driveline system, verify tha1 the
propeller shaft and the pinion flange runout are
within specification.
Important: Do not overheat the engine when
performing this procedure.
1. Raise the vehicle to curb height. Support the
vehicle on a hoist or on safety stands. Do not
allow the axle to hang. Refer to Lifting and Jacking
the Vehicle in General Information.
2. Remove the rear tire/wheel assemblies. Refer to
Tire and Wheel Removal and Installation in Tires
and Wheels.
3. Determine which end of the propeller shaft has
the most vibration in order to identify where to
begin installing the hose clamps.
182285
These guidelines apply to the two-piece propeller shaft

only, First-order driveline vibrations that occur mainly
at the center support bearing are usually the result
of excessive runout at the stub (splined) shaft.
Unlike other first-order driveline vibrations, these
vibrations can appear at unusually low speeds (
of 40 km/h (25 mph) and up.
Perform the following procedure in order to correct this
type of vibration:
1. Mark the position of the rear propeller shaft at
both ends for proper reassembly.
2. Remove the rear propeller shaft from the vehicle.
3. Measure the runout of the stub shaft splines (3)
approximately 12.7 mm (0.5 in) from the end.
4. Replace the shaft if the runout exceeds the
tolerances.
Stub shaft/spline runout 0.076 mm (0.003 in). 182137
Correcting the stub shaft/spline runout will usually 4. Mark the end of the propeller shaft (1) which has
eliminate the vibration. If some residual vibration is still the most vibration at four points (2), 9.0 degrees
present, perform a road test on the vehicle. Determine apart. Number the marks 1 through 4.
if an on-vehicle system balance of the driveline is The following procedure uses a trial and error me1hod
necessary. of determining where to· place the hose clamps on
the shaft. Use the following tips in order tO help locate
the clamps:
1. Because the imbalance may be related to
propeller shaft runout, begin installing the clamps
at the low point of the propeller shaft runout.
2. When the plant workers balance the propeller
shaft, they use weights in graduated increments:
2 g (1/16 oz), 4 g (1/8 oz), etc. If the stock
weight is too light or too heavy, place the hose (
clamp either directly in line with or opposite fo the
stock weight.
General Information Vibration. Di~gnosis and. Correction 0-57
The last method involves running the vehicle at a Continue the trial and error procedure using different
) speed which the vibration is felt. weights in different locations until you achieve the best
1. Carefully hold a piece of chalk up to the very end balance. If more that thre.e clamps aligned in the
of the propeller shaft. Barely touch the chalk to same position are required, replace the propeller shaft.
the shaft. If you are able to reduce the vibration in the stall,
2. Shut the engine OFF in order to stop the propeller but are unable to eliminate the vibration completely,
shaft from rotating. Do not step on the brake perform a road test on the vehicle. A slight vibration
pedal. Do not put the transmission in PARK. noticeable in the stall may not be noticeable on
3. Inspect the chalk mark. the road.
Driveline System Balance with Electronic
Vibration Analyzer (EVA)
In order to pinpoint the source, you must reproduce
the vibration in the service stall. Determine which
component is vibrating the most using the EVA.
Perform the following steps:
1. Support the vehicle on a suitable hoist or on
safety stands. Ensure that the rear of the rear
axle is at curb height. Do not allow the axle
to hang. Refer to Lifting and Jacking the Vehicle
in General· Information.
2. Remove the rear tire/wheel assemblies. Refer to
0.0 1.0 2.0
and Wheels.
3. Ensure that the propeller shaft is free of
undercoating. Inspect for dents or damage to the
propeller shaft or the U-joint.
) 182176 4. Start the engine.
If you performed the above procedure correctly, the 5. Place the transmission in gear.
chalk. mark will indicate the heavy spot on the
6. Run the engine at the vehicle speed at which the
shaft. The heavy spot will deflect downward and touch
the chalk. If the chalk mark circles the entire shaft, vibration is occurring.
touch the chalk more gently to the shaft. Ensure that Caution: Do not run the vehicle higher than
the chalk touches only the heavy spot. Once the 89 km/h (55 mph). Stay clear of the universal joints
heavy spot is located, place the hose clamp and the balance weight area in order to avoid
180 degrees opposite to the chalk mark (1 ). Perform personal injury. Do not run the vehicle on the hoist
the following steps: for extended periods of time. Running the vehicle
1. Place the hose clamp at the light spot, .or at any on the hoist for extended periods of time may
of the 4 points marked previously. cause the engine or the transmission to overheat.
2. Test drive the vehicle at the speed at which the
vibration occurred. Record any changes in the Determine which end of the propeller shaft is
vibration. vibrating the most. Hold the EVA's sensor against the
pinion nose and the transmission tailshaft assembly.
3. Move the clamp to the other positions.
The higher the amplitude reading, the greater the
4. Test drive the vehicle each time you move the vibration.
clamp. Record any changes in vibration.
Remember which position gives the best balance. • If the vehicle has a two-piece propeller shaft,
inspect the center support bearing .
., If the vibration did not change at all or if the
vibration becomes worse, then one clamp is either .. If the transmission tailshaft vibrates, inspect the
too light or too heavy. Repeat the procedure transmission crossmember under the transmission
using the two clamps together (2). mount. The vibration should not be present if
• If the previous step did not correct the problem, the mount is functioning correctly.
repeat the procedure using the two clamps
separated in order to reduce the spinning weight.
Strobe Balance Testing with the Electronic 4. Position the sensor as close to the propeller shaft
Vibration Analyzer (EVA) as possible. Verify that the following
Ensure that the runout of the various driveline conditions exist:
components are within specifications. If the runouts • The UP side of the sensor faces upward.
are within specifications, strobe balance the driveline. • The sensor is horizontal.
The EVA is able to simplify the.balancing process,
5. Start the engine.
using the following procedure:
1. Use the EVA in order to determine which end of 6. Turn OFF all of the engine accessories.
the propeller shaft has the most vibration. 7. Place the transmission iri gear.
8. Run the vehicle at the speed which causes the
most. vibration in the propeller shaft.
--l
9. Hook the timing light clip to the trigger wire.
2
10. Plug the vibration sensor into Input A of the EVA.
Input B is not applicable for this test.
... 11. Verify that the predominant frequency on the EVA
display matches the frequency of the original
vibration. Use the strobe light only if the rotation
speed of the propeller shaft is the predominant
frequency.
12. The EVA displays a series of questions inorder to
select the correct filter. Press YES in order to
select the desired filter. Ensure that the frequency
is in the middle of the filter range. Use the full
range only as a last resort.
13. The display shows the test frequency, the
amplitude and the filter range. The driveline
is balanced when the amplitude is near 2. In some
cases, a slightly higher amplitude will provide
182137
adequate balance. (
2. Mark the end of the propeller shaft (1) that has 14. Point the timing light at the propeller shaft. The
the most vibration at four points (2), 90 degrees
strobe effect will appear to freeze the propeller
apart. Number the marks 1 through 4.
shaft. Remember which of the numbered marks is
3. Mount the EVA sensor onto the bottom of the at the bottom of the propeller shaft, or the
following components: six o'clock position. This position is the light spot.
• The differential housing 15. Turn the engine OFF.
.. The center bearing support (for 2-piece
16. Install a weight directly on the light spot.
propeller shafts that use a center bearing
support) 17. Start the engine.
• The transmission tailshaft assembly 18. Run the vehicle at peak vibration speed.
Ge.nE!ral. Information Vibration Diagnosls and Correction o~sg
- The weight and the original light spot are
within 180 degrees of the six o'clock .
) position.
Move the weight towards the six o'clock
position. Inspect the·balance again
using the strobe light. Adjust the weight
~:~.-
@ '
120
I
.
as necessary. Refer to the previous
two conditions.
If the shaft will not balance using two weights, place a
third weight on the light spot. Split the first two weights
in order to produce a total weight between two and
three weights.
1
If three weights fail to balance the driveline; replace
0.0 1.0 2.0 the propeller shaft.
When the propeller shaft balances, road test the
vehicle in order to verify that the vibration is eliminated.
Propeller Shaft Balance Weights
182176
When using clamps in order to balance a propeller
19. Strobe the propeller shaft again. shaft with the total weight method, the correction
weight required will often be a fraction or a multiple of
• The propeller shaft is balanced ifthe strobe one hose clamp. Use the following phasing procedure
. image is erratic and the amplitude is with two hose clamps in order to accurately place
near two. any required amount (0.0-2.0 total weights).
• ThE! ·propeller shaft is not balanced if one of
the following conditions exist:
- The weight and the original light spot are at
) the six o'clock position (1). ·
The above condition means that there is
not enough weight on the propeller
shaft. In order to correct the balance,
add a second weight next to the
fir$t weight. Inspect the balance again
using the strobe light.
If the weights are now 90-180 degrees
off (between the nine o'clock and
the three o'clock positions) too much 1
weight exists. In order to correct 0.0 1.0 2.0
the balance, split the two weights equally
on either side of the original light
spot (1) in order to produce a total
weight between 1-2 weights (between
0-120 degrees apart). Inspect the 182176
balance again using the strobe light.
Adjust the weights as needed. 1. Ensure that the clamps are located with even
spaces on either side of the light spot, or
- The weight and original light spot are ; 80 degrees opposite the heavy spot (i ).
90-180 degrees off (between the
nine o'clock and the three o'clock positions). The table containing the weight amounts in terms
of the total weight and the included angle
The above condition means that (spread) between the clamps is in specifications.
one weight is too much. In order to Refer to Propeller Shaft Balancing Weight
correct the balance, split the two weights Amounts.
equally on either side of the original 2. If the vibration does not change at all or gets
light spot in order to produce a worse, then one clamp is too light or too heavy.
) total weight less than one Repeat the procedure using the two clamps
(120-180 degrees apart). Inspect the together.
balance again using the strobe
3. If the previous step did not correct the problem,
light. Adjust the weights as needed.
repeat the procedure using the two clamps
separated in order to reduce the spinning weight.
4. Continue the trial and error procedure using If the vibration does not occur during the above
different weights in different locations until procedure, install the brake drums and the tire/wheel I
you achieve the best balance. assemblies, adding additional load on the system. \
5. If more than three clamps aligned in the same Then repeat the above test.
position are required, replace the propeller shaft. Ensure that both axle shafts rotate at the same speed.
6. If you are able to reduce the vibration in the stall, The differential may mask a vibration when one tire
but are unable to eliminate the vibration is spinning faster than the other tire. Adjust the brakes
completely, road test the vehicle. A slight vibration in order to correct unequal tire rotation speed.
that is noticeable in the stall may not be
If you are unable to reproduce the vibration in the
noticeable on the road.
stall, apply the brake lightly in order to load the system
First-Order Driveline Vibration Analysis further. Maintain the vehicle speed at which the
(Torque Sensitive) vibration was noticed. Do not overheat the brakes.
If the following conditions are true, the internal rear If the pinion nose vibrates under acceleration and/or
axle components are the probable cause of the deceleration, and the other driveline components are
vibration: eliminated as the cause of the vibration, then one of the
• The vehicle has a vibration that is equal to following conditions may cause the vibration:
first-order driveline rotation, and the vibration is • A high spot on the pinion gear
not present you test the vehicle in the stall.
• A bent pinion stem
• You were able to correct the vibration in the stall,
but the vibration returned during the road test. .. A cocked pinion bearing
Internal rear axle vibrations may be aggravated by the • An improper axle housing bore
load of the vehicle working against the ring and
Anything that effects the pinion gear and how the
pinion gear seat.
pinion gear contacts the rotating ring gear may
Since the propeller shaft and the pinion gear are contribute to a first-order, torque-sensitive driveline
bolted together through the pinion flange, the propeller vibration. The only.way to correct the.condition
shaft and the pinion gear operate at the same is to replace the faulty components. In most cases,
speed. Vibration in the pinion gear will therefore have you must replace the ring and pinion gear set and the (
the same frequency and symptoms as the
related bearings. In some cases, you must replace
propeller shaft.
the axle housing. Complete a close-up visual
In order to isolate the vibration to the pinion gear, use inspection for damage or unusu.al wear in order to
the following procedure: measure or identify the specific faulty component.
1. Raise the vehicle to curb height. Support the It is possible to isolate an internal axle vibration. Install
vehicle on a hoistor on safety stands. Refer
a known good axle assembly from a stock unit.
Verify that the known good axle assembly does not
Information.
have a vibration problem ..
2. Remove the tire and wheel assemblies. Refer to
Tire and Wheel Removal and Installation in Tires Once you correct the internal axle problem, road test
and Wheels. the vehicle.· Inspect the vehicle· for vibration.
Balance the driveline, as necessary, in order to
3. Touch the pinion nose or hold the EVA vibration
eliminate any remaining vibration.
sensor up to the pinion nose.
4. With the aid of another technician, accelerate and
decelerate the vehicle through the speed range at
which the vibration was noticed during the
road test.
Example
• If the vibration was originally noticed at
88 km/h {55 mph), accelerate from 72 km/h
{45 mph) to 107 km/h (65 mph). Then
decelerate from 107 km/h (65 mph) back to
72.km/h (45 mph).
• Repeat the above step and remember whether
or not the pinion nose vibrates under load
during acceleration and/or deceleration,
Gc;meral Information Vibration Diagnosis and Correction 0-61
Diagnosing Second-Order Driveline Canceled Out Driveline Angles
) Vibration
Second-Order Driveline Vibration. Theory
182180
Legend
(1) Front Working Angle
182178
(2) Rear Working Angle
A faulty universal joint (U-joint) may cause a vibration
that occurs twice for each rotation of the propeller
shaft. This type of vibration is called a second-order Engineers design drivelines in order to compensate for
vibration. the accelerations and decelerations in order to ·
produce a smooth, constant flow of power, as
) Second-order driveline vibrations are independent of
runout or balance of a driveline component listed below: ·
The following dei;,cription .of.basicU:-joint theory will • The transmissi.on drives .the front yoke of the
help you to understanc:l. where second-order driveline propeller shaft at a smooth and constant speed.
~ibrations originate and why they 9ccur. · • The first U-joint causes the power to fluctuate
• As the propeller shaft rotates, the U-joint speeds twice for each revolution of the propeller shaft.
upand slows down twice for each rotation of
• The second U-joint, oriented 90 degrees from the
·the propeller shaft.
first U-joint, causes the power to fluctuate
• . The aQc~lera.tion and c:lece.le.ration of the U-joint is opposite that of the first U-joint.
not visible. lfthere is vibration in the U-joint, the
acceleration an.d deceleration will be audible • As the first U-joint slows down, the second U-joint
and tactile. speeds up.
• Compare the u:joibt in a vehicle to a . This design causes one U-joint to cancel· out the effect
universal-type soQket When a universaHype. of the othedJ-joint. The cancelled effects result in a
socket is used to tighten a bolt, the· socket will bind smooth, constant power flow from the output yoke
and release as the socketturns .toward of the propeller shaft.
90 degrees. The bind and release occurs twice for
each revolution of the socket. · Second-order .driveline vibrations occur when the
cancellation becomes unequal between the front
• The U-joint in a vehicle works in the. same way as
U-joint and the rear U~joint.
the universal-type socket. .The bind and release
effect is directly proportional to the angle that The main objective of this section is to correct the
the U-joint operates: the greater the angle, conditions that interfere with the proper cancellation
the greater the effect. effect of the U~joint. The most common condition,
• Because the transmission output speed is especially where the launch shudder is concerned, is
constant, the binding and releasing of the U-joint in.correct driveline working angles (1,2). Other
is better described as an acceleration and factors may aggravate the condition.
deceleration which occurs twice for each revolution
\ of the propeller shaft.
)
• If the propeller shaft is running slowly, the
accelerating and decelerating effect is visible. The
acceleration and deceleration may create a
vibration due to the fluctuations in force that are
generated at high speeds.
Address the following factors before you attempt to Driveline Working Angles
measure or correct the driveline working angles:
Tools Required
• Worn, failed, damaged or improperly installed
U-joint • J 38460 Digital Inclinometer
• Worn, collapsed, or improper powertrain mounts • J 23498-A Driveshaft Inclinometer
• Incorrect vehicle trim height adjustment for • J 23498-20 Driveshaft Inclinometer Adapter
the front suspension which aggravates the launch
shudder
• Incorrect trim height adjustment for the rear
suspension
• Trim height inspection includes trim heights that
are too low or too high.
2
On rear drive vehicles, the pinion nose tilts upward as
you lower the rear trim height.
If a second-order driveline vibration exists after you
correct these conditions, measure and correct
the driveline angles.
If the complaint is present only with cargo in the
vehicle, perform the measurements with the vehicle
fully loaded. Once you correct a second-order driveline
vibration with the vehicle loaded, the vibration may
reappear with the vehicle unloaded. The reverse of this
condition is also true. You may have to reach a
compromise with the customer in this case. 6498
Second-Order Driveline Vibration Symptoms Driveline working angle does not refer to the angle of
Second-Order driveline vibration has the following any one shaft, but to the angle that is formed by · (
signs and symptoms: the intersection of two shafts.
• The vibration .is always related to vehicle speed. The procedure for measuring and correcting driveline
working angles depends on whether the vehicle is
• The vibration is usually torque-sensitive.
equipped with a propell~r shaft consistin'g of one piece,
• The vibration is worse under a torque load. two pieces, or three pieces.
Launch shudder is the most common complaint of a In order to verify the accuracy of the adapter, inspect
second-order driveline vibration. the angle of an ac.cessible joint with the inclinometer
Launch shudder occurs during acceleration from prior to assigning the adapter on an inaccessible joint.
0-40 km/h (0--:25 mph}. Launch shudder appears as a One-Piece Propeller Shaft System
low frequency shake, wobble, or shudder. The driver
may feel the vibrations in the seat or steering wheel at Raise the vehicle on a suitable hoist or on safety
low speeds of0-24 km/h (0-15 mph). The vibrations stands. Ensure that the rear axle is supported at curb
will increase in frequency as the vehicle speed height and that the wheels are free to spin. Refer
increases. Launch shudder feels more like driveline to Lifting and Jacking the Vehicle in General
roughness at higher speeds of 24-40 km/h Information. Place the transmission in NEUTRAL.
(15-25 mph}. At speeds greater than 40 km/h (25 mph) Ensure that the vehicle has a full tank of fuel or the
the vibration usually disappears. equivalent amount of weight in the rear to simulate a
full tank. The weight of 3.8 liters of gasoline
Launch shudder vibration is equal to a second-order (1 gallon) is approximately 2.8 kg (6.2 lb} ..
vibration of the driveline. The EVA will not perceive
frequency information due to the transitory nature of
launch shudder.
\
Checking Phasing of U-joint The out of phasing of the single-piece propeller shaft
is very unusual. If the shaft is visibly out of place,
) Inspect the propeller shaft for correct phasing. Correct
the end yokes are welded on in the wrong position or
phasirig means that the front and the rear U-joint
are directly in. line or parallel with each. other so that the shaft is damaged due to twisting. In either
proper cancellation takes place. case, replace the propeller shaft before continuing
with this procedure.
Measuring the Working Angles
i
182316
1. Rotate the propeller shaft so that the propeller

shaft rear U-joint bearing cap is vertical.
182180
) The working angle of a u~joint is the difference

between the angles formed when two shafts intersect.
One piece propeller shaft systems have two working
angles, the front (1) and the rear (2).
• The two working angles should be equal within
V2 of a degree.
• The working angles should not exceed 4 degrees.
• The working angles should not be equal to
ZERO because a ZERO working angle will cause
premature U-joint wear due to lack of rotation
of the U-joint.
• The angle formed by the propeller shaft and the
rear axle pinion from the rear working angle (2)
• The angle formed by the propeller shaft and the
transmission output shaft form the front working
angle (1)
182325
The angles of these components are most accurately
measured from the U-joint bearing caps. Verify
2. Ensure that the front bearing cap is also vertical. that the bearing caps are free of corrosion or foreign
3. Place the inclinometer on the propeller shaft material in order to ensure accurate readings. Remove
rear U-joint bearing cap in order to ensure any snap rings that may interfere with the correct
1hat both U-joints are vertical. placement of the inclinometer. Reinstall the snap rings
4. Set the indicator line above the sight glass on 15 after you take the measurements.
[the horizontal reference). Rotate the propeller
shaft until the bubble centers in the sight Take the measurements from the same side of the
glass. This action brings th.e rear U-joint to vertical. propeller shaft in order to maintain consistent
angle measurements (either on the driver side or on
5. Remove the inclinometer without disturbing
the setting. Leave the setting on 15. the passenger side).
6. Install the inclinometer on the front U-joint. The
bubble should remain centered plus or minus
3 degrees if the shaft is properly phased.
• The third angle (6) is the. rear working angle. It is
formed by the angle of the rearpropeller shaft
and the angle of the pinion yoke of the. rear axle.
If the launch shudder or the second-order driveline
vibration is still present, measure and correct the
driveline angles.
Measuring Two-Piece Propeller Shaft Working
Angles
This procedure is essentially the same as for the
one-piece propeller shafts. You must, however, take
into account the third angle.
182332
Record the readings on a diagram like the one shown

as you proceed through the measurements.
Evaluation
The two working angles in a one-piece propeller shaft
system should be equal to within 1/2 of a degree
for effective cancellation.
Measuring Two-Piece Propeller Shaft System
Working Angles
(
Two-piece propeller shaft systems have three working
angles instead of two working angles as in the 6499
one-piece systems.
1. Place the inclinometer on the.propeller shaft
bearing cap.
2 3
182335
O The first angle is the front working angle (8). It is 6502

formed by the angle of the output shaft of the
transmission and the angle of the front 2. Center the bubble in the sight glass. (
propeller shaft. 3. Record the measurement. The bearing cap must
" The second angle (7) is the middle working angle. be straight up and down. in order to obtain an
It is formed by the angle of the front propeller accurate measurement. ·
shaft and the angle of the rear propeller shaft. 4. Enter the measurements on your diagram.
5. Rotate the propeller shaft 90 degrees and place Two-Piece Propeller Shaft Phasing
the inclinometer on the transmission output yoke The setup and measurement techniques are identical
bearing cap. The bearing cap must be straight to that of.a the one-piece propeller shaft system.·
up and down in order to obtain an accurate. First, test for proper phasing, using the following
measurement. procedure:
6. Center the bubble in the sight glass.
7. Record the measurement.
8. Subtract the smaller reading from the larger
reading in order to obtain the front U-joint
working angle.
2 3
182339
1. Turn the rear propeller shaft so that the rear

U-joint is straight up and down. Verify thatthe
front U-joint of the rear propeller shaft is also
) straight up and down.
182335 2. Rotate the shafts 90 degrees so that the front
The front angle is considered the odd U-joint because propeller shaft front U-joint is straight up and
this angle does not have another joint to provide down. Ensure that the front propeller shaft is also
cancellation. The rear working angle (6) and the middle straight up and down. (actually part of the slip
working angle (7) act as a pair of U-joints in order to yoke on the rear shaft).
cancel each other.out, as in the one-piece propeller If the two U-joint of the front propeller shaft are not in
shaft systems. Because of this condition, keep this phase, the two halves of the propeller shaft ·
the working angle of the odd U-joint (8) at or under may have been assembled incorrectly.
1/2 of a degree.
Keep the working angle of this odd joint to a minimum
so that there are not any great fluctuations in speed
that need to be canceled out. The front joint is used as
the odd joint because the front joint angle does not
change with suspension bounce, rebound, or axle
windup. For this reason, think of the front propeller
shaft of a two-piece system as an extension of
the transmission output shaft.
)
Two-Piece Propeller Shaft Lateral Alignment Rear Axle Shims
The procedure for lateral alignment of a two-piece Wedge shims of different sizes are available through
propeller shaft is used for launch shudder or any the parts' system and independent suppliers for
second-order driveline vibrations. Adjust the lateral the purpose of shimming the rear axle angle. Wedge
alignment before you measure and adjust the driveline shims are available in 2, 3, and 4 degrees.
angles.
Caution: Never attempt to shim a rear axle using
1. Raise and suitably support the vehicle on a hoist.
anything except shims that are designed for
Refer to Lifting and Jacking the Vehicle in
General Information. this purpose. Failure to do so will result in the
shims falling out and a loss of vehicle control and
2. Look down the front of the propeller shaft. that could cause personal injury.
3. If the propeller shaft is not straight, or if the center
bearing support is off to one side, relocate the
center support bearing (2) in order to make
the propeller shaft assembly as straight as
possible. Ensure that you do not create a 1
ground-out condition against the exhaust or
another component.
Evaluation
The working angle is within tolerance, following the
rule that the working angle of an odd joint in a
two-piece joint system is 1/2 degree or less. Notice
that in each of the good examples the front working
angle (FWA) is 1/2 degree or less and is treated as a
separate joint. The middle working angle (MWA)
and the rear working angle (RWA) are subtracted. The
difference (DIFF) is 1/2 degree or less. The middle
and the rear joints may cancel each other. ·
Correcting Working Angles (
In order to change the working angles, shim the
components up or down. Look closely at the existing 182361
angles. Use the existing angles and the .shims in
order to achieve the correct working angles, Install the shims (5) in order to increase or decrease
the angle of the rear axle pinion. Install the shims
Compared to horizontal or true level, the components
located at the rear of the vehicle are usually lower than between the leaf spring (3) and the spring seat (2).
the components located at the front of the vehicle. This Depending on the design of the suspension [leaf spring
condition is called down in. the rear. If a component with on top or underneath the axle (1)], and the direction
a down in the rear angle is shimmed up .at the rear, the of the desired change, install the shims with either the
shim will bring the component closer to the horizontal thick side toward the front of the vehicle or toward
(zero). Alternately, if a component with a down in the the rear of the vehicle.
rear angle is shimmed down, the component will move
Important: After installing the shims, ensure that the
farther from the horizontal (zero).
U-bolt has two or three threads above the nut.
Rear Axle Wind-Up Ensure a.lso that the center bolt, located in the spring
Rear axle wind-up may cause launch shudder even seat, is long enough to seat in the locator hole .. If
when all of the working angles are within specifications. these two conditions do not exist, use longer U-bolts
Rear axle wind-up occurs when heavy torque during and center bolts. Longer U-bolts and center bolts
acceleration causes the pinion nose to point upward. In are available through local spring shops. . ·
order to compensate for axle wind-up, tip the pinion
nose downward. Install the axle shims incrementally,
performing a road test after each shim. Add shims until
the road test indicates that the shudder is eliminated.
General information Vibration Diagnosis and Correction 0-67
Transmission Shims First-Order Engine Imbalance
Notice: Proper flywheel installation requires carefully
WALKING the flywheel onto the crankshaft and
stagger-tightening the bolts. Proper torque converter
to flywheel installation then requires gradually
WALKING the torque converter to be flush with the
flywheel, prior to installing the bolts. Do not
draw the torque converter to the flywheel with the
bolts. If these precautions are not followed,
warping or bending of the flywheel and/or damage to
the transmission torque converter may result.
Engine imbalance is a condition that exists when a

component that rotates at crankshaft speed is
either unbalanced or has excessive runout. In rare
cases, the crankshaft may be unbalanced. In
any case, balancing the component or correcting the
runout may reduce the disturbance to an
acceptable level.
Symptoms
182364
O Vehicle shake at speeds of 500-1200 RPM,
If a transmission requires shims, order the shims or 8-20 Hz
through the parts distribution system.
• Roughness and BOOM at speeds of
Installing most shims will change the transmission 1200-3000 RPM, or 20-50 Hz
angle approximately 1/2 degree.
• Vibration usually detected during the neutral
When shimming transmissions, use a shim made from
run-up test
steel stock at the necessary thickness. Ensure that
the shim contacts the full width of the area to be
) shimmed. Do not use washers.
Isolating the Components
1. Perform the neutral run-up test, noting the RPM at
which the vibration is the worst, and the severity.
Engine Related Vibration Refer to Road Test.
Engine vibration is usually due to one or more of the 2. Inspect all powertrain mounts. Repair or replace
as needed.
" First-order engine imbalance
3. Inspect for any bindings or ground-outs in the
" Inherent. engine firing sequence exhaust system.
O Inherent engine shaking forces 4. Matchmark the torque converter and the flywheel.
• Engine-driven accessories 5. Disconnect the torque converter from the
Because these vibrations are engine-speed related, flywheel.
they are also usually torque sensitive. These vibrations 6. Tie up the converter, away from the flywheel.
may appear and disappear at different vehicle or
road speeds, but will always appear at the same 7. Perform the neutral run-up test again.
engine speed. • If the flywheel shows any wobble or lateral
For example, if a customer states that a vibration is runout, replace the flywheel. Refer to
present at 40 km/h (25 mph), 64 km/h (40 mph), Engine Flywheel Replacement in Engine
and again at 104 km/h (65 mph), and that the Mechanical-3.8 L or Engine Flywheel
symptoms of the vibration are similar at each of these Replacement in Engine Mechanical-5.7 L.
speeds, the vibration is probably engine-speed O Re-index the torque converter in three different
related. Any disturbance or vibration that is present
positions. If the disturbance still exists,
during the following road tests would be considered
replace the torque converter.
engine-speed related:
• The neutral run-up test
" The downshift test
) " The brake torque test
Any vibration that is present during the neutral
coast-down test is not engine-speed related. The
engine-related vibrations covered in this diagnosis are
engine-speed sensitive only.
8. If the vibration still exists, inspect the propeller Engine Vibration Diagnosis with the EVA
shaft runout.
9. If the vibration still exists, inspect the harmonic
balancer.
10. If the vibration still exists, the problem is related to INPUT A INPUT B
residual engine imbalance. Refer to the

procedure below.
Excessive Inherent Engine Firing Frequency
95611
i. Place the EVA vibration sensor on the seat track

rail with the UP label facing upward.
2. Plug the EVA into a 12 volt power supply.
3. Prepare the EVA for data recording:
3.1. Press RECORD
183028
3.2. Select a snapshot tag number (
3.3. Press ENTER in order to begin recording
Firing frequency is a term used to describe the pulses
created as the engine fires in each cylinder. All 4. Slowly accelerate until the vibration occurs.
engines have a firing frequency. The intention here is 5. Note the vehicle speed and the engine RPM
to keep these disturbances from entering the where the disturbance occurs.
passenger compartment. Initially, inspect for the
6. Press ENTER on the EVA in order to record the
vibration data.
• The engine and the exhaust system are mounted
7. Perform the road test diagnoses in order to
in the correct position.
determine engine-speed or vehicle-speed
• All of the mounts and hangers are in good sensitivity. Refer to Road Test.
condition and are correct for the application.
Engine Firing Frequency Symptoms
.. No components, hoses, or lines are grounding to
the frame or to the body. " The vibration may be torque sensitive.
The frequency of these disturbances will depend on .. The vibration is engine-speed related.
the number of cylinders. The engine order will always " The vibration is heard as a boom or a moan.
be equal to one-half the number of cylinders. This
" The vibration is felt as a shake, roughness or buzz
is because a four-stroke engine requires two complete
(depending on the number of cylinders).
revolutions of the crankshaft in order to fire all of
the cylinders. .. The vibration affects the resonance of a system or
a component, causing the system or the
For example, a V6 engine will fire cylinders 1, 3,
component to have a narrow RPM range.
and 5 on the first revolution. Cylinders 2, 4, and 6 will
fire on the second revolution. This results in The key to correcting these types of complaints is to
three firing pulses per revolution of the crankshaft. isolate the vibration from the passenger compartment
or the body.
(
General Information Vibration Diagnosis and Correction Q.;;.69
Diagnosis and Repair of Engine Firing 4. Inspect the A/C and P/S lines.
) Frequency-Related Vibrations " Isolate the hoses from the body.
1. Raise and suitably support the vehicle. Refer to .. Install the retainers.
Information. 5. Inspect the drive belt for the proper tension.
Caution: Refer to Work Stall Test Caution in 6. Inspect the accessory unit fasteners for damage
Cautions and Notices. or looseness.
2. Attempt to duplicate the vibration. 7. Inspect the body panels for missing or
3. While the vibration is present, find the area of the loose welds.
vehicle affected by the vibration. 8. Remove any aftermarket equipment that may
4. Inspect for witness marks caused by rubbing complete a transfer path into the passenger
components . compartment.
. 5. Isolate the component and re-evaluate the 9. Inspect the exhaust system and powertrain
vibration. mounts. Re-bed the engine and align the exhaust
6. Inspect for proper torque on the affected system as follows if needed:
component. Tighten as needed. " Loosenthe mounts and hangers.
7. Ii the vibration still exists, follow the
.. Tighten all fasteners with the powertrain in the
procedure below.
relaxed position.
Engine Firing-Frequency Related Vibration Some residual vibrations may be normal. Compare the
Causing Components vibrations with a similar vehicle to get a feel for what is
1. Inspect for collapsed engine mounts. commercially acceptable, preferably with the customer
Replace as needed. Refer to Engine Mount present. Also, refer to bulletins for updates on the use of
Replacement in Engine Mechanical - 3.8 L or, mass damper weights for specific applications.
refer to Engine Mount Replacement (Left)
or Engine Mount Replacement (Right) in Engine Inherent Engine Shaking Forces
Mechanical - 5.7 L. Just as with firing frequency, some engine
) 2. Inspect for a collapsed or broken transmission disturbances are the result of normal operation. Some
mount. Replace as needed. Refer to Transmission engines can have additional inherent vibration due
Support and Mount Assembly in Manual to the cylinder arrangement, the design, or the
Transmission - M49, Transmission Support and firing order.
Mount Assembly in Manual Transmission - MM6 or Before attempting to repair a disturbance, compare
Transmission Support Replacement in Frame the disturbance to another, known good, vehicle. Some
and Underbody.
vibrations could be normal though they may not be
3. Inspect the exhaust hangers. pleasing to the customer.
• Exhaust systems can expand one to two inches The key to resolving an inherent engine disturbance is
when hot. to isolate the vibration from the passenger
• Remove the hangers one at a time. compartment. Follow the same procedures as outlined
• Adjust or replace the exhaust hangers as for the engine firing-frequency related vibrations.
needed.
)
0-70 Vibration Diagnosis and Correction Genera.I Information
Engine-Driven Accessories 6. Inspect the A/C system for overcharging. Evacuate
and recharge as needed. Refer to Refrigerant (
Recovery and Recharging in Heating, VenUlation
and Air Conditioning.
7. Inspect the engine oil level. Add or drain oil as
needed.
Tire and Wheel Vibration

Tire and wheel assembly vibrations are the next level
of testing for low-frequency vibrations that are
vehicle speed sensitive. The tires, wheels, brake
rotors and wheel hubs should be systematically tested,
according to the symptoms.
First-Order Tire and Wheel Assembly Vibration
The following are symptoms of first-order vibrations
caused by tire and wheel assemblies:
" The vibration is always vehicle-speed related.
If the vibration is affected by the speed of
95613 the engine, or is eliminated by placing the
transmission in NEUTRAL, then the vibration is
Engine driven accessories that exhibit vibration pose
not related to the tire and wheel assemblies.
some special challenges. For example, the drive belts
can no longer be removed one at a time in order to .. The vibration will feel like a SHAKE, usually in the
isolate the condition. If removing the belt eliminates the steering wheel or the seat:
vibration, reinstall the belt and operate each accessory - Tire and wheel vibrations that are felt in the
individually in order to determine which has the most steering wheel are most likely related to the
effect on the vibration. However, one component may front tire and wheel assemblies.
affect another because the drive belt drives all of the
- Tire and wheel vibrations that are felt in the (
accessories.
seat or the floor are most likely related to
Verify that the accessory load is not affecting the the rear tire and wheel assemblies.
engine firing frequency.
Diagnosis
a
This may not always hold true, but is general
rule that may serve to initially isolate a
1. Compare the vibrations to a known good vehicle problem to the front or the rear of the vehicle.
in order to ensure they are abnormal.
" The customer may complain of a WADDLE at low
2. Remove the drive belt.
speeds of 8 to 56 km/h (5 to 35 mph).
3. If the vibration stops, perform the following steps:
.. The frequency on the EV A will correspond to the
3.1. Install the drive belt.
first-order of tire rotation. This frequency w.ill
Important: The drive belt drives all of the engine usually be in the 10 to 20 Hz range, depending on
accessories. Therefore, one component may affect the speed of the complaint and the size ofthe
another. tire. The smaller the tire, the faster it will rotate at
3.2. Operate each accessory individually in any given speed.
order to determine which has the most .. The range of the human ear begins at 20 Hz. For
effect on the vibration. this reason, first-order tire vibrations are rarely
4. Test for the accessory load affecting the engine produce noise. The exception to this would be if
firing frequency. the tires display an irregular tread pattern or
5. Inspect the pulleys for misalignment or lateral flat spots, causing a GROWLING or
runout. Repair or replace as needed. SLAPPING noise.
(
Repair Instructions
Balancing Tires and Wheels
Tire Balancer Calibration Test
Caution: Failure to adhere to the following
precautions before tire balancing can result in
personal injury or damage to components:
.. Clean away any dirt or deposits from the inside
of the wheels.
.. Remove any stones from the tread.
.. Wear eye protection.
" Use coated weights·on aluminum wheels.
Important:. Tires may be balanced either on-vehicle
or off-,-vehicle, but the off-vehicle balancing procedures
are recommended. Off-vehicle methods are better
because tire rotation will not affect the balancing. The
off-vehicle balancers are also more accurate than
the on-vehicle balancers. Off-vehicle balancers can
perform dynamic balancing as well as static balancing.
Tire and wheel balancers can drift out of calibration
without warning or become inaccurate as a result
of abuse. The balancer calibration should be inspected
every two weeks or whenever the readings become
questionable.
1. Spin the balancer without a wheel or any of the
adapters on the shaft.
2. Inspect the balancer readings.
Specification
0.00-0.25 oz.
95621
3. Balance a tire and wheel that is within radial and
lateral tolerances to ZERO.
4. Add a 3-ounce test weight to the wheel at any
location.
5. Spin the tire and wheel again. Observe the
readings.
0 In the static and dynamic modes, the balancer
should call for 3 ounces of weight, 180 degrees
opposite the test weight.
.. In the dynamic mode only, the weight should
be called for on the flange of the wheel
opposite the last weight.
6. With the wheel unbalanced to 3 ounces, cycle the
balancer five times.
7. Take the balancer readings:
Specification
Variation: 0.25 oz or less.
8. Index the tire and wheel at four separate locations
on the balancer shaft, 90 degrees apart.
9. Cycle the balancer with the weights at each
location.
10. Take the balancer readings:
Specification
Variation: 0.25 oz or less.
Tire Balancing Guidelines
Static and dynamic balance are two kinds of tire/wheel (
balancing:
,:,. - -- ~
1. Static balance, also called single plane balance,
affects the distribution of weights around the
wheel circumference.
i ~ 2. Dynamic balance, or two-place balance, affects
~ the distribution of weight on each side of the
tire/wheel centerline.
3. Most off-vehicle balancers can check both types
of balance simultaneously.
f 1
·~ 4. As a general rule, most balancers are most
~ 'l
~
-- -- :.:,, sensitive to static imbalance that to dynamic
imbalance. As little .as 0.50 - 0.75 oz may induce
a vibration in some vehicles. Vibration
induced by static imbalance will cause a vertical,
or bouncing motion of the tire. Dynamic
imbalance results in a side-to-side motion of the
tire, or shimmy.
95623
5. Balance all four tires/wheels as close to ZERO as

possible.
6. Carefully follow the wheel balancer manufacturers
instructions for proper mounting techniques for
different types of wheels.
7. Aftermarket wheels, especially tho.se incorporating
universal lug patterns, are potential sources of
runout and mounting problems.
8. Use the correct coated weights on· aluminum·
(
wheels.
9. Retest the tire and wheel for excessive runout
after correction and installation.
10. Evaluate the vehicle at the complaint speed and
note if the vibration has been corrected.
11. If the vibration is still present, or is reduced but
still unacceptable, consider thes.e possibilities:
• On-vehicle imbalance
• Radial or lateral force variation
95624
Wheel Weight Usage (Aluminum Wheels)

1. Locate the wheel weights on the inboard rim
flange. If during static balancing more than
28 grams (1 ounce) is needed, split the weights
as equally as possible between the inboard ..
and outboard flanges.
2. Use special polyester-coated clip-on wheel
weights in order to balance factory aluminum
wheels. These weights are designated MC or P,
and must be used on aluminum wheels
having a wide 7.6 mm (19/64 in) flange. Use a
plastic tipped hammer in order to prevent
damage to the weight's coating during
TYPE MC TYPEP installation.
(
218175
3. Adhesive wheel weights are also available. Use For example, performing the following steps will help
the following procedure in order to install adhesive demonstrate the vibration theory:
wheel weights.
3.1 . Determine where the wheel weigh is to be
located on the inboard side of the wheel.
3.2. Clean that area by sanding to bare
aluminum. Do NOT sand the outboard
side of the wheel as this will damage the
clear coat finish.
3.3. Wipe the sanded area with a mixture of half
ispopropyl alcohol and half water. Use a
clean cloth or paper towel.
3.4. Dry the area with hot air until the wheel
surface is warm to the touch.
3.5. Warm the adhesive backing on the wheel
balance weight to room temperature.
3.6. Remove the tape from the back of the
weight. Do not touch the adhesive tape.
3.7. Apply the wheel weight and press on with
hand pressure. · 95587
3.8. Secure the wheel weight .with a 70-11 O N·m 1. Clamp a yardstick to the edge of a table, leaving
· (16..:.25 lb ft) force applied with a roller. about 50 cm (20 in) hanging over the edge of
the table.
Description and Operation 2. Pull down on the edge of the stick and. release
while observing the movement of the stick.
) Basic Terms·. The motion of the stick occurs in repetitive cycles. The
cycle begins at midpoint, continues through the
The following are the two primary components of
lowest extreme of travel, then back past the midpoint,
vibration diagnosis:
through the upper extreme of travel, and back to
• The physical properties of objects the midpoint where the cycle begins again.
• The object's properties of conducting mechanical The cycle occurs over and over again at the same
energy rate, or frequency. In this case, the frequency is about
The repetitive up/down or back/forth movement of a 10 cycles per second. If we measure the. frequency
component causes most customer vibration to reflect the number of complete cycles that the
complaints. The following are the components that yardstick made in one minute, the measure would be
often vibrate: 1O cycle~ x 60 seconds = 6QO cycles per minute (cpm).
• The steering wheel We could have also found a specific amount of
motion,· or amplitude, in the total travel of the yardstick
• The seat cushion
·from the very top of the cycle to the very bottom of
• The frame the cycle. Redo the experiment as follows:
• The instrument panel 1. Reclamp the yardstick to the edge of a table,
Vibration diagnosis involves the following steps: leaving about25 cm (10 in) hanging over the
edge of the table.
1. Measure the repetitive motion and assign a value
to the measurement in cycles per second or '2. PuU down on the edge of the stick and release
cycles per minute. · while observing the movement of the stick.
2. Relate the frequency to the rotational.speed of a The stick vibrates at a much faster frequency:
component that is operating at the same rate 30 cycles per second (1800 cycles per minute). The
or speed, total travel, or amplitude, is less.
3. Inspect and test the components for conditions
that cause vibration.
0-74 Vibration Diagnosis and CorrecUon General-Jnformation
Vibration
Vibration is the repetitive motion of an object, back
and forth, or up and down. The following conditions
cause most vehicle vibrations:
.. A rotating component
" The engine combustion process firing impulses
Rotating components will vibrate with excessive
imbalance .or runout. During vibration diagnosis, the
amount of allowable imbalance or runout should
be considered a toleran_ce and not.a specification. In
other words, the less imbalance or runout the better.
A vibration concern will occur when the firing impulses
of the engine are. not properly isolated from the
passenger compartment.
A vibrating component operates at a consistent rate
(km/h, mph, or RPM). Measure the rate of vibrati_on in
question. When the rate/speed is determined, relate the
vibration to a component that operates at an equal
rate/speed in order to pinpoint the source. Vibrations
also tend to transmit through the body structure to other 95586
components. Therefore, just because the seat vibrates Vibration· can also produce hoise. As an· example,
doesn't mean the source of the vibration is in the seat. consider a vehicle that has an exhaust pipe whichjs
Vibrations consist of the following three elements: grounded to the frame. The source of the vi_bration ·
• The source - the cause of the vibration is the engine firing impulses traveling through ·
• The transfer path - the path the vibration travels the exhaust. The transfer path is a grounded or
through the vehicle bound-up exhaust hanger. The responder is the frame.
• The responder - the component where the The floor panel vibrates, acting as a large speaker,
vibration is felt which produces noise. The best repairwould be
to eliminate the transfer path. Aligning the exhaust
system and correcting the grounded condition at 1he (
frame would eliminate the transfer path.
95585
In the preceding figure, the source of the vibration is

the unbalanced tire. The transfer path is the route
the vibrations travels through the vehicle's suspension
system into the steering column. The responder is
the steering wheel, which the customer reports
as vibrating. Eliminating any one of these three
elements will usually correct the condition. Decide,
from the gathered information, which element makes
the most sense to repair. Adding a brace to the (
steering column may keep the steering wheel from
vibrating, but adding a brace is not a practical solution.
The most direct and effective repair would be to
properly balance the tire.
Cycle
--- ----- ------- --- .....+...•- -- -- -- -- -- -- ---- _..,_...,,... __ -- ------ ---- ---- ~
1 2 3
95588
Legend
(1) 1st Cycle (3) 3rd Cycle
(2) 2nd Cycle (4) Time
Vibration Cycles in··Powertrain Components
95589
Legend
(1) Spindle
(2) Pinion Nose
The word "cycle" comes from the same root as the

word "circle." A circle begins and ends at the
same point, and so does a cycle. All vibrations consist
of repetitive cycles.
0·76 Vibration Diagnosis and Correction Ge.neral Information
Frequency
1 1
2 1 2
4
(
95590
Legend
(1) Amplitude (3) Time in Seconds
(2) Reference (4) 1 Second
Frequency is defined as the rate at which an event

occurs during a given period of time. With a vibration,
the event is a cycle, and the period of time is
one second. Thus, frequency is expressed in cycles
per second, or Hertz (Hz). Multiply the Hertz by 60 to
get the cycles, or revolutions, per minute (RPM).
(
General Information Vibration Diagnosis and Correction o;..77
Amplitude Legend
(1) Maximum
(2) Minimum
(3) Zero-to-Peak Amplitude
1 (4) Peak-to-Peak Amplitude
~----~-----~----------- Amplitude is the maximum value of a periodically
varying quantity. Used in vibration diagnostics,.
amplitude·is the magnitude of the disturbance. A
severe disturbance would have a high amplitude; a
minor disturbance would have a low amplitude.
Amplitude is measured by the amount of actual
movement, or the displacement. For example, consider
the vibration caused by an out-of-balance wheel at
80 km/h (50 mph) as opposed to 40 km/h (25 mph). As
the speed increases, the amplitude increases.
2 Free Vibration
Free vibr11tion is the continued v.ibration in the absence
of any outsid.e force. In the yardstick example, the
yardstick continued to vibrate even after the end was
95593 released.
Forced Vibration
Forced vibration is when an object is vibrating
continuously as a result of an outside force.
Centrifugal Force Due to an Imbalance
90 i80 270 360 90
2
t • t
95594
Legend
(1) Location of Imbalance (Degrees) (2) Centrifugal Force Acting on Spindle
A spinning object with an imbalance generates a The stiffness and the natural frequency of a material
centrifugal force. Performing the following steps will have a relationship. Generally, the stiffer the ma1erial,
help to demonstrate centrifugal force: the higher the natural frequency. The opposite is
1. Tie a nut to a string. also true. The softer a material, the lower its natural
2. Hold the string. The nut hangs vertically due to frequency. Conversely, the greater the mass, the
gravity. higher the natural frequency.
3. Spin the string. The nut will spin in a circle.
Resonance
Centrifugal force is trying to make the nut fly outward,
causing the pull you feel on your hand. An unbalanced
tire follows the same example. The nut represents
the imbalance in the tire. The string represents
the tire/wheel/suspension assembly. As the vehicle 2 4
speed increases, you can feel the disturbing force of
the unbalanced tire in the steering wheel, the seat, and
the floor. This disturbance will be repetitive (Hz) and
the amplitude will increase. At higher speeds, both the
frequency and the amplitude will increase. As the
10-1--~~+-~--t~-7'-'-+--'-~--t-~~+
tire revolves, the imbalance, or the centrifugal force,
will alternately lift the tire up and force the tire 1
downward, along with the spindle, once for each
revolution of the tire:
Natural or Resonant Frequency
0 64/40 97/60 129/80 161/100
km/h/mph
3 5
95596
Legend (
(1) Frequency - cps
(2) Suspension Frequency
(3) Unbalanced Excitation
(4) Point of Resonance
(5) Problem Speed
All objects have natural freql)encies. The natural.

frequency of a typical automotive front suspension is
in the 10-15 Hz range. This natural frequency is
the result of the suspension design. The suspe,:,sion's ,
natural frequency is the same at all vehicle speeds.
95595 As the tire speed increases along with the vehicle
The natural frequency is the frequency at which an speed, the disturbance created by the tire increases in
object tends to vibrate. Bells, guitar strings, and tuning frequency. Eventually, the frequency of the unbalanced
forks are all examples of objects that tend to vibrate tire will intersect with the natural frequency of the
at specific frequencies when excited by an suspension. This causes the suspension to vibrate.
external force. The intersecting point is called the resonance.
Suspension systems, and even engines within their The amplitude of a vibration will be greatest at the
mounts, have a tendency to vibrate at certain point of resonance. While you may feel the vibration
frequencies. This is why some vibration complaints above and below the problem speed, you will feel
occur only at specific vehicle speeds or engine RPM. the vibration the most at the point of resonance.
(
Damping
)
95597
Legend
(1) Low Damping (2) High Damping
Damping is the ability of an object or material to

dissipate or absorb vibration. The automotive shock ·
absorber is a good example. The function of the shock
absorber is to absorb or dampen the oscillations of
the suspension system.
Beating (Phasing)
1 +2=3
i 10 Hz
2 8Hz
(
95599
Two separate disturbances that are relatively close Beating occurs when two vibrating forces are adding
together in frequency will lead to a condition to each other's amplitude. However, two vibrating
called beating,· or phasing. A beating vibration forces can also subtract from each other's amplitude.
condition will increase in intensity or amplitude in a The adding and subtracting of amplitudes in sirnilar
repetitive fashion as the vehicle travels at a steady frequencies is called beating. In many cases,
speed. This beating vibration can produce the familiar eliminating either one of the disturbances can correct
droning noise heard in some vehicles. the condition.
(
Genera.I Information Vibration Diagnosis and Correction 0-81
Order Reed Tachometer
Order refers to how many times an event occurs
during one revolution of a rotating component.
<JD
RESONANT REED
20 30 40 50 60 70 80
<ID
386790
The reed tachometer consists of two rows of reeds

95600
arranged side-by-side. Each reed vibrates when
For example, a tire with one high spot would create a excited by a specific frequency. The reeds are tuned
disturbance once for every revolution of the tire. to vibrate at increasing frequencies from left to
This is called first-order vibration. right This allows for a visual display of the frequency
range from 10-80 Hz.
) Due to increasing costs, limited availability and limited

diagnostic capability, the reed tachometer is no
longer recommended as the primary tool in diagnosing
vibration.
J
Electronic Vibration Analyzer (EVA)
The J 38792 Electronic Vibration Analyzer (EVA), with
the J 38792-60 Electronic Vibration Analyzer
Cartridge, is specifically designed to diagnose
vibrations. This hand-held device is similar to a scan
tool. A standard 12-volt power feed supplies the power.
The vibration sensor, or the accelerometer, is at the
end of a 6 mm (20 ft) cord. The vibration sensor
can be mounted virtually anywhere on the. vehicle
where a vibration is felt.
EVA Basic Hookup
1. Verify that the software cartridge is correctly
95601
inserted at the bottom of the unit. (The cartridge
An oval-shaped tire with two high spots would create a usually remains there at all times.)
disturbance twice for every revolution. This is called 2. Connect the vibration sensor cord into either
second-.order vibration. Three high spots would Input A or B.
be third-order, and so forth. Two first-order vibrations
3. Line up the sensor connector so that the release
may add or subtra.ct from the overall amplitude of
button is at the bottom.
the disturbance, but that is aH. Two first-order
vibrations do not equal a second-order vibration. Due 4. Push the sensor connector into the input until the
to centrifugal force, an unbalanced component will connector clicks and locks into place.
) always create at least a first-order vibration. 5. Plug the power cord into a 12-volt power feed in
order to turn the EVA on. (The EVA is not
equipped with an ON-OFF switch.)
To disconnect the sensor connector, press the release
button and gently pull the connector straight out
EVA Sensor Placement EVA Display
Up to three dominant vibration frequencies are (
displayed on the EVA's liquid crystal screen. On the
left is the frequency reading, followed by a description
of the vibration source. At the right side of the
screen, the actual strength, or amplitude, is shown in
acceleration force (G's).
Frequencies can be displayed in revolutions per
minute (RPM) or in Hertz (Hz). Switch between the
two readings by pressing the RPM/Hz button on
the keypad.
Important: Verify that the letter on the display
matches the correct sensor input.
95603
Proper EVA sensor placement is critical in order to

take proper vibration readings. You can place
the sensor anywhere on the vehicle where vibrations EJBOOOOB
are felt (1 ). Use putty or a hook and loop fastener
in order to hold the sensor in place on non-ferrous ~DDDB
surfaces, such as the surface of the steering column. l\alDDDl~~~1
!\vG l D jeNTERl EXIT j J,AE•z•!
J (
95605
Next to the frequency data on the top line of the

screen is the letter A or B. This letter indicates which
input is activated. Press the NB button on the
keypad in order to switch between the two inputs and
set to the correct input that is being used.
The EVA offers the following main display features, all
of which are described below:
• Freeze
• Record/Playback
• Averaging/Non-Averaging Modes
" Strobe Balancing
• Smart Strobe
95604
• Auto Mode
A magnet holds the sensor to ferrous surfaces.
Freeze
Vibrations are typically felt in an up-and-down
direction. The sensor is directionally sensitive. Pressing the FREEZE button on the keypad activates
the freeze function, which locks the display of data.
Therefore, place the sensor as flat as possible with
The display changes to Hz_FR_V == XX G
the side marked UP facing upward. Place the UP side
and a caret symbol points to a vibration source.
of the sensor in the exact position every time for Additional diagnostic information or that vibration
consistent results when repeating the tests or making source can be viewed by pressing ENTER. The freeze
a comparison. function is useful when conducting an (
acceleration/deceleration test in which the significant
amount of vibration registers only for a very short t'1me.
Pressing EXIT or the FREEZE button again
deactivates the freeze function.
Record/Playback Strobe Balancing
The displayed vibration information can be recorded
for later playback. The EV A retains stored data J 38792
for approximately 70 hours after the unit has been
unplugged from a power source. Data is recorded as
snapshots of vibration information. Each snapshot
consists of 10 different frames. Up to i O snapshots can
be recorded.
Press the RECORD button in order to record a
snapshot. The screen will display R? in order to
request a tag number between O and 9. These tag
numbers are the individual frames of the snapshot
recording. Then press ENTER to begin recording. New
data will replace the existing data when a number is
chosen that has already been used in order to
tag a snapshot.
Pressing the PLAYBACK button plays back the
recorded data. The screen shows P? in order to
request the tag number for the wanted snapshot. Once
the number is entered, the snapshot data displays 95606
the letter P followed by the tag number then
press ENTER to play back the data. Then the screen The J 38792 can strobe balance a rotating component.
displays the letter F followed by a number between A trigger wire is located on the top of the EVA,
O and 9 in order to indicate which frame of the which is used with an inductive pick-up strobe light
snapshot is being displayed. (timing light). The EV A triggers the strobe light at the
same frequency as the most predominant vibration.
Use the freeze function in order to freeze the display
The timing light clips on to the trigger wire. The
at any point in the sequence during playback. You
vibration sensor must be attached to input A. Input B
can view individual frames in a forward or backward
does not provide the strobe function.
sequence using the UP and DOWN arrow keys.
Pressing the STROBE button starts the strobe
The display returns to the active screen when the
balancing function. The EV A will ask a series of
recording or playback of a snapshot is finished,
questions in order to determine the correct filter range:
or when EXIT is pressed.
low, medium or high.
Averaging/Non-Averaging Modes The low, medium and high ranges prevent other
The EV A normally operates in an averaging mode that vibrations from interfering with the operation of the
averages multiple vibration samples over a period of strobe light. Press YES in order to select a range.
time. The averaging mode minimizes the effects Press NO in order to go on to the next range.
of a sudden vibration that is not related to the problem The vibration/strobe frequency must fall within the
(such as from potholes or from uneven road selected range.
surfaces). Most tests use the averaging mode. The EVA will display the signal frequency; signal level
The EV A is more sensitive to vibrations in the (amplitude), and filter range. The EVA is now ready
non-averaging mode. The display is more to begin the strobe balance procedure.
instantaneous and not averaged over a period of time.
The non-averaging mode is used when measuring
a vibration that exists for only a short period of time,
and during acceleration/deceleration tests.
Pressing the AVG button switches between the
averaging and non-averaging modes. During the
averaging mode, the screen will display AA. During
the instantaneous mode the top of the screen will
display IA
)
Auto Mode 9. Press the EVA up or down keys to manually
Auto Mode considers the suspected source of vibration adjust the RPM until only one mark is seen
in conjunction with the vehicle's baseline data to and the mark on the object appears stationary. (
identify a suspected source of vibration. i 0. As the test is run, the strobe speed must be
1. Select AUTO MODE from the EV A main menu. manually adjusted to match the actual object RPM.
The EVA will ask to select the suspected source·
of vibration as ENGINE RPM or VEHICLE SPEED. EVA Calibration
• If engine RPM is selected, move the cursor to The EV A features the following two built-in calibration
the correct number of engine cylinders then procedures:
press ENTER. Using the EVA keypad, • Sensor calibration
enter the engine RPM (500-6000 RPM) where
" Phase shift calibration
the vibration occurs at a maximum level.
Calibrate a replaced or an added sensor in order to
" If vehicle speed is selected, enter the tire size
function properly with the EVA unit. The phase
information with one of the following
shift calibration is performed at the factory. Do NOT
three options:
repeat this calibration under normal use.
- RPS at 5 mph - Look up the revolutions
per second (RPS) for specific tire size. Sensor Calibration
- Database - Select tire type and tire size 1. Lay the sensor on a flat stationary surface with
from each selection screen. the UP side facing upward.
- Manual Entry - Select Manual Entry when 2. Plug the sensor into either input A or B.
the vehicle is fitted with specialty tires.
3. Plug the EVA into a 12-volt power supply.
2. Enter one of the following driveshaft
4. After the display initializes, select the. proper input.
configurations:
• FWD (Front Wheel Drive) 5. Press the number 1 to initiate sensor calibration.
• RWD (Rear Wheel Drive) 6. Press the number 2 three times on the keypad.
The message BURNING will appear, followed
• AWD (All Wheel Drive)
by a request to turn the sensor over.
• 4WD (Four Wheel Drive)
7. Turn the sensor over. (
3. Enter the axle ratio only if FWD is not selected.
8. Press any key in order to commence calibration:
4. Select the vehicle speed units in
mph (miles-per-hour) or " Calibration will take approximately 20 seconds.
km/h (kilometers-per-hour). s The display will return to the active mode
when calibration is complete.
Smart Strobe
The Smart Strobe mode enables complete control of Phase Shift Calibration
the frequency at which the strobe light will flash. Smart i. Plug the EVA into a 12-volt power supply.
Strobe is well suited for identifying the speed at which
objects are rotating at. This is helpful for identifying the 2. Press the number 5 to initiate phase shift
source of a vibration. The pulley RPM can be converted calibration.
to a frequency by pressing the RPM/Hz key. 3. Press the number 2 on the keypad three times in
1. To use the Smart Strobe function, begin by order to begin calibration:
clipping the inductive pickup of the timing O
Do not press any key until the message ANY
light to the "wiring loop" of the EV A. KEY TO CONTINUE appears. Pressing a
2. Connect to a 12-volt power source. key will cancel the calibration process.
3. If a timing light with an advance feature is used, " The display will flash numbers for 5-6 minutes.
set advance to O degrees. (If the numbers flash for more than 10 minutes,
4. From the Main Menu, select Smart Strobe. the EVA is defective.)
5. With the engine off, mark the object you suspect " The message BURNING PHASE SHIFT
is causing vibration. A dab of white paint or CONSTANTS will appear for one minute.
correction fluid works well. " The BURNING CENTER FREQUENCIES
6. Enter an initial test point strobe frequency LOW=40, MEDIUM=50, HIGH=60 message will
between 10-200 Hz (600-12000 RPM). appear.
7. Run the engine at the RPM at which the vibration e The ANY KEY TO CONTINUE message
is the greatest and trigger the strobe. should appear.
8. As you point the strobe light at the spinning 4. Press any key in order to return to the (
object, press the Strobe Light trigger. active mode.
Keypad Reference FREEZE: Locks the display data at that moment and
displays the word FRZ at the top of the screen. This
key operates in the active display or during playback.
Pressing the FREEZE key again or pressing the
EXIT key unlocks the display.
RECORD: Places the EV A in the record mode.
Pressing the EXIT key will return the screen to the
active display.
PLAYBACK: Places the EVA in the playback mode
in order to view vibration information that was
previously recorded. Pressing the EXIT key will return
the key screen to the active display.
Numeric Keys (0-9): The numbered keys are used
in order to select one of ten snapshot tag numbers
between O and 9 when recording or playing back
information.
Arrow Keys: The arrow keys are used in order to
move through the individual frames of a snapshot
during a freeze in the playback mode. Pressing the UP
arrow moves forward one frame and pressing the
95605 DOWN arrow moves backward one frame.
ENTER: Once the EVA is in the record mode and
A/B: Switches the display between the A Input and
you have selected a snapshot tag number, press
the B Input. You must use Input A when strobe
ENTER in order to start recording.
balancing.
STROBE: Places the EV A in the strobe mode for
AVG: Switches the display between the driveshaft balancing and diagnosis. Pressing the EXIT
non-averaging mode and the averaging mode. The key will return the screen to the active display.
non-averaging mode is more sensitive to sudden YES and NO: Used in order to select a filter range
) vibration variations. When in the averaging mode, the
word AVG appears at the top of the display.
when in the strobe balancing mode.
EXIT: Returns the screen to the active display when
RPM1HZ: Switches the frequency display between the EVA is in the freeze mode, the record mode,
RPM and Hz. . the playback mode, or the strobe mode.
Illustration Tool Nuniber/ Description Illustration Tool Number/ Description
J 7872 J 35819
Magnetic Base Dial Flange Runout Gauge
Indicator Set
35463 1512
J 8001
111 ° V)~,
09
#
· 1 ~ I (2 J 38460
Dial Indicator Set Digital Inclinometer
!KENT-MOORE
..,nuc, DIQl'JAL AAOmACTOR
2014 198883
J 38792 (
I) J 23409
Dial Indicator Extension
Electronic Vibration
Analyzer (EVA) · ·
1517
J 38792-50
J 23498-A
Electronic Vibration Analyzer
Driveshaft Inclinometer Cartridge
8224 580649
J 23498-20
Driveshaft Inclinometer
Adapter
180348
(
HVAC Table of Contents 1-1
)
Section 1
HVAC
Heating, Ventilation and Air Compressor Control Valve Assembly

Conditioning ..................................... 1-3 Removal (V5 - Conventional Mount) ......... 1-42
Specifications .................................................. 1-3 Compressor Control Valve Assembly
Fastener Tightening Specifications ................. 1-3 Removal (V7 - Direct Mount) .................... 1-42
Fitting and Line Tightening Compressor Shaft Seal Removal
Specifications ............................................. 1-3 (V5 - Conventional Mount) ........................ 1-43
System Capacities ................. ,....................... 1-3 Compressor Shaft Seal Removal
Refrigerant Oil Distribution (V7 - Direct Mount) .................................. 1-45
Specifications ............................................. 1-4 Compressor Pressure Relief Valve
GM SPO Group Numbers .............................. 1-4 Removal (V5 - Conventional Mount) ......... 1-46
Diagnostic Information and Procedures ......... 1-5 Compressor Pressure Relief Valve
Leak Testing ................................... :.............. 1-5 Removal (V7 - Direct Mount) .................... 1-46
Cooling Insufficient, A/C System .................... 1-7 Compressor Control Switches Removal
(V5 - Conventional Mount) ........................ 1-47
Cooling Insufficient, A/C System -
Pressure Zone A ...................................... 1-1 o Compressor Control Valve Assembly
Install (V5 - Conventional Mount) .............. 1-47
Pressure Zone B ...................................... 1-13 Compressor Control Valve Assembly
. Install (V7 - Direct Mount) ........................ 1-47
) Pressure Zone C ...................................... 1-16 Compressor Clutch Plate/Hub Assembly
Pressure Zone D ...................................... 1-18 Compressor Clutch Plate/Hub Assembly
Install (V7 - Direct Mount) ........................ 1-49
Defrosting Insufficient ......................... ,......... 1-21
Clutch Rotor and/or Bearing Install
Heating Insufficient ....................................... 1-21
(V5 - Conventional Mount) ........................ 1-50
Noise Diagnosis - Blower Motor ................... 1-21
Noise Diagnosis - A/C System ..................... 1-24 (V7 - Direct Mount) .................................. 1-52
Cold Drafts on Floor .................................... 1-27 Compressor Clutch Coil Install
Odor Diagnosis ............................................ 1-27 (V5 - Conventional Mount) ........................ 1-53
Repair Instructions ........................................ 1-28 Compressor Clutch Coil Install
Odor Correction ........................................... 1-28 (V7 - Direct Mount) .................................. 1-55
Refrigerant Recovery and Recharging .......... 1-28 Compressor Shaft Seal Install
Compressor Replacement (3.8 L} .................. 1-29 (V5 - Conventional Mount) ........................ 1-56
Compressor Replacement (5.7 L} ................. 1-32 Compressor Shaft Seal Install
Compressor Clutch Plate and Hub (V7 - Direct Mount) ........•......................... 1-57
Assembly Removal
Compressor Pressure Relief Valve
(V5 - Conventiona.1 Mount) ........................ 1-35
Compressor Clutch Plate and Hub
Assembly Removal Compressor. Pressure Relief Valve .
(V7 - Direct Mount) .................................. 1-36 Install (V7 - Direct Mount) .. ···.· ................... 1-59
Clutch Rotor. and/or Bearing .Removal Compressor Control Switches Install
(V5 - Conventional Mount) ........................ 1-37 (V5 - Conventional Mount) ........................ 1-59
Clutch Rotor and/or Bearing Removal Compressor Leak Testing
(V7 - Direct Mount) .................................. 1-38 (V5 - Conventional Mount) ........................ 1-60
Compressor Clutch Coil Removal Compressor Mounting Bracket
(V5 - Conventional Mount) ........................ 1-40 Replacement (3.8 L} ................................. 1-61
Compressor Clutch Coil Removal Compressor Mounting Bracket
) (V7 - Direct Mount) .................................. 1-41 Replacement (5.7 L) ................................. 1-64
1-2 Table of Contents HVAC
Compressor Sealing Washers HVAC Connector End Views ...................... 1-113
Replacement ............................................ 1-65 Diagnostic Information and Procedures ..... 1-115
Compressor Hose Assembly A Diagnostic Starting Point ........................ 1-115 (
Replacement (3.8 L) ................................. 1-65 A Diagnostic System Check .................. ,.... 1-115
Compressor Hose Assembly Symptoms .................................................. 1-115
Replacement (5. 7 L) ................................. 1-68 HVAC Compressor Clutch Does Not
Evaporator Tube Replacement ..................... 1-69 Engage ................................................... 1-116
Expansion (Orifice) Tube Filter HVAC Compressor Clutch Does Not
Replacement ............................................ 1-70 Disengage .............................................. 1-118
Compressor Relay Replacement .................. 1-71 Blower Motor Inoperative at Any Speed ..... 1-119
Service Port Valve Core Replacement ......... 1-72 Blower Motor Operates at High
A/C Refrigerant Pressure Sensor Speed Only ............................................ 1~ 121
Replacement ............................................ 1-72 Blower Motor Inoperative in One Speed
Condenser Replacement .............................. 1-74 Only (High Speed Operates Normally) .... 1.:.121
Accumulator Replacement ............................ 1-78 Blower Motor High Speed Inoperative ..... ,.. 1-122
Evaporator Core Replacement ..................... 1-79 Blower Motor Always On ............................ 1-123
Heater Hose Assembly Air Delivery Improper .......................... ;...... 1-123
Replacement (3.8 L) ................................. 1-83 Repair Instructions .................................. :,.;1-124
Heater Hose Assembly Blower Motor Resistor Replacement ........... 1-124
Replacement (5. 7 L) .................................. 1-85 Blower Motor and Fan Replacement ..... :: ... 1-125
Blower· Motor Relay Replacement ................ 1-87 Control Assembly Replacement .................. 1-1. 26
Heater Core Replacement ............................ 1-88 HVAC Control Lamp Bulb Replacement ..... 1-128
Description and Operation ............................ 1-89 HVAC Control Lamp Bulb Wiring
A/C System Description ............................... 1-89 Harness Replacement ...................... ,...... 1-128
Heater Core Description ............................... 1-89 HVAC Control Blower Switch
Refrigeration System Description .................. 1-90 Replacement ... ,..................................... ,.1-129
Refrigerant R-134a ........................................ 1-91 HVAC Control Vacuum Valve
Handling Refrigerant R-134a ........................ 1-91 Replacement .................................... ,...... 1-130
Handling Compressor Oil ............................. 1-91 HVAC Control Selector Switch (
Handling of Refrigerant Lines and Replacement ........................................... 1-130
Fittings ..................................................... 1-91 Temperature Control Cable
Handling A/C Compressor .............·............... 1-92 Replacement ........................................... 1-131
Maintaining Chemical Stability ...................... 1-92 Temperature Control Cable Adjustment ...... 1-132
Refrigerant Oil Distribution ........................... 1-92 Inside Air Valve Actuator Replacement ....... 1-134
Expansion (Orifice) Tube Description .... ,...... 1-93 Vacuum Actuator Replacement ........... :., .... 1-135
Evaporator Description ....... ,......................... 1-93 Defroster Valve Actuator Replacement ..... ,.1-136
Condenser Description ................................. 1-93 Mode Valve Actuator Replacement ... ;., ....... 1-136
Accumulator Description ............................... 1-93 Air Distributor Duct Replacement ................ 1-137
Compressor Description (3.8 L) .................... 1-94 Air Outlet Replacement - Right
Compressor Description (5. 7 L) ............. ,...... 1-95 Defogger ........................................ : ..... :.1-138
High Pressure Relief Valve Description ........ 1-97 Air Outlet Replacement - Floor .......... :, ........ 1-138
Relays and Sensors Description ............. , ..... 1-97 Air Outlet Replacement - Side Window ...... 1-139
0-Ring/Flat Washer Description ................... 1-97 Vacuum Tank Replacement ..... ,......... ,....... 1-140
Special Tools and Equipment ....................... 1-97 Vacuum Hose Harness Replacement ......... 1-141
HVAC Control Vacuum Harness
HVAC Systems - Manual ............................ 1-101 Replacement ................... : .. , .. .. .. ..... .< ... 1-142
Specifications .............................................. 1-101 Description and Operation ................ ,.........1-144
Fastener Tightening Specifications ......... , ... 1-101 Air Distribution System Description .............. 1-144
GM SPO Group Numbers .......................... 1-101 Blower Motor Description ............................1-145
Schematic and Routing Diagrams .............. 1-102 Blower Motor Resistor Description ..............1-145
HVAC Schematic Icons .............................. 1-102 Control Assembly Description (Pontiac) ...... 1- i 45
HVAC Blower Control Schematics .............. 1-103 Control Assembly Description
HVAC Compressor Control Schematics ...... 1-104 (Chevrolet) ........................ ,, .......... , .......... 1-147
Component Locator ..................................... 1-106 Vacuum Hose Harness Description ............ 1-149
HVAC Components .................................... 1-106 HVAC Blower Controls Circuit
HVAC Component Views ........................... 1-108 Description ............................................. 1-150 (
HVAC Heating, Ventilation and Air Conditioning 1-3
Heating, Ventilation and Air Conditioning

)
Specifications
Fastener Tightening Specifications
Specification
Air Conditioning Accumulator Bracket Bolt 6N-m 53 lb ft
Air Conditioning Accumulator Bolt (At Module) 16 N-m 12 lb ft
Air Conditioning Accumulator Hose Bracket Nut (At Strut Tower) 8N-m 71 lb in
Air Conditioning Compressor and Condenser Hose Bolt
16 N-m 12 lb ft
(At Accumulator)
Air Conditioning Compressor and Conden.ser Hose Nut (At Condenser) 16 N-m 12 lb ft
,Air Conditioning Compressor and Condenser Hose Bolt
33N-m 24 lb ft
(At Compressor)
Air Conditioning Compressor B.racket Bolt (3.8 L} 50N-m 37 lbft
Air Conditioning Compressor Bracket Rear Bolt (3.8 L) 30N-m 22 lb ft
Air Conditioning Compressor Bracket Bolt (5.7 L) 50N-m .· 37 lb ft
Air Conditioning Compressor Bolt (5.7 L} 50N-m 37 lb ft
Air Conditioning Compressor Bolt (3.8 L} 50N·m 37 lb ft
Air Conditioning Crankcase Oil Drain Bolt 20N-m 15 lb ft
Air Conditioning Compressor Rear Bolt (3.8 L) 30N-m 22 lb ft
Air Conditioning Evaporator Bracket Bolt 2N-m 181bin
Air Conditioning Evaporator Tube Bolt (At Module) 16N-m 12 lb ft
Air Conditioning Evaporator Tube Bolt (At Condenser) 16 N-m 12 lb ft
Air Conditioning Evaporator Upper and Lower Case Bolt 2N·m 18 lb in
Heater Core Clamp Bolt 1.8 N·m 16 lb in
Heater Core Tube Clamp Bolt 2.0N-m .18 lb in
Heater Hose Bracket Bolt 14 N·m 10 lb ft
Heater Rear Case Bolt 2.0N·m 18 lb in
Negative Battery Cable Nut to Engine Block Stud (3.8L) 25N·m 18 lb ft
Temperature Control Cable Bolt 1.9 N·m .17 lb in
Fitting and line Tightening Specifications

Specification
Air Conditioning Refrigerant Pressure Sensor 6N-m 531bin
Air Conditioning Refrigerant Service Valve 11 N-m 98lbin
Compressor Pressure Relief Valve 9N·m BO lb in
System Capacities
Specification
Application Metric I English
Air Conditioning (A/C) System R-134a Charge Capacity 0.68 kg I 1.50 lb
)
1-4 Heating, Ventilation ~nd Air Conditioning HVAC
Refrigerant Oil Distribution Specifications
Specification
DEFINITION: During A/C refrigerant system component replacement and conditions stated, new refrigerant system oil
quantities should be added to the system as indicated.
A/C Compressor 60 ml I 2 oz
Add 60 ml (2 oz) more than amount drained from
Accumulator
old accumulator
Condenser 30ml I 1 oz
Evaporator 90ml I 3 oz
Add 90 ml (3 oz) plus required amount for 1he
Abrupt oil loss due to large refrigerant leak
component being replaced (cause of large leak)
GM SPO Group Numbers

Application GM SPO Group Number
Air Conditioning Accumulator 9.000
Air Conditioning Clutch 9.000
Air Conditioning Clutch Coil 9.000
Air Conditioning Compressor 9.000
Air Conditioning Compressor and Condenser Hose Assembly 9.000
Air Conditioning Compressor Pressure Relief Valve 9.000
Air Conditioning Compressor Pulley 9.000
Air Conditioning Compressor Pulley Bearing 9.000
Air Conditioning Compressor Relay 9.000
Air Conditioning Compressor Shaft Seal Kit 9.000
Air Conditioning Compressor Suction Screen 9.000 (
Air Conditioning Compressor Variable Displacement Control Valve 9.000
Air Conditioning Condenser 9.000
Air Conditioning Evaporator · 9.000
Air Conditioning Evaporator Tube 9.000
Air Conditioning Evaporator Tube Orifice 9.000
Air Conditioning Refrigerant Pressure Sensor 9.000
Air Conditioning Refrigerant Service Valve 9.000
Blower Motor Relay 9.000
Temperature Control Cable 9.000
(
HVAC Heating, Ventilation al)d Air Conditioning .1-5
leak Testing
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 methods and special tools are available for
this purpose; however, no matter which tool is used,
0 J 39400"':".'"A
care and diligence are the biggest keys to success.

Electronic Leak Detection Method
Tools Required
J 39400-A Halogen Leak Detector
Use the electronic leak detector when inspecting for
refrigeration system leaks'. This unit operates on
a 12 volt DC. The leak detector prdvides an audible.
)
signal which increases in frequency when a refrigerant
leak is detected. Properly calibrate the tool. Use the
.tool at the proper setting for the system that you
are testing. The electronic leak detector has the
82101
following three settings:
" R-12 2. Service valves.
• R-134a
• Gross leaks
This setting isolates very large leaks that are
found at one of the other settings
) The halogen leak detectors are sensitive to windshield
washing solution, many solvents and cleaners, and
some adhesives. Work on a clean and dry surface.
Complete the following actions when you test
the joints:
• Completely circle each joint.
·... , Move the tool 25-50 mm (1-2 inch) per second.
• Ensure that the tip of the probe is no more
than 6 mm (0.25 inch) from the surface.
You may use this detector in order to inspect the
following joints:
82106
3. Evaporator inleVoutlet.
4. Accumulator dryer inleVoutlet.
5. Compressor rear head.
6. Compressor housing joints.
7. A leak is indicated when the audible tone goes
from a steady 1-2 clicks per second to a solid
alarm. Adjust the balance knob frequently in order
to maintain the 1-2 clicks per second.
If a leak is not found, proceed to the Refrigerant
Leak Diagnosis table.
82107
1. Refrigerant pressure sensor.

1-6 HeaUng, Ventilation and Air Conditioning HVAC
Refrigerant Leak Diagnosis c
c
Step "
Action Value(s) Yes No (
DEFINITION: Inspecting the refrigeration system for leaks.
1. Inspect the refrigeration system components for
proper torque.
1
2. Tighten the components as needed.
-
Has the leak stopped? System OK .. Go to Step 2
1·,
1. Inspect the 0-rings for damage, dirt or lack of
lubrication.
2
2. Replace the 0-rings as needed. -
Has the leak stopped? System OK Go to Step 3
1. Inspect the refrigeration system connections. Refer to
Electrical Diagnosis.
3 -
2. Repair as needed.
Has the leak stopped? System OK Go to Step 4
1. Turn the blower to the highest setting for at least
15 seconds.
2. Wait for 10 minutes.
3. Remove the blower motor resistor. Refer to Blower
4
Motor Resistor Replacement in HVAC Systems - 1·
-
Manual.
4. Insert the probe into the resistor opening.
Is the alarm solid? Go to Step 5 Go to Step 6
Repair the leak as needed.
5
Has the leak stopped?
- System OK Go to Step 6
1. Blow compressed air behind and in front of the
compressor clutch and pulley for at least 15 seconds. (
2. Wait 1-2 minutes.
6 -
3. Insert the probe behind and in front of the
compressor clutch and pulley.
Is the alarm solid? Go to Step 7 System OK
Repair the leak as needed.
7
Has the leak stopped?
-
System OK
-
Florescent Leak Detection Method Liquid leak Detection/Pressure Testing

Tools Required Methods
• J 41447Tracer Dye Due to their lack of sensitivity and restricted visibility in
today's refrigerant systems, liquid/bubble leak
• J 41436 Tracer Dye Injector
detectors have very limited usefulness. Therefore, the
• J 28428-E High Intensity Black Light liquid leak detection/pressure testing methods are
The R-134a refrigerant is uniquely different from the not recommended for this vehicle.
R-12 used in the past and may require additional .
methods for leak detection. The R-134a molecule is Service Port Seal/Cap
smaller than the R-12 molecule and can leak through The primary seal for the service ports is the sealing
smaller openings. R-134a also does not contain cap. The cap contains a specially designed 0-ring or
chlorine, which is easily detected using the black light. gasket which provides a leak free seal. Should the
The efflorescence leak detection method is meant cap be loose, missing, or the wrong usage, a loss of
to be used in conjunction with the electronic method, refrigerant could result.
and will pinpoint smaller leaks. The R-134a takes
time to work. Depending on the rate of the leak, the
dye may take up to 7 days to become visible.
(
Cooling Insufficient, A/C System
) A/C System Pressure - Zone Classification Graph
(kPa) (Psi)
690 100
621 90
552 80
483 70
414 60
Q)
"O
Cf.) 345 50
~
...J
276 40
207 30
138 20
69 10
) iOO 200 300 400 (Psi)
690 1379 2069 2750 (kPa)
High Side
590674
Cooling Insufficient, A/C System

Step Action Value(s) Yes No
The following test measures the air conditioning (A/C) system operating efficiency by comparing the following:
• The ambient air temperature
• The ambient air humidity
• The pressure at the high-pressure side of the refrigeration system
• The pressure at the low-pressure side of the refrigeration system
• The temperature of the air being discharged into the passenger compartment "
1. Park the vehicle inside or in the shade.

2. Open the windows in order to ventilate the interior of
the vehicle.
3. If the engine is at operating temperature, allow the
engine to cool.
4. Ensure that the ignition key is in the OFF position.
1 5. Install J 39500-8. 345 kPa (50 psi)
6. Record the readings of the low and high side STATIC
pressures.
The low and high side pressure readings should be
almost equal to each other once the system has
) come to rest.
Are both the low and high side pressures above the Go to Leak
specified value? Go to Step 2 Testing.
1-8 Heating, Ventilation and Air Conditioning HVAC
Cooling Insufficient, A/C System (cont'd)
Step Action Value(s) Yes No (
1. Start the vehicle. Go to HVAC
2. Turn the A/C on. Compressor
Clutch Does Not
2 3. Visually inspect under the hood to see if the - Disengage in
A/C compressor clutch is engaged. HVAC Sys1ems -
Does the A/C compressor clutch engage? Go to Step 3 Manual
Important: Record the relative humidity and the ambient
temperature AT THE TIME OF THE TEST;
1. Record the ambient temperature at the vehicle.
2. Record the relative humidity, using one of the
following methods:
• Use a psychrometer
• Consult the local weather bureau
3. Close the vehicles doors and windows.
4. Set the HVAC control to the following positions: .
• The A/Con
• The blower control to the highest position
• The HVAC control to discharge air through the
IP outlets
• The temperature control to the coldest position
5. Install a thermometer into the IP center air .outlet.
6. Apply the park brake.
3 7. Place the transmission in one of the following -
positions:
• PARK
• NEUTRAL (
8. Start the engine and elevate and maintain the engine
RPM to 2000.
9. Run the A/C until the outlet air temperature reaches
the lowest temperature.
This will take approximately 3 minutes.
10. Record the following information:
• The outlet air temperature ..
• The low-side pressure ..
• The high-side pressure

11. Compare the low and high side pressures and the
output temperature to the table.
Does all the data recorded fall within the specified ranges
of the table below? Go to Step 8 Go to Step 4
Compare the recorded pressures to the A/C System Go to Cooling
Pressure - Zone Classification Graph. Insufficient,
4 -
Do both the low and high side pressures fall within Zone A A!C System -
on the graph? Pressure Zone A Go to Step 5
Do the pressures fall within Zone B? Go to Cooling
Insufficient,
5 - A/C System -
Pressure Zone B Go to Step 6
(
Cooling Insufficient, A/C System (cont'd)
Do the pressures fall within Zone C? Go to Cooling
Insufficient,
6 - A/C System -
Pressure Zone C Go to Step 7
Do the pressures fall within Zone D? Go to Cooling
Insufficient,
7 - A/C System -
Pressure Zone D Go to Step 8
Operate the system in order to verify the repair. Go to Symptoms
8 Did you correct th~ condition? - in HV AC System
System OK - Manual
·.
A/C Performance Table
Center Outlet
Temperature Humidity Low Gauge Pressure High Gauge Pressure Temperature
165-234 kPa 793-1310 kPa
Less than 50% 3°-9°C (38°-48°F)
(24-34 psi) (115-190 psi)
21 °-27°C (70°-80°F)
172-255 kPa 793-1379 kPa
More than 50% 4°-13°C (40°-55°F)
(25-37 psi) (115-200 psi)
193-262 kPa 965-1482 kPa
Less than 50% 3°-13°C (38°-55°F)
(28~38 psi) (140-215 psi)
27°-33°C (80°-90°F)
207°276 kPa 1034-1620 kPa
More than 50% 7°-18°C (45°-65°F)
•.'
(30-40 psi) (150-235 psi)
234-296 kPa 1138-1793 kPa
Less than 40% 7°-17°C (45°-63°F)
(34-43 psi) (165-260 psi)
33°·38°C (90°-100°F)
251-331 kPa 1276-1862 kPa
More than 40% 13°-20°C (55°-68°F)
(36-48 psi) (185-270 psi)
276-338 kPa 1448-2000 kPa
Less than 20% 12°-18°C (53°-64°F)
(40-49 psi) (210-290 psi)
38°-44°C (100°-110°F)
296-359 kPa 1517-2137 kPa
More than 20% 14°-21°C (58°-70°F)
(43-52 psi) (220-310 psi)
.. ..
)
1-10 Heating, Ventilation and Air .Conditioning HVAC
Cooling Insufficient, A/C System - Pressure Zone A
A/C System· Pressure - Zone Classification Graph
(kPa) (Psi)
690 100
621 90
552 80
483 70
414 60
345 50
276 40
207 30
138 20
69 10
300
1379 2069 (
High Side
590674
Cooling Insufficient, A/C System - Pressure Zone A

Step Action Value(s) Yes No '
Were you sent here from the Cooling Insufficient, Go to Cooling

1 A/C System diagnostic table? - Insufficient,
Go to Step 2 A/C System
During continued operation of the A/C system, does the
compressor clutch disengage and re-engage with no
2
abnormal change to the low and high side pressure
-
readings? Go to Step 3. . Go .to .Step 4.
1. Check for an intermittent in the clutch coil and/or the
clutch coil circuit. Refer to 1-/VAC Compressor Clutch
Does Not Engage in HVAC Systems - Manual.
2. If replacement of the clutch coil is necessary, recover
the refrigerant.
3. Replace the clutch coil and/or repair the clutch coil
circuit.
3 - -
For clutch coil replacement, refer to Compressor
Clutch Coil Removal (V5 - Conventional Mount) and
Compressor Clutch Coil Install (V5 - Conventional
Mount) or Compressor Clutch Coil Removal
(V7 - Direct Mount) and Compressor Clutch Coil
Install (V7 - Direct Mount). (
Is the repair complete? Go to Step 12
Cooling Insufficient, A/C System - Pressure Zone A (cont'd)
) Step Action Value(s) Yes No
Did the customer concern mention that the A/C system
4 output temperatures are good at first, but then turn warm -
during extended drives? Go to Step 5 Go to Step 7
The engine still running with a speed of 2000 RPM.
During extended operation of the A/C system, does the Go to Cooling
5 low side (and possibly the high side} pressure increase - Insufficient,
significantly (possibly accompanied by heavy frost on the AIC System -
liquid line between the orifice and the evaporator)? Pressure Zone B Go to Step 6
Take the vehicle on a test drive under the same conditions Go to Cooling
as the customer, to verify the concern. Insufficient,
6 -
Has the concern been verified? AIC System -
Pressure Zone B Go to Step 11
Compare the low and high side pressures to those listed in
the A/C performance table. Refer to Cooling Insufficient,
7 AIC System. -
Is the high side pressure slightly above normal pressure? Go to Step 8 Go to Step 9
1. The refrigerant system oil charge level may be
too high.
2. Evacuate the refrigerant system.
3. Check the amoun.t of refrigerant oil removed from the
system.
8 - -
4. Charge the refrigerant system to specifications, using
. care to maintain the proper oil level.
5. Leak test the refrigerant system. Refer to Leak
Testing.
Are the operations completed? Go to Step 10
1. The refrigerant system may contain too much
moisture.
3. Charge the refrigerant system to specifications.
9 4. Leak test the refrigerant system. - -
Refer to Leak Testing.
5. If no leaks are found, replace the accumulator. Refer
to Accumulator Replacement.
Compare the outlet temperature to those listed in the Go to A
A/C performance table. Refer to Cooling Insufficient, Diagnostic
10 AIC System. - System Check in -
Is the outlet temperature within specifications? HV AC Systems -
Manual
)
Cooling Insufficient, A/C System - Pressure Zone A (cont'd)
1. Start the engine and allow the engine to idle.
2. With an accurate thermometer still installed to the
IP center air outlet.
3. Set the HVAC control to the following positions:
• The A/Con
• The temperature control to coldest position
• The mode control knob to UPPER {IP outlets)
• The blower switch to high
4. Elevate and maintain the engine speed at 2000 RPM.
11 5. Allow the low and high side pressure readings to - -
stabilize, if necessary.
(Stabilization usually requires 2-3 minutes.)
6. Record the low and high pressure readings and the
delivered air output temperature.
output temperatures to those listed in the
A/C Performance Table.
Refer to Cooling Insufficient, A/C System.
Are both the low and high side pressures as well as the
output temperatures within specifications? System OK
1. Evacuate and charge the refrigerant system.
2. Leak test the refrigerant system.
12 - -
1. Start the engine and allow the engine to idle. (
• A/C button to ON
• Temperature control to full cold
• Mode control knob to UPPER {IP outlets)
• Blower switch to high
output temperatures to those listed in the Go to A
A/C Performance Table. Refer to Cooling Insufficient, Diagnostic
A/C System. System Check in
Are both the low and high side pressures as well as the HVAC Systems -
output temperatures within specifications? Manual
(
Cooling Insufficient, A/C System - Pressure Zone B
A/C System Pressure - Zone Classification Graph
(kPa) (Psi)
690 100
621 90
552 80
483 70
414 60
Q)
""O
en 345 50
~
0
...I
276 40
207 30
138 20
69 10
)
I
100 200 300 400 (Psi)
690 1379 2069 2750 (kPa)
High Side
590674
Cooling Insufficient, A/C System - Pressure Zone B

Were you sent here from the Cooling Insufficient,
1
A/C System - Pressure Zone A.
- Go to Step 3 Go to Step 2
2 A/C System. - Insufficient,
Go to Step 3 AIC System
1. The engine still idling in PARK.
.
2. The HV AC control still set to the following positions:
• Mode control knob to UPPER (IP outlets)
e Blower switch to high
3. Close the vehicle windows and doors.

3 4. The vehicle hood fully raised. -
5. Both engine cooling tans operating.
6. Elevate and maintain the engine speed to 3000 RPM.
7. Cycle the A/C from ON to OFF to ON - by
depressing the A/C button on the HV AC control -
every 20 seconds for 3 minutes.
8. Record the low and high side pressure readings.
Are the low and high side pressure readings within
207 kPa (30 psi) of each other? Go to Step 4 Go to Step 11
Cooling Insufficient, A/C System - Pressure Zone B (cont'd)
· is the pressure rise slow on both the low and high
4 -
side gages? Go to Step 10 Go to Step 5
1. Turn the engine OFF.
2. Ensure that the compressor clutch is disengaged.
5 3. Attempt to rotate the compressor clutch driver -
(NOT the pulley) by hand.
Does the compressor clutch driver (NOT the pulley) turn
freely by hand? Go to Step 10 Go to Step 6
2. Turn the A/C ON by depressing the A/C button on the
HV AC control.
3. Observe the low side pressure readings.
6 -
4. Elevate the engine speed to
between 3000-3800 RPM.
Is there a rapid rise in the low side pressure between
3000-3800 engine RPM? Go to Step 7 Go to Step 10
2. The HVAC control still set to the following positions:
• The A/Con
3. Set the blower switch to low 69-345 kPa
7
4. The vehicle windows and doors still closed. (10-50 psi)
5. The vehicle hood still fully raised.
6. Both engine cooling fans operating. (
7. Record the low side pressure reading.
Is the low side pressure reading within the specified
values? Go to Step 8 Go to Step 9
2. The HVAC control set to the following positions:
O Temperature control to full cold

8 4. Allow the low and high side pressure readings to -
5. Record the low and high pressure readings.
6. Compare the low and high side pressures to the A/C
System Pressure - Zone Classification Graph above.
Do both the low and high side pressures fall within Zone B
on the chart (low side pressure still high and high side
pressure· still low)? Go to Step 10 Go to Step 11
1. Recover the refrigerant.
2. Replace the control valve.
Refer to Compressor Pressure Relief Valve Removal
(V5.- Conventional Mount) and Compressor Pressure
9 Relief Valve Install (V5 - Conventional Mount) or - -
Compressor Pressure Relief Valve Removal
(V7 - Direct Mount) and Compressor Pressure Relief (
Valve Install (V7 - Direct Mount).
Cooling Insufficient, A/C System - Pressure Zone B (cont'd)
2. Replace the NC compressor.
10 Refer to Compressor Replacement (3.8 L) or - -
Compressor Replacement (5. 7 L).
• NC button to ON
11 - -
5. Allow the low and high side pressure readings to
6. Record the. low and high pressure readings and the
output temperatures to those listed in Cooling
Insufficient, AIC System
Are both the low and high side pressures as well as the
output temperatures within specifications? System OK
12 - -
2. An accurate thermometer still installed to the
• NC button to ON
O Mode control knob to UPPER (IP outlets)
output temperatures to those listed in the Go to A
NC Performance Table. Refer to Cooling Insufficient, Diagnostic
A/C System. System Check in
Are both the low and high side pressures as well as the HV AC Systems -
)
t-16 Heating, Ventilation and Air Conditioning HVAC
Cooling Insufficient, A/C System - Pressure Zone C
A/C System Pressure - Zone Classification Graph
(kPa) (Psi)
690 100
621 90
552 80
483 70
414 60
Q)
"O
(/.) 345 50
:\';
0
....I
276 40
207 30
138 20
69 10
100 200 300. 400 (Psi)
690 1379 2069 2750 (kPa) (
High Side
590674
Cooling Insufficient, A/C System - Pressure Zone C

Go to Step 2 A/CSystem
Visually inspect for restricted air flow at the condenser.
2
Is the air flow through the condenser restricted
1. Repair the condition (air flow restriction) or replace
the condenser, if damaged.
2. If replacement of the condenser is necessary, recover
the refrigerant, then refer to Condenser
Replacement.
3 - -
Is the repair complete? Go to Step 4 ·.

2. Turn ON the A/C, using the A/C button.
4
3. Inspect for proper cooling fan operation. Refer to
Electric Cooling Fan Diagnosis (Description) in -
(
Engine Controls - 3.8 L or Electric Cooling Fan
Diagnosis in Engine Controls - 5.7 L.
Are the cooling fans ON and operating properly? Go to Step 6 Go to Step 5
Cooling Insufficient, A/C System - Pressure Zone C (cont'd)
Repair the cooling fan operation fault. Refer to Electric
Cooling Fan Diagnosis (Description) in Engine
5 Controls -3.8 L or Electric Cooling Fan Diagnosis in Engine - -
Controls - 5. 7 L.
2. The A/C still turned ON.
6 3. Feel the liquid line on both sides of the expansion -
(orifice) tube.
Is the temperature the same before and after the orifice? Go to Step 7 Go to Step B
2. Replace the damaged/faulty expansion (orifice) tube
(orifice opening too large and/or the 0-ring is
7 damaged or missing), - -
Refer to Expansion (Orifice) Tube Filter
Replacement.
1. Air is in the refrigerant system, or the system is
overcharged.
8 - -
4. Charge the refrigerant system to specifications.
Is the repair complete? ·. Go to Step 10
1. Evacuate a.nd charge the refrigerant system;
) 9
., - -
3. Set the HV AC control to the following positions:
e Mode control knob to UPPER (IP outlets)
• Blower sw.itch to high

output temperatures to those listed in the
Go to A
A/C Performance Table.
Diagnostic
Refer to Cooling Insufficient, A/C System. System Check in
Are both the low and high side pressures as well as the HV AC Systems -
)
Cooling Insufficient, A/C System - Pressure Zone D
A/C System Pressure - Zone Classification Graph (
(kPa) (Psi)
690 100
621 90
552 80
483 70
414 60
345 50
276 40
207 30
138 20
69 10
100 200 300 400 (Psi)
(
690 1379 2069 2750 (kPa)
High Side
590674
Cooling Insufficient, A/C System - Pressure Zone D

Go to Step 2 A/CSystem
2. The A/C still ON.
2
3. Feel the liquid line before the expansion (orifice) tube.
-
Is the liquid line cold before the orifice? Go to Step 3 Go to Step 5
1. The A/C system still operating.
2. Carefully feel along the surfaces of the following high
side components for a sudden drop in temperature.
(The high side components should feel warm/hot from
the compressor all the way to the orifice.)
3 • The compressor discharge hose -
• The condenser
• The liquid line between the condenser and the
orifice.
Was an abrupt drop in temperature noted along the
surfaces of any of the components listed? Go to Step 4 Go to Step 5
2. Remove the restriction from the component, or (
4 replace the component which produced an abrupt - -
temperature drop
HVAC Heating, Ventilation and Air Conditioning t,;19
Cooling Insufficient,. A/C System - Pressure Zone D (cont'd)
2. Evacuate the system.
0.68 kg
5 3. Weigh the charge which was removed.
(1.50 lb)
Is the weight of the removed refrigerant charge equal to or
above the specified value? Go to Step 9 Go to Step 6
Add 0.40 kg (14 oz) of R-134i3. to the refrigerant system.
6
Does the cooling performance improve?
Leak test the system. Refer to Leak Testing.
7
Was a refrigerant leak found?
Repair the refrigeraRt leak,
8
Is the repair complete?
-
Go to Step 17
-
2. Feel the liquid line at the orifice location for extreme
cold, possibly accompanied by heavy frost, then feel
9 along the liquid lin.e after the orifice location for warm -
temperature.
Was the liquid line extremely cold at the orifice location
and warm after the orifice location? Go to Step 10 Go to Step 11
1. The orifice tut>e is nearly plugged or damaged/faulty
(opening too small).
3. Replace the qriflce tube.
Refer to Expansion (Orifice) Tube Filter
10 Replacement. - -
4. If the orifice tube was plugged or nearly plugged,
note the amount of debris present.
5. If heavy debris is present, components in-line before
the orifice may need to be flushed.
;
2. Carefully feel along the surfaces of the following low
side components for a sudden change in
temperature.
• The liquid line between the orifice and the
evaporator core
11 -
• The vapor hose between the evaporator core and
the accumulator
O The accumulator
• The compressor suction hose

Was an abrupt temperature change noted along the
surfaces of any of the components listed? Go to Step 12 Go to Step 13
1. Recover the refrigerant
2. Remove the restriction from the component, or
12 replace the component which produced an abrupt -- -
temperatur.e drop
Are the operations complete? Go to Step 17
Ensure that the. A/C has been operating for several
minutes.
2. Carefully feel along the surfaces of the following low
AND high side components to compare the overall
temperatures of the low and high sides.
O The liquid line between the orifice and the
evaporator core
• The vapor hose between the evaporator core and
13 the accumulator -
• The accumulator
• The compressor suction hose
) • The compressor discharge hose
• The condenser
• The liquid line between the condenser and the
orifice.
Are the overall temperatures of the low and high side
components close to the same (both only mildly warm)? Go to Step 14 Go to Step 18
Cooling Insufficient, A/C System - Pressure Zone D (cont'd)
2. Disconnect the compressor hose from the
compressor.
Refer to Compressor Hose Assembly
Replacement (3.8 L) or Compressor Hose Assembly
14
Replacement (5. 7 L).
-
. 3. Inspect for the presence of heavy debris on the
compressor suction port screen.
Is heavy debris present on the compressor suction port
screen? Go to Step 15 Go to Step 16
1. Remove the debris from the suction port screen.
2. Inspect the orifice for damage, in order to determine if
the debris originated from the high side.
3. If the orifice does not show any signs of damage,
15 inspect the accumulator for damage, in order to - -
determine if the debris originated from the
evaporator core.
4. Replace any components found damaged.
Is the repair complete? .. Go to Step 17
Install components or connectors which were removed or
16 disconnected. - -
Is the action complete? Go to Step 17
17
- -
2. With an accurate thermometer still installed to the IP
(
center air outlet.
7. Compare the low and high side pressures
and the output temperatures to those listed in the
A/C Performance Table. Go to A
Diagnostic
Refer to Cooling Insufficient, A/C System. System Check in
Are both t.he low and high side pressures as well as the HVAC Systems -
(
Defrosting Insufficient 4. Inspect for the incorrect operation of the controls.
1, Inspect for an obstruction in both of the defroster Advise the driver of the proper operation of the
nozzles. controls.
Perform the following steps, as necessary: 5. Inspect the engine for low engine coolant level.
• Remove any foreign objects. Perform the following steps, as necessary:
• .Repair any loose instrument panel pad that • Add coolant.
blocks an outlet. • Inspect the engine for coolant leaks.
2. Inspect for the proper operation of the defroster • Run the engine in order to clear any air locks.
air valve. 6. Inspect for a faulty engine thermostat.
3. Inspect for one of the following conditions. Replace the thermostat, if necessary.
Replace the defroster vacuum actuator or hose if 7. Inspect for a kinked heater hose.
one of the following conditions exist:
Perform the following steps, as necessary:
• A faulty defroster air valve vacuum actuator
'" Straighten tile heater hose.
• A faulty defroster air valve vacuum hose
• Replace the heater hose.
4. Inspect for insufficient heating.
8. Inspect for obstructed heater core tubes.
Refer to Heating Insufficient.
An obstruction usually causes a squishing noise in
the heater core.
Heating Insufficient Perform the following steps, as necessary:
1. Inspect the duct work for the following conditions: • Remove any foreign material from the
• The proper installation heater core.
• Obstructions • Replace the heater core.
2. Inspect the blower operation. 9. Inspect for one of the following conditions:
3. Inspect the following components for the proper • A faulty blower motor
installation and the proper operation: Replace a faulty blower motor.
• The temperature lever • A faulty blower circuit
• The temperature motor Repair or replace faulty wires or connecUons.
Noise Diagnosis - Blower Motor
DEFINITION: Noise originating from the blower motor and/or the air delivery system. No loss of battery or ground is
occurring in the blower motor circuit. The blower motor resistor and the blower motor are not exhibiting any intermittent
internal shorts. For electrical diagnosis of the blower motor circuit, refer to Blower Motor Inoperative at Any Speed in HVAC
Systems - Manual
Were you sent here from A Diagnostic System Check? Go to A
Diagnostic
1 - System Check in
HV AC Systems -
Go to Step 2 Manual
1. Sit inside the vehicle.
2. Close the vehicle doors and windows.
3. Turn the ignition switch to ON; engine OFF.
4. Turn the blower switch to position 5 (high).
5. Set the temperature control to full cold.
6. Set the mode control to UPPER (1/P outlets).
7. Cycle through all the blower motor speeds, modes
(including outside air and recirc) and temperature
2 control positions to determine where noise occurs -
and where noise does not occur.
8. Attempt to define the type of noise:
• Scrape, pop
• Tick/click, chirping, groaning, scraping
) • Air rush/whistle
Is a scrape or pop noise evident when selecting modes or
temperature settings (moving a mode or temperature
valve)? Go to Step 12 Go to Step 3
Noise Diagnosis - Blower Motor (cont'd)
Step . Action Value(s) Yes No
Is a tick/click, chirping, groaning or scraping noise present
3 - constantly but decreases as. blower motor speed is -
decreased, or only at start-up/intermttent - in all modes? Go to Step 6 Go to Step 4
Is an air rush/whistle noise evident in all modes but not all
4
temperature settings?
Is an air rush/whistle noise evident only in defrost or
5 lower mode?
- Go to Step 14 Go to Step .15
Check for blower motor and impeller excess vibration at
6 each blower motor speed by feeling the blower case. -
Is excessive .vibration present? Go to Step? Go to Step 9
1. Remove the blower motor (w/impeller).
Refer to Blower Motor and Fan Replacement.
2. Examine the blower motor impeller for the following
conditions:
• Deposits of foreign material
• Wear spots
7 -
• Cracked blades
• Cracked hub
• Loose impeller retainer
• Improper impeller alignment
Does the blower motor impeller exhibit any of these
abnormal conditions? Go to Step B Go to Step 9
1. Repair or replace the blower motor impeller.
2. Install the blower motor and impeller.
8
- -
(
1. Remove the blower motor (w/impeller).
9 2. Check for the presence of foreign material at the -
opening of the blower intake.
Was foreign material found? Go to Step 11 Gb to Step 10
1. Replace the blower motor.
2, Install the blower motor and impeller.
10 - -
1. Remove the foreign material from the blower case.
11 2. Repair as necessary. - -
Is the action complete? Go tb Step 17
1. Remove the instrument panel (IP) upper trim pad.
Refer to Trim Pad Replacement - IP Upper in
Instrument Panel, Gauges and Console.
12 2. Check the defroster, mode, air inlet and temperature ·- -
valve function.
3. Repair or replace as necessary.
(
Noise Diagnosis - Blower Motor (cont'd)
1. Remove the IP upper trim pad.
13
2. Check the t$mperature valve seals.
- -
lnstr.ument Panel, Gauges and Console.
2. Check the ducts tor obstructions or foreign materials.
14
3. Remove any obstructions or foreign material found.
- -
4. Check the defroster valve function.
2; Check the ducts tor obstructions or foreign materials.
15
3. Remove any obstructions or foreign material found.
- -
4. Check the defroster valve seals.
•
1. Turn OFF the ignition switch.
2. Reconnect or install any connectors or components
which were disconnected or removed. Go to A
16 - . Diagnostic
3. Recheck tor the presence of blower motor/air delivery System Check in
system noise. HVAC Systems -
Is the noise still present? Go to Step 10 Manual
2. Reconnect or install any connectors or components
which were disconnected or removed. Go to A
17 - Diagnostic
3. Recheck tor the presence of blower motor/air delivery System Check in
system noise. HV AC Systems -
Is the noise still present? Go to Step 2 Manual
)
Noise Diagnosis - A/C System
Were you sent here from A Diagnostic System Check? Go to A
Diagnostic
1 - System Check in
HVAC Systems -
Go to Step2 Manual
1. Sit inside the vehicle.
2. Close the vehicle doors and windows.
3. Turn the ignition switch to the ON position;
engine OFF.
4. Turn the blower switch to position 5 (high).
2 -
5. Set the temperature con.trol to the full cold position.
6. Set the mode control to the UPPER (1/P outlets).
7. Depress the air conditioning (A/C) button to the OFF Go to Noise
position. Diagnosis -
Is an abnormal noise present? Blower Motor Go to Step 3
.
1. Start the engine and allow the engine to idle Go to HVAC
in PARK. Compressor
2. Depress the A/C button to the ON position. Clutch Does_ Not
3 - Engage in HVAC
Is the A/C clutch engaged and supplying cold air to the Systems -
passenger compartment?
Go to Step 4 Manual
A/C system noises can be generally categorized into
three areas:
• Screech/Squealing noises
4 • Moaning noises -
• Vibration/Rattle noises (
Is a screech/squealing noise heard when the A/C clutch is
engaged? Go to Step 5 Go to Step 14
Inspect the A/C compressor drive belt for excessive wear
5 or oil coverage. -
Is the drive belt excessively worn or covered with oil? Go to Step 6 Go to. Step 7
!
1. Repair the source of the oil leak, if a leak was
present.
Refer to Oil Leak Diagnosis in Engine Mechanical.
2. Replace the A/C compressor drive belt. -
6 -
Refer to Drive Belt Replacement in Engine
Mechanical - 3.8 L or Drive Belt Replacement - A!C in
Engine Mechanical - 5. 7 L.
1. Start the engine and allow the engine to idle
in PARK.
2. Engage the A/C compressor clutch.
7 3. Using a stethoscope, check the A/C compressor drive -
belt idler pulley for any abnormal noises.
Is the idler pulley-operating normally without
abnormal noise? Go to Step 9 Go to Step 8
Replace the A/C compressor drive belt idler pulley. Refer
to Drive Belt Idler Pulley Replacement in Engine
8 Mechanical - 3.8 L or Drive Belt Idler Pulley Replacement - - -
A!C in Engine Mechanical - 5.7 L.
HVAC Heating, Ventilation and Air Conditioning 1..;25
Noise Diagnosis -.A/C System (cont'd)
1. A/C compressor clutch engaged and engine idling
in PARK.
2. Using a stethoscope, check the A/C compressor drive
belt tensioner pulley for any abnormal noises.
9 -
3. Turn the ignition switch to the OFF position.
4. Check the tensioner for proper spring load
Is the tensioner pulley operating normally with proper
tension and without noise? Go to Step 11 Go to Step 10
Replace the A/C compressor drive belt tensioner/tensioner
pulley as needed. Refer to Drive Belt Tensioner
Replacement in Engine Mechanical - 3.8 L or Drive Belt
10 Tensioner Replacement - A/C in Engine - -
Mechanical - 5.7 L.
11 Is the A/C compressor locked up? - Go to Step 12 Go to Step 13
2. Replace the A/C compressor.
Compressor Replacement (5. 7 L).
2. Remove the A/C compressor clutch coil.
Refer to Compressor Clutch Coil Removal·
(VS - Conventional Mount) or Compressor Clutch Coil
) 13
Removal (V7 - Direct Mount).
- -
3. Install the compressor clutch coil.
Refer to Compressor Clutch Coil Install
(VS - Conventional Mount) or Compressor Clutch Coil
Install (V7 - Direct Mount).
Does a moaning noise exist when the A/C clutch is
14 -
1. Connect an R-134a manifold gage set to the low and
high side service ports on the vehicle refrigerant
system.
2. Increase and maintain the engine speed at
2000 RPM, in PARK.
3. Engage the A/C clutch.
15
4. Check the low and high side refrigerant pressures.
-
5. Compare the pressure readings to those listed in the
Cooling Insufficient, A/C System.
Refer to Cooling Insufficient, AIC System.
Are the high and low side refrigerant pressures withiri the
normal specified limits? Go to Step 17 Go to Step 16
1. Recover the refrigerant, evacuate and charge the
refrigerant system to specifications.
2. Start the engine and allow the engine to idle
16 in PARK. -
3. Engaged the A/C compressor clutch.
Does the moaning noise exist when the A/C clutch is
)
Inspect the A/C compressor mounting, idler pulley, and
tensioner for concerns using a stethoscope.
17 -
Are any of these components loose, damaged or
excessively worn? Go to Step 18 Go to Step 19
Noise Diagnosis -A/C System (cont'd)
I·
Repair or replace the A/C compressor mounting, idler
pulley or tensioner/tensioner pulley as needed.
• For A/C compressor drive belt idler pulley
replacement, refer to Drive Belt Idler Pulley
Replacement in Engine Mechanical - 3.8 L or Drive
Belt Idler Pulley Replacement - A/C in Engine
18 Mechanical - 5.7 L. - -
• For A/C compressor drive belt tensioner/tensioner
pulley replacement, refer to Drive Belt Tensioner
Replacement in Engine Mechanical - 3.8 L or Drive
Belt Tensioner Replacement - A/C in Engine
Mechanical - 5.7 L.
Is the repair or replacement complete? Go to Step 30
in PARK.
2. Using a stethoscope, move around the entire
19 refrigerant plumbing system checking for any -
abnormal noises being caused by component
ground-out.
Are any of the A/C components grounding out and causing
a noise? Go to Step 20 Go to Step 21
1. Recover the refrigerant, if necessary.
2. Repair or replace the component which is causing the
20
moaning concern as needed.
- -
Is the repair or replacement complete? Go to Step 31
Does the concern go away with the A/C clutch disengaged Go to Engine
and the engine idling in PARK? Related Vibration
2·1 - in Vibration
Diagnosis and
Go to Step 22 Correction
2. Replace the A/C compressor.
Compressor Replacement (5. 7 L). i
Is the_ repair complete? Go to Step 31

Does a vibration or rattle noise exist when the A/C clutch
23 -
is engaged? Go to Step 24 System OK
Inspect the A/C compressor mounting, idler pulley, and
tensioner for concerns using a stethoscope.
24 -
Are any of these components loose, damaged or
excessively worn? Go to Step 18 Go to Step25
25 Is the A/C compressor drive belt misaligned ? - Go to Step 26 Go to Step 27
Repair any alignment concern with the A/C pulley system
and replace the drive belt as needed. Refer to Drive Belt
26 Replacement in Engine Mechanical - 3.8 L or Drive Belt - -
Replacement - AIC in Engine Mechanical - 5.7 L.
in PARK.
2. Using a stethoscope, move around the entire
27 A/C system checking for any abnormal noises being -
caused by a component.
Are any of the A/C components causing an
aonormal noise? Go to Step 28 Go to Step 29
(
2. Repair or replace the component which is causing the
28
vibration/rattle concern as needed.
- -
Noise Diagnosis - A/C System (cont'd)
Is th!,! vibration/rattle coming from the A/C compressor Go to Engine
.internally? Related Vibration
29 - in Vibration
Diagnosis and
Go to Step 12 Correction
2. Reconnect or install any connectors or components Go to A
Diagnostic
30 which were disconnected or removed. - System Check in
3. Recheck for the presence of the A/C system noise. HVAC Systems -
Is the A/C system noise still present? Go to Step 2 Manual
t. Evacuate and charge the refrigerant system.
31
- -
Are the actions completed? Go to Step 32
Recheck for the presence of the A/C system noise. Go to A
Is the A/C system noise still present? Diagnostic
32 - System Check in
HV AC Systems -
Go to Step 2 Manual
Cold Drafts on Floor 2. Inspect all of the side door seals for the following
conditions. Repair or replace faulty seals as
1. Inspect for a partially open air inlet valve.
necessary.
Ensure that the air inlet valve closes properly in all
modes except the MAX air conditioning mode. .. Damaged seals
Perform repairs as necessary. • Missing seals
) Odor Diagnosis
'
Problem Possible Cause Correction
O Locate and repair any water leaks.
• Water leaks (body) Refer to the appropriate repair
• The evaporator drain is blocked. procedure in Water Leaks.
Musty Smell
• There is mold or mildew on the • Clean the evaporator drain.
evaporator core. ~ Clean the evaporator. Refer to Odor
Correction.
• Replace the heater core. Refer to
Heater Core Replacement.
• The heater core is leaking. • Replace the heater core pipes or
Coolant Smell • The heater core pipes or hoses are hoses. Refer to Heater Hose
leaking. Assembly Replacement {3.8 L) or
Heater Hose Assembly
Replace the evaporator core. Refer to
Refrigerant Oil Smell The evaporator core is leaking.
' Evaporator Core Replacement.
Mold/mildew odor problem-Under certain climate and operating conditions a musty odor can develop. The odor is caused
by a microbial growth in the evaporator core. This odor is generally temporary, and as climate conditions change, the odor
will disappear. Should the odor persist it may become necessary to clean the evaporator core with an appropriate cleaner.
Repair Instructions
Odor Correction 6.3. Use short spray bursts and vary the (
direction of spray for a 2-3 minute period
Eliminating Air Conditioning Odor of time, in order to dispense the contents of
Odors may be emitted from the air conditioning the can into the duct.
system primarily at start up in hot, humid climates. 7. Shut the engine OFF. Allow the vehicle to s~ for
The following conditions may cause the odor: 3-5 minutes.
" Debris is present in the heating, ventilation and air 8. Seal the 3.175 mm (0.125 in) hole with body
conditioning (HVAC) module. sealer or RTV gasket compound.
" Microbi.al growth on the evaporator core. 9. Start the engine.
When the blower motor fan is turned on, the microbial 10. Operate the blower motor on high for
growth may release an unpleasant musty odor into 15-20 minutes to dry.
the passenger compartment. 11. Reconnect the A/C compressor clutch coil
A service kit that can correct the condition is available electrical connector.
through General Motors Service Parts 12. Verify proper clutch operation.
Operation (GMSPO) to address this condition.
To remove odors of this type, it is necessary to
Refrigerant Recovery and Recharging
eliminate the mirocbial growth and prevent its
recurrence. To accomplish this, these two procedures Tools Required
0 J 39500-B AIC Refrigerant Recovery, Recycling
must .be completed.
• Deodorize the evaporator core using Deodorizing and Recharging (ACR4) System
O J 41810 PureGuard 2
Aerosol Kit P/N 12377951
.. Install the new air conditioning (A/C) Delayed " J-41810-100A Active Flow Control Valve
Blower Control Package, P/N 12370470 Caution: Refer to Caution - Breathing R-134a in
The blower control package will enable the blower to Cautions and Notices.
run at high speed for 5 minutes. It will do so Caution: For personal protection, goggles and
approximately 50 minutes after the ignition has been gloves should be worn and a clean cloth wrapped
turned off it the compressor had been engaged for 4 or around fittings, valves, and.connections when
more minutes prior to shutting off the engine. By doing work that includes opening the refrigerant (
doing so, the evaporator case and core are dried out, system. If R-134a comes in contact with any part of .
reducing the chances of a recurring A/C odor. the body severe frostbite and personal injury
Perform the following steps in order to deodorize the can result. The exposed area should be flushed
A/C system: immediately with cold water and prompt medical
1. Ensure that the plenum that draws outside air into help should be obtained.
the HVAC module is clear of all debris. Notice: R-i 34a is the only approved refrigerant for use
2. Disable the A/C compressor clutch operation by in this vehicle. The use of any other refrigerant may
disconnecting the clutch coil electrical connector. result in poor system performance or component failure.
3. Dry the evaporator core by performing the Notice: To avoid system damage use only R-134a
following steps: dedicated tools when servicing the A/C system.
Notice: Use only Polyalkylene Glycol Synthetic
3.1. Start the vehicle.
Refrigerant Oil (PAG) for internal circulation through the
3.2. Set the temperature control on R-134a A/C system and only 525 viscosity mineral oil
maximum heat. on fitting threads and 0-rings. If lubricants other than
3.3. Set the control to the MAX setting. those specified are used, compressor failure and/or
3.4. Run the blower motor on high for fitting seizure may result.
10 minutes. Notice: R-12 refrigerant and R-134a refrigerant must
4. Locate an area in the air conditioning duct never be mixed, even in the smallest of amounts, as
between the blower motor and the evaporator core they are incompatiblE:l with each other. If the refrigerants
downstream of the blower motor. are mixed, compressor failure is likely to occur. Referto
5. Drill a 3.175 mm (0.125 in) hole where it will not the manufacturer instructions included with the service
interfere with, or damage the following equipment before servicing.
components: The J 39500-8 removes the Refrigerant-134a from the
" The blower motor vehicle's A/C system. The recovery procedure uses
• The evaporator core one filtering cycle. The evacuation procedure uses an
" Any other operating part the of system automatic multiple pass filtering cycle. These
6. Wear safety goggles and latex gloves in order to filtering cycles ensure a constant supply of clean, dry
perform the following actions: refrigerant for A/C system charging.
6.1. Continue to operate the blower motor The Initial Set-Up Instruction Manual, provided with (
on high. the J 39500-B, contains specific procedures for proper
6.2. Insert the extension tube of the deodorizer recovery, evacuation and recharging.
GM P/N 12377951 into the hole, past the For ACR4 technical assistance in the U.S., call
mark on the extension tube. 1-800-345-2233.
HVAC Heating, Ventilation and Air Conditioning 1.;29
Compressor Replacement (3.8 l)
) Removal Procedure
Important: Compressor related noise is generally air
conditioning (A/C) system related and not always
caused by the compressor itself. Prior to replacing
compressor, refer to Noise Diagnosis - A/C System.
1. Recover the refrigerant. Refer to Refrigerant
Recovery and Recharging.
2. Remove the serpentine drive belt. Refer to Drive
Belt Replacement in Engine Mechanical - 3.8 L.
3. Disconnect the electrical connector at the air
conditioning (A/C) compressor.
365420
4. Remove the negative battery cable nut from the

engine block stud.
5. Remove the negative battery cable from the stud.
6. Raise and support the vehicle. Refer to Lifting
and Jacking the Vehicle in General Information.
43679
7. Remove the A/C compressor and condenser

hose bolt.
8. Discard the 0-ring. ',..__---,
G'(_'---
569444
9. Remove the A/C compressor rear bolts (2, 3).
1
365440
10. Remove the A/C compressor bolts.

11. Remove the A/C compressor.
282953
Installation Procedure
Important: NEW A/C compressors are shipped
WITHOUT poly-alkylene glycol (PAG) oil.
1. If a NEW A/C compressor is being installed, add
60 ml (2 oz) of PAG oil to the compressor.
2. If reinstalling the old A/C compressor perform the
following:
2.1. Drain, measure and record the amount of
PAG oil in the A/C compressor.
2.2. If the measured amount of PAG oil drained
is less than or equal to 60 ml (2 oz), add
60 ml (2 oz) of new, clean PAG oil to
the A/C compressor.
is greater than 60 ml (2 oz), add the same
amount of new, clean PAG oil to the
A/C compressor.
282953
Notice: Refer to Fastener Notice in Cautions and
Notices.
2.4. Install the compressor crankcase oil drain
bolt to the replacement compressor.
Tighten
Tighten the compressor crankcase oil drain
bolt to 20 N-m (15 lb ft).
3. Install the A/C compressor.
4. Install the A/C compressor bolts.
Tighten
Tighten the A/C compressor bolts to
50 N,m (37 lb ft).
5. Install the A/C compressor rear bolts (2, 3).
Tighten 1
Tighten the A/C compressor rear bolts (2, 3) to
30 N·m (22 lb ft).
365440
6. Install a new 0-ring.

Lightly coat the 0-ring with a mineral
base 525 viscosity refrigerant oil.
7. Install the A/C compressor and condenser
hose bolt.
Tighten
Tighten the A/C compressor and condenser hose
bolt to 33 N·m (24 lb ft).
8. Lower the vehicle.
569444
)
9. Install the negative,battery cable to the stud.
10. Install the negative battery cable nut to the engine
block stud. (
Tighten
Tighten the negative battery cable nut to the
engine block stud to 25.N·m (18 lb ft).
43679
11 . Connect the electrical connector at the

A/C compressor.
12. Install the serpentine drive belt. Refer to Drive
13. Charge the A/C system. Refer to Refrigerant
14. Perform a leak test on the A/C system. Refer to
Leak Testing.
365420
Compressor Replacement (5.7. L)

Removal Procedure
Important: Compressor related noise is generally air
conditioning (A/C) system related and not always
the compressor itself. Prior to replacing the
compressor, refer to Noise Diagnosis - AIC System.
2. Raise and suitably support the vehicle. Refer to
Information.
Belt Replacement - AIC in Engine
Mechanical - 5.7 L.
4. Remove the air conditioning (A/C) compressor
(
and condenser hose bolt.
5. Discard the 0-ring.
365448
6. Remove the transmission oil cooler pipes from the
engine bracket, if necessary.
)
208334
7. Disconnect the electrical connector from the

A/C compressor.
365446

282955
HVAC
Important: NEW A/C compressors are shipped
WITHOUT poly-alkylene glycol (PAG) oil.
1. If a NEW A/C compressor is being installed, add
60 ml (2 oz) of PAG oil to the compressor.
2. If reinstalling the old A/C compressor perform the
following:
PAG oil in the A/C compressor.
is less than or equal to 60 ml (2 oz), add
60 ml (2 oz) of new, clean PAG oil to
the A/C compressor.
is greater than 60 ml (2 oz), add the same
amount of new, clean PAG oil to the
A/C compressor.
282955
Notices.
2.4. Install the compr13ssor crankcase oil. drain
bolt (1) to the replacement compressor:
Tighten
Tighten the compressor crankcase oil drain
bolt (1) to 20 N-m (15 lb ft).
Tighten (
50 N·m (37 lb ft).
5. Connect the electrical connector to the
A/C compressor.
365446
(
HVAC Heating, Ventilation and Air Condjtioning 1-35
6. Install the transmission oil cooler pipes to the
engine bracket, if removed.
208334

Lightly coat the 0-ring with a mineral
hose bolt.
Tighten
) 9.
Install the serpentine drive belt Refer to
Drive Belt Replacement - AIC in Engine
Mechanical 5.7 L.
11. Recharge the A/C system. Refer to Refrigerant
Leak Testing.
365448

Assembly Removal (V5 Conventional
M
J 33022
Moa.mt)
Tools Required
" J 33022 Shaft Nut Socket
" J33027-A Clutch Hub Holding Tool
" J33013-B Hub And Drive Plate Remover And
Installer
"' J 34992 Compressor Holding Fixture
i. Clamp the J 34992 in a vise.
2. Attach the compressor to the holding fixture using
the thumb screws.
3. Use the J 33027-A in order to prevent the clutch
hub and drive plate assembly from turning.
4. Use the J 33022 in order to remove the shaft nut.
237075
5. Thread the J 33013-8 into the hub.
J33013-B 6. Use a wrench in order to hold the body of the
J 33013-8.
7. Turn the center screw into the body of the
J 33013-8 in order to remove the clutch plate and
hub assembly.
8. Remove the shaft key. Retain the shaft key for
reassembly.
237077

Assembly Removal (V7 - Direct Mount)
Tools Required
• J 33013-8 Hub and Drive Plate Remover/Installer
• J 33027-A Clutch Hub Holding Tool
• J 41790 Compressor Holding Fixture
1. Remove the compressor from the vehicle. (
2. Clamp the compressor holding fixture, J 41790 in
a vise and attach the compressor to the J 41790.
157595
3. Hold the clutch hub and drive plate assembly (2)

in place using the J 33027-A.
4. Remove the compressor shaft nut with a
13 mm socket (1).
157218
5. Thread the J 33013-8 into the hub.
6. Remove the hub and drive plate assembly (1) by J 33013-B
) turning the center screw into the body of the
J 33013-8 and against the compressor shaft.
1
7. Remove the shaft key and retain for reassembly.
157221
Clutch Rotor and/or Bearing Removal

(VS - Conventional Mount)
Tools Required
)
/
• J 6083 Snap Ring Pliers
• J 9398 Bearing Remover
• J 8092 Driver Handle J 34992
) • J 33020 Pulley Puller
• J 33023-A Puller Pilot
1. Remove the clutch plate and hub assembly. Refer
to Compressor Clutch Plate and Hub Assembly
Removal (V5 - Conventional Mount).
2. Use the J 6083 in order to remove the rotor and
bearing assembly retaining ring.
237119
3. Install the J33023-A to the front head ..

J33023-A
237120
1.:3g Heating, Ventilation and Air Conditioning HVAC
4. Install the J 33020 into the inner circle of. slo1s in
the rotor.
5. Turn the J33020 clockwise in the slots in order to
engage the tangs of the puller with the segments
between the slots in the rotor.
6. Hold the J 33020 in place. Tighten the puller
screw against the puller guide in order to
remove the puller rotor and bearing assembly.
237121
7. Support the rotor hub in order to prevent damage

to the pulley rotor during bearing removal.
7.1. Remove the forcing screw from the
J 33020.
7.2. With the tangs of the J 33020 still engaged
in the rotor slots, invert the assembly onto a
solid, flat surface or blocks.
J 9398-A
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.
8. Use a J 9398 with the J 8092 in order to drive the
bearing out of the rotor hub.
J 33020
210141
Clutch Rotor and/or Bearing Removal

(V7 Direct Mount)
D
Tools Required
" J 33023-A Puller Pilot
• J 41552 Compressor Pulley Puller
O J 41790 Compressor Holding Fixture
1. Remove the compressor from the vehicle.

157595
HVAC Heating, Ventilation and Air Conditioning 1·39
Removal (Vl - Direct Mount).
4. Using external snap ring pliers (1 ), remove the
clutch rotor and bearing assembly retaining
ring (3). J 41790
157223
5. Place the J 33023-A on the clutch rotor.
157224
6. Install the·J 41552 down into the inner circle of

slots in the rotor.
Turn the J 41552 clockwise in the slots to engage
J 41552
the puller tangs with the rotor.
7. Hold the J 41552 in place and use a wrench to
turn the center forcing screw against the
J 33023-A to remove .the clutch rotor and bearing
assembly.
157225
Compressor Clutch Coil Removal
) Tools Required
/
• J 8433-1 Puller Bar
J 34992 " J 8433-3 Forcing Screw
• J 33020 Pulley Puller
• J 33025 Clutch Coil Puller Legs
Removal (VS - Conventional Mount).
2. Use the J 6083 in order to remove the rotor and
bearing assembly retaining ring.
237119
3. Install the J 33023-A to the front head.

J33023-A
237120
4. Install the J 33020 into the inner circle of slots in

the rotor.
5. Turn the J 33020 clockwise in the slots in order to
engage the tangs of the puller with the segments
between the slots in the rotor.
6. Hold the J 33020 in place. Tighten the puller
screw against the puller guide in order to
remove the puller rotor and bearing assembly.
237121
7. Mark the location of the clutch coil terminal (1) on
the compressor front head.
J 8433-1 J 8433-3
8. Install the J 33023-A on the front head of the
compressor.
9. Install the J 8433-1 and the J 8433-3 with the
J 33025 on the front head of the compressor.
10. Tighten the J 8433-3 against the J 33023-A in
order to remove the clutch coil (2).
1
J 33023-A
237123
Compressor Clutch Coil Removal

(V7 · Direct Mount)
Tools Required
.. J 8433-3 Forcing Screw
" J 33023-A Puller Pilot
) " J 33025 Clutch Coil Puller Legs
157595
3. Remove the compressor clutch plate and hub

assembly. Refer to Compressor Clutch Plate and
Hub Assembly Removal (V7 - Direct Mount).
4. Install the J 33023-A onto the front hea.d of the
compressor.
5. Remove the compressor rotor and bearing
assembly. Refer to Clutch Rotor and/or Bearing
Removal (V7 - Direct Mount).
157224
6. Mark the clutch coil terminal location (2) on the
J 8433-3 compressor front head.
7. Install the J 33025 onto the J 8433.
8. Install the J 8433 onto the compressor clutch
coil (1) and tighten the puller leg bolts.
9. Tighten the center forcing screw J 8433-3 of 1he
compressor pulley puller J 8433 against the
J 33023-A to remove the compressor clutch coil
from the compressor.
10. Remove the J 8433-3, the J 33023-A, the J 33025
and the J 8433.
157234
Compressor Control Valve Assembly

Removal (VS - Conventional Mount)
Tools Required
" J 39500-8 A/C Refrigerant Recovery, Recycling
and Recharging (ACR4) System
1. Recover the refrigerant using the J 39500-B.
2. Remove the control valve retaining ring using
(
the J 5403.
3. Remove the control valve assembly (5).
237069

Removal (V7 - Direct Mount)
Tools Required
J 41790 Compressor Holding Fixture
157595
3. Using internal snap ring pliers, remove the
compressor control valve retaining ring.
) 4. Remove the compressor control valve from the
compressor.
214740
Compressor Shaft Seal Removal

(V5 · Conventional Mount)
Tools Required
• J 39400-A Electronic Halogen Leak Detector
• J 9553-01 0-Ring Remover
) • J 5403 Snap Ring Pliers
• J23128-A Seal Seat Installer and Remover
Important: Do not change a shaft seal because of
small amounts of oil found on an adjacent surface.
The seal allows some oil to pass for lubrication
purposes. Change the shaft seal when the following
conditions exist:
• A large amount of sprayed oil is found.
• Actual refrigerant leak is found, using a J 39400-A
or equivalent.
1. Install the compressor into the J 34992. 237126

Removal (VS - Conventional Mount).
3. Remove the shaft seal retaining ring using
the J 5403.
4. In order to prevent dirt or foreign material from
damaging the compressor, thoroughly clean the
following parts:
• The inside of the compressor neck area
surrounding the shaft
• The exposed portion of the seal
• The compressor shaft
• The 0-ring groove
)
1 a44 Heating, Ventilation and Air Conditioning HVAC
Important: Securely hand-tighten the handle of the
J 23128-A. Do not use a wrench or pliers.
(
5. Fully engage the knurled tangs of the J 23128-A
J 23128-A into the recessed portion of the seal by turning
the handle clockwise.
6. Remove the seal from the compressor using a
rotary-pulling motion. Discard the seal.
210205
(
7. Remove the .seal 0-ring from the compressor
neck using the. J 9553-01. Discard the seal 0-ring.
J 9553-01
8. Inspect the shaft and the inside of the compressor
neck again for dirt and foreign material.
9. Ensure that the shaft and the inside of the
compressor neck are perfectly clean prior to
installing new parts.
237127
(
Compressor Shaft Seal Removal
(V7 - Direct Mount)
Tools Required
• J41790 Compressor Holding Tool
• J42136 AIC Lip Seal Remover
157595
3. Remove the compressor clutch plate and hub

assembly. Refer to Compressor Clutch Plate and
Hub Assembly Removal (Vl - Direct Mount).
4. Using internal snap ring pliers (1 ), remove the
compressor shaft seal retainer ring (2).
5. To keep any dirt or foreign material from getting
into the compressor, thoroughly clean the
following components:
) • The inside of the compressor neck area
surrounding the shaft
• The exposed portion of the compressor
shaft seal
• The compressor shaft
• The 0-ring groove
157228
6. Fully engage the lip of the J 42136 into the

recessed portion of the seal (1) by turning the
handle clockwise.
7. Remove the compressor shaft seal from the
compressor with a rotary pulling motion.
8. Recheck the shaft and inside of the compressor
neck for dirt or foreign material and make sure
1hese areas are perfectly clean before installing
1he new compressor shaft seal.
157231
HVAC
Removal (V5 - Conventional Mount)
(
Tools Required
J 39500-8 A/C Refrigerant Recovery, Recycling and
Recharging (ACR4) System
1. Recover the refrigerant using the J 39500-8.
2. Remove the pressure .relief valve (2).
237069

Removal (V7 - Direct Mount)
Tools Required
(
157595
3. Remove the pressure relief valve from the rear

head of the compressor.
186933
Compressor Control Switches Removal
(VS · Conventional Mount)
Tools Required
• J 9553-01 0-Ring Remover
• J39500-B R-134a Air Conditioning Refrigerant
Recovery, Recycling And Recharging System
1. Recover the refrigerant using the J 39500-8.
switch (3 or 4) in the rear head of the compressor.
3. Remove the switch retaining ring using the J 5403.
4. Remove the switch (3 or 4) from the compressor.
Notice: If the existing switch will be reinstalled in the
compressor, a new 0-ring seal must be used and
preferably a new retainer should also be used. A new
switch kit has the 0-ring and retainer ring included.
5. Remove the old 0-ring seal from the switch cavity
using the J 9553-01.
237069

Install (VS - Conventional Mount)
Tools Required
J 5403 Snap Ring Pliers
1. Coat the 0-rings with 525 viscosity
refrigeration oil.
) 2. Using thumb pressure, push the 0-rings in place.
Important: Ensure that the retaining ring is properly
seated in the ring groove.
3. Using the J 5403, install the valve retaining
ring (5) with the high point of the curved sides
against the valve housing.
4. Evacuate the system. Recharge the system.
5. Perform a leak test. Refer to Compressor Leak
Testing (V5 - Conventional Mount).
237069

Install (V7 - Direct Mount)
Tools Required
1. Coat the control valve 0-rings with
clean 525 viscosity refrigeration oil.
2. Push the compressor control valve into the
compressor with thumb pressure.
3. Using internal snap ring pliers, install the
compressor control valve retaining ring.
Make sure the retaining ring is properly seated in
the ring groove.
4. Remove the compressor from the J 41790.
5. Install the compressor into the vehicle.
214740
Compressor Clutch Plate/Hub Assembly
1 Install (VS - Conventional Mount) (
Tools Required
• J 33013-8 Hub And Drive Plate Remover And
Installer
2 • J 33022 Shaft Nut Socket
O J 33027-A Clutch Hub Holding Tool
1. Install the compressor into the J 34992.
3 2. Install the shaft key (4) into the key groove of the
clutch plate arid hub (1 ).
• Allow the key to project 3.2 mm (0.126 in) out
of the key groove. ·
• The shaft key is curved slightly in order to
provide an interference fit in the key groove of
the hub.
237078
3. Clean the frictional surfaces of the clutch plate
and hub and the clutch pulley rotor (2).
4. Align the shaft key with the shaft keyway (3).
Notice: Do not drive or pound on the clutch hub or the
shaft. Internal damage to the compressor may
result.
5. Place the clutch plate and hub assembly onto the
compressor shaft.
6. Remove the center screw from the J 33013-B.
J 33013-B 7. Reverse the body direction of the center screw of
the J 33013-8.
8. Install the J 33013-8 with the bearing.
9. Back off the body of the J 33013-8 in order to
allow the center screw to be threaded onto the
end of the compressor shaft.
10. Hold the center screw of the J 33013-8 with a
wrench.
Notice: It 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.
11 . Tighten the. hex portion of the body of the
J 33013-8 in order to press the hub onto the shaft.
12. Tighten the body of the J 33013-8 several turns.
13. Remove the J 33013-8.
237079
14. Verity that the shaft key remains in the keyway
before installing the clutch plate and hub
assembly to the final position.
15. Ensure that the gap between the frictional
surfaces of the clutch plate and the clutch rotor is
within 0.40-0.50 mm (0.016-0.020 in).
17. Verify that the shaft key is even with or slightly
above the clutch hub.
18. Install the shaft nut. (
19. Hold the clutch plate and hub assembly with
the J 33027-A.
Notices.
20. Tighten the shaft nut against the crankshaft
shoulder, using a 17.5 N·m (12.5 lb ft) torque
wrench and the J 33022.
Tighten
Tighten the nut to 16.5 N-m (12 lb ft).
21. Spin the pulley rotor by hand in order to verify
that the rotor does not rub the clutch drive plate.
Compressor Clutch Plate/Hub Assembly

i
Install (V7 - Direct Mount)
Tools Required
• J 33013-8 Hub and Drive Plate Remover/Installer
• J 33017 Pulley and Bearing Assembly Installer
• J 33027-A Clutch Hub Holding Tool
1. Install the shaft key into the hub key groove (4)
approximately 3.2 mm (1/8 in) out of the keyway.
The shaft key is curved slightly to provide an
interference fit in the hub key groove.
2. Clean the surfaces of the clutch plate (1) and the
clutch rotor (2) before installing the clutch plate
and hub assembly.
3. Align the shaft key with the shaft keyway in the
clutch plate and the hub assembly and place
onto the compressor shaft (3).
157219

4.1 . Remove the center screw from the body of
the J 33013-8.
4.2. Install the center screw into the opposite
end of the J 33013-8.
5. Install the J 33013-8 and bearing tools (1) onto
the clutch plate (3) and the hub assembly (2).
5. 1. Back the body of the J 33013-8 off enough
to allow the center screw to be threaded
onto the end of the compressor shaft.
5.2. Thread the center screw several turns onto
the end of the compressor shaft.,
Do not tighten the center screw on the
compressor shaft.
6. Hold the center screw with a wrench.
6.1. Tighten the hex portion of the J 33013-B
body several turns. ·
6.2. Remove the J 33013-8 from the clutch
157222
plate and hub.
6.3. Make sure that the shaft key is still in place
in the keyway:
7. Reinstall the J 33013-8.
1.;50 Heating, Ventilation and Air Conditioning HVAC
8. Place a feeler gage between the clutch plate and
the clutch rotor.
(
Important: Make sure that the air gap is even all
around the clutch plate and hub assembly.
9. Tighten the hex portion of the J 33013-8 until the
air gap between the clutch plate and clutch rotor
is 0.40 mm (0.015 in).
187363

11. Hold the clutch plate and hub assembly (2) .with
the J 33027-A.
12. Install the compressor shaft nut.
Tighten
·Tighten the compressor shaft nut to
17.5N·m (13 lb ft).
13. Spin the pulley rotor by hand to make sure the (
rotor is not rubbing against the clutch drive plate.
157218

(V5 - Conventional Mount)
Tools Required
J8092 • J 6083 Snap Ring Pliers
• J 8092 Driver Handle ·
• J 8433-3 Forcing Screw
• J 9481-A Bearing Installer
• J 21352-A Support Block
• J 33017 Pulley And Bearing Assembly Installer
• J 33019 Bearing Staking Tool
(
210146
HVAC Heating, Ventilation.and Air Conditioning 1-51
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.
1. Place the pulley rotor on the J 21352-A in order to
fully support the rotor hub during the bearing
installation.
2. Align the new bearing with the hub bore.
3. Using the J 9481-A and the J 8092, drive the
bearing into the hub.
The J 9481-A applies force to the outer race of
the bearing.
4. Place the J 33019 and the staking pin in the
hub bore.
5. Shift the rotor and bearing assembly on the
J21352-A in order to fully support of the hub J 33019
under the location of the staking pin.
6. Use a heavy-duty rubber band (1) in order to hold
the stake pin in the guide of the J 33019.
Important: Do not allow a metal stake to contact the
outer face of the bearing in order to prevent.
distortion of the outer race.
7. Using care in order to prevent injury, strike the
staking pin of the J 33019. Properly position the
stake pin in the guide after each impact on the pin.
8. Continue to strike the pin of the J 33019 until
a stake, similar to the original stake, is formed
down to, but not touching, the bearing.
210151
9. Stake three places 120 degrees apart.
6147
1.;.52 Heating, Ventilation and Air Conditioning HVAC
iO. With the compressor mounted to the J 34992,
position the rotor and bearing assembly on the
J 8433-1 J 8433-3 front head. (
11. Position the J 33017 and the J 33023-A directly
over the inner race of the bearing.
12. Position the J 8433-1 on the J 33023-A.
13. Assemble the two through bolts and the washers
of the J 349Q2 through the slots of the J 8433-1 ..
14. Thread the tvvo through bolts into the· J 34992.
Ensure that the thread of the through bolts
engages the full thickness of the J 34992.
15. Tighten the J 8433-3 in the J 8433-1 in order to
force the pulley rotor and bearing assembly onto
the front head of the compressor.
16. If the J 33017 slips off direct, in-line contact With
inner face of the bearing, use the following steps:
J 33017 16.1. Loosen the J 8433-3.
16.2. Realign the J 33017 and the J .33023-A in
order to ensure that the in$taller clears the
237122 front head.
17. Install the rotor and bearing assembly retainer

ring using the J 6083. ·
) 18. Install the clutch plate and hub assembly. Refer to
/ Compressor Clutch Plate/Hub Assembly Install
(VS - Conventional Mount). ·
J 34992
(
237119

J 33013-B (V7 - Direct Mount)
Tools Required
" J 33013-B Hub and Drive Plate Remover/Installer
" J 33017 Pulley and Bearing Assembly Installer
1. Position the clutch rotor and bearing assembly (2)
onto the compressor.
2. Position the J 33017 and bearing (1) from the
J 33013-B directly over the inner race of the
bearing.
3. Place the washer (3) from the J 42126 tool kit
onto the body of the J 33013-B.
4. Remove the center screw from the body of (
the J 33013-8.
5. Install the center screw into the opposite end of
the J 33013-8.
157226
6. Back the body of the J 33013-8 oft enough to
allow the center screw to be threaded onto the
7. Thread the center screw several turns onto the
Do not tighten the center screw on the
compressor shaft.
8. Hold the center screw with a wrench.
9. Tighten the hex portion of the J 33013-8 body
several turns.
10. Remove the J 33013-8 from the clutch rotor and
bearing assembly.
11. Make sure that the clutch rotor and bearing (2) is
pressed onto the nose of the compressor far
enough to clear the groove for the retaining ring.
If the clutch rotor and bearing does not clear
the groove, repeat steps 7, 8 and 9.
12. Install the clutch rotor and bearing retaining
ring (3) using external snap ring pliers (1 ).
Make sure,.that the camphor side of the retaining
ring is facing up when the retaining ring is
being installed. ,
13. Install the clutch plate and hub assembly. Refer to
Compressor Clutch Plate/Hub, Assembly lnstal!
(Vl - Direct Mount).
)
157223
Compressor Clutch Coil Install

(VS · Conventional Mount) J 8433-1 J 8433-3
Tools Required
• J 33024 Clutch Coil Installer
• J 33025 Clutch Coil Puller Legs
1. Place the clutch coil assembly on the front head
with the terminals positioned at the marked
location.
2. Place the J 33024 over the ,internal opening of the
clutch coil housing.
3. Align the J 33024 with the compressor front head.
4. Center the J 8433-1 on the countersunk center
hole of the J 33024.
5. Install the through bolts and the washers of the 237124
J 34992 through the slots in the J 8433-1.
6. Thread the through bolts into the J 33025 in order
to achieve full fixture thickness.
Important: Ensure that the clutch coil and the J 33024
stay in-line during the installation.
7. Turn the J 8433-3 of the J 8433-1 in order to force
the.clutch coil onto the head.
8. With the compressor still mounted to the J 34992
and the coil seated on the front head, stake the
front head using a drift punch with a diameter
of 3.175 mm (0.125 in).
J 34992
237125
9. Stake the front head at 3 places 1.20. degrees

apart in order to ensure that the clutch coil ·
remains in position. . · ·
10. Ensure that the stake size is only one half' of the
area of the punch tip and only 0.28.c.:.0.35 mm
(0.010-0.015 in) in depth.
6997
11. With the compressor. mounted to the J 34992,

position the rotor and bearing ass~rnbly on th.e
J 8433-1 J 8433-3 front head. ·
12. Position the J 33017 and the J 33023-A directly
over the inner race of the bearing; .
13. Position the J 8433-1 on the J 33023-A.
14. Assemble the two through bolts and the washers
of the J 34992 through the slots of the J 8433-1.
15. Thread the two through bolts into the J 34992.
Ensure that the thread of the through bolts
engages the full thickness of the J 34992.
16. Tighten the J 8433-3 in the J 8433-1 in order to
force the pulley rotor and bearing assembly onto
the front head of the compressor.
17. If the J 33017 slips off direct, in-line contact With
inner face of the bearing, use the following steps: (
J 33017 17 .1. Loosen the J 8433-3.
17.2. Realign the J 33017 and the J 33023-A in
order to ensure that the installer clears the
237122
front head.
HVAC Heating, Ventilation and Air. Conditioning 1-55
18. Install the rotor and bearing assembly retainer
ring using the J 6083.
19. Install the clutch plate and hub assembly. Refer to )
Compressor Clutch Plate/Hub Assembly Install /
(VS - Conventional Mount).
20. Install the shaft nut.
J 34992
237119
Compressor Clutch Coil Install

(V7 - Direct Mount)
Tools Required
• J 33024 Clutch Coil Installer Adaptor
') • J 33025 Clutch Coil Puller Legs
• J.41790 Compressor Holding Fixture
1. Place the clutch coil assembly (1) on the front
head with the clutch coil terminal positioned at
the mark made during disassembly.
2. Place the J 33024 over the internal opening of the
clutch coil housing and align installer with the
compressor front head.
3. Install the J 8433-3 into the J 8433 and center the
screw in the countersunk center hole of
the J 33024.
157238
4. Install the 4 inch through bolts and washers from
the J 42136 tool kit into the J 33025 and attach
them to the compressor mounting boss.es.
5. Turn the center forcing screw of the J 8433 to
press the clutch coil onto the front head until
the clutch coil is fully seated.
Make sure the elute~ coil and the J 33024 stay
in-line with each other while pressing the
clutch coil onto the compressor.
6. Install the compressor clutch rotor and bearing
assembly. Refer to Clutch Rotorand/orBearing
Install (V7 - Direct Mount).
7. Install the compressor clutch plate and hub
assembly. Refer tci Compressor Clutch Plate/Hub
Assembly Install (V7 - Direct Mount).
) 8. Remove the compressor from the J 41790.
HVAC
Compressor Shaft Seal Install
(V5 - Conventional Mount) (
Tools Required
• J 23128-A Seal Seat Installer And Remover
• J 33011 0-Ring Installer
• J 34614 Shaft Seal Protector
• J 39500-8 AJC Refrigerant Recovery, Recycling
And Recharging System
• J 39893 Pressure Testing Connector
Notice: Seals should not be re-used. Always use a
new specification service seal kit. Be sure that the seal
to be installed is not scratched or damaged in any
way. Make sure that the seal is free of lint and dirt that
could damage the seal surface or prevent sealing.
1. Thoroughly clean the seal 0-ring groove in
the front head.
210186
2. Dip the new seal 0-ring in clean 525 viscosity
refrigerant oil.
Notice: Any attempt to use makeshift or inadequate
service tools or equipment may result in damage
and/or improper compressor operation.
3. Assemble the 0-ring onto the J 33011.
4. Install the 0-ring.
4.1. Insert the J 33011 into the compressor neck
until the installer bottoms out. (
Important: The top groove in the compressor neck is
for the shaft seal retainer ring.
4.2. Lower the moveable slide of the J 33011 in
order to release the 0-ring into the seal
0-ring lower grove. ·
4.3. Rotate the J 33011 in order to seat the
0-ring.
4.4. Remove the installer.
5. Dip the new shaft seal in clean 525 viscosity
refrigerant oil.
6. Assemble the seal to the J 23128-A by turning the
handle clockwise.
6.1. Ensure that the stamped steel case side of
the lip seal engages with the knurled tangs
of the J 23128-A.
6.2. Ensure that the flared-out side of the lip
seal. faces toward the compressor.
Notice: Use care when handling the seal protector.
Do not nick the seal protector. This may damage
the seal during installation. Ensure that the bottom of
the seal protector is not flared. This may damage
J 23128-A the seal during installation. ·
7. Install the J 34614 on the lip seal.
J 34614 8. Install the lip seal onto the shaft.
8.1. Place the J 34614 over the end of the (
compressor shaft.
210212
8.2. Slide the new seal onto the shaft using a
rotary motion of the J 23128-A.
8.3. Ensure that the seal makes good contact
with the 0-ring.
Do not dislodge the 0-ring.
8.4. Disengage the J 23128-A from the seal.
8.5. Remove the J 23128-A and the J 34614
from the compressor.
9. Use the J 5403 in order to install the new seal
retainer ring with the flat side against the seal.
J5403
10. Use the sleeve of the J 33011 in order to press in
the seal retainer ring. Ensure that the ring snaps
into the groove.
11. Leak test the compressor.
11.1. Install the J 39893 on the rear head of the
compressor.
11.2. Connect the gage charging lines using the
J 39500-8.
11.3. Pressurize the suction and the high-side of
the compressor using R-134a Refrigerant.
11.4. Temporarily install the shaft nut.
11.5. With the compressor in a horizontal
position, rotate by hand the compressor
shaft several turns in the operating
direction.
11.6. Leak test the seal area. Correct any
leaks found. 237126
11. 7. Recover the refrigerant.

11.8. Remove the shaft nut.
12. Remove any excess oil from the shaft and the
inside of the compressor neck.
13. Install the clutch plate and hub assembly. Refer to
Compressor Clutch Plate/Hub Assembly Install
(VS - Conventional Mount).
14. Install the compressor and the compressor belt.
Tighten the bracket.
15. Evacuate and charge the refrigerant system using
the J 39500-8.
Compressor Shaft Seal Install

(V7 ~ Direct Mount)
Tools Required
• J 39893 Pressure Test Adaptor
• J 34614 Shaft Seal Protector
• J 42136 AIC Lip Seal Remover
1. Dip the new compressor shaft seal (1) in
clean 525 viscosity refrigerant oil and assemble
the seal onto the J 42136, by turning the
handle clockwise.
2. Install the J 34614 onto the compressor shaft.
3. Using a rotary motion, slide the new compressor
shaft seal onto the compressor shaft until the seal
is fully seated.
4. Remove the J 34614 by turning the handle
counterclockwise.
157231
5. Install a new compressor shaft seal retaining
ring (2), using internal snap ring pliers (1 ).
Make sure that the chamfer side of the retaining
ring is facing up and that the retaining ring
snaps into the groove.
157228
6. Leak test the compressor, using the J 39893.

6.1. Install the J 39893 onto the compressor and
J 39893 pressurize the suction and high-side of the
compressor with R-134a.
6.2. Temporarily install the sh£tft nut.
6.3. With the compressor in a horizontal
position, rotate the compressor shaft in
the normal direction of rotation, several
turns by hand.
(
6.4. Leak test the seal area and repair if
necessary.
Remove the shaft nut.
8. Remove the J 39893.
9. Remove and clean any excess oil resulting from
installing the new seal parts from the shaft and
inside the compressor neck. ·
10. Install the compressor clutch plate and h.ub
157239
assembly. Refer to Compressor Clutch Plate/Hub
Assembly Install (V7 - Direct Mount).
Compressor Pressure ReliefValve Install
)
1. Clean the valve seat area on the rear head.
2. Lubricate the 0-ring of the new pressure relief
valve and the 0-ring assembly using new
525 viscosity refrigerant oil.
Notices.
3. Install the new pressure relief valve (2).
Tighten
Tighten the valve to 9 N-m (80 lb in).
4. Evacuate and recharge the system.
Testing (VS - Conventional. Mount).
237069
Compressor Pressure Relief Valve Install

(V7 • Direct Mount)
Tools Required
J 41790 Compressor Holding. Fixture
1. Clean the pressure relief valve seat area of the
rear head.
2. Lubricate the 0-ring of the new pressure relief
) valve with clean 525 viscosity refrigerant oil.
Notices.
3. Install the new pressureJelief valve. into the .
compressor.
Tighten
Tighten the compressor pressure relief valve to
9 N·m (80 lb in).
186933
Compressor Control Switches Install

(V5 • Conventional Mount)
Tools Required
J 5403 Snap Ring Pliers
1. Inspect the switch cavity and the 0-ring groove in
the rear head for dirt or foreign material.
Clean the cavity and groove as necessary.
2. Coat the new 0-ring using clean 525 viscosity
refrigerant oil.
3. Install the 0-ring into the groove in the switch
cavity.
4. Lubricate the switch housing using
clean 525 viscosity refrigerant oil.
5. Carefully insert the switch (3 or 4) into the switch
cavity until the switch bottoms in the cavity.
237069
6. Using the J 5403, install the switch retaining ring
with the high point of the cuNed. sides adjacent t.o
the switch housing. (
7. Ensure that the retaining ring is seated in the
retaining ring groove in the switch cavity.
8. Evacuate and recharge the system.
Testing (VS - Conventional Mount). ·
Compressor Leak Testing

• J 39400-A Electronic Halogen Leak Detector
• J 39500-8 A/C Refrigerant Recovery, Recycling
and Recharging (ACR4) System
• J 39893 Pressure Testing Connector
1. With the sealing washers in place, install the
J 39893 on the rear head of the compressor.
2. Connect the gage charging lines and
the J 39500-8.
3. Pressurize the suction and the high-side of the
compressor using R-134a refrigerant.
4. With the compressor in a horizontal position,
rotate the compressor shaft several turns by
hand in the operating direction.
5. Using the J 39400-A, inspect for leaks at the
following locations:
237130 • The pressure relief valve
• The rear head switch

• The front head seal
• The rear head seal
• The through bolt head gaskets
• The compressor shaft seal
6. Perform the measures necessary to correct any
external leaks found.
7. Inspect for leaks again following any repair.
9. Disconnect the hoses from the J 39893.
(
Compressor Mounting Bracket
J Replacement (3.8 l)
Removal Procedure
conditioning (A/C) compressor.
365420

engine block stud.
5. Raise '.and support the vehicle .. Refer to Lifting
43679
6. Remove the A/C compressor bracket rear

bolts (2, 3).
1
365440
8. Move the A/C compressor forward in order to
allow access to the bracket.
282953
9. Remove the A/C compressor bracket

bolts (1, 2, 3).
10. Remove the A/C compressor bracket.
Transfer the idler pulley from the old bracket to
the new bracket.
282958
1. Install the A/C compressor bracket
Notices.
2. Install the A/C compressor bracket bolts (1, 2, 3).
Tighten
• Tighten the A/C compressor bracket
bolt (1) to 30 N-m (22 lb ft).
O Tighten the A/C compressor bracket
bolts ( 2, 3) to 50 N-m (37 lb ft)
282958
3. Move the A/C compressor rearward to the
bracket.
Tighten
Tighten the A/C compressor bracket bolts to
50 N-m (37 lb ft).
282953

Tighten 1
Tighten the A/C compressor bracket rear
bolts (2, 3) to 30 N-m (22 lb ft).
365440
7. Install the negative battery cable to the stud.

8. Install the. negative battery cable nut to the engine
block stud.
Tighten
engine block to 25 N-m (18 lb ft).
43679
9. Connect the electrical connector at the
AJC compressor.
365420
Compressor Mounting Bracket

Replacement (5.7 L)
Removal Procedure
1 . Remove the air conditioning (A/C) compressor.
Refer to Compressor Replacement (5. 7 L). ·. · ·
2. Remove the A/C compressor bracket. bolts.. · •{
3. Remove the A/C compressor bracket. (

4. Remove the A/C belt tensioner from the bracket.
Refer to Drive Belt Tensioner Replacement -
A/C in Engine Mechanical - 5.7 L.
5. Remove the A/C belt idler pulley from the bracket.
Refer to Drive Belt Idler Pulley Replacement -
A/C in Engine Mechanical - 5. 7 L.
282957
1. .Install the A/C belt idler pulley from the bracket. ·.·
Refer to Drive Belt Idler Pulley Replacement~
2. install the A/C belt tensioner from the bracket.
Refer to Drive Belt Tensioner Replacement:
3. Install the A/C compressor bracket.
Notices.
4. Install the A/C compressor bracket bolts.
Tighten
Tighten the A/C compressor bracket bolts to
50 N,m (37 lb ft).
5. Install the A/C compressor. Refer to Compressor
282957
HVAC Heating, Ventilation and Air Conditioning 1.,55
Compressor Sealing Washers
Replacement
1. Keep dirt and foreign material from the sealing
surfaces of the washers, the hose block, and
the compressor ports.
Clean all of the sealing surfaces with a
lint-free rag.
2. Do not reuse sealing washers.
3. The sealing washers do not need oiling prior to
assembly.
4. Ensure that the sealing washers are seated within
the compressor machined surfaces.
5. The washers must bottom against the surface of
the block fitting.
"257968
Compressor Hose Assembly

Replacement (3.8 L)
Removal Procedure
and condenser hose bolt at the accumulator.

engine block stud.
6. Raise and suitably support the vehicle. Refer
Information.
43679
1.;.55 Heating, Ventilation and Air Conditioning HVAC
7. Remove the NC compressor and condenser
hose bolt.
8. Discard the 0-ring. (
569444
9. Remove the NC compressor and condenser hose

nut at the condenser.
12. Remove the NC compressor arid condenser hose
from the vehicle.
365450
Lightly coat the 0-rings with a mineral · ·
1. Install the A/C compressor and condenser hose to
the vehicle.
2. Raise and suitably support the vehicle. Referto
Information.
Notices.
4. Install the NC compressor and condenser hose
Tighten (
Tighten the NC compressor and condenser hose
nut at the condenser to 16 N-m (12 lb ft).
365450
hose bolt.
Tighten
569444
8. Install the negative battery cabl.e to the stud.

9. Install the negative battery cable nut to the engine
block stud.
Tighten
engine block stud to 25 N·m (18 lb ft).
43679

11. Install the A/C compressor and condenser hose
bolt at the accumulator.
Tighten
bolt at the accumulator to 16 N-m (12 lb ft).
Leak Testing.
282936
HVAC
Replacement (5.7 L)
Removal Procedure
and condenser hose from the clip on the fan
shroud.
3. Remove the A/C compressor and condenser hose
Information.
282941

8. Remove the A/C compressor. Refer to
Compressor Replacement (5.7 L}.
from the vehicle.
365450
Lightly coat the 0-rings with the mineral
1. Install a new 0-ring to the A/C compressor and
condenser hose.
2. Install the compressor and condenser hose to the
vehicle.
3. Install the A/C compressor. Refer to Compressor
Notices.
Tighten (
nut at the condenser to 16 N·m (12 lb ft).
365450
Tighten
9. Install the A/C compressor and condenser hose to
the clip on the fan shroud.
1O. Recharge the A/C system. Refer to Refrigerant
Leak Testing. ·
282941
Evaporator Tube Replacement

Removal Procedure
conditioning (A/C) refrigerant pressure sensor.
)
282947
3. Remove the A/C evaporator tube bolt at the

module.
condenser.
5. Remove the A/C evaporator tube from the vehicle.
6. Discard the 0-rings.
7. Remove the orifice and the pressure sensor, if
replacing the tube.
282946
HVAC
1. Lightly coat th.e 0-rings with a mineral
2. install the orifice and the pressure sensor, if
replacing the tube.
3. Install new 0-rings.
4. Install the A/C evaporator tube to the vehicle.
Notice: Refer to Fastener Notice in Cautions
and Notices.
5. install the A/C evaporator tube bolt at the
condenser.
Tighten
Tighten the A/C evaporator tube bolt at the
condenser to 16 N·m (12 lb ft).
6. Install the A/C evaporator tube bolt at the module.
Tighten
282946 module to 16 N·m (12 lb ft).
7. Connect the electrical connector at the
A/C refrigerant pressure sensor.
Recov.ery and Recharging.
Leak Testing.
282947
Expansion (Orifice) Tube Filter.

Replacement
Removal Procedure
1. Recover the refrigerant. Refer to Refrigerant.
2. Remove the air conditioning (A/C) evaporator.
Refer to Accumulator Replacement.
3. Remove the orifice from the A/C evaporator tube.
247323
Important: Install the long screen inlet end toward the
condenser.
1. Install the orifice in the A/C evaporator tube.
2. Install the A/C evaporator. Refer to Accumulator
Replacement.
4. Leak test the fitting for leaks. Refer to Leak
Testing.
247323
Compressor Relay Replacement

Removal Procedure
1. Remove the cover from the number 2 underhood
electrical center.
relay. Refer to Electrical Center Identification
) Views in Wiring Systems.
401242
1. Install the A/C compressor relay. Refer to
Electrical Center Identification Views in Wiring
Systems.
2. Install the cover on the number 2 underhood
electrical center.
401242
Service Port Valve Core Replacement
Removal Procedure
Tools Required
J 34611-A Valve Core Remover and Installer
2. Remove the valve core using J 34611-A.
297244
Tools Required
J 34611-A Valve Core Remover and Installer
Notices...
1. Install the valve core using J 34611-A.
Tighten.
Tighten the service core to 11 N·m (97 lb in).
2. Recharge th~ air conditioning (NC) system. Refer
to Refrigerant Recovery and Recharging.
3. Test the fitting for leaks. Refer to Leak Testing.
297244
A/C Refrigerant Pressure Sensor

Replacement ·
Removal Procedure
Important: The air conditioning (NC) refrigerant
pressure sensor is mounted on a Schrader® valve.
Recovery of the air conditioning NC system is
not needed.
1. Disconnect the electrical connector at the
NC refrigerant pressure sensor.
282947
2. Remove the A/C refrigerant pressure sensor and
the seal.
3. Discard the seal.
282951
Coat the seal with a mineral base 525 viscosity
refrigerant oil. '
1. Install a new seal to the A/C refrigerant pressure
sensor fitting.
Notices.
) 2. Install the A/C refrigerant pressure sensor.
Tighten
Tighten the A/C refrigerant pressure sensor to
6 N·m (53 lb in).
282951
3. Connect the electrical connector to the

A/C refrigerant pressure sensor.
282947
Condenser Replacement
Removal Procedure (
2. Disconnect the intake air temperature (IAT)
sensor connector at the air intake duct, if equipped
with the 3.8 L engine.
208554
3. Disconnect the intake air temperature (IAT) .

sensor and mass airflow (MAF) sensor connectors
at the air intake duct, if equipped with the
5.7 L engine.
208553
4. Remove the air intake duct; if equipped with the

3.8 L engine.
554755
5. Remove the air intake duct, if equipped with the
5.7 L engine.
6. Remove the radiator support. Refer to Radiator
Support Replacement in Engine Cooling.
Information.
208569

and condenser hose nut at the condenser.
365450

condenser.
12. Remove the radiator air upper baffle from the
condenser. Refer to Radiator Air Baffle
Assemblies and Deflectors (Upper) in Engine
Cooling.
282946
13. Remove the condenser from the radiator.
282959
1. Install the condenser to the radiator.
2. Install the radiator air upper baffle to the
condenser. Refer to Radiator Air Baffle Assemblies
and Deflectors (Upper) in Engine Cooling.
282959

Notices.
4. Install the A/C evaporator tube bolt at the
condenser.
Tighten
condenser to 16 N-m (12 lb ft).
282946
Tighten
8. Install the radiator support. Refer to Radiator
Support Replacement in Engine Cooling.
365450
9, Install the air intake duct, if equipped with the

5.7 L engine.
208569
10. Install the air intake duct, if equipped with the

3.8 L engine. ·
554755
11. Connect the intake air temperature (IAT)
sensor and mass airflow (MAF) sensor connectors (
at the air intake duct, if equipped with the
5. 7 L engine.
208553
12. Connect the intake air temperature (IAT) sensor

connector at the air intake duct, if equipped with
the 3.8 L engine.
13. Recharge the NC system. Refer to Refrigerant
14. Perform a leak test on the NC system. Refer to
Leak Testing.
(
208554
Accumulator Replacement
Removal Procedure
2. Disconnect the air conditioning (NC) compressor
and condenser hose bolt at the accumulator.
3. Remove the accumulator bolt (2) at the module.
4. Remove the accumulator hose bracket
nut (1) at the strut tower.
5. Remove the accumulator bracket bolt.
6. Remove the accumulator from the bracket.
(
282943
1. Before installing a new, or reinstalling the old 1 2
accumulator perform the following:
poly-alkylene glycol (PAG) oil in the
accumulator that was removed.
1.2. Add 60 ml (2 oz) of new, clean PAG oil
MORE than the amount drained from the
removed accumulator.
2. Install the new 0-ring.
3. Install the accumulator to the bracket.
Notices.
4. Install the accumulator bracket bolt.
Tighten
Tighten the accumulator bracket bolt to
6 N-m (53 lb in).
5. Install the accumulator hose bracket nut (1) at the 282943
strut tower.
Tighten
Tighten the accumulator hose bracket nut (1) at
the strut tower to 8 N-m (71 lb in).
6. Install the accumulator bolt (2) at the module.
Tighten
Tighten the accumulator bolt (2) at the module to
16 N-m (12 lb ft).
) 7. Connect the NC compressor and condenser hose
Tighten
Tighten the NC compressor and condenser hose
8. Recharge the NC system. Refer to Refrigerant
9. Perform a leak test on the NC system. Refer to
Leak Testing.
Evaporator Core Replacement

Removal Procedure
1. Drain the engine coolant. Refer to Draining and
Filling Cooling System (3.8 L) or Draining and
Filling.Cooling System (5.7 L) in Engine Cooling.
3. Remove the heater core. Refer to Heater Core
Replacement.
4. Remove the temperature control cable bolt.
5. Remove the temperature control cable from the
module.
282922
6. Remove the accumulator bolt (2) at the module.
2 7. Discard the 0-ring seal.
282943
8. Remove the air conditioning (A/C) evaporator tube

bolt at the module.
9. Discard the 0-ring seal.
282946
10. Remove the heater rear case bolts.

11. Remove the heater rear case (4):
11.1. Slide the heater rear case (4) downward in
order to disengage the upper case clip.
6
11.2. Remove the heater rear case.
11.3. Use a small hand saw to remove the
perforated section of the heating,
ventilation and air conditioning (HVAC)
5 evaporator module.
This section will be reused.
11.4. Water may leak onto the carpeting when
performing this procedure. Place a mat on
the passenger side floor.
11.5. Remove the A/C evaporator bracket (
nut (1 ).
11.6. Remove the A/C evaporator bracket.
571431
11. 7. Remove the bolts from the engine
compartment side of the A/C evaporator
upper and lower case.
Open the case slightly.
11.8. Remove the A/C evaporator seal.
11.9. Remove the evaporator (6).
11.10. Transfer the A/C evaporator air filter (5) to
the new evaporator.
1. Install the NEW A/C evaporator (6).
2. install a NEW A/C evaporator seal.
3. Apply sealer between the evaporator upper and 6
lower case.
Do not use epoxy glue as a sealer.
Notices.
4. Install the bolts to the engine side of the
5
A/C evaporator upper anc;I lower case.
Tighten
Tighten the A/C evaporator upper and lower. case
bolts to 2 N-m (18 in).
5. Install the A/C evaporator bracket.
6. Install the A/C evaporator bracket bolt (1 ).
Tighten
) Tighten the A/C evaporator bracket bolt (1) to
571431
2 N-m (18 lb in).
7. Position the perforated section of the evaporator
module.
Use epoxy glue in order to adhere the perforated
section to the module.
Allow the epoxy to dry.
8. Use your thumb in order to grade the sealant on
the inside and the outside in order to ensure a
water-tight seal.
9. Use the following steps in order to install the
heater rear case (4):
9.1: ·Slide the heater rear case upward into
position until the upper clip engages.
9.2. Engage the snap on the left edge of the
heater rear case to the distributor case.
9.3. Install the bolts to the heater rear case.
Tighten
Tighten the heater rear case bolts to
2.0 N-m (18 lb in).
10. Install a new 0-ring seal.
11. Install the A/C evaporator tube bolt at the module. (
Tighten
Tighten the A/C evaporator tube bolt to
16 N-m (12 lb ft):
282946
12. Install a new 0-ring seal.

2 13. Install the accumulator bolt at the module.
Tighten
Tighten the accumulator bolt (2) to
16 N-m (12 lb ft),
282943
14. Install the temperature control cable to the

·module.
15. install t~e temperature control cable bolt.
Tighten
Tighten the temperature. control cable bolt to
1.9 N·m (17 lb in).
16. Install the heater core. Refer to Heater Core
Replacement.
17. Recharge the refrigerant. Refer to Refrigerant
18. Refill the cooling system. Refer to Draining and
Filling Cooling System (5. 7 L) in Engine Cooling.
282922
Heater Hose Assembly
J Replacement (3.8 L)
Removal Procedure
1. Partially.drain' the engine coolant.·.
Notice: Remove the. heater hose quick connect fittings
by hand. Do not attempt to pry the. quick conne.ct
fittings from the drive belt tensioner. Pryingthe quick
connect fittings may damage the quick connect
fittings.
2. Disconnect the heater hose quick connect fittings
from the drive belt tensioner. ·
Twist and pull the quick connect fittings from the
drive belt tensioner.
282933
4. Remove the bolt attaching the inlet and outlet ·

hose bracket at the mid rail.
282932
Notice: Do not apply excessive force on the heater

core pipes during hos.e removal. Applying excessiv.e
force on the heater core pipes may damage the heater
core pipes.
5. Remove the inlet and outlet hoses from.the
heater core.
5.1. Squeeze the hose clamp .with the pliers.
5.2. Slide the clamp away from the heater core
fittings.
5.3. Gently twist· and· pull the heater hose from
the heater core fitting.
6. Remove the inlet hose from the module retainer.
7. · Remove the inlet and outlet hoses (4) from
) the vehicle.
282931
1. Install the inlet and outlet hoses to the vehicle.
2. Install the inlet hose to the module retainer.
3. Install the inlet and outlet hoses to the heater core.
3.1. Apply lubricant to the inside diameter of the
heater hose, if necessary.
3.2. Push the heater hose onto the fitting with a
twisting motion. · ·
3.3. Squeeze the hose clamp ends together and
slide the clamp over the end of the
heater hose.
3.4. Install the clamp beyond the bead around
the fitting. . .
3.5. Install the other heater hose.
282931

Notices.
4. Install the bolt attaching the inlet and outlet hose
bracket at the mid rail.
Tighten
Tighten the heater hose bracket bolt to
14 N·m (10 lb ft).
(
282932
5. Install the 0-rings to the quick connect fittings.

Snap the quick connect fittings to the drive belt
tensioner.
6. Pull back on the quick connect fittings in order to
verify proper conn~ctor engagement.
7. Add the engine coolant.
• lfthe previously drained coolant is
uncontaminated, use the previously drained
coolant.
• If the previously drained coolant is
contaminated, discard the. contaminated
coolant.
Then, add a fresh .50/50 DEX-COOL and water
mixture. ·
(
282933
HVAC Heating,. Ventilation and Air Conditioning 1".'85
Heater Hose Assembly Replacement (5.7 l)
) Removal Procedure
1. Partially drain the engine coolant.
2. Remove the inlet and outlet heater hoses from the
water pump.
2.1. Squeeze the hose clamp together with pliers.
2.2. Slide the hose clamp away from the water
pump fitting.
2.3. Gently twist and pull the he.ater hose from
the water pump fitting.
2.4. Remove the heater hose.
2.5. If the heater hoses cannot be removed
easily perform the following steps:
2.5.1. Cut the hose forward of the
hose pipe.
2.5.2. Cut the hose remaining on the
water pump fitting lengthwise.
Remove the heater hose. 282934
3. Remove the bolt attaching the inlet and outlet

hose bracket at the mid rail.
282932
Notice: Do not apply excessive force on the heater

core pipes during hose removal. Applying excessive
force on the heater core pipes may damage the heater
core pipes.
4. Remove the inlet and .outlet hoses from the.
heater core.
4.1. Squeeze the hose clamp with pliers.
4.2. Slide the clamp away from the heater core
fittings. ·
4.3. Gently twist and pull the heater hose from
the heater core fitting. .·
5. Remove the inlet hose from the module retainer.
6. Remove the inlet and outlet hoses from the
vehicle. ·
)
282931
1. Install the inlet and outlet hoses to the vehicle.
2. Install the inlet hose to the module retainer.
(
3. Install the inlet and outlet hoses to the heater core.
twisting motion.
heater hose.
the fitting.
3.5. Install the. other heater hose.
282931

Notices.
4. Install the bolt attaching the inlet and outlet hose
bracket at the mid rail.
Tighten
Tighten the heater hose bracket bolt to
14 N-m (10 lb ft).
282932
5. Install the inlet ahd outlet heater hoses to the

water pump.
twisting motion.
heater hose.
pump fitting.
the fitting.
5.6. Install the other heater hose.
(
282934
HVAC Heating, Ventilation and Air Conditjoning 1-87
6. Add the engine coolant:
uncontaminated, use the previously drained
coolant.
contaminated, discard the contaminated
coolant.
Then, add a fresh 50/50 DEX-COOL and water
mixture.
Blower Motor Relay Replacement

Removal Procedure
1. Remove the driver side instrument panel (IP)
insulator. .Refer to Closeout/Insulator Panel
Replacement - Left in Instrument Panel, Gauges
and Console.
2. Remove the knee bolster. Refer to Knee Bolster
and Console.
3. Remove the blower motor relay from the IP
tie bar.
blower motor relay.
365453
1. Connect the electrical connector to the blower
motor relay.
2. Install the blower motor relay to the IP tie bar.
3. Install the knee bolster. Refer to Knee Bolster
and Console.
4. Install the driver side IP insulator. Refer to
Closeout/lnsulatorPanel Replacement - Left
in Instrument Panel, Gauges and Console.
365453
HVAC
Heater Core Replacement
Removal Procedure
1. Drain the engine coolant. Refer to· Draining and
2. Remove the heater hoses/pipes. Refer to Heater
Hose Assembly Replacement (3.8 L) or Heater
Hose Assembly Replacement (5. 7 L).
3. Remove the heater core tube clamp bolt.
4. Remove the heater core tube clamp.
5. Remove the heater core shroud seal.
6. Remove the heater rear case bolts (2).
7. Remove the heater rear case (4): ·
7.1. Slide the heater rear case (4) downward in
order to disengage the upper case clip.
7.2. Remove the heater rear case.
8. Remove the instrument panel (IP) compartment
door. Refer to Door Replacement - IP Storage
571433
Compartment Door
9. Remove the heater core clamp bolt (3).
10. Remove the heater core clamp.
11 . Remove the heater core ( 1).
1. Install the heater core.
2. Install the heater core clamp.
Notices.
3. Install the heater core clamp bolt.
Tighten
(
Tighten the heater core clamp bolt to
1.8 N·m (16 lb in).
heater rear case (4): ·
4.1 . Slide the heater rear case upward into
position until the upper clip engages.
4.2. Engage the snap on the left edge of the
heater rear case to the distributor case.
4.3. Install the bolts to the heater rear case.
Tighten
Tighten the heater rear case bolts to
2.0 N-m (18 lb in).
571433
5. Install the heater core shroud seal.
6. Install the heater core tube clamp.
7. Remove the heater core tube clamp bolt.
Tighten
Tighten the heater core tube clamp bolt to
2 N·m (18 lb in).
door. Refer to Door Replacement - IP Storage
Compartment Door
9. Install the heater hoses/pipes. Refer to Heater
Hose Assembly Replacement (3.8 L) or Heater
Hose Assembly Replacement (5. 7 L).
10. Drain the engine coolant. Refer to Draining and (
Description and Operation
J A/C System Description Heater Core Description
The heating, ventilation and air conditioning (HVAC) The heater core is the main component of the heater
system delivers air that has been heated or cooled and system. The heater core is located inside of the
dehumidified for occupant comfort. The HVAC heater and evaporator module. Engine coolant is
system also provides the following features: pumped into the heater core from the engine whenever
the engine is operating. The heater core fins transfers
• Ventilation the heat from the engine coolant to the air passing
• Windshield defrosting over the heater core. The heater core has specific inlet
and outlet tubes. The placement of the heater hoses
• Side window defogging
should be noted prior to servicing the heater core
During most operating condition, the blower motor or the heater hoses.
draws the outside air through the heater and air The temperature control is linked to the temperature
conditioning module. The forward movement of the valve by a flexible control cable. When you rotate
vehicle forces additional air into the vehicle. The temperature control counterclockwise to the full COLD
following actions occur in the evaporator core when position, the temperature valve is held snugly
the compressor is on: against the air entrance to the heater core. The
• The air is filtered following actions occur:
• The air is dehumidified • All of the airflow from the evaporator bypasses the
heater core.
• The air is cooled to about 2°C (35°F) • No heat transfer occurs.
Some of the air then passes through the heater core When you turn the temperature control away from the
where the flow of hot coolant reheats the air. full COLD position, the temperature valve begins to
Depending on the temperature door position, the direct air to the heater core. This action allows
heated air is mixed with cold air from the evaporator air to flow through the heater core. The farther the
before the air enters into the passenger compartment. temperature control is rotated clockwise, the more the
The air enters the passenger compartment through temperature valve directs air through the heater
\ the upper, lower, or defroster outlets. This provides core. The air discharge is warmer when most of the
) positive air flow even if the windows are closed. airflow is heated in this manner. The air discharge
is warmer because the heated and unheated air flows
When the Recirc mode is selected, most of the air
join and mix together thoroughly beyond the
entering the evaporator and heater core module
heater core.
is recirculated from the passenger compartment.
Recirculated air is most likely cooler and dryer than When you rotate the temperature lever clockwise to
outside air in very hot weather. the full HOT position, the temperature valve blocks off
the passage that allows air to bypass the heater
core. This action causes passage of the airflow
through the heater core.
)
Refrigeration System Description
VDOT Refrigeration System
~ Low Pressure Liquid

c::J Low Pressure Vapor
~ High Pressure Liquid
EJ High Pressure Vapor
1 2 4
3
6 5
194971
Legend
(1) Compressor (5) Expansion (Orifice) Tube
(2) Condenser (6) Liquid Line
(3) Evaporator (7) Pressure Relief Valve
(4) Accumulator
The variable displacement orifice tube (VDOT} system When the A/C capacity demand is high, the suction
is comprised of the following components: pressure will be above the control point. The valve
.. A variable displacement compressor (1) performs the following functions:
" A fixed expansion tube (5) .. Maintains a bleed discharge gas into the
This system matches the air conditioning demands crankcase
under all modes without cycling. The basic compressor
mechanism is a variable angle wobble-plate with .. Closes off a passage from the crankcase to the
five cylinders. The five cylinders are oriented around a suction plenum
common axis. The center of control of the compressor The angle of the wobble-plate is controlled by a force
displacement is the control valve. The control valve balance on the five pistons. A slight elevation of
is actuated by a bellows. The control valve is located in the crankcase suction pressure differential creates a
the rear head of the compressor (1) that senses total force on the pistons. The force on the pistons
compressor suction pressure. the crankcase-suction produces a movement about the wobble-plate pivot pin
pressure differential controls the following conditions: that reduces the plate angle.
• The wobble-plate angle
.. The compressor displacement
Refrigerant R-134a Handling Compressor Oil
) Caution: Refer to Caution - Breathing R-134a in Use approved compressor oil from a closed, sealed
Cautions and Notices. container. When adding refrigerant oil, the transfer
Refrigerant performs the following functions in the air device and container should be clean and dry to
conditioning system: minimize the possibility of contamination. Refrigerant
oil is moisture-free and will readily absorb moisture
" Absorbs heat from the air. Do not open the oil container until
" Carries heat the service procedure requires oil. Cap the oil
• Releases heat immediately after use. Always store compressor oil in
a closed sealed container. Compressor oil left in
These vehicles use Refrigerant-134a (R-134a).
open or improperly sealed containers will absorb
RefrigeranH 34a is a nontoxic, nonflammable, clear,
moisture. Do not reuse oil that has been removed from
colorless liquefied gas.
the refrigeration system. Dispose of used oil properly,
according to local regulations.
Handling Refrigerant R-134a
Caution: Avoid breathing the A/C Refrigerant 134a Handling of Refrigerant lines and Fittings
(R-134a) and the lubricant vapor or the mist. • Ensure that the metal lines do not exhibit the
Exposure may irritate the eyes, nose, and throat. following conditions.
Work in a well ventila.ted area. In order to remove
R-134a from the A/C system, use service This will preventthe loss of system capacity due
equipment that is certified to meet the to line restriction:
requirements of SAE J 2210 (R-134a recycling - Dents
equipment). If an accidentt;1I system discharge - Kinks
occurs, ventilate the work area before continuing
• Do not bend the flexible hose line to a radius of
service. Additional health and safety information
less that 4 times the diameter of the hose.
may be obtained from the refrigerant and lubricant
manufacturers. • Do not allow the flexible hose line to come within
a distance of 63.5 mm (2 1/2 in) of the exhaust
Important: manifold.
• Use only the approved lubricant for the R-134a
) system and the R-134a components. If lubricants
• Inspect the flexible hose lines regularly.
Replace the flexible hose line with new hose if
other than those specified are used, compressor
one of the following conditions exist:
failure may occur. Coat all of the fittings and
the 0-ring seals with a clean approved refrigerant - Leaks
oil. This action will provide a leak-proof seal - Brittleness
and to aid in assembly and disassembly. - Deterioration
• Do not store or heat the refrigerant containers • Before disconnecting any fitting in the refrigeration
above 125°F (52°C). system, discharge all of the Refrigerant-134a.
• Do not heata refrigerant container with an open Refer to Refrigerant Recovery and Recharging.
flame, If the container must be warmed, place • Once you open a refrigerant line to the
the bottom of the container in a pail of warm water. atmosphere, cap or tape the line immediately.
• Do not drop, puncture, or incinerate the This will prevent any of the following items from
refrigerant containers. entering the line:
.. Refrigerant will displace oxygen. Work in - Moisture
well-ventilated areas in order to prevent
suffocation. - Dirt
• Do nbt introduce compressed air to any refrigerant • Use the proper wrenches when you make
container or refrigerant component. The action connections on the 0-ring fittings.
may cause the contamination of the refrigerant. Back-up the opposing fitting with a wrench in
order to prevent distortion of the following areas:
" If i1 is necessary to carry a container of Dot CFR
Refrigerant-134a in a vehicle, do not carry it in - The connecting lines
the passenger compartment. - The components
" Tighten all of the tubing connections to the Use the following general practices to maintain
specified torque. chemical stability in the refrigeration system:
Too much or too little torque may result in the • Wipe away dirt and/or oil before you break a
following conditions: refrigerant connection. This will reduce the
- Loose joints possibility of particulate contamination.
- Deformed joint parts .. Cap, plug or tape both sides of an open
connection as soon as possible. This will minimize
- Refrigerant leakage the amount of dirt and moisture entering the
- An inoperative A/C system system.
.. Ensure that the 0-rings and the seats are in " Ensure that the following remain clean and dry:
perfect condition. - The tools being used for the repair
A burr or a piece of dirt may cause a - The surrounding area of the repair
refrigerant leak. - The hoses and connectors for the ACR4
.. Install new 0-rings that you have lubricated with machine or manifold gage set
the mineral base 525 viscosity refrigerant oil. - The replacement parts
Do not use polyalkylene glycol (PAG) synthetic oil. • When adding polyalkylene glycol (PAG) lubricant,
Do not wipe the threads with a cloth. ensure the transfer device and the container
.. Keep PAG synthetic refrigerant oil off fitting remain clean and dry to minimize moisture
threads. Long term contact of PAG synthetic intrusion.
oil on threads may cause future disassembly • Do not· ,eave the A/C system open any longer
difficulties. Flush threads of fitting with mineral .than necessary.
base 525 viscosity refrigerant oil. Do not use PAG • Before recharging an A/C system that has been
synthetic oil. Do not wipe threads with a cloth. opened, properly evacuate and vacuum test·
the system.
Handling A/C Compressor • Service parts are dehydrated and sealed prior to
Do not strike, drop, or turn the compressor upside shipping. Retain the parts in their sealed
down. If the compressor is knocked over or turned packages until you are ready to use them.
upside down, rot.ate the compressor's clutch 5-6 ti.mes • Ensure the parts are at room temperature before (
by hand to circulate the oil which has settled in the opening the packages. This prevents condensation
cylinder. Sudden rotating with oil in the cylinder on the parts from humidity in the atmosphere.
can cause valve damage and adversely affect • Attach the A/C service equipment quick-connects
durability. as soon as possible after removing the
service caps.
Maintaining Chemical Stability
Refrigerant Oil Distribution
The chemical stability of the refrigeration system plays
an important role in the efficient operation and Notice: Use only Polyalkylene Glycol Synthetic
longevity of the A/C system. Refrigerant Oil (PAG) for internal circulation through
the R-134a A/C system and only 525 viscosity mineral
When air, moisture or particulate contamination are
oil on fitting threads and 0-rings. If lubricants other ·
introduced into the refrigeration system, the following
results will occur: · · · than those specified are used, compressor failure
and/or fitting seizure may result.
" The chemical stability of R-134a and polyalkylene
The following informations should be used to service
glycol (PAG) synthetic lubricant will change. ·
the air conditioning (A/C) system:
" The pressure/temperature symmetry will change, • A/C system internal lubricant (including
O
The A/C system efficiency will be diminished. compressor) use GM P/N 12345923 or equivalent.
" lnternalA/C system parts may corrode and/or • A/C system 0-ring and fitting lubricant use
wear in an abnormal manner. GM P/N 12301108 or equivalent.
HVAC Heating; Ventilation and Air Conditioning 1-93
"
Expansion (Orifice) Tube Description Condenser Description
The condenser receives high pressure, high
temperature refrigerant vapor from the A/C
compressor. The condenser is made up of aluminum
tubing and cooling fins which allow rapid heat
transfer away from the high-pressure, high temperature
refrigerant vapor. The cooling fins cause the high
pressure, high temperature refrigerant vapor to
condense into a high-pressure, medium temperature
liquid.
Accumulator Description
1
2
8
82109
The plastic expansion (orifice) tube (2) is made of a

mesh-screen (1) and orifice (3). The expansion (orifice)
tube is located in the evaporator inlet pipe at the
orifice conne.ction. The tube restricts the high pr~ssure
liquid refrigerant in the liquid line. This restriction
meters the refrigerant flow to the evaporator as a low
pressure liquid. The expansion tube and orifice
\ have filter screens which protect from contamination
on both the inlet and outlet sides of the tube. When the
engine is OFF the refrigerant in the system flows
from the high pressure side of the system to the low 82105
pressure side until the pressure is equalized. This may Legend
be detected as a hissing sound for 30-60 seconds
and is a r\ormal condition. (1) Refrigerant Vapor Inlet
(2) Inlet
Evaporator Description (3) Baffle
(4) Internal Tube
The evaporator cools and dehumidifies air before the (5) Desiccant Bag
air enters the passenger compartment. The following
events occur in the evaporator: (6) Filter
(7) Oil Bleed Hole Location-In the Tube
1. Low-pressure, low temperature liquid/vapor
refrigerant enters the evaporator. (8) Outlet
2. The refrigerant flows through the evaporator's The sealed accumulator is connected to the evaporator
tubing. outlet pipe. The accumulator stores the refrigerant
3. The refrigerant evaporates. (vapor and liquid) and the oil .from the evaporator. A
4. The refrigerant exits the evaporator as desiccant at the accumulator bottom dries any
low-pressure, low temperature, mostly vapor moisture in the system. An oil bleed hole at the
refrigerant. accumulator outlet pipe end provides the oi.1 return
path to the compressor. The accumulator is not
5. As the r,efrigerant evaporates, the refrigerant serviceable and should only be replaced when leaking
absorbs heat from the air flowing over the due to the following conditions:
evaporator.
• Perforation
As the process of heat loss from the air to the • A damaged sealing area
evaporator core is taking place, any moisture
(humidity) in the air condenses on the outside surface • Damaged fastener threads
of the evaporator core and the moisture drains off • Outside air has entered the system for extended
as water. periods of time
Compressor Description (3.8 L)
VS Compressor Components
(
11
10
9~
507542
Legend
(1) Compressor (10) Shaft Seals
(2) Variable Displacement Control Valve Ring (11) Shaft Seal Snap Ring
(3) Variable Displacement Control Valve (12) Clutch Coil
(4) Oil Drain Plug (13) Clutch Rotor
(5) Pressure Relief Valve Seal (14) Clutch Rotor Bearing
(6) Pr,essure Relief Valve (15) Clutch Rotor and Bearing Snap Ring
(7) Suction Port Screen (16) Clutch Plate and Hub
(8) Seal Washers (17) Shaft Nut
(9) Clutch Hub Key
(
The V5 compressor is a variable displacement and the suction pressure reaches the control point, the
compressor that can match the automotive air valve will bleed discharge gas into the crankcase and
conditioning demand under all conditions without close off a passage from the crankcase to the suction
cycling. The basic compressor mechanism is a variable plenum. The wobble-plate angle is controlled by a force
angle wobble-plate with five axially oriented cylinders. A balance on the five pistons. A slight increase in the
bellows actuated control valve located in the rear head wobble-plate pivot pin that reduces the plate angle.
of the compressor senses the compressor suction
pressure and is the center of control for the compressor The compressor has a unique lubrication system. The
displacement. The crankshaft-suction differential crankcase-suction bleed is routed through the
controls both the wobble-plate an.d the control rotating wobble-plate for lubrication of the wobble-plate
displacement. When the A/C capacity demand is high, bearing. The rotation acts as an oil separator,
the suction which causes no crankcase-suction removing some of the oil from the crankcase-suction
pressure differential giving the compressor maximum bleed, and rerouting the oil to the crankcase where the
displacement. When the A/C capacity demand is lower oil can be lubricate the compressor mechanism.
Compressor Description (5. 7. l)

V7 Compressor Components
11
y13I
157241
Legend
(1) Shaft Nut (3) Clutch Plate and Hub
(2) Clutch Hub Key (4) Clutch Rotor and Bearing Snap Ring
(5) Clutch Rotor Bearing (11) Compressor
(6) Clutch Rotor (12) Pressure Relief Valve
(7) Cluch Coil (13) Suction Port Screen
(8) Compressor Shaft Seal and Snap Ring (14) Special R-134a Suction Port
(9) Compressor Control Valve (15) Seal Washers
(10) Compressor Control Valve Retaing Ring (16) Special R-134a Discharge Port
The V7 compressor is a variable displacement When the A/C capacity demand is lower and the
compressor that can match the automotive air suction pressure reaches the control point, the valve
conditioning demand under all conditions without will bleed discharge gas into the crankcase and
cycling. The basic compressor mechanism is a variable close of a passage from the crankcase to the suction
angle wobble~plate with seven axially oriented plenum. The wobble-plate angle is controlled by a
cylinders. A bellows actuated control valve located in force balance on the seven pistons. A slight increase
the rear head of the compressor senses the in the crankcase-suction pressure differential
compressor suction pressure and is the center of creates a force on the pistons. This results in a
control for the compressor displacement. The movement of the wobble-plate pivot pin that reduces
crankcase-suction differential controls both the the plate angle.
wobble-plate and the compressor displacement. When The compressor has a unique lubrication system.
the A/C capacity demand is high, the suction The crankcase-suction bleed is routed through
pressure will be above the control point. The control the rotating wobble-plate for lubrication of the
valve will maintain a bleed from crankcase to wobble-plate bearing. The rotation acts an oil
suction which causes no crankcase-suction pressure separator, removing some of the oil from the
differential giving the compressor maximum crankcase-suction bleed, and rerouting the oil to the
displacement. crankcase where the oil can lubricate the compressor .
mechanism.
(
High Pressure Relief Valve Description Special Tools and Equipment
The V7 compressor is equipped with a pressure relief Illustration Tool Number/ Description
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. The valve is designed to open automatically
at approximately 3036 kPa (440 psi) in order to J 5403
prevent system damage. Snap Ring Pliers
Correct any condition that causes the valve to open.
Replace refrigerant oil as necessary. Inspect the
air conditioning refrigerant pressure sensor for proper
calibration. Refer to OTC P0530 Air Conditioning 10767
(AIC) Refrigerant Pressure Sensor Circuit in Engine
Controis-5. 7 L.
Relays and Sensors Description

Blower Motor Relay J 6083
Use the blower motor relay in order to provide battery Snap Ring Pliers
voltage to the blower motor only during high blower
motor speed. Use the blower motor resistor in order to
provide power to the blower motor at all other speed
settings. The blower motor relay is located under 6183
the instrument panel. Refer to Blower Motor Relay
Replacement.
Air Conditioning (A/C) Compressor Relay
Use the A/C compressor relay in order to provide
) battery voltage to the compressor clutch coil.
The powertrain control module (PCM) controls the
J 8092
Driver Handle
relay. The relay is located in the underhood electrical
center. Refer to Compressor Relay Replacement.
0-Ring/Flat Washer Description

2015
Install new approved service replacement air
conditioning 0-ring(s) and flat washers whenever a
joint or fitting is disassembled.
Some vehicles use flat sealing washers and 0-ring(s)
to seal the refrigerant system. The flat washers are
used on block fittings of refrigerant components. J 8433
The 0-ring(s) is used to seal the refrigerant tubes. Compressor Pulley Puller
The 0-ring fitting consists of:
" An aluminum alloy, externally threaded fitting
which is welded to an aluminum tube.
6185
• A free-spinning internally threaded nut.
.. An aluminum tube end which accommodates the
0-ring(s).
Verify that the flat washers or 0-ring(s) have not been
damaged prior to installation. Replace damaged parts.
Coat 0-ring(s) and flat washers with the approved J 8433-1
refrigerant oil. Puller Bar
Failure to use the proper service replacement parts
and procedures may result in a leak.
Service Caps Seal
210221
The primary seal for the service ports is the sealing
cap. The cap contains a specially designed 0-ring or
gasket which provides a leak free seal. Should the
cap be loose, missing, or the wrong usage, a loss of
refrigerant could result.
Illustration Tool Number/ Description Illustration Tool Number/ Description
J 8433-3 J 23128-A
Seal Seat Installer and
Forcing Screw
Remover
7029
J 9398
J 28428-E
Bearing Remover
High Intensity Black Light
6186
62292
J 9481-A
Bearing Installer J 33011
0-Ring Installer
210053
6207
J 9553-01 J 33013-B
0-Ring Remover
Hub and Drive Plate
Remover and Installer
J 21352-A J 33017
Support Block. Pulley and Bearing
Assembly Installer
6192 7032
J 33019 J 33025
Bearing Staking Tool Clutch Coil Puller Legs
7037
J 33020 J 33027-A
Pulley Puller Clutch Hub Holding Tool
7039
J 34611-A
J 33022 (or J 39923)
Shaft Nut Socket Valve Core Remover and
Installer
7033 283643
J 33023-A J 34614
Puller Pilot Shaft Seal Protector
7035 6206
J 33024 J 34992
Clutch Coil Installer Compressor Holding Fixture
7035 7038
J 39400-A J 41552
Halogen Leak Detector Compressor Pulley Puller
82132 157245
J 39500-B
A/C Refrigerant Recovery, J 41790
Recycling and Recharging Compressor Holding Fixture
(ACR 4) System
82133
J 39893 J 41810
Pressure Testing Connector Pureguard 2
353273
210224
J 41810-100A
J 41436 Active Flow Control Valve
Tracer Dye Injector
347269
283642
J 41447 J 42136
R134a: Tracer Dye A/C Lip Seal Remover
(24 1/4 oz. Bottles)
258343 208026
(
HVAC HVAC Systems - Manual 1-101
HVAC Systems .. Manual

Specifications
Specification
. Air Distributor Duct Bolt 2.2 N-m 191bin
Bi-Level Mode Actuator Screw 2 N·m 18 lb in
Blower Motor Bolt 2.3N-m 201bin
Blower Motor Resistor Bolt 2N-m 181bin
Floor Air Outlet Duct Bolt 1.9 N-m 17 lb in
Heating, Ventilation and Air Conditioning (HVAC) Control Blower
2N-m 18 lb in
Switch Screw
• Heating, Ventilation and Air Conditioning (HVAC) Control Bolt 2.2N-m 19 lb in
Heating, Ventilation and Air Conditioning (HVAC) Control Selector
2N-m 18 lb in
Switch Screw
Heater Module Screw 1.8 N-m 16 lb in
Instrument Panel (IP) Compartment Hinge Screws 2.8 N-m 251bin
Instrument panel (IP) Outer Air Outet Duct Bolt 2.2 N-m 191bin
Temperature Control Cable Bolt 1.9 N-m 171bin
Vacuum Tank Mounting Bolt 2.5 N-m 221bin
Vent Mode Valve Actuator Screw 2N-m 18 lb in

Air Valve Actuator Vacuum Harness 9.000
Blower Impeller 8.000
Blower Motor 8.000
Blower Motor Relay 9.000
Blower Motor Resistor 9.000
. Defrost Valve Actuator 9.000
Floor Air Outlet Duct 9.000
Heater and Air Conditioning Control 9.000
Heater and Air Conditioning Control Vacuum Harness 9.000
Heater and Air Conditioning Control Vacuum Tank 9.000
Inside Air Valve Actuator 9.000
Instrument Panel Outer Air Outlet Duct 9.000
Mode Valve Actuator 9.000
Side Window Defogger Outlet Duct 9.000
Vacuum Actuator 9.000
Windshield Defroster Nozzle and Air Distributor 9.000
1-102 HVAC Systems - Manual HVAC
Schematic and Routing Diagrams
HVAC Schematic Icons
Icon Icon Definition
Refer to ESD Notice in Cautions and Notices.
19384
Refer to OBD II Symbol Description Notice in Cautions and Notices.
19385
(
HVAC Blower Control Schematics (HVAC Control, Blower Resistor, Blower Motor Relay) :c
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- - -
c
- -
C2
- - - - - -
HVAC I
- "' HVAC
Control
~
L ._."""'"""" =
C10 I
0.35
CS Y
-----.!
I
.-----
!-----<<] I
I
A/C
Refrigerant
!
I
I DEF
Control I
Selector I
Switch
I
DK GRN/1459
.I . Pressure 1 1
WHT Sensor 1
c B" A 1
0.5 DK GRN159 0.35 0.35 I i
C BlC100 RED/B LK 380 LT BLU/ 1688 I I
BLK -"+" - - - - - - -
8114
0.5 DK GRN T~;-----. 0.35
GRY 72 0 Engine
IL. - - - - ..I
Control 0.35 DK AIC2

0.35 -"11 i Schematics
LT BLU/ 8121 i II-- - GRN/WHT 762
0.5 DK GRN I 59 Engine In Engine
Control BLK Control
0.35 DK GRN/WHT I 459 Schematics 8111
1688
3.8L F C230
A In Engine
Control
A/C
A/C
Clutch
Diode [ID
B -v
Compressor
Clutch
Ground
Distribution
Schematics
In Wiring
Systems
3.SL
0.35
LT BLU/ '1688
0.35
GAY 720
0.35 DK GRN/WHT I 762
P110
I
0.5 BLK I 450
$
0.5 BLK
450
l
I
I
• 8108
,. - - - 1'- - c
I NC ~-··-J Al
I
I
Relay
39
Sensor
-1-----------
Signal
1
BLK
?? '- ------------.?~ '- --~? ,._ -
5Volt
Reference
B
se.;;or- -
Ground
- - - - - -
NC
-
Request
Signal
-
22 I C2
-1- ----., PCM
c1:BLU
I
Powertram
I Control
I Module
(PCM)
8115 ; BLK I 450 I
control.
~ ~ SV ~ C2-CLR I
1..--------------------------------------J M~ :c
~ G112
<
).),
500621 0
~ ~
'----/ ~ ~
HVAC Compressor Control Schematics (V8 VIN G) ::c

<
).':!,
r- - - - - - - - -i1p
HVAC
Power I
Distribution Fuse
[FiofinFIUNOrSTARfl
.. -
G7+
NC
- - - - - ., Engine
~Power I ..
Distribution I Wmng
IL 0 c I 0
Fuse 6
20 A
Schematics I Block
In Wiring I I G6
CRUISE Schematics Harness
MiniFuse® In Wiring I Junction ~
Systems I e 15 A Systems i Block 2
L'.gJ
L------..----..1
L.-
1 BRN 241
--------1
Power
Power
Distribution
Schematics
I 0.5 PNK 139
<l\t- -
Si 65
- *~-'-------,
0.5 PNK 139
CB
In Wiring 0.5 PNKI 139
Distribution Systems
0.8. BAN
8248 Schematics
,. o-10J - - - - - oa} - - - - - ~ E~Qine
241 In Wiring
Systems ..-,...--------,,,..... NC Wiring
Compressor
I Harness
1 BRN 241
c C2
- - - - - - - "'HVAC
,_ - - - - - - - - ..
---·
Z Relay I Junction
I Block 2
I
I I
HVAC : Control
Def I Control
Selector I
Switch I
~ :_Bt o.s DK-Gi~r59- ---- ~
0.35 DK GRN/WHT 459
B C C100
59
0.35 DK GRN/WHTI~i: DK-:1~~ 0.5 DK GRN S114
-f
A I C2 59
0.5 DK GAN 59
43 0.5 DKGRN I 59
---------18 C2
0.35 DK GRN/WHT I 762 ~ - PCM-
g~:~t~
- - - - - - - - - ~~. h - - - - - - NC - - - - - ~ 6~~:~rain
4 J ~~:::~i::~rD :
I Relay \ Clutch I Module
: I'
I Control_l:-··
=
5V
=
Status I (PCM)
I~
>
A
[ ] ~~pressor
NC
Clutch
::c
<
I---------J
I NC _ NC Refrigerant NC Refrigerant Ground )>
Clutch Diode
Request
I Signal
- P'.essure Sensor Pressure Sensor _
1 0
&..-------------------- Signal 5V Reference -
en
T------------141
17 C2
0.35 DK GRN/WHT 762 0.35 RED/B~ 380
45 C1
0.35 GR: 474
57 '( C2
0.35 PPL 719 I
B
0.5 BLK 450
8115
-
'<
th
CD
3(/)
p
110
1 r~A ~iigerant
Pressure
!I
1 Engine
0.5 BLK 450
8108 -
Ground Distribution
-<Ii Schematics In
Wiring Systems
s:
m
F I C230 ....__ _ _ _ ____,._. Sensor ~ 0.35 Control ::;
A'( 8128 PPL Schematics 1 BLK I 450 c:
719 In Engine 3 BLKT 550 m
Control
5.7L
G112 ........
.....
I
0
sooe22 a CJ'I
Component Locator
HVAC Components
Name Location Locator View Connector End View
A/C Clutch Diode Sealed in a harness, approximately
{V6 VINK) 3 cm (1.2 in) from the injector 2 breakout
- -
Sealed in a harness, approximately
A/C Clutch Diode
(V8 VIN G)
17 cm (6.8 in) from the A/C compressor - -
clutch connector
Engine Controls
A/C Compressor Clutch In the front of the engine, on the lower
HVAC Component Views Connector End Views in
{V6 VINK) right side
Engine Controls
Engine Controls
A/C Compressor Clutch In the front of the engine, on the lower
HVAC Component Views Connector End Views in
{V8 VIN G) right side
Engine Controls
A/C Refrigerant Engine Controls
Above the right front wheelhouse, attached
Pressure Sensor HVAC Component Views Connector End Views in
to the refrigerant line
{V6 VINK) Engine Controls
A/C Refrigerant Engine Controls
Above the right front wheelhouse, attached
Pressure Sensor HVAC Component Views Connector End Views in
to the refrigerant line
(VS VIN G) Engine Controls
Body Control Module
Under the lower right side of the IP, HVAC Connector
Blower Motor Component Views in
mounted in the HVAC module End Views
Body Control Systems
Under the IP, above the floor tunnel,
Blower Motor Relay attached to the inflatable restraint HVAC Component Views -
instrument panel module bracket
In the HVAC module, forward and left of HVAC Connector
Blower Resistor
the temperature control cable attachment
- End Views (
Power and Grounding
Engine Wiring Harness In the left front corner of the engine
Junction Block 2 compartment
Component Views in -
Wiring Systems
HVAC Connector
HVAC Control In the center of the IP, above the radio HVAC Component Views
End Views
HV AC Control Blower
--
HVAC Connector
Switch (Part of HVAC Part of the HV AC control HVAC Component Views
End Views
Control)
HVAC Control Lamp HVAC Connector
(Part of HVAC Control)
Part of the HV AC control - End Views
HVAC Control Selector
HVAC Connector
Switch (Part of HVAC Part of the HVAC control HVAC Component Views
End Views
Control}
Instrument Panel,
Gauges, and Console
IP Fuse Block On the left end of the IP carrier Component Views in -
Instrument Panel,
Gauges and Console
Powertrain Control Power and Grounding
On the right side of the engine PCM Connector End
Module (PCM) Component Views in
compartment, rear of the wheelhouse Views in Engine Controls
{V6 VINK) Wiring Systems
Powertrain Control Engine Controls
(VS VIN G) Engine Controls
Engine to forward lamp harness, in the lnline Harness Connector
Harness Routing Views in
C100 (10 cavities) engine compartment, above the right
wheelhouse
Wiring Systems
End Views in Wiring
Systems
(
lnline Harness Connector
Forward lamp to IP harness, between the Harness Routing Views in
C200B (18 cavities) End Views in Wiring
left kick panel and the steering column Wiring Systems
Systems
HVAC Components (cont'd)
Part of the IP harness, between the left Harness Routing Views in
C2000 (48 cavities) End Views in Wiring
kick panel and the steering column Wiring Systems
Systems
IP to engine harness, under the right side Harness Routing Views in
of the IP, behind the knee bolster Wiring Systems
Systems
Attached to the rear of the left Harness Routing Views in
G112 -
cylinder head Wiring Systems
Near the left A-pillar, bolted to the IP Harness Routing Views in
G200
mounting stud behind the kick panel Wiring Systems
-
Near the right A-pillar, bolted to the IP Harness Routing Views in
G201 -
mounting stud behind .the kick panel Wiring Systems
Left side in the dash panel, engine to the Harness Routing Views in
P100 -
passenger compartment Wiring Systems
Right side in the dash panel, engine to the Harness Routing Views in
P110
-
In the engine harness at the A/C
8105 (VS VIN G)
refrigerant pressure sensor breakout
- -
In the engine harness, main branch,

8108 (V6 VIN K) approximately 15 cm (6 in) from - -
G 112 breakout
8108 (VS VIN G) In the engine harness, main branch,
(Automatic approximately 5 cm (2 iri) from the - -
Transmission) automatic transmission breakout
8108 (VS VIN G)
(Manual Transmission)
approximately 12 cm (4.7 in) from the - -
vehicle speed sensor breakout
In the engine harness, approximately
8110 (V6 VINK) 4 cm (1.6 in) from the powertrain control - -
module (PCM) breakout
8110 (VS VIN G) approximately 20 cm (7.9 in) from the - -
powertrain control module (PCM) breakout
8114 (V6 VINK)
3 cm (1.2 in) from the generator breakout
- -

8114 (VS VIN G) 17 cm (6.7 in) back from the A/C - -
compressor clutch breakout
In the engine harness at the generator
8115 (V6 VINK)
breakout
- -

8115 (VS VIN G) 20 cm (7.9 in) back from the A/C - -
8121 (V6 VIN K) approximately 8 cm (3.1 in) from the - -
8128 4 cm (1.8 in) from the manifold absolute - -
pressure (MAP) sensor breakout
In the forward lamp harness,
approximately 7 cm (2.8 in) from the main
8165
branch into the engine wiring harness
- -
junction block 2 breakout
In the IP harness, main branch,
8216 approximately 10 cm (4 in) from the - -
instrument cluster breakout
In the IP harness, approximately
8248 - -
2 cm (0.8 in) from DRL module breakout
HVAC Component Views
lower Right Front Side of the Engine (VG VIN K)
(
374360
legend
(1) A/C Compressor Clutch
(
HVAC HVAC Systems - Manual 1..;109
lower Right Front Side of the Engine (V8 VIN G)
374327
legend
(1) A/C Compressor
1·410 HVAC Systems - Manual HVAC
Under Center of the Instrument Panel
(
374324
Legend
(1) IP Wiring Harness (2) Blower Motor Relay
I
\.
Right Rear Side of the Engine Compartment
374328
Legend
(1) A/C Refrigerant Pressure Sensor (3) Engine Wiring Harness
(2) Right Shock Tower
Center of the Instrument Panel
4 3
567223
Legend
(1) IP Wiring Harness (4) HVAC Control
(2) Rear Defogger Switch (5) HVAC Control Selector Switch
(3) HVAC Control Blower Switch (6) Rear Defogger Timer/Relay
(
HVAC Connector End Views HVAC Control Connector C1
(Blower Switch)
Blower Motor
232132
287953 • 1202-0813
Connector Part
• 1206-4829 Information • 5-Way F Metri-pack
Connector Part 630 Series (BLK)
Information • 2-Way F Metri-pack
480 Series (BLK) Circuit
Pin Wire Color No. Function
Circuit
Pin Wire Color No. Function Blower Resistor LO
A YEL 60
Feed Output
A BLK 850 Ground
Blower Motor Relay HI
Blower Motor Relay B ORN 52
B PPL 65 Feed Output
Feed Input
Blow Resistor Ml
c TAN 63
Feed Ouput
Blower Resistor
Blower Resistor M2
D LT BLU 72
Feed Ouput
Selector Switch Power
E LTGRN 66
Feed Input
HV AC Control Connector C2
(Selector Switch)
n µ
62456
Connector Part
• 1206-4752
• 6-Way F Metri-pack Series
I WWW)
Information
280 (BLK)
Circuit
Blower Switch M1
A TAN 63 38596
Feed Input
® 1202-0557
Blower Switch LO Connector Part
B YEL 60 .. 3-Way F Metri-pack
Feed Input Information
480 Series (BLK)
Blow Motor Relay Feed
c DKBLU 101
Output Circuit
Blower Switch M2
D LT BLU 72 DK GRN/ PCM A/C Request
Feed Input A 762
WHT Signal Feed Output
) E-F Not Used
Blower Switch Feed
B LT GRN 66
Output
c BRN 241 Fused Input Feed
HVAC Control Connector C3 (Control Lamp) HVAC Control Connector C4
(Rear Defogger Switch)
r
I I n I
I
II i
I I
DD -
c3 cGc8c3
....
82383
365938
• 1204-7662
Connector Part • 1201-5664
Information • 2-Way F Metri-pack
Connector Part
150 Series (BLK) Information • 4-Way F Metri-pack
Circuit 630 Series (BLK)
Pin Wire Color No. Function Circuit
Blower Switch Lamp Pin Wire Color No. Function
A GRY 8
Feed Input A ORN 1240 Fused Input Feed
B BLK 650 Ground Rear Defogger Grid
B PPL 293 Fuse Feed Output
c BRN 241 Fused Input Feed
D BLK 650 Ground
(
A Dia.gnostic Starting Point A Diagnostic System Check
Begin the system diagnosis by reviewing the system Test Description
Description and Operation. Reviewing the Description The number(s) below refer to the step number(s) on
and Operation information will help you determine the diagnostic table.
the correct symptom diagnostic procedure when 2. Lack of communication may be due to a partial
a malfunction exists. Reviewing the Description and malfunction of the class 2 serial data circuit or
Operation information will also help you determine due to a total malfunction of the class 2 serial data
if the condition described by the customer is normal circuit. The specified procedure will determine
operation. Refer to A Diagnostic System Check the particular condition.
in order to identify the correct procedure for diagnosing 4. The presence of DTCs which begin with "U"
the system and where the procedure is located. indicate some of the modules are not
communicating.
A Diagnostic System Check
Step Action Yes No
Install a scan tool. Go to Scan Tool
Does the scan tool power up? Does Not Power Up
1
in Data Link
Go to Step2 Communications
1. Turn ON the ignition, with the engine OFF. Go to Scan Tool
2. Attempt to establish communication with each module on the Does Not
class 2 circuit serial data circuit. (If using a Tech 2, obtain this Communicate
2
information using the Class 2 Message Monitor feature.) w!Class 2 Data Line
in Data Link
Does the scan tool communicate with the modules?
Go to Step 3 Communications
1. Select the Display DTCs function for each module. (If using a
Tech 2, use the Class 2 DTC Check feature in order to
determine which modules do have DTCs set.)
3
2. Record all of the displayed DTCs, the DTC status, and the Go to Symptoms in
module which set the DTC. HV AC Systems -
Does the scan tool display any DTCs? Go to Step 4 Manual.
Does the scan tool display any DTCs which begin with a "U"? Go to Scan Tool
Does Not
Communicate
4
w!Class 2 Data Line
in Data Link
Communications Go to Step 5
Does the scan tool display any PCM DTCs? Go to Diagnostic
Trouble Code (OTC)
List/Type in Engine
Controls - 3.8 L and
5
Diagnostic Trouble
Code (OTC) Go to Symptoms in
List/Type in Engine HV AC Systems -
Controls - 5.7 L. Manual.
Symptoms Intermittent
Important: Review the system operation in order to Faulty electrical connections or wiring may be the
familiarize yourself with the system functions. Refer to cause of intermittent conditions. Refer to Testing for
Control Assembly Description (Pontiac) for Pontiac Intermittent and Poor Connections
or Control Assembly Description (Chevrolet) for Symptom list
Chevrolet.
Refer to a symptom diagnostic procedure from the
Visual/Physical Inspection following list in order to diagnose the symptom:
• Inspect for aftermarket devices which could affect .. Blower Motor Inoperative at Any Speed
the operation of the HVAC System. Refer to
" Blower Motor Operates at High Speed Only
Checking Aftermarket Accessories
• Inspect the easily accessible or visible system s Blower Motor Inoperative in One Speed Only
components for obvious damage or conditions (High Speed Operates Normally)
which could cause the symptom. o Blower Motor High Speed Inoperative
.. Blower Motor Always On .. Noise Diagnosis ~ Blower Motor in Heating,
" Air Delivery Improper Ventilation and Air Conditioning.
• Defrosting Insufficient in Heating, Ventilation and " Noise Diagnosis - A/C System in Heating,
Air Conditioning. Ventilation and Air Conditioning.
" Heating Insufficient in Heating, Ventilation and Air .. Odor Diagnosis in Heating, Ventilation and
Conditioning. Air Conditioning.
HVAC Compressor Clutch Does Not Engage
DEFINITION: A/C compressor clutch will not engage when an A/C request has been made and no Powertrain DTCs are set.
Did you perform the Diagnostic System Check? Go to A
1 - Diagnostic
Go to Step 2 System Check
2. Install both the high and low A/C freon
pressure gages.
3. Read the freon pressure with the engine off.
• Freon pressure in the high and low sides should
equal each other after the A/C system has come
to rest. 345 kPa (50 psi)
2
• Freon pressure will fluctuate depending on
ambient temperature.
• Proper clutch operation depends on correct Go to Leak
refrigerant charge. Low freon charge will shut off Testing in
A/C compressor operation. Heating,
Are the high and low side freon pressures below the Ventilation, and
specified value? Air Conditioning Go to Step 3
Are the high and low side freon pressures above the 690 kPa
3 (100 psi) Go to Step 4 Go to Step 5
specified value?
(
Evacuate and recharge the A/C system according to
4 proper freon fill specifications. - -
Has the A/C system been recharged properly? Go to Step 24
Test for and repair a short to ground in the supply voltage
circuit of the A/C compressor clutch. Refer to Circuit
5 Testing and Wiring Repairs in Wiring Systems. -
Did you find and repair a short to ground? Go to Step 24 Go to Step 6

1. Remove the A/C clutch relay from the engine wiring
harness junction block 2.
2. Disconnect the A/C compressor clutch coil connector.
3. Connect a fused jumper between the ignition voltage
terminal for the switch side of the A/C clutch relay
and the engine wiring harness junction block 2
6 connector C1 terminal F8. B+
4. Connect a DMM between the A/C compressor clutch
coil connector terminal B and ground.
5. Turn the ignition switch to the RUN position.
6. Measure the available voltage at the A/C compressor
clutch coil connector terminal B.
Is the voltage the same as the specified value? Go to Step 8 Go to.Step 7
Repair a poor connection or an open in the supply voltage
circuit of the A/C compressor clutch. Refer to Wiring
7 Repairs or Connector Repairs in Wiring Systems. - -
Did you complete the repair? Go to Step 24
Using a DMM, measure for continuity between terminal B
8 of the A/C compressor clutch coil connector and ground. 0- 2 Q
Is the resistance to ground less than the specified value? Go to Step 10 Go to Step 9
Repair a poor connection or an open in the ground circuit
of the A/C compressor clutch. Refer to Wiring Repairs or
9 Connector Repairs in Wiring Systems. - -
HVAC Compressor Clutch Does Not Engage (cont'd)
1. Disconnect the powertrain control module (PCM)
connector C2.
2. Reinstall the NC clutch relay.
3. Connect a fused jumper between the PCM connector
C2 terminal 39 and ground.
10 B+
5. Using a DMM, measure the voltage between the
NC compressor clutch coil connector terminal B and
ground.
Is the voltage the same as the specified value? Go to Step 11 Go to Step 12
1. Remove the fused jumper from the PCM connector
C2 terminal 39 and ground. Go to Cooling
2. Reconnect the NC compressor clutch coil connector. Insufficient,
11 3. Reinstall the fused jumper between the PCM - A/C System in
connector C2 terminal 39 and ground. Heating,
4. Turn the ignition switch to the ON position. Ventilation, and
Does the NC compressor clutch engage? Air Conditioning Go to Step 23
2. Remove the NC clutch relay.
12 3. Using a DMM, measure for continuity between the -
PCM connector C2 terminal 39 and the engine wiring
harness junction block 2 connector C1 terminal F7.
Is there continuity? Go to Step 14 Go to Step 13
Repair a poor connection or an open in the control circuit
of the NC clutch relay. Refer to Wiring Repairs or
13 Connector Repairs in Wiring Systems.
- -
Replace the A/C clutch relay and retest the NC system.
Refer to Compressor Relay Replacement in Heating,
14 -
Ventilation, and Air Conditioning.
Does replacing the NC clutch relay correct the concern? Go to Step 24 Go to Step 15
1. Disconnect the heater-NC control connector C2.
2. Connect a DMM between the PCM connector C2
terminal 22 and the heater-NC control connector C2
terminal B.
15 0-2 Q
3. Measure the NC request signal circuit for resistance
between these two connectors.
Is the NC request signal circuit resistance between the
specified values? Go to Step 17 Go to Step 16
Repair a poor connection or an open in the NC request
signal circuit. Refer to Wiring Repairs or Connector
16 Repairs in Wiring Systems. - -
1. Connect a DMM between the PCM connector C2
terminal 22 and ground.
17 2. Measure the NC request signal circuit for continuity -
to ground.
Is the NC request signal circuit continuous to ground? Go to Step 18 · Go to Step 19
Repair a short to ground in the NC request signal circuit.
18 Refer to Wiring Repairs in Wiring Systems. - -
1. Disconnect the DMM.
2. Re.connect all connectors back to their respective
modules.
3. Install the scan tool to the diagnostic link connector.
4. Start the engine and allow it to idle in park. -
19
5. Select the area of the scan tool which will read HVAC
button output status.
6. Depress the NC button on/off several times.
Does the scan tool read the NC request being sent by the
HV AC control head? Go to Step 20 Go to Step 22
1.. 11 s HVAC Systems - Manual HVAC
HVAC Compressor Clutch Does Not Engage (cont'd)
Test for and repair a poor connection at the PCM and at
the engine wiring harness junction block 2. Refer to
20 Testing for Intermittent and Poor Connections and -
Connector Repairs in Wiring Systems.
Did you complete the repair? Go to Step24 Go to Step 21
Replace the PCM. Refer to PCM
Replacement/Programming (V6) or PCM
21 Replacement/Programming (VB) in Engine Controls. - -
Did you complete the replacement? Go to Step 24
Replace the heater-A/C control. Refer to Control Assembly
22 Replacement. - -
Replace the A/C compressor clutch coil. Refer to
Compressor Clutch Coil Removal (V5 - Conventional
Mount) and Compressor Clutch Coil Install
23 (V5 - Conventional Mount) (V6) or Compressor Clutch Coil - -
Removal (V7 - Direct Mount) and Compressor Clutch Coil
Install (V7 - Direct Mount) (VB).
Operate the system in order to verify the repair.
24
Did you correct the condition?
HVAC Compressor Clutch Does Not Disengage

DEFINITION: A/C compressor clutch will not disengage when no A/C request has been made and no Powertrain DTCs
are set.
Did you perform the Diagnostic System Check? Goto A
1 - Diagnostic
1. Disconnect the Powertrain Control Module (PCM)
connector C2.
2
-
Does the A/C compressor clutch coil disengage? Go to Step 3 Go to Step 4
Replace the Powertrain Control Module (PCM). Refer to
PCM Replacement/Programming (V6) or PCM
3 Replacement/Programming (VB) in Engine Controls. - -
1. Disconnect the A/C CLU relay from the underhood
accessory wiring junction block.
4
-
Does the A/C compressor Clutch coil disengage? Go to Step 5 Go to Step 8
2. Powertrain Control Module (PCM) connector C2 still
disconnected.
3. A/C clutch relay still removed from the engine wiring
5 4. Connect a DMM between the Powertrain Control -
Module (PCM) connector C2 terminal 39 and ground.
5. Measure for.continuity in the control circuit of the
A/C compressor .relay to ground.
Is the air conditioning compressor coil control relay output
circuit continuous to ground? Go to Step 6 Go to Step 7
Repair a short to ground in the control circuit of the
A/C compressor relay between the engine wiring harness
6 junction block 2 and the PCM connector C2. Refer to - -
Wiring Repairs in Wiring Systems.
Did you complete. the repair? Go to Step 11 (
Replace the A/C clutch relay. Refer to Compressor Relay
7 Replacement in Heating, Ventilation, and Air Conditioning. - -
HVAC Compressor Clutch Does Not Disengage (cont'd)
1. Leave the Powertrain Control Module (PCM)
connector C2 still disconnected.
2. NC clutch relay still removed from the engine wiring
3. Disconnect the NC compressor clutch coil connector.
4. Connect a DMM between the NC compressor clutch -
8
coil connector terminal B and ground.
6. Measure for voltage on the supply voltage circuit of
the NC compressor clutch.
Is voltage present on the supply voltage circuit of the
NC compressor clutch? Go to Step 9 Go to Step 10
Repair a short to battery voltage in the supply voltage
circuit of the NC compressor clutch between the engine
9 wiring harness junction block 2 and the NC compressor - -
clutch coil. Refer fo Wiring Repairs in Wiring Systems.
Replace the NC compressor clutch coil. Refer to
Compressor Clutch Coil Removal (V5 - Conventional
Mount) and Compressor Clutch Coil Install
10 (V5 - Conventional Mount) (V6) or Compressor Clutch Coil - -
Removal (V7 - Direct Mount) and Compressor Clutch Coil
Install (V7 - Direct Mount) (V8).
11
Blower Motor Inoperative at Any Speed

Did you complete the Diagnostic System Check? Go to A
1 - Diagnostic
Goto Step 2 System Check
1. Place the ignition switch in the RUN position.
2. Place the selector switch in the VENT position.
2 3. With a test lamp, probe the HVAC control (blower -
switch) between connector C1 terminal E and ground.
Does the test lamp illuminate? Go to Step3 Go to Step 15
1. Place the blower switch in position 1 (low).
2. With a test lamp, probe the HVAC control (blower
3 switch) between connector C1 terminal A and ground.
-
Does the. test lamp illuminate? Go to Step 4 Go to Step 5
1. Place the ignition switch in the OFF position.
2. Disconnect the blower motor relay.
3. Connect a fused jumper between the blower motor
relay terminals 82 and C1.
4
4. Place the ignition switch in the RUN position.
-
5. Place the selector switch in the VENT position.
6. Place the blower switch in position 1 (low).
Does the blower motor run? Go to Step 8 Go to Step 7
Test for and repair a poor connection at the HVAC control
blower switch. Refer to Testing for Intermittent and Poor
5 Connections and Connector Repairs in Wiring Systems. -
Did you find and repair a poor connection? Go to Step 20 Go to Step 6
Replace the HVAC control blower switch. Refer to HVAC
) 6 Control Blower Switch Replacement. - -
Did you complete the replacement? Go to Step20
Blower Motor Inoperative at Any Speed (cont'd)
1. Leave the jumper connected from previous step.
3. Disconnect the blower motor connector.
7 4. Turn the ignition switch to the RUN position. -
5. Connect a test lamp between the blower motor
connector terminals A and B.
Does the test lamp illuminate? Go to Step 11 Go to Step 10
Test for and repair a poor connection at the blower motor
relay. Refer to Testing for Intermittent and Poor
Replace the blower motor relay. Refer to Blower Motor
9 Relay Replacement. - -
Did you complete the replacement? . Go to Step 20
1. Leave the jumper connected from the previous step.
2. Connect the test lamp between the blower motor
10
connector terminal B and ground. -
Test for and repair a poor connection at the blower motor.
Refer to Testing for Intermittent and Poor Connections and
11 Connector Repairs in Wiring Systems. -
Replace the blower motor. Refer to Blower Motor and Fan
12 Replacement. - -
Repair a poor connection or an open in the supply voltage
circuit of the blower motor. Refer to Connector Repairs or
13 Wiring Repairs in Wiring Systems. - -
of the blower motor. Refer to Connector Repairs or Wiring
Probe the HVAC control (selector switch) between
15 connector C2 terminal C and ground. -
Does the test lamp illuminate? Goto Step 16 Go to Step 19
Test for and repair an open or a poor connection in the
A/C request signal circuit at the HVAC control (selector
switch) connector C2 terminals B and C. Refer to Circuit
16 Testing or Testing for Intermittent and Poor Connections -
and Wiring Repairs or Connector Repairs in Wiring
Systems.
Did you find and repair an open or a poor connection? Go to Step 20 Go to Step 17
(selector switch). Refer to Testing for Intermittent and Poor
Did you complete the repair? Go to Step 20 Go to Step 18
Replace the HVAC control (selector switch). Refer to
18 Control Assembly Replacement. - -
Repair a poor connection or an open in the ignition
3 voltage circuit between the HVAC control (selector
19 switch) connector C2 terminal C and 8248. Refer to - -
Connector Repairs or Wiring Repairs in Wiring Systems.
Did you complete the repair? Goto Step 20
20
-
(
Did you correct the condition? ·system OK· Go to Step 3
Blower Motor Operates at High Speed Only
1 - Diagnostic
1.Place the ignition switch in the RUN position.
2.Place the selector switch in the VENT position.
3.Place the blower switch in position 1 (low).
2 -
4.Probe with a test lamp between the blower resistor
connector terminal C and ground.
Probe with a test lamp between the blower motor relay
3 connector terminal B2 and ground. -
Does the test lamp illuminate? Go to Step 6 Go to Step B
Test for and repair a poor connection at the blower
resistor. Refer to Testing for Intermittent and Poor
Replace the blower resistor. Refer to Blower Motor
5 Resistor Replacement. - -
Test for and. repair a poor connection at the blower motor
relay. Refer to Testing for Intermittent and Poor
Repair a poor connection or an open in the blower resistor
control circuit of the blower motor relay between the
8 blower resistor and the blower motor relay. Refer to - -
Connector Repairs or Wiring Repairs in Wiring Systems.
9
Blower Motor Inoperative in One Speed Only (High Speed Operates Normally)
1 - Diagnostic
1.Disconnect the blower resistor connector.
2.Place the ignition switch in the RUN position.
3.Place the blower switch in the inoperative position.
2 4.Connect a test lamp from the blower -
resistor connector inoperative terminal
(position 1 (low) =B, 2 (M1) =A, 3 (M2} =D) to
ground on the harness connector.
Test for and repair a poor connection at the blower
resistor. Refer to Testing for Intermittent and Poor
Replace the blower resistor. Refer to Blower Motor
4 Resistor Replacement. - -
) Did you complete the replacement? Go to Step 9
Probe with a test lamp between the HVAC control
(blower switch} connector C1 of the inoperative terminal
5 (position 1 (low) =A, 2 (M1) =C, 3 (M2) =D) and ground. -
1-122 HVAC Systems~ Manual HVAC
Blower Motor Inoperative in One Speed Only (High Speed Operates Normally) (cont'd)
(
Repair a poor connection or an open in the inoperative
circuit (position 1 (low) =60, 2 (M1) =63, 3 (M2) =72).
6 Refer to Connector Repairs or Wiring Repairs in Wiring - -
Systems.
(blower switch). Refer to Testing for Intermittent and Poor
8 Control Blower Switch Replacement. - -
9 -
Did you correct the condition? System OK Go.to Step 3
Blower Motor High Speed Inoperative

i - Diagnostic
Go to Step2 System Check
i. Place the HVAC control (selector switch) in the VENT
position.
2. Place the HVAC control (blower switch) in
2 position 4 (high). -
3. Connect a test lamp between the HVAC control
(blower switch) connector C1 terminal B and ground.
(
Connect a test lamp between the blower motor relay
3 terminal Ai and ground. -
(blower switch). Refer to Testing for Intermittent and Poor
5 Control Blower Switch Replacement. - -
Connect the test lamp between the blower motor relay
6 terminals A 1 and C2. -
Repair a poor connection or an open in the control circuit
of the high blower motor. Refer to Connector Repairs or

Connect a test lamp between the blower motor relay
8 connector terminals A2 and C2. -
of the blower motor relay. Refer to Connector Repairs or
Check for a poor connection at the blower motor relay.
Blower Motor High Speed Inoperative (cont'd)
Repair an open or a poor connection in the battery positive
voltage circuit of the blower motor relay. Refer to
12 Connector Repairs or Wiring Repairs in Wiring Systems. - -
13 -
Did you correct the coridition? System OK Go to Step 3
Blower Motor Always On

1 - Diagnostic
2. Disconnect the blower motor relay.
2 3. Connect a test lamp at the blower motor relay -
connector terminal A 1 and ground.
Repair a short to battery voltage in the control circuit of the
high blower motor. Refer to Wiring Repairs in Wiring
3 Systems. - -
Connect a test lamp at the blower motor relay connector
4 terminal B2 and ground. -
Repair a short to battery voltage in the blower resistor
5 control circuit of the blower motor. - -
Connect a test lamp at the blower motor relay connector
6 terminal C1 and ground. -
Repair a short to battery voltage in the supply voltage
circuit of the blower motor. Refer to Wiring Repairs iri
7 Wiring Systems. - -

9 -
Did you correct the condition? System OK Go to Step 3
Air Delivery Improper

The air delivery system uses an engine manifold
vacuum in order to position the heater A/C module
valves. The positioning of the valves allows the
air delivery system to achieve the desired air flow.
The engine manifold vacuum is controlled by the
heater A/C control.
)
Repair Instructions
Blower Motor Resistor Replacement

Removal Procedure
1. Remove the key from the ignition in order to ·
assure that the ignition switch will remain in
the OFF position.
2. Remove the right instrument panel insulator.
Refer to Closeoutllnsu/ator Panel Replacement ·
- Right in Instrument Panel, Gauges and Console.
3. Pull the carpet away from the heater,module.
4. Remove the blower motor resistor bolt (2).
5. Disconnect the blower motor resistor electical
connector.
I
6. Remove the blower motor resistor (1 ).
@---
~2
282923
1. Install the blower motor resistor (1 ).
2. Connect the blower motor resistor electical
connector.
Notice: Refer to Fastener Notice in Cautions.and ..
Notices. (
3. Install the blower motor resistor bolt (2).
Tighten
Tighten the blower motor resistor
bolt to 2 (18 lb in).
4. Reposition the carpet
5. Install the right instrument panel insulator. Refer
to C/oseoutllnsulatorPanel Replacement - Right
I
@--- in Instrument Panel, Gauges and Console.
1 6. Test the blower motor operation at each of the
~2 four speeds.
282923
(
Blower Motor and Fan Replacement
J Removal Procedure
1. Remove the key from the ignition switch in order
to ensure that the ignition switch will remain OFF.
2. Remove the right instrument panel insulator. Refer
to Closeout/Insulator Panel Replacement - Right 1
3. Disconnect the blower motor electrical connector.
4. Remove the blower motor bolts (2).
5. Remove tile blower motor (3).
6. Inspect the blower motor terminals for corrosion.
Perform the following tasks as necessary:
• Clean the corrosion from the terminals.
• Replace the blower motor.
2
7. Inspect the flange of the blower motor for any
damage or distortion which could cause an
air leak. 282924
Repair the flange of the blower motor as
necessary.
8. Inspect the blower motor fan for damage and
distortion.
Perform the following tasks as necessary:
• Repair the blower motor fan.
• Replace the blower motor fan.
1. Install the blower motor (3) using the
following steps:
1.1. Guide the blower motor (3) into position.
Do not catch the blower motor fan on the
protruding parts.
1
Notices.
1.2. Install the blower motor bolts (2).
Tighten
Tighten the blower motor bolts (2) to
2.3 N-m (20 lb in).
2. Connect the blower motor electrical connector.
3. Install the right instrument panel insulator. Refer to
Closeout/Insulator Panel Replacement - Right in 2
4. Check the blower for proper operation.
282924
Control Assembly Replacement
Removal Procedure (
1. Remove the accessory trim plate. Refer to Trim
Plate Bezel Replacement - IP Cluster (Chevrolet)
or Trim Plate Bezel Replacement - IP Cluster
(Pontiac) in Instrument Panel, Gauges and
Console.
2. Remove the heating, ventilation. and ai.r
conditioning (HVAC) control bolts. ·
3. Gently pull the HVAC control out from the
instrument panel (IP) far enough to access
the following connections:
., Vacuum
" Electrical
O Temperature cable
282916
4. Disconnect the vacuum harness conneGtor from

the vacuum selector valve.
282918
5. Disconnect the following electrical connectors

from the HVAC control:
1 2 3
e HVAC mode switch (1)
" HVAC control illumination (2)

" HVAC blower switch (3)
" Rear defogger (4)
6. Remove the temperature control cable (5) from
the control.
When releasing the control cable clips, use a
small screwdriver to gently pry the cable from the
control.
282917
1. Install the temperature control cable connector (5) 1 2 3
to the control.
2. Connect the following electrical connectors to the
HVAC control:
• Rear defogger (4)
• HYAC blower switch (3)
• HYAC control illumination (2)
• HYAC mode switch (1)
282917
3. Connect the vacuum harness connector to the

vacuum selector valve.
282918
4. Install the HYAC control.

Notices.
5. Install the HYAC control bolts.
Tighten
Tighten the HYAC control bolts to
2.2 N-m (19 lb in).
6. Install the accessory trim plate.Refer to Trim Plate
Bezel Replacement - IP Cluster (Chevrolet) or
Trim Plate Bezel Replacement - IP Clµster
Console.
282916
1~12s HVAC Systems - Manual HVAC
HVAC Control lamp Bulb Replacement
Removal· Procedure· (
1. Remove the heating, ventilation and air
conditioning (HVAC) control. Refer to Control
Assembly Replacement.
2. Remove the HVAC control wiring harness from
the control. ·
3. Gently, pull the burned out HVAC control lamp
bulb (1) from the control lamp harness.
517337
installation Procedure
1. Install a new HVAC control lamp bulb (1) to the
control lamp harness.
2. Install the HVAC control wiring harness to the
control.
3. Install the HVAC control. Refer to Control
(
517337
HVAC Control Lamp Bulb Wiring Harness

Replacement
Removal Procedure
conditioning (HV AC) control. Refer to Control
2. Remove the HVAC control wiring harness (2) from
the control.
3. Gently, pull the control lamp bul.bs from the
control lamp harness (2).
517337
1. Install the control lamp bulbs to the control lamp
harness (2).
2. Install the HVAC control wiring harness (2) to the
control.
517337
HVAC Control Blower Switch Replacement

Removal Procedure
2. Pull the HVAC control blower knob (1) off.
3. Remove the HV AC control blower switch
screw (2).
4. Remove the HVAC control blower switch (3). from
the control.
517336
1. Install the HVAC control blower switch (3) to the
control.
Notices.
2. Install the HVAC control blower switch screw (2).
Tighten
Tighten the HVAC control blower switch screw (2)
to 2 N·m (18 lb in).
3. Push the HVAC control blower knob (1) on.
517336
HVAC Control Vacuum Valve Replacement
4 Removal Procedure (
1. Remove the. heating, ventilation and air
2. Remove the HVAC control selector switch
screws (2, 4).
3. Remove the HVAC control vacuum valve (3) from
the selector switch (5).
517338
4 1. Install the HVAC control vacuum valve (3) to the
selector switch (5).
Notices.
2. Install the HVAC control selector switch
screws (2, 4).
Tighten (
Tighten the HVAC control selector switch screws
to 2 N-m (18 lb in).
517338
HVAC Control Selector Switch

4 Replacement
Removal Procedure
1 . Remove the heating, ventilation and air
conditioning (HVAC) control vacuum valve .. Refer
to HVAC Control Vacuum Valve Replacement.
2. Pull the HVAC control selector knob (1) off.
3. Remove the HVAC control selector switch (5) from
the control.
517338
1. Install the HVAC control selector switch (5) to the 4
control.
2. Push the HVAC control selector knob (1) on.
3. Install the HVAC control vacuum valve. Refer to
HVAC Control Vacuum Valve Replacement.
517338
Temperature Control Cable Replacement

Removal Procedure
1. Remove the right instrument panel (IP) insulator.
Refer to Closeout/Insulator Panel Replacement ~
Right in Instrument Panel, Gauges and Console.
3. Disconnect the temperature control cable at the
air conditioning
, .
(A/C) module.
. . .
4. Remove the accessory trim plate. Refer to Trim
Plate Bezel Replacement - IP Cluster (Chevrolet)
or Trim Plate Bezel Replacement - IP Cluster
Console.
282922

conditioning (HV AC) control bolts.
6. Pull the HVAC control out of the IP far enough to
access the temperature control cable connection.
7. Remove the temperature control cable from the
control. ·
8. When releasing the control cable clips, use a
small screwdriver to gently pry the cable from
the controL
282920
1. Install the temperature control cable to the control. (
Notices.
2. Install the HVAC control bolts.
Tighten
Tighten the HVAC control bolts to
2.2 N·m (19 lb in).
282920
3. Connect the temperature control cable to the

A/C module.
temperature control cable to the control:
4.1. Slip the temperature control cable into
position over the lever arm.
4.2. Align the shaft with the temperature control
cable shaft.
4.3. Press the temperature control cable clips
into the slot in the control.
4.4. Ensure that the temperature control cable
clips are .in place.
5. Install the temperature control cable bolt.
Tighten
Tighten the temperature control cable bolt to
1.9 N·m (17 lb in).
6. Install the accessory trim plate. Refer to Trim Plate
Bezel Replacement - IP Cluster (Chevrolet) or Trim
Plate Bezel Replacement - IP Cluster (Pontiac) in
282922
Temperature Control Cable Adjustment

1. Remove the right instrument panel (IP) insulator.
Refer to Closeout/Insulator Panel Replacement -
Right in Instrument Panel; Gauges and Console.
3. Disconnect the temperature control cable at the
air conditioning (A/C) module.
282922
Important: Ensure that the temperature control
cable (3) is still attached to the heating, ventilation and 10°- 15°
) air conditioning (HVAC) control.
1
4. Cycle the temperature control knob between the 4

following positions:
" Full cold position
• Full hot position
5. Replace the temperature control cable if one of
the following situations occur:
• The temperature control cable binds
O The temperature control cable does not rotate
freely
Refer to Temperature Control Cable
Replacement.
6. Set the temperature control knob to the detent 3
position half way between the full cold and the
full hot positions.
7. Inspect the position of the temperature control 282915
cable pulley (2).
Adjust the temperature control cable pulley (2):
• Do not adjust the pulley if the pulley is skewed
5-10 degrees toward the full cold side.
• Adjust the control cable if the pulley is skewed
toward the full hot side.
8. Remove the spring (4) from the temperature
control cable pulley.
) 9. Adjust the temperature control cable pulley
5-10 degrees toward the full cold position.
10. Install the temperature control cable spring (4) to
the temperature control cable pulley (2). 10°- 15°
1
11. Connect the temperature control cable (5) to the
heater module.
4
282915
12. Connect the temperature control cable to the
A/C module.
Notice: Refer to Fastener Notice in Cautions and (
Notices.
13. Install the temperature control cable bolt.
Tighten
Tighten the temperature control cable bolt to
1.9 N·m (.17 lb in).
14. Install the right IP insulator. Refer to
Closeout/Insulator Panel Replacement - Right in
282922
Inside Air Valve Actuator Replacement

2 Removal Procedure
1. Remove the right side insulator. Refer to
2. Remove the left side insulator. Refer to
Closeout/Insulator Panel Replacement - Left in
door hinge screws.
4. Remove the IP compartment door.
conditioning (HV AC) module screws.
6. Remove the HVAC module cover.
7. Disconnect the air inlet valve linkage.
8. Remove the air inlet valve actuator (2) and
vacuum hose.
571436
1 2 1. Install the air inlet valve actuator (2) and
vacuum hose.
2. Connect the air inlet valve linkage.
3. install the HVAC module cover.
Notices.
4. Install the HVAC module screws.
Tighten
Tighten the HVAC module screws to
1.8 N·m (16 lb in).
5. Install the IP compartment door.
6. Install the IP compartment hinge screws.
Tighten
Tighten the IP compartment hinge screws to
2.8 N-m (25 lb in).
571436
7. Install the left side insulator. Refer to
8. Install the right side insulator. Refer to
Vacuum Actuator Replacement

Removal Procedure
1. Remove the instrument panel (IP) carrier. Refer to
IP Carrier Replacement in Instrument Panel,
Gauges and Console.
2. Remove the front floor air duct. Refer to Air Outlet
Replacement - Floor.
3. Remove the air distributor case face (1) and
seal (2).
4. Disconnect the vacuum hose from the vent mode
valve actuator (4).
5. Remove the vent mode valve linkage screw (5).
6. Unsnap the vent mode valve actuator (4) from air
distributor case.
571441
i. Snao the vent mode valve actuator (4) to the air
distributor case.
Notices.
2. Install the vent mode valve linkage screw (5).
Tighten
Tighten the vent mode valve actuator screw to
2 N-m (18 lb in).
3. Connect the vacuum hose to the vent mode valve
actuator (4).
4. Install the air distributor case face (1) and
seal (2).
5. Install the front floor air duct. Refer to Air Outlet
6. Install the IP carrier. Refer to IP Carrier
Replacement in Instrument Panel, Gauges and
Console. 571441
)
Defroster Valve Actuator Replacement
1 2 Removal Procedure (
Gauges and Console.
seal (2).
4. Disconnect the vacuum hose from the defroster
4~' valve actuator.
5. Disconnect the defroster valve actuator linkage
from the defroster actuator.
6. Remove the defroster valve actuator (3).
571445
1 2 1. Install the defroster valve actuator (3).
2. Connect the defroster valve actuator linkage to
the defroster actuator.
3. Connect the vacuum hose to the defroster valve
actuator.
4. Install the air distributor case face (i) and
seal (2).
4~' 6. Install the IP carrier. Refer to IP Carrier
Console.
571445
Mode Valve Actuator Replacement

Removal Procedure
Gauges and Console.
seal (2).
4. Disconnect the mode valve actuator linkage from
the mode valve.
5. Remove the bi-level actuator (4) and linkage (3).
6. Remove the bi-level mode actuator screw (5).
(
571448
Notices.
1. Install the bi-level mode actuator screw (5).
Tighten
Tighten the bi-level mode actuator screw to
2 N-m (18 lb in).
2. install the bi-level actuator (4) and linkage (3).
3. Disconnect the mode valve actuator linkage from
the mode valve.
4. Install the air distributor case face (1) and
seal (2).
Console.
571448
Air Distributor Duct Replacement

Removal Procedure
Gauges and Console.
2. Place the IP carrier face down on a clean work
surface.
3. Remove the air distributor duct bolts.
4. Remove the air distributor from the IP carrier.
365456
1. Install the air distributor to the IP carrier.
Notices.
2. Install the air distributor duct bolts.
Tighten
Tighten the air distributor duct bolts to
2.2 N-m (19 lb in).
Console.
365456
Air Outlet Replacement - Right Defogger
Removal Procedure (
Gauges and Console.
2. Remove the IP outer air outlet duct bolts.
3. Remove the IP outlet air outlet duct.
365459
1. Install the IP outer air outlet duct.
Notices.
2. Install the IP outer air outlet duct bolts.
Tighten
Tighten the IP outer air outlet duct bolts to
2.2 N-m (19 lb in).
Console.
365459
Air Outlet Replacement - Floor

Removal Procedure
1. Remove the front floor console. Refer to Console
Replacement - Front Floor in Instrument Panel,
Gauges and Console.
2. Remove the front floor air outlet bolts.
3. Remove the front fJor air outlet.
365458
J 1. Install the front floor air outlet.
Notices.
2. Install the front floor air outlet bolts
Tighten
Tighten the floor air outlet bolts to
1.9 N-m (17 lb in).
3. Install the front floor console. Refer to Console ·
Replacement - Front Floor in Instrument Panel,
Gauges and Console.
365458
Air Outlet Replacement - Side Window

Removal Procedure
Gauges and Console.
2. Place the IP carrier face down on a clean work
surface.
3. Unsnap the side window defogger outlet duct from
the air distributor.
365462
1. Snap the side window defogger outlet duct to the
air distributor.
Console.
365462
Vacuum Tank Replacement
Removal Procedure (
Information.
2. Remove the front end fascia outer deflector. Refer
to Air Deflector Replacement - Front Bumper
Fascia in Bumpers.
3. Disconnect the vacuum line from the vacuum tank.
/
282928
4. Remove the vacuum tank mounting bolts

5. Remove the vacuum tank.
282929
1. Install the vacuum tank.
Notices.
2. Install the vacuum tank mounting bolts.
Tighten
Tighten the vacuum tank mounting bolts to
1.9 N·m (17 lb in).
282929
3. Connect the vacuum line to the vacuum tank.
4. Install the front end fascia outer deflector. Refer to
Air Deflector Replacement - Front Bumper Fascia
in Bumpers.
5. lower the vehicle.
/
282928
Vacuum Hose Harness Replacement

Removal Procedure
Gauge and Console.
2. Disconnect the vacuum hoses from the actuators.
') 3. Remove the vacuum harness.
282925
1. Install the vacuum harness.
2. Connect the vacuum hoses to the actuators.
Replacement in Instrument Panel Gauges and
Console.
282925
HVAC Control Vacuum Harness
Replacement (
Removal Procedure
1. It is not necessary to replace the entire vacuum
harness if there is a localized leakage or collapse
in the vacuum hose.
If there is a localized leak or collapse in the
vacuum hose, repair the vacuum hose:
1.1. Cut the vacuum hose.
1.2. Insert a plastic retainer into the
vacuum hose.
conditioning (HVAC) control. Refer to Control
3. Open the instrument panel (IP) compartment.
Push in on both sides of the IP compartment.
This will cause the IP compartment to drop open
282918 completely to allow access to the vacuum harness.
4. Disconnect the vacuum harness connector from
the vacuum selector valve.
5. Disconnect the vacuum harness jumper from the
main harness connector.
282926
(
1. Connect the vacuum harness jumper to the main
harness connector.
282926
2. Connect the vacuum harness connector to the

vacuum selector valve.
3. Close the IP compartment.
282918
)

Air Distribution System Description Heater (
Vacuum regulates air flow through the system.
Depending on the mode selected, the mode valves
mix and direct either cooled, heated, or outside
air through the air ducts. The various modes of
operation are as follows:
Vent
570793
Outside air is drawn into .the vehicle, heated . .

(depending on the position of the temperature control
knob) and directed to the floor air outlet. A small
amount of air is routed to the windshield through the
defrost outlet.
570788
Blend (
Outside air is delivered through the instrument
panel (IP) outlets to ventilate the vehicle. If preferred,
the air may be warmed by setting the temperature
control knob to the desired setting.
Bi-level
570800
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 outlet.
570784
Electrical power is supplied to the blower motor.

Outside air is drawn in and heated (depending on the
position of the temperature control knob). Then the
airflow is split between the IP outlets and the
floor outlet.
Defrost Blower Motor Resistor Description
The following components, when used in combination,
determine the blower speed:
• The blower resistor.
• The blower switch.
The blower resistor consists of 3 resistors located in
the same housing.
With the blower switch in LO, the following
actions occur:
• The blower circuit uses all 3 resistors.
• The blower motor runs at the lowest speed.
With the blower switch in M1, the following
actions occur:
• Two of the resistors are in use.
O The blower motor runs faster.
With the blower switch in M2, the following

actions occur:
• Only one of the resistors is in use.
570797
• The blower motor runs even faster.
Outside air is drawn into the vehicle, heated With the blower switch in HI, the following
(depending on the position of the temperature control actions occur:
knob) and directed to the defrost outlet. A small
amount of air is routed to the floor air outlet. • None of the resistors are in use.
• The blower motor runs at maximum speed.
Blower Motor Description
Control Assembly Description (Pontiac)
)
,;:J .;J
f ,.}
..!I
A/C \
MAX©-
...
FF_
#
~
282924
283259
The blower motor consists of the following
components: The heating, ventilation and air conditioning (HVAC)
control head uses three knobs and one push button in
• A permanent magnet type motor (3)
order to control the following features:
• A squirrel cage type fan (1) • The air delivery
The blower operates at various speeds. The various • The air temperature
speeds are determined by the resistance of the blower
motor resistor which is controlled by the blower • The blower motor speed
motor speed control. • The rear defroster
Temperature Control Knob Bl-LEVEL A/C
The temperature control knob regulates the HVAC The following actions occur when the knob is in the
system air temperature. The knob is located in Bl-LEVEL A/C position: (
the center of the HVAC control head. A temperature • An A/C request signal is sent to the PCM in order
control cable mechanically links the knob to the to allow the blower motor to operate in one of
temperature valve (door). four settings.
• Turn the knob toward the driver for heat. O Only outside air enters the HVAC module.
" Turn the knob toward the passenger for air • Air is distributed through the instrument panel
conditioning (A/C). outlets arid the floor outlets.
Mode Control Knob • A small amount of air is distributed to the defrost
The mode control knob is located on the right side of outlet.
the HVAC control head. The following are the
eight different modes: VENT
• OFF The VENT setting does not activate an A/C request
signal but allows the blower motor to operate normally.
• MAX The VENT setting is one of two economy settings
"A/C (other than OFF) in which there is no A/C request
.. Bl-LEVEL A/C signal. Air is discharged through the instrument panel
.. VENT outlets only .
• HEATER HEATER
" DEFROST/BLEND The HEATER setting functions the same as the VENT
• DEFROST setting, except that most of the air is discharged
OFF through the floor outlets with a small amount of air
discharged through the defroster outlets. Use
The following actions occur when the knob is in the
the HEATER setting for cold weather operation unless
OFF position:
windshield or side window defogging/defrosting is
• The blower motor does not operate. required.
• Electrical power is not supplied to the
blower motor. DEFROST/BLEND
" An A/C request signal is not sent to the powertrain The following actions occur in the DEFROST/BLEND
(
control module (PCM). setting:
• A small amount of air is forced into the HVAC • The blower motor operates.
module by the forward movement of the vehicle. • An A/C request signal is sent to the PCM.
The air is discharged through the heater and
• Air is discharged through the defroster and floor
defrost outlets.
air outlets.
MAX The DEFROST/BLEND setting provides greater
The following actions occur when the knob is in the passenger comfort :than the DEFROST setting, but it
MAX position: is not as effective in defogging/defrosting the
• An A/C request signal is sent to the PCM. windshield and side windows.
• The blower motor operates in one of four blower DEFROST
motor speed control settings.
The DEFROST setting functions the same as the
• Air is discharged only from the instrument panel
DEFROST/BLEND setting except that most of the air
air outlets.
is discharged through the defroster outlets. A small
• In order to provide MAX A/C, most of the air amount of air goes through the heater and side
entering the HVAC module is taken from the windows defoggers.
vehicle interior (re-circulated). This interior air is
cooler than the outside air. MAX is the only setting Blower Motor Speed Control
at which the air is re-circulated. • The blower motor runs in all mode positions
Use the MAX setting when the following except the OFF position when the ignition switch
conditions exist: is in the RUN position.
• High temperature • The blower motor speed is controlled by a
.. High humidity four-position electrical blower motor speed control
• The outside air has an objectionable odor switch. The switch is located at the left side of
the control.
A/C
• The blower motor speed control switch provides a
The A/C setting functions the same as the MAX choice of the following speeds: (
setting, except that only outside air enters the HVAC O Low
module. There may be a slight reduction of blower
noise compared to the MAX setting because the 0 Medium (two settings)
re-circulation valve (door) is closed. • High
• Power is routed from the HVAC fuse in the fuse Temperature Control Knob
block to the mode control switch. The temperature control knob regulates the HVAC
o The mode control switch breaks the circuit when system air temperature. The knob is located in
the switch is in the OFF position. The switch the center of the HVAC control head. A temperature
closes the circuit in all other positions. control cable mechanically links the knob to the
• From the mode control switch the circuit goes to temperature valve (door).
the blower motor speed control switch. " Turn the knob toward the driver for heat.
e When the blower motor speed control switch is
" Turn the knob toward the passenger for air
turned to the LOW setting, voltage is conducted
conditioning (A/C).
to the resistor. At the resistor, the voltage passes
through all three resistors and is reduced to Mode Control Knob
provide the low blower motor speed. The mode control knob is located on the right side of
• When the blower switch is in either of the the HVAC control head. The following are the
two medium speed positions, the switch closes. eight different modes:
This action sends voltage through one or "OFF
two of the resistors. Because the current follows
the path of least resistance, the circuit branch that "MAX
leads directly to all three resistors becomes .. A/C
ineffective. At this point the current bypasses ., Bl-LEVEL A/C
either one or two resistors, depending upon which O VENT
medium speed position is selected. The reduced ., HEATER

resistance increases the current flow and
e DEFROST/BLEND
blower motor speed.
• When the blower motor switch is turned to the ., DEFROST
HIGH setting, the action energizes the high bl.ower OFF
relay. Power is taken from a separate circuit
that is protected by a fusible link. The separate
OFF position:
power circuit is hot at all times. The circuit has the
capacity to handle the current demands of the
0
The blower motor does not operate.
blower motor at high speed. .. Electrical power is not supplied to the
• The circuit to the blower motor is completed to blower motor.
ground at the instrument panel through the .. An A/C request signal is not sent to the powertrain
instrument panel wiring harness. control module (PCM).
• A small amount of air is forced into the HVAC
Control Assembly Description (Chevrolet) module by the forward movement of the vehicle.
The air is discharged through the heater and
defrost outlets.
MAX
MAX position:
e An A/C request signal is sent to the PCM.
G The blower motor operates in one of four blower
motor speed control settings.
MAXe-~~
A/c,
,:n,,=
0
<;./ ;J '.,)
, r '!IJ7
0 Air is discharged only from the instrument panel
air outlets.
" In order to provide MAX A/C, most of the air
entering the HVAC module is taken from the
vehicle interior (re-circulated). This interior air is
cooler than the outside air. MAX is the only setting
at which the air is re-circulated.
Use the MAX setting when the following
conditions exist:
., High temperature
283258
.. High humidity
0 The outside air has an objectionable odor
The heating, ventilation and air conditioning (HVAC)
control head uses three knobs and one push button in A/C
order to control the following features: The A/C setting functions the same as the MAX
• The air delivery setting, except that only outside air enters the HVAC
• The air temperature module. There may be a slight reduction of blower
e The blower motor speed noise compared to the MAX setting because the
• The rear defroster re-circulation valve (door) is closed.
1-148 HVAC Systems m Manual HVAC
Bl-LEVEL A/C Blower Motor Speed Control
The following actions occur when the knob is in the • The blower motor runs in all mode positions
Bl-LEVEL A/C position: except the OFF position when the ignition switch
• An A/C request signal is sent to the PCM in order is in the RUN position.
to allow the blbwer motor to operate in one of • The blower motor speed is controlled by a
four settings. four-position electrical blower motor speed control
• Only outside air enters the HVAC module. switch. The switch is located at the left side of
the control.
• Air is distributed through the instrument panel
outlets and the floor outlets. • The blower motor speed control switch provides a
choice of the following speeds:
• A small amount of air is distributed to the defrost
outlet. • Low
• Medium (two settings)
VENT • High
The VENT setting does not activate an A/C request
• Power is routed from the HVAC fuse in the fuse
signal but allows the blower motor to operate normally. block to the mode control switch.
The VENT setting is one of two economy settings
(other than OFF) in which there is no A/C request • The mode control switch breaks the circuit when
signal. Air is discharged through the instrument panel the switch is in the OFF position. The switch
outlets only. closes the circuit in all other positions.
• From the mode control switch the circuit goes to
HEATER the blower motor speed control switch.
The HEATER setting functions the same as the VENT • When the blower motor speed control switch is
setting, except that most of the air is discharged turned to the LOW setting, voltage is conducted
through the floor outlets with a small amount of air to the resistor: At the resistor, the voltage passes
discharged through the defroster outlets. Use through all three resistors and is reduced to
the HEATER setting for cold weather operation unless provide the low blower motor speed.
windshield or side window defogging/defrosting is O When the blower switch is in either of the
required.
two medium speed positions, the switch closes.
DEFROST/BLEND This action sends voltage through one or
(
two of the resistors. Because the current follows
The following actions occur in the DEFROST/BLEND
the path of least resistance, the circuit branch that
setting:
leads directly to all three resistors becomes
• The blower motor operates. ineffective. At this point the current bypasses
O An A/C request signal is sent to the PCM. either one or two resistors, depending upon which
• Air is discharged through the defroster and floor medium speed position is selected. The reduced
air outlets. resistance increases the current flow and
blower motor speed.
The DEFROST/BLEND setting provides greater
passenger comfort than the DEFROST setting, but it • When the blower motor switch is turned to the
is not as effective in defogging/defrosting the HIGH setting, the action energizes the high blower
windshield and side windows. relay. Power is taken from a separate circuit
that is protected by a fusible link. The separate
DEFROST power circuit is hot at all times. The circuit has the
The.DEFROST setting functions the same as the capacity to handle the current demands of the
DEFROST/BLEND setting except that most of the air blower motor at high speed.
is discharged through the defroster outlets. A small • The circuit to the blower motor is completed to
amount of air goes through the heater and side ground at the instrument panel through the
windows defoggers. instrument panel wiring harness.
Vacuum Hose Harness Description
1 2
3 4 7
9 8
570879
legend
(1) Vacuum Tank (8) Heating, Ventilation and Air
(2) To Vacuum Source Conditioning (HVAC) Control
(3) Vent Mode Valve Actuator (9) Yellow Hose
(4) Black Hose (10) Violet Hose
(5) Red Hose (11) Green Hose
(6) Black Hose (12) Vacuum (Bi-Level Mode) Valve Actuator
(7) Orange Hose (13) Defroster Valve Actuator
1"'.150 HVAC Systems - Manual HVAC
The engine vacuum regulates all of the actuators (3, 10, HVAC Blower Controls .Circuit Description
12 and 13) (except the temperature valve) in the heater
and air conditioning (A/C) evaporator module. The LOW-M2 Positions (
vacuum is drawn from the vacuum tank (1 ). The tank is When the ignition switch is in the RUN position,
mounted to the right side body rail. voltage is applied through the HVAC Fuse 6 (20A),
A vacuum selector valve routes the vacuum to the ignition 3 voltage circuit of the HVAC control, to the
spring-loaded vacuum actuators (3, 10, 12 and 13) on HVAC control (selector switch). When the selector
the heater and A/C evaporator module. switch is switched to any position, except OFF, voltage
is supplied to the blower switch through the A/C
During conditions of low engine manifold vacuum, a
request signal circuit.
check valve in the vacuum source hose prevents
vacuum in the vacuum tank from bleeding back to the When the blower switch is in position 1 (low), voltage
vacuum's source. is applied to the blower switch, the blower resistor,
the blower motor relay and the blower motor.
The mode control regulates the vacuum selector
When voltage is applied to the blower motor, the
valve. At each mode control position, the valve
motor runs at lo.w speed.
performs the following actions:
When the blower switch is switched to position 2 (Mi)
" Directs vacuum to the specific hoses in order to
or 3 (M2), the blower control system works as
overcome the force of the spring within the
described above except for the speed of the blower
actuators.
motor. The blower motor has several resistors
O Vents the hoses to normal air pressure. This
that voltage flows through depending which position
action allows the spring to expand. The expansion the blower switch is in. In position 1 (low), voltage
results in the proper positioning of the valves passes through 4 resistors. In position 2 (M1 ), voltage
(doors) for the selected operating mode. passes 3 resistors and in position 3 (M2) voltage
The vacuum (bi-level) (10) and vent valves have passes through 2 resistors. As the resistance
two-position vacuum actuators. When vacuum is decreased the blower runs at a faster speed.
i.s directed to either actuator's vacuum chamber, the
HIGH Position
vacuum pulls in a flexible diaphragm. The diaphragm
forms one wall of the chamber. This action draws When the blower switch is moved to position 4 (high),
a movable shaft attached to the diaphragm. The shaft voltage is applied through the HVAC control (selector
is linked to the corresponding valve. The shaft switch) to the blower motor relay. The relay
operates the valve when the vacuum is applied. energizes, turning on the blower motor. This causes (
the motor to run at its fastest speed due to the fact that
An external spring moves the shaft back to its original
there is no resistor in the voltage path to the
position when the vacuum chamber is vented to
blower motor.
normal air pressure. The shaft, .in turn, returns the
valve to its original position.
The heater and defrost valve (13) 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 is in a
mid-position. This allows for a blend mode. Apply
vacuum to either end of the diaphragm in order
to move the heater and defrost valve to either stop.
This action directs airflow to either the defroster outlets
or the floor outlets.
When air is directed to the floor outlets, as in the
HEATER setting, a small amount of air still bleeds
through the defroster outlets. This. action helps
eliminate the refogging of the windshield.
Steering Table of Contents 2-1
)
Section 2
Steering
Power Steering System ..................................2-3 Power Steering Pump

Specifications ..................................................2-3 Replacement (V8) .....................................2-21
Fastener Tightening Specifications ................. 2-3 Power Steering Pump
Fluid Specifications .... , ...................................2-3 Replacement (V6) .....................................2-22
GM SPO Group Numbers .............................. 2-3 Power Steering Reservoir Replacement
Visual Identification .........................................2-4 - Off Vehicle (CB Series) .......... ,............... 2-24
Power Steering Gear - Disassembled Power Steering Pump Flow Control
View (Quiet Valve) .....................................2-4 Valve Replacement - Off Vehicle
(Return Tube) ...........................................2-24
Power Steering Pump - Disassembled
View (Return Tube) ....................................2-5 Power Steering Pump Flow Control
Valve Replacement - Off Vehicle
Power Steering Pump - Disassembled
(CB Series) ..............................................2-25
View (CB Series Pump) ............................. 2-6
Power Steering Pump Front Bracket
Diagnostic Information and Procedures ......... 2-7
Replacement ............................................2-26.
Hissing Noise In Steering Gear ...................... 2-7
Power Steering Pump Rear Bracket
Rattle in Rack and Pinion Replacement ............................................2-27
Steering Gear .............................................2-7
Flushing the Power Steering System ............ 2-28
Power Steering Gear and Pump Leaks .......... 2-7
Power Steering Cooler Pipe/Hose
Seal Replacement Recommendations ............ 2-9 Replacement ............................................2-29
Power Steering System Test Procedure ......... 2-9 Power Steering Return Hose
Excessive Wheel Kickback or Loose Replacement ............................................2-30
Steering ....................................................2-10 Power Steering Gear Replacement (V6) ....... 2-32
Increase in Effort While Turning Power Steering Gear Replacement (V8) ....... 2-34
Steering Wheel ......................................... 2-11
Rack and Pinion Gear Rack Bearing
Poor Return of Steering Wheel .................... 2-11 Preload Adjustment - Off Vehicle
Steering Wheel Surges/Jerks While (Quiet Valve) ............................................2-35
Turning .....................................................2-11 Rack and Pinion Boot Replacement -
Steering Wheel Kickback ............................. 2-11 Off Vehicle (Quiet Valve) ..........................2-35
Steering Effort Hard in Both Directions ......... 2-11 Tie Rod End Replacement - Outer - Off
Too Much Play in Steering .......................... 2-12 Vehicle .....................................................2-38
Wander or Poor Steering Stability ................ 2-12 Tie Rod Replacement - Inner ........................ 2-41
Vehicle Leads to One Side or the Other ...... 2-12 Steering Gear Cylinder Pipe
Foaming, Milky-Appearing Power Assemblies/0-Ring Seals
Steering Fluid ...........................................2-12 Replacement - Off Vehicle
Low Oil Pressure Due to Steering Gear ....... 2-12 (Quiet Valve) ............................................2-43
Low Oil Pressure Due to Steering Gear Stub Shaft Seals and
Steering Pump .........................................2-13 Bearing Replacement - Off Vehicle ...........2-45
Groan Noise in Steering Pump .................... 2-13 Description and Operation ............................2-47
Growl Noise in Steering Pump ..................... 2-13 Power Steering Pump Description ............. ,.. 2-47
Whine Noise in Steering Pump .................... 2-13 Power Steering Gear Description .................2-48
Repair Instructions ........................................2-13 Seal Replacement Recommendations ..........2-48
Checking and Adding Power Special Tools and Equipment ....................... 2-48
Steering Fluid ...........................................2-13
Bleeding Power Steering System ................. 2-14 Steering Wheel and Column - Tilt ..............2-50
Remote Power Steering Fluid Reservoir Specifications ................................................2-50
Replacement ............................................ 2-18 Fastener Tightening Specifications ...............2-50
Remote PS Fluid Reservoir Bracket GM SPO Group Numbers ............................ 2-50
Replacement ............................................ 2-19 Visual Identification .......................................2-52
Power Steering Pulley Replacement ............. 2-20 Steering Column - Disassembled View ......... 2-52
2-2 Table of Contents Steering
Diagnostic Information and Procedures ....... 2-54 Inflatable Restraint Steering Wheel
Lock System Does Not Unlock .................... 2-54 Module Coil - Assemble - Off Vehicle ....... 2-71
Lock System Does Not Lock ........................ 2-54 Turn Signal and Multifunction Switch
Key Cannot Be Removed in the Off Assembly - Disassemble - Off Vehicle ...... 2-72
Lock Position ............................................2-54 Turn Signal and Multifunction Switch
Lock Cylinder Can Be Removed Assembly - Assemble - Off Vehicle .......... 2-73
Without Depressing Retainer .................... 2-54
Ignition Switch Assembly - Disassemble
High Lock Effort Between the Off Lock
- Off Vehicle .............................................2-74
Positions ..................................................2-54
High Lock Effort ...........................................2-55 Ignition Switch Assembly - Assemble -
Noise in Steering Column ............................ 2-55 Off Vehicle ...............................................2-75
High Steering Shaft Effort ............................ 2-55 Dimmer Switch Assembly -
Looseness in Steering Column ..................... 2-56 Disassemble - Off Vehicle ........................ 2-75
Lower Housing Scraping Upper Housing ......2-56 Dimmer .Switch Assembly - .Assemble -
Loose Steering Wheel .................................. 2-56 Off Vehicle ...............................................2-76
Loose Steering Wheel Windshield Wiper and Washer Switch
(Every Other Tilt Position) ......· .................. 2-56 Assembly - Disassemble - Off Vehicle ...... 2-77
Steering Wheel Does Not Lock in Any Windshield Wiper and Washer Switch
Tilt Position ..............................................2-56 Assembly - Assemble - Off Vehicle .......... 2-77
Steering Wheel Not Returning to Top Steering Column Lock Cylinder Set -
Tilt Position ............................... ,.............. 2-57 Disassemble - Off Vehicle ........................ 2-78
Noise When Tilting Steering Column ............ 2-57
Steering Column Lock Cylinder .Set -
Turn Signal Does Not Indicate Lane Assemble - Off Vehicle ............................. 2-78
Change ....................................................2-57
Turn Signal Switch Does Not Stay in Tilt Spring - Disassemble - Off Vehicle ........ 2-79
Turn Position .......................... : ................. 2-57 Tilt Spring - Assemble - Off Vehicle .............2-81
Turn Signal Switch Does Not Cancel ...........2-57 Turn Signal Cancel Cam and Upper
Turn Signal Switch Difficult to Operate ......... 2-58 Bearing Inner Race - Disassemble -
Hazard Switch Cannot Be Turned Off .......... 2-58 Off Vehicle ...............................................2-82
Hazard Switch Does Not Stay On ................ 2-58 Turn Signal Cancel Cam and Upper
(
Ignition Switch Electrical System Does Bearing Inner Race - Assemble -
Not Operate ....,. ........................................2-58 Off Vehicle ...............................................2-83
Ignition Switch Does Not Turn ..................... 2-58 Steering Column Jacket - Disassemble
Ignition Switch Cannot Be Set Correctly ....... 2-58 - Off Vehicle ........................................ ; ..... 2-84
Repair Instructions ........................................2-59 Steering Column Jacket - Assemble -
Ignition Switch Replacement - On Off Vehicle ........................ ,, .....................2-85
Vehicle .....................................................2-59 Lock Housing Assembly - Disassemble
Multifunction Turn Signal Lever - Off Vehicle ............................................ :2-87
Replacement - On Vehicle ........................ 2-60
Lock Housing Assembly - Assemble -
Hazard Warning Switch Replacement -
Off Vehicle ...............................................2-88
On Vehicle .................. , ............................. 2-62
Tilt Lever Replacement - On Vehicle ........... 2-62 Steering Shaft, Lower Bearing, and
Horn Switch Replacement - On Vehicle Jacket - Disassemble - Off Vehicle ........... 2-89
(Chevrolet) ................................................2-63 Steering Shaft, Lower Bearing, and
Horn Switch Replacement - On Vehicle Jacket - Assemble - Off Vehicle ............... 2-91
(Pontiac) ...................................................2-64 Inflatable Restraint Coil Centering - Off
Steering Wheel Control Switch Vehicle
Assembly Replacement ............................. 2-64 (Column Shift And Floor Shift) ........... ,...... 2-93
Steering Wheel Replacement ....................... 2-65 Steering Column Accident Damage
Intermediate Steering Shaft Inspection - Off Vehicle.............................2-94
Replacement ............................................2-66 Description and Operation ............................2-96
Steering Column Replacement ..................... 2-68
Steering Wheel and Column Description ...... 2-96
Inflatable Restraint Steering Wheel
Module Coil - Disassemble - Off Ignition Lock System Description ..................2-97
Vehicle .....................................................2-70 Special Tools and Equipment ....................... 2-98
Steering Power Steering System 2-3
Power Steering System

)
Specifications
Specification
Hydraulic Pump Control Fitting-to-Power Steering Pump 75N·m 55 lb ft
Power Steering Fluid Reservoir Bolt/Screw (5.7L VIN G) 10N·m 891bin
Power Steering Fluid Reservoir Bracket Nuts (3800 VINK) 12 N-m 1071bin
Power Steering Gear Bolt/Screw 85 N-m 63 lb ft
Power Steering Gear Inlet Hose Fitting-to-Power Steering Gear 28 N-m 21 lb ft
Power Steering Gear Inlet Hose Fitting-to-Power Steering Pump 28N·m 21 lb ft
Power Steering Gear Outlet Hose Fitting-to-Power Steering Gear 28N·m 21 lb ft
Power Steering Pump Bolt/Screw (5.7L VIN G) 25N·m 18 lb ft
Power Steering Pump Nut (3800 VIN K) 30N·m 23 lb ft
Power Steering Pump Rear Bracket Bolt/Screw (5.7L VIN G) 50N·m 37 lb ft
Fluid Specifications
Application Type of Material GM Part Number
1050017
or
Warm Climate Power Steering Fluid 1052884
or equivalent meeting
GM Specification 9985010
12345867
Cold Climate (see note) Power Steering Fluid or
12345866
Important: Drain and refill the system prior to using this fluid.

Power Steering Gear 6.000
Power Steering Pump (VB) 6.000
Power Steering Pump (V6) 6.000
Remote Power Steering Fluid Reservoir (V6) 6.000
Power Steering Pulley (V6) 6.000
Power Steering Pulley (VB) 6.000
Power Steering Pump Front Bracket (V8) 6.000
Power Steering Pump Rear Bracket (V6) 6.000
Power Steering Hose Inlet (V6) 6.000
Power Steering Hose Inlet (V8) 6.000
Power Steering Hose Outlet (V6) 6.000
Power Steering Hose Outlet (VB) 6.000
Power Steering Cooler (VB) 6.000
2-4 Power Steering System Steering
Visual Identification
Power Steering Gear - Disassembled View (Quiet Valve)
Power Rack and Pinion - End Take Off
33
l
30
31
~
'~34
J:~.,
~36
441305
Legend
(1) Lubrication Fitting (13) Mounting Bracket Assembly
(2) Hexagon Slotted Nut (14) Mounting Grommet
(3) Cotter Pin (15) Cylinder Line (Left Hand) Assembly
(4) Tie Rod Seal (16) Cylinder Line (Right Hand) Assembly
(5) Outer Tie Rod Assembly (17) 0-Ring Seal
(6) Hexagon Jam Nut (18) 0-Ring Seal
(7) Tie Rod End Clamp (19) Seal Adapter
(8) Rack and Pinion Boot (20) Retaining Ring
(9) Boot Clamp (21) Stub Shaft Seal
(10) Inner Tie Rod Assembly (22) Annulus Bearing Assembly
(11) Adjuster Plug Lock Nut (23) Hexagon Lock Nut
(12) Shock Dampener Ring (24) Dust Cover
{25) Rack and Pinion (Partial} Gear Assembly (31) Hexagon Jam Nut
{26) Shock Dampener Ring {32) Outer Tie Rod Assembly
(27) Inner Tie Rod Assembly (33) Cotter Pin
{28) Boot Clamp (34) Hexagon Slotted Nut
(29) Rack and Pinion Boot {35) Tie Rod Seal
(30} Tie Rod End Clamp (36) Lubrication Fitting
Power Steering Pump - Disassembled View (Return Tube)

Power Steering Pump
391549
Legend
(1) Hydraulic Pump Housing Assembly (4) 0-ring Seal
(2) Flow Control Spring (5) 0-ring Union Fitting
(3) Control Valve Assembly
Power Steering Pump - Disassembled View (CB Series Pump)
Power Steering Pump Assembly-CB Series
(
391553
Legend
(1) Hydraulic Pump Reservoir Assembly (6) 0-ring Seal
(Typical} (7) 0-ring Union Fitting
(2) Reservoir Capstick Assembly (8) Hydraulic Pump Housing Assembly
(3) 0-ring Seal (9) Reservoir Retaining Clip (RH)
(4) Flow Control Spring (1 O) Reservoir Retaining Clip (LH}
(5) Control Valve Assembly

Hissing Noise In Steering Gear
Problem Action
There is a hissing noise in the • Inspect for loose intermediate steering shaft universal joints.
steering gear. • If the noise is very objectionable, replace the steering gear.
Rattle in Rack and Pinion Steering Gear

Problem Action
There is a rattling noise. Inspect for the following conditions:
• Contact between the outlet (pressure) hose and the frame
O Loose tie rod ends
• Loose steering gear attachment

• A loose pinion shaft
A rattling noise occurs when driving Inspect the front brake linings for the following conditions:
over bumps. • A loose fit
• Missing antirattle clips
Power Steering Gear and Pump leaks External leakage Check

., Determine if any of the following conditions exist: Use this procedure in order to help identify the exact
location of a leak. Some leaks can be easily
- The vehicle leaks fluid onto the garage floor.
located, but seepage type leaks may be more difficult
- Fluid leaks are visible on the steering to locate. To locate seepage leaks use the following
gear or the pump. method:
- There is a growling noise when you are 1. Turn the engine off.
parking the vehicle.
2. Wipe the complete power steering system dry.
- There is a growling noise when the engine
is cold.
- The power steering does not operate when
you are parking the vehicle.
- The vehicle requires excessive steering i
effort.
• Inspect for an overfilled power steering fluid
reservoir .
.. Inspect for fluid aeration and overflow.
• Inspect the hose connections.
" Identify the exact point of system leakage. 8efer
to External Leakage Check.
The point from which fluid is dripping is not
necessarily the point where the system is
leaking from.
291852
3. On vehicles with a 3800 engine, inspect the fluid

level in the power steering fluid reservoir (1 ).
Adjust the fluid level as necessary.
13. Replace the hydraulic pump fluid reservoir if you
detect these conditions.
1
291855
14. Torque the steering gear (1) pipe fitting seat to

specifications.
If leakage persists, replace the steering gear pipe
seal (0-ring).
291841 (
4. On vehicles with a 5.7L engine, inspect the fluid
level in the power steering fluid reservoir (1 ).
Adjust the fluid level as necessary.
6. Turn the steering wheel from stop to stop
several times:
• Do not hold the steering wheel at a stop for
any length of time.
Holding the steering wheel at a stop may
damage the power steering pump (3) .
.. Search for the seepage while an assistant
operates the steering wheel.
7. Find the exact location of the leak.
Repair any leaks that you find.
8. Replace the driveshaft seal (4).
291858
9. Ensure that the driveshaft is clean and free of
pitting at point 4. 15. Replace the steering gear (1) with a partial
10. Inspect the fluid level. steering gear.
Determine if leakage persists under the following 16. If you observe leakage between the torsion bar
conditions: and the steering gear pinion shaft, replace the
• The fluid level is correct. gear with a partial steering gear.
" The hydraulic pump reservoir cap is tight.
11. Replace the hydraulic pump reservoir cap if
leakage persists.
12. Inspect the hydraulic pump fluid reservoir for the
" Cracks
.. Bending
23. Tighten the following components to
specifications:
• The hydraulic pump hose fitting .
., The hydraulic pump hose fitting nut.
24. Replace the hydraulic pump seal (0-ring) if
leakage persists.
Seal Replacement Recommendations

Lip Seals
Lip seals seal the rotating shafts. The lip seals require
special treatment. Lip seals are used on the hydraulic
pump shaft of the power steering pump. When the
lip seals leak complete the following steps:
1. Inspect the sealing surfaces.
2. Thoroughly clean the sealing surfaces.
3. Replace the seal(s).
Replace the shaft if you find pitting. If there is slight
291861
corrosion in the lip seal contact zone, clean the surface
of the shaft with crocus cloth. Replace the shaft only
17. Determine if the following conditions exist: if you cannot stop the leakage by smoothing the
• You ob.serve a leakage at the driver side. shaft with crocus cloth.
• The leakage is not affected by the direction of 0-Ring Seals

the turn. When you remove a part which forms a sealing
surface for an 0-ring complete the following steps:
18. If the above conditions exist, replace the steering
gear (1) with a partial steering gear. i. Remove the original 0-ring seal.
2. Replace the original 0-ring seal with a new
19. Determine if the following conditions exist:
0-ring seal.
• You observe a leakage at the steering Lubricate all of the new 0-ring seals with power
gear housing end. steering fluid in order to ease the installation.
• The fluid spurts when bottomed in a left turn.
Power Steering System Test Procedure
20. If the above conditions. exist, replace the steering
gear with a partial steering gear. Tools Required
• J 5176-E Power Steering Pressure Tester
O
J 5176-92 Pressure Tester Adapter
" J 25323-D Power Steering System Analyzer
" J 29525 Steering Analyzer Adapter (18 mm)
If you suspect a hydraulic or mechanical malfunction
of one of the following components, perform this
procedure in order to determine the cause:
• The power steering pump
• The power steering gear
1. Place a drain pan under the reservoir.
2. Disconnect the outlet hose at the reservoir.
3. Connect a spare pressure hose to the reservoir.
Important: Test the power steering system using
the J5176-E. Testing the power steering system with
the J 25323-D will also measure the flow rate as
well as the pressure.
4. Connect the J 5176-E and the J 5176-92 or
J 25323-D and J 29525 to the following hoses:
291864
.. The outlet hose
21. Determine if leakage exists (2, 3). " The spare pressure hose
22. If the above conditions exist, replace the steering 5. Open the valve on the J 5176-E or J 25323-D.
gear (1) with a partial steering gear. 6. Start the engine and allow to reach a normal
operating temperature.
2...10 Power Steering System Steering
7. Ensure that the engine is at idle and that the 13. If the pressure readings are less than
valve on the J 5176-E or J 25323-D is open. 6 895 kPa (1,300 psi), complete the
8. Read the pressure reading. following steps:
Important: The pressure should be no more than 13.1. Replace the flow control valve.
1 050 kPa (150 psi). 13.2. Retest the flow control valve.
9. If the pressure is more than 1 050 kPa (150 psi), 13.3. If the pressure is still below
perform the following steps: 6 895 kPa (1,300 psi), replace the following
• Inspect the hoses for restrictions. components:
• Inspect the popper valve on the steering gear • The rotor
for the proper installation.
• The vanes
Notice: Do not leave the valve fully closed for more
than 5 seconds, or the pump could be damaged 14. If the pressure readings are within specifications,
internally. perform the following procedure:
10. Fully close the valve on the J 5176-E or J 25323-D 14.1. With the flow control valve open, have an
three times, assistant turn the steering wheel to
Record the pressure readings each time. both sides.
The power steering pump is functioning properly 14.2. Record the highest pressures.
when the pressure readings fall within the 14.3. Compare the pressure with the highest
following range: pump pressures that you recorded. earlier.
• Each reading is at least 6 895 kPa (1,300 psi).
15. If the pressurEl at both stops is not the same as
• The 3 readings are within 345 kPa (50 psi)
the maximum pressure previously recorded, then
of each other.
the steering gear is leaking internally.
11. The power steering pump control valve is sticking
if the following conditions exist: Repair the steering gear if the steering gear is
leaking. internally.
• The pressure readings are at least
6 895 kPa (1,300 psi). 16. Turn off the engine.
• The pressure readings are not within 17. Remove the J 5176-E and J 5176-92 or J25323-D (
345 kPa (50 psi) of each other. and J29525.
12. If the pressure readings indicate that there is a Notice: Refer to Fastener Notice in Cautions and
sticking flow control valve, perform the Notices.
following steps:
12.1. Remove the flow control valve. 18. Connect the outlet hose to the remote reservoir.
12.2. Clean the flow control valve. Tighten
Remove any burrs using a crocus cloth of Tighten the hydraulic pump hose fitting nut to
fine hone. · 28 N-m (21 lb ft). ·
12.3. Flush the. system if the system contains 19. Bleed the power steering system. Refer to
any contamination. Bleeding Power Steering System.
Excessive Wheel Kickback or Loose Steering
· Problem Action
There is excessive steering wheel Inspect the steering system for the following conditions:
kickback or loose steering. • Air in the power steering system
• · Loose steering gear adjustment
• Loose tie rod ends
• A worn wheel bearing
• A loose coupling on the stabilizer
• A loose thrust bearing preload adjustment
• A worn pipe fitting seat
(
Increase in Effort While Turning Steering Wheel
Problem Action
There is a momentary increase in Inspect the steering system for the following conditions:
effort when turning the steering wheel • High internal leakage
fast to the right or left.
• A sticking or damaged steering gear valve spool
• Insufficient pump pressure
• A low fluid level
Poor Return of Steering Wheel

Problem ·. Action
The steering wheel has poor Inspect the steering system for the following conditions:
returnability. • Incorrect caster setting
• A bind in the following components:
- The control arm ball stud
- The steering column
- The intermediate steering shaft joints
• A misadjusted steering gear
• An incorrect steering gear valve spool
Steering Wheel Surges/Jerks While Turning

Problem Action
The steering wheel surges or jerks. Inspect the vehicle for the following conditions:
• A defective tire
• A bad tire
• A sluggish steering gear valve spool
) • A serpentine drive belt which is in one of the following conditions:
- Loose
- Soaked with oil
• Air in the power steering system
Steering Wheel Kickback

Problem Action
There is kickback in the Inspect the steering system for the following conditions:
steering wheel. • Air in the power steering system
• A loose steering gear mounting
• Loose or worn joints from the steering column to the steering gear
• Loose tie rod ends
• A worn or missing pipe fitting seat
• A worn wheel bearing
• Misadjusted $teering gear
Steering Effort Hard in Both Directions

Problem Action
The steering is hard. • Perform the test on the hydraulic system. Refer to Power Steering System Test
Procedure.
• Inspect the steering system for the following conditions:
- Misadjusted steering gear
- A bind or catch in the steering gear
- A loose steering gear mounting
- A faulty pipe fitting seat
Too Much Play in Steering
Problem Action
There is too much play in the lnspectthe steering system for the following conditions:
steering wheel. • A loose steering gear mounting
• Loose or worn joints from the steering column to the steering gear
• Misadjusted .steering gear
Wander or Poor Steering Stability

Problem Action
There is a wander or poor stability in Inspect the vehicle for the following conditions:
the steering. • Mismatched tires
• Uneven tires
• Worn shock absorbers
• A loose stabilizer shaft
• A broken spring
• A sagging spring
• Misadjusted steering .gear
• A misaligned tire and wheel
Vehicle Leads to One Side or the Other

Problem Action
The vehicle pulls or leads. Inspect the vehicle for the following conditions:
• A misaligned front tire and wheel
• Mismatched tires
• Uneven tires
• Broken springs (
• Sagging springs
• Radial tire lead/pull
• An unbalanced steering gear valve spool
• A dragging front brake
Foaming, Milky-Appearing Power Steering Fluid

Problem Action
The following conditions exist: • Inspect for air in the fluid.
• The fluid is foamy or milky. • Inspect for an internal pump leak.
• The fluid level is low. • Extremely .cold temperatures will cause air bubbles if the fluid level is low.
• The fluid pressure is low. • If the fluid level is correct and the pump still foams, perform the following steps:
- Remove the reservoir.
- Inspect the reservoir for cracks.
If the reservoir is cracke·d, replace the reservoir.
Low Oil Pressure Due to Steering Gear

Problem Action
There is low pressure due to the Inspect the .steering gear for the following conditions:
steering gear. • A scored housing bore
• Leakage at one of the following areas:
- The valve rings
-The seals
·.
(
low Oil Pre~sure Due to Steering Pump
Problem Action
There is low pressure due to the Inspect the steering system for the following conditions:
power steering pump. • A stuck or inoperative flow control valve
• A pressure plate that is not flat against the ring
" An extremely worn ring
• Scoring on one of the following components:
- The pressure plate
- The thrust plate
- The rotor
• Vanes sticking in the rotor slots
• A break or crack on one of the following components:
- The thrust plate
- The pressure plate
• A high internal leakage
Groan Noise in Steering Pump

Problem Action
There is a groaning noise in Inspect the pump for the following conditions:
the pump. • Air in the fluid
• A low fluid level
• A loose pump mounting
Growl Noise in Steering Pump

Problem Action
) There is a growling noise. in the Inspect the system for the following conditions:
power steering pump. • Excessive back pressure that is caused by one of the following conditions:
- A restricted hose
- A restricted steering gear
• Scoring on one of the following components:
- The pressure plates
- The thrust plate
- The rotor
• A worn ring
Whine Noise in Steering Pump

Problem Action
There is a whining noise in the power Inspect the system for scoring on one of the following components:
steering pump. • The powE)r steering pump shaft bushing
• The pressure plates
• The vanes
Repair Instructions The fluid level is indicated by marks on the fluid level
indicator. The fluid level indicator is located on the
reservoir cap.
Checking and Adding Power
Steering Fluid • If the fluid is about 77°C (170°F), the fluid level
should be at the H mark.
Notice: When adding fluid or making a complete fluid
• If the fluid is about 21 °C (70°F), the fluid level
change, always use the proper fluid. Failure to use .
the proper fluid will cause hose and seal damage and should be at the C mark.
fluid leaks. Refer to Power Steering Fluid
Recommendations in this section.
Bleeding Power Steering System
Tools Required
• J 35555 Mity Vac
• J 43485 Power Steering Bleeder Adapter
Important: Use clean, new power steering fluid
type only.
• See the Maintenance and Lubrication subsection
for fluid specifications.
Notice: If the power steering system has been
.serviced, an accurate fluid level reading cannot be
obtained unless air is bled from the steering system.
The air in the fluid may cause pump cavitation
noise and may cause pump damage over a period
of time .
.Notice: When adding fluid or making a complete fluid
change, always use the proper power steering
fluid. Failure to use the proper fluid will cause hose
· 443541 and seal damage and fluid leaks.
Important: Hoses touching the frame, body, .or engine
may cause system noise.
• Verify that the hoses do not touch any other part
of the vehicle.
Important: Loose connections may not leak, but could
allow. air into the steering system.
• Verify that all hose connections are tight.
Important: Maintain the fluid level throughout the (
bleed procedure.
1. Remove the pump reservoir cap.
2. Fill the pump reservoir with fluid to the "FULL
COLD" level.
443644
3. A1tach J 43485 to J 35555 or equivalent.
) 4. Place J 43485 on or in the pump reservoir
filler neck.
5. Apply a vacuum of 68 kPa (20 in Hg) maximum.
6. Wait 5 minutes.
J 35555
Typical vacuum drop is 7-10 kPa (2-3 in Hg). If
the vacuum does not remain steady, refer to
Excessive Vacuum Drop Diagnosis at the end of
this procedure.
0
443646
7. Remove the J 43485 and the J 35555.

8. Reinstall the pump reservoir cap.
9. Start the engine. Allow the engine to idle.
10. Turn off the engine.
11. Verify the fluid level. Repeat steps 9 through 11
until fluid stabilizes.
443650
Important: Do not turn steering wheel to lock.

12. Start the engine. Allow the engine to idle.
13. Turn the steering wheel 180-360 degrees in both
directions 5 times.
443653
14. Switch the ignition off.
15. Verify the fluid level.
443655
16. Remove the pump reservoir cap.
443644
17. Attach J 43485 to J 35555 or equivalent.

18. Place J 43485 on or in the pump reservoir
filler neck.
20. Wait 5 minutes.
J35555
21. Remove the J 43485 and the J 35555.
22. Verify the fluid level.
0
443646
23. Reinstall the pump reservoir cap.
443656
Excessive Vacuum Drop Diagnosis

Tools Required
• J35555 Mity Vac
• J 43485 Power Steering Bleed Adapter
1. If the vacuum continues to drop, remove the
pressure and return hose from the pump.
2. Install the plugs (1) (2) supplied with J 43485 into
the pressure and return port.
443667
3. Attach J 43485 to J 35555 or equivalent.

4. Place J 43485 on or in the pump reservoir
filler neck.
6. If the vacuum drops again, repair or replace
J 35555
the pump. If the vacuum holds steady, continue
to check the other parts of the steering system.
)
0
443646
Important: Fluid must be free from bubbles and foam.
Be aware of periodic bubbles that indicate a loose
connection or leaking 0-ring seal in the return hose or (
the pressure hose.
Fluid must be free from discoloration.
7. Observe the fluid.
8. If condition persists, replace the following parts:
• The return hose clamps
" The return hose 0-rings
" The pressure hose 0-rings
• The gear cylinder line 0-rings
• The reservoir to pump 0-ring
9. Repeat the bleed procedure from the beginning.
10. Drive the vehicle approximately 16 kilometers
(1 O miles) to warm the system to operating
temperature. Evaluate vehicle on a smooth flat
surface.
443673
11. Verify the following conditions:
• There is smooth power assist.
" The vehicle operates quietly.
• The pump maintains the proper fluid level.
• There is no leaking in .the steering system.
• The fluid is free of foam or discoloration.
Remote Power Steering Fluid Reservoir

Replacement (
Removal Procedure
1. Place a drain pan under the reservoir (1 ).
2. Remove the cap from the reservoir (1 ).
3. Remove the reservoir (1) from the bracket (2).
4. Disconnect the reservoir and outlet hoses (4, 6)
from the reservoir (1 ).
290572
(
1. Connect the reservoir and outlet hoses (4, 6) to
the reservoir (1 ).
2. Install the reservoir (1) to the bracket (2).
3. Refill the reservoir and Install the cap to the
reservoir.
4. Remove drain pan.
5. Bleed the power steering system. Refer to
Bleeding Power Steering System.
290572
Remote PS Fluid Reservoir Bracket

Replacement
Removal Procedure
1. Remove the reservoir (1) from the bracket (2).
2. Use a wire, or an equivalent, in order to secure the
reservoir (1) in an upright position.
An upright position will prevent leakage.
3. Raise and support the vehicle. Refer to Lifting and
Jacking the Vehicle in General Information.
4. Remove the electrical harness from the
bracket (2).
290572
5. Remove the bolt/screw (1 ).

6. Remove the nuts (2).
290571
Notices.
1. Install the nuts (2).
Tighten
Tighten the nuts to 12 N-m (107 lb in).
2. Install the bolt/screw (1 ).
Tighten
Tighten the bolt/screw to 50 N-m (37 lb ft).
3. Install the electrical harness to the bracket (3).
290571
5. Install the reservoir (1) to the bracket (2).
290572
Power Steering Pulley Replacement

Removal Procedure
Tools Required
J 25034-C Power Steering Pump Pulley Remover
1. Remove the air intake resonator and mass airflow
assembly (LS1 only}.
2. Remove the serpentine belt.
3. Use the J 25034-C in order to remove the power
steering pulley from the power steering pump.
354410
Steering Power Steering System 2.;.21
) Tools Required
J 25033-C Power Steering Pump Pulley Installer
important: 2
" 3.8 Liter Engine: Ensure that the face of the pulley
hub is flush with the end of the pump shaft before
you apply a load to the pulley hub.
• 5.7 Liter Engine: Ensure that the pulley hub
shoulder bottoms out completely on the pulley
shaft before you apply a load to the pulley hub.
• Ensure that the pulley goes on snug when
installing the pulley with the special tool. If the
pulley installs onto the pump shaft too easily, it will
not relay engine power to the pump and should
be replaced.
1. Use the· J 25033-C in order to· install the power
steering pulley to the power steering pump.
2. Install the air intake resonator and mass airflow 290557
assembly (LS1 only)
3. Install the serpentine belt.
4. Check power steering operation and visibly check
pulley for any irregular wobble when operating.
Power Steering Pump Replace.ment (V8)

Removal Procedure
1. Place a drain pan under the power steering
pump (1).
2. Remove the air intake resonator and mass airflow
assembly.
4. Remove the power steering pump pulley: Refer to
Power Steering Pulley Replacement.
5. Remove the outlet hose and the clamp from the
reservoir (This allows fluid to drain from reservoir).
6. Remove the inlet hose fitting from the pump.
7. Remove power steering pump attaching bolts (4)
and power steering pump front brace (3) from
pump (1).
8. Remove pump (1) from rear bracket (2).
290570
2.;.22 Power Steering System Steering
Notices.
1. Install pump (1 ), pump front brace (3), and
attaching bolts (4) to rear bracket (2).
Tighten
Tighten the bolts/screws to 25 N-m (18 lb ft).
2. Install the inlet hose fitting from pump.
Tighten
Tighten the fitting to 28 N-m (21 lb ft).
3. Install the outlet hose and clamp to reservoir.
4. Install the power steering pump pulley. Refer to
6. Install the air intake resonator and mass airflow
assembly.
7. Remove. drain pan.
290570
8. Refill and bleed the power steering system. Refer
to Bleeding Power Steering System.
Power Steering Pump Replacement (V6)

1 3 Removal Procedure
1. Place a drain pan under the power steering
pump (1).
(
3. Remove the front air intake duct.
4. Remove the pulley from the power steering
pump (1 ). Refer to Remote Power Steering
Fluid Reservoir Replacement.
5. Disconnect the inlet hose (3) from the power
steering pump (1 ).
6. Disconnect the reservoir hose (2) from the power
steering pump (1 ).
354420
7. Remove the power steering pump nuts.
8. Remove the power steering pump. 1
3 2
290569
1. Position the power steering pump onto the
mounting studs.
Notices.
2. Tighten the power steering pump nuts.
Tighten
Tighten the power steering pump nuts to
30 N·m (23 lb ft).
3 2
290569
3. Connect the inlet hose to the power steering

pump (2).
4. Connect the reservoir hose (2) to the power
steering pump (1 ).
5. Install the pulley to the power steering pump (1 ).
Refer to Remote Power Steering Fluid Reservoir
Replacement.
6. Install the front air intake duct.
lo Bleeding Power Steering System.
354420
Power Steering Reservoir Replacement -
Off Vehicle (CB Series) (
Disassembly Procedure
1. Place the hydraulic pump (1) on a fixed, flat
surface, with the shaft facing upward.
2. Insert a screwdriver into the retaining clip tab (3).
1 3. Using the screwdriver, force the retaining clip
tab (3) outward.
4. Slide the reservoir clip (4) away from the hydraulic
pump assembly (1 ).
5. Remove the reservoir (2) from the hydraulic pump
housing (1 ).
6. Remove the 0-ring seal from the neck of the
reservoir (2) or the hydraulic pump housing (1).
Discard the 0-ring seal.
482358
Assembly Procedure
1. Lubricate the new 0-ring seal with power ·
steering fluid.
2. Install the new 0-ring seal onto the neck of the
reservoir (2).
3. Install the reservoir (2) onto the hydraulic pump
assembly (1 ). Ensure the reservoir neck is
completely engaged onto the hydraulic pump (
assembly (1 ).
4. Align the feet of the reservoir with the sides of the
hydraulic pump housing.
5. Install the new reservoir retaining clips (4)
(supplied with the pump). Ensure the retaining clip
tabs (3) fully engage with the hydraulic pump
housing (1 ).
482357
Power Steering Pump Flow Control Valve

Replacement - Off Vehicle (Return Tube)
Important: Handle the pump with care. Do not carry
the hydraulic pump housing assembly (1) by the return
tube (2).
Important: Replace the hydraulic pump housing
assembly (1) if the return tube (2) is cracked or loose.
Do not attempt to repair the hydraulic pump housing
assembly (1 ).
1. Inspect the return tube (2) on hydraulic pump
housing assembly (1 ).
391544
2. Remove the 0-ring union fitting (5) from the
hydraulic pump housing assembly (1 ).
3. Remove the 0-ring seal (4) from the 0-ring union
fitting (5).
5. Remove the flow control spring (2).
391535
Assembly Procedure
1. Install the flow control spring (2) to the hydraulic
pump housing assembly (1 ).
2. Install the control valve assembly (3).
3. Lubricate the 0-ring seal (4) with power
steering fluid.
4. Install the 0-ring seal (4) on to the 0-ring union
) fitting (5).
Notices.
5. Install the 0-ring union fitting (5) into the hydraulic
pump housing assembly (1).
Tighten
Tighten the 0-ring union fitting (5) to
75 N·m (55 lb ft).
391535
Power Steering Pump Flow Control Valve

Replacement - Off Vehicle (CB Series)
Removal Procedure
1. Remove the 0-ring union fitting (5) from the
hydraulic pump housing assembly (1).
2. Remove the 0-ring seal (4) from the 0-ring union
fitting (5).
4. Remove the flow control spring (2).
391490
2·26 Power Steering System Steering
1. Install the flow control spring (2) to the hydraulic
2. Install the control valve assembly (3).
3. Lubricate the 0-ring seal (4) with power
steering fluid. ·
4. Install the 0-ring seal (4) onto the 0-ring union
fitting (5).
5 Notices.
5. Install the 0-ring union fitting (5) into the hydraulic
Tighten
Tighten the fitting (5) to 75 N-m (55 lb ft).
391490
Power Steering Pump Front Bracket

Replacement
Removal Procedure
1. Place drain pan under pump (1 ).
2. Remove air intake resonator and mass airflow
sensor assembly.
3. Remove the serpentine belt. (
4. Remove the power steering pump pulley from the
pump. Refer to Power Steering Pulley
Replacement.
5. Support pump assembly with twine or rope ..
Important: The front power steering pump bracket
can be removed witho.ut the complete disconnection of
the pump. The hydraulic hoses do not need to be
disconnected.
6. Remove power steering pump attaching bolts (4)
and front power steering pump bracket (3).
290570
1. Install power steering pump attaching bolts (4)
and front power steering pump bracket (3).
2. Remove twine or rope used for support.
3. Install the power steering pump pulley to the
pump. Refer to Power Steering Pulley
Replacement.
5. Install the air intake resonator and mass airflow
sensor assembly.
6. Remove drain pan and verify power steering
operation.
290570
Power Steering Pump Rear Bracket
J Replacement
Removal Procedure
1. Remove the power steering pump {V8 only).
Refer to Power Steering Pump Replacement (VB).
2. Remove the rear power steering pump bracket
bolts (3).
3. Remove the rear power steering pump bracket (2)
from cylinder head (1 ).
3 2
~
354413
1. Install the rear power steering pump bracket (2) to
cylinder head (1 ).
Notices.
2. Install the rear power steering pump bracket
bolts (3).
) Tighten
Tighten the power steering pump bracket bolts (3)
to 50 N-m (37 lb ft).
3. Install the power steering pump (V8 only). Refer
to Power Steering Pump Replacement (VB).
3 2
354413
)
2~28 Power Steering System Steering
flushing the Power Steering System Notice: Do not hold the steering wheel against the
stops while flushing the power steering system.
Notice: When adding fluid or making a complete fluid Holding the steering wheel against the wheel stops (
change, always use the proper fluid. Failure to use will cause high system pressure, overheating,
the proper fluid will cause hose and seal damage and and damage to the power steering pump aric:1/or gear.
fluid leaks. Refer to Power Steering Fluid 5. Tur.n .the steering wheel from stop to stop.
Recommendations in this section. 6. Continue to drain the reservoir until all of the old
fluid is cleared from the power steering system.
1. Raise and support the front of the vehicle. Ensure 7. Add. approximately 0.94 liters (1 quart) of new fluid
that the tires and wheels are free to turn. Refer to in order to flush the system. ·
Lifting and Jacking the Vehicle in General 8. Inspect the fluid that is draining while you are
Information. refilling the fluid reservoir.
Do not reuse any drained fluid.
Important: Position the. inlet hose or the reservoir 9. If necessary, perform the following steps:
hose toward a large container in order to catch • Replace all of the lines.
any draining fluid. • Disassemble and clean the system
components.
2. Remove the reservoir hose at the fluid reservoir
inlet connector. • Replace the system components.
10. Unplug the reservoir hose at the fluid reservoir
3. Plug the fluid inlet connector port on the fluid inlet connector.
reservoir. 11. Turn the engine off.
· 4. While an assistant is filling the fluid reservoir with 12. Fill the fluid reservoir to the G mark on. the fluid
fluid, start the engine. level indicator.
Run the engine at idle. Bleeding Power Steering System.
(
Power Steering Cooler Pipe/Hose
l Replacement 1
Removal Procedure
1. Place drain pan under vehicle under cooler.
2. Drain engine coolant from engine.
3. Remove power steering gear outlet hoses (3) and
clips from cooler (1).
4. Remove hose clamps from radiator hoses at
cooler (1 ).
5. Remove radiator hoses from cooler (1 ).
6. Remove cooler (1) from radiator support bracket.
) 354416
1. Install cooler (1) to radiator support bracket. 1
Important: Ensure that the cooler is installed with the
"ENGINE" marking pointed toward the engine and
the "RADIATOR" marking pointing toward the radiator
(drivers side of the vehicle).
Alignment marks on cooler should align with alignment
marks on radiator hoses so cooler is properly
positioned (Power steering circuit outlets pointing
straight down).
2. Install radiator hoses to cooler (1 ).
3. Install radiator hose clamps to radiator hoses at
cooler.
4. Install the power steering gear outlet hoses (3)
and clips to the cooler (1 ).
5. Refill engine with coolant.
6. Refill and bleed power the power steering system.
Refer to Bleeding Power Steering System.
354416
Power Steering Return Hose Replacement
1 Removal Procedure
1. Place drain pan(s) under vehicle under steering
gear and pump.
2. Raise and suitably support vehicle. Refer to Lifting
3. Remove power steering gear inlet (3) and
outlet (2) hoses from steering gear (1 ).
3 2
354423
4. Lower vehicle.
3 5. Remove the serpentine belt.
6. Remove the power steering pump pulley. Refer to
7. Remove inlet hose fitting (3) from pump (1)
(V6 shown, VS similar).
354420
Important: If vehicle is equipped with a power
steering cooler (V8 only), outlet hose (3) and cooler
1
hose (if replacing) must be removed from the
power steering cooler (1) as the cooler is installed in
the outlet hose (return back to reservoir).
8. Remove outlet hose from reservoir (V8 with cooler
shown, remote-mount reservoir on V6).
354416
Important: Inlet and outlet hoses must be oriented so 1
as adequate clearance is maintained between both
hoses and surrounding components to prevent chafing.
Use minimum clearance of 12 mm (0.47 in). The
outlet hose (3) must not be twisted during installation.
Do not bend or distort inlet and outlet hoses to
make installation easier. Failure to follow these
procedures could result in component damage.
1. Install outlet hose to reservoir (V8 with cooler
shown, remote-mount reservoir on V6). (Pump
mounted on V8, body mounted on V6)
354416
2-32 Power Steering System . Steering
2. Install inlet hose fitting (3) to pump (1)
(V6 shown,V8 similar).
1 3
(
354420

1
5, Raise and suitably support vehicle. Refer to Lifting
6. Install inlet and outlet hoses (2, 3) to steering
gear (1 ). ·
Tighten
(
6.1. Tighten the inlet hose (3) to
28 N·m (21 lb ft).
6.2. Tighten theoutlet hose (2) to
28 N-m (21lb ft).
7. Lower vehicle.
9. Refill and bleed power steering system. Refer to
3 2
354423
Power Steering Gear Replacement (V6)·

1 Removal Procedure
1. Place drain pan(s) under vehicle under steering ·.
gear and pump.
2. Raise and suitably support vehicle. Refer to· Lifting
3. Remove power steering gear inlet (3) and
outlet (2) hoses from steering gear (1).
(
3 2
354423
Steering Power Steering System 2~33
4. Lower vehicle.
5. Remove the serpentine belt. 1 3
6. Remove the power steering pump pulley. Refer to
7. Remove inlet hose fitting (3) from pump (1).
8. Remove outlet hose from reservoir.
354420
Important: Inlet and outlet hoses must be oriented so 1 3
as adequate clearance is maintained between both
hoses and surrounding components to prevent chafing.
Use minimum clearance of 12 mm (0.47 in). The
outlet hose must not be twisted during installation. Do
not bend or distort inlet and outlet hoses to make
installation easier. Failure to follow these procedures
could result in component damage.
1. Install outlet hose to reservoir.
2. Install inlet hose fitting (3) to pump (1).
5. Raise and suitably support vehicle. Refer t.o Lifting
354420
Notice: Refer to Fas.tener Notice in Cautions and

Notices. ·
1
6. Install inlet and outlet hoses (2, 3) to steering
gear (1 ).
Tighten ..
• Tighten the inlet hose (3) to 28 N·m (21 lb ft).
• Tighten the outlet hose (2) to 28 N·m (21 lb ft).
7. Lower vehicle.
9. Refill and bleed power steering system: Refer to
3 2
354423
Power Steering Gear Replacement (V8)
Removal Procedure (
1. Remove the air intake resonator.
2. Remove the serpentine belt .
3. Support the engine with a hydraulic jack.
5. Remove the tires and wheels. Refer to Tire and
Wheels.
6. Place a drain pan under the steering gear (5).
7. Disconnect the steering gear outer tie rods.
8. Remove the generator.
9. Remove the left-side engine mount through bolt.
11. Raise the engine with the hydraulic jack.
12. Disconnect the following hoses from the steering
gear (5):
• The power steering gear inlet hose
• The power steering gear o.utlet hose
13. Remove the steering gear flexible coupling from
the steering gear (5). Refer to Intermediate
Steering Shaft Replacement in Steering Wheel
and Column.
14. Remove the nuts (4) and bolts/screws (1).
290561 15. Remove the steering gear (5). (
1. Position the steering gear (5) to the
crossmember (2).
2. Adjust the steering gear (5).
Ensure that the steering aligns as straight as
possible with the steering gear coupling shaft.
3. Hand start the bolts (1) and nut (4).
Notices.
4. Position the back-up wrench to the nuts (4).
Tighten
Tighten the bolts to 85 N·m (63 lb ft):
5. Install the steering gear flexible coupling· to the
steering gear. Refer to Intermediate Steering
Shaft Replacement in Steering Wheel and
Column.
Tighten
Tighten the bolts to 47 N·m (35 lb .ft).
6. Connect the following hoses to the steering
gear (5).
Tighten
6.1. Tighten the inlet hose to 28 N·m (21 lb ft).
6.2. Tighten the outlet hose to 28 N·m (21 lb ft).
7. Lower the vehicle. Allow the vehicle to stay slightly
above the ground while the tires and wheels are
not installed.
290561
8. Lower the engine with the hydraulic jack.
Lifting and Jacking the Vehicle.
10. Install the left side engine mount through-bolt.
11. Install the generator.
12. Connect the steering gear outer tie rods to the
steering knuckles.
13. Install the tire and wheels. Refer to Tire and
Wheels.
15. Remove the hydraulic jack supporting the engine.
17. Install the air intake resonator.
to Bleeding Power Steering System.
Rack and Pinion Gear Rack Bearing

Preload Adjustment - Off Vehicle
(Quiet Valve)
Adjustment Procedure
1. Loosen the adjuster plug lock nut (1 ).
2. Turn the adjuster plug clockwise until the adjuster
plug bottoms in the gear assembly.
3. Turn the adjuster plug back 50 degrees
) to 70 degrees (approximately one flat).
1
Notices.
4. Install the adjuster plug lock nut (1) to the adjuster
plug. Hold the adjuster plug stationary while
tightening the adjuster plug lock nut (1)
Tighten
Tighten the lock nut to 75 N-m (55 lb ft).
423455
Rack and Pinion Boot Replacement - Off

Vehicle (Quiet Valve)
Tools Required
J 22610 Service Boot Clamp Installer
1. Remove the outer tie rod. Refer to Tie Rod End
Replacement - Outer - Off Vehicle.
2. Remove the hex jam nut (2) from the inner tie rod
assembly (1 ).
297360
3. Remove the tie rod end clamp (2) from the rack
and pinion boot (1 ).
297362
4. Remove the boot clamp (1) from the rack and

pinion boot (2) with side cutters.
297364
5. Remove the rack and pinion boot (1) from the

rack and pinion gear assembly.
6. Discard the boot clamp.
7. Inspect the rack and pinion boot (1) for damage.
8. Look for gear oil leakage inside the rack and
pinion boot (1). ·
9. Drain. the oil. .
10. Clean the rack and pinion boot (1) with solvent.
441311
Steering Power Steering System 2;.37
Assembly Procedure
Tools. Required
J 22610 Service Boot Clamp lnstaHer
1. Install the new boot clamp (2) onto the rack and
pinion boot (1 ).
297362
2. Prior to rack and pinion boot installation, apply

grease to the inner tie rod assembly (2) and the
rack and pinion gear assembly (1).
3. Install the rack and pinion boot (3) onto the inner
tie rod assembly (2).
Important: The rack and pinion boot (3) must not be
twisted, puckered or out of shape. If the rack and
pinion boot (3) is not shaped properly, adjust the rack
and pinion boot by hand before installing the
boot clamp.
4. Install the rack and pinion boot onto the gear
assembly (1) until the rack and pinion boot (3)
is seated in the gear assembly groove.
297371
5. Install the boot clamp (1) on the rack and pinion

boot (2) with J 22610.
6. Crimp the boot clamp (1 ).
7. Pinch the pliers together on the rack and pinion
boot (2) in order to install the tie rod end clamp.
J 22610
441313
8. Install the hex jam nut (2) to the inner tie rod
assembly (1 ).
9. Assemble the outer tie rod assembly. Refer to Tie (
Rod End Replacement - Outer - Off Vehicle.
297638
Tie Rod End Replacement - Outer - Off

Vehicle
3
2;/ Disassembly Procedure

Tools Required
~
J 24319-01 Universal Steering Linkage Puller
1. Pull the cotter pin (3) and the hex slotted nut (2)
from outer tie rod assembly (1 ).
I (
423439
2. Loosen the jam.nut (2) on theinner tie rod

assembly (1) .
297349
Steering Power Steering System 2..:39
3. Remove the outer tie rod assembly (2) from the
steering knuckle (1) using J 24319-01. 2
297353
4. Remove the outer tie rod assembly (3) from the

inner tie rod assembly (1 ).
297358
Assembly Procedure
1 . Connect the outer tie rod assembly (3) to the
inner tie rod (1 ). Do not tighten the jam nut (2).
297355
2. Connect the outer tie rod assembly (2) to the
steering knuckle (1 ).
297628
3. Connect the hex slotted nut (2) to the outer tie rod
stud (1 ).
Notices.
Tighten
Tighten the hex slotted nut (2) to 47 N-m (35 lb ft).
Align the cotter pin slot by tightening the hex
slotted nut (2) up to 1/6 additional turn, or (
70 N-m (52 lb ft) maximum. Do not back off the
hex slotted nut (2) for the cotter pin (3) insertion.
4. Install the cotter pin (3) into the hole in the
tie rod stud.
Important: Be sure the rack and pinion boot is not
twisted or puckered during toe adjustment.
5. Adjust the toe by turning the inner tie rod. Follow
recommended manufacturer specifications.
Tighten
423439
Tighten the hex jam nut against the outer tie rod
to 68 N·m (50 lb ft).
(
Tie Rod Replacement - Inner
J Disassembly Procedure
1. To remove the rack and pinion boot; refer to Ra9k
and Pinion Boot Replacement - Off Vehicle
(Quiet Valve).
Important: The rack must be held during removal and
installation of the inner tie rod to prevent damage to
the rack. ·
2. Remove the shock dampener (2) from the inner
tie rod assembly (5).
3. Slide the shock dampener (2) back on the
rack (1 ). ·
4. Remove the inner tie rod assembly (5) from th.e
rack assembly (1) as follows:
4.1. Place a wrench on flats of rack
assembly (3).
4.2. Place another wrench on the flats of the
inner tie rod housing (4).
4.3. Rotate the inner tie rod housing (4)
counterclockwise until the inner tie
rod (5) separates from the rack (1).
5. Remove the old Loctite® from the threads (2) of
the rack (1) and the inner tie rod (3).
297389
2.;.42 Power Steering System Steering
Assembly Procedure
Important: The rack must be held during removal and
installation of the inner tie rod to prevent damage to (
the rack.
1. Slide the shock dampener (2) forward onto the
rack (1 ).
Important: Threads must be clean.prior to Loctite®
application. Check Loctite® (or equivalen~ container for
expiration date. Use only enough Loctite" to evenly
coat threads.
2. Apply Loctite® 262 (or equivalent) to the inner tie
2 rod threads.
Notices.
3. Attach the .inner tie rod (6) on the rack (1) as
follows:
3.1. Place a wrench on the flats of the rack
297392
assembly (3).
3.2. Place a torque wrench (5) on the flats of
the .inner tie rod housing (4).
Tighten
Inner tie rod to 100 N-m (74 lb ft).
4. Slide the shock dampener (2) over the inner tie
rod housing (3) until the front lip of the shock
dampener (2) bottoms against the inner tie
rod housing (3).
5. To assemble the rack and pinion boot; refer to
Rack and Pinion Boot Replacement - Off Vehicle (
(Quiet Valve).
297398
(
Steering Gear Cylinder Pipe
\ Assemblies/0-Ring Seals Replacement -
J Off Vehicle (Quiet Valve)
1. Loosen both cylinder line fittings (1) on the
cylinder end of the gear assembly (2).
2. Loosen both fittings on the cylinder line
assemblies (3) at the valve end of the gear
assembly (2).
423409
3. Remove both cylinder line assemblies (1) from the

423417
4. Remove the 0-ring seals (1) from the valve end

of line.
5. Discard the 0-ring seals (1 ).
423421
Assembly Procedure
1. Inspect the cylinder lines (1) for the
following items:
• Cracks
• Dents
• Damage to the threads
2. Replace the parts as needed.
423421
3. Install the new 0-ring seals (1) to the valve end of

the cylinder lines.
Important: Carefully align the threads on all of the
fittings.
4. Finger tighten the fittings in order to avoid
stripping and cross-threading the fittings.
423421
5. Install the cylinder line assemblies (1) to the gear

assembly (2).
Notices.
Tighten
Valve end fittings to 16.9 N-m (12.6 lb ft). Cylinder
end fittings to 27 N·m (20 lb ft).
Important: Flush and bleed power steering system
(hoses, reservoir and cooler lines) with power steering
fluid GM Part #1050017 (or equivalent meeting GM
Specification #9985010).
6. Flush and bleed power steering system. Refer to
423417
Steering Gear Stub Shaft Seals and
! Bearing Replacement ~ Off Vehicle
i . Remove the adjuster plug lock nut (5) from the
adjuster plug (4).
2. Remove the adjuster plug (4) from the gear
assembly (1 ).
3. Remove the adjuster spring (3) and the rack
bearing (2).
4. Remove the retaining ring (1) from the valve bore

of the rack and pinion gear assembly (2).
5. Remove the dust cover (4) from the bottom of the
Important: Hold the stub shaft in order to prevent
damage to the pinion teeth.
6. Remove the hex lock nut (3) from the lower end
) of the pinion and valve assembly while holding
the stub shaft with a 14 mm crowfoot wrench.
423458
Important: When performing the following procedure,

do not remove pinion and valve assembly from the
rack and pinion gear assembly (5). Press the I
pinion and valve assembly only far enough to allow
removal of the stub shaft bearing annulus (2) and the
stub shaft seal (2).
7. Using an arbor press (1 ), press on the threaded
end of the pinion until removal of the following
ilems is possible:
7.1. The stub shaft (4)
7.2. The stub shaft seal (3)
7.3. The stub shaft bearing annulus
assembly (2)
423459
Assembly Procedure
Tools Required
(
J 29810 Stub Shaft Seal Protector
Important: Hold the stub shaft in order to prevent
damage to the pinion teeth.
1. Install the hex lock nut (1) onto the pinion while
holding the valve stub shaft.
2. Install the dust cover (2) to the rack and pinion
gear assembly.
423460
3. Install the stub shaft bearing annulus assembly (1)

onto the valve stub shaft (2).
423461
4. Install the J 29810 onto the valve stub shaft.

5. Lubricate the stub shaft seal (2) with grease.
6. Install the .stub shaft seal (2) into the rack
and pinion. gear assembly.
7. Install the retaining ring (1) into the groove in the
rack and pinion gear assembly.
423462
8. Lubricate the following items with lithium base
grease:
8.1. The rack bearing (2)
8.2. The adjuster spring (3)
8.3. The adjuster plug (4) . . .
9. Install the following items into the gear assembly:
9.1. The rack bearing (2)
9.2. The adjuster spring (3)
9.3. The adjuster plug (4)
10. Turn the adjuster plug (4) clockwise onto the rack
and pinion gear assembly (1) until the adjuster
plug (4) bottoms in the rack and pinion gear
assembly (1 ), then turn the adjuster plug (4)
back 50 degrees to 70 degrees.
11. Inspect the rotational torque on the pinion. The
maximum pinion preload torque is
1.B N·m (16 lb in).
Notices.
12. Install the adjuster plug lock nut (5) to the adjuster
plug (4).
Tighten
Finger tighten the adjuster plug lock nut (5) while
holding the adjuster plug (4) stationary.

)
Power Steering Pump Description
A constant displacement vane-type pump provides
hydraulic pressure and flow for the power steering
system. The pump is located on the engine and is belt
driven by the serpentine belt through the power
steering pulley. The power steering reservoir is
integrally mounted on the LS1 VS system (engine
mounted) and is remote-mounted (radiator support
mounted) on L36 V6 systems.
The power steering pump contains the following major
components:
• The drive shaft
• The pump housing
• The pump fitting
• The flow control valve
• The flow control spring
• The thrust plates
• The pressure plates
• The pump ring
• The pump rotor
• The pump vanes
The power steering system has a remote reservoir.
The reservoir cap has an attached fluid level indicator
which shows the fluid level in the reservoir.
2~48 Power Steering System Steering
The bore at 1he front of 1he housing contains the flow· Seal. Replacement Recommendations
control fitting. The flow control fitting works with
the flow control valve and spring in order to limit the Lip Seals (
maximum flow of the pump. The pressure relief Lip seals, which seal rotating shafts, require special
valve is located inside of the flow controlvalve. The treatment. This type of seal is used on the hydraulic
;pressure relief valve limits the maximum pump pump shaft of the pump. When leakage· occurs in this
pressure. area, always replace the seal or seals, after
The casting boss that runs across the housing holds inspecting and thoroughly cleaning the sealing
.the following components: · surface. Replace the shaft if pitting .is found. If
• The flow control valve corrosion in the lip seal contact zone. is slight, clean
the. surface of the shaft with crocus cloth. Replace the
• The flow control spring shaft only if the leakage cannot be stopped by
• The pump fitting smoothing with crocus cloth first.
0-Ring Seals
Power Steering Gear Description
Whenever a part which forms a sealing surface 1or an
The power steering gear includes the following major 0-ring is removed, the 0-ring seal should also be
internal components: removed and replaced with a 0-ring seal. Lubricate all
• The power steering gear pinion and valve shaft new 0-rings with fresh power steering fluid to ease
installation;
• The steering gear rack and piston
• The inner tie rods
• The outer tie rods
Illustration Tool Number/ Description
The steering gear rack and piston is supported at the
ends in the steering gear housing. The steering
gear rack and piston is sealed in order to prevent
leakage across the piston. The pinion and valve
intersects with the rack and piston and meshes directly J 5176-E
with the teeth of the rack and piston.
Power Steering Pressure (
Manual steering is always available during the Tester
following situations:
• When the engine is not running
• In the event of power steering pump failure 65360
• In the event of serpentine belt failure

Steering effort is increased when the above conditions
exists.
The power steering pump provides hydraulic pressure
and fluid flow in order to move the gear components. J 5176-92
This action occurs when the vehicle is parked or Pressure Tester Adapter
moving. The valve directs pressurized fluid during a
steering maneuver. The fluid travels through the
external .steel cylinder lines in order to act on the rack
and piston. When the vehicle is turned right, the 293487
steering valve opens and routes pressurized fluid to
the left side of the piston. At the same time, the valve
allows fluid to escape from the right side of the
piston and return to the valve area. The fluid pressure
is converted into a mechanical force which is applied
J 22610
to the piston. This difference in force across the piston
Keystone Clamp Plier
causes the rack to move to the right. The opposite
action occurs when the gear is turned to the left.
The effort to steer the vehicle is created by the
pressure difference at the piston when the following
82243
conditions exist: (
• The power steering pump (3) provides pressurized
fluid to the gear.
• The valve is operating correctly.
J 24319-01 J 29810
Universal Linkage Puller Stub Shaft Seal Protector
82244 283637
J 25033-C J 35555
Power Steering Pump Pulley
Mity Vac
Installer
676 444239
J 25034-C J 43485
Power Steering Pump Pulley Power Steering. Bleeder
) Remover Adapter
675 443571
J 25323-D
Power Steering System
Analyzer
315384
J.29525
Steering Analyzer Adapter
(18 mm)
309644
)
2'."50 Steering Wheel and Column m Tilt Steering
Steering Wheel and Column - Tilt

Specifications
Specification
Dimmer and Ignition Switch Bolts/Screws 4N·m 351bin
Hazard Warning Switch Knob Bolt/Screw 0.7N·m 61b in
Hydraulic Pump.Fitting 75 N·m 55 lb ft
Hydraulic Pump Hose Fitting 28N·m 21 lb ft
Ignition Switch Bolt/Screw 2.5N·m 221bin
Inflatable Restraint Steering Wheel Mounting Plate Bolt/Screw
1.9 N·m 17 lb in
(Pontiac Only)
Intermediate Steering Shaft-to-Steering Column Bolt/Screw 47N·m 35 lb ft
Intermediate Steering Shaft-to-Steering Gear Bolt/Screw 47N·m 35 lb ft
Power Steering Gear Pipe Fitting Seat 28 N·m 21 lb ft
Radio Control Switch Bolt/Screw (Pontiac Only) 1.9 N·m 171bin
Steering Column Bolts/Screws 18 N·m 14 lb ft
Steering Column Guide Bolt/Screw 25 N·m 18 lb ft
Steering Column Upper Support Nuts 25N·m 18 lb ft
Steering Wheel Bolt/Screw (Pontiac Only) 2.8 N-m 251b in
Steering Wheel Horn Switch Contact Plate Shoulder Bolt/Screw
2.8N·m 25.lb in
(Pontiac Only)
Steering Wheel Nut 43 N·m 32 lb ft (
Steering Wheel-to-Inflatable Restraint Steering Wheel Module
2.8N·m 251bin
Bolts/Screw (Chevrolet Only)
Steering Wheel-to-Steering Wheel Horn Switch Bolts/Screws
1.9 N·m 171bin
(Chevrolet Only)

BTSI Shift Lock Actuator 4.000
Cable Shift Cam Assembly 4.000
Dimmer Switch 2.000
Hazard Warning Switch 2.000
Ignition Switch Assembly 2.000
Linear Shift Assembly 4.000
Lock Bolt Spring 6.000
Lock Module Assembly 2.000
Shift Lever 4.000
Shift Lever Seal 4.000
Steering Column Assembly 6.000
Steering Column Boot Seal 6.000
Steering Column Housing 6.000
Steering Column Housing Support 6.000
Steering Column Jacket Assembly 6.000
Steering Column Lower Shroud 6.000 (
Steering Column Shift Lever Actuator 4.000
Steering Column Spring Guide 6.000
Steering Column Tilt Lever 6.000
Steering Steering Wheel and Column - Tilt 2-51
GM SPO Group Numbers (cont'd)
Steering Column Tilt Spring 6.000 ·..
Steering Column Upper Shroud 6.000
Steering Gear Coupling Lower Shield 6.000
Steering Gear Coupling Shaft (Lower Intermediate Shaft) 6.000
Steering Shaft Lock Plate 6.000
Steering Shaft Lower Bearing 6.000
Steering Shaft Upper Bearing Race Seat 6.000
Steering Shaft Upper Bearing Spring 6.000
Steering Wheel 6.000
Steering Wheel lnflator Module 16.000
Steering Wheel Lock Pin 6.000
Turn Signal Canceling Cam 2.000
Turn Signal/Multifunction Switch Assembly 2.000
Upper Intermediate Shaft 6.000
2-52 Steering Wheel and Column~ Tilt Steering
Steering Column - Disassembled View
Tilt Steering Column
393980
legend
(1) Flanged Prevailing Torque Nut (13) Turn Signal Switch Assembly
(2) Retaining Ring (14) Upper Bearing Inner Race Seat
(3) SIR Coil Assembly (15) Inner Race
(4) Wave Washer (16) Pan Head 6-Lobed Socket Screw
(5) Bearing Retainer (17) Buzzer Switch Assembly
(6) Connector Shroud (18) Lock Retaining Screw
(7) Shaft Lock Shield Assembly (19) Lock Housing Cover and Sleeve Assembly
(8) Turn Signal Cancel Cam Assembly (20) Steering Column Lock Cylinder Set
(9) Upper Bearing Spring (21) Dimmer Switch Rod Actuator (
(10) Pan Head 6-Lobed Socket Screw (22) Switch Actuator Pivot Pin
(11) Round Washer Head Screw (23) Pivot and Pulse Switch Assembly
(12) Signal Switch Arm Assembly (24) Column Housing Cover End Base Plate
(25) Column Housing Cover End Cap (48) Spring· Guide
(26} Wiring Protector (49) Wheel Tilt Spring
)
I
(27) Steering Column Housing Assembly (50) Spring Retainer
(28} Bearing Assembly (51) Race and Upper Shaft Assembly
(29} Lock Bolt (52) Centering Sphere
(30} Lock Bolt Spring (53) Joint Preload Spring
(31} Steering Wheel Lock Shoe (54) Lower Steering Shaft Assembly
(32) Steering Wheel Lock Shoe (55) Steering Shaft Assembly
(33} Wire Protector Shield (56) Hexagon Washer Head Tapping Screw
(34} Drive Shaft (57) Steering Column Housing Support Assembly
(35} Dowel Pin (58) Steering Column Housing Shroud
(36} Pivot Pin (59) Steering Column Jacket Assembly
(37) Shoe Spring (60) Lower Bearing Adapter
(38} Release Lever Spring (61) Bearing Assembly
(39} Release Lever Pin (62} Bearing Adapter Retainer
(40) Shoe Release Lever (63} Lower Bearing Adapter Clip
(41) Bearing Assembly (64) Ignition Switch Assembly
(42) Switch Actuator Rack (65) Flat Head Screw
(43) Rack Preload Spring (66) Dimmer Switch Assembly
(44) Steering Column Housing (67) Hexagon Washer Head Tapping Screw
(45) Pivot Pin (68) Dimmer Switch Rod
(46) Switch Actuator Sector (69) Washer Head Screw
(47) Hexagon Washer Head Screw (70) Ignition Switch Rod Actuator Assembly
\
/
2.-54 Steering Wheel and Column - Tilt Steering
Lock System Does Not Unlock
(
Problem Action
The lock system will not unlock. Inspect the lock system for the following conditions:
• A collapsed shear flange on the sector shaft
• A damaged lock bolt
• A damaged lock cylinder
• A damaged housing
• A damaged sector
• A damaged rack
• A damaged or incorrectly cut key
Lock System Does Not Lock

Problem Action
The lock system will not lock. Inspect the lock system for the following conditions:
• A broken or worn lock bolt spring
• A damaged sector
• A burr on the lock bolt
• A damaged housing
• A damaged rack
• Interference between the bowl and the rack coupling
• A stuck ignition switch
• A restricted actuator rod
• An incorrectly installed sector (
Key Cannot Be Removed in the Off Lock Position
Problem Action
The key cannot be removed in the Inspect the column for the following conditions:
OFF-LOCK position. • An incorrectly set ignition
Lock Cylinder Can Be Removed Without Depressing Retainer

Problem Action
The lock cylinder can be removed Inspect the lock cylinder for a missing lock cylinder retaining screw.
without depressing the retainer.
High Lock Effort Between the Off Lock Positions

Problem Action
High effort is required in the lock Inspect the lock cylinder for a distorted rack.
cylinder between the OFF and
OFF-LOCK positions.
(
High lock Effort
.. Problem Action
High lock effort is required. Inspect the system steering for the following conditions:
• A damaged ignition switch
• A broken or deformed rack preload spring
• Burrs on the following components:
- The sector
- The rack
- The housing
- The support
- The actuator rod coupling
• A bent sector shaft
• A damaged rack
• A damaged or misadjusted park lock cable
• Misalignment of the housing to the. cover
• A distorted coupling slot in the rack
• A bent actuator rod
• A bent ignition switch mounting bracket
• A restricted actuator rod
• A worn or damaged key
Noise in Steering Column

Problem Action
There is noise in the steering column. Inspect the steering column for the following conditions:
O Loose joints from the steering column to the steering gear
• An incorrectly aligned steering column

• . An unh.ibricated horn contact ring
• A lack of grease on the bearings
• Loose sightshields
• A worn or broken upper or lower steering shaft bearing
• An unseated lock plate retainer ring
• An unlubricated spherical joint
High Steering Shaft Effort

Problem Action
High steering shaft effort is required. Inspect the steering system for the following conditions:
O A misaligned steering column
• An improperly installed or deformed dust seal

..
~ A damaged upper or lower steering shaft bearing
• A flash on the inside diameter of the shift tube
• A tight universal joint
)
2-56 Steering Wheel and Column - Tilt Steering
Looseness in Steering Column
Problem Action
There is a lash in the steering Inspect the steering column for the following conditions:
.. (
column. " Loose bolts/screws on the upper and lower bracket mounting of the instrument
panel (IP)-to-steering column
• Broken weld nuts on the jacket
• A sheared IP upper bracket capsule
" Loose shoes in the housing
• Loose pivot pins
• A loose lock pin in the housing support
• Loose housing support bolts/screws
• Loose bolts/screws on the steering column upper and lower bracket-to-jacket
• Loose bolts/screws on the lower bracket-to-adapter and bearing mounting
Lower Housing Scraping Upper Housing

Problem Action
The housing scrapes the bowl. Inspect the steering column for the following conditions:
• A bent bowl
• A bowl that is not concentric to the hub
• An improperly installed cover and housing end cap
Loose Steering Wheel

Problem Action
The steering wheel is loose. Inspect the steering column for the following conditions:
• Excessive clearance between the holes in the housing or housing support and
the pivot pin diameters ·
• A damaged anti-lash spring in the spheres
(
• A missing anti-lash spring in the spheres
O The steering shaft upper bearing· is not seated in the housing
• A missing steering shaft upper bearing inner race

• Loose housing support bolts/screws
• A missing bearing preload spring
• A broken bearing preload spring
Loose Steering Wheel (Every Other Tilt Position)

Problem Action
The steering wheel is loose in every Inspect the steering column for the following conditions:
other tilt position. • A loose fit between the shoe and the pivot pins
O The shoe is not free in the slot.
Steering Wheel Does Not Lock in Any Tilt Position

Problem Action
The steering column does not lock in Inspect the steering column for the following conditions:
any tilt position. • A seized shoe on the pivot pin
• Burrs or dirt on the shoe grooves
• A weak shoe lock spring
• A broken shoe lock spring
(
Steering Wheel Not Returning to Top Tilt Position
Problem Action
The steering wheel fails to return to Inspect the steering column for the following conditions:
the top tilt position. • Bound up pivot pins
• A broken wheel tilt spring
• A weak wheel tilt spring
• Tight turn signal switch wires
Noise When Tilting Steering Column

Problem Action
There is noise when tilting the Inspect the steering column for the following conditions:
steering column. • Worn upper tilt bumpers
• Rubbing of the shoe lock spring in the housing
Turn Signal Does Not Indicate Lane Change

Problem Action
The turn signal does not indicate a Inspect the steering column for the following conditions:
lane change. • A broken lane change pressure pad
• A broken lane change spring hanger
• A broken lane change spring
• A missing lane change spring
• A misplaced lane change spring
• A jammed base
• Jammed wires
) Tum Signal Switch Does Not Stay in Turn Position

Problem Action
The turn signal does not stay in the Inspect the steering column for the following conditions:
turn position. • Foreign material impeding the movement of the yoke
• Loose parts impeding the movement of the yoke
• A broken detent
• A broken canceling spring
• A missing detent
• .A missing canceling spring
Replace the switch if none of the above conditions are found.
Turn Signal Switch Does Not Cancel

Problem Action
The turn signal does not cancel. Inspect the steering column for the following conditions:
• Loose switch mounting screws
• A broken switch
• Broken anchor bosses
• A broken detent
• A missing detent
• An out-of-position detent
• A broken return
• A missing return
• An out-of-position return
• A broken canceling spring
) • A missing canceling spring
• An out-of-position canceling spring
• A worn canceling cam
Tum Signal Switch Difficult to Operate
Problem Action
The turn signal is difficult to operate. 1. Inspect for the following conditions:
• A loose turn signal switch arm
• Loose springs
• Misplaced springs
• Foreign parts or material
• Loose turn signal switch mounting screws
2. Replace the switch if the following conditions exist:
O A broken yoke
O
A distorted yoke
Hazard Switch Cannot Be Turned. Off

•.
Problem Action
The hazard switch cannot be 1. Inspect for foreign material between the hazard support canceling leg and
turned off. the yoke.
2. Replace the turn signal switch if no foreign material is found.
Hazard Switch Does Not Stay On

Problem Action
The hazard switch will not stay on or 1. Inspect the steering column for the following conditions:
is difficult to turn off. • A loose turn signal switch
• Interference with other components
• Interference from foreign material
2. Replace the turn signal switch if none of the above conditions are found.
(
Ignition Switch Electrical System Does Not Operate
Problem Action
The electrical system does not Inspect the steering column for the following conditions:
function properly. • A damaged ignition switch
• An improperly adjusted ignition switch
• A loose connector at the ignition switch
Ignition Switch Does Not Tum

Problem Action
The ignition switch does not turn. Inspect the steering column for the following conditions:
• A damaged ignition switch
• An improperly adjusted ignition switch
• A loose connector at the ignition switch·
Ignition Switch Cannot Be Set Correctly

Problem Action
The ignition switch cannot be Inspect the steering column for the following conditions:
correctly set. O A deformed switch actuator rod
• A sector to rack engaged in the wrong tooth
(
J Repair Instructions
Ignition Switch Replacement - On Vehicle
Removal Procedure
Caution: Refer to SIR Handling Caution in Cautions
and Notices.
Caution: Refer to Battery Disconnect Caution in \
Cautions and Notices.
1. Disconnect the negative battery cable.
2. Remove the inflatable restraint coil.
3. Insert the ignition key into the lock cylinder.
Leave the key in the LOCK position.
363517
4. Remove the lock retaining screw (2).

5. Remove the lock cylinder (1) and harness (4),
perform the following:
5.1. Disconnect the terminal connector from the
bulkhead connector.
2
5.2. Remove the wiring protector.
5.3. Disconnect the retaining clip (3) from the
lock housing cover sleeve.
5.4. Gently pull wire harness (4) through the
column. 3
5.5. Remove the lock cylinder (1) from the
vehicle.
363518
)
1. Install the lock cylinder (1) and harness (4), (
perfotm the following:
1.1. Install the lock cylinder (1) to the vehicle.
2
1.2. Gently pull wire harness (4) through
the column.
1.3. Connect the retaining clip (3) to the lock
housing cover sleeve.
1.4. Install the wiring protector.
1.5. Connect the terminal connector to the
bulkhead connector.
Notices.
2. Install the lock retaining screw (2).
Tighten
Tighten the lock retaining screw to
2.5 N-m (22 lb in).
363518
3. Remove the ignition key from the lock cylinder.

4. Install the inflatable restraint coil.
5. Connect the negative. battery cable.
363517
Multifunction Turn Signal lever

Replacement - On Vehicle
Removal Procedure
Caution: Refer to Battery Disconnect Caution in
Important: Position the windshield wiper switch in the
OFF position.
1. Disconnect the negative battery cable. Refer to
Battery Negative Cable Disconnect/Connect
Procedure in Engine Electrical.
2. Remove the steering column access cover.
367666
3. Disconnect the multifunction lever electrical
connector.
4. Remove the multifunction lever.
367668
1. Install the multifunction lever.
2. Connect the multifunction lever electrical
connector.
367668
3. Install the steering column access cover.

4. Connect the negative battery cable. Refer to
367666
Hazard Warning Switch Replacement • On
Vehicle
Removal Procedure
and Notices.
Important: Do not remove the steering column in
order to replace the hazard warning switch. Refer to
Steering Column Replacement.
1. Remove the bolt/screw (4).
2. Remove the button (3).
3. Remove the spring (2).
4. Remove the knob (1 ).
290205
1. Install the knob (1 ).
2. Install the spring (2).
3. Install the button (3).
Notices.
4. Install the bolt/screw (4).
(
Tighten
Tighten the bolt/screw to 0.7 N·m (6 lb in).
290205
Tilt lever Replacement - On Vehicle

Removal Procedure
1. Lower the steering wheel to access the tilt lever
easier.
2. Firmly grip and twist the tilt wheel release
lever (3) counterclockwise.
2 1
290197
" Firmly grip and twist the tilt wheel release 3
lever (3) clockwise.
O Raise the steering wheel.
290197
Horn Switch Replacement - On Vehicle

(Chevrolet)
Removal Procedure
and Notices.
1. Remove the inflatable restraint steering .wheel
) module (4).
2. Remove the screw (3) from the ground lead.
3. Disconnect the power lead (8) by pulling
straight out.
290190
1. Install the horn switch (2) to the inflatable restraint
steering wheel module (4).
Notices.
2. Install the screw (3) to the ground lead.
Tighten
Tighten the bolt/screw (3) to 1.9 N-m (17 lb in).
3. Connect the power lead (8) by pushing straight
into the outlet.
290190
1 (Pontiac)
Removal Procedure
Caution: Refer to SIR Handling Caution in Caut;ons
and Notices.
1. Disconnect the horn wiring connector (1) from the
steering column.
2. Remove the horn wiring connector bolts (2).
3. Remove the horn switch (3) from the steering
wheel (4).
581753
1 1. Position the horn switch (3) to the steering
wheel (4).
Notices.
2. Install the horn wiring connector bolts (2).
Tighten
Tighten the horn wiring connector bolts (2) to (
1.9 N-m (17 lb in).
3. Connect the horn wiring connector (1) to the
steering column. ·
581753
Steering Wheel Control Switch Assembly

Replacement
Removal Procedure
and Notices.
1. Remove the radio control wire harness retainer.
2. Pry out the radio control switch (5) at the
lower edge.
3. Remove the radio control switch (5) from the
steering wheel (7).
4. Disconnect the wire harness connector (3) from
the control(s).
(
6 5
290322
Steering . Steering Wheel and Column· Tilt ... 2-65
J 1. Connect the wire harness connector (3) to the
control(s).
2. Install the radio control switch (5) to the steering
wheel (7).
3. Install the radio control wire harness retainer.
290322
Steering Wheel Replacement

Removal Procedure 2 3
and Notices.
Tools Required
• J 1859-A Steering Wheel Puller
) • J 38720 Steering Wheel Puller Bolts
1. Remove the nut (3).
2. Disconnect the horn ground lead (5).
Notice: When removing the steering wheel, 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
rigidity.
Notice: When attaching J 1859-A and J 38720 to the
steering wheel, use care to prevent threading 290184
J 39720 (bolts) all the way through the steering wheel
hub into the SIR coil and damaging the SIR coil.
3. Use a J 1859-A and a J 38720 in order to remove
the steering wheel (2).
4. Remove the steering wheel horn switch. Refer to
(Chevrolet) or Horn Switch Replacement - On
Vehicle (Pontiac).
)
2-~6 Steering Wheel and Column - Tilt Steering
2 3 1. Route the SIR coil electrical connector to the (
steering wheel (2).
2. Install the steering wheel horn switch.
Important: Align the tooth on the steering wheel with
the block tooth on the steering column shaft within
one female serrat.ion.
3. Install the steering wheel (2).
4. Connect the horn ground lead (5).
Notices.
5. Install the nut (3).
Tighten
Tighten the nut to 43 N,m (32 lb ft).
7 6 5
290184
Intermediate Steering Shaft Replacement

Removal Procedure
Notice: The vehicle's wheels must be in a
straight-ahead position and the key must be in a
LOCK position when removing or installing the steering
column. Failure to do so may cause the SIR coil
assembly to become uncentered and may resul1 in (
unneeded SIR system repairs.
1. Remove the clamp (11) from the boot (12).
2. Remove the boot (12) from the shaft (5).
3. Remove the steering gear bolt (10) from the
gear (8). ·
4. Remove the shaft (5) from the steering gear (8).
5. Remove the shield (14) from the shaft (5) and
column (3) on 5.7L VIN G only.
6. Remove the bolt (13) from the column (3).
7. Remove the shaft (5) from the column (3).
581793
Steering Steering Wheel and Column - Tilt 2;.67
) 1. Position the shaft (5) to the column (3).
Notices.
2. Install the column bolt (13).
Tighten
Tighten the column bolt (13) to 47 N-m (35 lb ft).
3. Position the shaft (5) to the gear (8).
4. Install the steering gear bolt (10).
Tighten
Tighten the steering gear bolt (10) to
47 N·m (35 lb ft).
5. Install the boot (12) to the shaft (5).
6. Use a clamp (11) in order to secure the boot to
the shaft.
7. Position the shield (14) to the shaft (5) and
column (3) on 5.7L VIN G only.
8. On 5:7L VIN G only, insert the button into the
hole in the column (3) in order to install the
shield (14).
)
I
581793
Steering Column Replacement
Removal Procedure
Notice: The vehicle's wheels must be in a
straight-ahead position and the key must be in a
LOCK position when removing or installing the steering
column. Failure to do so may cause the SIR coil
assembly to become uncentered and may result in
unneeded SIR system repairs.
Notice: When the steering column is removed from
the vehicle, it is extremely susceptible to damage.
Dropping the column on its end could collapse
the steering shaft or loosen plastic injections that keep
the column rigid. Leaning on the column could
cause steering column jacket to bend or dE:Jform. Any
of the above conditions could impair column
assembly's collapsible design. If the steering wheel
must be removed, use only the specified steering
wheel puller and steering whee.I puller bolts. Never
hammer on the end of the steering shaft because
hammering could loosen plastic injections that keep
the column right.
1. Remove the left instrument panel insulator.
2. Remove the instrument panel driver knee bolster
and deflector.
3. Disable the SIR system.
4. Remove the steering wheel, if the column is to be
replaced. Refer to Steering Wheel Replacement.
5. Remove the intermediate steering shaft bol1 from (
\
290448 the steering gear coupling shaft and column.
6. Remove the bolts (2) that attach the cover (7) to
the dash panel.
7. Remove the cover (7) from the dash panel.
8. Disconnect the electrical connectors.
9. Remove the nuts (5) and shims (6) from the
steering column support.
10. Remove the automatic transmission park lock
cable from the ignition switch, if equipped.
11. Remove the column (3) from the vehicle.
) Notice: If a service replacement steering column is
being installed, do not remove the antirotation pin until
after the column has been connected to the steering
gear. Removing the antirotation pin before the column
is connected to the steering gear may damage the
SIR coil.
1. Position the column (3) into the vehicle.
2. Install the automatic transmission park lock cable
to 1he ignition switch, if equipped. Refer to
Au1omatic Transmission, On-Vehicle Service.
Notices.
3. Install the shims (6) and the nuts (5) to the
steering column support.
Tighten
Tighten the steering column support nuts to
25 N-m (18 lb ft).
4. Install the intermediate steering shaft bolt to the
steering gear coupling shaft. Refer to Steering
Gear Coupling Shaft.
290448
5. Install the cover to the dash. Install the bolt in the

following order:
5.1. Install the lower (3) bolt.
5.2. Install the outboard (4) bolt.
5.3. Install the inboard (2) bolt.
6. Position the cover to the dash panel.
7. Connect the electrical connectors.
8. Install the dash panel bolts.
Tighten
Tighten the dash panel bolts to 18 N,m (14 lb ft).
9. Install the steering wheel, if column is replaced.
Refer to Steering Wheel Replacement.
10. Enable the SIR system.
11. Install the instrument panel driver knee. bolster
and deflector.
12. Install the left instrument panel insulator.
290294
)
Inflatable Restraint Steering Wheel Module
Coil - Disassemble - Off Vehicle
Tools Required
J 41352 Modular Column Holding Fixture
1. Set the steering column and J 41352 into .a vise.
Important: Align the block tooth on the race and
upper shaft assembly to the 12 o'clock position.
Remove only those components necessary to do the
repairs.
2. Check the steering column jacket assembly for
any accident damage. Refer to Steering Column
Accident Damage Inspection - Off Vehicle.
3. Place the ignition in the "LOCK" position to center
the coil assembly.
4. Remove the wire harness assembly strap (1).
343711
5. Remove the retaining ring from the steering shaft

assembly.
343702
6. Remove the wire harness straps and the wire

protector from the steering column.
7. Disconnect the SIR coil assembly connector at
the base of the steering column, if needed.
8. Remove the SIR coil assembly from the steering
shaft assembly.
9. Attach mechanics wire to the SIR coil assembly
connectors for reassembly.
---,
i.;,::_:;a---
10. Pull the SIR coil assembly connectors through the
steering column, if needed.
343717
Steering Steering Wheel. and Column - Tilt 2-71
Inflatable Restraint Steering. Wheel Module
J Coil - Assemble - Off Vehicle
Assembly Procedure
Tools Required
Important: The SIR coil assembly must be centered
before it is assembled on the steering shaft assembly.
1. If reusing the original SIR coil assembly, Refer
to Inflatable Restraint Coil Centering - Off
Vehicle (Column Shift And Floor Shift).
2. Feed the SIR coil assembly connectors through
the steering column.
Important: A new SIR coil assembly will come
precentered. Do not remove the orange tab until the
SIR coil assembly is installed.
3. Install the SIR coil assembly (4) following
these steps: 322951
3.1. Position the SIR coil assembly (4) to.the

steering shaft assembly (2).
3.2. Align the opening in the SIR coil
assembly (4) with the horn tower (1) and the
"locating bump" between the 2 tabs cm
the lock housing cover and sleeve
assembly.
3.3. Seat the SIR coil assembly (4) onto the
) steering shaft assembly (2).
4. Remove and dispose, of the orange tab if using a
new SIR coil.
5. lristall the retaining ring (3) to the steering shaft
assembly (2).
Important: Pull carefully on all the wires to remove
any wire kinks that may be inside the steering column
asseml:)ly. If this is not done it may cause damage
to the wire harness..
6. Install the wiring protector and the wire harness
straps to the steering column.
7. Connect the SIR coil assembly connector at the
base of the column.
---,
im.i.=.---
343717
8. Install the small wire harness straps.
9. Install the wire harness assembly strap (1 ). (
10. Remove the steering column and J 41352 from
the vise.
343711
Turn Signal and Multifunction Switch

Assembly - Disassemble - Off Vehicle
1. Remove the tilt lever.
2. Remove the multifunction lever.
3. Remove the hazard knob.
4. Remove the turn signal cancel cam assembly. (
Refer to Turn Signal Cancel Cam and Upper
Bearing Inner Race - Disassemble - Off Vehicle.
5. Remove the round washer head screw (2) from
the signal switch arm assembly (3).
6. Pry out the signal switch arm assembly (3) from
the lock housing cover and sleeve assembly.
7. Remove the 3 pan head 6 lobed socket screws (1)
from the turn signal switch assembly.
354112
8. In order to remove the turn signal switch

assembly, use the following steps:
8.1. Remove the steering column wire
harness strap.
8.2. Remove the wiring protector.
354116
9. Disconnect the terminal connector from the turn
signal switch assembly connector.
10. Pull the turn signal switch assembly connector
through the steering column, if needed.
343824
Turn Signal and Multifunction Switch

Assembly - Assemble - Off Vehicle
Assembly Procedure
1. Thread the turn signal switch assembly connector
through the lock housing cover and sleeve
assembly, if the switch is hanging.
343961

Notices.
2. Install the turn signal switch assembly and secure
using 3 pan head 6 lobed socket screws (1 ).
Tighten
Tighten the 3 pan head 6 lobed socket screws to
$.5 N-m (31 lb in).
3. Lubricate the signal switch arm assembly (3) with
li1hium grease.
4. Install the signal switch arm assembly (3) onto the
turn signal switch assembly.
5. Secure the signal switch arm assembly (3) using
the round washer head screw (2).
) Tighten
Tighten the screw to 2.5 N·m (22 lb in).
354114
6. Install the terminal connector to the turn signal
switch assembly connector.
343824
7. Pull the turn signal switch assembly connector

towards the base. of the column.
8. Insert the wiring protector into the steering column
bracket. ·
9. Insert the steering column wire harness into 1he
steering column wire harness strap.
10. Install the turn signal cancel cam assembly. Refer
to Turn Signal Cancel Cam and Upper Bearing (
Inner Race - Assemble - Off Vehicle.
11. Install the tilt lever.
12. Install the multifunction lever.
13. Install the hazard knob.
354116
Ignition Switch Assembly - Disassemble -

Off Vehicle
1. Remove the dimmer switch assembly. Refer to_
Dimmer Switch Assembly - Disassemble ~ Off
Vehicle.
2. Slide the vehicle wire harness from the ignition
switch assembly (2).
3. Remove the flat head screw (1) from the igri~ion
4. Remove the ignition switch assembly (2) from the
ignition switch rod actuator assembly.
393976
Ignition Switch Assembly - Assemble -
Off Vehicle
Assembly Procedure
1. Install the vehicle wire harness into the ignition
2. Install the ignition switch assembly (2) to the
ignition switch actuator assembly.
3. Install the flat head screw (1) to the ignition switch
assembly (2).
4. Tighten the flat head screw (1) finger tight.
393976
5. Move the ignition switch assembly slider (2) to the

far right position.
6. Move the ignition switch assembly slider (2)
detent to the left. This is the OFF LOCK position. 2
7. Install a 3/32 inch drill bit into the hole on
the ignition switch assembly (1) to limit travel.
8 .. Push against the ignition switch actuator assembly
) to limit all the lash.
Notices.
9. Install the flat head screw.
Tighten
Tighten the screw to 4 N·m (35 lb in).
10. Install the dimmer switch assembly. Refer to
Dimmer Switch Assembly - Assemble - Off
Vehicle.
358702
Dimmer Switch Assembly - Disassemble -

Off Vehicle
Disassembl Procedure
Tools Required
1. Insert the steering column and J 41352 into
a vise.
2. Rel')'love-the hexagon washer head tapping
screw (1) from the dimmer switch assembly (3) .
3, .Remove the washer head screw (2) from the
dimmer switch assembly (3). 3
4. Remove the dimmer switch rod from the dimmer

) switch assembly (3).
5. Remove the dimmer switch assembly (3) from the
ignition switch assembly (4).
6. Remove the dimmer switch assembly (3) from the
vehicle wire harness.
393978
2-76 Steering Wheel and"'Column-:'f..ilt Steering
Dimmer Switch Assembly·.- Assemble ·
Off Vehicle
Assembly Procedure
Tools Required
J 41352 .Modular Column Holdtng Fixture
1. lnstaU the dimr:ne.r. S'!Vitch assembly (3) to the
ignition switch assembly (4). ·
2. lnstallth13 he~agon w~~her hea.d tapping screw (1)
.to. the dimmer switch assembly (3).
3.. Tight~nthe.hexagon washer head tapping
screw (1)fjnger tight. ·
4. In.stall the washer head screw (2) to the dimmer
.. switch assembly (3).
5. Tighten.the washer head screw (2) finger tight.
6. Insert the dimrner switch rod into the slot on
the dimrner switch.assembly (3).
393978
7 .. Adjust the dimmer: switch; assembly following

these steps: · . .
. 7: 1. Install a '3132 in'ch drill bit into the hole (1)
· on the dimmer switch· assembly to limi1
travel.
7.2,.. .Position .the c;:lin,mer switch assembly onto
· the cqlumn a.rid push it against the dimmer
switch· actuator rod to remove all the· ,ash.
(
7.3. Remove the drill bit.
Notic~:. ReferJo Fastener NotiQe in Cautions and

Notices.
8. lnstali the h~xagon washer head screw (1).

Tighten .
Tighten the hexagon washer' head· screw to
2.5 N-m (22 lb inf' · ·· .· ·
9. lnstallth~'washer head screw (2) ..
Tighten
Tighten the washer head screw to 4 N-m (35 lb in).
1O. Insert the vehicle wire harness into the dimmer
11. Remove the steering column and J 41352 from
the vise. (
393978
Windshield Wiper and Washer Switch
Assembly - Disassemble - Off Vehicle
1. Remove the lock housing cover and sleeve
assembly. Refer to Lock Housing Assembly -
Disassemble - Off Vehicle.
2. Remove the switch actuator pivot pin (2) from the
pivot and pulse switch assembly (1 ).
3. If removal of the pivot and pulse switch
assembly (1) is not needed let. the pivot and pulse
switch assembly (1) hang freely.
4. Remove the pivot and pulse switch assembly (1)
from the lock housing cover and sleeve assembly
following these steps:
4.1. Remove the wire protector shield.
4.2. Remove the pivot and pulse switch
assembly connector from the bulk head
connector. 343835
Important: Use care not to damage the wires when

pulling the pivot and pulse switch assembly wire
harness through the steering column.
4.3. Pull the wire harness through the steering
column.
Windshield Wiper and Washer·Switch

Assembly - Assemble - Off Vehicle
Assembly Procedure
1. Install the pivot and pulse switch assembly to the
lock housing cover and sleeve assembly.
2. Lubricate the switch actuator pivot pin (2) with
lithium grease.
3. Install the switch actuator pivot pin (2) into the
pivot and pulse switch assembly (1) and the
lock housing cover and sleeve assembly.
Important: Use care not to damage the wires when
pulling the pivot and pulse switch assembly wire
4. Pull the pivot and pulse switch assembly wire
5. Install the pivot and pulse switch assembly
connector to the bulkhead connector.
343861
6. Install the wire protector shield.
7. Install the lock housing cover and sleeve
assembly. Refer to. Lock Housing Assembly
- Assemble - Off Vehicle. ·
\
)
2-78 Steering Wheel' and Column - Tilt Steering
Steering Column lock Cylinder Set -
Disassemble - Off Vehicle
Important: The turn signal switch assembly does. not
have to be.pulled through the column when removing
unless necessary. Let the turn signal switch
assembly hang fr~ely after removal of the screws.
1. Remove the turn signal switch assembly. Refer to
Turn Signal and Multifunction Switch Assembly -
2. Put the key in .the LOCK position.
3. Disco11nect the steering column key lock cylinder
setterminal connectors.
4. Attach a wire to the terminal connectors. This will
make installation easier.
343824
5. Remove the byzzer switch assembly (3).

6. Remove the lock retaining screw (2).
7;, Remove the retaining clip (4) from the steering
column lock cylinder set terminal connector (5).
8. Remove the steering column lock cylinder set (1 ).
9. Gently pull the terminal connectors (5) through
the column.
(
343829
Steering Column lock Cylinder Set -

Assemble - Off Vehicle
Assembly Procedure
1. Pull the steering column lock cylinder set
terminal connectors through the column and
reconnect. ·
343824
2. Put the steering column passkey lock cylinder
set (1) into the lock housing cover assembly.
Notices.
3. Install the lock retaining screw (2).
Tighten
Tighten the screw to 2.5 N-m (22 lb in).
4. Install the buzzer switch assembly (3).
5. Install the retaining clip (4) onto the steering
column passkey lock cylinder set terminal lead
and the lock housing cover assembly.
6. Install the turn signal switch assembly. Refer to
Turn Signal and Multifunction Switch Assembly -
Assemble - Off Vehicle.
343829
Tilt Spring - Disassemble - Off Vehicle

Disassembly Procedure 1
Tool Required
J 39246 Tilt Spring Compressor
assembly. Refer to Lock Housing Assembly -
) Disassemble - Off Vehicle.
Caution: The tilt spring and the spring guide are
under pressure. The tilt spring and the spring
guide may become a projectile. Secure the spring
with locking pliers during removal. Secure the
spring with locking pliers during installation.
Bodily injury may result during removal and
installation of the tilt spring and the spring guide.
Always use caution during removal and
installation of the tilt spring and the spring guide.
2. Seat the counterbore of J 39246 over the
steering shaft assembly (1 ). 343839
3. Thread and seat the standard hexagon nut of the
tool onto the steering shaft assembly (2).
4. Thread the hexagon nut of the tool until it contacts
the block of J 39246. ·
)
2~80 Steering Wheel and Column - Tilt Steering
5. Insert the square end (2) of J 39246 into the
spring retainer ( 1) and seat. (
343842
6. Rotate the tool bolt clockwise with the. wrench

until it contacts the. surface of the .tool block.
7. Make a one fourth turn counter clockwise to the
hexagon section on the end of the tool· bolt.
8. Unscrew the tool boltuntil the wheel tilt spring
and the spring retainer (1) are free.
569765
9. Remove the spring retainer (2) from the steering

column housing assembly. ·
10. Remove the wheel tilt spring (1) from the steering
column housing assembly.
11. Remove the spring guide (3) from the steering
343856
Tilt Spring - Assemble - Off Vehicle
Assembly Procedure
Tools Required
J 39246 Tilt Spring Compressor
1. Install the spring guide (3) to the steering column
housing assembly.
2. Lubricate the wheel tilt spring (1) with lithium
grease.
3. Install the wheel tilt spring (1) to the steering
4. Install the spring retainer (2) to the steering
343856
Caution: The tilt spring and the spring guide are

under pressure. Th~ tilt spring and. the spring
guide may become a projectile. Secure the spring
with locking pliers during removal. Secure the
spring with locking pliers during installation.
Bodily injury may result during removal and
installation of the tilt spring and the. spring guide.
Always use caution during removal and .
installation of the tilt spring and the.spring guide.
5. Seat the counterbore of J 39246 over the
steering shaft assembly (2).
6. Thread and seat the standard hexagon nut onto
the steering shaft assembly (2).
7. Thread the hexagon nut until it contacts the
block (1) of J 39246.
343839
8. Insert the square en.d (2) of J.39246.into the .

spring retainer (1) and seat. ·
\
)
343842
2-82 Steering Wheel, c:1nd Column - Tilt Steering
9. Rotate the tool bolt clockwise with a wrench until
it contacts the surface of the tool block.
(
10. Make a one fourth turn counter clockwise to the
hexagon section on the end of the tool bolt.
11. Unscrew the tool bolt until the wheel tilt spring
and the spring retainer (1) ,are free.
12. Remove J 39246.
13. Install the lock housing cover and sleeve
assembly. Refer to Lock Housing Assembly
- Assemble - Off Vehicle.
569765
Turn Signal Cancel Cam ,and Upper

Bearing Inner Race - Disassemble -
Off Vehicle ,
Tools Required
J 23653-SIR Lock Plate Compressor
1. Remove the SIR coil assembly. Refer to Inflatable (
Restraint Steering Wheel Module Coil -
2. Remove the wave washer.
3. Compress the shaft lock using J 23653-SIR.
4. Remove the bearing retainer (1) from the steering
shaft assembly and dispose of it.
5. Remove J 23653-SIR.
343728
6. Remove the following 3 parts from the steering

shaft assembly:
6.1. Remove the shaft lock shield assembly (1 ).
6.2. Remove the turn signal cancel cam
assembly (2).
6.3. Remove the upper bearing spring (3).
344003
7. Remove the following 2 parts from the steering
shaft assembly:
7.1. Remove the upper bearing inner race
seat (1 ).
7.2. Remove the inner race (2);
344004
Turn Signal Cancel Cam and Upper

Bearing Inner Race - Assemble -
Off Vehicle
Assembly Procedure
Tools Required
J 23653-SIR Lock Plate Compressor
) 1. Install the following 2 parts onto the steering shaft
assembly:
1.1. Lubricate the inner race (2) with lithium
grease.
1.2. Install the inner race (2).
1.3. Install the upper bearing inner race seat (1 ).
343818
2. Install the following 3 parts onto the steering shaft

assembly.
2.1. Install the upper bearing spring (3).
2.2. Lubricate the turn signal cancel cam
assembly (2) with grease kit 26001884.
2.3. Install the turn signal cancel cam
assembly (2).
2.4. Install the shaft lock (1 ).
343821
2·84 Steering Wheel and Column - Tilt Steering
3. Install the new bearing retainer (i) using
J 23653-SIR.
4. Seat the bearing retainer (1) in the groove on the
steering shaft assembly.
5. Remove J 23653-SIR.
6. Install the wave washer.
7. Install the SIR coil assembly. Refer to Inflatable
Restraint Steering Wheel Module Coil - Assemble
- Off Vehicle.
343728
Steering Column Jacket - Disassemble -

Off Vehicle
Tools Required
• J 38639 Steering Column Housing Bearing
Installer
• J 8092 Driver Handle (
• J 22635 Lock Shoe and Release Lever Pin
• J 21854-01 Pivot Pin Remover
1. Remove the tilt spring assembly. Refer to Tilt
Spring - Disassemble - Off Vehicle.
2. Remove 2 pivot pins (1) and (2) using J 21854-01.
569767
3. Use the tilt lever (2) to pull back on the steering

column housing assembly (1) to release.
4. Remove the tilt lever (2).
344138
5. Disassemble the steering column housing
assembly, if needed:
5.1. Remove the bearing assembly (12).
5.2. Remove the wire protector shield (9):
12
5.3. Remove the switch actuator rack (17) and
the rack preload spring (16). ~/
5.4. Remove the drive shaft (8).
5.5. Remove the switch actuator sector (13).
5.6. Release the release lever pin (3) using
J22635.
5.7. Remove the shoe release lever (2).
5.8. Remove the release lever spring (4).
5.9. Remove the dowel pin (7).
5.10. Remove the steering wheel lock
shoes (10) and (11) using J 22635 and the
shoe springs (5).
5.11. Remove the bearing assembly (1 ).
354085
Steering Column Jacket - Assemble - Off

Vehicle
Assembly Procedure
12
Tools Required
• J 38639 Steering Column Housing Bearing ~/
Installer
) • J 8092 Driver Handle
• J 22635 Lock Shoe and Release Lever Pin
1. To assemble the steering column housing
assembly if needed:
2. Install the bearing assembly (1)
3. Install the shoe springs (5).
4. Install the steering wheel lock shoes (1 O) and (11 ).
5. Install the dowel pin (7).
6. Install the release lever spring (4).
354085
7. Install the shoe release lever (2).
8. Install the release lever pin (3) using J 22635.
9. Install the drive shaft (8).
10. Install the switch actuator sector (13).
11. Install the rack preload spring (16).
12. Install the switch actuator rack (17) to the switch
actuator sector (13).
13. Install the bearing assembly (12) using J 8092
and J 38639.
14. Install the wire protector shield (9).
Important: If the steering column housing assembly
and the pivot pins (1) have been staked (2) 3 times it
must be replaced.
15. Install th.e steering. column housing assembly.
354605
16. Install the steering column housing assembly

following these steps:
16.1. Install the tilt lever (2) and use it to pull
back on the steering column housing
assembly (1) to mount on the steering
column housing support assembly.
16.2. Position the steering column housing
assembly (1) onto the steering column (
housing support assembly. \
16.3. Align the switch actuator rack with the pin
on the end of the ignition switch actuator
assembly.
16.4. Pull back on the tilt lever (2) to position
the steering column housing assembly (1 ).
16.5. Push the steering column housing
assembly (1) into the steering column
housing support assembly.
16.6. Release the tilt lever (2) to lock the steering
wheel lock shoes and the dowel pin.
344138
16.7. Remove the tilt lever (2).
17. Install 2 pivot pins .(1) and (2).

18. Press the 2 pivot pins (1) and (2) until they are
firmly seated.
19. Stake the pivot pins in 3 places.
20. Install the tilt spring assembly. Refer to Tilt Spring
- Assemble - Off Vehicle.
569768
Lock Housing. Assembly - Disassemble -
Off Vehicle
1. Remove the steering column lock cylinder set.
Refer to Steering Column Lock Cylinder Set -
2. Remove the column housing cover end cap (2).
Remove the cruise control connector (3) from the
base plate (1) and disconnect.
1.----2
343830
3. Remove the 3 pan head 6-lobed socket tapping

screws: ( 1) at 12 o' clock, (2) at 3 o' clock and
(3) at 8 o' clock.
343832

assembly (1).
Remove the column housing cover end ba.se 1
plate (2) and the dimmer switch rod actuator. (3).
343833
5. Remove the switch actuator pivot pin (2).
6. Remove the pivot and pulse switch assembly (1)
from the lock housing cover assembly. (
343835
Lock Housing Assembly - Assemble· -

Off Vehicle
Assembly Procedure
1. Lubricate the switch actuator pivot pin (2) with
synthetic grease.
2. Install the switch actuator pivot pin (2) to the pivot
and pulse dimmer switch assembly (1 ).
3. Install the pivot and pulse assembly (1) into the
(
lock housing cover assembly.
343861
4. Lubricate the dimmer switch rod actuator (3) with

lithium grease.
1 5. Install the dimmer switch rod actuator (3) to the
column housing cover end base plate (2).
6. Install the column housing cover end base
plate (2) to the lock housing cover and sleeve
assembly (1 ).
Important: The bottom edge of the dimmer switch rod
actuator must rest on the bend of the dimmer
switch rod.
7. Align the lock housing cover and sleeve
assembly (1) onto the steering column.
343866
Steering Steering Wheel and Column - Ti.It 2-89
J Notices.
8. Install 3 pan head 6-lobe socket tapping screws:
(1) at 12 o' clock position first, (3) at 8 o' clock
position second, and (2) at 3 o'clock position third.
Tighten
Tighten the 3 pan head 6-lobed socket screws to
9 N-m (80 lb in).
343832
9. Mount the cruise control connector (3) on the

base plate (1).
10. Install the column housing cover end cap (2).
11. Install the steering column lock cylinder set. Refer
to Steering Column Lock Cylinder Set - Assemble
- Off Vehicle.
i---2
343830
Steering Shaft, Lower Bearing, and Jacket

- Disassemble - Off Vehicle
1. Remove the steering column housing assembly.
Refer to Steering Column Jacket - Disassemble -
Off Vehicle.
2. Remove the pivot and pulse switch assembly.
Refer to Windshield Wiper and Washer Switch
Assembly - Disassemble - Off Vehicle.
3. Remove the following 4 items from the steering
column jacket assembly:
3.1. Remove the lower bearing adapter clip (1 ).
) 3.2. Remove the bearing adapter (2).
3.3. Remove the bearing assembly (3).
3.4. Remove the lower bearing adapter (4).
569761
4. Remove the steering shaft assembly from the
steering column.
343889
Important: Mark the race and upper shaft assembly

and the lower shaft assembly before disassembly.
Failure to assemble the race and upper shaft assembly
and the lower shaft assembly correctly will cause ·
the steering wheel to be turned 180 degrees.
5. Tilt the race and upper shaft assembly (1)
90 degrees from the lower steering shaft
assembly (2) to disengage. (
6. Separate the race and upper shaft assembly (1)
from the lower steering shaft assembly (2).
7. Remove the ignition switch assembly. Refer to
Ignition Switch Assembly - Disassemble - Off
Vehicle
306318
8. Remove the 4 hexagon washer head tapping

screws (3).
9. Remove the steering column housing support
assembly (2) from the steering column housihg
3 shro.ud (1 ).
569763
10. Remove the steering column shroud (2) from the
steering column jacket assembly (1 ).
569762
Steering Shaft, Lower Bearing, and Jacket

- Assemble - Off Vehicle
Assembly Procedure
1. Install the steering column shroud (2) to the
steering column jacket assembly (1 ).
569762
2. Install the steering column housing support

assembly (2).
Notices.
3. Install the 4 hexagon washer head tapping
screws (3) to the steering column housing
assembly (2).
Tighten
Tighten the 4 hexagon washer head tapping
screws to 9 N·m (80 lb in).
4. Install the ignition switch assembly. Referto
Ignition Switch Assembly - Assemble - Off
Vehicle.
569763
2-92 . Steering Wheel and Colu.mn - Tilt Steering
5. Lubricate the exposed area of the race and upper
shaft assembly (1).
Important: Use the marks on the race and upper
(
shaft assembly and the lower shaft assembly from the
disassembly procedure. Failure to assemble the
race and upper shaft assembly and the lower shaft
assembly correctly will cause the steering wheel to be
turned 180 degrees.
6. Align the mark on the race and upper shaft
assembly (1) to the mark on the lower steering
shaft assembly (2).
7. Tilt the race and upper shaft assembly (1)
90 degrees to the lower steering shaft
assembly (2) to engage.
306318
8. Install the steering shaft assembly to the steering

column.
343889
9. Install the following 4 items to the steering column

jacket assembly:
9.1. Install the lower bearing adapter (4).
9.2. Install the bearing assembly (3).
9;3, Install the bearing adapter retainer (2).
9.4. Install the lower bearing adapter clip (1).
10. Install. the pivot and pulse switch assembly only.
Refer to Windshield Wiper and Washer Switch
Assembly - Assemble - Off Vehicle.
11. Install the steering column housing assembly.
Refer to Steering Column Jacket - Assemble -
Off Vehicle.
569761
Steering Steering Wheel and Column '." Tilt 2·93
Inflatable Restraint Coil Centering - Off
Vehicle (Column Shift And Floor Shift)
Centering Procedure
Notice: Refer to New SIR Coil Is Centered in Cautions
and Notices.
1. Verify the following before centering the SIR coil
assembly:
• The wheels on the vehicle are straight ahead.
• The block tooth (1) of the steering shaft
assembly is in the 12 o' clock position.
• The ignition switch is in the "LOCK" position or
J 42640 is installed in the upper tilt head
assembly.
293254
2. If the front (5) of the SIR coil assembly has a

centering window (4), and on the back side (2) a
spring service lock (1 ), perform the following steps:
2.1.: Hold the coil assembly with the face up.
2.2. While depressing the spring service
lock, rotate the coil hub clockwise until
the coil ribbon stops.
2.3. Rotate the coil hub slowly, counter
clockwise, until the centering window
appears yellow and both arrows (3) line up.
2.4. Release spring service lock between the
locking tab. The SIR coil is now centered.
2.5. Align the centered SIR coil assembly with 2
the horn tower and slide onto the steering
shaft assembly.
603737
3. If the front (4) of the SIR coil has a centering

window (3) and no spring service lock on the back
side (1 ), perform the following steps:
3.1. Hold the coil assembly with the face up.
3.2. Rotate the coil hub clockwise until the coil 4
ribbon stops.
3.3. Rotate the coil hub slowly, counter
clockwise until the centering window
appears yellow and both arrows (2) line up.
This is center position.
3.4. While holding the coil hub iri .center position,
align the SIR coil assembly with the horn
tower and slide onto the steering shaft
assembly.
)
594558
2-94 Steering Wheel and Column -Tilt Steering
4. If no centering window is. present on the front
side (3) of the SIR coil assembly, but a spring
service lock (1) is on the back side (2), perform the
following steps:
4.1. Hold the SIR coil assembly with the back
side up.
4.2. While depressing the spring service lock,
rotate the coil hub counter clockwise until
the coil ribbon stops.
4.3. Still pressing the spring service lock, rotate
the coil hub in the opposite direction
2 112 revolutions.
3 4.4. Release the spring service lock between
2 locking tabs. The SIR coil is now centered.
4.5. Align the centered SIR coil assembly with
the horn tower and slide onto the steering
shaft assembly.
603738
5. For no centering window on the front side (2) of

the SIR coil assembly and no spring service lock
on the back side (1 ), perform the following steps:
5.1. Hold the coil assembly with the face up.
5.2: Rotate the coil hub clockwise until the coil
ribbon stops.
5.3. Rotate the coil hub, slowly, counter
clockwise, for 2 112 revolutions. This is center
position. (
5.4. While maintaining the coil hub in center
position, align the centered SIR coil
assembly with the horn tower and slide
onto.the steering shaft assembly.
1
2
603739
Steering Column Accident Damage

Inspection - Off Vehicle
Inspection Procedure
• 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 restraint systems
deployed may also have a damaged or misal,igned
steering column.
" Check the capsules on the steering column
bracket assembly. All capsules must be securely
seated in the bracket slots and checked for
any loose conditions when pushed or pulled
by hand.
303713
• Observe how the bracket is attached to the jacket
assembly.
- If the capsules are not securely seated and
the bracket is bolted to the jacket assembly,
replace only the bracket.
- If the capsules are not securely seated and
the bracket is welded to the jacket assembly,
replace only the jacket assembly.
• Check for jacket assembly collapse by measuring
the distance from the lower edge of the upper
r-
jacket to a defined point on the lower jacket.
Replace the jacket assembly if the measured
dimensions are not within specifications.
324MM I
·~-----;I_______J
392279
) • Visually inspect the steering shaft for sheared

injected plastic (1 ). If the steering shaft shows
sheared plastic, replace the steering shaft.
• Any frame damage that could cause a bent
steering shaft must have the steering shaft runout
checked. Using a dial indicator at the lower
end of the steering shaft, rotate the steering wheel.
The runout must not exceed 1.60 mm (0.0625 in).
303724
)
2~96 Steering Wheel and Column - Tilt Steering
Steering Wheel and Column Description
12 7 6 4 3 2 1
19
24 23
290365
The locking, energy-absorbing column (20) includes The windshield washer and wiper lever (16) controls
the following three features in addition to the steering the windshield washer and wipers.
function:
The cruise control actuator controls the cruise control,
• In a front-end collision, the energy-absorbing if equipped.
column is designed to collapse. This action
minimizes the possibility of driver injury. In order to ensure energy-absorbing action, complete
the following steps:
• The steering column lock and ignition cylinder are
mounted on the column. • Use only specified bolts/screws and nuts.
• When locked, the column-mounted lock prevents • Tighten the bolts/screws and nuts to the specified
the operation of both the ignition and steering. torque.
This action acts as a theft deterrent. • Apply a thin coat of lithium grease to all friction
The turn signal controls the turn signals. points during reassembly.
The headlamp dimmer switch controls the headlamp
high beam.
Handle the column with care when removing the Ignition Lock System Description
column.
The automatic transmission uses a park lock system.
) • Do not use a steering wheel puller other than the This system uses a flexible automatic transmission
one recommended. park lock cable. The cable is attached at one end
• Do not hit the end of the steering gear coupling to the automatic transmission control lever and at the
shaft (26} sharply. other end to the ignition switch. The ignition switch
is mounted to the column where it actuates a locking
• Do not lean on the column. pin. The locking pin engages an ignition switch
• Do not drop the column. sliding contact when the lever is in the REVERSE
position. This action does not allow the ignition switch
Disregarding the above suggestions could shear or to move to the LOCK position.
loosen the plastic fasteners that keep the column rigid.
With the lever in PARK and the ignition switch slider in
LOCK, the following actions occur:
• The locking pin engages a cam on the cable.
• The locking pin prevents the lever from moving
into another position.
Vehicles with a manual transmission have a steering
column key release lever. A manual transmission
clutch start switch is also used. Depress the clutch in
order to crank the engine.
)
J 1859-A J 38639
Steering Column Housing
Steering Wheel Puller
Bearing Installer
802 354982
J.8092 J 38720
Universal Driver Handle Steering Wheel Puller Bolts
2015
J 21854-01
J 39246 (
Tilt Spring Remover and
Pivot Pin Remover
Installer
82217 581822
J 22635
J 41352
Lock Shoe and Release
Modular Column Holding
Lever Pin Remover and
Fixture
Installer
354985 82213
J 23653-SIR
Lock Plate Compressor
8669
Suspension Table of Contents 3-1
Section 3
Suspension
Suspension General Diagnosis ..................... 3-3 Repair Instructions ........................................3-18

Specifications ..................................................3-3 Wheel Hub Bolt Replacement ...................... 3-18
Trim Height Specifications ..............................3-3 Stabilizer Shaft Replacement ....................... 3-19
Diagnostic Information and Procedures ......... 3-4 Stabilizer Shaft Link Replacement ................ 3-20
Abnormal or Excessive Tire Wear .................. 3-4 Upper Ball Joint Replacement ...................... 3-20
Trim Height ...................................................3-4 Lower Ball Joint Replacement ...................... 3-23
Struts or Shock Absorbers Weak ................... 3-7 Wheel Bearing/Hub Replacement - Front ...... 3-24
Struts or Shock Absorbers Noisy ................... 3-8 Steering Knuckle Replacement ..................... 3-25
Struts or Shock Absorbers Leak .................... 3-8 Upper Control Arm Replacement .................. 3-29
Struts or Shock Absorbers Bench Test .......... 3-8 Lower Control Arm Replacement .................. 3-31
Struts or Shock Absorbers On-Vehicle Shock Absorber Replacement ...................... 3-33
Testing .......................................................3-9 Description and Operation ............................ 3-40
Description and Operation .............................. 3-9 General Description .....................................3-40
General Description .......................................3-9 Special Tools and Equipment ....................... 3-41
Rear Suspension ............................................ 3-43
Wheel Alignment ............................................3-10 Specifications ................................................ 3-43
Specifications ................................................3-1 O Fastener Tightening Specifications ............... 3-43
Wheel Alignment Specifications .................. ,.3-10 GM SPO Group Numbers ............................ 3-43
Fastener Tightening Specifications ............... 3-10 Repair Instructions ........................................3-44
Diagnostic Information and Procedures ....... 3-10 Bumper Replacement ................................... 3-44
Preliminary Alignment Inspection .................. 3-10 Rear Axle Lower Control Arm .
Replacement ............................................3-45
Repair Instructions ........................................ 3-11
Rear Axle Lower Control Arm Bushings
Measuring Wheel Alignment ......................... 3-11 Replace .................................................... 3-46
Front Caster and Camber Adjustment .......... 3-11 Torque Arm Replacement ............................ 3-47
Front Toe Adjustment .................................. 3-12 Stabilizer Shaft Replacement ....................... 3-50
Rear Thrust Angle Adjustment ..................... 3-12 Stabilizer Shaft Link Replacement ................ 3-53
Description and Operation ............................ 3-13 Shock Absorber Replacement ...................... 3-54
Caster Description .......................................3-13 Coil Spring Replacement .............................. 3-55
Coil Spring Insulators Replacement .............. 3-56
Camber Description ..................................... 3-13
Track Bar Replacement ...............................3-57
Toe Description ............................................3-14 Description and Operation ............................ 3-59
Special Tools and Equipment ....................... 3-14 General Description .....................................3-59
Front Suspension ..........................................3-15 Special Tools and Equipment ....................... 3-60
Specifications ................................................3-15 Tires and Wheels ........................................... 3-61
Fastener Tightening Specifications ............... 3-15 Specifications ................................................3-61
GM SPO Group Numbers ............................ 3-15 Tire and Wheel Specifications ...................... 3-61
Fastener Tightening Specifications ............... 3-61
Component Locator .......................................3-16
GM SPO Group Numbers ............................ 3-61
Front Suspension Components .................... 3-16 Diagnostic Information and Procedures ....... 3-62
Diagnostic Information and Procedures ....... 3-17 Wheel Mounting Surface Check ................... 3-62
Ball Stud Check ...........................................3-17 Radial Tire Lead/Pull Correction ................... 3-63
3-2 Table of Contents Suspension
Repair Instructions ........................................3-64 Description and Operation ............................ 3-70
Aluminum Wheel Hub Cap Tires Description ...........................................3-70
Replacement ............................................3-64
Tire Inflation Description .............................. 3-70
Aluminum Wheel Porosity Repair ................. 3-64
Aluminum Wheel Refinishing ........................ 3-64 Tire Chain Usage Description ...................... 3-71
Tire and Wheel Removal and P-Metric Sized Tires Description .................. 3-71
Installation ................................................3-66 Tire Placard Description ............................... 3-72
Tire Repair ..................................................3-68-
Replacement Wheels Description ................. 3- 72
Compact Spare Tire Replacement ................ 3-68
Tire Mounting and Dismounting .................... 3-68 Aluminum Wheels Description ...................... 3-72
Tire Rotation ..................................................3-69
(
Suspension Suspension General Diagnosis 3-3
Suspension General Diagnosis

Specifications
Trim Height Specifications
Trim Height Specifications (Front Fascia)
',•
Camaro Frt. Fascia Trans Am Frt, Fascia . ;

Firebird Frt. Fascia
Suspension Tire
Metric English Metric Engljsh Metric English
F41(Base) 235/55 443mm 17.4 in - - 342mm 13.4 in
FE2(Z28, Trans 235/55 443mm 17.4 in 416mm 16.3 in - -
Am Base) 245/50 443mm 17.4 in 416mm 16.3 in - -
FE4
(Z28, Trans Am 245/50 443mm 17.4 in 342mm 13.4 in - -
Special)
FE7(Z-28 SS,
B4C, WS6, 275/40 443mm 17.4 in 342mm 13.4 in - -
Firm, HD)
Trim Height Specifications (Rear Fascia)

Camaro Rear Fascia Fire/TA Rear Fascia Side Rocker (All)
Suspension Tire
Metric English Metric English Metric English
204mm
8.0 (Front)
F41(Base) 235/55 367mm 14.4 in 375mm 14.7 in (Front)
8.2 (Rear)
208 mm (Rear)
204mm
8.0 in (Front)
235/55 367mm 14.4 in 375mm 14.7 in (Front)
8.2 in (Rear)
FE2(Z38, Trans 208 mm (Rear)
Am Base) 204mm
8.0 in (Front)
245/50 367mm 14.4 in 375mm 14.7 in (Front)
8.2 in (Rear)
208 mm (Rear)
204mm
FE4(Z28, Trans 8.0 in (Front)
245/50 367mm 14.4 in 375mm 14.7 in (Front)
Am Special .. 8.2 in (Rear)
208 mm (Rear)
FE7 (Z-28 SS, 204 mm
8.0 in (Front)
B4C, WS6, 275/40 367mm 14.4 in 375mm 14.7 in (Front,)
8.2 in (Rear)
Firm, HD) 208 mm (Rear)
)
3-4 Suspension General Diagnosis Suspension

Abnormal or Excessive Tire Wear Measuring Trim Height at Vehicle Side Rocker
Molding
Many conditions, including the following list, can cause
irregular or premature tire wear:
• Incorrect inflation pressure
" Lack of regular rotation
• Driving habits
.. Improper tire and wheel alignment
If you reset tire and wheel alignment due to a tire
wear condition, always rest the toe as close to
O degrees as the specification allows.
Rotate the tires if you notice any of the following
conditions:
• Front and rear tire wear is unequal
.. The tread of any tire wear is uneven
.. Left and right front tire wear is unequal
Test the tire and wheel alignment if you notice any of
the following conditions:
.. The left and the right front tire wear is unequal
" The tread of any front tire wear is uneven
• The front tire treads have a scuffed appearance
with feather edges on one side of the tread ribs
or blocks
(
Trim Height
Incorrect trim heights can produce symptoms similar
to those which produce tire and wheel misalignment.
Inspect trim heights whenever you diagnose
steering and vibration concerns.
In order to measure the trim heights accurately, use
the following check list:
.. Tires should be at the correct pressure as shown
on the tire placard and up to vehicle capacity
" The fuel tank should be full
" The vehicle should have no additional weight or
passengers
349187
• Seats should be in the full back position
1. Calculate the trim heights (1, 2) as measured at
.. The rear compartment should be empty, except
the inner edge of the side rocker panels (3) to the
for a spare tire and a jack, and a simulated
fuel load if required ground after each jounce/rebound cycle. Record
your measurement.
" The vehicle should be on a known level floor
2. Verify the trim height measurements. Refer to
" Close all doors, the hood, and the rear Trim Height Specifications.
compartment lid
3. Continue to measure the vehicle trim heights at
" Jounce the front and/or rear bumper of the vehicle the front and at the rear fascia at locations shown.
at least 38 mm (1.5 in). After jouncing, let the
vehicle settle. After recording the trim height
measurements desired, repeat the jounce
operation for a total of two times. Trim heights are
the average of the high and the low measurements
Measure all dimensions vertical to the ground. In order
to be considered correct, trim heights should be
within 10 mm (0.4 in) of specification.
Measuring Trim Height at Front Fascia Measuring Trim Height at Front Fascia
(Chevrolet) (Pontiac Trans Am)
1
349201 349189
1. Calculate the trim heights (3) as measured from 1. Calculate the trim heights (3) as measured from
the ground to the bottom ofthe park/turn signal the ground to the bottom of the fog lamp cavity
lamp (1) after each jounce/rebound cycle. R~cord after each jounce/rebound cycle. Record your
your measurement. measurement.
2. Verify the trim height measurements for that 2. Verify the trim height measurements. Refer to
particular vehicle. Refer to Trim Height Trim Height Specifications.
Specifications. 3. Continue to measure the vehicle trim heights at
3. Continue to measure the vehicle trim heights at the front and at the rear fascia at locations shown.
the front and at the rear fascia at locations
shown below.
Measuring Trim Height at Front Fascia Measuring Trim Height at Rear Fascia
(Pontiac Non-Trans Am) (Chevrolet) (
1-=
349195 349202
1. Calculate the trim heights (3) as measured from 1. Calculate the trim heights (2) as measured from
the ground to the bottom of the park/turn signal the ground to the bottom ofthe:rear fascia (1)
lamp (1) after each jounce/rebound cycle. Record after each jounce/rebound cycle. Record
your measurement. your measurement.
2. Verity the trim height measurements. Refer to 2. Verify the trim height measurements. Refer to
Trim Height Specifications. Trim Height Specifications.
3. Continue to measure the vehicle trim heights at 3. Continue to measure the vehicle trim heights at
the fascia locations shown. the fascia locations shown.
Measuring Trim Height at Rear Fascia· Struts or Shock Absorbers Weak
(Pontiac)
1 Important: The single-tube shock absorbers are
highly gas-pressurized. The shock ab.sorbers require a
forceof 445 N (100 lb) in order to initiate movement
of the shock absorber rod. Do NOT dent or puncture
the shock absorber assemblies.
1. Test and adjust the tire pressures to those
pressures shown on the tire placard.
2. Notice the load conditions in effect when the
vehicle is driven under normal conditions.
3. If practical, ride. with the owner in order to be sure
that you understand the problem before ·
proceeding to the next step.
4. Test each shock a.bsorber in turn by quickly
pushing down, then lifting up, on the corner of the
bumper nearest to the shock absorber which
you ace testing.
4.1. Use the same amount of effort on each test
and notice the resistance on compression
and rebound.
4.2. Repeat this test on a similar vehicle having
acceptable ride quality. The shock
absorbers on both vehicles should provide
the same feeling of resistance. If you
notice much difference between the
two vehicles, continue with the next step.
5. Support the vehicle in order to expose the shock
mounts.
6. Remove the shock absorber assemblies.
Caution: The shock absorbers are highly
pressurized. Be sure to properly disassemble
module or personal injury could result.
7. Disassemble the plastic dust tube.
8. Remove the rod washer from the shock absorber.
Important: Do not fully compress the shock
absorber. Shock absorbers are highly gas-charged
and will extend when released.
9. Turn the shock absorber so that the lower mount
is up and the upper mount is down. Compress the
349191 shock absorber against the ground at various
rates of speed through approximately one-half of
1. Calculate the trim heights (2) as measured from
the length of the exposed chromed shock
the ground to the bottom of the rear fascia (1) absorber rod:
after each jounce/rebound cycle. Record
your measurement. • Rear - 75 mm (3 in)
• Front - 50 mm (2 in)
2. Verify the trim height measurements. Refer to
Trim Height Specifications. 10. ·Compare the right and the left shock absorbers
for compression resistance and rebound speed:
3. Continue to measure the vehicle trim heights at
• The right and the left shock absorbers
the fascia locations shown.
should feel comparable.
4. Correct any irregular trim height dimensions as • Differences between the front and the rear
necessary. shock absorbers are normal.
• If you are doubtful about the condition of any
shock absorber, compare with a shock
) absorber known to be good.
Struts or Shock Absorbers Noisy Struts or Shock Absorbers Bench Test
Important: The single-tube shock absorbers are Testing Procedure
highly gas pressurized and require a force of The shock absorbers installed on Camaro and Firebird
445 N (100 lb) in order to initiate movement of .the vehicles are non-spiral groove type units. These
shock absorber rod. Do NOT dent or puncture shock absorbers contain a gas-filled cell within the
the shock absorber assemblies. shock reservoir.
1. Examine all of the mountings for proper tightening. You are not required to purge air from non-spiral
Loose mountings will cause a noise. groove shock absorbers, unlike spiral groove shocks,
which contain an air-filled cell within the reservoir.
2. If all of the mountings are intact, test each shock
absorber by quickly pushing down, then lifting up, 1. Remove the shock absorber from the vehicle.
on the corner of the bumper near.est to the . Refer to Shock Absorber Replacement in Front
shock absorber which you are. testing. Suspension or Shock Absorber Replacement
in Rear Suspension.
2.1. Use the same amount of effort on each test
and notice the resistance on compression Important: Do NOT clamp the vise jaws on the shock
and rebound. upper stem threads or on the reservoir.
2. Place the shock absorber in a vise.
2.2. Repeat this test on a similar vehicle having
acceptable ride quality. The shock • Clamp the jaws on the top mounting stud of
absorbers on both vehicles should provide the shock.
the same feeling of resistance. If you • Hold the shock vertically in the vise with the
notice much difference between the bottom end up.
two vehicles, continue with, the next step. 3. Pump the shock at various rates of speed.
3. Remove the suspected shock absorber. Observe the rebound force.
• The rebound force normally is stronger than
4. Shake the shock absorber and listen for loose
the compression force (approximately 2-1).
metallic parts inside the shock absorber body. If
you hear a suspicious noise, replace the • The rebound force should· be smooth
shock absorber. and constant for.each stroke rate.
4. Compare this shock with a good shock absorber. (
5. Turn the shock absorber so that the lower mount
is up and the upper mount and rod are down. 5. If you observe any of the following· conditions,
Slowly compress the shock absorber. Do not allow replace the shock absorber:
the chromed portion of the shock absorber rod • A skip, or a lag, at revers.al near mid-stroke
to pass below the black seal cover. • A seizing (except at the extreme ends of travel)
6. Replace the shock absorber if you encounter a · • A noise, a grunt, or a squeal, after completing
seize condition with more than 25 mm (1 in) of one full stroke in both directions
the chromed portion of the shock absorber • A clicking noise at fast reversal
rod exposed above the seal cover.
Struts or Shock Absorbers Leak

Important: The single-tube shock absorbers are
highly gas-pressurized and require a force of
445 N (100 lb) in order to initiate .movement of the
shock absorber rod. Do NOT dent or puncture
the shock absorber assemblies.
1. Fully extend the shock absorbers, with the tires
and the wheels unsupported, in ord~r to expose
the .seal cover area for inspection.
2. Look for signs of leaks at the top of the shock
absorber:
• A small amount of fluid in not cause for
replacement. The seal permits some seepage
in order to lubricate the shock ab.sorber rod.
• You can easily determine a leaking shock (
absorber because an excessive amount of fluid
will cover the shock absorber.
3. Replace a leaking shock absorber.
Struts or Shock Absorbers On-Vehicle Testing
Step Action Yes No
Important: A light film of oil on the top portkm of the reservoir is
normal.
1
Inspect each shock absorber for external fluid leakage.
Is the shock absorber leaking? Go to Step 5 Go to Step 2
Inspect the vehicle trim height. Refer to Ttim Height.
2
,Is the vehicle trim height correct? · Go to Step 3 Go to Step 4
1. Use your hands in order to lifj: up and push down each corner of
the vehicle 3 times. · ·
3
.. 2: Remove your hands from the 'vehicle. ·•
Does
. . the vehicle
., . stop bouncing
. after 2)1::ydes? System OK Go to Step 5
Replace the springs. Ref~r to Coil Spring .Replacement in Rear
4 Suspension. -
Is the repair complete? System OK
Replace the shock absorber. Refer to Shock Absorber Replacement
5 in Front Suspension -
Is the repair complete?. System OK
General Description
Because the problems in steering, suspension, and
tires and wheels involve several systems, you
must consider all of these systems whenever you
diagnose a concern. _In order to avoid diagnosing the
) wrong symptom, alwaysroad test the vehicle first.
Proceed with the following preliminary tests, and .·
correci any substandard. conditions which you·
may find.
Inspect for the following conditions: ·
• Wrong pressure and uneven tire wear .
• Loose connections or wear on joints, from the
steering column to the steering gear
• Loose or damaged parts on the front and on the
rear suspension or on the steering gear
• Out-of-round or out-of-balance tires, bent wheels,
and loose or rough wheel bearings
• Leaks in the power steering system. Inspect the
power steering fluid level and inspect the
accessory drive belt for proper condition and
tension
3-10 Wheel Alignment Suspension
Wheel Alignment
(
Specifications
Wheel Alignment Specifications
Specification
Application Set Check
Front Caster 4.5 to 5.5 degrees 4.0 to 6.0 degrees
Cross Caster (Front) -0.7 to 0.7 degrees ~0.7 to 0.7 degrees
Front Camber -0.1 to 0.9 degrees -0.6 to 1.4 degrees
Cross Camber (Front) -0.7 to 0.7 degrees -0.7 to 0.7 degrees
Individual Toe (Front) -0.1 to 0.1 degrees -0.1 to 0.1 degrees
Total Toe (Front) -0.2 to 0.2 degrees -0.2 to 0.2 degrees
Steering Wheel Angle (Front) -3.5 to 3.5 degrees -3.5 to 3.5 degrees
---~-
Rear Camber -0.6 to 0.6 degrees -0.6 to 0.6 degre~s
Cross Camber (Rear) -0.6 to 0.6 degrees -0.6 to 0.6 degrees
Total Toe (Rear) -0.3 to 0.3 degrees -0.3 to 0.3 degrees
Rear Thrust Angle -0.15 to 0.15 degrees -0.15 to 0.15 degrees

Specification
Inner Tie Rod Nut 47N·m 35 lb ft
Lower Control Arm Nut 100 N-m 47 lb ft
(
Diagnostic Information and • Inspect the vehicle trim height. If the height is out
of limits and a correction is to be made, make
Procedures the correction before adjusting the alignment.
Refer to Trim Height Specifications in.General
Preliminary Alignment Inspection Diagnosis.
• Inspect the steering gear for looseness at
Steering and vibration concerns are not always the the frame.
result of improper alignment. Tire lead is a condition
caused by worn or improperly-manufactured tires. Tire • Inspect the control arms for loose bushings.
lead is the vehicle deviation from a straight path on • Inspect the stabilizer shaft for loose or
a level road without pressure on the steering wheel. In missing parts.
order to determine if the vehicle has a tire lead • Inspect the shock absorber and the springs for
problem, refer to Radial Tire Lead/Pu/I Correction in improper operation.
Suspension General Diagnosis. • Inspect the suspension and the steering
Before making any adjustment that will affect the tire components for damage. Replace the parts as
and wheel alignment, verify correct alignment readings necessary.
and alignment adjustments: • Inspect the vehicle for stability. The fuel tank
should be full, or the vehicle should have
• Inspect all tires for proper inflation pressures. Also
compensating ballast.
verify that all the tires have nearly even
tread wear. • Jounce the vehicle lightly 3 times in the rear and
3 times in the front.
• Inspect the control arm ball studs. If the studs are
Give consideration to excess loads, such as tool
loose, correct them before adjusting the tire and
boxes or sample cases, which are normally carried in
wheel alignment. Refer to Ball Stud Check in Front
the vehicle. These loads should remain in the
Suspension.
vehicle during alignment adjustments.
• Inspect the tie rod ends. If the ends are loose, Give consideration also to the condition of the
correct them before adjusting the tire and
wheel .alignment. Refer to Power Steering Gear
equipment being used in order to adjust the alignment. (
Follow the equipment manufacturer's instructions.
Replacement (V6) or Power Steering Gear Regardless of the equipment used, the vehicle must
Replacement (VB) in Power Steering. be on a level surface, both front-to-rear and
" Check the tires and wheels for runout. side-to-side.
Suspension Wheel Alignment 3-11
Repair Instructions
I Measuring Wheel Alignment
Satisfactory vehicle operation may occur over a wide
range of alignment settings. If settings vary beyond
the specifications, correct the alignment angles.
1. Measure the front alignment angles.
2. Install the alignment equipment according to the
manufacturer's instructions.
3. Jounce the front and rear bumpers lightly
three times in order to normalize the suspension
prior to measuring the angles.
4. Measure the alignment angles and record the
readings. If adjustments are required, make the
adjustments in the following order:
4.1. The camber
4.2. The caster
4.3. The toe
Front Caster and Camber Adjustment

Tools Required J 38658
J 38658 Caster/Camber Adjusting Tool
1. Befor~ making any adjustments. to the caster or
camber, jounce the front bumper three times in
order to allow the vehicle to return to the normal
height.
\ 2. Raise and suitably support the vehicle. Refer to
I Lifting and Jacking the Vehicle in General
Information.
3. Loosen the lower control arm nuts.
4. Install the J 38658 to the holes in the lower
control arm (2) and front crossmember (1 ).
5. Adjust the camber by rotating the turnbuckle on
J38658.
• Rotating the turnbuckle clockwise will increase
the camber.
• Rotating the turnbuckle counterclockwise will 208361
decrease the camber.
6. Install the J 38658 to the holes in the lower
control arm (1) and the front crossmember (2).
• Rotating the turnbuckle clockwise will increase
the caster.
• Rotating the turnbuckle counterclockwise will
decrease the caster.
7. Adjust caster by rotating the turnbuckle on the
J38658.
8. Remove the J 38658 from the holes.
Notices.
9. Tighten the lower control arm nuts.
Tighten
Tighten the lower control arm nuts to
100 N·m (74 lb ft).
J 38658
208366
Front Toe Adjustment
1. Set the steering wheel in a straight-ahead position (
within -3.5 to 3.5 degrees.
2. Make toe adjustments separately at each
5 individual tire and wheel.
3. Loosen the inner tie rod nut (4).
4. Adjust the toe to specifications by turning the
inner tie rod (3). Refer to Wheel Alignment
Specifications.
Notices.
5. Verify that the steering gear boot seal (5) is not
twisted.
4
Tighten
Tighten the inner tie rod nut (4) to
47 N-m (35 lb ft).
6. Check the toe alignment. Readjust the inner tie
180302 rod (3), if necessary. Refer to Wheel Alignment
Specifications.
Rear Thrust Angle Adjustment

If the thrust angle is not within specifications, inspect
the lower control arms for damage. If the control
arms are not damaged, check the frame dimensions.
Refer to Dimensions - Frame in Frame and
Underbody.
(
Suspension Wheel Alignment 3;.13

J Caster Description Camber Description
...... - 3
- i! I
-
82220 180281
Caster is the tilting of the front steering axis Camber is the tilting of the front tires and wheels (1)
(at the top) either forward or backward (3) from the from the vertical (2) as viewed from the front of
vertical (1). A backward tilt is positive(+) and a forward the vehicle. When the tires and wheels tilt outward (1)
tilt is negative(-). Caster influences the directional at the top, the camber is positive(+). When the
control of the steering but does not affect the tire wear. tires and wheels tilt inwa.rd at the top, the camber is
Caster is adjustable only at the front tires and negative(-). The amount of the tiltis measured
wheels. in degrees from the vertical and is called the camber
angle. The camber setting influences directional
control and tire wear.
180°
3
143180
Caster is affected by the vehicle height. Therefore you

82221
must keep the body at the designated trim height.
Vehicle overload or a weak sagging rear spring can When set to a positive camber angle (1 ), the tires and
affect the caster. When the rear of the vehicle is lower the wheels.will tend to roll in a path that is away
than the designated trim height, the front suspension from the true path of the vehicle. The effect of one tire
) moves to a more positive caster. If the rear of the and wheel tends to cancel the others. The suspension
vehicle is higher than the designated trim height, the geometry and the camber setting keep the tire
front suspension moves to a less positive caster.
tread surface perpendicular (flat) on the road through
For trim height information, refer to Trim Height
the full range of suspension travel.
Specitications in General Diagnosis.
Toe Description In other words, even when the tires and wheels are
set to toe in slightly when the vehicle is standing still,
ttie tires tend to roll parallel on the road when the
vehicle is moving. Toe affects tire wear.

Illustration Tool Number/Description
J 38658
( r31 ~
Caster/Camber
Adjusting Tool
l--J \ 604548
4
5
82222
Toe measures the amount in which the front tires and

wheels are turned in or out (5) from a straight-ahead
position (4). When the tires and the wheels are turned
in, toe is positive(+). When the tires and the wheels
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 tires and the
I
wheels roll parallel by compensating the· slight
tolerances that exist within the suspension \
components.
180285
You can also measure total toe, which is the

relationship or difference .between the front toe
dimension (1) and .the rear toe dimension (2). Total toe
indicates the tire-to-tire relationship, but does not
indicate the relationship of a tire to the vehicle (
centerline. Toe also serves to offset the small
deflections of the tire and the wheel support system
which occur when the vehicle is rolling forward.
Suspension Front Suspension 3-15
Front Suspension
Specifications
Specification
Application Metric · English
Brake Master Cylinder Nut 29N·m 21 lb ft
Lower Control Arm Mounting Nut 100N·m 74 lb ft
Lower Control Arm Nut 110 N·m 81 lb ft
Outer Tie Rod End Nut 47N·m 35 lb ft
Shock Absorber Lower Bolt 65N·m 48 lb ft
Shock Absorber Lower Nut 65N·m 48 lb ft
Shock Absorber Upper Mount Bolt 50N·m 37 lb ft
Shock Absorber Upper Mount Nut 43N·m 32 lb ft
'
Stabilizer Shaft Insulator Clamp Bolt/Stud 55N·m 41 lb ft
Stabilizer Shaft Upper Nut and Bushing .. ·23N·m · 17 lb ft
Upper Control Arm Nut 53N·m 39 lb ft
Wheel Bearing Hub Bolt .86 N-m 63 lb ft
GM SPO Group Numbers ...

Application ,. GM SPO Group Number
Ball Joint 6.000
Coil Spring ' 7.000
) Lower Control Arm .. 6.000
Stabilizer Shaft .. 7.000
Shock Absorber .... . ·~ - 7.000
Steering Knuckle 6.000
Upper Control Arm 6.000
Wheel Hub 6.000
3-16 Front Suspension Suspension
Component Locator
Front Suspension Components
18
(
~II
13 11
181103
Legend
(1) Arm, Front Upper Control (13) Bolt/Screw, Front Stabilizer Shaft
(2) Stud, Front Upper Control Arm Ball Insulator Clamp
(3) Nut, Front Shock Absorber Lower Bracket (15) Clamp, Front Stabilizer Shaft Insulator
(4) Nut, Front Upper Control Arm (16) Stabilizer Shaft, Front
(5) Pin, Front Upper Control Arm Cotter (17) Nut, Front Stabilizer Shaft Link
(6) Knuckle and Hub, Steering (18) Insulator, Front Stabilizer Shaft
(7) Hub, Front Wheel (19) Bolt/Screw, Front Lower Control Arm
(8) Stud, Front Lower Control Arm Ball (20) Nut, Front Lower Control Arm
(9) Arm, Front Lower Control (21) Nut, Front Lower Control Arm
(1 O) Bolt/Screw, Front Shock Absorber (22) Crossmember, Front
(11) Link, Front Stabilizer Shaft (23) Bolt/Screw, Front Lower Control Arm
(12) Sleeve, Front Stabilizer Shaft Link (24) Nut, Front Lower Control Arm
(25) Pin, Front Lower Control Arm Cotter
(26) Absorber, Front Shock (30) Nut, Front Shock Absorber Upper
(27) Spring, Front (31) Bolt/Screw, Front Shock Absorber
(28) Mount, Front Upper Shock Absorber Upper Mount
(29) Support, Front Upper Control Arm

Ball Stud Check
Important:
• The vehicle must be stable and should not rock
on the floor stands.
• Wipe the ball joints clean and inspect the seals for
cuts or for tears. If the .seal .is cut or torn,. replace
the ball joint.
1. Raise the vehicle and position the floor stands
under both lower control arms as nearly as
possible to each ball stud. Refer to Lifting and
190281
· 3. Pry between the lower control arm and the

) steering knuckle while reading the dial indicator.
Vertical deflection on the dial indicator should
not exceed 1.19 mm (0.046875 in).
4. If the dial indicator reading exceeds 1.19 mm
(0.046875 in), replace the ball stud.
5. Anytime the ball stud is disconnected from the
steering knuckle, test for looseness. If you are
able to twist the ball stud in its socket with
your fingers, replace the ball stud.
2009
2. Position the dial indicator against the wheel rim.
)
Repair Instructions
Wheel Hub Bolt Replacement
J 6627-A Removal Procedure
Tool Required
J 6627-A Wheel Stud Remover
Information.
2. 'Remove the tire and wheel. Refer to Tire and
Wheels.
3. Install J 6627-A onto the hub and over the
wheel stud.
4. Turn the forcing screw in until the wheel stud is
pushed out of the hub.
65316
1 2 3
1. Install a new wheel stud (3) in the hub.
2. Install somewashers (1) onto the wheel stud.
3. With the flat side of the wheel nut (2) against the
washers, tighten the wheel nut until the wheel
stud head seats against the hub flange. (
Important: Make sure that the wheel stud is fully
seated against the hub flange.
4. Remove the wheel nut and washers.
5. Install the tire and wheel. Refer to Tire and Wheel
Removal and Installation in Tires and Wheels.
65317
Stabilizer Shaft Replacement
) Removal Procedure
Information.
2. Remove the stabilizer shaft link. Refer to Stabilizer
Shaft Link Replacement.
3. Remove the stabilizer shaft insulator clamp
bolts (4) and stud.
4. Remove the stabilizer shaft insulator clamps (5).
5. Remove the stabilizer shaft (7) from the vehicle.
6. Remove the insulators (6) from the stabilizer
shaft (7), if necessary.
4
\
J 181093
Installation Procedure 1 . . .· .
Important: The slit in the insulator (6) must face
toward the front of the vehicle. i~ 1
1. Install the stabilizer shaft insulators (6) over the

stabilizer shaft (7), if necessary.
2. Place the stabilizer shaft (7) into position on the
vehicle.
3. Install the stabilizer shaft insulator clamps (5) over
the insulators.
;1 I
Notice: Refer to Fastener Notice in Cautions and lJ 2
Notices.
4. Install the stabilizer shaft insulator clamp bolts (4)
and stud.
Tighten
Tighten the stabilizer shaft ins.ulator clamp 3
bolts (4) and stud to 55 N-m (41 lb ft).
5. Install the stabilizer shaft link. Refer to Stabilizer
5
181093
Stabilizer Shaft Link Replacement
Removal Procedure (
1. Raise and suitably support the vehicle. Referto
Information.
2. Remove the stabilizer shaft upper nut and
bushing (7).
3. Remove the stabilizer shaft bolt (3).
4. Remove the stabilizer shaft spacer (5) between
the lower control arm (4) and stabilizer shaft (6).
181095
1. Install the stabilizer shaft spacer (5) between the
lower control arm (4) and the stabilizer shaft (6).
2. Install the stabilizer shaft bolt (3).
Notices.
3. Install the stabilizer shaft upper nut and
bushing (7).
(
Tighten
Tighten the stabilizer shaft upper nut and
bushing (7) to 23 N-m (17 lb ft).
181095
Upper Ball Joint Replacement

Removal Procedure
Tools Required
1 J 39549 Ball Joint/Tie Rod Separator
Information.
2. Remove the tire and wheel. Refer to Tire and
Wheels.
Important: During removal and installation, the floor
jack must remain under the shock absorber mounting
location on the lower control arm in order to hold
the spring and the lower control arm in position. (
3. Place a floor jack under the shock absorber
mounting location on the lower control arm.
181072
4. Remove and discard the upper control arm
cotter pin.
5. Remove the upper control arm nut.
6. Support the steering knuckle (3) with a floor jack.
7. Use J 39549 in order to separate the upper
ball joint (1) from the steering knuckle (3).
8. With the upper control arm in a raised position,
drill out the four rivets approximately
6 mm (0.25 in) deep using a 1/s inch drill bit.
1832
\ 9. Drill out the rivet heads using a V2 inch drill bit.

J
1833
10. Punch out the rivets using a small punch.
11. Remove the upper ball joint.
1834
1. Loosely install the new upper ball joint (2) into the
upper control arm (7).
2. Remove the temporary support from the steering
knuckle (5).
3. Align and install the upper ball joint (2) to the
steering knuckle (3).
4. Install the upper control arm nut (4) finger tight. (
5. Install the upper ball joint service kit bolts (6) and
nuts (4). Refer to the ball joint kit for torque
specifications.
Notices.
6. Torque the upper control arm nut (4) to
specifications.
Tighten
Tighten the upper control arm nut (4) to
181076
53 N·m (39 lb ft).
Important: Never loosen the control arm nut in order
to align the cotter pin slot, it is permissible to over
torque the control arm nut 1/6 of a turn MAX.
7. Install a new upper control arm cotter pin (3).
8. Remove the floor jack from under the shock
absorber seat.
9. Install the tire and the wheel. Refer to Tire and
Wheels.
(
Lower Ball Joint Replacement
J 9519-18
) Removal Procedure
Tools Required
• J 39549 Ball Jointrrie Rod Separator
• J 9519-7 Ball Joint Remover
• J 9519-18 Ball Joint Pressing Screw
• J 9519-23 Ball Joint C-Clamp
In1ormation.
2. Remove the tire and the wheel. Refer to Tire and
Whee/Removal and Installation in Tires and
Wheels.
3. Place a floor jack under the lower control arm (1 ).
4. Remove and discard the lower control arm
cotter pin.
5. Remove the lower control arm nut. 181070
Important: During removal and installation, the floor

jack must remain under the shock absorber mounting
location on the lower control arm in order to hold
the spring and the lower control arm in position.
6. Use J 39549 in order to separate the lower ball
joint from the steering knuckle.
7. Use J 9519-7, J 9519-18, and J 9519-23 in order
to press the lower ball joint out of the lower
) control arm (1 ).
Tools Required
• J 9519-9 Ball Joint Installer
• J 9519-18 Ball.Joint Pressing Screw
• J 9519-23 Ball Joint C-Clamp
1. Position the lower ball joint into the opening in
lower control arm (1 ).
2. Using J 9519-9, J 9519-18, and J 9519-23 press
in the ball joinfuntil it extends all the way through
the lower control arm (1).
The ball joint must fit firmly into the lower control
am. If the ball joint does not fit firmly into the
lower control arm, replace the lower control arm.
J 9519-9
3. Align and Install the ball joint to the steering
knuckle.
Notice: Refer to Fastener Notice in Cautions and J 9519-18
Notices.
4. Install the lower control arm nut. 181071
Tighten
Tighten the lower control arm nut to
110 N-m (81 lb ft).
) torque the control arm nut 1/6 of a turn MAX.
5. Install a new lower control arm cotter pin.
6. Remove the floor jack from under the lower control
am (1).
9. Check the wheel alignment. Refer to Measuring
Wheel Alignment in Wheel Alignment.
Wheel Bearing/Hub Replacement - Front

Removal Procedure
Lifting and Jacking the Vehicle in. General
Information.
Wheels.
3. Remove the brake caliper (3) from its mounting.
4. Support the brake caliper (3) on the steering
knuckle using mechanics wire.
5. Remove the brake rotor (5) from the wheel
bearing hub (4).
6. Disconnect the wheel speed sensor .electrical
connector.
7. Remove the wheel bearing hub bolts (6 and 7)
and. wheel speed sensor wire bracket (8).
181on 8. Pull the wheel bearing hub (4) from the steering
knuckle (1 ).
1. Align the wheel bearing hub (4) to tlie steering (
knuckle (1 ).
Notice: Refer to Fastener Notice in Cautions .and
Notices.
2. Install the wheel bearing hub bolts (6 and 7) and
wheel speed sensor wire bracket (8).
Tighten
Tighten the wheel bearing hub bolts (6 and 7) to
86 N·m (63 lb ft).
3. Connect the wheel speed sensor electrical
connector. Attach the wheel speed sensor wire to
the bracket (8). ·
4. Install the brake rotor (5) to the wheel bearing
hub (4).
5. Remove the brake caliper (3) from the mechanics
yvire support.
181077
6. Install the brake caliper (3) to its mounting.
Wheels.
(
Steering Knuckle Replacement
Removal Procedure
Tools Required
• J 24319-01 Universal Steering Linkage Puller
• J 39549 Ball Joint/Tie Rod Separator
Information.
3. Remove the wheel hub (4) from the steering
knuckle (1 ). Refer to Wheel Bearing/Hub
Replacement - Front.
181077
4. Remove and discard the cotter pin (3) from the

outer tie rod end (1 ).
5. Remove the outer tie rod end nut (2). 3
2 )/
~ I
423439
6. Using J 24319-01 separate the outer tie rod

end (2) from the steering knuckle (1 ). 2
7. Use a jack stand to support the lower control arm.
8. Remove the shock absorber lower bolts and nuts.
9. Remove and discard the upper control arm
cotter pin.
10. Remove the upper control arm nut.
297353
11. Using J 39549 separate the upper ball joint (1)
from the steering knuckle (3). (
12. Remove the upper control arm (2) and upper ball
joint (1) from the steering knuckle (3).
181072

cotter pin.
14. Remove the lo.wer control arm nut.
15. Using J 39549 separate the lower ball joint (7)
from the steering knuckle (5).
16. Remove the lower control arm (8) and lower ball
17. Remove the steering knuckle (5) from the vehicle. (
181096
(
I 1. Install the steering knuckle (5) to the vehicle.
2. Align and Install the lower ball joint (7) and control
arm (8) to the steering knuckle (5).
Notices.
3. Install the lower control arm nut.
Tighten
Tighten the lower control arm nut to
110 N-m (81 lb ft).
to align the cotter pin solt, it is permissible to over
4. Install a new lower control arm cotter pin.
5. Align and install the upper control arm and upper
ball joint to the steering knuckle.
6. Install the upper control arm nut.
Tighten
Tighten the upper control arm nut to ·
53 N-m (39 lb ft).
7. Install a new upper control arm cotter pin.
6
8. Install the shock absorber lower bolts and nuts.
Tighten
Tighten the shock absorber lower bolts or nuts to
65 N-m (48 lb ft).
) 9. Remove the jack stand supporting the lower
181096
control arm.
10. Connect the outer tie rod end (2) to the steering
knuckle (1 ).
297628
)
11. Install the outer tie rod end nut (2).
Tighten (
3 Tighten the outer tie rod end nut (2) to
47 N·m (35 lbft).
2 )/ 12. Install a new cotter pin (3) to the outer tie rod
~
1 end (1).
423439
13. Install the wheel hub (4) from the steering

knuckle (1 ). Refer to Wheel Bearing/Hub
Replacement - Front.
14. Install the stabilizer shaft. link. Refer to Stabilizer
16. Check the wheel toe-in. Refer to Front Toe
Adjustment in Wheel Alignment. (
181077
(
Upper Control Arm Replacement
Removal Procedure
Tools Required
J 39549 Ball Joint!Tie Rod Separator
1. If servicing the driver side upper control arm,
1.1. Remove the brake master cylinder nuts.
1.2. Gently, reposition the brake master cylinder
to the side.
2. Remove the shock absorber upper mounting
bolts (15) and nuts (14).
Information.
Wheels.
6. Remove the shock absorber lower bolts and ,
nuts (5).
7. Remove and discard the upper control arm cotter
pin (4).
8. Remove the upper control arm nut (3).
9. Support the steering knuckle (6). with a jack stand.
) 10. Use J 39549 in order to separate the upper ball
joint (2) from the steering knuckle (6). 181097
11. Remove the steering knuckle (6) and ball joint (2)
from the upper control arm (1 ).
12. Remove the upper control arm (1) an.d shock
absorber (8) from the vehicle.
13. Separate the shock absorber (8) from the upper
control arm (1 ).
)
1. Place the shock absorber (8) through the upper (
control arm (1 ).
2. Install the upper control arm (1) and shock
ab~orber. (8) to the vehicle.
3. Align and installthe upper control arm (1) and
upper ball joint (2) to the steering knuckle (6).
Notice: Refer to. Fastener Notice in Cautions and
Notices.
4. Install the upper control arm nut (3).
Tighten,
Tighten the upper control arm nut (3) to
53:N-m (39 lb ft).
5. Install a new upper control arm cotter pin (4).
6 .. Remove the jack stand supporting the lower
control arm.
7. Install the shock absorber lower bolts and
nuts (5). ·
Tighten
Tighten the shock absorber lower bolts or nuts (5)
to 65 N-m (48 lb ft).
9. Install the tire.and wheel. Refer to Tire and Wheel
(
181097
11. Install the shock absorber upper mounting
Tighten
• Tighten the shock absorber upper mounting
nuts (14) to 41 N-m (30 lb ft) .
.. Tighten the shock absorber upper mounting
bolts to 50 N-m (37 lb ft).
12. If servicing the driver side upper control arm,
12.1. Gently, reposition the brake master
cylinder into position.
12.2. Install the brake master cylinder nuts.
Tighten
Tighten the brake master cylinder nuts to
29 N-m (21 lb ft).
lower Control Arm Replacement
)
Removal Procedure 3
Tools Required
• J 24319-01 Universal Steering Linkage Puller
1 \~jy
Information. I
Wheels.
4. Remove and discard the cotter pin (3) from the
outer tie rod end (1 ).
5. Remove the outer tie rod end nut (2).
423439
6. Using J 24319-01 separate the outer tie rod -

end (2) from the steering knuckle (1 ). 2
297353
7. Remove the shock absorber lower bolts (6 and 8)
and nuts (1 and 20).
(
8. Remove and discard the lower control arm cotter
pin (18).
9. Remove the lower. control arm nut (17).
1O. Using J 39549 separate the lower ball joint (4)
12. Remove the lower control arm mounting
bolts (14 and 16) and nuts (12 and 13).
13. Remove the lower control arm (5).
(
181078
1. Align and install the lower control arm (5).
Notices.
2. Install the lower control arm mounting
Tighten
Tighten the lower control arm mounting
nuts (12 and 13) to 100 N-m (74 lb ft).
3. Align and Install the lower ball joint (4) and control
arm (5) to the steering knuckle (2).
4. Install the lower control arm nut (17).
Tighten
Tighten the lower control arm nut (17) to
110 N-m (81 lb ft).
5. Install a new lower control arm cotter pin (18).
6. Install the shock absorber lower
Tighten
Tighten the shock absorber lower bolts (6 and 8)
(
or nuts (1 and 20) to 65 N·m (48 lb ft).
181078
7. Install the outer tie rod end nut (2).
) 8. Install a new cotter pin (3) to the outer tie rod
end (1 ). 3
Shaft Link Replacement. ,'y
~
10. Install the tire and the wheel. Refer to Tire and 1
Wheels.
11. Raise and suitably support the vehicle. Refer to I
Information.
13. Perform a front end alignment. Refer to Measuring
Wheel Alignment in Wheel Alignment.
423439
Shock Absorber Replacement

Removal Procedure
Tools Required
J 39549 Ball Joint/Tie Rod Separator
1. If servicing the driver side shock absorber,
1.1. Remove the brake master cylinder nuts.
1.2. Gently move the brake master cylinder to
one side.
2. Remove the shock absorber upper mounting
Information.
Wheels.
6. Remove the shock absorber lower bolts (11) and
nuts (3).
cotter pin (7).
8. Remove the lower control arm nut (8).
9. Using J 39549 separate the lower ball joint (10)
joint (1 O) from the steering knuckle (6).
Important: Use chalk or paint in order to mark (do not
scribe) the lower mount location relative to the
. upper mount location before removing the shock
) abso.rber.
11. Remove the shock absorber (13) and the
spring (14) from the vehicle.
181083
J 34013-114
Tools Required (
• J 34013-8 Strut Spring Compressor
.. J 34013-114 Modular Shock Compressor Adapter
• J 34013-88 Strut Compressor Adapter
• J 39642 Modular Shock Nut Removal Set,
15 mm (0.60 in)
• J 34013-115 Modular Alignment Rod
1. Install J34013-114and J34013-B.
181087
2. Use wing nuts in order to secure the tool to the

following mounting holes: ·
KENT-MOORE
" For the driver-side shock absorber
- C-H (lower left corner)
J 34013- B Strut Spring Compressor - P (upper right corner)
Read lns1ruction Sheet J 34013 29/29A
Before Using • For the. passenger-side shock absorber
C-H-E/K - A-X-P (upper left corner)
- C-H (lower right corner)
NOVA
...!
I
zI
"")
J-N-L
J 3401344C Nova Twin-Cam
181084
(
Important: Align J 34013-114 and J 34013-88 so that
) these tools may open and close together. If
J 34013-114 and J 34013-88 do not align properly, the
tools will not open.
3. Install J 34013-114 and J 34013-88
181088
Important: Align the top of the shock absorber flat

against J 34013-114.
4. Install the driver side shock absorber to the top of
J 34013-114.
181089
5. Install the passenger side shock absorber to the

top of J 34013-114.
J 34013-B
181090
6. Install the shock absorber (1) into J 34013-114
and J 34013-88. (
7. Close J 3'4013-114 and J 34013-88 and install the
locking pin.
Important: If the mounting ears of the shock absorber
are not facing downward, toward the rear of
J 34013-8, the shock absorber will not align properly.
8. Turn the screw on J 34013-8 counterclockwise
in order to raise the shock absorber up to
J 34013-114. Align the top of the shock absorber
flat against the tool with the studs going through
the guide holes in J 34013-114.
Caution: Do not over compress the spring. Severe
overloading may cause tool failure which could
result in bodily injury.
9. Compress the front spring approximately
13 mm (0.50 in), or 3-4 complete turns of
the screw on J 34013-114.
181088 10. Insert J 39642 -1 on the shock absorber nut, then
insert J 39642 -2 through J 39642 -1 in order to
hold the shock absorber rod in place.
11. Remove the shock absorber nut with J 39642 -1
while holding the shock absorber rod from rotating
with J 39642 -2.
12. Discard the shock absorber nut.
13. Turn J 34013-8 clockwise in order to fully relieve
spring pressure.
Assembly Procedure
(
Tools Required
• J 34013-8 Strut Spring Compressor
• J 34013-114 Modular Shock Compressor Adapter
• J 34013-88 Strut Compressor Adapter
• J 39642 Modular Shock Nut Removal Set,
15 mm (0.60 in)
• J 34013-115 Modular Alignment Rod
1. Install J 34013-114 to J 34013-8.
181087
2. Use wing nuts in order to secure the tool to the
following mounting holes: KENT-MOORE
• For the driver-side shock absorber
- C-H (lower left corner)
- P (upper right corner) J 34013- B Strut Spring Compressor
Read Instruction Sheet J 34013 l!9/29A
• For the passenger-side shock absorber Before Using
- A-X-P (upper left corner)

- C-H (lower right corner)
3. Install J 34013-114 and J 34013-88.
J-N-L
J340t344C Nova Twin-Cam
181084
)
3.;33 Front Suspension Suspension
4. Install the shock absorber (1) to J 34013-114 and
J 34013-88.
Important:
• Face the mounting ears of the shock absorber
downward, toward the rear of J 34013-8 or
the shock absorber will not align properly.
• Before removing the shock absorber, use chalk or
paint in order to mark the lower. mount location
relative to the upper mount location, or you will not
be able to properly reinstall the shock absorber.
Do NOT scribe.
5. Close J 34013-114 and J 34013-88 and engage
the locking pin.
6. Position the upper and lower spring seats
correctly.
Important: Align the top of the shock absorber flat
against J 34013-114.
7. Install the shock absorber to the top of
181088
J 34013-114.
Important: Only turn the screw until the shock
absorber secures itself in J 34013-8. Do not load the
spring.
8. Turn the screw on J 34013-8 counterclockwise in
order to raise the shock absorber up to
J 34013-114 without compressing the spring.
Important: Ensure that J 34013-115 is straight with
the shock absorber. If J 34013-115 is angled,
repeat steps 1 through 5 until the tool is straight. (
9. Place J 34013-115 down through the top
of J 34013-8 through the top of the shock
absorber and onto the top of the shock
absorber rod.
Caution: Do not over compress the spring. Severe
overloading may cause tool failure which could
result in bodily injury.
10. Turn the operating screw clockwise in order to
compress the spring until the threaded portion
of the shock absorber rod is through the top of the
shock absorber.
11. Remove J34013-115.
Important: Always use a new shock absorber nut.
Never reinstall the original nut.
12. Insert the new shock absorber nut on the shock
absorber rod.
13. Place J 39642 -1 on the shock absorber nut.
Notice: Turning the shock absorber while tightening
the nut may damage the shock absorber. In order
to prevent damage, keep the shock absorber in
a stationary position while tightening the nut.
14. Insert J 39642 -2 through J 39642 -1 and tighten
the shock absorber nut.
15. Tighten the shock absorber nut while holding onto
J 39642-2. (
16. Remove the shock absorber from J 34013-8.
Suspension Front Suspension 3.;.39
l 1. Align and install the shock absorber (13) and
spring (14) to the lower control arm (12).
Notice: Refer to Fastener Notice in Cautions and 17
Notices.
2. Install the shock absorber lower bolts (11) and
nuts (3).
Tighten 16
Tighten the shock absorber lower bolts (11) or
nuts (3) to 65 N-m (48 lb ft).
3. Align and Install the lower ball joint (10) and
control arm (12) to the steering knuckle (6).
4. Install the lower control arm nut (8). 3
Tighten
Tighten the lower control arm nut (8) to
110 N-m (81 lb ft).
5. Install a new lower control arm cotter pin (7).
3
Wheels.
) 9. Install the shock absorber upper mounting
Tighten
• Tighten the shock absorber upper mounting 10
nuts (17) to 41 N-rn (30 lb ft).
• Tighten the shock absorber upper mounting
bolts (18) to 50 N-m (37 lb ft).
10. If servicing the driver side shock absorber,
10.1. Gently, reposition the brake master 181083
cylinder into position.
10.2. Install the brake master cylinder nuts.
Tighten
29 N-m (21 lb ft).
)
3·40 Front Suspension Suspension
General Description
Front Suspension
181103
The short/long arm front suspension design allows • Upper and lower ball studs (2,8)
each wheel to compensate for changes in the • Upper and lower control arms (1,9)
road surface level without appreciably affecting the
opposite wheel. Each wheel independently connects to The steering knuckle and the hubs (6, 7) move in a
the frame by the following: prescribed three-dimensional arc. The front wheels are
• A steering knuckle (6) held in proper relationship to each other by the
two front tie rods. The front tie rods connect to the
• A wheel hub (7) steering arms on the knuckles and connect to
• A shock absorber (26) and spring (27) the steering gear.
2000 · F Car (September 27, 1999)

Springs (27) mount to the lower control arms (9). Special Tools and Equipment
Direct-acting shock absorbers (26) provide ride control.
The upper portion of the shock absorber connects Illustration Tool Number/ Description
to the front upper shock absorber mount (28).
The upper mount (28) extends through the upper
control arm support (29) and through the center
wheelhouse. The upper mount attaches with
two bolts/screws (31) and two nuts (30). J 6627-A
The stabilizer shaft (16) controls idle roll of the front Wheel Stud Remover
suspension. The stabilizer shaft mounts to the
stabilizer shaft insulators (18). These insulators attach
to the frame side rails by the stabilizer shaft brackets,
The ends of the stabilizer shaft (16) connect to the
lower control arms (9) by the stabilizer shaft links (11 ).
These ends are isolated by bushings.
The inner ends of the lower control arm (9) have
pressed-in bushings. Bolts (19) pass through
the bushings and attach the lower control arm (9) to J 9519-7
the crossmember (22).
Ball Joint Remover
The upper ball stud (2) is riveted to the upper control
arm (1). This stud attaches to the steering knuckle (6)
with a nut (4) and a cotter pin (5). The control arm
bolts to the shock absorber (26) through an upper 153086
control arm support (29) which attaches to the body.
The lower ball stud (8) is press fit into the lower control
arm (9). This ball stud attaches to the steering
knuckle (6) with a nut (24) and a cotter pin (25).
Rubber seals are provided at the ball sockets in order J 9519-9
to keep dirt and moisture from entering the stud Ball Joint Installer
and damaging the bearing surfaces.
J 9519-18
Ball Joint Pressing Screw
153089
J 9519-23
Ball Joint C-Clamp
) 153090
Illustration Tool Number/ Description Illustration Tool Number/ Description ·

(
J 24319-01 J 34013-115
Universal Steering Linkage
Modular Shock
Puller
Alignment Rod
297656
181114
J 34013-8
Strut Spring Compressor J 39549
Ball Joint/Tie Rod Separator
144083
181116
J 34013-88 J 39642
Strut Compressor Adapter
Modular Shock Nut Removal
Set, 15 mm (0.60 in) (
181126
J 34013-114
Modular Shock Compressor
Adapter
181112
Suspension Rear Suspension 3.;.43
Rear Suspension
Specifications
Specification
Center Support Bearing Bolt 50N·m 37 lb ft
Jounce Bumper Bolt 27N-m 20 lb ft
Lower Control Arm Bolt 118 N-m 87 lb ft
Tie Rod Bracket Brace Bolt 47N-m 35 lb ft
Tie Rod Bolt 118N·m 87 lb ft
Tie Rod Nut 75N·m 55 lb ft
Torque Arm Bolt . 130 N·m 96 lb ft
Torque Arm Bracket Nut 45N·m 33 lb ft
Torque Arm Outer Bracket Bolt (Manual Transmission) 50 N-m 37 lb ft
Torque Arm Inner Bracket Bolt (AutomaticTransmission) 50N·m 37 lb ft
Torque Arm Nut 132 N-m 97 lb ft
Torque Arm Outer Bracket Bolt (Manual Transmission) 27N-m 20 lb ft
Shock Absorber Nut To Rear Axle 90N·m 66 lb ft
Shock Absorber Nut 17N-m 13 lb ft
Stabilizer Shaft Bracket Bolt 47N·m 35 lb ft
Stabilizer Shaft Insulator Clamp Nut 24N·m 18 lb ft
Stabilizer Shaft Bolt 23N·m 17 lb ft

Coil Spring 7.000
Coil Spring Insulator 7.000
Control Arm 7.000
Jounce Bumper 7.000
Propeller Shaft Center Support Bearing 5.000
Rear Axle 5.000
Shock Absorber 7.000
Stabi!lizer Shaft 7.000
Tie Rod 7.000
Tie Rod Bracket Brace 7.000
Torque Arm 7.000
)
3-44 Rear Suspension Suspension
Repair Instructions
(
Bumper Replacement
Removal Procedure
1 . Raise and suitably support the. vehicle. Refer to
Information.
2. Support the rear axle with an adjustable
jack stand.
3. Remove the jounce bumper bolts (1).
1
481848
4. Remove the jounce bumper (2), .

5. Remove the jounce bumper spacer, if equipped;.
181230
Suspension Rear Suspension 3-45
J 1. 1.nstall the jounce bumper spacer, if equipped.
2. Install the jounce bumper (2).
181230

Notices.
3. Install the jounce bumper bolts (1 ).

Tighten
Tighten the jounce bumper bolts (1) to
. 27 N·m (20 lb ft).
4. Remove the rear axle support.
481848
Rear Axle Lower Control Arm

Replacement
Removal Procedure
Important: If replacing both lower control arms,
remove and replace only one control arm at a time in
order to prevent the rear axle from rolling or slipping
sideways.
Information.
2. Remove the lower control arm bolts (5), nuts (2)
2
and washers (4) from the rear axle ( 1).
3. Remove the lower control arm bolts, nuts and
washers from the underbody pan.
4. Remove the lower control arm (3).
181238
1. Position and align the lower control arm (3) to the (
rear axle (1) and the underbody pan
1 Important: Do not tighten the bolts unless the
suspension is at the curb height position.
Notices.
2. Install the lower control arm bolts (5), washers (4)
and nuts (2) to the rear axle (1) from the inboard
side out.
2 Tighten
Tighten the lower control arm bolts (5) to
118 N·m (87 lb ft).
3. Remove the adjustable rear axle support.
3 - -.. . . 4. Lower the vehicle.
181238
Rear Axle lower Control Arm Bushings

Replace
Removal Procedure
Tools Required
• J 21474-5 Bushing Receiver
• J 21474-23 Bushing Rerriover
Important: If replacing both lower control arrns,,
(
remove and replace only one control arm at a time in
order to prevent the rear axle from rolling or slipping
sideways.
1 . Raise and suitably support the vehicle. Refer to
Information.
jack stand.
3. Remove the lower control arm. Refer to Re8r Axle
181231
Lower Control Arm Replacement.
4. Install J 21474-5 over the flanged side of the
bushing.
5. Using a arbor press (1), place the large outside
diameter of J 21474-23 in contact with. the
outside diameter of the outer sleeve in orderto
force the bushing out of the lower control arm. ,
(
J 2i470-20
J Tools Required
• J 21474-5 Bushing Receiver
• .J 21474-20 Front and Rear Bushing Installer
I 1
1. lnstaH J 21474-5 over the flanged side of the

bushing.
2. Install the bushing into position using J 21474-20.
3. Install the lower control arm. Refer to Rear Axle
Lower Control Arm Replacement.
J 21474-5
181233
Torque. Arm Replacement

Removal Procedure 1
Important: When raising the vehicle, support the

vehicle by the frame, allowing the suspension to fully
extend (unloaded).
Lifting a.n.d Jacking the Vehicle in General
Information.
jack stand.
3. Remove the center support bearing (2) bolts from
the torque arm (1 ), if equipped with a two-piece
propeller shaft only.
483066
4. Remove the torque arm bolts (2), washers (3) and

nuts (4) from the .rear axle (1 ).
181239
5. If equipped with a automatic transmission remove
the following:
5.1. Remove the torque arm inner bracket
(
bolts (3 and 8) and mits (5).
5.2. Remove the torque arm oufer bracket (9).
5.3. Remove the torque arm inner bracket (10).
5.4. Remove the torque arm (6).
181240
6. If equipped with a manual transmission (M49

shown, MM6 similar) remove the following:
6.1. Remove the torque arm outer bracket
bolt (5), washer and nut (7).
6.2. Remove the torque arm inner bracket
bolt (6) and nut (7).
6.3. Remove the torque arm outer bracket (3).
6.4. Remove the torque arm inner bracket (2). (
6.5. Remove the torque arm (4).
181241
1. If equipped with a manual transmission (M49
shown, MM6 similar) install the following:
2. Install the torque arm inner bracket (2) to the
7 transmission (1 ).
3. Install the torque arm outer bracket (3) to the
inner bracket (2) and loosely install the torque
arm outer bracket bolts (5 and 6), washer,
and nuts (7).
-~ 4. Insert the torque arm (4) into the torque arm
brackets (2 and 3).
181241
Suspension Rear Suspension 3..49
Notices.
5. Tighten the torque arm outer bracket
bolts (5 and 6) or nuts (7).
Ti,ghten
• Tighten the torque arm outer bracket bolt (5) to
27 N-m (20 lb ft).
• Tighten the torque arm outer bracket bolt (6) to
50 N-m (37 lb ft).
• Tighten the torque arm bracket nuts (7) to
45 N-m (33 lb ft).
6. If equipped with a automatic transmission install
the following:
6.1. Install the torque arm inner bracket (10) to
the transmission (4).
6.2. Install the torque arm outer bracket (9) to
the inner bracket (10) and loosely install the
torque arm inner bracket bolts (3 and 8),
washer, and nuts (1).
6.3. Insert the torque arm (6) irito the torque
arm brackets (9 and 10).
Notices.
6.4. Tighten the torque arm inner bracket
bolts (3 and 8) or nuts (1).
Tighten
• Tighten the torque arm inner bracket
bolts (3 and 8) to 50 N-m (37 lb ft).
• Tighten the torque arm bracket nuts (1)
181240
to 45 N-m (33 lb ft).
7. Position the torque arm (5) onto the rear axle (1).
8. Install the torque arm bolts (2), washers (3) and
the nuts (4).
9. Tighten the torque arm bolts (2) or nuts (4).
Tighten
• Tighten the torque arm bolt (2) to
130 N·m (96 lb ft).
• Tighten the torque arm nuts (4) to
132 N-m (97 lb ft).
181239
10. Install the center support bearing (2) bolts to the
torque arm (1), if equipped with a two piece
1 propeller shaft. (
Tighten
Tighten the center support bearing (2) bolts to
50 N·m (37 lb ft).
11. Remove the adjustable jack stand.
483066
Stabilizer Shaft Replacement

Removal Procedure
2. Remove the stabilizer shaft insulator clamp
nuts (2) and bolt (1).
490650
3. Remove the stabilizer shaft insulator clamp (1 ).
490653
4. Remove the stabilizer shaft insulator (1 ).
490659
5. Remove the stabilizer: shaft rod bracket (1 ).
490656
6. Remove the stabilizer shaft (1 ).
490663
Important: Install the rear stabilizer shaft with the (
bend of the shaft facing down.
Important: The slit of the shaft insulator must face the
rear of the vehicle.
1. Install the stabilizer shaft insulator (1) over the
stabilizer shaft.
490659
2. Install the stabilizer shaft insulator clamp (1) over

the insulator.
490653
3. Place the stabilizer shaft rod bracket (1) against

rear axle.
490656
2000 - F Car (September 27, 1999)

l Notices.
4. Install the stabilizer shaft insulator bolt (1) and
clamp ntJts (2).
Tighten
Tighten the s.tabilizer shaft insulator clamp
nuts (2) to 24 N·m (18 lb ft).
Shaft Link Replacement. ·
490650
Stabilizer Shaft Link Replacement

Removal Procedure
Information.
2. Remove the stabilizer shaft nut (1), bolt (3) and
bushings.
3. Remove the stabilizer shaft spacer and bushings.
4. Remove the stabilizer shaft bracket bolts (2)
and bracket (5), if necessary.
5. Remove the stabilizer shaft bracket (5) from the
underbody pan (6), if necessary.
181244
1. Align the stabilizer shaft bracket (5) to the
underbody pan (6).
Notices. ·
2. Install the stabilizer shaft bracket (5) and bolts (2).
Tighten
Tighten the stabilizer shaft bracket bolts (2) to
47 N·m (35 lb ft).
3. Install the stabilizer shaft spacer and bushings.
4. Install the stabilizer shaft bushings, bolt (3),
nut (1 ).
Tighten
Tighten the stabilizer shaft bolt (3) to
23 N-m (17 lb ft).
181244
3;..54 Rear Suspension Suspension
Shock Absorber Replacement
Removal Procedure (
1. Fold down the rear seatback.
2
2. Remove the quarter trim panel. Refer to Trim
Panel Replacement - Cargo Area Side (Coupe)
in Interior Trim.
3. Fold the carpet back.
----4 Lifting and Jacking the Vehicle in General
Information.
Notice: The rear axle must be supported before
removing the nut in order to avoid possible damage to
6 the break hose lines, the tie rod and the
propeller shaft.
5. Support the rear axle (8) with an adjustable
jack stand.
6. Remove the shock absorber nut (1 ).
7. Remove the shock absorber insulator retainer (2)
and insulator (3).
8. Remove the shock absorber lower retainer and
the insulator (5).
9. Remove .the shock absorber.nut (7) to the rear
axle (8).
10. Remove the shock absorber (6).
(
181246
1 . Install the shock absorber (6) stud to the rear
axle (8).
Notices.
2. Install the shock absorber nut (7) to rear axle.
Tighten
Tighten the shock absorber nut (7) to rear axle to
90 N·m (66 lb ft).
3. Install the shock absorber lower insulator (5) and
retainer to the shock absorber (6).
4. Position the shock absorber. (6) through the
underbody pan (4) and seat the insulator.
5. Install the shock absorber insulator (3) and
retainer (2) to the shockabsorber (6).
Notice: Turning the shock absorber while tightening
the nut could damage the shock absorber. In order to
prevent damage, keep the shock absorber stationary
while you tighten the nut.
6. Install the shock absorber nut (1 ).
Tighten
Tighten the shock absorber nut (1) to
17 N-m (13 lb ft).
9. Place the folded carpet into position.
181246
1o. Install the quarter trim panel. Refer to Trim Panel
Replacement - Cargo Area Side (Coupe) in
Interior Trim.
11. Fold the rear seatback into the upright position.
Coil Spring Replacement

Removal Procedure
extend (unloaded).
Information.
jack stand.
3. Remove the shock absorber to rear axle nut.
Notice: Do not suspend rear axle by brake hoses.
Damage to hoses could result.
4. Slowly lower the rear axle (2).
5. Remove the rear coil spring (1 ).
181234
3-56 Rear. Suspension .Suspension
Important: The lower end of the rear SJ:)ring should be (
facing forward. Do not chip or damagE3 the corrosi.on
protection coating ori the rear spring. Avoid contact
with hard steel. If the coating is chipped or damaged,
replace the rear spring.
1. Install the rear spring (1) to the rear axle (2).
2. Raise the rear c3xle (2).
Notices.
3. Install the shock absorber to rear axle nut.
Tighten
Tighten the shock absorber to rear axle nut to
90 N-m (66 lb ft).
181234
(
Coil Spring Insulators Replacement
Removal Procedure
extend (unloaded).
1. Remove the rear coil spring (1). Refer to Coil
Spring Replacement.
2. Remove the spring upper insulator (3).
181234
1. Position the spring upper insulator (3) to the top
of the coil spring (1).
2. Install the rear coil spring (1). Refer to Coil Spring
Replacement.
) 181234
Track Bar Replacement

Removal Procedure
Information.
jack stand.
3. Remove the tie rod bolt ((3) and nut (8) from the
spring seat.
4. Remove the tie rod bracket brace bolts (7) from
the body brace bracket (1).
5. Remove the tie rod bolts (10) and nuts (9) from
the body brace and tie rod bracket (3).
6. Remove the tie rod (5).
7. Remove the tie rod bracket brace (4).
181235
2000 - F Car (September 27, 1999)

1. Install the tie rod bracket brace (4) to the body (
brace and tie rod bracket (3).
2. Loosely install the upper tie rod bolt (10) 'and
nut (9) to the body brace and tie rod bracket (3).
3. Install the tie rod (5) to the body brace and tie rod
bracket (3).
4. Loosely install the lower tie rod bolt (10) and
nut (9) to the body brace and tie rod bracket (3).
Notices.
5. Install the tie rod bracket brace bolts (7) to the
body brace bracket '(1 ).
Tighten
• Tighten the tie rod bracket brace bolts (7) to
47 N-m (35 lb ft).
" Tighten the upper tie rod bolt (10) to
118 N·m (87 lb ft) or tighten the tie rod nut (9)
to 75 N-m (55 lb ft).
6. Install the tie rod bolt (6) and nut (8) to the
spring seat.
Tighten
Tighten the tie rod bolt (6) to 118 N-m (87 lb ft).
Or tighten the tie rod nut (8) to 75 N-m (55 lb ft).
181235
(
General Description
454513
" The rear axle (1) attaches to the vehicle with a • The rear shock absorbers (9) mount to the rear of
link suspension system. the axle housing and provide ride control. A rear
stabilizer shaft (10) is also part of the suspension
• The rear axle housing connects to the floor
system.
panel (2) by two lower control arms (3) and a track
bar (4). A single torque arm (5) is used in place • The rear shock absorbers (9) mount at the bottom
of an upper control arm. with a nut to brackets (11) welded to the rear of
the rear axle housing and also mount at the top of
• The torque arm (5) rigidly mounts to the rear axle the floor panel (2) with a nut.
housing at the rear.
" The only service that the rear shock absorbers
• The torque arm (5) mounts through a torque arm require is replacement tor the following
bushing (6) at the front. conditions:
• On some vehicles, the torque arm (5) also mounts - Loss of resistance
to the two piece propeller shaft center support - Damage or leaking fluid
bearing (7) with two bolts.
• For rear shock absorber diagnosis, refer to
• The rear springs (8) support the weight of the Suspension General Diagnosis.
vehicle.
3.;50 Rear Suspension Suspension
Illustration Tool Number/Description Illustration Tool Number/Description (
J 21474-5 J 21474-23
Bushing Receiver Bushing Remover
3288 2021
J 21474°20
Front and Rear Bushing
Installer
2020
(
Suspension Tires and Wheels 3-61
Tires and Wheels

Specifications
Tire and Wheel Specifications
Application I Specification
I Metric I English
Maximum Radial Runout
Aluminum Wheels I 0.76 I 0.030
Steel Wheels I 1.01 I 0.040
Maximum Lateral Runout
Aluminum Wheels I 0.76 I 0.030
Steel Wheels I 1.14 I 0.045
Tire Pressures
Compact Spare I 420 I 60
Front/Rear I 210 I 30

Specification
Jack Stowage Bolt/Screw 6.5N·m 581bin
Wheel Nut- M12 x 1.5 140 N,m 1001bft
Wheel Nut Cap - 16 x 8 Aluminum Wheel 6N·m 531bin
Wheel Trim Cover (Chevrolet) 6N·m 531bin
)
Aluminum Wheel Hubcap .. 5.000
Aluminum Wheels 5.000
Conpact Spare Tire. 5.000
3-62 Tires and Wheels Suspension
Wheel Mounting Surface Check (
It is necessary to replace any wheels which are bent,
dented, or which have excessive lateral or radial
runout. Also, wheels with runout greater than specified
may cause objectionable vibrations.
981
3. Inspect the mounting wheel/nut holes for damage

caused from over-torquing the wheel nuts. Inspect
for collapsed wheel/nut bosses. lnspectfor
cracked wheel bosses. · · ·
979
1. Use a straight edge 203 to 229 mm (8 to 9 in)

long. Place the straight edge on the wheel
inboard mounting surface. Try to rock the straight
(
edge up and down within the mounting surfa.ce.
-+
I
-+
I
980
Notice: The use of non-GM original equipment wheels

may cause:
• Damage to the wheel bearing, the wheel fasteners
and the wheel
980 • Tire damage caused by the modified clearance to
2. Repeat this procedure on at least three or the adjacent vehicle components
four different positions on the inboard mounting • Adverse vehicle steering stability caused by the
surface. modified scrub radius
• The outer ring of the mounting surface • Damage to the vehicle caused by the modified
normally is raised above everything inside the ground clearance
mounting surface. • Speedometer and odometer inaccuracy
O The mounting surface will be raised above the
outer ring if the wheel mounting surface has

been bent on a tire changer.
Important: • A wheel of incorrect size or type may effect the
. • Replacement wheels must be equivalent to the
- Wheel and hub-bearing life
original equipment wheels in the following ways:
- Brake cooling
- Load capacity - Speedometer/odometer calibration
- Wheel diameter - Vehicle ground clearance
- Tire clearance to the body and the chassis
- Rim width
4. Replace the wheel if the wheel is bent. Replace
- Wheel offset the wheel if the wheel/nut boss area is cracked.
- Mounting configuration Identify steel wheels with a 2 or 3 letter code stamped
into the rim near the valve stem. Aluminum wheels
have the code, the part number, and the manufacturer
identification cast into the back side of the. wheel.
Radial Tire Lead/Pull Correction
DEFINITION: Lead/pull is the deviation ofthe vehicle from a straight path on a level road with no pressure on the steering
wheeL Lead is usually caused by the following conditions:
,• Off center belt
• Uneven brake assemblies
• Improper tire and wheel alignment In the front tires (rear tires will not cause lead)
Tir~. construction. can be a cause of lead i.n a vehicle. An example of this is placement of the belt. Off center belts on radial
tires can cause the .tire to de\/elop a side force while rolling straight down the road, and the tire will tend to roll like a cone.
Important: Use the lead/pull correction table in· order to verify that improper tire and wheel alignment is not mistaken for
tire lead.
Inspect and repair/replace tire/wheel assemblies .for:
• Correct tire pressure.
• Excessive/uneven tire wear.
) 1 • Co.rrect tire size. - -
• Excessive radial/lateral wheel runout.
• Out of balance.
Is action complete? Go to Step2
Inspect and repair front and rear suspensions for:
• Damage.
• Excessive wear.
2 - -
• Loose Components.
• Excessive wheel bearing play.
Is action complete? Go to Step 3
Inspect and repair power steering gear and pump for:
•,Damage.
3 •. Excessive wear. - -
• Variable Effort steering for DTCs.
· Is action complete? Go to Step 4
1. Cross-switch front tire/wheel assemblies.
4 -
2. Road test vehicle. Does vehicle .still lead/pull? Go to Step 5 System OK
Does the vehicle lead/pull in the opposite direction? Go to Measuring
5 -
Go to Step 6 Wheel Alignment
1. Cross-switch left front tire/wheel assembly with left
rear tire/wheel assembly.
6 2. Road test the vehicle.
-
Does vehicle still lead/pull? Go to Step 7 Go to Step 8
1. Cross-switch right front tire/wheel assembly with right
rear tire/wheel assembly.
7
2. Road test the vehicle.
-
Go to Measuring
Does vehicle still lead/pull? Wheel Alignment Go to Step 9
Radial Tire Lead/Pull Correction (cont'd)
Replace left rear tire.
(
8
Is repair complete?
-
System OK
-
Replace right rear tire.
9 - -
Is repair complete? System OK
Repair Instructions Installation Procedure

1. Install the tire to the wheel. Refer to Tire Mounting
Aluminum Wheel Hub Cap Replacement and Dismounting.
2. Align the matchmark on the tire with the
Removal Procedure
valve stem.
Use the following procedure in order to remove the
hub cap: · 3. Pressurize the tire to 280 kPa (40 psi) and inspect
for leaks.
1. Insert a flat-bladed tool into the slot between the
rim and the hub cap. 4. Adjust the tire pressure in order to meet the
2. With the tool in position, pry off the hub cap. specifications on the tire placard.
3. Remove the hub cap. 5. Balance the tires and wheels. Refer to Balancing
Tires and Wheels in Vibration Diagnosis and
Installation Procedure Correction.
Install the hub cap. 6. Install the tire and the wheel. Refer to Tire and
. .
Use a rubber mallet in order to fully seat the hub cap Wheel Removal and Installation.
into the rim. ·
Aluminum Wheel Porosity Repair
Aluminum Wheel Refinishing
Removal Procedure
Wheel Refinishing·
1. Raise and suitably support the vehicle. Refer to (
Vehicle Lifting and Jacking in General Information. A protective clearcoat and/or base color is applied to
2. Remove the tire and the wheel. Refer to Tire and the surface of the original equipment cast aluminum
wheels. Surface degradation can begin to develop
Wheel Removal and Installation
if uncoated balance weights are used, or if frequent,
3. Locate the leaking areas by inflating the tire to repeated automatic car wash cleaning wears off
280 kPa (40 psi) and dipping the tire and the the factory applied protective clearcoat and/or base
wheel into a water bath. color. This can happen at some automatic car
4. Mark the leak areas wash facilities that use aggressive silicone carbide
5. Mark the tire at the valve stem. tipped tire brushes to clean the whitewalls and
the tires. Exposure to caustic .cleaners and/or to road
6. Remove the tire from the wheel. Refer to Tire
salt causes further surface degradation once the
Mounting and Dismounting.
protective clearcoat is damaged.
7. Scuff the inside rim surface at the leak area with a
The refinishing of aluminum wheels requires that the
number 80 grit sandpaper.
wheel surface be plastic media blasted to remove
8. Clean the area with a general purpose cleaner old clearcoat or paint. The remachining or the use of
such as 3M part number 08984 or the equivalent. chemical strippers is not recommended due to the
9. Apply 3 mm (1/8 in) thick layer of concerns for repair durability. The se.rvice procedure
adhesive/sealant, GM P/N 1052366 or the details how to strip, how to clean, and how to
equivalent, to the leak test area. Allow six hours recoat the aluminum wheels that are affected by the
of drying time. above condition.
(
Wheel. Refinishing Service Procedure 6. Mask off the wheel mounting surface and the lug
nut contact surfaces. These areas must remain
.Caution: To avoid serious personal injury when free of paint and/or clearcoat.
applying any two part component paint system,
follow the specific precautions provided by 7. Follow the individual formula and process provided
.the paint manufacturer. Failure to follow these by the manufacturer of each specific paint system
to perform the painting process.
precautions may cause lung irritation and allergic
respiratory· reaction. 8. Unmask the wheel.
9. Install new valve stem.
1. R.emove the tire and wheel assembly from the 1O. Install the tire. to the wheel. Refer to Tire Mounting
vehicle. Refer to Tire and Wheel Removal and and Dismounting
Installation · ·
11. Rebalance the tire and wheel using new coated
2. Remove the balance weights and valve stem from balance weights. Refer to Balancing Tires and
the wheel. Wheels in Vibration Diagnosis and Correction.
3. Remove the tire from the wheel. Refer to Tire 12. Clean all the wheel mounting surfaces of the
Mounting and Dismounting following:
4. Use a suitable remover to wipe the following from • Of any corrosion.
the wheel: • Of any overspray.
• Wipe the excess grease from the wheel. • Of any dirt.
• Wipe the exc:ess wax from the wheel. 13. Install the tire and wheel assembly to the vehicle.
Refer to Tire and Wheel Removal and Installation
• WipE3 the excess dirt from the wheel.
Important:
• Do not re-match the aluminum wheels.
• Do not use chemical strippers.
5. Remove the old clearcoat and the old paint from
the wheel by plastic media blasting the wheel.
Ught sanding of the wheel, while manually
spinning the wheel, may also be done to restore
the circ.ular machined appearance.
Tire and Wheel Removal and Installation
Caution: If penetrating oil gets on the vertical
surfaces between the wheel and the. rotor or drum~
it could cause the. wheel to work loose as the
vehicle is driven, resulting in a·/oss ()f control t1n,'d
an injury accident; · · ··
Notice: Improperly tightened wheel nuts can l.ead to
brake pulsation ar:id rotor damage. To avoid expensive
brake repairs, evenly tighten the .wheel nuts in the.,,
proper torque specification. ..
Notice: NEVER use heat to loosen a tight wheel. It
can shorten the life of the wheel, wheel nuts and wheel
bearings. Excessive force, such as hammering the
wheel or tire, can. also cause damage and is not
recommended. Slight tapping of the tire side wall, such
as with one's hand or a rubber mallet, is normally
4 acceptable.
Important: Penetrating oil has not been found to be
effective in removing tight wheels. However, if
186689
used, you should apply the oil sparingly on the wheel
centerhole area only.
Sometimes the wheels can be difficult to remove due
to foreign material or a tight fit between the wheel
centerhole and the rotor.
You can remove the wheel without damage through
the following steps: ·
1. Retighten all the wheel nuts on the affected
wheeL Then loosen each nut two turns. Rock
the vehicle from side to side. If this is not effective, (
go to step 2.
2. Rock the vehicle from Drive and Reverse allowing
the vehicle to move several feet in each direction.
Apply quick, hard pressure on the brake pedal
in order to loosen the wheel. If the wheel still does
not loosen, then rock the vehicle again from
side to side as hard as possible using one or more
person's body weight. If the wheel is still tight,
repeat the procedure.
Removal Procedure
1. Raise the vehicle. Support the vehicle. Refer to
Information.
2. Remove the wheel nut cap, if equipped.
3. Remove the hub cap or the wheel trim cover (4).
4. Remove the special security lock nut, if
equipped. Use a special security wheel lock key
located in the front floor console.
5. Remove the wheel nuts (3).
6. Mark the location of the tires and the wheels to
the hub.
7. Remove the tire and the wheel (2).
Caution: Refer to Buildup of Corrosion Removal
Caution in Cautions and Notices.
8. Clean the following components:
" The wheel nuts (3)
• The wheel hub bolts (1)
" The wheel (2)
• The brake drum or rotor mounting surfaces
Suspension Tires and Wheers 3-67
Caution: Never use qil or grease on studs or nuts. 1
Tighten the wheel nuts with your fingers until
they are snug. Then, tighten the nuts (in the
sequence shown) to the fastener tightening
specification shown in Specifications in this
Section. Improperly tightened wheel nuts could
eventually allow the wheel to come. off while
the vehicle is moving, possibly causing loss of
control, personal injury, and property damage.
1. Install the tire and wheel (2).
2. Install the wheel nuts (3) and the security wheel
lock nut, if equipped.
186689

Notices. ·
3. Tighten the wheel nuts to specifications.

Tighten
Tighten the wheel nuts in increments of
27 N-m (20 lb ft) in sequence up to
140 N·m (100 lb ft).
) 4, Tighten the special security wheel lock nut, if
equipped. Use a special security wheel lock
key located in the front floor console.
5. Install the hub cap or the wheel trim cover, if
equipped. ·
Tighten
Tighten the whe~I trim cover to 6 N-m (53 lb in).
6. Install the wheel nut cap, if equipped.
70082
)
Tire Repair Tire Mounting and Dismounting
There are many different materials and techniques on
the market used in order to repair tires. Not all of
(
the materials and techniques work on some types of
tires. Tire manufacturers have published detailed
instructions on how and when to repair tires. Obtain
the instructions from the manufacturer. Do not
repair the compact spare tire.
Compact Spare Tire Replacement
70081
Use a tire changing machine in order to mount or

dismount tires. Follow the equipment manufacturer's
instructions. Do not use hand fools or tire irons to
change the tire as they may damage the tire beads,
wheel rim or flanges.
Notice: Damage to either the tire bead or the wheel
mounting holes can result from the use of improper
wheel.attachment or tire mounting procedures. It takes (
up to 70 seconds for all of the air to completely exhaust
156984
from a large tire. Failure to follow the proper procedures
Caution: To avoid serious personal injury, do not could cause the tire changer to put enough force on the
stand over tire when inflating. The bead may tire to bend the wheel at the mounting surface. Such
break when the bead snaps over the safety hump. damage may result in vibration and/or shimmy, and
Do not exceed 275 kPa (40 psi) pressure when under severe usage lead to wheel cracking. ·
inflating any tire if beads are not seated. If Important: Do not lubricate the tire beads or wheel
275 kPa (40 psi) pressure will not seat the beads, rim with the lubricant containing silicone. Silicone
deflate, relubricate the beads and reinflate. will allow the tire to rotate on the wheel rim, throwing
Overinflation may cause the bead to break and the tire and wheel out of balance.
cause serious personal injury. · Clean the rim bead seats with a wire brush or a coarse
steel wool to remove old rubber and light rust or
Notice: The compact spare wheel should not be used corrosion. Before mounting or dismounting a tire, the
with standard tires, snow tires, wheel covers or trim bead area should be well-lubricated with GM
rings. If such use is attempted, damage to these items P/N 9985555 (50% lubricant and 50% water) or
or other parts of the vehicle may occur. The compact equivalent.
spare should be used only on vehicles that offer it
Caution: To avoid serious personal injury, do not
as original equipment. stand over tire when inflating. The bead may break
when the bead snaps over the safety hump. Do not
Notice: Do not take the vehicle through an automatic
exceed 220 kPa (32 psi) pressure when inflating any
car wash with the compact spare installed. The vehicle
tire if beads are not seated. If 220 kPa (32 psi)
may get caught, which could result in property damage. pressure will not seat the beads, deflate, relubricate
the beads and reinflate. Overinflation may cause the
Important: Use of the compact spare may result in bead to break and cause serious personal injury.
activating a wheel sensor fault code.
Measure the compact spare inflation pressure
periodically and maintain the inflation pressure at
420 kPa (60 psi). You can mount or dismount the tire
(
from the wheel using present tire-changing equipment
procedures.
Suspension Tires and Wheels 3.;.59
After mounting the tire, inflate the tire so that the
beads are completely seated. Never exceed
280 kPa (40 psi).
Important: When mounting blackwall tires, be sure
that the TPC specification number faces the outboard
side of the vehicle.
Install the valve stem and inflate the tire to the
pressure specified on the tire placard. Inspect the
locating rings of the tire in order to determine that the
rings show around the rim flanges on both sides of
the wheel.
Tire Rotation
• In order to equalize tire wear, rotate the. tires. at
intervals specified in Maintenance and Lubrication
in General Information. If you notice uneven
tire wear, investigate the cause.
• Due to design, fadial tires tend to wear faster in
the shoulder area, particularly in drive locations.
ill]
Radial tires in non-drive locations may develop
and irregular wear pattern that can generate
tire noise. This wear makes regular rotation
especially important.
• Always use a four-wheel rotation. After rotatjon,
be sure to measure wheel nut torque and set
the tire pressure. Never use oil or grease on the
wheel bolts or nuts.
• On vehicles with P245/50ZR16 or P275/40ZR17
\ tires, follow special rotation provisions because
the tires are directional.
• Rotate the tires. If you have directional tires, be 231490
sure the color-coded arrows on the tires roll
forward.
• Balance the tires and wheels using a
polyester-coated clip-on wheel balancing weights.
Refer to Balancing Tires and Wheels in Vibration
Diagnosis and Correction.
• Adjust the tire pressures and tighten the wheel
nuts to the specified torque. Refer to Tire and
Wheel Removal and Installation.
)
3~70 · Tires and Wheels Suspension
Tires Description Replace the tires under the following conditions: (
• Tires are worn to a point where 1.6 mm (1.16 in)
or less tread remains, or the cord fabric shows.
To help detect this condition, tires have builtdn
tread wear indicators .that appear between
the tread grooves when the tread is worn to
1.6.mm (1/16 in) or less.
Replace the tire when the indicators appear in
two or more adjacent grooves at three spots
around the tire. ·
• The tread or sidewall is damaged in one of the
following ways:
The tread or sidewall is cracked or either cu1 or
snagged. deeply enough to expose the cord or the
fabric. · ·
- The tread or .sidewall is cracked.
- The tread or sidewall is cut deeply enough in
order to expose the cord or the fabric.
- The tread or sidewallis snagged deeply
70080
enough in order to expose the cord or
the fabric.
• A tire performance criteria (TPC) specification
• One of the following conditions exists in the tire:
number is molded in the sidewall near the tire size
of all original equipment tires. - A bump
• The TPC specification number ensures that the - A bulge
tire meets GM's performance standards for the - A split
following conditions: Slight sidewall indentations are normal and (
- Traction should not affect the ride.
- Endurance • One of the following conditions exists in the tire:
- Dimension - A puncture
- Noise - A cut
- Handling - Other damage that cannot be correctly
- Rolling resistance repaired because of the size or location
of the damage. · ·
• A specific TPC number is usually assigned to
each tire size.
Tire Inflation Description
• The following characteristics on replacement tires
should be the same as on the original tires: When you inflate the tires to the recommended
- Load range inflation pressures, the factory-installed wheels and
tires are designed to handle loads to the tire's
- Speed Rating rated load capacity. Incorrect tire pressures, or
- Construction under-inflated tires, can cause the following conditions:
• Replace the original tires with tires of the same • Vehicle handling concerns
TPC specification number. • Poor fuel economy
• Use of any other tire size or type may affect the • Shortened tire life
following conditions: • Tire overloading
- Ride Inspect the tire pressure when the following
- Handling conditions apply:
- Speedometer/odometer calibration • The vehicle has been sitting at least 3 hours.
- Antilock brake system • The vehicle has not been driven for more
- Vehicle ground clearance than 1.6 km (1 mi).
• The tires are cool.
- Tire clearance to body and chassis
Inspect the tires monthly or before any extended trip.
• Install new tires in pairs on the same axle. Adjust the tire pressure to the specifications on
• If it is necessary to replace only one tire, the tire the tire label. Install the valve caps or the extensions
should be paired with the tire having the most on the valves. The caps or the extensions keep
tread in order to equalize the braking traction. out dust and water.
Suspension Tires and Wheels 3·71
The kilopascal (kPa) is the metric term for pressure. Tire Chain Usage Description
The tire pressure may be printed in both
Notice: Tire chains should not be used wlth
kilopascal (kPa) and psi. One psi equals 6.9 kPa.
P245/50ZR16 or P235/55R1.6 tires. The chains could
damage the vehicle. Tire chains are only .· . ·
Inflation Pressure Conversion (Kilopascals recommended for emergency use or when required
to PSI) . .
by law .
kPa psi kPa . psi
140 20 215 31 . P-Me.tric Sized Tires Description , .
145 21 220 32
· ...
155 22 230 33
160 23 235 34 '
165 24 240 35
170 25 250 36
;• 180 26 275 40
185 27 310 45
190 28 345 50
200 29 380
... 55 SECTION
WIDTH RIM
205 30 415 60 (MILLIMETERS) DIAMETER
.Conversion: 6.9 kPa = 1 psi 235 (INCHES)
245 16
Tires with a higher than recommended pressure can 275 17
cause the following conditions:
• A hard ride ASPECT
RATIO CONSTRUCTION
• Tire bruising (SECTION HEIGHT) TYPE
R..:.RADIAL
• Rapid tread wear at the center of the tire (SECTION WIDTH) B-:81AS-BEL TEO
55 ·.
D.,-DIAGONAL(BIA~)
Tires with a lower than recommended pressure can 50
) cause the following conditions: 40
• A tire squeal on turns
e Hard steering
" Rapid wear and uneven wear on the edge of SECTION --+----~+-----llllol
the tread WIDTH SECTION
HEIGHT
• Tire rim bruises and tire rim rupture
• Tire cord breakage
---1
• High tire temperatures
70078
• Reduced vehicle handling
• High fuel consumption AH GM vehicles now use passenger-metric (P-metric)
sized tires. P-metric tires are available in the
• Soft riding
following two load ranges:
Unequal pressure on the same axle can cause the • Standard load with 210 kPa (30 psi) maximum
following conditions: pressure
• Uneven braking • Extra load with 240 pKa (35 psi) maximum
• Steering lead pressure
• Reduced vehicle handling Most P-metric tire sizes do not have exact
See 1he Tire Placard for specific tire and wheel corresponding alpha-numeric tire sizes. For example,
applications and tire pressures. a P205/75R15 is not exactly equal in size and
load carrying capacity to an FR78-15. Replacement
tires should be of the same TPC specification number
as those originally on the vehicle. If the TPC
specification number is the same then the following
conditions are the same:
• The size
• The load range
) • The construction
If you must replace the P-metric tires with other sizes,
consult a tire dealer. A tire company can best .
recommend the closest match of alpha-numeric to
P-metric sizes within their own tire lines.
3;.72 Tires and Wheels Suspension
The metric term for tire pressure is the Steel wheel identification is stamped into the wheel
kilopascal (kf>a). Tire pressure may be printed in both near the valve stem.
k!::113: ~nd pounqsper.square inch.(psi). One.psi Aluminum wheel identification is cast into the inboard (
equals 6.9 kPa: Refer to the tire placard or side of the wheel.
Speqifications for tlre pressures.
Caution: If you are replacing the wheel(s), the
wheel stud(s}, the wheel nut(s) or the wheel bolt(s},
Tire Placard Description install only new GM original equipment parts.
The tire placard is permanently located on the rear Installation of used parts or non-GM original
face of the driver's door. The tire placecard should be equipment parts may cause the wheel to loosen,
referred to for tire information. The placard lists the loss of tire air pressure, poor vehicle handling and
following specifications: loss of vehicle control resulting in personal
• The maximum vehicle load . injury, · ·
• The tire size (including the spare) . Notice:. The use of non-GM original equipment .wheels
may cause: . ·. ·.
• The cold inflation pressure (including the spare)
. . . • Damage to the wheel bearing, the wheel fasteners
Replacement Wheels Description and the wheel
• Tire damage caused by the m~dified cileararice to
Replace the wheel if any of th.e following the· adjacent vehicle components
conditions exist: ·
• Adverse vehicle steering stability caused by the
• The wheel exhibits excessive runout modified scrub radius ·
• The wheel is bent • Damage to the vehicle caused by the modified
• The wheel is cracked ground clearance
• The wheel is severely rusted • Speedometer and odometer inaccuracy
• · The wheel is· severely corroded
• The wheel IE3aks ·air Aluminum Wheels Description
Important: .Air leaks caused by porosity on aluminum Clean aluminum wheels with mild soap and water.
wheels may be repaired. Wax aluminum wheels regularly. Do not use abrasive
or caustic cleaners. These .c.ould damage the ·
Replace the wheel, the wheel studs and the wheel protective coating of the wheel. (
.nuts (or the wheel bolts if applicaple) if any of
the following conditions exist:
• The wheel has elongated bolt holes
• The wheel nuts (or bolts if applicable) loosen
repeatedly
Driveline/Axle Table of. Contents 4-1
Section 4
Driveline/Axle
Propeller Shaft ................................................ .4-3 Rear Axle Usage ........................................ .4-22

Specifications ................................................. .4-3 Pinion Bearing and Differential Bearing
Fastener Tightening Specifications ................ .4-3 Pre load .....................................................4-22
Propeller Shaft Runout Specifications ............ .4-3 GM SPO Group Numbers ........................... .4-22
GM SPO Group Numbers ..............................4-3 Diagnostic Information and Procedures ...... .4-23
Diagnostic Information and Procedures ........ .4-4 Noise Diagnosis ....... !.................................. .4-23
Propeller Shaft Diagnosis .............................. .4-4 Repair Instructions ... ,.. , ................................. 4-25
Leak at Front Slip Yoke .................. :............. .4-5 Lubricant Level Check ................................ .4-25
Roughness or Vibration .................................4-5 Rear Axle Housing Cover and Gasket
Ping, Snap, or Click Noise ............. '. ............... 4-6 Replacement ........................................... .4-25
Knock or Clunk Noise ................................... .4-7 Axle Shaft Replacement .............................. .4-26
Scraping Noise ............................................. .4-7 Differential Carrier Replacement .................. .4-28
Shudder on Acceleration at Low Speed ......... 4-7 Rear Axle - Disassemble ............................ .4-29
Repair Instructions ......................................... .4-8 Drive Pinion Disassemble ........................... .4-30
Propeller Shaft Replacement - One Pinion Depth Adjustment ............................ ..4-32
Piece .............................................................4-8 Drive Pinion Assemble ................................ .4-34
Propeller Shaft Replacement - Two Rear Axle - Assemble ................................. .4-36
Piece ..................................... "" ................. 4-1 O Oil Seal and/or Bearing Replacement ......... .4-36
) Universal Joint and Slip Yoke Pinion Oil Seal Replacement ........................4-38
Replacement ........................................... .4-14 Inspection Before Disassembly .................... .4-40
Description and Operation ........................... .4-18 Rear Axle Housing Inspection ..................... .4-40
Propeller Shaft Description .......................... .4-18 Differential Inspection .................................. .4-41
Propeller Shaft Phasing Description ............ .4-19 Bearings Inspection ..................................... .4-41
Universal Joint Description .......................... .4-19 Differential Side Bearing Preload
Center Bearing Description ......................... .4-19 Adjustment .............................................. .4-41
Special Tools and Equipment ...................... .4-20 Backlash Adjustment ................................... .4-42
Gear Tooth Contact Pattern Check ............. .4-43
Rear Drive Axle ............................................. .4-21
Rear Axle Replacement ............................... 4-46
Specifications ............................................... .4-21
Pinion Flange Replacement ........................ .4-47
Fastener Tightening Specifications .............. .4-21
Pinion and Ring Gear Inspection ................. .4-48
Rear Axle Specifications
(General Specifications) ........................... .4-21 Description and Operation ........................... .4-52
Rear Axle Specifications Rear Axle Description ................................. .4-52
(Bearing Shim Thickness) ........................ .4-21 Special Tools and Equipment ...................... .4-53
)
4-2 Table of Contents Driveline/Axle
(
BLANK
(
Driveli ne/Axle Propeller Shaft . 4-3
Propeller Shaft
Specifications
Specification
Propeller Shaft Bolt/Screw 22N·m 16 lb ft
Propeller Shaft-To-Center Support Bearing Bolt/Screw 50N·m 37 lb ft
Propeller Shaft Runout Specifications

Specification
Propeller Shaft Runout '
1.40 mm I 0.055 in

Center Support Bearing 5.000
One-Piece Propeller Shaft (VS) 5.000
Two-Piece Propeller Shaft (V6) 5.000
·.
Universal Joints 5.000
\
)
)
4-4 Propeller Shaft Driveline/Axle
Propeller Shaft Diagnosis 4. If the pinion gear yoke runout is 0.15 mm
(0.006 in). or less, remove the pinion gear
Tools Required
yoke balance weight if the pinion gear yoke
O J 8001 Dial Indicator Set
balance weight is used.
O J 35819 Runout Gage
5: No further action is required if the following
• J 35819-100 Runout Gage Adapter Sleeves
circumstances exist:
1. Raise and suitable support the vehicle. Refer to
Lifting and Jacking the Vehicle in General .. The pinion gear yoke runout is between
Information. 0.15-0.28 mm (0.006:-0.011 in)
Ensure that the following conditions are met: • The balance weight is near or at the low point
• The vehicle is supported on the rear axle of pinion gear runout
housing If the balance weight is not near or at the low
.. The rear wheels can rotate freely point of pinion gear runout, remove the
2. Remove the propeller shaft. Refer to Propeller weight.
Shaft Replacement - One Piece or Propeller · 6. No further action is required if the following
Shaft Replacement - Two Piece. circumstances exist:
• The pinion gear yoke runout is between
0.28-0.38 mm (0.011-0.015 in)
.. The balance weight is near or. at the low. point
of pinion gear runout ·
7. If the balance weight is not at or near the low
point of the pinion gear runout, complete the
following steps:
7 .1. Remove the weight.
7.2. Rotate the pinion gear yoke until the runout
is 0.25 mm (0.01 O in) or less.
(
8. If a runout of 0.25 mm (0.01 O in) or less cannot
be attained, complete the following steps: ·
Important: Service replacement differential pinion
gear yokes may be equipped with balance weights. Do
not remove these weights. · ·· ·
J 8001-3 8.1. Install a new differential pinion gear yoke.
164321
8.2. Inspect again in order to determine if
the runout is 0.25 mm (0.010 in) or less.
3. Use the J 8001 the J 35819 and the J 35819-100
in order to measure and record the pinion gear 9. Install the propeller shaft. Refer to Propeller Shaft
yoke runout. Replacement - One Piece or Propeller Shaft
Mark the high point and the low point of the pinion Replacement - Two Piece.
gear yoke. 10. Lower the vehicle.
Oriveline/Axle Propeller Shaft 4-5
Leak at Front Slip Yoke
Important: An occasional drop of fluid from the slip yoke is normal.
Inspect the outside surface of the slip yoke for roughness.
1 -
Is the outside surface of the slip yoke rough? Go to Step2 Go to Step 3
Replace the yoke.
2 - System OK
Is there still a leak at the front Slip yoke? Go to Step 3
Inspect the seal for cuts caused by burrs on the slip yoke.
3 -
Are there cuts on the seal? Go to Step 4 .Go to Step 5
Replace the seal.
4 -
Is there still a leak at the front slip yoke? Go to Step 5 System OK
Inspect the rear transmission oil seal for damage.
5 - -
Is the rear transmission oil seal damaged? Go to Step 6
Replace the rear transmission oil seal. Add fluid if fluid is
6 needed. - -
Is there still a leak at the front slip yoke? System OK
Roughness or Vibration
Inspect the propeller shaft for the following conditions:
• Bending
1 -
• Damage
Is the propeller. shaft bent or damaged? Go to Step 2. Go to Step 3
Replace the propeller shaft.
2 -
Is there still roughness or vibration? Go to Step 3 System OK
Inspect for undercoating on the propeller shaft ...
3 -
Is there undercoating on the propeller shaft? Go to Step 4 Go to Step 5
Remove the undercoating from the propeller s.haft.
4 -
Is there still roughness or vibration? · Go toStep5 System OK
Inspect the tires for the following conditions:
• Unbalance
5 • Vibration during vehicle operation at a speed of -
48-'--80 km/h (30-50 mph)
.Do the above conditions exist? .· Go to Step 6 Go to Step 7
..
Balance the tires.
6 -
Is there still roughness or vibration? · ·. Go to Step 7 System OK
Inspect the universal joints for tightness.
7 -
Are the universal joints tight? Go to Step B Go to Step9
If the universal joints are equipped with snap rings, tap on
the yokes with a hammer in order to free up the universal
joints.
8 -
If the joints cannot be freed up or if the joints feel rough,
replace the joints.
Inspect the universal joints for wear.
9 -
Are any of the universal joints worn? Go to Step 10 Go to Step 11
Replace the worn universal joint(s).
10 -
Inspect the fixed yoke for bending and inspect the flange
) 11 for excessive runout. -
Does either of the above conditions exist? Go to Step 12 Go to Step 13
Replace the fixed yoke.
12 -
4;.5 Propeller Shatt DrivelinefAxle
Roughness or Vibratiqn (cont'd)
..
Step Action .. Value(s) Yes No
Inspect the propeller shaft for lack of balance. (
13
Is the propeller shaft unbalanced?
-
Go to Step .14 Go to Step 15
Inspect for the missing balance weight on the propeller
14 shaft. Rotate the shaft 180 degrees on the fixed. yoke. -
Inspect the universal joint for incorrect angle placement.
. .
15 -
16
Is the universal joint at an incorrect angle?
Correct the universl:l.1 joint angle.
-
Go tb Step 16
. .Go to Step 17
Is there still roughness or vibration? Go to Step 17 ·System OK
Inspect the yokes and the flanges for the following ,. ..
conditions:
17 • Damage -
• Distortion
Are the yokes and/or the flanges damaged or distorted? Go to Step 18 Go toStep 19
Replace the yokes and/or the flanges.
18
Is there still roughness or vibration?
- Go to Step 19 System OK
Inspect the shaft for yokes that are out of phasEl. .
19
Are the yokes out of phase on the shaft?
-
Go to Step20 Go to Step21
Replace the propeller shaft if the propeller shaft is a
one-piece shaft.
20 Reindex the propeller shaft ifthe propeller shaft is a -
two-piece shaft.
Is there still roughness orvibration? Go to Step21 System .OK
"
Inspect for driveline vibration during vehicle operation at a
21 speed of 80 km/h (50 mph). - -
Is there driveline vibration at the specified speed? . Gq.to Step 22
(
Inspect the propeller shaft runout.
22 Inspect for missing balance weights on the propeller shaft. - -
Is there driveline vibration at the specified speed? .. System OK
Ping, Snap, or Click Noise

Step . Action ·"
Value(s) Yes No
DEFINITION: A ping, a snap or a clicking noise in the driveline that is usually heard during initial load after the transmission
is in gear. .
Inspect the rear axle lower control arm for loose .. ·
1 bolts/screws. -
• Are there looseb61ts/screwsJn the lower control.arm? GotoStep2 Go to Step.3
Tighten the bolts/screws to the specified torque. Refer to
2 Rear Suspension in Suspension. -
Is there still a ping, a snap or a clicking noise? I Go to Step3 System OK
Inspect the universal joints for the following conditions: .
• Wear
3 -
• Damage
Are any of the universal joints worn or damaged? Go to Step 4 Gb to Step 5
Replace the worn or damaged universal joint(s);
4 -
Is there still a ping, a snap or a clicking noise? . Go toStepB System OK
Inspect the fixed yoke in order to .determine if the fixed
5 yoke is loose. - -
Is the fixed yoke loose? Go to Step 6
.. .
Tighten the drive pinion gear nut to the specified forque.
6 Refer to Fastener Tightening Specifications. - - (
Is there still a ping, a snap or a clicking noise? System OK
Driveline/Axle Propeller Shaft 4-7
Knock or Clunk Noise
DEFINITION: A knock or a clunking noise in the driveline that occurs during operation of the vehicle in high gear or during
coasting in neutral at a speed of 16 km/h (10 mph.)
Inspect the universal joints for the following conditions:
• Damage
1 -
• Wear
Are any of the universal joints damaged or worn? Go to Step2 Go to Step 3
Replace the worn or damaged universal joint(s).
2 -
Is there still a knock or a clunking· noise? Go to Step 3 System OK
<
Inspect the differential side gears for wear.
3 - -
Are any of the differential side gears worn? Go to Step 4
Replace the worn differential side gear(s)?
4 - -
Is there still a knock or a clunking noise? System OK
Scraping Noise
1 Is the vehicle equipped with drum brakes? - Go to Step2 Go to Step 4
Inspect the backing plate for contact with the brake drum.
2 Is there contact between the brake drum and the -
backing plate? Go to Step 3 Go to Step 4
Replace the brake drum or the backing plate.
3
Is there still a scraping noise?
- Go to Step 4 System OK
Inspect the pinion flange and the center support bearing
for rubbing.
4
Is there rubbing between the pinion flange and the center
- -
support bearing? Go to Step 5
Correct the interference.
5 - -
Is there still a scraping noise? System OK
Shudder on Acceleration at low Speed

DEFINITION: A shudder during acceleration from 0-24 km/h (0-15 mph)
Inspect the universal joint angle in order to determine of
1 the universal joint angle is incorrectly set or excessive. -
Is the universal joint angle incorrectly set or excessive? Go to Step2 Go to Step 3
Add or remove transmission mount shims as needed.
2 -
Is there a shudder during acceleration? Go to Step 3 Go to Step 5
Inspect the flanges for loose or missing bolts/screws?
3 -
Are there loose or missing bolts/screws in the flanges? Go to Step 4 Go to Step 5
Replace or tighten the bolts/screws to the specified torque.
4 -
Is there a shudder during acceleration? Go to Step 5 System OK
Inspect the universal joints for wear.
5 - -
Are the universal joints worn? Go to Step 6
Replace the worn universal joints.
6
Is there a shudder during acceleration?
- -
System OK
Repair Instructions
Propeller Shaft Replacement - One Piece
Removal· Procedure
Notfce: Do not strike or drop the propeller shaft, or
allow the uhiversal joints to bend to extreme angles, as
internal joint 'damage might.occur.
1. Rc1ise and suitably support the vehicle. Refer to
Lifting and .Jacking the Vehicle in General
lnforniation.. ,. , ·
2. Mark the relationship of the propeller shaft (2) to
the.pinion gear yoke (1).
180335
3. Remove the propeUer shaft bolts/screws (2).

4. Remove the propeller shaft retainers (l).
2 1
180340
Important: Support the propeller shaft during rem~val.
5. Use the following steps in order to remove tlie 2
propeller shaft:
5.1. Withdraw the slip yoke (3) from the
transmission.
5.2. Move the propeller shaft (1) rearward and
pass the propeller shaft under the
housing· (2).
If the bearing caps are loose, tape the
bearing caps together in order to prevent
dropping and· losing the needle roller
bearings.
6. Inspect the transmission.output shaft splines
for burrs.
180341
7. Inspect the outer diameter of the slip yoke (1)

for burrs.
8. Inspect the outer splines ofthe slip yoke (1) for
the following conditions: ·
• Damage
• Twisting
• Wear
9. Inspect the relationship of the outer splines of the
slip yoke (1) to the transmission output shaft
splines. The outer splines of the slip yoke should
meet the following requirements:
• The outer splines should agree in number with
the transmission output shaft splines.
• The outer splines should fit with the
transmission output shaft splines.
180343
1o. Inspect the pinion gear yoke (1) at the universal

joint cap connecting surface for the following
conditions:
• Burrs .
~ Foreign material ·
180344
4~1o Propeller Shaft Driveline/Axle
Notice: The propeller shaft must be supported (
carefully during handling to avoid jamming or bending
of parts.
Important: Do not place any tool between the
propeller shaft slip yoke and the splines. Placing any
tool between the propeller shaft slip yoke and the
splines may cause damage to the transmission
oil seal.
1 . Lubricate the slip yoke wit.h chassis lubricant.
2. Install the slip yoke onto the transmission
output shaft.
Important: Be sure to align the mark on the pinion
gear yoke with the mark on the propeller shaft.
3. Install the rear of the propeller shaft (2) to the
pinion gear yoke (1 ).
4. Install the rear universal joint to the pinion
180335
gear yoke.
Ensure that the bearing caps are properly seated.
5. Install the propeller shaft retainers (1).
Notices.
6. Install the propeller shaft bolts/screws (2).
Tighten
Tighten the propeller shaft bolts/screws evenly to
22 N-m (16 lb ft). .
7. Lower tAe vehicle .. (
2 1
180340
Propeller Shaft Replacement ~ Two Piece

Removal Procedure
Notice: Do not strike or drop the propeller shaft, or
allow the universal joints to bend to extreme angles, as
internal joint damage might occur.
Important: The two-piece propeller shaft and the
center support bearing used with the 3800 (VIN K)
engine are not serviceable separately. The propeller
shaft and the support bearing should be replaced as a
complete assembly only.
Information.
2. Mark the relationship of the propeller shaft (2) to
the pinion gear yoke (1 ).
180337
Drive line/Axle Propeller Shaft 4-11
3. Remove the bolts/screws (4) from the center ;
support bearing (3).
4. Remove the following components from the
torque arm (2):
• The center support bearing (3)
• The washers (1)
180339
5. Remove the propeUer shaft bolts/screws (2).

6. Remove the propeller shaft retainers (1 ).
2 1
180340
Important: Support the propeller shaft during removal.

7. Use the following steps in order to remove the 2
propeller shaft:
7.1. Withdraw the slip yoke (3) from the
transmission.
7.2. Move the propeller shaft (1 and 4) rearward
and pass the propeller shaft under the
housing (2).
If the bearing caps are loose, tape the
bearing caps together in order to prevent
dropping and losing the needle roller
bearings.
8. Inspect the transmission output shaft splines
for burrs.
180342
4-12 Propeller Shaft Dr.iveline/Axle
9. Inspect the outer diameter of the slip yoke (1)
for burrs.
10. Inspect the outer splines of the slip yoke (1) for (
the following conditions:
O
Damage
" Twisting
.. Wear
11. Inspect the relationship of the outer splines of the
slip yoke to the transmission output shaft splines.
The outer splines of the slip yoke should meet
the following requirements:
" The outer splines should agree in number with
the transmission output shaft splines .
.. The outer splines should fit with the
transmission output shaft splines.
180343
12. Inspect the pinion gear yoke (1) at the universal

joint cap connecting surface for the following
conditions:
.. Burrs
" Foreign material
180344
Notice: The propeller shaft must be supported
carefully during handling to avoid jamming or bending
of parts.
Important: Do not place any tool between the propeller
shaft slip yoke and the splines. Placing any tool
between the propeller shaft slip yoke and the splines
may cause damage to the transmission oil seal.
1. Lubricate the slip yoke with .chassis lubricant.
2. lnstallthe slip yoke onto the transmission
output shaft.
Important: Be sure to align the mark on the pinion
gear yoke with the mark on the propeller shaft.
3. Install the rear of the propeller shaft (2) to the
pinion gear yoke (1 ).
4. Install the rear universal joint to the pinion
(
gear yoke.
Ensure that the bearing caps are properly seated.
180337
2000 - F Car (September 27, 1999)

5. Install the propeller .shaft retainers (1 ).
Notice: Refer to Fastener Notice in Cautions and ·
Notices.
6. Install the propeller shaft bolts/screws (2).
Tighten
Tighten the propeller shaft bolts/screws evenly to
22 N,m (16 lb ft).
2 1
180340
7. Install the following components to the torque

arm (2):
• The washers (1)
• The center support bearing (3)
• Install the bolts/screws (4) to the center
support bearing.
Tighten
) Tighten the propeller shaft-to-center support
bearing bolts/screws to 50 N·m (37 lb ft).
180339
4:-14 Propeller Shaft DrivelinefAxle
Universal Joint and Slip Yoke
Replacement
(
Tools Required
.• J 9522-3 U-Joint Bearing Separator
• J 9522-5 U-Joint Bearing Spacer Remover
Notice: Never clamp propeller shaft tubing in a vise.
Clamping propeller shaft tubing in a vise could dent or
deform the tube causing an imbalance or unsafe
condition. Always clamp on one of the yokes
and support the shaft horizontally. Avoid damaging the
slip yoke sealing surface. Nicks may damage the
bushing or cut the lip seal.
Important: Nylon injected ring universal joints cannot
5 6 be reassembled. Replace nylon injected ring
universal joints with external snap ring universal joints.
453758
When reassembling a propeller shaft, always install
a complete propeller shaft universal joint service kit.
This kit includes the following components:
• One pregreased spider (1)
• Four service bearing caps with seals (2)
• One needle roller bearing (3) ·
• Delrin round washers (4)
• Delrin flat washers (5)
• Grease
• Four retainer rings (6)
Ensure that the seals are in place on the.service
bearing caps (2) during handling. The seals will hold
the needle roller bearings (3) in place during handling.
Important: There are no bearing retainer grooves
in production bearing caps. Production bearing caps
cannot be reused.
1. Support the propeller shaft in a horizontal position
that is aligned with the base plate of a press.
2. Place the universal joint so that the lower
ear of the shaft yoke is supported on a
28.6 mm (1.125 in) socket (2).
3. Use the following procedure in order to remove
the lower bearing cap from the yoke ear:
3.1 . Place the J 9522-3 on the open horizontal
bearing cap.
3.2. Press the lower bearing cap out of the
yoke ear.
This process shears the nylon injected ring
on the lower bearing cap.
1222
4. If the bearing cap (1) is· not completely removed,
use the following steps in order to completely J 9522-5
remove the bearing cap:
4.1 . Lift the J 9522-3 •
4.2: Insert the J 9522-5 between the seal and
the bearing cap (1 ).
4.3. Press the bearing cap (1) out of the yoke.
5. Rotate the propeller shaft.
5.1 . Repeat Step 3 in order to shear the
opposite nylon injected ring.
5.2. Repeat Step 4 in order to remove the
opposite bearing cap from the yoke.
6. If the front universal joint is being replaced, use
the above procedure in order to remove the
two bearing caps from the propeller shaft
slip yoke.
164308
7. Remove the spider (1) from the yoke.

8. Clean the yoke in the area that will hold the
retainer ring in order to ensure proper assembly.
9. Clean all of the sheared nylon from the universal
·. joint cup bore.
Important: Do not loosen or damage the dust seals.
'\; If the dust seals are loose pr damaged, replace
the entire universal joint.
Important: These universal joints are designed for
extended life and do not require periodic inspections or
lubrication.
When these joints are taken apart, repack the bearing.
Lubricate the reservoir at the end of the trunnions
with chassis lubricant or linkage joint lubricant.
10. Remove the U-joint spider bearing retainer 5 6
rings (6). If the retainer ring does not snap readily
out of the grooves, lightly tap the end of the
bearing cap (2) in order to relieve the pressure 453758
against the retainer ring. After relieving the
pressure, remove the retainer ring.
11. Support the propeller shaft in a horizontal position
that aligns with the base plate of a press,
)
4-16 Propeller Shaft DrivelineJAxle
12. Place the universal joint so the ear of the yoke is.
supported on a 28.6 mm (1.125 in) socket.
J 9522-3 (
13. Use the following procedure in order to remove
the lower bearing cap from the yoke ear:
13.1. Place the J 9522-3 on the· open horizontal
bearing cap.
13.2. Press the lower bearing cap out of the
yoke ear.
1222
14. If the bearing cap (1) is not completely removed,

J 9522-5 use the following steps in order to completely
remove the bearing cap: · ··
14.1. Lift the J 9522-3.
14.2. Insert the J 9522-5 between the seal and
the bearing cap (1).
14.3. Press the bearing cap (1) out of the yoke.
15. Rotate the propeller shaft. (
16. Press the opposite bearing cap out of the yoke.
17. Remove the spider from the yoke.
164308
Assembly Procedure
1. Install one bearing cap partially into one side of
the yoke.
2. Rotate the yoke so that this yoke ear is on the
bottom.
3. Insert the J 9522-3 in order to seat the trunnion in
the bearing cap.
4. Repeat Steps 1 and 2 in order to partially install
the opposite bearing cap.
5. Inspect both trunnions in order to ensure their
straight positioning into the bearing caps (1).
6. Press against the two opposite bearing caps while
working the spider in order to ensure free
movement of the trunnions in the bearings. (
1223
7. Inspect the needle roller bearing (3) for binding.
If binding exists, one or more of the needle roller 2
bearings may have tipped under the end of
the relevant trunnion.
8. Stop pressing on the bearing caps (2) when
one bearing retainer groove clears inside of
the yoke.
5 6
453758
9. Press the U-joint spider bearing retainer ring

into place;
1225
10. Continue pressing on the retainer ring until the

opposite side of the ring can be snapped
into place.
If necessary, strike the yoke with a hammer in
order to facilitate seating of the retainer rings.
(Striking the yoke with a hammer slightly springs
the yoke ears.)
11. Repeat the above procedure for the other half of
the universal joint.
1226
2000 - F Car (September 27, 1999)

Propeller Shaft Description Two Piece Propeller Shaft
(
One Piece Propeller Shaft
.c®J_ ___.l~....---1
156377
Vehicles equipped with the 3800 (VIN K) engine and

3649
the 5-speed manual transmission (M49) are
equipped with a two-piece propeller shaft assembly.
Important: When undercoating a vehicle, keep the
The two-piece shaft assembly consists of a front
propeller shaft free from undercoating material.
propeller shaft, a rear propeller shaft, and a cen1er
Undercoating or any other foreign material will upset
the propeller shaft balance and may produce
support bearing. The center support bearing prevents
angular movement (or "whipping") of the propeller
(
serious vibrations. shaft. The support bearing is a ball bearing type. The
The propeller shaft is a hollow shaft or tube that support bearing mounts in a rubber cushion. The
connects the transmission to the differential. The rubber cushion mounts to the torque arm.
propeller shaft connects to the transmission with a The bearing is prelubricated and sealed by the
splined slip yoke and connects to the rear axle with a manufacturer.
universal joint. The spline coupling has internal splines which accept
Propeller shafts have universal joints at each end in the rear propeller shaft.
order to accommodate angle variations between
the transmission and rear axle, and the rear axle
position caused by suspension motion. All propeller
shafts are the balanced tubular type.
Vehicles with the 5.7L (VIN G) engine and both the
6-speed (MM6) and the automatic transmission (M30)
are equipped with a one-piece propeller shaft of
either stamped steel design or a lightweight aluminum.
Driveline/Axle Propeller Shaft 4~19
Universal Joint Description
5 6
156961
A propeller shaft joint (sometimes referred to as 453758

constant velocity joint) is located on the front of the
Universal joints are designed to handle the effects of
rear propeller shaft. The propeller shaft joint fits
various ioadings and rear axle windup during
into the spline coupling of the front propeller shaft.
acceleration and braking. Within the designed angle
The propeller shaft joint (orconstant velocity
variations, the universal joint operates efficiently
joint) allows adjustment of the propeller shaft angle
and safely. When the design angle changes or is
without interrupting the power flow. The up and down
exceeded, the operational life of the joint may
movement of the vehicle requires the above action.
decrease.
\ Vehicles with two or more propeller shafts use a center
)
bearing. The center bearing is usually near the rear The trunnion bearings (3) used in universal joints are
the needle roller type. Round bearing cups (2)
of the front propeller shaft. The slip joint is at the
hold the needle rollers in place on the trunnions.
forward end of the rear propeller shaft.
Either snap rings (6) or injected plastic hold the
bearing cups in the yokes.
Propeller Shaft Phasing Description
The Original Equipment Manufacturer (OEM) universal
The propeller shaft is designed and built with the yoke joints are lubricated for life and cannot be lubricated
lugs (ears) in line with each other which produces on the vehicle. A service kit which consists of a ·
the smoothest running shaft possible. A propeller shaft spider (1) with bearing assemblies.snap rings and
designed with built in yoke lugs in line is known as derlin washers (4 and 5) may be installed if a universal
in-phase. joint becomes worn or noisy. If it is necessary to
An ou1 of phase propeller shaft often causes vibration. repair a universal joint, you must remove the propeller
The p1opeller shaft generates vibration from speeding shaft from the vehicle. Avoid jamming, bending, or
up and slowing down each time the universal joint over-angulating any parts of the propeller shaft
goes around. The vibration is the same as a person assembly. Avoid damaging the propeller weld yokes
snapping a rope and watching the wave reaction and slip yoke ears upon installation or removal of
flow to the end. An in phase propeller shaft is similar U-joints.
to two persons snapping a rope at the same time
and watching the waves meet and cancel each other Center Bearing Description
out. A total cancellation of vibration produces a
Center bearings support the driveline when using
smooth flow of power in the drive line. Since phasing
two or more propeller shafts. The center bearing is a
of a propeller shaft is between the front and center
ball bearing assembly mounted in a rubber cushion
universal joints, you must reference mark the front and
that attaches to the rear axle torque arm in the Camaro
rear propeller shafts before removal in order to
and Firebird models. The manufacturer prelubricates
ensure proper phasing upon reinstallation. Some
and seals the bearing. The cushion allows vertical
splined shaft slip yokes are keyed in order to ensure
motion at the driveline and helps isolate the vehicle
proper phasing.
from driveline vibrations. Since the center bearing is a
sealed assembly, it must be replaced as an assembly
) as it can not be overhauled.
4-20 Propeller Shaft Driveline!Axle
Illustration Tool Number/Description Illustration Tool Number/Description
J 8001 J 23498-A
Dial Indicator Set Driveshaft Inclinometer
25473 8224
J 9522-3 J 35819
U-Joint Bearing Separator Runout Gage
803 1512
J 9522-5
U-Joint Bearing Spacer
Remover
[)[) J 35819.-100
Runout Gage Adapter
Sleeves
(
805 180346
Driveline/A:xle Rear Drive Axle 4-21
Rear Drive Axle

Specifications ·
Specification .· ·
,·,
Application •: Metric English
Important: Use a reliable torque wrench in order to tighten the parts listed. A reliable torque wrench will ensure proper ·
tightening of the parts without straining or distorting the parts. The following specifications are for clean and lightly-lubricated
threads only. Dry or dirty threads produ,ce increased friction. Friction prevents the measurement of tightness. '
Differential Carrier Bearing Cap Bolt/Screw 75N-m 55 lb ft

Differential Drive Pinion Gear Setting Gauge Nut 2.3N-m 201bin
Differential Pinion Gear Shaft Lock Bolt/Screw · 36N-m· 27 lb ft
Differential Ring Gear Bolt/Screw 120 N-m 89 lb ft
Rear Axle Housing Cover Bolt/Screw '
30N-m 22 lb ft
Rear Axle Housing Drain Plug 35N-m 26 lb ft
Sensor Plug Mounting Bolt/Screw ' 10 N-m 891bin
·', '
Wheel Bolt ·' 140 N·n:i 100 lb ft
Wheel Speed Sensor Mounting Plug ''
10N-m ' 891bin
Rear Axle Specifications (General Specifications)

Specification
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 I 3.5 pt. ·

Rear Axle .Lubricant
Synthetic 75W-90 Gear Lubricant
Standard and Limited Slip Differential (GM P/N 12378261) meeting GM spec. 9986115,
or equivalent
Limited Slip Differential Additive (GM P/N 1052358), or equivalent 118 ml
"
I 4 fl. oz.
'"
Rear Axle Specifications Service Differential Bearing Shim Thickness

(Bearing Shim Thickness) (Standard Spacer)
Metric English Metric English
DEFINITION: The total thickness of both the production DEFINITION: The total thickness of the service
differential bearing shims removed. differential bearing shims to be used as a starting point.
10.57 mm 0.416 in 1.52 mm 0.060 in
,,
10.92 mm 0.430 in
1.78 mm 0.070 in
11.18 mm 0.440 in
2.03 mm 0.080 in
11.43 mm 0.450 in
2.29 mm 0.090 in
11.68 mm 0.460 in
2.54 mm 0.100 in
11.94 mm 0.470 in
12.19 mm 0.480 in 2.79 mm 0.110 in
12.45 mm 0.490 in 3.05 mm 0.120in
12.70 mm 0.500 in 3.30 mm 0.130 in
12.95 mm 0.510 in 3.56 mm 0.140 in
13.21 mm 0.520 in 3.81 mm 0.150 in
13.46 mm 0.530 in 4.06 mm 0.160 in
13.97 mm 0.550 in
) 4.32 mm 0.170 in
4.83 mm 0.190 in
4-22 Rear Drive Axle Driveline!Axle
Rear Axle Usage
Engine (RPO) Transmission

Rear Axle
Ratio Rear Axle RPO
Ring Gear
Diameter Rear Brake
Teeth Ring
Gear: Pinion
(
5-SPD 194 mm
3800-V6 (L36) 3.23 GU5 Disc 42:13
Manual (M49) (7 5/8")
3800-V6 (L36) 5-SPD ~94mm
3.23 GU5 Disc 42:13
Y87 Package Manual (M49) (7 5/8")
4-SPD 194mm
3800-V6 (L36) 3.08 GU4 Disc 40:13
Automatic (M30) (7 5/8")
3800~V6 (L36) 4~SPD •. 194 mm
3.42 GU6 Disc 41:12
Y87 Package Automatic (M30) (7 5/8") '
6-SPD 194mm
5.7L-V8 (LS1) 3.42 GU6 Disc 41 :12
Manual (MM6) (7 5/8")
194mm
.
5.7L-V8 (LS1) 6-SPD
3.42 GU6 Disc 41 :12
WS6 Package Manual (MM6) (7 5/8'.')
4-SPD 194 mm·
5.7L-V8 (LS1) 2.73 GU2 Disc 41 :15
Automatic (M30) (7 5/8")
5. 7L-V8 (LS1) 4-SPD 194mm
3.23 GU5 Disc 42:13
WS6 Package Automatic (M30) (7 5/8")
Pinion Bearing and Differential Bearing Preload

Specification
Differential Drive. Pinion Gear hiner and Outer Bearing Preload
(Measured at the Drive Pinion Gear Nut) ..
New Bearings
(
1.7-3.4 N·m 15-30lbin
(Rotating Torque With a New Seal)
.
Used Bearings
1.0-1.7 N·m 10-151bin
.·
Total Preload
(Measured at the Drive Pinion Gear Nut)
Ne_w Bearings
3.6-6.2 N-m 32-551bin
Used Bearings
1.8...:3.1 N-m 16-281bin
(Rotating Torque With a New Seal) .
Differential Ring Gear-to Differential
Drive Pinion Gear Backlash 0.13-0.23 mm (0.005-0.009 in)

Axle Shaft 5.000
Differential Carrier 5.000
Drive Pinion 5.000
Inner Bearing 5.000
Oil Seal and Bearing '
5.000
Outer Bearing 5.000
Pinion Flange 5.000
Rear Axle 5.000
(
Rear Cover and .Gasket 5.000
Drive Ii ne/Axle Rear Drive Axle 4-23

Noise Diagnosis 6.2. Test drive the vehicle. Coast at speeds
under 48 km/h (30 mph).
Many noises that are H~ported as .coming from the
rear axle actually originate from other components: The following characteristics of tire and. rear
axle noise may help in determining if the
• The tires and wheels
tires cause the noise:
• The road surfaces
• Rear axle nois~ usually stops when the
• The wheel bearings vehicle is coasting at speeds under
·.• ·The engine 48 km/h (30 mph).
• The transmission • Tire noise usually continues. The tone of
" The muffler the tire noise becomes lower as the
speed of the vehicle is reduced. ,
• The body
Thoroughly inspect for the source of the noise before • Rear axle;noise usually sounds different
disassembling the rear axle. Noise that originates during driving and during coasting. Tire
noise remains the same during
in other places cannot be corrected by adjustment or
driving and during coasting.
replacement of rear axle components. The rear
axle differential gears are not absolutely quiet (like any • Exhaust and axle noises change during
other.mechanical devices). The rear axle differential sudden acceleration and deceleration.
gears should be. accepted as commercially quiet Tire noise re.mains constant during
unless some abnormal noise exists. sudden changes in vehicle speed.
Use the following procedure in order to inspect for • Tire noise is the most noticeable at the
axle noise under standard conditions: speeds of 32-48 km/h (20-30 mph).
1. Measure the rear axle lubricant in order to ensure • Tire noise changes on different road
the correct level. surfaces, but rear axle noise does
2. · Drive the vehicle far enough in order to thoroughly not change. Drive the vehicle. over
warm up the rear axle lubricant. smooth pavement or dirt roads
(not gravel) with the tires at normal
,SelElct g. level asphalt road, which reduces tire pressure. Tire noise will noticeably
noise and body drumming. change, or will disappear and reappear
3. N.ote the speed at .w.hich the noise occurs. with the road surface.
4. Stop the vehicle. 7. Determine if loose or rough front wheel inner or
5. Determine if the exhaust muffler roar. or other outer bearings cause the noise.
engine conditions cause the noise: • Noise in front wheel inner or outer bearings
5.1. Place the transmission range selector lever does not change between drive and coast.
in NEUTRAL • Light application of the brake pedal while
5.2. Run the engine slowly up and down holdihg the vehicle speed steady takes
through the engine speeds that correspond some weight off of the bearings. This action
to the speed at which· the nois,e was will. often cause noise in front wheel inner
m913t pronounced. or outer bearings to diminish.
6. Determine if the tires cause the noise: • Use. the following steps in order to determine if
6.1. Temporarily inflate all of the tires to the front wheel inner and outer bearings
approximately 345 kPa (50 psi). are loose:
This will alter the noise caused by the tires, 7.1. Jack up the tires and the wheels.
but will not affect the noise made by the 7.2. Spin or shake the tires and the
rear axle.
wheels in order to determine if the
bearings are loose.
8. Rear axle noise is dampened when the rear
suspension rubber bushings and the spring
insulators are correctly installed.
Determine if any metallic contact exists between
the following components:
• The spring and the spring opening in the
underbody
• The lower control arm bushings and the
underbody or axle housing brackets
Metal-to-metal contact at these points may
increase road noise and normal axle noise.
4.;.24 Rear Drive Axle Drive line/Axle
Rear Axle Noises Use the following steps in order to.determine if a
After verifying that a noise exists in the rear axle, noise is caused by a rough rear wheel bearing:
determine the type of the noise. Determining the type 1. Raise the rear tires and wheels. ·
of the rear axle noise will aid in repair.
2. Spin the rear tires and wheel by hand.
Gear. Noise 3. Listen at the hubs for evidence of rough (noisy)
Gear noise (whine) is audible from 32-89 km/h rear wheel bearings.
(20-55 mph) under the following driving conditions:
• Drive - Acceleration or heavy pull
Knock At Low Speeds
• Road Load - The vehicle driving load or the One of the following conditions may cause a knock at
. constant speed low speeds:
• Float - Using enough throttle in order to keep the • A worn universal joint
vehicle from driving the engine, the vehicle slows • Aworn or oversized side gear hub counterbore in
down gradually but the engine still pulls slightly. the differential case
• Coast - The throttle closes and the vehicle is Inspect and replace the above components as
in gear.
necessary.
Gear noise is most noticeable when the vehicle is
operating at the following speeds: Backlash Clunk
- 64-80 km/h (40-50 mph) One of the following conditions may cause excessive
- 97-105 km/h (60-65 mph) backlash clunk with acceleration and deceleration:
Bearing Noise • A worn differential drive pinion gear shaft
Poor bearings generally produce a rough growl or • A worn differential case
grating sound, rather than the whine typical of • Excessive clearance between the following
gear noise. components:
Bearing noise frequently "wow-wows" at constant - The rear axle shaft splines and the side gear
RPMs. This noise may indicate that the following
splines
components are faulty:
• The differential drive pinion gear - The side gear hub and the counterbore in (
the case
• The side bearings
• A worn differential drive pinion gear and worn side
The "wow-wow" bearing noise may be confused with
gear teeth
rear wheel bearing noise. Inspect and replace as
necessary. • Worn differential pinion gear thrust washers
Rear Wheel Bearing Noise • Excessive differential ring gear-to-differential drive
pinion gear backlash
The noise that is produced by a rough .rear wheel
bearing is evident under the following conditions: Replace the worn components as necessary. Select
• The vehicle is coasting at low speeds close fitting replacement parts.
• The transmission range selector leveris in Adjust the differential ring gear-to-differential. drive
NEUTRAL pinion gear backlash. Refer to· Backlash Adjustment
The bearing noise may diminish with gentle braking.
Driveline/Axle Rear Drive Axle 4-25
Repair Instructions
lubricant Level Check
Iniormation.
2. Clean any dirt or foreign material.from around the
rear axle housing drain plug.
3. Remove the rear axle housing drain plug.
4. Verify that the axle lubricant level is within the
following range:
• No higher than the bottom of the plug opening
O
No lower than 15 mm (9/16 in) below the
plug opening
5. If necessary, add to or replace the axle
lubricant. Use synthetic 75W-90 gear
lubricant (GM P/N 12378261 ), meeting
GM specification 9986115, or equivalent.
6. If 1he vehicle has a limited slip differential, add
118 ml (4 fl oz) of limited slip differential additive
(GM P/N 1052358), or equivalent.
Notices.
7. Install the rear axle housing drain plug.
· Ti~hten
Tighten the rear axle housing drain plug to
) 35 N·m (26 lb ft).
Rear Axle Housing Cover and Gasket

Replacement
Removal Procedure
Lifting and Jacking the· Vehicle in General
Information.
2. Clean all of the dirt from the area of the rear axle
housing cover before removing the cover.
3. Remove the following components:
• The rear axle housing cover bolts/screws
• The parking brake cable guides
4. Pry the rear axle housing cover loose. Remove
the rear axle housing cover.
5. Allow lubricant to drain ..
6. Remove the rear axle housing cover gasket. ··
7. Clean both of the gasket sealing surfaces with
brake parts cleaner. · 1500
4:-26 R~t:n· Drive Axle Driveline/Axle
1. Install a new rear axle housing cover gasket
2. Install the rear axle housing cover.
3 .. Install the park brake cable guides,
Notices.
4. Install the rear axle housing cover bolts/screws.
Tighten
Tighten the rear axle housing cover bolts/screws
in a crosswise pattern to 30 N-m (22 lb ft).
5. Refill rear axle with lubricant. Refer to Lubricant
Level Check.
1500
Axle Shaft Replacement

Removal Procedure
Tools Required
J 39446 AB.S Exciter Ring Protector Kit
1. Remove the rear tire and wheel. Refer to Tire and
Wheels. (
2. Remove the rear brake rotor. Refer to Brake
Rotor Replacement (Rear) in Disc Brakes.
3. Remove the rear axle. housing cover. Refer t6
Replacement.
4. Install a J 39446 onto the speed sensor reluctor
wheel (6) on v~hicles that are equipped with
non~traction control axles.
5. Remove the pinion gear shaft lock bolt/screw (5)
6 from the differential case.
164023
6. Remove the pinion gear shaft from the
differential case.
7. Push the flanged end of the axle shaft into the
rear axle housing (7) in order to access the rear
axle shaft lock.
8. Remove the rear axle shaft lock (1 ),
Important: Do not damage the rear wheel speed
sensor reluctor wheel (6) during axle shaft removal on
vehicles thafare equipped with traction control.
The rear wheel speed sensor reluctor wheel is located
on the axle shaft.
If the rear wheel speed sensor reluctor wheel is
damaged, replace the rear axle shaft.
9. Remove the rear axle shaft from the rear axle
housing (7). (
'! 1. Install the rear axle shaft into place.
Ensure that the following conditions are met:
• The splines on the end of the axle shaft do not
damage the rear wheel bearing seal.
• The splines on the end of the axle shaft
engage with splines of the differential
side gear.
2. Install the rear axle shaft lock (1 ).
Push the axle shaft outward so that the rear axle
shaft lock (1) seats in the counterbore of the
difierential side gear.
3. Install the pinion gear shaft through the following
components:
• The differential case
• The pinion gear thrust washers
• The pini~n gears 6
Align the hole in the pinion gear shaft with the 164023
rear axle shaft lock bolt/screw hole in the

differential case.
Notice: Refer· to Fastener Notice in Cautions a.nd
Notices.
4. Coat the pinion gear shaft lock bolt/s.crew (5) with
Loctite 242 or an equivalent.
5. Install the. pinion gear shaft lock bolt/screw (5).
Tighten
Tighten the differential pinion gear shaft lock
bolt/screw (5) to 36 N·m (27 lb ft).
6. Remove J 39446 from the speed sensor reluctor
wheel (6) if the vehicle has a standard rear axle.
If a new speed sensor reluctor wheel (6) was
installed, remove and discard the plastic covering.
7. Install the rear axle housing cover. Refer to Rear
Axle Housing Cover and Gasket Replacement.
8. Install the rear brake rotor. Refer to Brake Rotor
Replacement (Rear) in Disc Brakes.
9. Install the rear tire and the rear wheel. Refer to
and Wheels.
\
)
4-28 Rear Drive Axle Driveline/Axle
Differential Carrier Replacement
Removal Procedure (
1. Raise and suitably support vehicle. Refer to Lifting
2. Place drain pan under rear axle cover.
3. Remove the rear axle cover and the gasket. Drain
the rear axle fluid. Refer to Rear Axle Housing
Cover and Gasket Replacement.
4. Remove rear axle shafts. Refer to Axle Shaft
Replacement.
5. Remove the differential carrier bearing cap
bolts (2,3). ·
Important: Move the bearing caps (4) .back and forth
slightly to loosen and remove. Never use screwdrivers
to pry on the parting surfaces of the cap and the
housing because surface damage will occur.
6 6. Remove the differential carrier bearing caps (4).
164023
Important: Group the shims together with the original

installed location labeled. If you remove or replace the
J 39446 ring and pinion gearset, perform the bearing preload,
backlash, and tooth contact pattern test in order
to ensure proper contact of the .gears. If you reinstall
or replace the differential carrier without replacing
any other component (e.g. pinion & ring gear
set, bearings, etc) then you may reinstall the carrier
with the original shims in the original locations. Always (
perform a .tooth contact pattern test, even when you
remove only the carrier.
7. Remove.the differential carrier (1) and the shims
from the rear axle housing (2).
164239
Tools Required
J 25588 Side Bearing Shim Installer
1. Install the differential carrier and the shims (1) into
the housing (2) with the shims in the original
location with J 25588 and a deadblow hammer.
375040
Notices.
I
2. Install the differential bearing caps (4) and cap
bolts (2,3).
Tighten
Tighten the differential bearing cap bolts to
75 N-m (55 lb ft).
3. Perform a backlash adjustment. Refer to· Backlash
Adjustment.
4. Perform a tooth contact pattern test. Refer to
Gear Tooth Contact Pattern Check.
5. lnstall;the rear axle shafts. Refer to Axle Shaft
Replacement.
6. Install the rear axle cover and the gasket. .Refer to
Replacement. ·
7. Lower the vehicle. 6
8. Road test the vehicle in order to ensure proper 164023
differential operation. If any whines or howls are
now present, repeat the backlash and contact
pattern test.
Rear Axle - Disassemble

Important: It is not necessary to remove the rear axle
\. assembly for .overhaul of the rear axle components
) because this can be done in the vehicle. If you
are replacing the rear axle housing, remove the rear
axle assembly from the vehicle and overhaul the
assembly on the bench. If the rear axle housing is
damaged, use the following procedure in order
to remove and install the rear axle housing:
Information.
2. Support the rear axle with an adjustable lifting
device.
3. Remove rear torque arm. Refer to Torque Arm
Replacement in Rear Suspension.
4. Remove propeller shaft from vehicle. Refer to
Propeller Shaft Replacement - One Piece or
Propeller Shaft Replacement - Two Piece
in Propeller Shaft.
5. If the rear axle housing is being replaced, remove
the rear axle assembly from the vehicle. Refer to
Rear Axle Replacement.
6. Remove the rear axle cover and gasket from
housing. Refer to Rear Axle Housing Cover
and Gasket Replacement.
7. Remove the axle shafts. Refer to Axle Shaft
Replacement.
8. Remove the differential case from housing. Refer
to Differential Carrier Replacement.
9. Remove the differential drive pinion gear and
bearing races from housing. Refer to Drive
Pinion Assemble.
10. Inspect all components for excessive wear.
Replace as necessary.
2000 - F Car (September 27, 1999)

4-30 Rear Drive Axle Driveline!Axle
Drive Pinion, Disassemble
Drive Pinion Removal Procedure (
Tools Required
J 22536 Pinion Driver
1. Remove the differential case. Refer to Rear Axle -
Disassemble.
2. Measur,e .the differential drive pinion gear .inner
and outer bearing preload.
3. If no preload reading exists, then inspect for
looseness of tl]e drive pinion gear by shaking.
The following conditions may c.ause loosenes.s:
• A worn drive pinion gear yoke
• Defective inner or outer drive pinion gear
bearings
4. If the rear axle was opened for an extended
period with very loose inner and outer drive
164053
pinion gear bearings, the following components
will· require replacement:
• The ring gear
• The drive pinion gear
5. Remove the differential drive pinion gear yoke (1).
Refer to Pinion Oil Seal Replacement.
6. With channel-locking pliers (4) and a wrench (1 ),
Install J 22536 to the differential drive pinion
gear (2) .. ,
(
164249
(
7. Apply heavy hand pressure on J 22536 toward
the rear axle housing (2). This pressure keeps the
outer drive pinion gear (1) bearing seated in
order to avoid damage to the outer race.
2 1
164254
Outer Bearing Removal Procedure

1. Remove the differential drive pinion gear seal
from the rear axle housing.
2. Remove the drive pinion gear outer bearing from
the rear axle housing.
3. Use a punch in order to remove the drive pinion
gear outer bearing race from the rear axle
housing, if the drive pinion gear outer bearing is
) being replaced.
Place the punch into the slots in the rear axle
housing.
Inner Bearing Removal Procedure
Tools Required
J 22912-01 Rear Pinion Bearing Cone Remover
1. Remove the drive pinion gear bearing spacer from
the drive pinion gear. Discard the drive pinion
gear bearing spacer.
2. Use a punch in order to remove the drive pinion
gear inner bearing race from the rear axle
housing, if the inner drive pinion gear bearing is J 22912-01
being replaced. Place the punch into the slots
in the rear axle housing.
3. Use the J 22912-01 in order to drive the inner
drive pinion gear bearing from the drive
pinion gear.
1
164261
4-32 Rear Drive Axle DrivelineJAxle
Pinion Depth Adjustment
Tools Required r
" J 8001 Dial .lndicatpr Set .. . \
• J 23597-1 Pinion Setting Guage Arbor
" J 23597-11 Pinion Setting Guage Plate
" J 21777-40 Rear Pilot Washer
.. J 21777-42 Front Pilot Washer
.. J 21777-43 Stud Assembly-Bolt
" J 21777-45 Side Bearing Discs
Use a pinion setting gauge in order to measure
differential drive pinion gear depth. The gauge provides
a normal or zero pinion as a gauging reference.
i. Install J 21777-40, J 21777-42, J 21777-43, and
J 21777-45.
2. Install J 23597-11.
3. Install J 21777-42 into the rear axle housing.
and Notices.
164276
4. Install the drive pinion gear setting gauge nut into
the rear axle housing.
Tighten .
Tighten the differential drive pinion· gear setting
gauge nut. to 2.3 N-m (20 lb in). ·
5. Rotate J 23597~ 11 ih order to seat the following
components: . .
• The differential drive pinion gear outer
bearing (2) · ·
• The differential drive pinion gear inrier (
bearing (1)
6. Mount J 8001 onto J 23597-1.
J 21777-45 7. Preload the dial indicator against the plunger
about 1.27 mm (0.050 in).
8. Install J 21777-45 onto J 23597-11.
Position this unit into the rear axle housing.
9. Install the following components:
• The carrier bearing caps (3)
"The bearing cap bolts/screws (2)
Tighten
2 Tighten the differential.carrier bearing cap
bolt/screws (2) to75N·m (551b.ft).
10. Use the following steps in order to measure the
differential drive pinion gear depth:
10.1. Rotate J 23597-1 slowly back and forth
until J 8001 reads the greatest deflection.
The deflection is the point where the needle
changes direction.
164343 10.2. At the point of deflection, set J 8001
to zero.
10.3. Repeat the rocking action in order to verify
the zero setting.
10.4. After obtaining the zero setting, rotate
J 23597-1 until the plunger no longer
touches J 23597-11.
This action provides the gauge reference of
a zero or nominal drive pinion gear.
10.5. Use the following information in order to
select the correct shim:
• Record the J 8001 reading at the pointer
position.
The required drive pinion gear shim
th.ickness is equal to the J.8001 reading.
For example, if the pointer moved
counterclockwise 1.70 mm (0.067 in) to
a dial reading of 0.84 mm (0.033 in),
a shim thickness of 0.84 mm (0.033 in)
is required.
.. Drive pinion gear shims are available in
0.03-0.94 mm (0.001-0.037 in).
The thickness of each shim is etched on
the flat surface of the shim.
11. Loosen the J 21777-43.
12. Remove all of the special tools from the rear axle
housing.
13. Remove the inner (1) and the outer (2) drive
pinion gear bearings from the rear axle housing.
14. Install the correct.drive pinion gear shim on the
drive pinion gear.
15. Use the following steps in order to set the proper
drive pinion gear depth:
15.1. Use the set-up dimension determined by
J 8001 as a starting point.
15.2. Perform a ring gear tooth pattern test in
) order to fine tune the drive pinion
gear depth.
The test may indicate additional necessary J 21777-40
drive pinion gear shim changes.
Refer to Pinion and Ring Gear Inspection.
i 6. Install the following components:
164276
• The drive pinion gear inner bearing
• The drive pinion gear outer bearing
Refer to Drive Pinion Assemble.
17. Assemble the differential case. Refer to Rear Axle
-Assemble.
18. Measure the total preload at the drive pinion gear
nut bearings.
The preload should measure within the following
specifications:
• With new inner and outer drive pinion gear
bearings and a new drive pinion gear
seal, the preload should measure
3.6-6.2 N-m (32-55 lb in).
• With used inner and outer drive pinion
gear bearings and a new drive pinion gear
seal, the preload should measure
1.8-3.1 N·m (16-28 lb in) when rotating
with a new drive pinion gear seal.
)
4-34 Rear Drive Axle DrivelineJAxle
Drive Pinion Assemble
ln.ner Bearing Installation Procedure
Tools Required
• J 8092 Driver Handle
• · J 29609 Rear Pinion Bearing Cup Installer
• J 5590 Rear Pinion Bearing Cone Installer
1. Use J 5590 in order fo install the inner drive
pinion gear bearing (1) onto the drive pinion
gear (2).
164265
2. Use J 8092 and J 29609 in order to drive the

inner bearing race (1) into the rear axle housing,
if the inner drive pinion gear bearing was
replaced.
3. Install the new drive pinion gear bearing spacer
onto the drive pinion gear.
164270
Outer Bearing Installation Procedure

Tools Required
J 8092 • J 8092 Driver Handle
• J 7817. Front Pinion Bearing .Cup Installer
1. Use J 8092 and J 7817 in order to install the drive
pinion gear outer bearing race into the rear axle
housing if you remove the pinion gear outer
bearing race ..
2. Install the drive pinion gear outer bearing into the
rear axle housing. ·
3. Install the differential drive pinion gear seal.
164257
Drive line/Axle Rear Drive Axle 4-35
Drive Pinion Installation Procedure
Tools Required
J 7817 Front Pinion Bearing Cup Installer
i. If a new ring gear and a new drive pinion gear will
be installed, measure the differential drive pinion
gear depth.
(Refer to Pinion Depth Adjustment).
2. Install the drive pinion gear into the rear axle
housing.
3. Use J 7817 in order to install the new drive pinion
gear seal (1 ).
4. Apply pipe sealant (GM p/n 12346004) or an
equivalent onto the pinion shaft splines.
5. Install the drive pinion gear yoke.
6. Install the drive pinion gear washer and nut.
Finger tighten the drive pinion gear washer
and nut.
7. Perform the following actions in order to tighten
the drive pinion gear nut. 164048
• Hold the drive pinion gear yoke in place.
• Rotate the drive pinion gear in order to seat
the inner and outer drive pinion gear
bearings.
• While rotating the drive pinion gear, tighten the
drive pinion gear nut until the end play is
taken up.
Important:
" Preload.specifications are being approached when
the following conditions occur:
- The holder will no longer pivot freely as the
drive pinion gear rotates.
- No further end play exists
Do not attempt further tightening until after
measuring the preload if the above
conditions exist.
O Exceeding the preload specifications will compress
the collapsible drive pinion gear bearing spacer

too far.
8. Set the preload to the following specifications on
the inner and outer drive pinion gear bearings:
• 1. 7-3.4 N·m (15-30 lb in) on new inner
and outer drive pinion gear bearings
• 1.0-1.7 N·m (10-15 lb in) on used inner and
outer drive pinion gear bearings
9. Rotate the drive pinion gear several times.
Ensure that the inner and outer drive pinion gear
bearings seat.
10. Carefully tighten the drive pinion gear nut.
11. Continue to gradually tighten the drive pinion
gear nut.
Measure the preload after each tightening.
(Additional tightening of the drive pinion gear nut
may add additional torque).
) 12. Measure the preload again.
13. Reset the preload to specifications if the preload
decreased by rotating the drive pinion gear.
14. Install the differential case. Refer to Rear
Aide - Assemble.
4.;35 Rear Drive Axle Driveline/Axle
Rear Axle - Assemble
Assembly Procedure (
1. Inspect all components for excessive wear and
replace as necessary,
2. Perform pinion depth measurement and
adjustment. Refer to Pinion Depth Adjustment.
3. Install the differential drive pinion gear, bearing
races, and new pinion seal from housing. Refer
to Drive Pinion Assemble.
4. Install the differential carrier .to. housing. Refer to
Differential Carrier Replacement.
5. Perform side bearing preload adjustment and
measurement. Refer to Differential Side Bearing
Preload Adjustment.
6. Perform a backlash adjustment and measurement.
Refer to Backlash Adjustment. ·
Oil Seal and/or Bearing Replacement

Removal Procedure
Tools Required
• J. 2619-01. Slide Hammer
• J 22813-01 Axle Bearing Remover
1. Remove .the rear axle shaft. Refer to Axle Shaft
Replacement.
2. Place a pry bar behind the steel case of the
seal (3). Use the pry bar in order to remove
the rear wheel bearing seal (3) from the rear axle (
housing (2).
Do NOT damage the housing (2).
164285
3. Insert J 22813-01 into the bore.

Position J 22813-01 behind the rear wheel bearing
so that the tangs on the tool engage the bearing
.· outer race:. . .
J 22813-01 4. Use J 2619-01 in order to remove the rear wheel
bearing.
J 2619-01
(
228698
Tools Required
• J 8092 Driver Handle
• J 23765 Axle Bearing Installer
• J 23771 Axle Oil Seal Installer
1. Lubricate the new rear wheel bearing (1 ).
Use one of the following lubricants:
• Axle lubricant
• SAE BOW-90 GL-5 gear lubricant or an
equivalent
164285
2. Use J 23765 and J 8092 in order to install the

rear wheel bearing.
Ensure that the tool bottoms against the shoulder
in the rear axle housing.
3. Lubricate the sealing lips. Use one of the following
lubricants:
• Axle lubricant
• SAE BOW-90 GL-5 gear lubricant or an
equivalent
J 23765
375043
4. Position the rear wheel bearing seal onto J 23771.

5. Use J 23771 in order to direct the bearing seal (3)
into the housing bore.
6. Install the rear wheel bearing seal into place.
J 23771
Ensure that the rear wheel bearing seal is
flush with the axle tube.
7. Install the rear axle shaft. Refer to Axle Shaft
Replacement.
8. Road test and Inspect for correct operation of the
rear axle.
·~
)
228693
4--38 Rear Drive Axle DrivelineJAxle
Pinion Oil Seal Replacement
Removal Procedure
(
Tools Required
J 8614-01 Pinion Flange Remover and Installer
Lifting and Jacking the. Vehicle in General
Information.
2. Remove the propeller shaft. Refer to Propeller
Shaft Replacement - One Piece or Propeller
Shaft Replacement - Two Piece in Propeller Shaft.
3. Mark the position of the following components
before disassembly:
• The drive pinion gear yoke (1)
• The drive pinion gear nut
This action will ensure that.the correct drive
164053
pinion gear inner and outer bearing preload
can be maintained.
4. Use J 8614,0,1 in order to remove the following
components:
. • The. drive pinion ~e_ar nut
2 • The drive pinion gear washer
5. Use a suitable container in order to hold any fluid
that may drain from the rear axle.
\ (
;/
J 8614-01
164050
6. Use J 8614-01 in order to remove the drive pinion

gear yoke (1). ·'
J 8614-2
164041
Important: Do not damage the rear axle housing
when removing the drive pinion gear seal.
7. Use a blunt chisel in order to drive the drive
pinion gear seal (1) out of the rear axle housing.
8. Inspect the drive pinion gear seal (1) surface of the
drive pinion gear yoke for the following conditions:
• Tool marks
• Nicks
• Damage, such as a groove worn by the drive
pinion gear seal.
9. If the drive pinion gear yoke is damaged, replace
the drive pinion gear yoke.
10. Inspect the housing bore for burrs.
Burrs might cause leaks around the outer
diameter (OD) of the drive pinion gear seal (1).
Remove any burrs that might cause leaks around
the outer diameter (OD) of the drive pinion
gear seal (1 ). 164048
Tools Required
• J 8614-01 Pinion Flange Remover and Installer
• J 23911 Pinion Oil Seal Installer
1. Use the J 23911 in order to install a new drive
pinion gear seal (1 ).
2. Apply chassis lubricant or an equivalent to the
) following components:
• The outside diameter of the drive pinion
gear yoke
• The sealing lip of the new drive pinion gear
seal (1)
164048
3. Install the drive pinion gear yoke (1 ).

• The drive pinion gear washer
J 8614-2
Finger tighten the drive pinion gear nut.
164041
4-40 Rear Drive Axle Driveli ne/Axle
Notices.
5. Hold the drive pinion gear yoke. Use J 8614-01 in
(
order to tighten the.drive pinion gear nut toth.e
position that was marked.
Tighten
Tighten the drive pinion gear nut to 1.59 mm
--·/\ -
6.
(1/16 inch) beyond the alignment mark.
Install the propeller shaft. Refer to Propeller Shaft
Replacement - One Piece or Propeller Shaft
Replacement - TwoPiece in Prop13ller Shaft.
7. Measure the rear axle lubricant level and add
lubricant, if necessary. Refer tp Lubricant
Level Check.
J 8614-01 9. Inspect for correct operation of the rear axle.
164050
Inspection Before Disassembly

Important: If possible, determine the cause the axle
problem before you d.isassemble the axle.
1. Remove the cover.
2. Drain the oil.
Important: Use this information in the diagnosis of an
axle problem. Information on ring gear backlash (
also helps in setting shim packs for locating and
preloading the differential case'.
3. Inspect the ring gear backlash. Refer to Backlash
Adjustment.
4. Inspect the case for metal chips and shavings.
Determine the source of the chips and shavings,
such as a broken gear or a bearing cage.
Rear Axle Housing Inspection

Before assembly, carefully and thoroughly inspect all
drive unit parts for wear or stress. Replacement of
worn parts eliminates costly drive component
repair after assembly.
• Inspect for nicks or burrs that could prevent the
outer diameter of the pinion seal from sl:laling.
Remove any burrs.
• Inspect the bearing cup bores for nicks or burrs.
Remove any burrs that are found .
.. Inspect the housing for cracks. Replace the
housing if you find any cracks.
• Inspect the housing for foreign material such as
metal chips, dirt, or rust.
(
Differential Inspection Important:
Before ~ssembly, carefully and thoroughly inspect all • Do not reinstall the production bearing shims.
drive unit parts for wear or stress. Replacement of The production bearing shims may break
worn parts eliminates costly drive component ·· · when tapped by a hammer.
repair after assembly. • Service bearing shims are reusable. The
" Inspect the pinion gear shaft for unusual wear. differential bearings must have the original outer
races in place when the bearings are reused.
• lnsp'ect the pinion gear and the side gear teeth for
wear, cracks, scoring, and spalling. 1. Determine the approximate required thickness of
the replacement bearing shims. Measure each
• Inspect the thrust washers for wear.
production bearing shim, each service bearing
• Inspect the fit of the side gears in the spacer, and each bearing shim pack.
differential case.
2. Determine the necessary service bearing shims.
• Inspect the fit of the side gears on the axle shafts. Select a starting point in service bearing shim
• Inspect the differential case for cracks and scoring. thickness. Refer to Service Differential Bearing
• Inspect all parts for wear. Replace parts as Shim Thickness (Standard Spacer) in Rear
necessary. Axle Specifications (General Specifications).
3. Position the following components into the rear
Bearings Inspection axle housing:
• The differential case
Important: Bearings and cups are matched sets.
Replace both bearing and cup when either part • The differential bearing outer races
requires replacement. 4. Slip the correct service bearing spacer between
• Before assembly, carefully and thoroughly inspect each differential bearing race and the rear axle
all drive unit parts for wear or stress. Replacement housing. Place the chamfered edge of the service
of worn parts eliminates costly drive component bearing spacer against the rear axle housing.
repair after assembly. Notice: Install the left side bearing cap loosely so the
• Oil the bearings. Inspect the bearings for smooth differential case may be moved while checking
rotation. adjustments. Another differential bearing cap
bolt/screw can be added in the lower right side
) • Inspect the bearing rollers for wear.
differential bearing cap hole. This will prevent the case
• Inspect the bearing cups for wear, cracks,
from dropping while making shim adjustments.
brinelling, and scoring.
5. Select one or two bearing shims. Refer to Service
Differential Bearing Shim Thickness in Rear Axle
Differential Side Bearing Preload Specifications (General Specifications) for the
Adjustment correct total thickness.
Perform the differential bearing preload adjustment 6. Position the shims between the right side of the
before installing the drive pinion gear. If the drive differential bearing race and the service bearing
pinion gear is installed, remove the ring gear. Refer to spacer.
Rear Axle - Assemble.
Position the left side of the differential bearing
When adjusting the differential bearing preload, race and the bearing spacer against the left side
change the thickness of both the right and the left of the rear axle housing.
bearing shims by an equal a.mount. This will ensure
7. Insert progressively larger feeler gauge sizes
that the original backlash remains constant.
between the right bearing shim and the service
Production bearing shims are cast iron. Production bearing spacer until you notice an increase
bearing shims vary in thickness from in drag.
5.33-6.91 mm (0.210-0.272 in) in increments of
The following measurements are examples of
0.05 mm (0.002 in).
progressively larger feeler gauge sizes.:
Steel service bearing shims are available from
1.02-2.08 mm (0.040-0,082 in) in increments of. • 0.25 mm (0.01 O in)
0.05 mm (0.002 in). • 0.30 mm (0.012 in)
Standard service bearing spacers are 4.32 mm • 0.36 mm (0.014 in)
(0.170 in) thick. 8. Push a feeler gauge downward until the end of
Refer to. Production Differential Bearing Shim the gauge touches the rear axle housing bore.
Thickness (Standard. Spacer) and Service Differential This position will ensure an accurate reading. You
Bearing Sh.im Thickness (Standard Spacer) in have selected the correct feeler gauge thickness
Rear Axle Specifications (General Specifications). at the point just before additional drag begins.
9. In order to ensure an even reading, rotate the
differential case while using the feeler gauge. (
• The weight of the differential case against the
rear axle housing causes the original light
drag. The differential bearing preload causes
the additional drag.
• Start with a thin feeler gauge. This provides a
sense of feel that. is necessary in order to
recognize the beginning of the preload
and obtain zero clearance.
• Work the differential case in, out, and to the
left in order to insert the feeler gauge.
10. Remove the following components from the rear
axle housing:
• The left side differential bearing cap
• The left side bearing shim
11 . With no pre load on. the differential bearings, add
the following measurements in order to obtain the
size of the total shim pack: ·
• The feeler gauge reading measured in Step 7.
• The thickness of the bearing shims that
were installed in Step 6.
12. Select two bearing shims of approximately equal
size. The total thickness of the two shims must be
equal to the value obtained in Step 9 ..
When installing the differential case into the rear
axle housing, install the bearing shims between
• Each differential bearing race
• Each service bearing spacer
Add the additional preload after you install the ·
differential case.
13. When the drive pinion gear is in position, install
the ring gear. Refer to Rear Axle - Assemble.
Backlash Adjustment
Tools Required
J 8001 J 8001 Dial Indicator Set
1. Remove the rear axle housing cover. Refer to
Replacement.
2. Rotate the differential case (1) several times in
order to se.at the bearings.
3. Mount the J 8001.
4. Use a small button on the indicator stem in order
to make contact with the near heel end of
the tooth.
5. Set the J 8001 so that the following conditions
are met:
• The stem is in line with the gear rotation
J 39446 • The stem is perpendicular to the tooth a.hgle
6. Measure the backlash at three or four points
164245
around the ring gear (3). Hold the drive pinion
gear stationary when checking backlash.
Driveline/Axle Rear Drive Axle 4·43
7. The lash must not vary over 0.05 mm (0.002 in)
around the ring gear (3). If the variation is over
0.05 mm (0.002 in), inspect for the following
conditions and correct as necessary:
• Burrs
• Uneven bolting conditions
• A distorted case flange
8. The back.lash at the point of minimum I.ash should
bl:l 0,13-0.23 mm (0.005-0.009 in) for all new
gears. Adjust the backlash as necessary by
increasing the thickness of one bearing shim and
decreasing the thickness of the other bearing
shim by the same amount.
Transfer 0.05 mm (0.002 in) in bearing shim
thickness for each 0.03-mm (0.001-in) change in
backlash desired.
For example, use the following steps in order to
decrease the backlash by 0.03 mm (0.001 in):
8.1. Decrease the thickness of the right bearing
shim by 0.05 mm (0.002 in).
8.2. Increase the thickness of .the left bearing
shim by 0.05 mm (0.002 in). Refer to
Differential Side Bearing Preload
Adjustment for further information.
Gear Tooth Contact Pattern Check

Tools Required
J 39446 ABS Exciter Ring Protector Kit
Notice: It is very important that tooth contact be
tested after the differential is taken apart. Variations in
the differential or differential drive pinion gear inner
bearing may cause the differential drive pinion gear to
be too far away from, or close to, the differential
ring gear. Therefore, the tooth contact pattern must be
tested and corrected, (if necessary) to prevent
gear noise.
1. Clean all of the dirt from the area of the rear axle
housing cover before removing the rear axle
housing cover.
2. Remove the rear axle housing cover., Refer to Rear
Axle Housing Cover and Gasket. Replacement.
3. Wipe the oil out of the rear axle housing.
4. Carefully clean each tooth of the ring gear:
5. Select the correct exciter ring protector from
J39446.
Attach the exciter ring protector to the speed
sensor reluctor wheel on vehicles with non-traction
control rear axles only.
6. Using a medium stiff brush, apply a mixture of
gear marking compound sparingly to all of the
ring gear teeth. The area of tooth contact of the
) differential drive pinion gear should remain visible
4.;.44 Rear Drive Axle DriveIi ne/Axle
Notices.
7. Tighten the differential carrier bearing cap (
bolts/screws.
Tighten
Tighten the differential carrier bearing cap
bolts/screw to 75 N-m (55 lb ft).
8. Apply the park brake until a torque of
54-70 N-m (40-52 lb ft) is required in order to turn
the drive pinion gear.
Important: A test made without loading .the gears will
not give a satisfactory pattern.
9. Use .the following procedure in order to obtain a
ring gear tooth contact pattern:
9.1. Turn the pinion gear yoke with a wrench so
that the ring gear rotates one full revolution.
9.2. Reverse the rotation so that the ring gear
rotates one revolution in the opposite
direction.
10. Inspect the differential ring gear teeth for a tooth
contact pattern (1 ). ·
11. The pattern is acceptable if the area of differential
drive pinion gear contact (1) remains in the center
of the differential ring gear tooth. If the pattern
is not acceptable, proceed to Step 14.
12. If the differential ring gear tooth pattern is
acceptable, remove J 39446.
13. Install the rear axle housing cover. Refer to Rear (
180092
14. Inspect the differential ring gear teeth for a low

1 flank contact pattern (2). -
15. If this contact pattern (2) exists, repair the low
flank contact by decreasing the shim thickness
of the bearing on the differential drive pinion gear.
This moves the smaller diameter of the
contact (2) out toward the center line (1) of the
differential ring gear.
16. Remove J 39446.
180096
18. Inspect the differential ring gear teeth for a heel
contact pattern (1 ).
19. If this contact pattern (1) exists, repair the heel
contact by decreasing the backlash. This moves
the area of differential drive pinion gear contact (1)
toward the toe.
20. Remove J 39446.
180095
22. Inspect the differential ring gear teeth for a high

face contact pattern (2).
23. If this contact pattern (2) exists, repair the high
face contact by increasing the thickness of the
bearing shim of the differential drive pinion gear.
This moves .the area of .differential drive pinion
gear contact (2) out toward the differential
ring gear center line (1 ).
) 24. Remove.J 39446.
180094
26. Inspect the differential ring gear teeth for a toe

contact pattern (1 ).
27. If this contact pattern (1) exists repair the heel
contact by Increasing the backlash. This moves
the area of differential drive pinion gear contact (1)
toward the heel.
28. Remove J 39446.
180093
Rear Axle Replacement Installation Procedure
1. With the aid of a helper, install the rear axle
Removal Procedure housing. (
1. Raise and suitably support the vehicle. Refer to 2. Install the rear axle lower control arms. Refer to
Lifting and Jacking the Vehicle in General Rear Axle Lower Control Arm Replacement in
Information. Rear Suspension.
2. Remove the rear tires and wheels. Refer to Tire 3. Install the rear axle torque arm. Refer to Torque
and Wheel Removal and Installation in Tires and Arm Replacement in Rear Suspension.
Wheels. 4. Connect the electrical connectors to the rear
wheel sensor.
5. Connect the parking brake cables to the rear axle
housing.
6. Install the rear springs. Refer to Coil Spring
4. Remove the rear stabilizer shaft. Refer to Replacement in Rear Suspension.
Stabilizer Shaft Replacement in Rear Suspension. 7. Install the rear brake (center) hose to the rear
5. Use an adjustable lifting device in order to support brake hose junction block;
the rear axle housing. 8. Install the rear axle track bar. Refer to Track Bar
6. Remove the rear shock absorbers. Refer to Shock Replacement in Rear Suspension.
Absorber Replacement in Rear Suspension. 9. Install the rear shock absorbers. Refer to Shock
Absorber Replacement in Rear Suspension.
7. Remove the rear axle track bar. Refer to Track
Bar Replacement in Rear Suspension. 10. Remove the adjustable lifting device from the rear
axle housing.
8. Remove the rear brake (center) hose from the 11. Install the rear stabilizer shaft. Refer to Stabilizer
rear brake hose junction block. Shafi Replacement in Rear Suspension.
9. Remove the rear springs. Refer to Coil Spring 12. Ins.tall the propeller shaft. Refer to Propeller Shaft
Insulators Replacement in Rear Suspension. Replacement - One Piece or Propeller Shaft
10. Disconnect the parking brake cables from the rear Replacement - Two Piece in Propeller Shaft.
axle housing. 13. Bleed the brake system. Refer to·HydraulicBrake
11. Disconnect the electrical connectors from the rear System Bleeding (Manual Bleeding) in Hydraulic (
wheel sensor. Brakes.
14. Install the rear tires and wheels. Refer to Tire and
12. Remove the rear axle torque arm. Refer to Wheel Removal and Installation in Tires and
Torque Arm Replacement in Rear Suspension. Wheels.
13. Remove the rear axle lower control arm. Refer to 15. Refill the rear axle with lubricant. Refer to
Rear Axle Lower Control Arm Replacement in Lubricant Level Check.
Rear Suspension. 16. Lower the vehicle.
14. With the aid of a helper, remove the rear axle 17. Road test the vehicle in order to ensure proper
housing: rear axle operation.
(
Pinion Flange Replacement
Removal Procedure
Tools Required
J 8614-01 Pinion Flange Holder
Lifting and Jacking (he Vehicle in General
Information.
Shaft Replacement - Two Piece.
3. Mark the following components with a punch in a
\
---· -
straight line before disassembly:
• The drive pinion gear flange
/
4. Use J 8614-01 in order to remove the following
components: J 86i4-0i
• The drive pinion gear washer 164050
5. Remove the drive pinion gear flange (1).

6. If the drive pinion gear flange or flange seal is J 8614-2
damaged, replace the component.
164041
Tools Required
• J 8614-01 Pinion Flange Holder
• J 23911 Pinion Oil Seal Installer
1. Install new flange seal (1) with J 23911 into
housing, if removed.
2. Apply chassis lubricant or an equivalent to the
1ollowing components:
• The outside diameter of the drive pinion gear
flange
• The sealing lip of the new drive pinion
gear seal.
) 3. Install the drive pinion gear flange (1 ).
• The drive pinion gear washer
• The drive pinion gear nut (finger tight)
164048
5. Hold the drive pinion gear flange.
6. Use J 8614-01 in order to tighten the drive pinion (
gear nut to the position previously marked.
Tighten
Tighten the nut to 1.59 mm (1/6 inch) beyondthe
alignment mark.
7. Install the propeller shaft. Refer to Propeller Shaft
or
\
--·/ -
Replacement ~ One Piece
Replacement - Two Piece.
Propeller Shaft
9. Road test for any abnormal rear axle operation,

such as whines or howls.
J 8614-01
164050
Pinion and Ring Gear Inspection

Inspect the rear axle before disassembly. This will aid
in determining the type of repairs or adjustments
that are necessary.
The following conditions may cause rear axle noise:
• Improper backlash
• The inner bearing preload of the differential drive (,·
pinion gear
• The outer bearing preload of the differential drive
pinion gear
• The differential side bearing preload
• Any combination of the above items
Measure the following items before removing the
differential case from the housing:
• The backlash
• The total differential preload
• The tooth contact pattern
Record and analyze these measurements before you
remove the differential case from the housing.
Do not allow foreign matter (such as dirt. or sand) near
the rear axle. The presence of foreign matter in the
rear axle may cause rear axle failure.
(
Differential Ring Gear Tooth Nomenclature
The drive side (5) of the differential ring gear tooth
curves outward (convex).
The tooth contact (4) of the differential ring gear is the
center area of the drive side (5) that makes the
most physical contact with the pinion gear. Refer to
Effects Of Increasing Load On Tooth Contact Pattern.
The coast side (3) of the differential ring gear tooth
curves inward (concave).
The toe end (2) of the differential ring gear tooth is the
end that is nearest to the center of the differential
ring gear.
The heel end (1) of the differential ring gear tooth is
the end that is farthest away from the center of
the differential ring gear. The toe end of the tooth is
smaller than the heel end.
164018
Effects Of Increasing Load On Tooth

Contact Pattern
The load on the differential ring and on the drive
pinion gear is increased during vehicle acceleration.
An increased load on the differential ring and on
the drive pinion gear may cause the tooth contact (4)
to spread out. Under a very heavy load, the tooth
) contact may extend from the near toe to the near heel
on the drive side.
Increasingly heavier loads cause the following changes
in tooth contact:
• The entire contact tends to shift toward the heel
.. The entire contact becomes broader with
respect to the tops and the bottoms of the teeth
The following tooth contact pattern test recreates the
effects of a light load. For this reason, the patterns
that will be obtained by the following test will only
extend to about half of their potential expansion.
Important: The contact pattern is centrally located up
and down on the face of the differential· ring
gear teeth.
The following conditions may cause a change in the
tooth contact pattern under a load:
• A drive pinon gear is insufficiently preloaded
• The differential bearings are insufficiently
preloaded
)
Adjustments Affecting Tooth Contact
7 The following two adjustments will affect the tooth (
contact pattern:
• An adjustment to the backlash
" An adjustment to the position of the drive pinion
gear ('7) in the rear axle housing
4 The effects of bearing preloads are. not readily
apparent on hand-loaded tooth contact pattern tests.
Use differential bearing shims (6) in order to adjust the
5 backlash. The shims (6) move.the entire differential (5)
closer to or farther from the drive pinion gear (7) ..
You can also use bearing shims (2) can in order 10 set
both the differential bearing preload and the pinion
depth (1 ).
" Make the following changes in order to increase
the backlash:
6 - Increase the thickness of the right bearings
shim (6)
- Decrease the thickness of the left bearing
375039 shim (3)
" Make the following changes in order to decrease
the backlash: ·
- Decrease the thickness of the right bearings
shim (6)
..c: Increase the thickness of the left bearing
shim (3)
You can adjustthe position of the drive pinion gear (1)
by changing .the thickness of the shims (2) between
the. following components:
., The drive pinion gear head (7)
(
•. The race of the differential drive pinion gear inner
bearing ·
The drive pinion gear shim (2) is used in the rear axle
in order to compensate for manufacturing tolerances.
e Increasing the shim thickness moves the drive
pinion gear (7) closer to the centerline of the
differential ring· gear (4).
• Decreasing shim thickness moves the drive pinion
gear (7) farther away from the centerlin.e of the
differential ring gear (4),
Effects Of Differential Drive Pinion Gear
Position On Tooth Pattern
1 The following tooth contact pattern exists when the
differential drive pinion gearis too far away from
the centerline of the differential ring gear:
• High heel(2) contact on the drive Side (4)
• High toe (i) contact on the coast side (3)
4 3
7560
Decrease the backlash in order to move the differential
drive pinion gear closer to the centerline of the
differential ring gear. This will cause the following
tooth contact pattern:
• High heel (2) contact on the drive side (4) moves
down and toward the toe (1).
• High toe (1) contact on the coast side (3) moves
down and toward the heel (2).
4 3
7566
The following tooth contact pattern exists when the

differential drive pinion gear is too close to the
centerline of the differential ring gear: 1
• Low toe (1) contact on the drive side (4)
• Low heel (2) contact on the coast side (3)
4 3
7579
Increase the backlash in order to move the differential

drive pinion gear further away from the centerline of
the differential ring gear. This will cause the following
tooth contact pattern to exist:
• Low toe contact on the drive side (4) moves up
and toward the heel (2). · ·
• Low heel contact on the coast side (3) moves up
and toward the toe (1 ).
4 3
7566
Rear Axle Description The differential case is one piece. Two differential side
(
bearings support the differential case in the rear
Standard (Open) Rear Axle axle .housing. The differential side bearings are
The solid rear axle found in the Camara and Firebird preloaded by the insertion of differential bearing shims
is a semi-floating hypojd rear axle, which is designed between the following components: ·
for use with the following components: · • The differential side bearings
0 An open driveline (with or without i3. torque arm) • The rear axle housing
• Coil springs . Vary the shim thickness from side to side. This
" One-piece or two-piece propeller shafts positions the differential case for proper backlash.
between the differential ring gear and the differential
The rear axle has a hypoid type differential ring gear.
drive pinion gear.
The centerline of the differential drive pinion gear
is located below the centerline of the hypoid Bolts attach the differential ring gear to the differential
type differential ring gear. The rear axle housing case. The following components have splined bores
encloses all of the components that are necessary for used for driving the axle shaft:
transmitting power from the propeller shaft to the • The left differential pinion gear
rear wheels and tires. Bolts attach the rear axle • The right differential pinion gear
housing cover .to the back of the rear axle housing.
The rear axle housing cover is removable in order to The position of these pinion gears permits the gears
permit service of the differential case without to turn in counterbored cavities of the differential case.
removing the entire axle from the vehicle. The following components have smooth bores:
A universal joint connects the rear end of the propeller • The upper differential pinion gear
shaft to the drive pinion gear yoke. The drive pinion • The lower differential pinion gear
gear yoke has a splined end that fits over the The differential pinion gear shaft holds these pinion
drive pinion gear. The splined end of the drive pinion gears in position. The differential pinion gear shaft
gear yoke also drives the pinion gear. Two preloaded mounts and locks in the differential case. All four of the
tapered drive pinion gear bearings support .the gears mesh with each other.
drive pinion gear in the rear axle housing ..The races
of the following components are press fit into the
The following components turn freely on the pinion (
gear shaft:
rear axle housing: ·
• The upper differential pinion gear
" The inner drive pinion gear bearing press fits onto
the drive pinion gear. • The lower differential pinion gear
.. The outer drive pinion gear bearing combines a These pinion gears act as idler gears when the rear
light press fit to a close sliding fit on the yoke wheels turn at different speeds.
end of the drive pinion gear. The following components back the differential
The races of the inner drive pinion gear bearing and pinion gears:
the outer pinion gear bearing press against shoulders • Differential pinion thrust washers
which are recessed in the rear axle housing. • Differential side gear thrust washers
Tightening the drive pinion gear nut compresses a Vehicles that are equipped with the standard rear axle
collapsible drive pinion gear spacer. This bears against and the Antilock Brake System (ABS) only; have a
the following components: single rear wheel speed sensor mounted on the
" The. outer drive pinion gear bearing differential carrier behind the ring gear. A wheel speed
" A shoulder on the drive pinion gear sensor is bolted to the top of the rear axle housing
opposite the reluctor wheel. This sensor provides
The drive pinion gear spacer performs the following wheel speed information to the electroniGbrake control
actions:
module (EBCM)
" Enables au.tomatic. bearing preload adjustment. Vehicles that are equipped with the limited slip rear
• Maintains a preload on the inner drive pinion gear. axle, ABS, and a Traction Control System (TCS) have
bearing. rear wheel speed sensors mounted on the axle
• Maintains apreload on the outer drive piniongear shafts just behind the axle flange. The axle mounted
bearing. reluctor wheels are an integral part of the rear
Enable the adjustment of the fore-and-aft position of axle shaft and cannot be replaced separately. If the
the drive pinion gear by placing selective drive wheel needs to be replaced, you must replace
pinion gear shims between the following components: the entire axle.
• The head of the drive pinion gear
• The inner drive pinion gear bearing
Operation Rear Axle Identification
When the vehicle turns a corner, the differential allows
the outer rear tire and wheel assembly to turn faster
than the inner tire and wheel assembly.
The inner tire and wheel assembly moves more slowly
than the outer tire and wheel assembly. The inner
tire and wheel assembly slows its (side) differential
pinion gear. The side differential pinion gear is slowed
because the axle shaft is splined to the side gear.
The differential pinion gears roll around the slowed
(side) differential pinion gear. This action causes
the other differential pinion gear and the tire and wheel
assembly to move faster.
2 3
Limited Slip Rear Axle
Limited slip rear axles have several definite operating
characteristics. An understanding of these
characteristics is necessary in order to aid diagnostics.
The rear axle limited slip differential found in Camaro
and Firebird vehicles is the Zexel Torsen® rear 5794
axle. This axle differs from the previous Auburn®
limited slip units. The Torsen® axle does not utilize You must know the rear axle identification code (1)
clutches or cone clutches as in other limited slip units. and the manufacturer's code (2) before adjusting
The Zexel Torsen® axle is a unique design which or repairing the repair axle shafts or the differential.
utilizes parallel axis helical gearing to develop The following information is stamped onto the forward
side gear separating force in an axial direction and side of the right axle tube or on a metal tag on the
planetary gear separating force in a radial direction. housing cover:
) There are not any major servicing differences between • The rear axle ratio
the Torsen® and Auburn® differentials except for a
• The differential type
thrust block is used in the Torsen® differential
for retention of the C-clip as compared to a pin used • The manufacturer's code (2)
in the Auburn® differential. • The build date (3)
All the following rear axle components are RPO codes for the rear axle are also printed on the
interchangeable (except for the differentials): service parts identification label:
• Vehicles with the limited slip rear axle
Maintenance and Lubrication
" Vehicles with the standard rear axle
Refer to Lubricant Level Check for information on
The Zexel Torsen® limited slip differential is measuring or adding lubricant.
non-serviceable. The differential cases of the
2 vehicles are not interchangeable. The following
procedures are the same for both the Torsen® limited Special Tools and Equipment
slip differential case and the standard rear axle Illustration Tool Number/ Description
differential case:
• Removal of the differential
• Replacement of the differential
• Service of the side bearings J 2619-01
• Service of the ring and pinion gear set
• All backlash and tooth contact pattern procedures
~o Slide Hammer With 1/2 X 13
Adapter
982
4;.54 Rear Drive Axle DrivelineJAxle
Illustration Tool Number/ Description' Illustration .Tool Number/ Description
.J 5590 J 21777-40
Rear Pinion Bearing Cone Pinion Setting Gauge-Rear
Installer Pilot Washer
5335
0
J 7817 J 21777-42
Front Pinion Bearing Cup Pinion Setting Gauge-Front
Installer Pilot Washer
12439
J 8001 J 21.777-43
Dial Indicator Set Pinion Setting Gauge-Stud
Assembly Bolt
(
25473 9878
J 8092
J 21777~45
Driver Hcindle Pinion Setting Gauge-Side
· Bearing Discs
7016 9879
@---------.-u J 8614-01
J 22536
([).·~ Pinion Flange Remover and
Installer C
i---~=--0~_0 Pinion Driver
1507 180153
(
J 22813-01 J 23771
Axle Bearing Remover Axle Oil Seal Installer
1508 1510
J 22912-01
J 23911
Rear Pinion Bearing Cone
Remover Pinion Oil Seal Installer
994 1509
J 23597-1 J 25588
) Pinion Setting Gauge Arbor Side Bearing Shim Installer
9880
J 23597-11 J 29609
Pinion Setting Gauge Plate Rear Pinion Bearing Cup
Installer
180157
J 23765 J 39446
Axle Bearing Installer ABS Exciter Ring
Protector Kit
(
BLANK
(
Brakes Table of Contents 5-1
Section 5
Brakes
Hydraulic Brakes ......................... ,., .................. 5-5 Hydraulic Brake System Bleeding
Specifications ..................................................5-5 (When To Bleed) ...................................... 5-47
Fastener Tightening Specifications ................. 5-5 Hydraulic Brake System Flushing ................. 5-47
Brake System Specifications .. ,....................... 5-5 Vacuum Brake Booster Replacement ........... 5-48
GM SPO Group Numbers ., ............................ 5-5 Vacuum Brake Booster Hose
Schematic and Routing Diagrams .................. 5-6 Replacement ...... : .....................................5-50
Hydraulic Brakes Schematic Icons ................. 5-6 Stoplamp Switch Replacement ..................... 5-50
Brake Warning System Schematics ................ 5-7 Stoplamp Switch Adjustment ........................ 5-51
Component Locator ............. ,.......................... 5-8 Description and Operation ............................ 5-52
Hydraulic Brakes Components ., ..................... 5-8 Master Cylinder Description ......................... 5-52
Hydraulic Brakes Component Views ............... 5-9 Bral<e Fluid and Brake. Fluid Handling ..... ,.... 5-53
Hydraulic Brakes Connector End Views ....... 5-11 Vacuum Brake Booster Description .............. 5-53
Diagnostic Information and Procedures ....... 5-11 Brake Warning System Description .............. 5-54
A Diagnostic Starting Point - Brake Warning System Circuit
Hydraulic Brakes ......................................5-11 Description ............................................... 5-54
Hydraulic Brake Diagnostic Special Tools and Equipment ....................... 5-55
System Check ..........................................5-11 Disc. Brakes ....................................................5-56
) Symptoms - Hydraulic Brakes ...................... 5-16 Specifications ................................................ 5-56
Brake Warning Indicator Always On ............. 5-17 Fastener Tightening Specifications ............... 5-56
Brake Warning Indicator Inoperative ............. 5-18 Component Specifications ............................ 5-56
Brake System Testing .................................. 5-20 GM SPO Group Numbers ............................ 5-56
Brake Pedal Travel ...................................... 5-20 Diagnostic Information and Procedures ....... 5-57
Brake Fluid Leak ......................................... 5-20 Brake Rotor Thickness Variation Check ....... 5-57
Master Cylinder Diagnosis ............................ 5-20 Brake Rotor Lateral Runout Check ............... 5-57
Repair Instructions ........................................ 5-22 Brake Rotor Tolerance .................................5-57
Master Cylinder Reservoir Filling .................. 5-22 Repair Instructions ........................................5-58
Master Cylinder Reservoir Replacement ....... 5-23 Brake Pad Inspection ................................... 5-58
Master Cylinder Replacement ....................... 5-24 Brake Pads Replacement (Front) ................. 5-58
Master Cylinder Bench Bleeding .................. 5-25 Brake Pads Replacement (Rear) .................. 5-60
Master Cylinder Fluid Level Sensor Burnishing Pads and Rotors ........................ 5-62
Replacement ............................................ 5-26 Brake Caliper Replacement (Front) .............. 5-63
Brake Pedal Replacement ............................ 5-28 Brake Caliper Replacement (Rear) ............... 5-66
Brake Pedal Bracket Replacement ............... 5-32 Brake Caliper Inspection .............................. 5-69
Brake Pipe Replacement .............................. 5-36 Brake Caliper Overhaul (Front) .................... 5-70
ISO Flares Replacement .............................. 5-36 Brake Caliper Overhaul (Rear) ..................... 5-73
Brake Hose Inspection .......................... :...... 5-38 Brake Caliper Bracket
Brake Hose Replacement - Front .................. 5-39 Replacement (Front) ................................. 5-76
Brake Hose Replacement - Rear Brake Caliper Bracket
(To Brake Caliper) ....................................5-40 Replacement (Rear) .................................. 5-77
Brake Hose Replacement - Rear Brake Rotor Replacement (Front) ................. 5-77
(Without Traction Control) .... ,................... :5-41 Brake Rotor Replacement (Rear) ................. 5-78
Brake Hose Replacement - Rear Refinishing Brake Rotors (Front) .................. 5-79
(With Traction Control) .............................. 5-43 Refinishing Brake Rotors (Rear) ................... 5-80
Hydraulic Brake System Bleeding Description and Operation ............................ 5-82
) (Manual Bleeding) ...... , ............................. 5-44 Disc Brakes System Description (Front) ....... 5-82
Hydraulic Brake System Bleeding Disc Brakes System Description (Rear) ........ 5-82
(Pressure Bleeding) .................................. 5-46 Special Tools and Equipment ....................... 5-83
5-2 Table of Contents Brakes
Park Brake ......................................................5-84 OTC C0055 Rear Wheel Speed Circuit
Malfunction ............................................ .5-154
Specifications ................................................5-84
OTC C0056 Rear Wheel Speed CKT
(
Fastener Tightening Specifications ............... 5-84
GM SPO Group Numbers ............................ 5-84 Range/Performance ............................... .5-157
Repair Instructions ........................................5-85 OTC C0060 LF ABS Solenoid #1 Circuit
Park Brake Shoe Replacement .................... 5-85 Malfunction ............................................ .5-160
Park Brake Shoe Adjustment ....................... 5-86 OTC C0065 LF ABS Solenoid #2 Circuit
Park Brake Lever Replacement .................... 5-86 Malfunction ............................................ .5-161
Park Brake Cable Replacement (Front) ........ 5~88 OTC C0070 RF ABS Solenoid #1
Circuit Malfunction ................................. .5-162
Park Brake Cable Replacement (Rear) ........ 5-90
Brake Drum Inspection ................................. 5-93 OTC C0075 RF ABS Solenoid #2
Circuit Malfunction ..................................5-163
Backing Plate Replacement ......................... 5-94
Park Brake Actuator Replacement ................ 5-94 OTC C0080 LR ABS Solenoid #1
Description and Operation ............................ 5-96
System Description .................................... ,.5-96 OTC C0085 LR ABS Solenoid #2
Special Tools and Equipment ....................... 5-96
OTC C0090 RR ABS Solenoid #1
Anti lock Brake System .................................5-97 Circuit Malfunction ..................................5-166
Specifications ................................................5-97 OTC C0095 RR ABS Solenoid #2
Fastener Tightening Specifications ............... 5-97 Circuit Malfunction ..................................5-167
ABS Diagnostic Specifications ...................... 5-97 OTC C0100 Rear ABS Solenoid. #1
GM SPO Group Numbers ................... :........ 5-97 Circuit Malfunction ..................................5-168
Schematic and Routing Diagrams ................ 5-97 OTC C0105 Rear ABS Solenoid #2
ABS Schematic Icons ..................................5-97 Circuit Malfunction ..................................5-169
ABS Schematics ..........................................5-98 OTC C0110 Pump Motor Circuit
Component Locator .....................................5-110 Malfunction .............................................5-170
ABS Components .......................................5-110 OTC C0121 Valve Relay Circuit
ABS Component Views .............................. 5-114 Malfunction .............................................5-173
ABS Connector End Views ........................ 5-122 OTC C0161 ABS/TCS Brake Switch (
Diagnostic Information and Procedures ..... 5-125 Circuit Malfunction ..................................5-175
A Diagnostic Starting Point ........................ 5-125 OTC C0166 TCS Priming Line Valve
Scan Tool Diagnostics ............................... 5-125 CKT Malfunction .....................................5-178
Scan Tool Data List ...................................5-125 OTC C0171 TCS Pilot Valve Circuit
Scan Tool Data Definitions ......................... 5-126 Malfunction .............................................5-179
Diagnostic Trouble Code (OTC) OTC C0181 Throttle Reduction Motor
List/Type .................................................5-127 CKT Malfunction ..................................... 5-180
Self-Diagnostics .........................................5-128 OTC C0182 Throttle Reduction Motor
Initialization Sequence ................................ 5-128 CKT Range Perf ..................................... 5-183
Enhanced Diagnostics ................................5-128 OTC C0236 TCS RPM Signal Circuit
Electromagnetic Interference ...................... 5-128 Malfunction ............................................. 5-185
A Diagnostic System Check - ABS ............. 5-129 OTC C0237 TCS Throttle Position
OTC C0035 LF Wheel Speed Circuit Signal Malfunction .................................. 5-188
Malfunction .............................................5-130 OTC C0238 TCS TP Sensor
OTC C0036 LF Wheel Speed Circuit Comparison Malfunction .......................... 5-190
Range/Performance ................................ 5-133 OTC C0239 TCS Spark Retard
OTC C0040 RF Wheel Speed Circuit Monitoring Malfunction ............................ 5-192
Malfunction .............................................5-136
OTC C0240 PCM Traction Control
OTC C0041 RF Wheel Speed Circuit
Not Allowed ............................................5-194
Range/Performance ................................5-139
OTC C0241 PCM Indicated Requested
OTC C0045 LR Wheel Speed Circuit
Torque Malf ............................................ 5-196
Malfunction .............................................5-142
OTC C0046 LR Wheel Speed Circuit OTC C0244 PWM Delivered Torque
Range/Performance ................................ 5-145 Malfunction .................... : ........................ 5-199
OTC C0050 RR Wheel Speed Circuit OTC C0245 Wheel Speed Sensor
Malfunction ............................................. 5-148 Frequency Error ...................................... 5-202
OTC C0051 RR Wheel Speed Circuit OTC C0266 ADS Controller Malfunction ..... 5-205 (
Range/Performance ................................5-151 OTC C0550 ECU Malfunction ..................... 5-208
Brakes Table of Contents 5-3
OTC C0896 Device Voltage Range/ Wheel Speed Sensor Replacement
Performance ........................................... 5-209 (With Traction Control) ............................ 5-242
OTC C0901 Device #2 Voltage Low ........... 5-211 Wheel Speed Sensor Jumper Harness
Symptoms .................................................. 5-212 Replacement (Front Right) ...................... 5-243
Traction Control System Off Indicator Wheel Speed Sensor Jumper Harness
Always On .............................................. 5-213 Replacement (Front Left) ........................ 5-244
Traction Control System Off Indicator Wheel Speed Sensor Jumper Harness
Inoperative .............................................. 5-215 Replacement
Acceleration Slip Regulation Indicator (Rear with out Traction Control) .............. 5-244
Always On .............................................. 5-218 Wheel Speed Sensor Jumper Harness
Acceleration Slip Regulation Indicator Replacement
Inoperative .............................................. 5-220 (Rear with Traction Control) .................... 5-245
No Communication with EBCM .................. 5-223 Wheel Speed Sensor Ring
ABS Indicator Always On ........................... 5-225 Replacement
ABS Indicator Inoperative ........................... 5-227 (With out Traction Control) ...................... 5-246
Low Traction Indicator Always On .............. 5-229 Wheel Speed Sensor Ring
Low Traction Indicator Inoperative .............. 5-231 Replacement (With Traction Control) ....... 5-246
Repair Instructions ...................................... 5-233 Traction Control Switch Replacement
Electronic Brake Control (Pontiac) ................................................. 5-246
Module (EBCM) Replacement ................. 5-233 Traction Control Switch Replacement
Accelerator and Servo Control (Chevrolet) ..............................................5-247
Module (ASM) Replacement .................... 5-236 Description and Operation .......................... 5-248
Brake Pressure Modulator Service Precautions ...................................5-248
Valve (BPMV) Replacement .................... 5-237 General System Description ....................... 5-249
Adjuster Assembly Replacement ................ 5-239
Abbreviations and Definitions ..................... 5-249
Cable Adjustment Procedure ...................... 5-241
Basic Knowledge Required ......................... 5-249
Wheel Speed Sensor
Replacement (Front) ............................... 5-241 ABS Description ......................................... 5-249
Wheel Speed Sensor Replacement ABS Operation ........................................... 5-251
(With out Traction al Control) ................... 5-242 Special Tools and Equipment ..................... 5-255
)
5-4 Table of Contents Brakes
BLANK
\.
Brakes Hydraulic Brakes 5-5
Hydraulic Brakes
Specifications
Specification
Brake Caliper Bleed Screw 12 N·m 1061bin
Brake Pedal Bracket Bolt 25N·m 18 lb ft
Brake Pedal Nuts 20 N-m 15 lb ft
Brake Pedal Pivot Nut 54N·m 40 lb ft
Brake Pipe Tube Nut 16 N·m 12 lb ft
Clutch Master Cylinder Nut 27 N·m 20 lb ft
Combination Valve Pipe Fitting 32 N·m 24 lb ft
Front Brake Hose Clip Bolt 13 N·m 115 lb in
Front Brake Hose Fitting 40N·m 30 lb ft
Brake Master Cylinder Nut 29N·m 21 lb ft
Master Cylinder Tube Nut 32N·m 24 lb ft
Negative Battery Cable 15 N·m 11 lb ft
Rear Brake (Center) Hose Fitting Bolt 21 N-m 15 lb ft
Rear Brake Front Pipe to Rear Brake (Center) Hose 15 N·m 11 lb ft
Rear Brake Hose Fitting 45 N-m 33 lb ft
Rear Brake Pipe to Rear Brake (Center) Hose 24 N·m 18 lb ft
) Rear Brake Pipe to Rear Brake Hose 15 N·m 11 lb ft
Brake System Specifications

Specification
Brake Pedal Travel (see note) 51-89 mm I 2.0-3.5 in
Brake Pipe Clearance (Minimum)
Moving Components 19 mm I 0.75 in
Vibrating Components 13 mm I 0.50 in
Hydraulic Brake (Glycol) Fluid GM P/N 1052535 or equivalent DOT-3 fluid
Important: Brake pedal travel maximum with 445 N (100 lb) of force applied to the pedal with the engine running at idle.

Brake Hose 4.000
Brake Pedal 4.000
Brake Pedal Bracket 4.000
Brake Pipe 4.000
Master Cylinder 4.000
Mas1er Cylinder Fluid Level Sensor 4.000
Master Cylinder Reservoir 4.000
Stoplamp Switch 4.000
Vacuum Brake Booster 4.000
) Vacuum Brake Booster Check Valve 4.000
Vacuum Brake Booster Hose 4.000
5-6 Hydraulic Brakes Brakes
(
Hydraulic Brakes Schematic Icons
Refer to ESD Notice in Caution and Notices.
19384
(
'---._____/
~ ~
~rake Warning System Schematics (Brake Fluid level Sensor, Instrument Cluster and Park Brake Swiitch) m
""'
£1)
IHot ln~FIUN, Bulb Test AndSTAFIT I

'" - -
I G3
- - - - - - - - .,IP
GAUGES I Fuse
lL 0 c l rJ"
ti)
I Fuses I Bl ck ~
I H3 10A H4 I O
L:hl
L. - - --- - - - - - - .I Power
0.5 PNK 39 Distribution
8206 -------. Schematics
In Wiring
0.35 PNK 39 Systems
A3
r-------------- - ., Instrument
Gauges,
Indicator
---~~D-~~~~~~~~~-e
Solid State
# Brake
I cluster
1-------,
:
I~
I
. ~ ~
}.
L--------------~-..1
Manual
Transmission
only
Release
Systems.
I1--~::-"".....;.."'-'.....;..;.;..;._~-..,_.---------------------
Schematics .....
0.35 TAN/WHT
A5
0.35 TAN/WHTl 33
8228
ln Body 33 0.35TAN/WHT133
Rear End 0.5 TAN/WHT I 33
82 C200D
C200B
Domestic
And Gulf States
DIC2
IJapanAnd Europe!
f[ZJP100
0.35 TAN/W~T 33
Brake
Fluid
Daytime~
Running I·
Lights
--;r--.,
Park
Brake
.
· _1
I
0.5 TANJWHT I 33
Level
Indicator
Br Sensor
(DRL) ~ Input _ _ _ .aI . 0.3~~;: 1~0- ________
1
Module - - EIC2
~- 1 ::c
~ 0.5 LT BLU 1134
Ground
Distribution
'<
c.
3 BLKI 150 Schematics
In Wiring
""'c:
£1)
~ 5·
T -
AI Park Brake
m
iiJ
;~~~t1~0- - - - - - - _1.i BLKI 150
Switch · @"
{Closed with ti)
~ park brake set)
G106
(Tl
502368 -!.!
Component locator
(
Hydraulic Brakes Components
Brake Fluid Level Hydraulic Brakes
Part of the master cylinder -
Indicator Sensor Connector End Views
Data Link
Communications Lighting Systems
Daytime Running Mounted behind the radio and the HVAC
Component Views Connector End Views
Lamps (DRL) Module control, left of the IP compartment
in Data Link in Lighting Systems
Communications
Instrument Panel, Instrument Panel,
Gauges, and Console Gauges, and Console
Instrument Cluster On the left side of the IP Component Views in Connector End Views in
Instrument Panel, Instrument Panel, .
Gauges and Console Gauges and Console
Instrument Panel,
Gauges, and Console
IP Fuse Block On the left end of the IP ca.rrier Component Views in -
Instrument Panel,
Gauges and Consol.e
Below the center console, at the base of Hydraulic Brakes
Park Brake Switch -
the park brake lever Component Views
C200B (18 cavities)

Forward lamp to IP harness, between the Harness Routing Views
lnline Harness
Connector End Views
.
left kick panel and the steering column in Wiring Systems
in Wiring Systems ·
lnline Harness
C200D (48 cavities)
Part of the IP harness, between the left Harness Routing Views
Connector End Views (
kick panel and the steering column in Wiring Systems
in Wiring Systems
Attached to the top left side of the radiator Harness Routing Views
G106 -
support in Wiring Systems
Left side in the dash panel, engine to the Harness Routing Views
P100
passenger compartment in Wiring Systems
-
In the forward lamp harness approximately
7 cm (2.8 in) from the electronic throttle
8113
control (ETC) module/cruise control
- -
module breakout
approximately 27 cm (10.6 in) from the
8155
electronic throttle control (ETC)
- -·
module/cruise control module breakout
In the IP harness, at the rear compartment
8206
lid release relay breakout
- -

8228 approximately 20 cm (7.9 in) from the rear - -
compartment lid release relay breakout
Hydraulic Brakes ComponentViews
) Under Center Console (Manual Transmission)
374372
Legend
(1) Park Brake Switch (4) Ash Tray Lamp
(2) Park Brake Lever
(3) Inflatable Restraint Sensing and Diagnostic
Module (SOM)
)
5-1 O Hydraulic Brakes Brakes
Under Center Console (Automatic Transmission)
(
1 2
5 4 3
374369
Legend
(1) Park Brake Switch (4) IP Wiring Harness
(2) Park Brake Lever (5) PRNDL Lamp
(3) Inflatable Restraint Sensing and Diagnostic
Module (SDM)
Hydraulic Brakes Connector End Views Diagnostic Information and
Procedures
Brake Fluid Level Indicator Sensor
A Diagnostic Starting Point - Hydraulic
Brakes
Begin the system diagnosis by reviewing the system
Description and Operation. Reviewing the Description
and Operation information will help you determine
the correct symptom diagnostic procedure when
~
a malfunction exists. Reviewing the Description and
Operation information will also help you determine
if the condition described by the customer is normal
operation. Refer to Symptoms - Hydraulic Brakes
in order to identify the correct procedure for diagnosing
62471 the system and where the procedure is located.
• 1216-2195
Connector Part
Information • 2 Way F Metri-Pack
150 Series Pull to Seat (BLK)
Circuit
Brake Warning Indicator
A TAN/WHT 33
Sensor Output
B BLK 150 Ground
Hydraulic Brake Diagnostic System Check

Symptom Causes
Improper Brake Pedal Travel • Leaking brake line or connection. Refer to Hydraulic
Brakes.
• Leaking piston seal. Refer to Disc Brakes.
• Leaking master cylinder (internal). Replace master
cylinder.
• Air in brake system. Refer to Hydraulic Brake System
Bleeding (Manual Bleeding) or Hydraulic Brake System
Bleeding (Pressure Bleeding).
• Contaminated or improper brake fluid. Refer to Brake
Fluid and Brake Fluid Handling.
• Leaking vacuum or booster system. Refer to Hydraulic
Brakes.
• Damaged vacuum booster. Refer to Vacuum Brake
Booster Replacement.
• Uneven brake lining wear. Refer to Disc Brakes.
• Brake lining damage by abuse. Refer to Disc Brakes.
• Improper thickness variation in rotor. Refer to Brake
Rotor Thickness Variation Check.
• Excessive lateral runout in rotor. Refer to Brake Rotor
Lateral Runout Check.
• Brake assembly attachments loose (including splash
shield).
• Improperly adjusted stoplamp switch or cruise control
vacuum dump. Refer to Stop/amp Switch Adjustment.
• Incorrect vacuum booster pushrod length.
• Low brake fluid. Refer to Master Cylinder Reservoir
Filling.
• Improper rear brake adjustment.
• Low engine vacuum.
)
Hydraulic Brake Diagnostic System Check (cont'd)
Symptom Causes (
Brake Pedal Travel Gradually Increases • Leaking brake line or connection. Refer to Brake
Fluid Leak.
• Leaking piston seal. Refer to Brake Caliper Overhaul
(Front) or Brake Caliper Overhaul (Rear).
cylinder.
• Restricted passage in the vacuum booster.
• Restricted brake fluid passage.
Excessive Brake Pedal Effort • Leaking vacuum or booster system.
• Worn out brake lining.
• Glazed brake lining.
• Incorrect brake lining material.
• Contaminated brake lining.
• Brake lining damage by abuse.
• Improper rotor surface finish.
• Brake pedal linkage interference or binding.
• Operator riding the brake pedal.
• Excessive vehicle loading.
~ Rotor corroded.
Excessive Braking Action • Damaged vacuum booster. Refer to Vacuum Brake

• Unevenbrake lining wear.
(
• Scored rotor. Refer to Refinishing Brake Rotors (Front).
shield).
Brakes Slow To Respond • Air in the brake system. Refer to Hydraulic Brake
System Bleeding (Manual Bleeding) or Hydraulic Brake
System Bleeding (Pressure Bleeding).
• Leaking vacuum or booster system.
O Glazed brake lining.

• Sticking caliper or caliper pistons. Refer to Brake Caliper
Overhaul (Front) or Brake Caliper Overhaul (Rear).
Brakes Slow To Release • Contaminated or improper brake fluid. Refer to Brake
• Parking brake not releasing.
• Caliper to knuckle clearance.
Brakes Hydraulic' Brakes 5-13
) Symptom Causes
Brakes Drag • Contaminated or imprope'r brake fluid. Refer to Brake '
shield).
• Brake pedal linkage interference or binding. · ·
• Loose front suspension parts.
• Operator riding the brake pedal.
• Parking brake cables seized.
Uneven Braking Action (Side to Side) • Contaminated or improper brake fluid. Refer to Brake
• Uneven brake lining wear.
) • Improper rotor surface finish.
• Scored rotor. Refer to Refinishing Brake Rotors (Front)
or Refinishing Brake Rotors (Rear).
shield).
• Incorrect front wheel alignment.
• Incorrect tire pressure.
• Rotor corroded.
)
Symptom Causes
Uneven Braking Action (Front to.Rear) • Leaking brake line or connection. Refer to Brake
Fluid Leak.
cylinder.
• Brake assembly attachments. loose (including splash
shield).
Filling.
• Excessive Vehicle Loading.
Scraping Noise from Brakes • Worn out brake lining. (
shield).
• Rotor corroded.
Brakes Squeak without Application • Worn out brake lining.
• Scored Rotor. Refer to Refinishing Brake Rotors (Front)
Brakes Squeak During Application O Worn out brake lining.
shield).
Symptom Causes
Brakes Chatter (Roughness) • Scored rotor. Refer to Refinishing Brake Rotors (Front)
shield).
• Out-of-balance wheel assembly.
• Improperly torqued wheel nuts.
• Rotor corroded.
• Grease or dirt on the rotor.
Brakes Groan at the End of Stop • Incorrect lining material.
• Grease or dirt on the rotor.
Brake Warning Lamp ON ' • Leaking brake line or connection. Refer to Brake
Fluid Leak.
cylinder. Refer to Master Cylinder Replacement.
) • Parking brake switch circuit grounded.
Filling.
Premature Lining Wear • Leaking brake line or connection. Refer to Brake
Fluid Leak.
• Incorrect lining material.
• Brake lining damaged by abuse.
• Operator riding brake pedal.
''
O Improper rear brake adjustment.

• Parking brake cable seized.
Parking Brake Won't Hold • Worn out brake lining.
• Brake lining damaged by abuse.
Parking Brake Won't Release • Sticking caliper or caliper pistons. Refer to Brake Caliper
) Overhaul (Front) or Brake Caliper Overhaul (Rear).
Symptom Causes
Brake Pulsation • Incorrect lining material.
• Brake linings damaged by abuse.
• S.cored rotor. Refer to Refinishing Brake Rotors (Front)
• Out-of-balance wheel assembly.
• Improperly torqued wheel nuts.
• Rotor corroded.
Brake Pulls • Worn out brake lining.
• Brake linings damaged by abuse.
• Incorrect front wheel alignment.
• Incorrect tire pressure.
• Rotor corroded.
(
Symptoms - Hydraulic Brakes Intermittent
Important: Revjew the system description in order to Faulty electrical connections or wiring may be the
familiarize yourself with the system functions. Refer cause of intermittent conditions. Refer to Testing for
to one of the following descriptions: Intermittent and Poor Connections in Wiring Systems.
• Master Cylinder Description Symptom List
• Vacuum Brake Booster Description Refer to a symptom diagnostic procedure from the
• Brake Warning System Description following list in order to diagnose the symptom:
Visual/Physical Inspection • Brake Warning Indicator Always On
• Inspect for aftermarket devices which could affect • Brake Warning Indicator Inoperative
the operation of the Brake Warning System. Refer
• Brake System Testing
to one of the following descriptions: Checking
Aftermarket Accessories in Wiring Systems. • 'Brake Pedal Travel
• Inspect the easily accessible or visible system • Brake Fluid Leak
components for obvious damage or conditions
which could cause the symptom.
Brake Warning Indicator Always On
Important:
• Check for ABS diagnostic trouble codes prior to performing this diagnosis. Refer to A Diagnostic System Check - ABS.
• .Check the brake fluid level prior to performing this diagnosis. Refer to Master Cylinder Reservoir Filling.
Did you review the systern operation and perform the Go to Symptoms
1 necessary inspections? - - Hydraulic
Go to Step2 Brakes
Turn the ignition to the RUN position. Go to Testing for
Does the brake warning indicator illuminate during the bulb Intermittent and
2 test and then turn off? - Poor Connections
in Wiring
Systems Go to $tep 3
1. Disconnect the brake fluid level indicator sensor.
Is the brake warning indicator still on? Go to Step 4 Goto Step 9
1. Disconnect the park brake switch.
Is the brake warning indicator still on? Go to Step 5 Go to Step 10
Determine if this vehicle is either of the following types:
O Domestic
5 -
• Gulf States
Is the vehicle one of the above types? Go to Step 6 Go to Step 7
1. Disconnect the daytime running lights (DRL) module.
) Is the brake warning indicator on? Go to Step 7 Go to Step 11
Test for and repair a short to ground in circuit 33. Refer to
7 Circuit Testing and Wiring Repairs in Wiring Systems. -
Did you find and repair a short? Go to Step 13 Go to Step 8
Replace the instrument cluster. Refer to IP Cluster
8 Replacement in Instrument Panel, Gauges, and Console. - -
Replace the brake fluid level indicator sensor.
9
Did you complete the replacement?
- Go to Step 13
-
Replace the park brake switch.

10
-
Go to Step 13
-
Test for and repair a short to ground in circuit.1134. Refer
11 to Circuit. Testing and Wiring Repairs in Wiring Systems. -
Did you find and repair a short? Go toStep 13 Go to Step 12
Replace. the DRL module. Refer to. Daytime Running
12 Lights (DRL) Control Module Replacement in Lighting. - -
·.
Operate the system in order .to verify the repair.
13 -
)
Brake Warning Indicator Inoperative
Step Action Value(s) Yes No;
Did you review the system operation and perform the Go to Symptoms
1 necessary inspections? - - Hydraulic
Go to Step.2 Brakes
1. Turn the ignition to the RUN position. Go to Testing for
2. Set the park brake. Intermittent and
2 - Poor Connections
Does the brake warning indicator illuminate? in Wiring
Systems . Go to Step 3
Did the brake warning indicator illuminate for the bulb test
3
and then turn off?
i. Disconnect the brake fluid level indicator sensor.
2. Connect a 1OA fused jumper from the brake fluid
level indicator sensor connector terminal A to
4 terminal B. Refer to Circuit Testing in Wiring Systems. -
Is the brake warning indicator on? Go to Step 5 Go to Step 7
Test for and repair a poor connection at the brake fluid
level indicator sensor. Refer to Testing for Intermittent and
5 Poor Connections and Connector Repairs in Wiring -
Systems.
Replace the brake fluid level indicator sensor. Refer to
6 Master Cylinder Fluid Level Sensor Replacement. - -
1. Connect a 1OA fused jumper from the brake fluid
level indicator sensor terminal A to ground. Refer to
(
7 Circuit Testing in Wiring Systems. -
Is the brake warning indicator on? Go to Steps Go to Step 9
..
Repair the open in circuit 150 between the brake fluid level
indicator sensor terminal B and 8155. Refer to Wiring
Repair the open or poor connection in circuit 33 between
the brake fluid level indicator sensor terminal A and 8228.
9 Refer to Wiring Repairs or Connector Repairs in Wiring - -
Systems.
Did you complete the repair? Go to Step23
Replace the instrument cluster. Refer to IP Cluster
10 Replacement in Instrument Panel, Gauges, and Console. - -
Did you complete the replacement? Go to Step23
1. Disconnect the park brake switch connector.
2. Connect a 1OA fused jumper from the park brake
switch connector to ground. Refer to Circuit Testing in
11 Wiring Systems. - ., ..

Test for and repair a poor connection at the park brake
switch. Refer to Testing for Intermittent and Poor
Brake Warning Indicator Inoperative (cont'd)
Test and repair a poor connection at the park brake switch
grbund. Refer.to Testing for Intermittent and Poor
13 'Connections and Connector Repairs .in Wiring Systems. -
Did you find and repair a poor connection.? Go to Step 23 Go to Step 14
Replace the park brake switch.
14 -
Go to Step23
-
Determine if this vehicle is either otthe following types:
• Domestic
15 -
• Gulf States
Is the veh.icle one of the above types? Go to Step 16 Go to Step 19
1. Leave the 1OA fused jumper connected between the
park brake switch connector and ground.
2. Disconnect the daytime running lights (DRL) module
I
connector C2.
16 3. Connect a.fused jumper between the DRL module -
connector C2 terminal D and terminal E. Refer to
Circuit Testing in Wiring Systems.
1. Connect a 1OA fused jumpeUrom the DRL module
connector C2 terminal D to the ground. Refer to
17 Circuit Testing in Wiring Systems'. -
2. Turn the ignition switch to the HUN position.
) 3; rs the brake warning·indicatoron? Go to Step 18 Go to Step 19

Repair the open in circuit 1134 between ihe DRL module
connector C2 terminal E and the park brake switch. Refer
18 to Wiring Repairs in Wiring Systems. - -
Test for and repair a poor co.nnection at the instrument
cluster connector terminal A5. Refer to Testing for
19 Intermittent and Poor Connections and Connector Repairs -
in Wiring Systems.
Repair the open in circuit 33 between the instrument
cluster connector terminal A5 and the DRL module
20 .· connector C2 terminal D (Domestic or Gulf States) or the - -
park brake switch .(Europe orJapan). Refer to Wiring
Repairs in Wiring Systems.
Test for and repair a poor connection at the DRL module
connector C2 terminal D and terminal. E. Refer to Testing
21 for Intermittent and Poor Connections and Connector -
Did you find and repair a poor conn.ection? Go to Step 23 Go to Step 22
Replace the DRL module. Refer to Daytime Running
22 Lights (ORL) Control Module Replacement in Lighting. - -
Did you. complete .the replacement? Go to Step 23
Operate the system in orderto verify the repair.
23 -
)
Brake System Testing Brake Fluid Leak
Test the brakes on a roadway that meets all of the 1. Run the engine at idle.
following conditions: 2. Put the range selector lever in NEUTRAL.
.. Dry 3. Depress the brake pedal. Hold the brake pedal
.. Clean with constant foot pressure.
.. Reasonably smooth 4. If the pedal gradually falls away with constant
" Level pressure, the brake hydraulic system may be
Test the brakes at different vehicle speeds with both leaking. Inspect the hydraulic system for
light and heavy brake pedal force. any suspected leaks.
Do not test the brakes on a roadway with the following 5. Inspect the master cylinder fluid level.
conditions because the tires will not grip the road • A slight drop in the master cylinder resewoir
equally: level results from normal pad wear. The
• Wet reservoir may be as low as 25.4 mm (1.0 in)
., Greasy from the top if the pads are worn. This
condition is not abnormal.
.. Covered with loose dirt
• An abnormally low level in the reservoir
Do not test the brakes on a crowned roadway because indicates a leak in the system. The brake
the weight of the vehicle will be thrown toward the hydraulic system may be leaking either
wheels on one side. internally or externally. Refer toHydrau/ic Brake.
Do not test the brakes on a rough roadway because Diagnostic System Check. The system may
the wheels will tend to bounce. appear to pass this test but still h~ve a slight
leakage.
Brake Pedal Travel
6. Inspect the brake pipe and the brake hose
Tools Required connections for brake fluid Jeaks.
J 28662 Brake Pedal Effort Gauge 7. If any leaks are found, replace the hose or the pipe.
One of the following conditions may be the cause of 8: If any hoses or pipes are replaced, inspect the
most low brake pedal problems: connecting brake component for damage. If
.. Air in the brake system. Bleed the system until the damage is found, rebuild or replace the (
air is purged. Refer to Hydraulic Brake System component.
Bleeding (Manual Bleeding) or Hydraulic 9. Inspect the brake caliper boots and rear wheel
Brake System Bleeding (Pressure Bleeding). cylinder boots for leaks.
" Misadjusted rear drum brakes. Inspect the rear 10. If any leaks are found, rebuild or replace the part
brake adjustment. in question. Refer to Disc Brakes.
The following conditions may be other less frequent
causes of excessive brake pedal travel: Brake Hose and Pipe Inspection ·
• Incorrect pushrod length Notice: Do not allow components to hang from the
• Malfunctioning rear brake shoe adjusters flexible brake hoses as damage to the hoses
" Excessively worn pads may occur. Some brake hoses have protective rings
or covers to prevent direct contact ofthe hose
" Brake hydraulic system leakage
with other chassis parts. Besides causing possible
One of the following conditions is usually the cause of structural damage to the hose, excessive tension could
high brake pedal effort problems: cause the hose rings to move out of their proper
.. Low engine vacuum locations .
.. Vacuum leak Inspect the brake hoses at least twice a year for the
" Improperly functioning vacuum booster following conditions:
1. Install the J 28662 onto the brake pedal. • Road hazard damage
2. Hook the end of the tape measure over the top • Cracks
edge of the pedal. • Chafing of the outer cover
3. Measure the distance from the top edge of the • Leaks
pedal to the rim of the steering wheel. • Blisters
4. Block the tires and the wheels. Use a light and a mirror for an adequate inspection.
5. Run the engine at idle. Replace any hoses with any of the above conqitions.
6. Put the range selector lever in NEUTRAL.
7. Apply 445 N (100 lb) of force to the brake pedal.
8. Remeasure the distance from the top edge of
the pedal to the rim of the steering wheel. The
difference between both of the readings is
the actual brake pedal travel. The brake pedal
travel should be between 51-89 mm (2.0-3.5 in).
\ Master Cylinder Diagnosis High Pressure Check
) Notice: Avoid spilling brake fluid on any of the painted This procedure tests 'tor the following conditions:
vehicle's surfaces, wiring, cables or electrical 0 Leaks at the following locations:
connectors. Brake fluid will damage paint and electrical - Connections

connections. If any fluid is spilled on the vehicle,
- Hoses
immediately flush the area with water to minimize
potential for damage. - Casting
" Large Internal Leaks
Visual Inspection
1. With the engine running, apply the brake pedal
• Check for a cracked casting or brake fluid leaks
slowly (approximately 3 mm {1/8 in} per second).
around the master cylinder. A leak will have at
This generates pressure in the master cylinder.
least one drop of fluid. A damp condition is normal.
2. Gradually increase pedal force. Observe for
• Check the pedal linkage for .binding and for
gradually increasing brake pedal travel
incorrect pushrod length. Disassemble the master
(Falling Away).
cylinder if you do not find improper brake pedal
travel or brake pedal binding. 3. Check for evidence of external fluid leaks.
Examine the. follqwing items:
• Check the master cylinder for swollen or elongated
primary piston seals. If you find swollen seals, • The ground
refer to Brake Fluid and Brake Fluid Handling. • The pipe connections
Low Pressure Check • The tires
This procedure inspects the following conditions: 4. If you observe fluid around any component, that
component has failed and needs to be replaced.
• Internal seal damage
5. If you find a leak at a connection, tighten
• Porosity the connection to specification, Refer to Fastener
• Component bore integrity Tightening Specifications.
1. With the ignition switch in the OFF position, pump 6. Perform the High Presssure Check again.
the brake pedal in order to relieve the vacuum.
) • Pump the brake pedal five times tor.
vacuum-assisted brakes.
• Pump the brake pedal twenty-five ti.mes for
hydraulic-assisted brakes.
2. Apply the brake pedal slowly (approximately
3 mm {1/8 in} per second). This generates
pressure in the master cylinder.
3. Gradually increase pedal force. Observe for
gradually increasing brake pedal travel
(Falling Away).
4. If !he brake pedal travel tends to gradually
increase, preform the High Pressure Check.
5. If the High Pressure Check does not locate a
leak, then the master cylinder has an internal leak.
)
Repair Instructions
(
Master Cylinder Reservoir Filling
Filling The Master Cylinder Reservoir
Caution: Use only SUPREME 11 or equivalent
DOT 3 brake fluid from a clean, sealed. container.
Do not use fluid from an open container that
may be contaminated with water. Improper or
contaminated fluid will result in damage to
components or loss of braking, with possible
2 personal injury.
Ensure that the master cylinder reservoir (2) is kept
properly filled. An adequate reserve of brake fluid will
prevent air from entering the brake hydraulic system.
However, because heat absorbed from the brakes and
the engine expands the brake fluid, do not overfill
the reservoir.
A drop in the brake fluid level is normal as the pads
wear. If the master cylinder reservoir is filled before
new pads are installed, brake fluid may spill over once
182425 the new pads are in place. Unless there is a leak in
the brake hydraulic system, or the brake hydraulic
system has been serviced, do not top off the master
cylinder reservoir.
Clean the master cylinder reservoir cap thoroughly
before removal in order to avoid contaminating
the reservoir. Remove the reservoir cap and the
reservoir diaphragm. (
Add brake fluid to the reservoir in order to bring the
fluid level to the fill line. The fill line is located on
the side of the reservoir.
Brakes Hydraulic Brakes 5~23
Master Cylinder Reservoir Replacement
) Removal Procedure
1. Remove the master cylinder (5). Refer to Master
Cylinder Replacement.
Notice: Do not overtighten vise, or damage to the
master cylinder will result. 3
2. Clamp the flange on the master cylinder body in
a vise.
3. Drive out the master cylinder reservoir pins (6).
Use a 1/8-inch punch.
4. Remove the master cylinder reservoir (3) by
pulling the reservoir straight up and away from
the cylinder body. 7
5. Remove the master cylinder reservoir
grommets (4 and 7) from the grooves in the 4
reservoir. Discard the grommets.
6. Inspect the reservoir for cracks or deformation.
Replace the reservoir if necessary.
7. Use clean denatured alcohol to clean the
reservoir.
8. Use non-lubricated compressed air to dry the
reservoir.
6 5
) 182445
1. Use clean brake fluid to lubricate the new
grommets (4 and 7) and the grooves in the
reservoir.
2. Insert the grommets into the grooves in the
reservoir. Verify that the grommets are properly
seated. 3
3. Connect the reservoir (3) to the master cylinder
body (5). Use your hand in order to press the
reservoir straight down into the cylinder body.
4. Drive in the master cylinder reservoir pins (6) in
order to retain the reservoir.
5. Install the master cylinder. Refer to Master
Cylinder Replacement. 7
)
6 5
182445
Master Cylinder Replacement
Removal Procedure
1. Remove and discard the brake flLJid.from the
reservoir.
451525
2. Remove the combination valve pipes in order to

prevent fluid loss and contamination.
3. Disconnect the brake fluid level sensor connector.
4. Remove the master cylinder nuts.
5. Remove the master cylinder.
222987
1. Bench bleed the master cylinder. Refer to Master
CyfinderBench Bleeding.
2. Install the master cylinder.
Notices.
3. Install the master cylinder nuts.
Tighten
Tighten the master cylinder nuts to
29 N-m (21 lb ft).
4. Fill the master cylinder reservoir. Refer to Master
Cylinder Reservoir Filling.
5. Install the brake combination valve pipes onto the
master cylinder one at a time. Complete the
following steps:
5.1. Remove the locally fabricated plugs.
5.2. Install the brake pipe fitting finger tight.
222987
Brakes Hydraulic Brakes 5;.25
5.3. Have an assistant depress the brake pedal
in .order to remove air at the loose brake
pipe fittings.
Tighten
Tighten the combination valve pipe fittings
to 32 N·m (24 lb ft).
5.4. Have an assistant quickly release and
pump the brake pedal several times.
5.5. If the brake pedal remains high and firm,
.. start the vehicle. If the brake pedal still
feels firm, test drive the vehicle.
If the. brake pedal feels soft or spongy,
bleed the entire brake hydraulic system.
Refer to Hydraulic Brake System Bleeding
(Manual Bleeding) or Hydraulic Brake
System Bleeding (Pressure Bleeding).
6. Connect the brake fluid level sensor connector.
Master Cylinder Bench Bleeding

Tools Required
• One 11 x 1.5 mm tube fitting nut
• One 12 x 1.0 mm tube fitting nut
• Two pieces of 4.75 mm (0.187 in) brake pipe,
approximately 50 mm (1.969 in) long
1. Fabricate two plugs in order to plug the master
cylinder outlet ports. Use the following procedure:
1.1. Fashion two ISO flares on one end of
each tube.
1.2. Install the nuts onto the flared tubes.
1.3. One at a time, place approximately
13 mm (0.51 in) of the unflared tube end
in a vise.
1.4. Compress the end of the tube with the vise
in order to collapse the tube.
1.5. Bend the tube to a 90 degree angle.
1.6. Remove the tube from the vise.
1.7. Put the tube back in the vise. Fold the tube
end against itself in order to form an
air-tight seal.
4. Plugthe master cylinder outlet ports with the
fabricated plugs.
Notice: Do not overtighten vise, or damage to the
master cylinder will result.
3. Place shop towels around the master cylinder in
order to absorb the bled fluid.
4. Mount the master cylinder in a vise. Tilt the front
end of the master cylinder down slightly.
5. Fill the master cylinder with clean brake fluid.
Important: As air bleeds from the brake master
cylinder, resistance to primary piston strokes will
increase, not allowing a full stroke.
) 6. Using a tool with a smooth, rounded end, stroke
the primary piston about 25 mm (0.948 in)
several times.
7. Reposition the master cylinder in the vise. Tilt the
master cylinder slightly up.
8. Stroke the primary piston several times.
9. Reposition the brake master cylinder in the vise.
Level the master cylinder. (
10. Loosen the fabricated plugs one at a time.
11. Push the primary piston into the rnaster cylinder
bore in order to force the air out of the master
cylinder.
Important: In order to prevent air from sucking back
into the master cylinder, tighten the fabricated
plugs before allowing the primary piston to return to its
original position. ·
12. Repeat the previous 6 steps until no air escapes
past the plugs.
13. Install the master cylinder into .the vehicle. Refer
to Masterc;ytinder Replacement.
Master Cylinder Fluid Level Sensor

Replacement
Removal Procedure
1. Disconnect low brake fluid sensor electrical
connector (2) from the sensor (1).
385563
Important: If the sensor is being replaced, remove

and replace the sensor float that resides within 1he
master cylinder reservoir. ·
2. Using needlenose pliers, remove the sensor (2)
from the reservoir (1) by squeezing the outer
tangs together and removing th.e sens.or by hand.
400336
Brakes Hydraulic. Brakes 5-27
1. Insert the low brake fluid sensor (2) and float
sensor if removed, into reservoir (1) cavity
ensuring it is fully seated. Sensor should "snap"
into position as the tangs engage.
400336
2. Connect the low brake fluid sensor electrical

connector (2) to the sensor (1).
385563
)
Brake Pedal Replacement
Removal Procedure
1. Disconnect the negative battery cable.
2. Remove the left side instrument panel insulator.
Left in Instrument Panel, Gauges and Console.
3. Remove the following components from the brake
pedal pin (10):
• The brake pedal pushrod pin retainer (7)
• The brake pedal pushrod (8)
• The brake pedal pushrod washer (11)
182817
4. Remove the brake pedal pivot nut (12).
5. Slide out the brake pedal pivot bolt/screw (2)
partway in order to give enough clearance in
order to remove the brake pedal (7).
6. Remove the brake pedal (7).
7. Remove the brake pedal pivot bushings (10) ftom
the brake pedal (7), if necessary.
8. Remove the brake pedal pivot spacer (8) from the
brake pedal (7), if necessary.
9. Clean all the components with a suitable solvent.
10. Inspect all the components for wear. Repair or
replace the components as needed.
11
9
6 5
182814
)
Installation· Procedure
1. Install the brake pedal pivot spacer (8) to the
I
brake pedal (7), if removed. \
2. Install the brake pedal pivot bushings (10) to the
brake pedal (7), if removed.
3. Install the brake pedal (7).
4. Lubricate the brake pedal pivot bolt/screw (2) with
chassis lubricant.
Notices.
5. Install the brake pedal pivot bolt/screw (2) and the
brake pedal pivot nut (12).
Tighten
Tighten the brake pedal pivot nut (12) to
54 N·m (40 lb ft).
11
9
6 5
182814
6. Lubricate the brake pedal pin (10) with chassis
lubricant.
7. Install the following components to the brake
pedal pin (10):
• The brake pedal pushrod pin retainer (7)
8. Install the left side instrument panel insulator.
Refer to Closeout/Insulator Panel Replacement
- Left in Instrument Panel, Gauges and Console.
9. Connect the negative battery cable.
Tighten
Tighten. the negative battery cable to
15 N-m (11 lb ft).
10. Adjust the following qomponents. Refer to
Stop/amp Switch Adjustment.
. • Cruise control release switch
• Stoplamp and TCC switch
• Cruise control clutch switch or cruise control
clutch anticipate switch
182817
)
Brake Pedal Bracket Replacement
Removal Procedure (
1 . Disconnect the negative battery cable.
3. Remove the following components from the pedal
with the bracket. Refer to Stop/amp Switch
Replacement.
• Cruise control release switch
• Stoplamp and Torque Converter Clutch (TCC)
switch
" Cruise control clutch· switch or cruise control
4. Remove the clutch start switch from the brake
pedal with the bracket, if equipped with a
manual transmission.
5. Remove the accelerator pedal (11 ).
6. Remove the following components from the brake
pedal pin (9):
O The brake pedal pushrod pin retainer (5)

6 5
182814
(
7. Remove the clutch pedal lever pin retainer (4) and
the clutch pushrod (5) from the clutch pedal
pin (6), if equipped with a manual transmission.
8. Remove the brake pedal nuts (3) and the brake
pedal bracket bolts/screws (1).
9. Remove the clutch master cylinder nuts (13), if
equipped with a manual transmission.
10. Remove the brake pedal with the bracket (16).
182817
)
5.;34 Hydraulic Brakes Brakes
Important: When installing the brake pedal with the
bracket, ensure that the dash panel insulator material
does not get pinched between the brake pedal and
the dash panel.
1. Install the brake pedal with the bracket (13).
11
6 5
182814
2. Install the clutch master cylinder nuts (13), if
) Notice: Refer to Fastener Notice in Cautions and
Notices.
3. Install the brake pedal nuts (3) and brake pedal
bracket bolts/screws (1 ).
Tighten
• Tighten the clutch master cylinder nuts (13) to
27 N·m (20 lb ft), if equipped with a manual
transmission.
• Tighten the brake pedal bracket bolts (1) to
25 N-m (18 lb ft).
• Tighten the brake pedal nuts (3) to
20 N-m (15 lb ft) in the following sequence:
3.1. Inboard upper
3.2. Outboard lower
3.3. Outboard upper
3.4. Inboard lower
4. Install the accelerator pedal (14).
5. Lubricate the clutch pedal pin (6) with chassis
lubricant.
6. Install the clutch pedal lever pin retainer (4) and
the clutch master cylinder pushrod (5) to the
clutch pedal pin (6), if equipped with a manual
transmission.
7. Lubricate the brake pedal pin (1 O) with chassis
lubricant.
) 8. Install the following components to the brake
pedal pin:
• The brake pedal pushrod pin retainer
• The brake pedal pushrod
• The brake pedal pushrod washer
9. Install the following components to the pedal with
the bracket (16). Refer to Stop/amp Switch
Replacement.
• Cruise control release switch 182817
1O. Install the clutch start switch to the brake pedal
with the bracket, if equipped with a manual
transmission. ·
11. Adjust the following components. Refer to
Stop/amp Switch Adjustment.
" Cruise control release switch
12. Install the left side instrument panel insulator.
- Left in Instrument Panel, Gauges and Console.
) 13. Connect the negative battery cable.
Tighten
Tighten the negative battery cable to
15 N-m (11 lb ft).
Brake Pipe Replacement
Important: Do not use ISO flares for the rear brake (
pipe connections to the rear wheel cylinders.
0 Refer to Master Cylinder Description for an
illustration depicting the brake pipe layout

and locations. Brake pipes that are to be locally
fabricated, should only be ISO flared, and
not double lap flared.
e Rear brake front pipes (mid) should not be locally
fabricated. These pipes should be ordered
through your GM parts dealer.
ISO Flares Replacement

Tools Required
J 29803-A ISO Flaring Kit
Caution: Always use double walled steel brake
pipe when replacing brake pipes. The use of any
other pipe is not recommended and may cause
brake system failure. Carefully route and retain
replacement brake pipes. Always use the correct
fasteners and the original location for replacement
brake pipes. Failure to properly route and retain
brake pipes may cause damage to the brake pipes
and cause brake system failure.
Notice: Do not use single lap flaring tools. Double lap
flaring tools must be used to produce a flare strong
enough to hold the system pressure. Using single lap
flaring tools could cause system damage. (
1. Obtain the correct size pipe and the correct size
steel fitting nuts.
63933
Use the outside diameter of the pipe in order to
specify the size.
2. Cut the pipe to the correct length using a pipe
cutter.
Advance the tool only a small amount per turn of
the tool. Do not force the cutter.
3. Measure the old pipe in order to determine the
correct length of the pipe. Use a string in order
to measure, and add 3.2 mm (0.125 in) for
each ISO flare.
4. Install the fittings before starting the flare.
5. Chamfer the inside and the outside· diameter of
the pipe using a de-burring tool.
6. Remove all traces of lubricant from the brake pipe
and the J 29803-A.
7. Clamp the J 29803-Ain a vise.
8. Select the correct size collet (2) and forming
mandrel for the pipe size used. J 29803-A
63931
9. Insert the properly formed mandrel (3) into the

J 29803-A.
10. Hold the forming mandrel (3) i.n place using
your finger. J 29803-A
11. Thread in the forcing screw (2) until contact is
made and the screw begins to move the forming
mandrel (3).
63927
12. Turn .the forcing screw back one complete turn.

13. Slide the clamping nut over the brake pipe.
14. Insert the prepared brake pipe into the.correct J 29803-A
collet (2). ·.
Leave approximately 19 mm (0. 750 in) of tubing
extending out of the collet.
Insert the assembly into the J 29803-A.
Ensure that the brake pipe end contacts the face
of the forming mandrel.
15. Tighten the clamping nut (1) into the J 29803-A
body tightly in order to ensure that the pipe will
not push out.
16. Wrench tighten the forcing screw until the screw
bottoms. Do not over tighten the forcing screw or
the flare may become oversized.
) 17. Back the clamping nut (1) out of the J 29803-A.
18. Disassemble the clamping nut (1) and the
collet assembly.
19. The flare is now ready for use.
63931
20. Use a tube bender in order to bend the new pipe
to match the old pipe.
21. Maintain the following clearances: (
• Maintain the minimum clearance of
19 mm (0.75 in) to all moving components.
13 mm (0.50 in) to all vibrating components.
7 mm (0.25 in) to any shielded lines, unless
clipped to a component.
219471
Brake Hose Inspection

Inspect the brake hoses and the brake pipes at least
two times a year for the following problems:
• Check the outer cover for road damage.
• Check for fluid leaks.
• Check for damage at the brake hose and pipe
connections.
• Check that all hose and pipe mounting hardware (
is securely in place. Repair the mounting
hardware as needed.
• Make sure all mounting hardware is in place and
secure.
• Replace or repair any parts as necessary.
Power Brake Booster Hoses, Pipes And
Fittings
Check all pipes, hoses and fittings for leaks at regular
intervals. Make sure the fittings are tight. Make
sure all clamps, clips and unions supporting the pipes
and hoses are in place and properly secured. Make
sure all hoses are installed in a matter that does
not cause chafing or wear on the hoses. Check for
leaks by wiping the suspected area clean. Spotting
leaking fluid is easier when the suspected area
in clean. When fluid leaks appear, tighten, repair or
replace nearby fittings and bolts.
Brake Hose Replacement - Front
J Removal Procedure
Wheels.
2. Clean all dirt and foreign material from the front
brake hose and the front brake hose fitting (4).
3. Remove the front brake pipe from the front
brake hose.
4
• Use a backup wrench on the hose fitting.
• Do not bend the front brake hose bracket (2)
or fro~t brake pipe.
4. Remove the brake hose retainer from the hose
fitting at the brake hose bracket.
5. Remove the brake hose (5) from the brake hose
bracket (3).
6. Remove the following components from the front
brake caliper (4): 373244
• The brake hose fitting (2)

• The brake hose clip bolt (1)
• Two brake.hose fitting gaskets
Discard the two old brake hose fitting gaskets.
g
1. Lubricate the brake hose bolt (1) threads with
clean brake fluid.
) 2. Install the following components to the front
caliper (4):
• The brake hose clip bolt (1)
• Two new brake hose fitting gaskets
4
Notices.
3. Ensure that the hose fitting flange engages the
front caliper orientation ledge.
Tighten
Tighten the front brake hose fitting to
40 N-m (30 lb ft).
4. Install the brake hose (5) into the brake hose
bracket (3). Ensure that. there are no !<inks in
the brake hose. 3732M
5. Install the brake hose retainer at the brake hose

bracket.
6. Install the front brake pipe to the brake hose.
7. Install the brake hose retainer.
8. Secure the retainer to the brake hose bracket
using the screw.
• Use a backup wrench on the hose fitting.
Ensure that the brake hose does not contact
any part of the suspension.
• Inspect the hose in the extreme right and
) extreme left turn conditions. ·
Tighten
Tighten the front brake hose clip bolt (1) to
13 N-m (115 lb in).
5·40 Hydraulic Brake.s Brakes
9. Bleed the brake hydraulic system. Refer to
Hydraulic Brake System Bleeding (Manual
Bleeding) or Hydraulic Brake System Bleeding (
(Pressure Bleeding).
10. Install the tire' and the wheel. Refer to Tire and
Wheels.
Brake Hose Replacement - Rear

2 1 (To Brake Caliper)
Removal Procedure
1. Remove the wheel and the tire. Refer to Tire and
Wheel Removal and Installation in Tires· and
Wheels.
2. Clean all dirt and foreign materialfrom the.hose
and fitting (4). ·
3. Remove the rear brake hose (2) from the rear
brake pipe (3).
• Use a backup wrench on the hose fitting (2).
• Do not bend the rear brake hose bracket or the
rear brake pipe (3).
4. Remove the rear brake hose retainer (1) from the
brake hose bracket and the rear brake hose (2).
5. Remove the following components from the rear
brake caliper (5): .
222984
• The brake hose fitting bolt (4)
.. Two brake hose fitting gaskets.
Discard the brake hose fitting gaskets.
• The rear brake hose· (2)
2 1 1. Lubricate the bolt fitting threads. Use clean
brake fluid.
2. Install the following components to the rear brake
caliper (5):
" The brake hose fitting (4)
• Two new brake hose fitting gaskets
• The rear brake hose (2)
Notices.
3. Ensure that the hose fitting flange engages the
caliper orientation ledge.
Tighten
Tighten the rear brake hose fitting (4) to
45 N-m (33 lb ft).
4. Install the rear brake hose retainer (1) to the
brake hose bracket and the brake hose (2),
22298 4 5. Install the rear brake hose (2) to the rear brake
pipe (3).
• Use abackup wrench on the hose fitting (2).
• Do not bend the brake hose bracket or
the brake pipe (3).
Tighten
Tighten the rear brake pipe (3) to the brake
hose (2) to 15 N·m (11 lb ft).
6. Bleed the hydraulic brake system. Refer to
Bleeding) or Hydraulic Brake System Bleeding
7. Install the wheel and the tire. Refer to Tire and
Wheels.

(Without Traction Control)
Removal Procedure
2. Clean all dirt and foreign material from the brake
hose (3) and the brake pipe fittings.
3. Remove the rear brake front pipe (2) from the
brake hose (3).
• Use a backup wrench on the· brake hose
fitting.
• Do not bend the brake hose bracket (6) or the
brake front pipe (2).
4. Remove the brake hose retainer (7) from the
brake hose bracket (6) and the brake hose (3).
5. Remove the rear brake hose (3).
6. Remove the left rear pipe (1) and the right rear
pipe (5) from the hose (3). Do not bend the left
rear pipe (1) or the right rear pipe (5).
) 7. Note the position of the brake hose (3) for proper
location during installation.
8. Remove the rear brake hose fitting bolt (8) and
the brake hose (3) from the rear axle (4).
184635
)
Notices.
1. Install the brake hose (3) and the. brake hose
fitting bolt(8) to the rear axle (4). ·
Tighten
Tighten the rear brake (center) hose fitting bolt (8)
to 21 N·m (15 lb ft).
2. Install the left rear pipe (1) and the right rear,
pipe (5) to the brake hose (3).
Tighten
• Tighten the left rear pipe (1) and the right rear
pipe (5) at the rear brake (center) hose (3) to
24 N-m (18 lb ft).
• Tighten the left rear pipe (1) and the right rear
pipe (5) at the left hand brake hose to
15 N·m (11 lb ft).
3. Install the brake hose (3) into the brake hose
bracket (6). Ensure that the brake hose (3) is
properly seated and not twisted.
4. Install the rear brake hose retainer (7) to the rear
brake .hose bracket (6) and the brake hose (3).
5. Install the rear brake front pipe (2) to the brake
hose (3).
• Use a backup wrench on the brake hose (3).
• Do not bend the brake hose bracket (6) or
the rear brake front pipe (2).
Tighten
(
Tighten the rear brake'front pipe (2) to the
rear brake (center) hose (3) to
15 N·m (11 lb ft).
184635
(With Traction Control)
Removal Procedur.e
Information.
2. Clean all dirt and foreign material from the brake
hose and the brake pipe fittings.
3. Remove the right rear brake pipe (6) or the left
rear brake pipe (7) from the rear brake
hoses (3 or 4).
• Use a backup wrench on th.e brake hose
fittings.
• Do not bend the rear brake hose bracket (10)
or the brake pipes (6 or 7).
4. Rernove the rear brake pipe clips (8 or 9) from
the brake hose bracket (10) and the rear brake
hoses (3 or 4),
5. Remove the left rear brake pipe (2) or the
right rear brake pipe (5) from the rear brake
hoses (3 or 4).
• Use a backup wrench cm the brake hose
fittings.
• Do not bend the rear brake hose bracket (1) or
the rear brake pipes (2 or 5).
6. Remove the rear brake pipe clips (8 or 9) from
\ the brake hose bracket (1) arid the rear brake
) hoses (3 or 4).
7. Remove the rear brake hqses (3 or4).
182798
)
1. Install the rear brake hose (3 or 4).
2. Install the rear brake pipe clips (8 or 9) to the
(
brake .hose bracket (1) and t.he rear brak.e
hoses (3 or 4}. Ensure that the rear brake
hoses (3 or4) are properly seated and not twisted.
and Notices.
3. Install the. rear bra.ke pipes (2 or 5) to the rear
brake hoses (3 or4). ··
• Use a backup wrench on the. brake hose
fittings.
• Do not bend the bracket (1) or the rear brake
pipes (2 or 5).
Tighten
Tighten the rear brake pipes (2 or 5) to the
rear brake hoses (3 or 4) to 15 N·m (11 lb ft).
4. Install the rear brake pipe clips (8 or 9) to the rear
brake hose. bracket (10) and the rear brake
ho.ses. (3 or 4). Ensure that the rear brake
hoses (3 or 4) are properly seated and not twisted.
5. Install the right rear brake pipe (6) or the left rear
brake pipe (7) to the rear brake hose (3 or 4).
• .Use. a backup. wrench on the brake hose
fittings.
• Do not bend the rear b.rake hose b.racket (1 O)
or the brake pipes (6 or 7). ·
Tighten
Tighten the right rear brake pipe (6) or the
left rear brake pipe (7) to the rear brake
hoses (3 or 4) to 15 N-m (11 lb ft).
182798
Hydraulic Brake System Bleeding

(Manual Bleeding)
The time required to bleed the hydraulic system can
be reduced if the master cylinder reservoir is filled with
brake fluid and as much air as possible is expelled
before the master cylinder is installed on the vehicle.
Pumping the piston can evacuate the air from the
piston cavities.
Power brakes require the vacuum reserve be depleted
by applying the brakes several times with the engine
off. Care must be taken to prevent brake fluid from
contacting any painted surface.
1. Fill the master cylinder reservoir with brake fluid
and keep the reservoir at least half full of fluid
----
during the bleeding operation.
171922
2. If the master cylinder is known or suspected to
have air in the bore, then it must be bled in the
following manner, before bleeding any caliper:
2.1. Disconnect the forward (blind end)
brake pipe connection at the master
cylinder.
2.2. Allow the brake fluid to fill the master
cylinder piston bore until it begins to flow
from the forward pipe connector port.
2.3. Connect the forward brake pipe to the
master cylinder and tighten.
Notices.
2.4. Depress the brake pedal slowly one time
and hold. Loosen the forward brake pipe
connection at the master cylinder to
purge air from the bore. Tighten the
connection and then release the brake
pedal slowly. Wait 15 seconds. Repeat the
sequence, including the 15 second wait,
until all air is removed from the bore.
Tighten
Tighten the brake pipe tube nut to
16 N·m (12 lb ft).
2.5. When clear fluid flows from the forward
connection, repeat steps 1 and 2 to bleed
the mastercylinder at the rear (cowl)
connection.
) 3. Individual brake calipers are bled only after all air
is removed from the master cylinder. If it is known
that the brake calipers do not contain any air,
then it will not be necessary to bleed them.
3. i. Place a proper size box end wrench, or
equivalent, over the brake caliper
bleed screw.
3.2. Attach a clear tube over the screw.
3.3. Submerge the other end of the tube in ~
clear container partially filled with
brake fluid.
3.4. Depressthe:bra,ke pedal slowly one time
and hold. ·
3.5. Loosen the brake caliper bleed screw to
purge the air from the cylinder.
3:6. Tighten the brake caliper bleed screw and
slowly release the pedal. Wait 15 seconds.
Tighten
Tighten the brake caliper bleed screw to 63934
12 N·m (J 06 .lb in).

3.7. Repeat the.sequence (including the
15 second wait), until all of the air is
removed. It may be necessary to repeat the
sequence ten or more tim.es to remove.
all of the air.
)
3.8. If it is necessary to bleed all of the brake
calipers, the following sequence should
be Used:
3.8.1. Right rear
3.8.2. Left rear
3.8.3. Right front
3.8.4. Left front
3.9. Test drive the vehicle. Check the brake
pedal for sponginess.
3.10. Ensure that vehicle exceeds 5 km/h (3 mph)
for ABS modulator actuation (self-test). If
after ABS modulation the brake pedal is
spongy or soft, then re-bleed system until
pedalis firm. ·

J 35589 (Pressure Bleeding)
Tools Required
J 35589 Pressure Bleeding Adapter
1. Remove the master cylinder reservoir cap.
Replace it with J 35589.
2. Charge the bleeder to 140-172 kPa (20-25 psi).
3. Connect the hose to J 35589.
Information.
(
171934
5. If it is necessary to bleed all of the brake calipers,

the following sequence should be used:
5.1. Right rear
5.2. Left rear ·
5.3. Right front
5.4. Left front
6. Place the proper size box end wrench, or
equivalent, over the brake caliper bleed screw.
Attach a clear tube over the screw and allow the
tube to hang submerged in a clear container
partially filled with brake fluid.
7. Open the brake caliper bleed screw at least
three quarters of a turn and allow the brake
fluid flow to continue until no air is seen in the
brake fluid. Apply intermittent pressure to
the brake pedal while pressure bleeding.
Notices.
8. Close the brake caliper bleed screw.
63934 Tighten
Tighten the brake caliper bleed screw to
12 N·m (106 lb in).
9. Repeat steps 6 through 8 until all of the calipers
have been bled.
11. Test drive the vehicle, checking for brake pedal
for sponginess or softness. Ensure that vehicle
exceeds 5 km/h (3 mph) for ABS modulator
actuation (self-test) which will purge any air from
the secondary circuit of the modulator. If after
ABS modulator actuation the pedal is still soft or
spongy, then re-bleed entire system.
12. Remove the brake bleeding equipment from the
master cylinder_

(When To Bleed)
A bleeding operation is necessary to remove air when
it is introduced into the hydraulic brake system.
It may be necessary to bleed the hydraulic system at
all four corners if air has been introduced through
low fluid level or by disconnecting brake pipes at the
master cylinder. If a brake hose is disconnected. at one
wheel, only that wheel caliper needs to be bled. If
brake pipes or hoses are disconnected at any fitting
located between master cylinder and brakes, then the
brake system served by the disconnected pipe or
hose must be bled.
Hydraulic Brake System Flu!;hing ·

The entire hydraulic brake syst~m should be
thoroughly flushed with clean brake. fluid if there is any
) doubt as to the grade of the fluid in the system or if
the fluid used contains the slightest trace of mineral oil.
All rubber parts which have been subjected to
contam.inated fluid must be replaced before flushing
the system.
Flushing is performed at each wheel similarly to
bleeding. The new fluid must be forced through the
system until it emerges clear in color. Approximately
one quart of new fluid is needed to flush the system:
After completing the flushing operation at all of
the bleeder valves check that the master cylinder is
filled to the correct level.
)
Vacuum Brake Booster Replacement
8 1 Removal Procedure
1. Remove the hood rear seal. Refer to Seal
Replacement - Hood Rear in Body Front End.
2. Remove the left side air inlet screen. Refer to Air
Inlet Grille Panel Replacement in Body Front End.
3. Remove the brake booster vacuum hose (8) and
clamp (9) from the check valve (10).
4. Remove the master cylinder form the brake
booster. Refer to Master Cylinder Replacement.
5. Remove the left side 1/P insulator. Refer to
Closeout/Insulator Panel Replacement O Left
6 5 4
184981
6. Remove the brake pedal nuts (3) attaching the

brake booster to the brake pedal with bracke1 (6).
7. On manual transmission equipped vehicles only,
loosen the clutch master cylinder nuts (5).
8. Disconnect the brake booster pushrod (8) from
the brake pedal lever pin.
8.1. From inside the vehicle, remove the brake
pedal pushrod retainer (7) and pushrod (
washer (4).
8.2. Tilt the entire brake booster slightly in order
to work the brake booster pushrod (8) off
the brake pedal pin. Do not put undue side
pressure on the pushrod.
9. Remove the power brake booster from the
vehicle.
184982
1. Install the power brake booster onto the vehicle.
2. Install the brake booster pushrod (8) to the
brake pedal lever pin (1 ).
2.1. Tilt the entire brake booster slightly in order
to work the brake booster pushrod onto the
brake pedal pin.
2.2. From inside the vehicle, install the brake
pedal pushrod washer (4) and retainer (7).
Notices.
3. Install the brake pedal nuts (3) attaching the brake
booster to the brake pedal with bracket (6).
Tighten
Tighten the brake pedal nuts to 20 N·m (15 lb ft)
in the following sequence:
3.1. Inboard upper
3.2. Outboard lower 184982
3.3. Outboard upper

3.4. Inboard lower
4. On man.ual transmission equipped vehicles only,
install the clutch master cylinder nuts (7).
Tighten
Tighten the clutch master _cylinder nuts to
27 N·m (20 lb ft).
5. Install the master cylinder (6) onto the brake
) booster (1 ).
8 9 10 1 2
6. Install the master cylinder nuts (7) attaching the
master cylinder to the brake booster.
Tighten
29 N-m (21 lb ft)
7. Connect the vacuum hose (8) and the clamp (9)
to the check valve (10).
8. Install the left side instrument insulator. Refer to
9. Install the left side air inlet screen. Refer to Air
Inlet Grille Panel Replacement in Body Front End.
10. Install the hood rear seal. Refer to Seal
Replacement - Hood Rear in Body Front End. 6 5 4
11. Bleed the brakes. Refer to Hydraulic Brake
System Bleeding (Manual Bleeding) or Hydraulic
184981
Brake System Bleeding (Pressure Bleeding).
)
Vacuum Brake Booster Hose Replacement
Removal Procedure
1 . Reposition the vacuum brake boost.er hose
clamps (VS shown, V6 similar).
2. Reposition the hose clamp from the engine side
of the vacuum hose.
3. Remove the vacuum brake booster hose from the
engine fitting and the vacuum check valve.
222997
1. Connect the vacuum brake booster hose to the
engine fitting and the vacuum check valve.
2. Reposition the hose clamp to the engine side of
the vacuum hose.
3. Reposition the vacuum brake booster hose clamp.
222997
Stoplamp Switch Replacement

i Removal Procedure
switch.
3. Remove the Stoplamp and TCC switch (3) from
3 the bracket (1 ).
374062
1 . Install the Stoplamp and TCC switch (3) to the 1
bracket (1).
2. Connect the. electrical connector to the switch.
3. Adjust the Stoplamp and TCC switch ... Refer
to Stop/amp Switch Adjustment.
4. .Install the left side instrument panel insulator.
- Left in Instrument Panel, Gauges and Console. 3
374062
.. ------------,
Stoplamp Switch Adjustment
Notice: Proper stoplamp switch adjustment is ._--1
essential. Improper stoplamp switch adjustment may
cause brake drag, heat buildup and excessive
brake lining wear.
1. Adjust the cruise control release switch (2) and
the stoplamp and Torque Converter Clutch (TCC)
switch (3) at the same time.
) · 2. Adjust the cruise control clutch switch (4) or the
cruise control clutch anticipate switch (6) if
equipped after the clutch pedal is installed.
3. Depress the brake or the clutch pedal.
4. Insert the following switches into the pedal '11.'.ith
the bracket until the retainers on the switches
are fully seated:
• Cruise control release switch (2)
• Stoplamp and TCC switch (3)
• Cruise control clutch switch (4) or cruise
control clutch anticipate switch (6) if equipped.
Important: Apply the proper amount of force to the
brake pedal during adjustment.
• Too much force may damage the vacuum
booster.
• Too little force may cause the brakes to drag.
5. Slowly pull the brake or clutch pedal rearward I
with a force of 222 N (50 lbs) until clicking I
sounds are no longer heard. At this point, the
retainers on the switches will be adjusted.
6. Measure the cruise control release switch (2).
. ~ -L_ -----.,
7. Measure the stoplamp and TCC switch (3).
8. The switch contacts should be open at
4
25.4 mm (1.0 in) or less of pedal travel. The switch
contacts should occur at the same time or
) before the onset of braking. The brake pedal
6
travel can be up to 25.4 mm (1.0 in) before the OPTIONAL
cruise control system disengages. L.----------..1
182813
Master Cylinder Description The master cylinder has an aluminum body and a (
plastic reservoir. The brake system is a conventional
Important: front-to-rear split system. The master cylinder
• Replace all of the components thatare included in primary piston provides the fluid pressure to the front
the repair kits used to service this .master cylinder. disc brakes. The secondary piston provides the
• Lubricate the rubber parts in order to ease fluid pressure to the rear disc brakes. If pressure is
assembly. Use clean brake fluid. lost from either system, the remaining system will
• Do not use lubricated compressed air on the function in order to stop the vehicle.
brake parts. This action may cause damage to the Brake Master Cylinder Reservoir
rubber components.
• If you remove or disconnect any hydraulic part, The reservoir has a maximum fluid level indicator
you may have to bleed all or part of the brake mark. The fluid level indicator mark is located on the
system. side of the reservoir.
• The specified torque values are for dry,
non-lubricated fasteners.
• Perform the service operations on a clean bench
that is free from all mineral oil materials.
Brake Pipe Routing and Location
186982
Brake pipe (1,2,3,4 and 5) location and routing can be

found in the attached graphic. For brake pipe
replacement, refer to Brake Pipe Replacement. For
information on flaring new brake pipes, refer to
ISO Flares Replacement.
Brake Fluid and Brake Fluid Handling Vacuum Brake Booster Description
Caution: Use only SUPREME 11 or equivalent Important:
DOT 3 brake fluid from a clean, sealed.container.
Do not use fluid from an open container that • Do not use lubricated compressed air on the
may be contaminated with water. Improper or brake parts. This action may result in damage to
contaminated fluid will result in damage to the rubber parts.
compcments orlcss of braking, with possible • Replace all of the components that are included in
personal injury. the repair kits used to service this booster.
Notice: Avoid spilling brake fluid on any of the • Lubricate the rubber parts in order to ease
vehicle's painted surfaces, wiring, cables, or electric assembly. Use fresh brake. fluid.
connectors. Brake fluid will damage the paint and
the electrical connections. If any fluid is spilled .on the O
If you remove or disconnect any hydraulic
vehicle; flush the area to lessen the damage. component, bleed all or part of the brake system.
lmpe>rtant: . • The specified torque values are for dry,
non-lubricated fasteners.
• Do not re-use fluid accumulated during brake
hydraulic system bleeding. This vacuum booster is a tandem vacuum suspended
• Store brake fluid in a closed container. unit. When the service brakes are released, the
tandem vacuum booster operates with vacuum on
• Reseal brake fluid containers immediately
both sides of the diaphragm. When the brakes
after use. ·
are applied, air at atmospheric pressure is admitted to
• Do not use fluid left in an open or improperly one side of the diaphragm. This draws air from the
sealed container. Fluid left in an open or booster through the vacuum check valve to the
improperly sealed container absorbs moisture and vacuum source. The internal components of this
may become contaminated. booster cannot be serviced. Do not unstake and
If rubber deterioration is evident, complete the separate the housing. Separating the housing will
following procedure: cause permanent deformation of the booster and
1. Disassemble all hydraulic parts. prevent the booster from holding the proper volume.
\ 2. Wash all the hydraulic parts with alcohol.
Routing
) 3. Dry the parts with non-lubricated compressed air
before reassembly in order to keep alcohol out of
the system.
4. Replace all the rubber parts in. the system,
including the following components:
•, Brake. hoses
• Master cylinder rubber parts
• Brake caliper boots and seals
• Wheel cylinder boots and seals
5. Replace the combination valve and the brake
pressure modulator valve. Both valves have
rubber components inside which are not
serviceable.
6. Inspect the pads for brake fluid. If excessive
brake fluid is present, replace the pads.
Substandard or Contaminated Brake Flui.d
Caution: .Use only SUPREME 11 or equivalent
DOT 3 brake fluid from a clean, sealed container.
222994
Do not use fluid from an open container that
may be contaminated with water. Improper or Power brake booster vacuum hose routing on the
contaminated fluid will result in damage to 3800 V6 series engine.
components or loss of braking, with possible
personal injury.
)
O When the engine is started, .the amber ABS INOP
lamp and the red BRAKE lamp should turn off. (
The amber LOW TRAC indicator lamp may turn
on and off.
The operation of the three lamps is an important part
of the Antilock Brake System (ABS) diagnosis. A
malfunction is present if the warning/indicator lamps
turn on while driving the vehicle. If the warning
lamps do not turn on under normal conditions as
described above, service the lamps as soon as
possible. For further information regarding the
operation ofthe warning/indicator lamps for the
Antilock Brake System (ABS), refer to Antilock Brakes ..
Brake Warning System Circuit Description

Circuit Operation
The brake warning indicator on the instrument cluster
222997
illuminates under the following conditions:
Power brake booster vacuum .hose routing on the • The instrument cluster bulb test .is occurring.
5.7L VB series engine. • The park brake is set.
• The master cylinder brake fluid level is low.
Brake Warning System Description
• The electronic brake control module sends a
Brake Class 2 message to the instrument cluster.
The. brake system uses a single red BRAKE warning These conditions are explained in detail below. In all
lamp located in the instrument cluster. When the cases positive voltage is applied to the brake
ignition switch is in the START position, the BRAKE warning indicator through circuit 39.
warning lamp should turn on. When the ignition switch (
is in the RUN position, the BRAKE warning lamp Instrument Cluster Bulb Test
should turn off. When the ignition switch is turned to the RUN position,
The following conditions activate the BRAKE the instrument cluster performs an internal bulb test
warning lamp: on the brake warning indicator. The indicator
• The parking brake is applied. The lamp should be illuminates for approximately 3 seconds and then
on when the parking brake is applied and the turns off.
ignition switch is ON.
Park Brake
• The brake pressure differential warning switch
detects a failure. Refer to Electrical Diagnosis The park brake switch closes when the park brake is
for diagnosis. set. On Domestic and Gulf States vehicles, ground
• The BRAKE warning lamp remains on while is applied through circuit 1134, the DRL module
cranking the engine. This indicates that the circuit and circuit 33 to the instrument cluster. The brake
is operating properly. indicator illuminates. On Europe and Japan vehicles,
ground is applied through circuit 33 to the cluster.
Antilock
The Antilock Brake System (ABS) uses Brake Fluid level
three indicator lamps: When the brake fluid level in the master cylinder is
• The red BRAKE warning lamp low, the brake fluid level indicator sensor closes.
• An amber ABS INOP indicator lamp Ground is applied through the sensor and circuit 33 to
the instrument cluster. The brake indicator illuminates.
• An amber LOW TRAC indicator lamp
The lamps operate normally under the following EBCM Class 2
conditions: The brake indicator is also controlled by the ABS
• When the ignition is turned to the RUN position, system through the class 2 serial data line. The
prior to starting the engine, the amber ABS electronic brake control module (EBCM) sends a
INOP indicator lamp should turn on and the red class 2 message to illuminate the brake indicator. The
BRAKE warning lamp should flash. indicator warns the customer that a problem exists
• While the engine is cranked, the red BRAKE in the ABS system. Refer to ABS brakes for further
warning lamp and the amber ABS INOP indicator information.
lamp should turn on. The amber LOW TRAC
indicator lamp may turn on and off.
Illustration Tool Number/Description
J 28662
Brake Pedal Effort Gauge
1006
J 29803-A
ISO Flaring Kit
1089
)
J 35589
Bleeding Adapter
153149
)
5-56 Disc Brakes Brakes
Disc Brakes
(
Specifications
Specification
Bleeder Valve 12 N·m 1061bin
Brake Caliper Mounting Bracket Bolt 100 N-m 74 lb ft '.
Brake Hose Bolt 40N·m 30 lb ft

Caliper Guide Pin Bolt 31 N·m 23 lb ft
Wheel Nut 140 N-m 100 lb ft
Component Specifications
Specification
Front Brakes \
Discard Thickness (See Important) 30.7 mm 1.209 in

Maximum Lateral Runout 0.13 mm 0.005 in ..
Minimum Thickness After Refinish 31.08 mm 1.223 in
Minimum Wear Thickness 31.08 mm 1.223 in
Rotor Thickness (New) 32mm 1.26 in (
Thickness Variation 0.013 mm 0.0005 in
Rear Brakes
Discard Thickness 24.51 mm 0.965 in
Maximum Lateral Runout 0.15 mm 0.006 in
Minimum Wear Thickness 24.89 mm 0.980 in
Rotor Thickness (New) 25.90 mm 1.020 in
Minimum Thickness After Refinish 24.89 mm 0.980 in
Rear Axle Shaft Flange 0.05 mm 0.002 in
Thickness Variation 0.013 mm 0.0005 in
Important: All brake rotors have a discard dimension cast into the rotor. Replace any rotor that does not meet this
specification. After refinishing the rotor, replace any rotor that does not meet the maximum or minimum thickness after
refinish specifications.

Brake Caliper (Front) 4.000
Brake Caliper (Rear) 4.000
Brake Caliper Bracket (Front) 4.000
Brake Caliper Bracket (Rear) 4.000
Brake Pads (Front) 5.000
Brake Pads (Rear) 5.000 (
Brake Rotor Front 5.000
Brake Rotor (Rear) 5.000
Brakes Disc Brakes 5-57
Brake Rotor Thickness Variation Check 5. Turn the rotor one complete revolution. Inspect
the runout indicated on the dial. If the TIR
Measure the rotor thickness at four or more points exceeds 0.15 mm (0.006 in), refinish or replace
around the circumference of the rotor in order the rotor.
to inspect the thickness variation. Use a micrometer
calibrated in ten-thousandths of an inch. Inspect each In some cases, excessive lateral runout of the
measurement at the same distance from the edge rotor may be improved by indexing the rotor on the
of the rotor. hub, one or two bolt positions from the original
position. Indexing the rotor requires removal and
A rotor that varies in thickness by more than installation of the front brake caliper. For
0.013 mm (0.0005 in) may cause pedal pulsation or removal of the front brake rotor, refer to Brake
front end vibration during brake applications. Refinish Rotor Replacement (Front). For rear brake
or replace a rotor that does not meet the above rotor replacement, refer to Brake Rotor
specifications. Replacement (Rear).
If the lateral runout cannot be corrected by
Brake Rotor Lateral Runout Check indexing the front rotor, inspect the hub and the
Removal Procedure front wheel bearing for excessive lateral runout or
looseness. If the hub lateral runout exceeds
Tools Required 0.040 mm (0.015 in), replace the hub and bearing.
J 8001 Dial Indicator Set If lateral runout of the hub and bearing is within
specifications, refinish or replace the rotor as
Notice: Any time the brake rotor is separated from the
necessary.
wheel bearing flange, clean any rust or foreign material
from the mating surfaces of the wheel bearing flange If the lateral runout cannot be corrected by
and the rotor. Failure to do so can result in increased indexing the rear rotor, inspect the rear axle shaft
lateral runout of the rotor and brake pulsation. flange for excessive lateral runout. If the axle
flange lateral runout exceeds 0.040 mm (0.015 in),
replace the axle shaft. If lateral runout of the
1 2 axle flange hub is within specifications, refinish or
replace the rotor as necessary.
Brake Rotor Tolerance

Tolerances of the braking surfaces for the following
conditions are held closely during the manufacture of
the brake rotor:
• Flatness
• Parallelism
• Lateral runout
The maintenance of close tolerances on the shape of
the braking surfaces is necessary in order to
prevent brake roughness or· pulsation. The surface
finish must be held to a specified range of a 60 degree
radius of roughness or less. A new rotor conforms
to the above specifications, as will a correctly
refinished rotor. For front brake. rotors, refer to
181819
Refinishing Brake Rotors (Front). For rear brake rotors,
1. Clean the rotor surface (1 ). refer to Refinishing Brake Rotors (Rear). Control of
the braking surface finish will eliminate the following
problems:
Notices.
• Hard pedal application
2. Reinstall the wheel nuts (2) in order to retain
the rotor. • Excessive brake fade
Tighten • Pulls
Tighten the wheel nuts in a star pattern to • Erratic performance.
140 N·m (100 lb ft). Control of the braking surface finish will improve
3. Fasten the J 8001 to the steering knuckle for front lining life.
) or to the brake mounting flange on the rear axle Light scoring of the rotor surfaces not exceeding
for rear so that the indicator button contacts 1.5 mm (0.060 in) in depth is not detrimental to brake
the rotor surface about 13 mm (0.5 in) from the operation. Normal use may cause light scoring.
rotor edge.
4. Set the J 8001 to zero.
Repair Instructions
(
Brake Pad Inspection
• Inspect the disc brake pads every
10,000 km (6,000 miles) and anytime the
wheels are removed.
• Inspect both ends ofthe outer pad by looking in at
each end of the caliper. The highest rate of wear
normally occurs at the ends.
• Inspect the thickness of the inner pad in order to
ensure that it has not worn prematurely. Look
through the window in the top of the caliper
in order to view the inner pad.
• Both front and rear disc brakes have wear
indicators that make a noise when the pads wear
below specifications. The wear indicator is an
integral part of the outer pad. When the pad
is worn the wear indicator contacts the rotor and
produces a warning noise as indicated in the
illustration above.
• Replace the pads when the thickness is worn
below specification. Replace all pads in axle sets.
Refer to Component Specifications.
• Measure the flatness of the inner and outer pads;
Place the pad surfaces together and measure
the gap between the surfaces. If a gap larger than
the specification exists midway between the
attaching lugs, replace the pads. Refer to (
Component Specifications.
Brake Pads Replacement (Front)

Removal Procedure
1. Remove two-thirds of the brake fluid from the
master cylinder reservoir.
Information.
3. Remove the tire and wheel assembly. Refer to
Tire and Wheel Removal and Installation in
Tires and Wheels.
4. Remove front brake caliper. Refer to Brake
Caliper Replacement (Front).
451525
5. Remove the inner and outer brake pads from the
caliper mounting plate.
Use a screwdriver if necessary to remove the
pads from their installed position.
6. Inspect the caliper guide pins for free movement
in the caliper mounting plate.
7. Inspect the caliper guide pin boots for proper
seating in the retaining groove of the caliper
guide pin and the rear caliper mounting plate.
8. Replace the caliper guide pins and/or guide pin
boots if any of the following conditions exist:
e Excessive Corrosion
O Excessive Wear
• Visible Damage
171937
1. Install the inner and outer pads into the caliper
mounting plate. Ensure that the wear sensor is
at the trailing edge of the outer brake pad
when the wheel is rotating forward. If the wear
sensor is not at the trailing edge, the outer brake
pad is on the wrong side.
2. Install the front brake caliper. Refer to Brake
171937

Notices.
3. Install the caliper mounting pin bolts.
Tighten
Tighten the mounting pin bolts to 31 N-m (23 lb ft).
4. With the engine running, pump the brake pedal
slowly and firmly until the inner and outer brake
pads are positioned against rotor (firm pedal).
5. Install the tire and wheel assembly. Refer to Tire
and Wheel Removal and Installation in Tires and
Wheels.
7. Refill the master cylinder to the proper level with
) clean, fresh brake fluid.
8. Inspect the hydraulic brake system for brake
fluid leaks.
'
~
9. Burnish the new pads. Refer to Burnishing Pads
and Rotors.
63984
Brake Pads Replacement (Rear)
Removal Procedure
master cylinder.
Information.
Wheels.
451525
4. Install two wheel nuts (1) in order to retain the

rotor (2).
465503
5. Position a C-clamp (2) over the caliper

housing (1 ).
6. Tighten the C-clamp until the caliper piston
bottoms in the base of the brake caliper.
Verify that one end of the C-clamp rests on the
brake hose fitting bolt/screw and the other
end rests against the outer pad.
181856
7. Remove the rear brake caliper from the mounting
plate. Refer to Brake Caliper Replacement (Rear).
Ensure that weight of caliper is adequately
supported.
171937
8. Remove the inner and outer brake pads (2) from

the mounting plate (1 ).
9. Clean all the residue from the shoe guide surfaces
on the caliper mounting plate and the rear brake
caliper.
) 11. Inspect the caliper guide pin boot for proper seating
in the retaining groove of the guide pin and the
caliper mounting plate. Replace the caliper guide
pins or the guide pin boots, if corrosion or damage
exists. Refer to Brake Caliper Overhaul (Rear).
221494
Important:
.. Install the inner pad with wear sensor near the
piston.
• Ensure that the wear sensor .is on the leading
edge of the inner pad during forward wheel
rotation. If the wear sensor is not on the leading
edge, use the other inner pad in the
replacement kit.
• Replace the inner and outer pads in axle sets only.
1. Install new inner and outer pads (2) into mounting
plate (1 ).
221494
2. Install the rear brake caliper to the mounting plate.
Refer to Brake Caliper Replacement (Rear). (
171937
3; Remove the wheel nuts (1) securing the rotor(2).

Removaland Installation in Tires and Wheels.
5. Lower the vehicle. ·
6. With engine running, pump brake pedal until
· · brake pads are positioned against rotor (firm
brake pedal). ·
7. Verify that there are no leaks in the brake (
hydraulic system.
8. Burnish the new pads. Refer to Burnishing Pads
and Rotors. ·
465503
Burnishing Pads and Rotors

Burnish the new braking surface after the brake pads
hav<3 been replaGe<:l and .the rotors have been
refinished or replac<3d: · ·
Burnishing ''bre.aks in" the new pads or rotors.
Burnishing also removes. light corrosion on the rotors.
Burnish the brakes by making 20 stops from
48 km/h (30 mph) using medium to firm pressure on
the brake pedal. Allow 0.8 km (0:5 miles) between
stops in order. to avoid overheating the. brakes.
(
Brakes Disc· Brakes 5~63
Brake Caliper Replacement (Front)
J Removal Procedure
master cylinder.
Information.
Wheels.
451525
4. Push the piston into the housing bore in order to

provide clearance between the pads and the rotor.
4.1. Install a large C-clamp (2) over the top of
the caliper housing (1) and against the back
of the outboard pad.
4.2. Slowly tighten the C-clamp until the piston
is pushed into the caliper bore enough to
slide the caliper off the rotor. Do not
overtighten the C-clamp. Overtightening the
C-clamp will.deform the outboard shoe.
181856
5. Complete the following steps if the caliper is. being

removed from the vehicle for overhaul or
replacement:
5.1. Remove the brake hose bolt attaching the
brake hose fitting to the· ca.liper. ·
5.2. Remove the following components:
• The brake hose fitting (1}
• The copper gaskets (2)
Discard the copper gaskets. 3
• The brake hose from the caliper (3)
5.3. Plug the openings in the caliper housing
and the hose in order to prevent loss or
contamination of the brake fluid.
1
6. Ii the caliper is being removed for service of the
mounting plate or the brake pads,. do not
disconnect the inlet fitting.
581444
7. Remove the brake caliper guide pin bolts.
63984
8. Remove the caliper housing from the rotor and

the brake caliper mounting bracket.
If the caliper is not being removed from the
vehicle, suspend the caliper from the front
suspension using a fabricated wire hook.
9. Remove the caliper guide pin bolts and discard.
10. Inspect the following parts for corrosion, cuts,
nicks or blockage. Replace any damaged parts. (
• The caliper guide pin bushings
• The brake hose fitting
If corrosion and/or excessive wear is found,
use new parts, including bushings, when
installing the caliper. Do not attempt to polish
away corrosion.
171937
1. Lubricate the inMr diameters of the caliper bolt
bushings (2) with silicone grease.
2. Lubricate the caliper bolts. (1). Use silicone
1 grease. Do not lubricate the threads.
3. Inspect the caliper guide pins.
• The caliper pin should slide through the pin
bushings and caliper pin bores using only
hand pressure.
• If greater force is required, remove the caliper
pin and the bushings.
4. Inspect the mounting bores for corrosion.
• If corrosion exists, remove the corrosion using
a 1-inch wheel cylinder brush.
2 • Clean the mounting bores using clean
3
denatured alcohol.
5. Replace the caliper pin and bushings. Refer to
142246
Brake Caliper Overhaul (Front).
6. .Install the caliper and pad$ onto the mounting
bracket.
171937

Notices.
7. Install the front brake caliper guide pin bolts.
Tighten
Tighten the front brake caliper guide pin bol.ts to
31 N·m (23 lb ft).
63984
8. If. the following components were remo'(ed, install

them onto the caliper housing using new copper
gaskets:
• The brake hose fitting
• The brake hose
Tighten
Tighten the front brake hose fitting to .
40 N·m (30 lb ft).
Wheels.
373249
Important: If the brake hose was removed, bleed the
caliper. Refer to Hydraulic Brake System Bleeding
(Manual Bleeding) in Hydraulic Brakes.
11. Fill the master cylinder reservoir to the proper
level with clean brake fluid.
12. With engine running, pump brake pedal until firm
brake pedal is attained.
13. Check for leaks.
Brake Caliper Replacement (Rear)

Removal Procedure
1. Raise and suitably the vehicle. Refer to Lifting
Wheels.
3. Reinstall two wheel nuts (1) in order to secure the
rotor (2).
465503 (
4. Complete the following steps if you are removing
the caliper (5) from the vehicle:
2 1
4.1. Remove the brake hose bolt attaching the
brake hose fitting (4).
4.2. Remove the following items:
• The copper gaskets
Discard the copper gaskets.
• The brake hose from the caliper
4.3. Plug the openings in the caliper housing
and the hose in order tc> prevent loss or
contamination of the brake fluid;
222984
(
5. Remove the brake caliper guide pin bolts and
) · discard.
63984
6. Remove the rear brake caliper (3) from the inner

and outer pads (2) and mounting plate (1 ).
If the caliper is not being removed from the vehicle
for unit repair, suspend the caliper from the rear
suspension using a fabricated wire hook.
221490
7. Remove the inner and outer brake pads (2) from

the mounting plate (1) if the following
conditions exist:
• The brake pads are also being replaced.
• The brake caliper mounting plate is also being
removed.
9. Inspect the caliper guide pin boot for proper
seating in the retaining groove of the caliper guide
pin and the rear caliper mounting plate.
10. Replace the guide pins or guide pin boots if the
following conditions exist:
) • Excessive Corrosion
• Significant Wear
• Visible Damage
221494
11. Lubricate the inner diameters of the caliper bolt
bushings with silicone grease. Also lubricate the
caliper bolts with silicone grease. (
12. Inspect the inner and outer pads for wear.
13. Inspect the inner and outer pads for
maximum taper.
• Maximum taper of the rear brake pads is
0.15 mm (0.006 in).
• If the pads are tapered beyond the maximum
specification, replace the inner and outer
pads as a complete set only.
1. Install the inner and outer pads (2) into the
mounting plate (1 ).
(
221494
2. Install the rear brake caliper (3) over the brake

pads (2) and into the caliper mounting plate (1 ).
Notices.
3. Install new brake caliper guide pin bolts.
Tighten
Tighten the brake caliper guide pin bolts to
37 N-m (72 lb ft).
221490
4. Install the following components, if removed:
• The brake hose
• The new brake hose fitting gaskets
5. Install the brake hose fitting bolt.
Tighten
Tighten the brake hose fitting bolt to
30 N;m (22 lb ft).
6. Bleed the brake hydraulic system, if the brake
hose fitting was removed. Refer to the following
procedures:
• Hydraulic Brake System Bleeding
(Manual Bleeding) ·
(Pressure Bleeding)
(When To Bleed)
7. Remove the wheel nuts securing the rotor.
8. Install the tire and wheel. Refer to Tire and Wheel 465503
10. While the engine is running, pump the brake
pedal slowly and firmly three times in order to
seat the inner and outer pads.
11. Check the brake hydraulic system for leaks.
Brake Caliper Inspection

) • Check the calipers for outward signs of leaking
fluid and cracked or damaged piston boots.
• .Check the calipers for excess.ive corrosion on the
br.ake pad guiding surface.
• Perform all other types of caliper inspections
during unit repair.
)
Brake Caliper Overhaul (Front)
Disassembly Procedure (
Important:
" Replace all the components included in the repair
kits used to service th.is brake caliper.
• Lubricate the rubber parts with clean brake fluid to
make assembly easier.
• lfany hydraulic component is removed or
disconnected, it may be necessary to bleed all or
part of the brake system.
O Replace the brake pads in axle sets only.
• The torque values specified are for dry,

unlubricated fasteners.
.. Perform the service operations on a clean bench,
free from all mineral oil materials.
63980
(
Caution: Do not place your fingers in front of the
piston in order to catch or protect the piston while
applying compressed air. This could result in
serious injury.
1. Remove the brake caliper from the vehicle. Refer
to Brake Caliper Replacement (Front).
2. Remove the pistons by directing compressed air
into the brake hose inlet fitting port of the brake
caliper housing.
171956
I
(
Brakes Disc Brakes 5;.71
3. Remove the piston boots (2).
) 4. Remove the piston seals (1).
581456
5. Remove the brake caliper bleed screw cap.

6. Remove the brake caliper bleed screw (1 ).
7. Inspect the brake caliper bores and piston seal
grooves for scoring and corrosion. If badly
scored or corroded around the piston seal area,
replace the brake caliper housing.
581457
8. Inspect the brake caliper mounting bracket guide

surfaces for corrosion and wear. Remove and
replace the brake caliper mounting bracket
if necessary.
9. Clean all the residue from the brake pad guiding
surfaces on the brake caliper housing and the
brake caliper mounting bracket.
10. Clean all the parts not included in the repair kit
with denatured alcohol.
11. Dry all the parts with filtered unlubricated
compressed air.
12. Blow out all passages in the brake caliper housing
and the brake caliper bleeder valve.
171985
Assembly Procedure
Notice: Refer to Fastener Notice in Cautions·. and (
Notices.
1. Install the brake caliper bleed screw (1 ).
Tighten
12 N-m (106 lb in).
2. Install the brake caliper bleed screw cap.
581457
3. Lubricate the new piston seals and the brake

caliper bore seat grooves with brake fluid.
4. Install new s~als (1) into the brake caliper bore
seal .grqoves.
5. Make sure the seals are not twisted.
6. Lubricate the brake caliper bores and the pistons
with brake fluid.
7. Install the boot (2) and piston (3). (
7.1. Install the boot over the end of the piston
so that the fold will face toward the brake
caliper housing piston bore opening.
7.2. Seat the boot into the brake caliper bore
groove and slide the piston into the brake
caliper bore.
7 .3. Push down the piston to the bottom of the
brake caliper bore.
7.4. Make sure the boot is properly seated into
the piston groove and into the groove in the
501455 brake caliper bore.
7.5. Repeat Steps 5 and 6 for the remaining
piston: ·
8. Install the brake caliper to the vehicle. Refer to
Brake Caliper Replacement (Front).
Brake Caliper Overhaul (Rear)
Important:
• Replace all the components included in the repair
kits used to service this brake caliper.
• Lubricate the rubber parts with clean brake fluid to
make assembly easier.
• If any hydraulic component is removed or
disconnected, it may be necessary to bleed all or
part of the brake system.
• Replace the brake pads in axle sets only.
• The torque values specified are for dry,
unlubricated fasteners.
• Perform the service operations on a clean bench,
free from all mineral oil materials.
)
,63982
Caution: Do not place your fingers in front of the

piston in order to catch or protect the piston while
applying compressed air. This could result in
serious injury.
1. Remove the brake caliper from the vehicle. Refer
to Brake Caliper Replacement (Rear).
2. Remove the piston by directing compressed air
into the brake hose inlet fitting port of the brake
caliper housing.
171956
)
3. Remove the piston boot (2).
4. Remove the piston seal (1). (
581465
5. Remove the brake caliper bleed screw cap.

6. Remove the brake caliper bleed screw (1 ).
7. Inspect the brake caliper bore and piston seal
groove for scoring and corrosion. If badly scored
or corroded around the piston seal area,
replace the brake caliper housing.
581466
8. Inspect the brake caliper mounting bracket guide

surfaces for corrosion and wear. Remove and
replace the brake caliper mounting bracket
if necessary.
9. Clean all the residue from the brake pad guiding
surfaces on the brake caliper housing and the
brake caliper mounting bracket.
10. Clean all the parts not included in the repair kit
with denatured alcohol.
11. Dry all the parts with filtered unlubricated
compressed air.
12. Blow out all passages in the brake caliper housing
and the brake caliper bleeder valve.
171985
Assembly Procedure
) Notice: Refer to Fastener Notice in Cautions and
Notices.
1. Install the brake caliper bleed screw (1 ).
Tighten
12 N·m (106 lb in).
2. Install the brake caliper bleed screw cap.
581466
3. Lubricate the new piston seal and the brake

caliper bore seal groove with .brake fluid.
4. Install the new seal (1) into the brake caliper bore
seal groove.
5. Make sure the seal is not twisted.
6. Lubricate the brake caliper bore and· the piston
with brake fluid.
) 7. Install the boot (2) and piston.
7.1. Install the boot over the end of the piston
so that the fold will face toward the brake
caliper housing piston bore opening.
7.2. Seat the boot into the brake caliper bore
groove and slide the piston into the brake
caliper bore.
7.3. Push down the piston to the bottom of the
brake caliper bore.
7.4. Make sure the boot is properly seated into
the piston groove and into the groove in the
brake caliper bore. 581465
7.5. Repeat Steps 5 and .6 for the remaining

piston.
8. Install the brake caliper to the vehicle. Refer to
Brake Caliper Replacement (Rear).
)
Brake Caliper Bracket Replacement (Front)
Removal Procedure (
1. Remove the inner and outer pads. Refer to Brake
Pads Replacement (Front). '
Caution: These fasteners MUST be replacedwith
new fasteners anytime they become loose or
are removed. Failure to replace these fasteners
after they become loose or are removed may cause
Joss of vehicle control and personal injury.
2
2. Remove the caliper bracket bolts (2).
3. Remove the caliper bracket (1 ).
177036
4. Remove .the following components from the

bracket (1 ):
• The boot bolts (2)
• The bushings
5. Inspect the bracket for cracks.
6. Replace the bracket if necessary.
177068
1. Lubricate the following components with silicone
grease:
• New bolt boots
• New bushings
2 2. Install the following components into the caliper
bracket (1 ):
.. The bolt boots (2)
• The bushings
Notices.
3. Install the caliper bracket with the bracket bolts.
Tighten (
Tighten the caliper bolts to 100 N-m (74 lb ft).
4. Install the inner and outer brake pads. Refer to
Brake Pads Replacement (Front).
177063
Brakes Disc Brakes 5-..77
Brake Caliper Bracket Replacement (Rear)
J Removal Procedure
1. Remove the inner and outer brake pads, Refer to
Brake Pads Replacement (Rear).
Caution: These fasteners MUST be replaced with
new fasteners anytime they become loose or
are removed. Failure to replace these fasteners
after they become loose or are removed may cause
loss of vehicle control and personal injury.
2
2. Remove the caliper bracket bolts (2).
3. Remove the caliper bracket (1 ).
177036
1. Lubricate the following components with silicone
grease:
• New bolt boots
• New bushings
2. Install the following components into the caliper 2
bracket (1):
) • The bolt boots (2)
• The bushings
Notices.
3. Install the caliper bracket with the bracket bolts.
Tighten
Tighten the caliper bolts to 100 N·m (74 lb ft).
4. Install the inner and outer brake pads. Refer to
Brake Pads Replacement (Rear).
177063
Brake Rotor Replacement (Front)

Removal Procedure
Information.
Wheels.
3. Remove the front brake caliper. Refer to Brake
4. Remove the caliper mounting bracket bolts and
the caliper mounting bracket.
5. Remove the brake rotor (1) from the wheel ·
) hub (2).
6. Clean the metal contact surfaces between the
brake rotor and the hub bearing flange.
581489
1. Install the brake rotor (1) onto the wheel hub (2). (
2. Install the caliper mounting bracket and caliper
mounting bracket bolts.
3. Install the front brake caliper. Refer to Brake
Wheels.
6. Pump the brake pedal several times until firm.
581489
Brake Rotor Replacement (Rear)

1 Removal Procedure
The rear brake rotor can be removed without separating
the caliper from the mounting plate (remove as an
assembly).
Lifting and Jacking the Vehicle in General (
Information.
Wheels.
3. Remove the rear brake caliper (2) and mounting
bracket. Support with a locally fabricated hook (1).
Refer to Brake Caliper Replacement (Rear).
181861
4. Remove the brake rotor (1) from the wheel

hub (2).
1
221499
) Notice: Any new rotor must have the protective
coating removed from the friction surfaces before being
placed in service. Use Goodwrencih Brake Parts
Cleaner P/N 123777981. or the eqL1ivalent, and wipe
the surface clean with clean cloths. Do not use
gasoline, kerosene, or other oil base solvents which
may leave an oily residue. This residue is damaging to
the brake lining and is flammable. ·
1. Install the brake rotor (1) onto th~ wheel hub (2).
2. Install the rear brake caliper and mounting
plate assembly. Refer to'Brake.Caliper .
Replacement (Rear).
Wheels.
5. Pump the brake pedal several times untii the
pedal is firm. 221499
Refinishing Brake Rotors (Front)

Important: DO NOT refinish brake rotors when
performing routine brake maintenance, such as
replacing worn disc brake pads. Refinish a rotor ONLY
under the following circumstances:
• Th~re is a complaint of brake pulsation. ·
) • There is scoring greater than 1.5 mm (0.060 in).
All brake rotors have a minimuinthickness dimension
a
cast into the rotor. This dimension is not miniinu111
refinishing dimension. The minimum refinishing
dimension is· larger than the discard dimension. Do not
use a brake rotor that, after refinishing, will not meet
the minimum thickness .shown on the rotor. Replace it
with a new rotor. Refer to Component Specifications.
Accurate control of. the rotor tolerance is necessary
for proper performance of the disc brakes. Machine the
rotor using precise equipment. Service machining
equipment on a regular basis. Follow the
manufacturer's recornmendt3d maintenance procedure.
Ensure.that the following tool accessories are in.
good condition when refinishing the rotors:
• The attaching adapters
• The tool holders
• The vibration dampeners
• The tool bits
Always use sharp cutting tools and bits. Replace
cutting bits using equipment recommended by
the manufacturer. Dull or worn.tools leave a poor
surface finish which will affect braking performance.
Always use an.ti-chatter silencer attach.ments when
refinishing braking surfaces. The attachments eliminate
tool chatter and will result in a better surface finish.
) Ensure that the adapters are clean and free bf nicks.
In order to correct brake pulsation, refinish the rotors Refinishing Brake Rotors (Rear}
using an on-vehicle brake lathe. Follow the equipment
manufacturer's recommended specifications and Important: DO NOT refinish brake rotors when (
procedure. performing routine brake maintenance, such as
replacing worn disc brake pads. Refinish a rotor ONLY
Important: Remove any rust and scale from the rotor under the following circumstances:
and spindle hub mating surfaces. Failure to do so
may introduce excessive lateral runout when the rotor • There is a complaint of brake pulsation.
is mounted on the brake lathe, or when the rotor is • There is scoring greater than 1.5 .mm (0.060 in).
reinstalled on the spindle hub. All brake rotors have a minimum thickness dimension
The following two procedures are recommended and cast into the rotor. This dimension is not a minimum
achieve adequate results using two different refinishing dimension. The minimum refinishing
off-vehicle disc brake lathes. If any other lathe is used, dimension is larger than the discard dimension. Do not
follow that lathe's instructions and recommendations: use a brake rotor that, after refinishing, will not meet
the minimum thickness shown on the rotor. Always use
Accu Turn® Brake lathe a new rotor. Refer to Component Specifications.
1. Locate the deepest score and turn the rotor Accurate control of the rotor tolerance is necessary for
micrometer knob until the tool bit bottoms out proper performance of the disc brakes. Machine the
at the deepest point of the score. rotor using precise equipment. Service the machining
2. Zero the scale and back out the tool bit. equipment on a regular basis. Follow the
3. Advance the cutter handwheel until the bits have manufacturer's recommended maintenance procedure.
cleared the inner edges of the rotor face. Ensure that the following tool accessories are in
4. Adjust the micrometer knobs for approximately good condition when refinishing the rotors:
0.127 mm (0.005 in) more than the first reading. • The attaching adapters
Use this method in order to resurface the • The tool holders
rotor in one cut.
• The vibration dampeners
Front Rotor Finish Cut • The tool bits
Spindle Speed 105 rpm Always use sharp cutting tools and bits. Replace
cutting bits using equipment that is recommended. by
Depth of Cut As necessary the manufacturer. Dull or worn tools leave a poor
Cross Feed (per rev.) 0.08 mm (0.003 in) surface finish which will affect braking performance.
Vibration Dampener Yes Always use anti-chatter silencer attachments when
refinishing braking surfaces. The attachments eliminate
Nondirectional Finishing tool chatter and will result in a better surface finish.
Ensure that the rotor surface is nondirectional by Ensure that the adapters are clean and free of nicks.
dressing the rotor surfaces. Use a non-directional rotor In order to correct brake pulsation, refinish rotors
finisher such as the 54-433179 Non-Directional using an on-vehicle brake lathe. Follow the equipment
Rotor Refinisher listed in the GM Dealer Equipment manufacturer's recommended specifications and
Catalog, or a suitable equivalent. procedure.
If the brake lathe is not equipped with an adequate lmp·ortant: Remove any rust and scale from the rotor
nondirectional finishing tool, use a sanding block with and spindle hub mating surfaces. Failure to do so
150 grit aluminum oxide sandpaper. may introduce excessive lateral runout when the rotor
With the rotor turning at the equipment manufacturer's is mounted on the brake lathe, or when the rotor is
highest recommended cutting speed, sand each reinstalled on the spindle hub.
rotor surface for a minimum of 60 seconds using The following two procedures are recommended and
moderate pressure. achieve adequate results using two different
After the rotor has been sanded, clean each surface off-vehicle disc brake lathes. If any other lathe is used,
with denatured alcohol or a suitable brake cleaner. follow that lathe's instructions and recommendations:
Important: Replace any rotor that does not meet the Accu Turn® Brake lathe
minimum thickness specification recommended by 1. Locate the deepest score. Turn the rotor
the manufacturer. Do not resurface new brake rotors. micrometer knob until the tool bit bottoms out at
New brake rotors are manufactured with the proper the deepest point of the score.
surface finish.
2. Zero the scale and back out the tool bit.
The finished rotor surface should be as close as
3. Advance the cutter handwheel until the bits have
possible to that of a new rotor. Failure to obtain the
cleared the inner edges of the rotor face.
best possible rotor finish may affect braking
performance. 4. Adjust the micrometer knobs for approximately
0.127 mm (0.005 in) more than the first reading.
Use this method in order to resurface the
rotor in one cut.
Rear Rotor Finish Cut 5. Install the anti-chatter silencer onto the rotor.
Spindle Speed 105 rpm 6. Set the spindle speed to approximately 150 RPM
(or mid-range).
Depth of c.ut As necessary
7. While the machine is running, bring the tool bit up
Cross Feed (per rev.) 0.08 mm (0.003 in)
and touch off.
Vibration Dampener Yes " Stop the machine .
..
• Inspect the witne.ss mark. If the witness mark
Rotor Mounting Adapter
goes% oft.he way around, the rotor is
Tools Required mounted properly. · · ··
• J37160-A Rotor Mounting Adapter • Continue turning the rotor using normal
" J 37160-50 Rotor Mounting Adapter Sleeve methods in order to resurface the rotor.
8. If the witness mark does not go % of the way
Important: Verify that the mounting surfaces of these around, repeat the above steps.
components are clean arid free from nicks, burrs
or rust. Nondirecticmal Finishing
1. Inspect all of the mounting hardware for the Ensure that the rotor surface is nondirectional by
following conditions: · dressing the rotor surfaces. Use a non-directional rotor
finisher such as the 54-433179 Non-Directional
• Rust Rotor Refinisher listed in the GM Dealer Equipment
• Nicks Catalog, or a suitable equivalent.
• Dirt If the brake lathe is not equipped with an adequate
• Abnormal wear nondirectional finishing tool, use a sanding block with
150 grit aluminum oxide sandpaper.
For proper results, ensure t.hat all components ·
are in good condition and clean. After the rotor has been sanded, clean each surface
with denatured alcohol or a suitable brake cleaner.
2. Inspect the rotor:
With the rotor turning atthe equipment manufacturer's
• Measure the lateral runout. Refer to Brake highest recommended cutting speed, sand each
Rotor Lateral Runout Check.
) • Measure the thickness variation. Refer to
rotor surface for a minimum of 60 seconds using
moderate pressure.
Brake Rotor Thickness Variation Check.
Important: Replace any rotor that does not meet the
Ensure that the mounting surface of the rotor minimum thickness specification recommended by
is clean and free from rust and nicks. the manufacturer. Do not resurface new brake rotors.
3. Mount the J 37160-Aon a spindle arbor. New brake rotors are manufactured with the proper
surface finish.
O
Use a suitable combination of spacers or
collets in order to tighten the J37160-A The finished rotor surface should be as close as
to the arbor. possible to that of a new rotor. Failure to obtain the
best possible rotor finish may affect braking
O
When using lathes with a 7/8-inch spindle
performance.
arbor, use the J 37160-50 with the J 37160-A.
e The J 37160-50 is not required with lathes
using a· 1.,-inch spindle arbor.
Notices.
4. Mount the rotor onto the J 37160-A

• Mount the clamp plate to the rotor using the
enclosed bolts/screws.
• The rotor may be installed and removed while
the J 37160-A is mounted on the machine
spindle.
Tighten
Tighten the rotor mounting adapter nuts in
a cross pattern to 34 N-m (23 lb ft).
)
Description and Operation causes the vehicle to stop. In addition, it is this sliding
action that allows a disc brake caliper to compensate (
for wear of the inner and outer pads. If upon
Disc Brakes System Description (Front) inspection, it is found that. one pad is significantly
Front Brake Rotor thicker or thinner than its counterpart, it would be an
indication that the caliper is not sliding freely, and
The front brake rotor is a machined, cast iron therefore not self-adjusting as it is should,
ventilated rotor. The rotor is cast with cooling fins
between the friction surfaces. The internal fins The brake caliper piston seals, while sealing the
or vanes radiate from the center of the rotor to the hydraulic circuit at the wheels, have a second function.
outer edge of the rotor. This design enables the rotor These seals while firmly mounted in their channels,
to act as its own cooling fan. do distort very slightly under brake actuation. When the
brakes ;:ire applied, the movement of the pistons out
Front Brake Caliper of the caliper bores distort the piston seals. When
the brake pedal is released, the piston returns only as
far as the seal was distorted. While this distortion
of the seal shape is very minimal, it is enough to allow
the brake pads to retract very slightly so as to
eliminate any significant drag of the brakes.
Disc Brakes System Description (Rear)

Rear Brake Rotor
The rear brake rotor is a composite cast iron ventilated
rotor. The rear brake rotor has a stamped sheet metal
flange which is insert cast. The internal fins or vanes
between the friction surfaces radiate from the center of
the rotor to the outer edge of the rotor. This design
enablesthe rotor)o act as its own cooling fan.
Rear Brake Caliper
63980
The aluminum dual piston front caliper used on this 5

vehicle is mounted onto the front brake caliper
mounting plate, and ultimately to the steering knuckle.
Applying the brake pedal creates hydraulic pressure.
This pressure exerts equally against the bottom of the
465589
pistons and against the bottom of the cylinder bores.
The pressure applied to the pistons transmits to The rear brake caliper has a single piston (1) in an
the inner pad and forces the pad against the inner aluminum housing (2). The housing is suspended in an
rotor surface. The pressure applied to the bottom of anchor bracket (3) on two guide pins (4). The caliper
the cylinders forces the caliper to slide in the mounts to the steering knuckle with two mounting bolts.
caliper bolt bushings toward the center of the vehicle. Applying the brake pedal creates hydraulic pressure.
This movement forces the outer section of the This pressure exerts equally against the bottom of the
caliper against the back of the outer pad and presses piston and against the bottom of the cylinder bore. The
the pad against the outer rotor surface. As hydraulic pressure applied to the piston transmits to the brake
pressure builds, the pads press against the rotor pads (5). The brake pads clamp down on the rotor,
surface with increasing force. The increasing force creating friction in order to stop the car.
Application of the parking brake causes the following Special Tools and Equipment
) components to move outward:
Illustration Tool Number/ Description
• The pushrod (23)
• The actuating collar (10)
• The clamp rod (19)
The outward motion of the above components causes
the caliper to move inward. Inward motion of the
J 8001
caliper forces the brake pads against the rotor in order
to hold the vehicle in place. The parking brake Dial Indicator Set
rnE3chanism is completely independent of the hydraulic
braking system.
2014
J 37160-A
Brake Rotor Mounting
··· Adapter
155093
) J 37160-50
Brake Rotor Mounting
Adapter Arbor
180911
)
5-84 Park Brake Brakes
Park Brake
(
Specifications
Specification
Park Brake Indicator Switch Screw 2.8N·m 251bin
Park Brake Lever Bolt 12 N·m 106 lb iri · '

Backing Plate 5.000
Park Brake Actuator 4.000
Park Brake. Cable (Front) 4.000
Park Brake Cable (Rear) 4.000
Park Brake Drum 5.000
Park Brake Lever 4.000
Park Brake Shoe 5.000
(
Brakes Park Brake 5-85
) Repair Instructions
Park Brake Shoe Replacement
Removal Procedure
1. Remove the brake rotor. Refer to Brake Rotor
2. Remove the parking brake shoe retaining clip and
attaching screw.
3. Remove the parking brake shoe by sliding the
brake shoe downward off tappet slot.
64007
1. TurnJhe adjustable tappet until the tappet is
seated against adjuster nut. Orient the. slot
radially (parallel with mounting flange).
2. Install the parking brake shoe by sliding the. shoe
) upwards into the tappet slots.
Notice: Refer to Fastener Notice in a Cautions and
Notices.
3. Install the parking brake shoe retaining clip and
the attaching screw.
Tighten
Clip screw to 5 N·m (44 lb in).
4. Adjust the parking brake shoe to drum clearance.
Refer to. Park Brake Shoe Adjustment.
5. Install the brake rotor. Refer to Brake Rotor
64007
)
5.;86 Park Brake Brakes
Park Brake Shoe Adjustment
Important: Do not operate the park brake lever while (
the rotor is removed.
1. Remove the rear tires and wheels. Refer to Tire
and Wheel Removal and Installation in Tires and
Wheels. ·
2. Disconnect the rear cable from the brake
shoe lever.
3. Pull on the lever until there is a firm stop. Release
the lever and measure free lever travel at the
cable interface. If the travel is less than 10 mm,
adjustment is complete. If the travel is more
than 10 mm, further adjust brake shoe.
4. Remove the brake rotor. Refer to Brake Rotor
5. Rotate the adjustment nut with a screwdriver in
order to extend the slotted tappet in order to
increase the gap between the adjuster nut and
465503 the screw by .38 mm.
6. Install the rotor onto the axle mounting flange.
Ensure that the rotor is flush against the flange.
Use two hand-tightened lugnuts (1) in order
to keep the rotor (2) in position.
7. Measure the lever (free) travel perstep 2. Repeat
the adjuster in order to obtain the ideal 3-8 mm
free travel of the brake shoe lever;
8. Check the rotor for drag. The rotor must rotate (.
freely within the stud hole clearance. .
9. Install rear tires and wheels. Refer to Tire and
Wheels.
Park Brake lever Replacement

Removal Procedure
Notice: Do not lubricate the parking brake cables.
Lubrication may damage the plastic coating on
the parking brake cables.
If the park brake lever does not adjust the cable,
lubricate the following components using chassis
lubricant or the equivalent:
• The adjust pawl pin
• The handle ratchet
• The adjusting ratchet
Tools Required
5
J 37043 Parking Brake Cable Release Tool
1. Remove the front floor console.
Important: If the park brake handle cannot be pulled
up far enough in order to lift out console, then
182184 release handle and hold the adjuster pawl disengaged.
The lever handle can then be pulled up further.
2. Disconnect the electrical connector from the park
brake indicator switch (6).
3. With the park brake lever (1) in the up position,
remove the park brake lever spring (2).
4. With the park brake lever (1)in the down position,
rotate the adjuster arm toward the front of the
vehicle until the adjuster arm stops.
5. On the adjuster ratchet, bend the tab at the
barrel-shaped front cable end back in order
to allow the cable strand to pass by.
6. Unhook cable front end button from adjuster
ratchet.
7. Remove the barrel-shaped front cable end fitting
from the adjuster track on the pulley.
8. Remove the park brake lever bolts (3) and the
park brake lever (1) from the floor pan.
9. Use the J 37043 in order to remove the park
brake front cable (4) from the park brake
lever (1) and remove the lever from vehicle.
1. On the new park brake lever assemblies, pull the
lever up to full travel. Remove the adjuster
spring (2).
2. Push out the plastic shear pin.
3. Install the park brake front cable (4) to the park
brake lever (1 ).
Notices.
4. Install the park brake lever (1) and the park brake
lever bolts (3) to the floor pan.
) Tighten
Tighten· the park brake lever bolts (3) to
12 N·m (1061b in).
5. Connect the electrical connector to the park brake
indicator switch (6).
6. With the park brake lev.er in the down position
and adjuster pawl released, rotate the adjuster 182184
arm toward the front of the vehicle until the
adjuster arm stops.
7. Connect the barrel-shaped front cable end fitting
to the adjuster track on the pulley. ·
8. If the rear cables were not disconnected from the
equalizer, skip to step 12.
9. Raise the vehicle. Suitably support the vehicle.
Refer to Lifting and Jacking the Vehicle in
General Information.
10. Connect the rear cables (2) to the equalizer (1 ).
)
214860
s~ss Park, Brake Brakes
12. Rotate the adjuster arm toward the rear of the
vehicle and completely raise the park brake
lever (1 ). (
13. Install the park brake adjuster spring (2).
14. Cycle the park brake lever 3 times.
15. Install the front floor console.
182184
Park Brake Cable Replacement (Front)

Removal Procedure
Tool Required
J 37043 Parking Brake Cable Release Tool
Notice: Use care when performing service 'operations
on or around parking brake cables. Damage to the
plastic coating will reduce corrosion protection and if (
the damaged area .passes through the seal,
increased parking brake effort could re.suit Contacting
the coating with sharp-edged tools, or with sharp
surfaces of the vehicle underbody, should be avoided.
1. Ensure that the park brake hand lever is inthe
down position in order to disengage the ·
adjuster pawl.
Information.
182210 3. Pull down on the front cable strand until the
strand stops and stays extended: .
4. Remove the rear cables (2) from the equaiizer (3).
5. Use the J 37043 in order to remove .the fitting of
the park brake front cable from the bracket.
214860
6. Remove the cable grommet from the underbody
cavity.
8. Remove the front floor console.
9. Remove the park brake spring (2) while the park
brake lever is in the up position.
10. With the park brake lever (1) in the down position,
rotate the adjuster arm toward the front of the
vehicle until the adjuster arm stops.
11. On adjuster ratchet, bend tab at barrel-shaped
front cable end back in order to allow the cable
strand to pass by.
12. Remove the barrel-shaped front cable end fitting
from the adjuster track on the pulley.
13. Use the J 37043 in order to remove the park
brake front cable (4) from the park brake
lever (1 ).
14. Remove the park brake front cable (4) from the
182184
floor plan.
1. Install the park brake front cable (4) and the
grommet (5) into the slot in the floor pan. Use
the following procedure in order to install
the grommet into the floor pan:
1.. 1, .Use soapy water as a lubricant.
1.2. Feed the forward end of the grommet (5)
into. the slot.
) 1.3. Use a small, curved, flat-ended pry bar in
order to gently press the rearward end of
the grommet (5) into the slot.
1.4. Ensure that the.grommet (5) is properly
seated in the .slot in the floor pan.
2. Connect the front park brake cable (4) to the park
brake lever (1).
3. Install the barrel-shaped front cable end fitting into
the adjuster track on the pulley.
4. Rotate the adjuster arm toward the rear of the
182184
vehicle and install the adjuster spring.
5. Ensure that the park brake lever (1) is in the down
position.
Lifting and Jacking the Vehicle in Gener.al
Information.
)
5-90 Park Brake . Brakes
7, Connect the rear fitting of the front cable conduit
to the floor panbracket (1 ).
" Pull the equalizer (3) back until the (
equalizer stops'.
" Connect the rear cables (2) to the equalizer (3).
9. Cycle the par!< brake lever (1). three times.
10. Install the front floor console.
214860
Park Brake Cable Replacement (Rear.)

Removal .Proc.edure
Tools Required ·
J 37043 Parking Braker Cable Release Tool
1. Fully disengage the park brake lever. Ensure that
the handle is down and that the bra:ke indicator
lamp is not lit.
(
Important: If the park brake lever is partially engaged,
you will not be abl.e to pull the equalizE3r rearward
later in this procedure.
Information.
3. Pull down on the front cable strand until the
strand stops and stays extended.
4. Cut off the tie strap.
182210
5. Remove the rear cable from the underbody

bracket.
Use the J37043 in order to compress the retainer
fingers on the casing and pull the rear.cable
from the underbody bracket.
6. Remove the rear park brake cables (2) from the
park brake cable equalizer (3).
214860
7. Pull the park brake rear cable (3) through the
guides (2) that are installed on the rear axle
housing.
2 3
214857
8. Unhook the rear cable eyelet (1) from the park

brake actuator lever (2).
1 2
214859
9. Use the J 37043 in order to compress the retainer

fingers on the conduit fitting (1) and pull the rear
cable from the cable bracket (2).
)
1 2
214854
1. Install the rear (1) conduit fitting to the park brake (
cable bracket (2).
1 2
214854
2. Install the rear cable eyelet(1) to the park brake

actuator lever (2).
1 2
214859
3. Seat the retainer fingers into the park brake cable

bracket (2).
1 2
214854
4. Pull the rear cable (3) through the park brake
cable guides (2) on the rear axle housing. Ensure
that the LH cable is routed over the tie rod
bracket.
2 3
214857
5. Connect the rear park brake cable to the park·

brake cable equalizer (3).
6. Install the rear cable (2) into the underbody
bracket (1).
If the tie strap was removed, install a new
tie strap.
) 8. Cycle the park brake lever 3 times.
214860
Brake Drum Inspection

Refinishing Rear Brake Rotor Parking Brake
Surface
The rear brake rotor parking brake contact surface
should not be refinished. If the parking brake system
can't effectively hold the vehicle, and all other
parking brake components are functioning properly,
replace the rotor. In addition, If the parking brake
surface is excessively scored (vehicle driven
with parking brake on), replace the rotor.
)
Backing Plate Replacement
Removal Proce.dure (
i. Unhook the rear cable eyelet (i) from the park
brake actuator lever (2).
2. Remove the parking brake shoe. Refer to Park
Brake Shoe Replacement.
3. Remove the parking brake actuator. Refer to Park
Brake Actuator Replacement.
4. Remove the brake backing plate bolts.
5. Remove the brake backing plate from the axle.
1 2
214859
i. Install the brake backing plate to axle.
Notices.
2. Install the brake backing· plate ,bolts.
Tighten
Tighten the brake backing plate bolts to
58 N·m (43 lb ft). (
3. Install the parking brake actuator. Refer to Park
Brake Actuator Replacement.
4. Install the parking brake shoe. Refer to Park
5. Hook the rear cable eyelet (i) onto the park brake
actuator lever (2).
1 2
214859
Park Brake Actuator Replacement

Removal Procedure
; . Remove the parking brake shoe. Refer to Park
Brake Shoe.Replacement.
64007
2. Move the brake lever back and forth in order to
push out the tappets (2).
) 3. Pull out the following components:
• The tappets (2)
• The pin (3)
• The lever (4)
64006
1. Push the brake lever into the housing.
2. Apply grease to positions 1, 2, and 3.
Important: Check operation by pinching the tappets
together and moving the brake lever. One or both
tappets must extend. With the tappets pinched
together, the brake lever must feel firmly seated. You
) must not be able to pull outthe lever.
3. Install the pin and the tappets (2 and 3).
64006
4. Install the parking brake shoe. Refer to Park

64007
Description and Operation The left and. right rear cables are joined to the. front
cable at the park brake cable equalizer. This vehicle is (
System Description equipped with coatectpark brake cables . .The cable
is coated with a plastic material which slides over the
Park Brake System plastic seals inside the conduit end fittings. The
The park brake system for this vehicle has been plastic material coating is for corrosion protection, and
changed and now contains the "drum in hat" parking reduced park brake effort.
brake system instead of the previous system which
relied on the disc brake caliper tor parking brake BRAKE Warning lamp
system operation. The park brake system allows a • The red BRAKE warning lamp illuminates when
mechanical application of the rear parking brake shoes the ignition switch is in the START position
to the inner rotor surface by pulling the park brake and the park brake lever is applied or is not fully
lever. When the park brake system is applied, released.
the effort with which the brake lever is moved is
transmitted by the cables to the brake levers which
O The park brake warning switch is located on the
force the rear brake shoes outward against the park brake lever.
inner rotor surface. As the brake shoe lining wears the " The park brake lever will ground the BRAKE
park brake system must be manually adjusted to warning lamp circuit and cause the BRAKE
prevent excessive hand lever travel. warning lamp to illuminate.
Park Brake lever
This vehicle is equipped with a self-adjusting park Special Tools and Equipment
brake lever. This mechanism automatically' takes up Illustration Tool Number/Description
any slack in the cables and provides the correct
amount of tension in the cables when the system is
released. The park brake cables cannot be manually
adjusted. When operating correctly, the rear park
~
brake actuator applies force to the rear brake shoe and
J 37043
forces it against the inner rotor surface. When the
parking brake lever is released, the parking brakes will Parking Brake Cable
Release Tool
fully return to their mechanical stops eliminating any (
drag on the brake rotor.
Park Brake Cables
157368
The park brake system uses the following
three separate cables:
• The front cable
• The left rear cable
• The right rear cable
(
Brakes Antilock Brake System 5-97
Antilock Brake System

)
Specifications
Specification
Brake Pipe Fittings At Brake Pressure Modulator Valve (BPMV) 15 N-m 11 lb ft
Brake Pressure Modulator Valve Bracket Bolt/Nut 10 N·m 7 lb ft
Brake Pressure Modulator Valve Bracket Nut to Brake Pressure
12 N-m 8 lb ft
Modulator Valve
Electronic Brake and Traction Control Module (EBCM/EBTCM) to
2.9N·m 261bin
Brake Pressure Modulator Val.ve Bolt/Screw
Wheel Speed Sensor Mounting Bolt 10 N-m 891bin
Adjuster Assembly Attaching Nuts 25N·m 19 lb ft
ABS Dia.gnostic Specifications

WSS Temperature vs. Sensor Resistance
Sensor oc OF Ohms
Fron1 Wheel Speed Sensor -34 to 4 -30 to 40 800 to 1100
Fron1 Wheel Speed Sensor 5 to 43 41 to 110 950 to 1300
Fron1 Wheel Speed Sensor 44 to 93 111 to 200 2250 to 3280
Rear Wheel Speed Sensor -34 to 4 -30 to 40 2032 to 3107
Rear Wheel Speed Sensor 5 to 43 41 to 110 2417 to 3615
) · Rear Wheel Speed Sensor
.
44 to 93 111 to 200 2812 to 4266

Brake Pressure Modulator Valve 4.730
Brake Pressure Modulator Valve Bracket 4.730
Electronic Brake and Traction Control Module 4.720
Stoplamp Switch 2.447
Wheel Speed Sensor ·. 4.710
Wheel Speed Sensor Jumper Harness 4.720

ABS Schematic Icons
) 19384
ABS Schematics (Without Traction Contro1.1 of 3) (11
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Valve Valve Valve Valve
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181~=~
Left Right
Bt:~r,
Front (')
~
Front
~
:;i:;-
m
AY BY AY BY
Al m
""I
0.5 BLK 884

~ @"
I 0.5WHT 885
-
0.8 YELi 833 Cl)
0.8 YELi 873 I JI; '<
~
(/)
0.8 LT BLU I 830 I 0.8 LT BLU I 872 ( I)
3
cl
C1 r-------01i Dlc405C
C405B
0.35 BLK 1884
A BJ..C120 A BJ..C130 0.35 RED I 885
A15 J ---- _!')~ 1 g~gg~

0.5 YELi 873 I I ~ ----- - - ~ P100
0.5TAN 833
0.5 LT BLU 1830 0.5 DK GRN 1872
'
0.5 BLKI 884
0.5 RED I 885
~
I
I
..
--r- ---r------------
Jl Low
~
I
Vl/'v
I--------I----
High
>
-r--
21 J__ ______ ?Q _1 ___________ ~ _1 ______ _?_1 ____________ ?? _1 ______ ?? _l C1
Jl Low Vl/'v
High
> <
High
Vl/'v
Low _dt
~ ~~~~~Onie
I Control
I
1: ,· -=- LeftFrontWheel -=- RightFrontWheel RearWheel -=- IM( OdCUle)
Speed Sensor·. Speed Sensor Speed Sensor EB M
1 I m
L• --------------------------------------J ,~.~ ~
500489 m
--· _....
~ ~ ~
ABS Schematics (5. 7L With Traction Control 1 of 5) OJ

""Ii
D>
l= ------r--------,~g~
ABS BAT1 L2 ABS BAT 2
s, Power
Distribution
1 •.
I Wrnng
(tt~RUN, BULB TEST And STAA11
- - -
ABS IGN
- Pow;; - "I Engine
Distribution I Wiring
IL 0 cl I Im
MaxJFuse®
40A K2
MaxiFuse® Schematics
________ ..
50 A in Wiring
Systems
Harness
I Junction
I Block 1
MinlFuse ®
10A
Schematics I Harness
in Wiring
Systems
I Junction
I Block 2
lEscl
0
L- L-1---------.1
3 RED 1302
5RED 1802
0.8 PNK 1739 ~
r - - - - - - - - - - - - -P;.,e; - "'Engine
Distribution I Wiring
[B
ABS BAT SOL
MiniFuse
25 A
®
TCS BAT
MiniFuse ®
20 A in Wiring
I
Schematics Harness
I Junction
8181 T 739
0.8 PNK I A
~
------ ________ ... Power
Systems I Block 1 ~
Distribution Electronic
30RN I 440 Schematics 0.8 PNK 1739 Brake
in Wiring Control
Systems
Module
(EBCM)
13 14
.. -------------------------------------------------------------------,I
8 C1 ,:,.
5 .
Battery Battery 12V Ignition
I Positive Positive T Solenoid Positive
I Voltage Voltage / Valve Voltage I
I I
i ~~u:tl~~ --~~-i-~I
Left
Front
Inlet
Solenoid
Valve
Left
Front
Outlet
Solenoid
Valve
Right
Front
Inlet
Solenoid
Valve
Right
Front
Outlet
Solenoid
Valve
Left
Rear
Inlet
Solenoid
Valve
Left
Rear
Outlet
Solenoid
Valve
Right
Rear
Inlet
Solenoid
Valve
Right
Rear
Outlet
Solenoid
Valve
USV 1
Solenoid
Valve
ASV 1
Solenoid
Valve
Pump
2 '( 1 'f C2 12 y - -15'( C1
3 BLK I 150
)>
::s
!:!::.
0
(')
Motor 2 BLK 1651
,---- 8113 """
OJ
l 3BLK 150 ;
Brake
Pressure
Modulator
Valve
(BPMV)
Solenoid Coils Are
Part Of The Electronic
Brake Control Module
(EBCM)
Ground
Distribution
Schematics
in Wiring
Systems
1BLKI~
~- trlbution
Schematics
Wiring
ystems
l'
fi
en
'<
!!?.
(I)
3
L - "'
G101 (11
G106-=-
.....
I
0
500492 (11
ABS Schematics (5. 7l With Traction Control 2 of 5) en
I
...I,
r - - -
I Instrument
I Cluster
Schematics
- - - - -
BRAKE
- - - - - - -
~ LOW TRAC
- - - -
h
- - -
ABS !NOP
- - -
h
- - -
IChevrolet I
ASR_
- - - - , Instrument
I Cluster
I A
1 ;111!1'4
r-----,-
I Power
Distribution
I Schematics
IHot At An limes!
H1
G
1
------~1/P
STOP/HAZARD
Fuse 1
20 A
Fuse
I Block
I
IL 0 c
[SJc
I I I~ )>
:::I
~
I .in Instrument Indicator Indicator Indicator IPontiac I I~ I In Wiring I
0
I Panel TCS OFF I
L-------
I Systems ____ - .1
.
0.8 ORN (')
~
I Indicator :::,.-
I I 0.8 ORN 1140
140 a,
~
I I
I ________________________ ..I AC1
~
s»
s
L------- A5
Stop
Exterior
Ughts
0.35
B6I
GR: 1036
Lamp
[ ] Switch
(Normally
Schematics
in Lighting
Systems ~
J> ~
en
0.35 TAN/WHT I 33 BIC1 open) A
i
3
l""'.""'.":----I,splice
I Data Link . I 0.8 LT BLU 20 ________ j
I Connector + - 1 Pack .
8243 - - - -
Schematics SP200
I in Data Link I
I Communications I
Brake
Warning
L-------..1 0.8 LTBLU 20
A4. . C200D
0.35 LT BL~ 11122 C200A
A3vC200D P100
C200A
P100 0.8 LT BLU 20
0.8 LTBLU Cruise Control

0.35 LT BLU I 1122 8154 Schematics in
20 Cruise Control
0.8 LTBLU 20
25 A. --...: :..- :..-.:. -~ :..-::-___

• - - ,;;;,;;;
- ---s-;;;plamp
""""
1
6 .,l- C1- - - ____ - - - ,I Electronic
- -.:. -~ .:.. Brake
I Control
I Module
°"' ....
~
I I (EBCM)
I , , ,Ii,
~-------------
I ----------------
a,
;
$"
500496 I en
~ .,,---.... ~
~ ~ ~
r
ABS Schematics (5. 7L With Traction Control 3 of 5) 0:,
'"'Ii
I»
~
I
I
- - - - - 12v -
DelivereJ. Requested
TP Position
Input
Logic
TP Position
Output
- -
q-
-
-=-
- - - -
...r
PWM
.
- - - -
Spark
-
Retard
Control
- - -
•----T
Jl
- - -
Tachometer]
Input ·
- - - - - - , Electronic Brake
Control Module
1I (EBCM)
I A
I Jiii'
I
J91
- - - - - - - , Engine
---.,.
TCS BAT
MiniFuse ®
_________ _
._I JS 20 A
Power I W' .
Distribution I mng
Schematics Harness
in Wiring I Junction
[SJ I If
E;Jc
:.35TAN/8; T.-.:.- ---- "'l--~-~~ ~~~/~::11~~--------~1-11
.
C1 ...
0.35 WHT 121
~
I
1 ORN I 1540
Systems ~ Block 1
~
[B
0.35
ORN/BLK 163
-------- P1::5 GRY/BLK

KIC101
1687 0.35 WHTI121

G C105
P100
----11118 8203
1 ORN I 1540 ~
.
1 ORN 11540
II
A J. C212 53 10 C2
0.5 TAN/BLK I 464

---------~
0.5
.. 1 ;--~f" -- - -1=;;;,.; ;. I
I
Signal
-------------
PCM
C1=BLU
~.~~:~rain
I Module
i(PCM)
.. B 1 ____
·0. 8 PNK 739
~ 1C·.212
0.8 OR. N 1540 I
CJ.. C211
ORN/BLK 463 I C2-RED I ·~ 0.8

.. - - - - - - - - - - - - - - ... ~ o~~ 1540 51
r· p
35J.. 37 1 .
...Delivered -
I TP Position( PWM
I Output ·
I .,,.
-
Requested
TP Position
l
...r -. . ·rr12V - - - - - - - - - - - - - - - - - - - - - - - - - -
l
• •----T •---·T
Ignition -
Positive
Voltage
Battery -
Positive
Voltage
- Battery -
Positive
Voltage
- - - ,
I
I
I
Accelerator
And Servo
Control
Module (ASM)
"*- "*-
- - - - - - - - - -.. .·.· - - - - - - . . ..
1
. - - - -- - - - - - -- - -- - - _l _- - - _!_ - - - - - - - - - - ---
I Ground Input . Ground ---- ·---
281
0.8 BLK/WHT 151
551 0.8 WHT
221 560 491 0.8 GRY
0.8 WHT 560
531561 261
0.8 GRY 561
~
0.8BLK/WHT 151 D .... C212 .D C211
B .. .... ---------· F .. C212 )>
::,
!:!:.
G
·-
C212 E
·-
C211
1 WHTI 560
1 WHT 560
I 1 GRYI 561
1 GAY I 561
0
(')
:;Iii"
8204 8205 m
1 BLK/WHT 1151
al
2 WHT I 560 2 GAY I 561 [
1 BLK/WHT I 151
en
8209------
P100 A B
Accelerator
P100 '<
-
en
CD
3
E@=!I
M Control And
.__ _ _ _....., Adjuster (11
I
...!,
c
500500 D "..J
ABS Schematics (5. 7l With Traction Control 4 of 5) (11
I
_,A,
r---
IRoiTri1illfJI
, -------,W
H3', 10A
GAUGES
Fuse 9
I
1Block
I
Fuse
r -
II
I
- - .-
PCM
C1=BLU
C2=RED
- -
TP
~
-
Sensor
-
TI I
- - - - -------
5V
TP
___ -
SV Sensor
~~
- -
O
- -
Sensor
Ground
- -
II (PCM)
I~
I Powertrain
'I
I
Control
Module
~
IL 0 c
~c
I I Ig )>
:::;
=
1.---------~4 - - __ ~-
0
I I _ _:-__ ...
...,
C2- - - - 8 -':'-'"!=~-':'601C1 (')
..-----. 0.5 PNK I 39

Power
Distribution
Schematics
In Wiring
~-- 8206
- - - - - - - - ~4
.....---------,, $118
7
0.35 DK BLU 41 0.35 GRY 596 0.35 BLK I 452 I ~
[B
""'00
'"'ll
I»
@
0.35 DK BLU 417 8116
Systems 0.8PNKI 39 en
~
I
Q ----
.
•·--1
Momentary
Switch
B
,---"'Traction
-¥ I Co.ntrol
IS 't h
0.35 DK BLU I 417
c
0.35 GRY 596
It .·i IE;
A
~
~
-
'<
tn
(I)
3
I---
I._ . WIC [TP)
_ _ _ _ _ _ _ . ljwithNW9!
B
Fy Ey 0.3; - A .I
0.35 GRY I 596 0.35 BLK 452
o35 PPL/WHT 1572 8119-----------~
BLK/WHT 1451 I. C4 C200D
"C200B El D 1 .
0.35 BLK 452
K C100
0.35
BRN/WHT I 1571 o.35 DK BL;f:~;~~-~~~~--_-- ~~-~~+ ~;~o
0.8
8215
BLK/WHT 451 i
r-_--, !
A13J, C200D
C200A
~
40
TP-1-- - -
41
-1r--------1- --
0.5 DK BLUI 417~~Y/BLKrs~e- - - - - -0~5 BLK14.52
43
12V - - - - - ~ Accelerator
Ground
0.35 ·PPL/WHT I 1572 Sensor
1 Signal
_r ~nso~ Requested
I
And Servo
Distribution PWM roun TP Position Control
Schematics 1 I
· _ TP Sensor Delivered ..- Input Module (ASM)
In Wiring
Systems - - - - - - - - - - - ....-- P1 00
I
I._ _____________________________ ..,
- 5V REF ..- TP P iii
os on
Output
Logic I
I A
~
/1111
T l' 0.35
E JC220 I BRN/WHT I 1571
0_8
BLK/WHT 451
1: I
P110 I
I ·
0.5 TAN/Btir464
C
0.35 TAN/BLKI
0.5 ORN/Bt~r463
4~~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~~~5~ ~~~~~K}~~ 00

A C212
8110 - - .J
3 BLKI 451
r----.J
G110
1
:--1r---~,-; ~=OOJ r------. ~:;-T;----:~:::mc
..
..: Logic
111 ___________1!31 __________
•--J ~
_________________________________________ ..,(~~~~)
Control lnp~~gic
_;~T-_____________________2;fc1
Output PWM : J~ 00
iiJ
@
500503 I ti)
.,.----., ~
'-_../ ~ ---/
ABS Schematics (5. 7l With Traction Control 5 of 5) lo:J

-,:
s»
[SJ 11!
~Wh~ I
Speed
Sensor, @
Wheel
Speed
Sensor,
@ @ !°Esc!
Left
~Front
Right
Front
1r?:S1~~ I
Sensor,
181~;~ Senso~
1.
AY BY A'( B'( 81 A Left 8 A Right
[B
.
Rear
0.8 BLK I 884 0.8 BRN 882 Rear
0.8 RED 885 0.8 WHT 883
I
--,'l--- - - - - ~l- ---·a; =~
~
0.8 YEL I 873
0.8 LT BLU 830
0.8YEL 1833
cl D
0.8LTBLU 872 0.5 B~r:· - l'
0.5 BRN 882
0.5 RED 885 O·5 WHT 1883
Al 1C120
--------""'
B ,... ________B . C130
Al 1 1
A15 .I. A14 .I. A10 A11 J, C200D

0.5YEL 1873 0.5TAN 1833 - - - - - - - - -· C200A
0.5 LT BLU I 830 0.5 DK GRN I 872
0.5 RED I 885 0.5WHTI 883
)>
:::,
:::!:.
0
(")
0.5 BLKI 884
0.5 BRN I 882
""
m
--r-----r------1-----I--------I-----r--------r----1---
-,:
s»
21 20 5 4 22 23 1 3 l C1
~
~ ~ ~~~~~Onie en
I
I
1
I
... Low
~
Viv
High
Left Front Wheel
Speed Sensor
> .._
~
Low
Viv
High
Right Front Wheel
Speed Sensor
> <
High
Viv
Left Rear Wheel
Speed Sensor
Low !
~
<
High ·
Viv
Low ...
Right Rear Wheel
Speed Sensor
~
I Control
I
1
I
d
M(EOBCUMle) -
"'<
en
Cl)
3
L, - m m m m m rm - - m m - m m rm m rm rm m rm rm rm rm m rm - - rm rm m rm rm - rm m. - m - rm m rm m rm rm rm m m rm - m rm rm m rm .I ~ (11
..,,,
I
0
500508 I (0
5-110 Antilock Brake System Brakes
Component locator
(
ABS Components
Name Location Locator View Connector End 'View
ABS Connector
Accelerator and Servo Under the left side of the instrument panel, ABS Component Views
End Views in Antilock
Control Module (ASM) near the kick panel in ABS Traction Control
Brake System
Cruise Control ABS Connector
Accelerator Control and In the engine compartment, in the forward End Views in Antilock
Component Views in
Adjuster of the right front wheelhouse
Cruise Control Brake System
Hydraulic Brakes
Brake Fluid Level
Indicator Sensor
Part of the master cylinder - Connector End Views in
Hydraulic Brakes
Brake Pressure
ABS Component Views in
Modulator Mounted to the left front frame rail
ABS Traction Control
-
Valve (BPMV)
Center High Mounted
Stop Lamp (CHMSL)
In the center of the rear spoiler - -
Cruise Control Cruise Control

Mounted to the left frame rail, forward of Connector End Views in
Cruise Control Module Component Views in
the wheelhouse Cruise Control
Cruise Control
Data Link Data Link
Communications Communications
Data Link
Under the IP, right of the steering column Component Views in Connector End Views
Connector (DLC)
Data Link in Data Link
Communications Communications
ABS Connector
Electronic Brake Control Mounted with brake pressure modulator ABS Component Views in
Module (EBCM) valve on the top of the left front frame rail ABS Traction Control
Brake System (
Power and Grounding
Wiring Systems
Power and Grounding
Wiring Systems
.. Gauges and Console Gauges and Console
Instrument Panel,
Gauges, and Console
IP Fuse Block On the left end of the .IP carrier Component Views in -
Instrument Panel,
Gauges and Console
Engine Controls
Park/Neutral Position Under the center console, on the base of
Switch the shift control lever
- Connector End Views in
Engine Controls
(V6 VINK) Wiring Systems
(V8 VIN G) Engine Controls
Second Gear Start Engine Controls
Switch (V6 VIN K)
In the center of the IP, above the HVAC ABS Component Views
Connector End Views in (
control in ABS Traction Control
(Chevrolet w/o NW9) Engine Controls
Cruise Control Lighting Systems
Stop Lamp/TCC Switch
Mounted on the brake pedal bracket Component Views in Connector End Views in
(Automatic)
Cruise Control Lighting Systems
ABS Components (cont'd)
Engine Controls
Throttle Actuator Control
On the plenum, with throttle body - Connector End Views in
(V6 VINK)
Engine Controls
Throttle Actuator Engine Controls
Control (TAC) Module Mounted on the acc.elerator pedal bracket - Connector End Views in
(V6VIN K) Engine Controls
Engine Controls Engine Controls
Throttle. Position (TP)
Mounted to the. front of the throttle body Component Views in Connector End Views in
Sensor (VB .VI.N G)
Engine Controls Engine Controls
ABS Connector
Traction Control Switch In the center of the IP, above the HVAC ABS Component Views in
· (Cbevrolet with NW9) control ABS Traction Control
Brake System
Power Roof Systems ABS Connector
Traction Control Switch
.. .. (Pontiac) On the left side of the upper console Component Views End Views in Antilock
in Roof Brake System
Instrument Panel,
Gauges,. and Console Engine Controls
Vehicle Speed Sensor
On the rear right side of the transmission Component Views in Connector End Views in
(Automatic) (V6 VIN K)
Instrument Panel, Engine Controls
Gauges and Console
Instrument Panel,
Gauges, and Console Engine· Controls
On the rear right side of the transmission Component Views in Connector End Views in
(Automatic) (V8 VIN G)
Gauges and Console
Instrument Panel,
) Vehicle Speed Sensor
Gauges, and Console Engine Controls
On the rear left side of the transmission Component Views in Connector End Views in
(Manual) (V6 VIN K)
Gauges and Console
Instrument Pane!,
Gauges, and Console Engine Controls
On the rear left side of the transmission Component Views in Connector End Views in
(Manual) (V8 VIN G)
Gauges and Console
ABS Connector
Wheel Speed On the middle of the left and right front ABS Component Views in
Sensor, Front steering knuckle ABS Traction Control
Brake System
Wheel Speed ABS Connector
Mounted to the left and right rear backing ABS Component Views in
Sensor, Rear End Views in Antilock
plate of the wheel disc ABS Traction Control
(VB VIN G with NW9) Brake System
.
ABS Connector
Wheel Speed Sensor, ABS Component Views in
On the top of the rear differential End Views in Antilock
Rear (w/o NW9) ABS Traction Control
Brake System
Data Link
Lighting Systems Communications
Splice Pack SP200 Under the left side of the IP, near the DLC Component Views in Connector End Views
Lighting Systems in Data Link
Communications
Engine to forward lamp harness, in the lnline Harness
.Harness RoutingYiews in
C100 (10 cavities) engine compartment, above the right Connector End Views in
Wiring Systems
wheelhouse Wiring Systems
Forward lamp to wheel speed sensor lnline Harness
.Harness Routing Views in
C120 (2 cavities) jumper harness, mounted to the left Connector End Views in
Wiring Systems
frame rail Wiring Systems
fnline Harness
Forward lamp to IP harness, between the .Harness· Routing Views in
C200A (17 cavities) Connector End Views in
Wiring Systems
Name Location Locator View Connector End View (
lnline Harness
C200B (18 cavities) Connector End Views in
Wiring Systems
lnline Harness
Cross car to IP harness, between the left Harness Routing Views in
C200C (13 cavities) Connector End Vievvs in
Wiring Systems
lnline Harness
C200D (48 cavities) Connector End Vievvs in
Wiring Systems
Forward lamp to traction control module lnline Harness
C211 (8 cavities) jumper harness, under the left side of the Connector End Vievvs in
Wiring Systems
IP, near the kick panel Wiring Systems
Forward lamp to traction control module lnline Harness
C212 (10 cavities) jumper harness, under the left side of the Connector End Vievvs in
Wiring Systems
IP, near the kick panel Wiring Systems
lnline Harness
C220 (10 cavities) Connector End Vievvs in
Wiring Systems
lnline Harness
IP harness pass through connector, Harness Routing Views in
C405B (16 cavities) Connector End Vievvs in
forward of the rear axle Wiring Systems
Wiring Systems
Rear wheel speed sensor jumper to the IP lnline Harness
HarnessRouting Views in
C405C (4 cavities) harness pass through connector, forward Connector End Vievvs in
Wiring Systems
of the rear axle to the speed sensor Wiring Systems
On the lower right side of the engine, Harness Routing Views iri
G100 (V6 VIN K) -
above the A/C compressor Wiring Systems (
On the lower right side of the engine, Harness Routing Views in
G100 (V8 VIN G)
above the starter solenoid Wiring Systems
-
In the engine compartment, attached to Harness Routing Views in
G101 -
the front of the left wheelhouse Wiring Systems
Attached to the top left side of the radiator Harness Routing Views in
G106
support Wiring Systems
-
In the front of the engine, bolted to the Harness Routing Views in
G110 (V6 VINK)
pulley above the A/C clutch connector Wiring Systems
-
Attached to the rear of the left Harness Routing Views in
G110 (V8 VIN G)
cylinder head Wiring Systems
-
P100 -
P110 -
8110 (V6 VIN K) 4 cm (1.6 in) from the powertrain control - -
module (PCM) breakout
8110 (V8 VIN G) approximately 20 cm (7.9 in) from the - -
7 cm (2.8 in) from the electronic throttle
8113
- -
module breakout
In the engine harness, approximately (
8114 (V8 VIN G) 17 cm (6.7 in) back from the A/C - -
In the engine harness at the
8115 (V6 VINK)
generator breakout
- -
Name Location locator View Connector End View
8116 (VS VIN G) 9 cm (3.5 in) from the manifold absolute - -
Si i8 (VS VIN G) 15 cm (6 in) from the manifold absolute - -
8119 (VS VIN G) In the engine harness, main branch,
(Automatic approximately 8 cm (3.1 in) from the - -
Transmission) automatic transmission breakout
8119 (VS VIN G)
approximately 9 cm (3.5 in) from the - -
vehicle speed sensor breakout
8121 (V6 VINK) approximately 8 cm (3.1 in) from the - -
Si 54 (Chevrolet)
Ci 20 (left front wheel speed sensor)
- -
breakout
8154 (Pontiac)
Ci 20 (left front wheel speed sensor)
- -
breakout
8181 approximately 20 cm (8 in) from the engine - -
) wiring harness junction block 1 breakout
In the forward lamp harness, main branch,
8203 approximately 4 cm (1.6 in) from the - -
ignition switch breakout
I the forward lamp harness, main branch,
8204
at the ignition switch breakout
- -

8205 approximately 4 cm (1.5 in) from the - -
In the IP harness, at the rear compartment
8206 - -
lid release relay breakout
8207 approximately 4 cm (i .6 in) from the data - -
link connector (DLC) breakout
.
8209 approximately .11 cm (4.3 in) from the - -
antenna cable breakout
·-
instrument cluster breakout
-·
ABS Component Views
Center of Instrument Panel (Chevrolet) (
374362
legend
(1) Rear Fog Lamp Switch (Export) (3) Second Gear Start Switch or Fog
(2) Second Gear Start Switch or Traction Lamp Switch
Control Switch or Rear Fog Lamp
Switch (Export)
Behind the lower left Side of the Instrument Panel
374363
Legend
(1) Accelerator and Servo Control Module (2) Forward Lamp Wiring Harness
)
5..;116 Antilock Brake System Brakes
Inside of Left Steering Knuckle
(
1
374393
Legend
(1) Front Wheel (3) Lower Control Arm
(2) Left Front Wheel Speed Sensor (4) Brake Line
(Right side similar)
Lower Left Front of the Engine Compartment
374373
Legend
(1) Brake Pressure Modulator Valve (BPMV) (3) Left Front Frame Rail
(2) Electronic Brake Control Module (EBCM)
)
Right Side of the Automatic Transmission (V6 VIN K M30)
(
1 2
374368
Legend
(1) Automatic Transmission (3) Vehicle Speed Sensor
(2) Engine Wiring Harness
Brakes Antilock Brake System 5;.119
Left Side of the Manual Transmission
374377
Legend
(1) Engine Wiring Harness (3) Vehicle. Speed Sensor
(2) Reverse Lockout Solenoid (4) Skip Shift Solenoid
)
Rear Wheel Speed Sensor (VS VIN G With Traction Control)
(
374381
Legend
(1) Rear Wheel Speed Sensor Jumper Wiring (3) Left Rear Wheel Speed Sensor
Harness (4) Rear Axle
(2) Right· Rear Wheel Speed Sensor
Rear Wheel Speed Sensor (VS VIN G Without Traction Control and V6 VINK)
374388
Legend
(1) Rear Wheel Speed Sensor (3) Brake Line
(2) Rear Axle (4) Park Brake Cable
ABS Connector End Views Accelerator and Servo Control
Module (ASM) (cont'd) (
Accelerator Control and Adjuster
28 1
[ ' ,..! •1111

• • • •I •llilllllllllilljl
I II II 11111111111 • I •11
• •I • /J
[m~~mp
L__J l
55 88 56 29
\. ,J
235270
68721 Connector Part ., 1218-6485

Information 0 55 Way F (NAT)
• 1530-0027
Connector Part
• 2 Way F Metri-Pack Circuit
Information
280 Series (BLK) Pin Wire Color No. Function
Circuit 25 - - Not used
Pin Wire Color No. Function Accelerator control and
26 GRY 561
Accelerator control and adjuster retur.n '
A WHT 560 adjuster feed 27 - - Not used
Accelerator control and 28 BLK/WHT 151 Ground
B GRY 561
adjuster return
29-34 - - Not used
Delivered TP position
Accelerator and Servo Control 35 TAN/BLK 464
output (
Module (ASM)
36 - - Not used
Requested TP
37 ORN/BLK 463
28 1 position input
'
.· 38-39 - - Not used
'
[ ' , , , , , , , , II II II II II 111111 , , , , ,
J
.
11111111111111111110• 1111 l
/J 40
41
DKBLU
GRY/BLK
417
596
Throttle position sensor
signal
5 volt reference
42 - - Not used
55 88 56 29
43 BLK 452 ground
44-48 - - Not used
235270
Accelerator control and
• 1218-6485 49 WHT 560 adjuster feed
Connector Part
Information • 55 Way F (NAT) 50 - - Not used
Circuit 51 ORN 1540 Fused battery feed
52 - - Not used
1 PNK 739 Fused ignition feed
Accelerator control and
2-21 - - Not used 53 GRY 561
adjuster return
Accelerator control and 54 - Not used
22 WHT 560 -
adjuster feed
55 BLK/WHT 151 Ground
23 - - Not used
24 ORN 1540 Fused battery feed
56-88 - - Not used
Electronic Brake Control Module Electronic Brake Control Module (cont'd}
11 1 11 1
~~DDDDDDODO m
~DDDDDDDDD~
DDD[I]OD ~~DDDODDDdb • DDD[]]00
~DDDDDDDDD~
30 20 30 20
231364 231364
0
1532-6390 0 1532-6390
Connector Part Connector Part
30 Way F GT 150 Series . • 30 Way F GT 150 Series
.
0
Information Information
Sealed (BLK) Sealed (BLK)
Circuit Circuit
Pin Wire Color No. Function Pin Wire Color No. Function
Right rear wheel Traction control switch
1 BRN 882 speed sensor 17 BRN/WHT 1571
·signal (with NW9)
signal (LS1 with NW9)
Traction control lamp
2 - - Not used 18 PPL/WHT 1572
control
Right front wheel TCS spark retard signal
speed sensor 19 GRY/BLK 1687
3 DKGRN 872 (LS1 with NW9)
signal (LS1 without NW9
and L36) Left front wheel speed
20 LT BLU 830
sensor signal
) 3 WHT 883
Right rear wheel speed
sensor return 21 YEL 873
Left front wheel speed
sensor return
Right front wheel
4 DKGRN 872 speed sensor Rear wheel speed sensor
signal (LSI with NW9) 22 BLK 884 signal (LS1 without NW9
and L36)
Right front wheel speed
5 TAN 833
sensor return Left rear wheel
22 BLK 884 speed sensor
6 LT BLU 20 Stop lamp feed
7 - - Not used
Rear wheel speed sensor
8 PNK 739 Fused ignition feed 23 RED 885 return (LS1 without NW9
Delivered torque input and L36)
9 TAN/BLK 464
(with NW9) Left rear wheel
iO - - Not used 23 RED 885 speed sensor
Tachometer input
11 WHT 121 24 - - Not used
(with NW9)
12 BLK 150 Ground 25 LT BLU 1122 Class 2 serial data
13 RED 302 Fused battery feed 26 - - Not used
14 ORN 440 Fused battery feed Requested torque input
27 ORN/BLK 463
(with NW9)
15 BLK 651 Ground
16 - - Not used
28-30 - - Not used
)
Traction Control Switch Wheel Speed Sensor, left Rear (With NW9)
(
304345 35437
• 1217-7195 0 1205-2644
Connector Part Connector .Part
Information • 6 Way F Metri-Pack o 2 Way F Metri-Pack
Information
150 Series (B LK) . 150 Sealed (GRY)
Circuit Circuit
Pin Wire Color No. Function Pin Wire Color No. Function
Traction control lamp Left Rear Wheel Speed
A PPUWHT 1572 A RED 885
control Sensor Signal - Low
B BRN 141 Fused ignition feed
Left Rear Wheel Speed
Switch illumination B BLK 884 Sensor Signal - High
c GRY 8
lamp feed
D Not used Wheel Speed Sensor, Right Front
Traction control switch
E BRN/WHT 1571
signal
F BLK/WHT 451 Ground (
Wheel Speed Sensor, Left Front
35437
• 1205-2644
Connector Part
150 Sealed (GRY)
Circuit
35437
• 1205-2644
Connector Part Right Front Wheel Speed
• 2 Way F Metri-Pack A YEL 833 Sensor Signal - Low
Information
150 Sealed (GRY)
B LT BLU 872 Right Front Wheel Speed
Circuit .___...,__ _ _ _..___ _......_s_e_n~or Signal - High
Left Front Wheel Speed
A YEL 873
Sensor Signal - Low
Left Front Wheel Speed
B LT BLU 830 Sensor Signal - High
Wheel Speed Sensor, Right Diagnostic Information and
Rear (With NW9)
Procedures
A Diagnostic Starting Point
Begin the system diagnosis with the A Diagnostic
System Check - ABS. The Diagnostic System Check
will provide the following information:
• The identification of the control module(s) which
command the system.
• The ability of the control module(s) to
communicate through the serial data circuit.
• The identification of any stored diagnostic trouble
35437 codes (DTCs) and their status.
• 1205-2644 The use of the Diagnostic System Check will identify
Connector Part the correct procedure for diagnosing the system
150 Sealed {GRV) and where the procedure is located.
Circuit
Pin Wire Color No. Function Scan Tool Diagnostics
Right Rear Wheel Speed
A WHT 883 Plug the scan tool into the Data Link Connector (DLC).
Sensor Signal - Low
The scan tool becomes part of the vehicle's electronic
Right Rear Wheel Speed system. The scan tool performs the following
B BRN 882 Sensor Signal - High
functions:
• Display ABS/TCS data
Wheel Speed Sensor, Rear (Without NW9)
• Display diagnostic trouble codes
) • Clear ABS/TCS diagnostic trouble codes
• Control ABS/TCS components
• Perform extensiveABS/TCS diagnosis
• Provide diagnostic testing for intermittent
ABS/TCS conditions
Each test mode has specific diagnostic capabilities
which depend upon various keystrokes.
The keys on the scan tool perform the following
functions: ·
- Select operating modes
35437
• 1205-2644
- Perform functions within an operating mode
Connector Part - Enter DTC designations
Information • 2 Way F Metri~Pack
150 Sealed (LT GRY) - Enter model year designations
Circuit Refer to Enhanced Diagnostics for more scan tool
diagnostic information.
Rear Wheel Speed
A BLK 884 Sensor Signal -.High
Scan Tool Data list
Rear Wheel Speed
B WHT 885 Sensor Signal - Low The EBCM Scan Tool Data Lists contain all the
antilock brake system related parameters that are
available on the scan tool. The parameters in the list
are arranged in alphabetical order. The column,
'Data List,' indicates the location of the parameter
within the scan tool menu selections.
)
Use the EBCM Scan Tool Data Lists as directed by a The Typical Data Values are obtained from a properly
diagnostic table or in order to supplement the operating vehicle under the conditions specified in
diagnostic procedures. Begin all the diagnostic the first row of the Scan Tool Data List table. (
procedures with the ABS Diagnostic Starting Point. Comparison of the parameter values from the suspect
Use the EBCM Scan Tool Data Lists only after vehicle with the Typical Data Values may reveal
the following is determined: the source of the customer concern.
" There is no published DTC procedure nor The ID Information menu is located on the EBCM
published symptom procedure for the customer main screen.
concern.
OR
.. The DTC or symptom diagnostic procedure
indicated by the diagnostic system check does not
resolve the customer concern.
EBCM Scan Tool Data List
Ignition is ON, engine OFF, and vehicle is stationary
Scan Tool Parameter Data list Units Displayed Typical Data Value
Brake Switch Status ABS Applied/Released Released
EBCM to PCM Requested
TCS % 90
Torque
Engine Speed ABS/TCS RPM 0
Left Front Wheel Speed ABS/TCS km/h.or mph 0
Left Rear Wheel Speed ABS/TCS km/h or mph 0
Pump Monitor State ABS On/Off Off
Right Front Wheel Speed ABS/TCS km/h or mph 0 ..
Right Rear Wheel Speed ABS/TCS km/h or mph 0

Rear Wheel Speed ABS/TCS Km/Hor mph 0
TCS State ABS/TCS Active/Inactive Inactive
TCS Status
.·
ABS/TCS Inab le/Disable lnable (
TCS Switch State TCS On/Off Off
Throttle Angle ABS/TCS % 0
Valve Relay State ABS/TCS On/Off Off
Vehicle Speed ABS/TCS km/h or mph 0
Scan Tool Data Definitions RR Wheel Speed: The scan tool displays 0-255 km/h
or 0-158 mph - The scan tool displays the actual speed
The ABS Scan Tool Data Definitions contain a brief
of the right rear wheel.
description of all the ABS/traction scan tool
parameters. This list is in alphanumeric order. TCS State: The scan tool displays Active or Inactive
Brake Switch Status: The scan tool displays Applied - This parameter indicates if the TCS is currently in
or Released - The scan tool displays the state of the a TCS event or not.
brake switch. TCS Status: The scan tool displays lnable or
Engine Speed: The scan tool displays 0-10200 RPM Disable - The parameter indicates the state ofthe
- This is essentially a digital tachometer display. TCS based on if the operator has disabled TCS
by pressing the TCS On/Off switch, or if the TCS is
LF Wheel Speed: The scan tool displays 0~255 km/h
disabled because of a malfunction.
of the left front wheel. TCS SwitchState: The scan tool displays On or Off
LR Wheel Speed: The scan tool displays 0-255 km/h - This parameter indicates the state of the traction
or 0-158 mph - The scan tool displays the actual speed control switch.
of the left rear wheel. Throttle Angle: The scan tool displays % - The
Pump Monitor State: The scan tool displays On. or scan tool displays in percent of throttle open.
Off - This parameter indicates the state of the Valve Relay State: The scan tool displays On or Off
return pump relay. - This parameter indicates the state of the valve relay.
Rear Wheel Speed: The scan tool displays Vehicle Speed: The scan tool displays 0-255 km/h or
0-255 km/h or 0-158 mph - The scan tool displays 0-158 mph - The scan tool displays the vehicle speed.
the actual speed of the rear wheels. (
RF Wheel Speed: The scan tool displays 0-255 km/h
of the right front wheel.
Diagnostic Trouble Code (DTC) List/Type
Illuminate Indicator or
OTC/Description Type Turn ON DIC Message
OTC C0035 LF Wheel Speed Circuit Malfunction ABS ABS/TCS/BRAKE
OTC C0036 LF Wheel Speed Circuit Range/Perfqrmance ABS ABS/TCS/BRAKE
OTC C0040 RF Wheel Speed Circuit Malfunction ABS ABS/TCS/BRAKE
OTC C0041 RF Wheel Speed Circuit Range/Performance ABS ABS/TCS/BRAKE
OTC C0045 LR Wheel Speed Circuit Malfunction ABS ABS/TCS/BRAKE
OTC C0046 LR Wheel Speed Circuit Range/Performance ABS ABS/TCS/BRAKE
OTC C0050 RR Wheel Speed CircuitMalfunction ABS ABS/TCS/BRAKE
OTC C0051 RR Wheel Speed Circuit Range/Performance ABS ABS/TCS/BRAKE
OTC C0055 Rear Wheel Speed Circuit Ma/function ABS ABS/TCS/BRAKE
OTC C0056 Rear.Wheel Speed CKT Range/Performance ABS ABS/TCS/BRAKE
OTC C0060 LF ABS Solenoid #1 Circuit Ma/function ABS ABS/TCS/BRAKE
OTC C0065 LF ABS Solenoid #2 Circuit Ma/function ABS ABS/TCS/BRAKE
OTC C0070 RF ABS Solenoid #1 Circuit Ma/function ... ABS ABS/TCS/BRAKE
OTC C0075 RF ABS Solenoid #2 Circuit Ma/function ABS ABS/TCS/BRAKE
OTC COOBO LR ABS Solenoid #1 Circuit Malfunction ABS ABS/TCS/BRAKE
OTC C0085 LR ABS Solenoid #2 Circuit Ma/function ABS ABS/TCS/BRAKE
OTC C0090 RR ABS Solenoid #1 Circuit Malfunction ABS ABS/TCS/BRAKE
OTC C0095 RR ABS Solenoid #2 Circuit Malfunction ABS ABS/TCS/BRAKE
OTC C0100 Rear ABS Solenoid #1 Circuit Ma/function ABS ABS/TCS/BRAKE
OTC C0105 Rear ABS Solenoid #2 Circuit Malfunction ABS ABS/TCS/BRAKE
) OTC C0110 Pump Motor Circuit Malfunction ABS ABS/TCS/BRAKE
OTC C0121.Valve Relay Circuit Malfunction ABS ABS/TCS/BRAKE
OTC C0161 ABS/TCS Brake Switch Circuit Ma/function ABS ABS/TCS/BRAKE
OTC C0166 TCS Priming Line Valve CKT Ma/function ABS ABS/TCS/BRAKE
OTC C0171 TCS Pilot Valve Circuit Malfunction ABS ABS/TCS/BRAKE
OTC C0181 Throttle Reduction Motor CKT Malfunction ABS ABS/TCS/BRAKE
OTC C0182 Throttle Reductio.n Motor CKT Range Pert ABS ABS/TCS/BRAKE
OTC C0236 TCS RPM. Signal Circuit Malfunction ABS ABS/TCS/BRAKE
OTC C0237 TCS Throttle Position Signal Ma/function ABS ABS/TCS/BRAKE
OTC C0238 TCS TP Sensor Comparison Ma/function ABS ABS/TCS/BRAKE
OTC C0239 TCS Spark Retard Monitoring Malfunction ABS ABS/TCS/BRAKE
OTC C0240 PCM Traction Control Not Allowed ABS ABS/TCS/BRAKE
OTC C0241 PCM Indicated Requested Torque Malt ABS ABS/TCS/BRAKE
OTC C0244 PWM Delivered Torque Malfunction ABS ABS/TCS/BRAKE
OTC C0245 Wheel Speed Sensor Frequency Error ABS ABS/TCS/BRAKE
OTC C0266 ADS Controller Malfunction ·.·. ABS ABS/TCS/BRAKE
OTC C0550 ECU Ma/function ABS ABS/TCS/BRAKE
OTC COB96 Device Voltage Range/Performance ABS ABS/TCS/BRAKE
OTC C0901 Device #2 Voltage Low ABS ABS/TCS/BRAKE
OTC U1000 and OTC U1255 Class 2 Communication Malfunction ABS ABS/TC/BRAKE
OTC U1300 C/ass.2 Data Link Low ABS ABS/TC
) OTC U1301 Class 2 Data Link High ABS ABS/TC
Self-Diagnostics Review the following malfunction example:
The EBCM/EBTCM performs system self-diagnostics, • A malfunction occurred 1 out of 50 drive cycles
and can detect and often isolate system malfunctions.
(
• This malfunction is intermittent and has not
When a malfunction is detected the EBCM/EBTCM recurred for 49 drive cycles
sets a Diagnostic Trouble Code (DTC). The OTC
represents the malfunction, and may turn on the • A malfunction of this type is difficult or impossible
Antilock Indicator, Red BRAKE Warning Indicator, and to duplicate·
Traction Control indicators (if equipped), and may • The malfunction may have been caused by a
disable the ABS/TCS functions as necessary for the severe vehicle impact such as a large pot hole or
duration of the ignition cycle. speed bump at high speed, etc.
• A severe vehicle impact can momentarily open an
Initialization Sequence electrical connector
The EBCM/EBTCM performs the Initialization test once
• A severe vehicle impact can cause unusual
each ignition cycle, when the vehicle speed reaches
6 Km/h (4 mph) and the EBCM/EBTCM does not see a vehicle suspension movement
brake switch input, if the EBCM/EBTCM sees a brake • A malfunction resolution is unlikely
switch input the initialization test runs when the vehicle • The malfunction may never recur
speed reaches 15 Km/h (9 mph). The Initialization
sequence cycles each valve solenoid and the pump • Check the diagnostic aids provided for that OTC
motor (as well as the necessary relays) to check Review the following examples:
component operation. If any error is detected, the
EBCM/EBTCM will set a DTC. The Initialization • A malfunction occurred 3 out of 15 drive cycles
sequence may be heard and felt while it is taking place, •. The odds of finding the cause are not good
and is considered part of normal operation. • However, the occurrence rate ·is known
Enhanced Diagnostics • A malfunction occurred 1O out of 20 drive cycles

Enhanced diagnostic information is found in the • The odds of finding the cause of the malfunction
DTC HISTORY function of the scan tool. Enhanced are good
diagnostic information provides the service technician • The malfunction may be easily reproduced
with specific malfunction occurrence information. (
A malfunction that occurs more frequently increases
The following occurs for each of the first five diagnostic
the odds of finding the cause of the malfunction.
trouble codes stored and the very last diagnostic
trouble code stored: Use the additional malfunction data to determine if a
• Data is stored to identify the specific DTC malfunction is randomly intermittent. Use the additional
malfunction data to determine if it has not recurred
• The number of diagnostic trouble code
for long periods of time due to whether changes or a
occurrences are stored
repair prior to this visit.
• The number of drive cycles since the malfunction
first and last occurred are stored. A drive cycle Review the following example:
occurs when the ignition is turned to ON. • A DTC occurred 1O of 20 drive cycles, but has not
• The drive cycle counter will increment by turning recurred for 10 drive cycles
the ignition to ON and OFF if a malfunction is • This means a malfunction occurred 10 of 10 driver
present. cycles, but has not reoccurred since.
• The first five diagnostic trouble codes are stored
• A significant environment change or a repair may
in the order of occurrence. The order of the
have occurred 1O drive cycles ago
first five diagnostic trouble codes are used to
determine if a previous malfunction is linked to the • If customer information confirms a recent repair,
most recent malfunction, such as an intermittent repair may not be necessary.
wheel speed sensor which later becomes • If no repair was made, focus on diagnosis
completely open. techniques used to locate difficult-to-recreate
In difficult diagnostic situations use the above problems.
information to identify malfunction occurrence trends.
• Did the malfunction only occur once over a Electromagnetic Interference
large number of drive cycles, indicating an unusual
condition present when it occurred? Due to the sensitivity of electronics to Electromagnetic
Interference (EMI), the following checks should be
• Does the malfunction occur infrequently over a
performed if an intermittent malfunction is suspected. (
large number of drive cycles, indicating that
special diagnostic techniques may be required to 1. Check for proper installation of wiring harnesses
identify the source of the malfunction? resulting from add-on options.
2. Check for proper routing of front wheel speed
sensor wiring near spark plug wires.
A Diagnostic System Check - ABS
) Circuit Description very reliable component and is not likely the cause of
The ABS Diagnostic System Check is an organized the malfunction. Most system complaints are linked
approach to identify problems associated with the to faulty wiring, connectors, and occasionally to
EBCM, This check must be the starting point for any components. Understanding the ABS system and
EBCM complaint, and will direct you to the next logical using the tables correctly will reduce diagnostic time
step in diagnosing the complaint. The EBCM is a and prevent unnecessary parts replacement.
A Diagnostic System Check - ABS

Install a scan tool. Go to Scan Tool
Does Not Power
1 Does the scan tool power up? - Up In Data Link
Go to Step2 Communications
1. Reconnect all previously disconnected components. Go to Scan Tool
2. Turn ONJhe ignition, with the engine OFF. Does Not
Communicate
2 3. Attempt to establish communications with the EBCM. · - w/Class 2 Data
Does the scan tool communicate with the EBCM? Line In Data Link
Go to Step 3 Communications
1. With the scan tool, in ABSffCS Special Functions in
order to run the Automated Test.
3 2. Select the ABSffCS display DTC function on the -
scan tool.
Does the scan tool display any DTCs? Go to Step 4 Go to Symptoms
Does the scan tool display any DTCs which begin with Go to Diagnostic
a U (i.e. DTC U1016, U1000 or U1300, U1301)? Go to Scan Tool Trouble
Does Not Code (OTC)
4 - Communicate List/Type
w/Class 2 For The
.. Data Line Applicable OTC
)
5-130 Anti lock Brake System Brakes
DTC C0035 LF Wheel Speed Circuit Malfunction
(
LFWheel
Speed
Sensor
0.8YEL 873
'LDC I
{0}11 [5:J
N
0.8 LT BLU 830

B A C120
0.5 LT BLU 830 0.5 YEL 873
~
I
------------1--:;;_ .- -. !1'." --
20 21
..
C1
~ ~=o~~ntrol
I Module (EBCM)
I LFWheel ·· . I 4
Speed Sensor -=- I Jiii'&
I Signal ~ ·
~------------------ -----J 519697
Circuit Description • The following conditions may cause an intermittent

The speed sensor used on this vehicle is a multiple malfunction:
pole magnetic pickup. This sensor produces an - A poor connection
AC signal that the EBCM uses the frequency from .to - Rubbed-through wire insulation .
calculate the wheel speed. - A broken wire inside the insulation
• If the customer's comments reflect that the amber
Conditions for Setting the DTC ABS/TCS indicator is on only during moist (
The DTC can be set any time the ignition is in the environmental conditions (rain, snow, vehicle
RUN position and the EBCM .detects an open or wash), inspect all the wheel speed sensor circuitry
a short to voltage. for signs of water intrusion. If the DTC is not ·
current, clear all DTCs and simulate the effects of
Action Taken When the DTC Sets
water intrusion by using the following procedure:
" A malfunction DTC stores.
1. Spray the suspected area with a five percent
" The ABS/TCS disables. saltwater solution.
" The amber ABS/TCS indicator(s) turn on. Add two teaspoons of salt to twelve ounces
.. The Red BRAKE Warning indicator could turn on. of water to make a five percent saltwater
Conditions for Clearing the DTC solution.
2. Test drive the vehicle over various road
.. The condition responsible for setting the DTC no
surfaces (bumps, turns, etc.) above
longer exists and the scan tool Clear DTCs 40 km/h (25 mph) for at least 30 seconds.
function is used.
3. If the DTC returns, replace the suspected
e 100 ignition cycles pass with no DTC(s) detected. harness.
Diagnostic Aids • If an intermittent malfunction exists refer to
Testing for Intermittent and Poor Connections in
" It is very important that a thorough inspection of
Wiring Systems.
the wiring and connectors be performed. Failure
to carefully and fully inspect wiring and connectors Front Wheel Speed Sensor Resistance
may result in misdiagnosis, causing part Use the following table that contains resistance values
replacement with reappearance of the malfunction. for the front wheel speed sensors at varying sensor
• Thoroughly inspect any circuitry that may be temperatures for use in diagnosis. The values are
causing the complaint for the following conditions: approximate and should be used as a guideline
- Backed out terminals for diagnosis. Refer to ABS Diagnostic Specifications.
- Improper mating Test Description
- Broken locks The numbers below refer to step numbers on the
- Improperly formed or damaged terminals diagnostic table.
- Poor terminal-to-wiring connections 6. This step checks for an open in the WSS or
- Physical damage to the wiring harness WSS CKT.
13. Checks for a short to voltage in the WSS CKT.
15. Checks for a short to voltage in the WSS CKT.
DTC C0035 ·LF Wheel Speed Circuit Malfunction
Was the Diagnostic System Check performed? Goto A
Diagnostic
1 - System
Go to Step2 Check-ABS
Inspect the WSS for physical damage.
2 -
Is physical damage of the WSS evident? Go to Step 3 Go to Step 4
Replace the WSS. Refer to Wheel Speed Sensor
3 Replacement (Front) in Front Suspension. - -
Is the replacement complete? Go to Step 18
Inspect the jumper harness for physical damage.
4 -
Is physical damage of the jumper harness evident? . Go to Step 5 Gd to Step 6
Replace the jumper harness. Refer to Wheel Speed
5 Sensor Jumper Harness Replacement (Front Left). - -
2. Disconnect the EBCM connector C1.
3. Install the J 39700 Universal Pinout Box using the
J 39700-530 cable adapter to the EBCM harness
6 connector C1 only. 800-1600 Q
4. Using J 39200 DMM, measure the resistance
between terminals 20 and 21 of J 39700.
Is the resistance within the range specified in the value(s)
column? Go to Step 13 Go to Step 7
1. Disconnect the Wheel Speed Sensor.
) 2. Using J 39200 DMM, measure the resistance
between terminals A and B of the Wheel Speed
7 800-1600 Q
Sensor Connector.
. column? Go to Step 8 Go to Step 3
Using J 39200 DMM, measure the resistance between
terminal 20 of J 39700 and terminal B of the WSS harness
8 connector. 0-5Q
Repair CKT 830 for an open or high resistance. Refer to
Wiring Repairs. If an open or high resistance is found in
the jumper harness, replace the jumper harness. Refer to
9 Wheel Speed Sensor Jumper Harness Replacement - -
(Front Left).
terminal 21 of J 39700 and terminal A of the WSS harness
10 connector. 0-5Q
(Front Left).
DTC C0035 LF Wheel Speed Circuit Malfunction (cont'd)
Malfunction is intermittent. Inspect all connectors and
harnesses for damage that may result in an open or high
12 resistance when connected. Refer to Wiring Repairs. - -
2. Turn the ignition switch to the RUN position,
engine off. ·
13 3. Using J 39200 DMM, measure the voltage at Above 1V
terminal 20 of J 39700.
Is the voltage within the range specified in the value(s)
Repair CKT 830 for a short to voltage. Re.fer to Wiring
Repairs. If a short to voltage is found in the jumper
14 harness, replace the jumper harness. Refer to Wheel - -
Speed Sensor Jumper Harness Replacement (Front Left).
Using J 39200 DMM, measure the voltage at terminal 21
of J 39700.
15 Above 1V
Repair CKT 873 for a short to voltage. Refer to Wiring
16 harness, replace the jumper harness. Refer to Whee/ - -
Speed Sensor Jumper Harness Replacement (Front Left).
Replace the EBCM. Refer to Electronic Brake Control Go to A (
Module (EBCM) Replacement. Diagnostic
17 - System
-
Is the replacement complete?
Check-ABS
1.Reconnect all previously disconnected components.
2.Using a scan tool clear the OTC.
3.Remove the scan tool from the DLC.
18 - Go to A
4.Carefully drive the vehicle above 12 Km/h (8 mph) for Diagnostic
several minutes. System
Does the DTC reset as a current DTC? Go to Step 2 Check-ABS
DTC C0036 LF Wheel Speed Circuit Range/Performance
LFWheel
· Speed
0.8YEL 873
Sensor
@11
0.8 LT BLU 830
B A C120
0.5 LT BLU 830 0.5 YEL 873
~
I
------------~--------- :~~~!
20
· ·· ·
21 C1
~ 0~~cntrol
I Module (EBCM)
I ~~ I A
. $.peed Sensor .,,. I PA.. .
I ~
L------------------------J
Signal
· 519697
Circuit Description Diagnostic Aids .

The speed sensor used on this vehicle is a multiple • It is very important that a thorough inspection of
'pole magnetic pickup. This sensor produces an the wiring and connectors be performed. Failure
AC signal that the EBCM uses the frequency from to to carefully and fully inspect wiring and connectors
calculate the wheel speed. may result in misdiagnosis, causing part
replacement with reappearance of the malfunction.
\ Conditions for Setting the DTC O Thoroughly inspect any circuitry that may be
)
• The DTC will set if one wheel speed = O and the causing the complaint for the following conditions: ·
other WSS are greater than 40 km/h (25 mph) - Backed out terminals
for 10 ms, or if the EBCM detects a short to - Improper mating
ground. - Broken locks
• The DTC will set if during drive off, one wheel - Improperly forrned or damaged terminals
speed = 0, and the other WSS are greater - Poor terminal-to-wiring connections
than 12km/h (7,5 mph}. - Physical damage to the wiring harness
Action Taken When the DTC Sets • The following conditions may cause an intermittent
malfunction:
• A malfunction DTC stores.
- A poor connection
• Th.e ABS/TCS disables. - Rubbed-through wire insulation
• The amber ABS/TCS indicator(s) turn on. - A broken wire inside the insulation
• The Red BRAKE Warning indicator could turn on. • If the customer's comments reflect that the amber
ABS/TCS indicator is on only during moist
Conditions for Clearing the DTC environmental conditions (rain, snow, vehicle
• The condition responsible for setting the OTC no wash), inspect all the wheel speed sensor circuitry
longer exists and the scan tool Clear DTCs for signs of water intrusion. If the DTC is not
function is used. current, clear all OTCs and simulate the effects of
• 100 ignit!on cycles pass with no DTC(s) detected. water intrusion by using the following procedure:
Important: After the OTC is cleared by ignition saltwater solution.
cycle default, the vehicle must be driven above Add two teaspoons of salt to twelve. ounces
12 km/h (8 mph) for the ABS/TCS indicator(s) to of water to make a five percent saltwater
turn off. solution.
) 40 km/h (25 mph) for at least 30 seconds.
3. If the OTC returns, replace the suspected
harness.
" If an intermittent malfunction exists refer to
Testing for Intermittent and Poor Connections in
Wiring Systems.
5..134 Antilock Brake System Brakes
Front Wheel Speed Sensor Resistance Test Description
Use the following table that contains resistance values The number(s) below refer to the step number(s) on (
for the front wheel speed sensors at varying sensor the diagnostic table.
temperatures for use in diagnosis. The values are 6. This step checks for the proper resistance in
approximate and should be used as a guideline the WSS.
for diagnosis Refer to ABS Diagnostic Specifications. 7. This step checks for the proper WSS output.
DTC C0036 LF Wheel Speed Circuit Range/Performance

Step Action · Value(s) Yes No
Was the Diagnostic System Check performed? Go to A
Diagnostic
1 -
System
Go to Step 2 Check-ABS
2 -
4 -
Is physical damage of the jumper harness evident? Go to Step 5 Go to Step 6
5 Sensor Jumper Harness Replacement (Front Left). - -
Is the replacement complete? Go to Step 16 .
1. Disconnect the WSS connector directly at the WSS.

6 between terminals A and B of the WSS. 800-1600 Q
Is the resistance within the range specified in the value(s) (
column? Go to Step 7 Go.to Step 3
1. With the J 39200 DMM still connected to the WSS
select the mV AC scale.
2. Spin the wheel as fast as you can by hand while
7 Above 100 mV
monitoring the AC output.
Is the AC voltage within the range specified in the value(s)
Using J 39200 DMM, measure the resistance between the
WSS terminal A and ground.
8 OL (infinite)
column? Go.to Step 9 Go to Step 3
1. Disconnect the EBCM harness connector C1.
connector C1 only.
9 OL (infinite)
Is the resistance within the range specified in the values
Repair short between CKT(s) 830 and 873. Refer to Wiring
Repairs. If a short between wheel speed sensor circuits is
found in the jumper harness, replace the jumper harness.
10 Refer to Wheel Speed Sensor Jumper Harness - -
Replacement (Front Left).
DTC C0036 LF Wheel Speed Circuit Range/Performance (cont'd)
Using J 39200 OMM, measure the resistance between
terminals 20 and 15 of J 39700.
11 OL (infinite)
Repair CKT 830 for a short to ground. Refer to Wiring
Repairs in Electrical Diagnosis. If a short to ground is
12 Refer to Wheel Speed Sensor Jumper .Harness - -
Using J 39200 OMM, measure the resistance between
13 OL (infinite)
Repairs in Electrical Diagnosis. If a short to ground is
found in the jumper harness, replace the jumper harness ..
14 Refer to Wheel Speecf Sensor Jumper Harness - -
'
Replace the EBCM. Refer to Electronic Brake Control Go to A ..
15 - System
-
Check-ABS '
1. Reconnect all previously disconnected components.
2.Using a scan tool .clear the OTC.
)
16 - Go to A
4.Carefully drive vehicle above 12 Km/h (8 mph) for Diagnostic
Does the OTC reset as a current OTC? Go to Step 2 Check-ABS
)
DTC C0040 RF Wheel Speed Circuit Malfunction
(
RF Wheel
Speed
0.8YEL 833
Sensor
@11
0.8 LT BLU 872
8
0.50K GAN 872 0.5 TAN 833

3 5 C1 (ABS)
4 5 C1 (ABS!TCS)
Ir - - - - - - - - - -
I
~High
-.1. -. -.·.'Wv.-
.
.. - ....-
. .· .
·JT·. --.,
-.
Low .
I .Ele.ct.ron.lc
Control Module
I (EBCM)
Brak.. e
I RFWheel . . I .A .
Speed Sensor · · -=- · :· III/IJ
I 1 M.
L----------~--------~--~-~ Signel
519701
Circuit Description • Th.e following conditions may cause an intermittent

The speed sensor used on this vehicle is a multiple · malfunction:
pole magnetic pickup. This sensor produces an - A poor connection
AC signal that the EBCM uses the frequency from to - Rubbed-through wire insulation
calculate the wheel speed. - A bmken wire inside the insulation
a If the customer's comme,:its reflect that the amber
Conditions for Setting the DTC ABS!TyS indicator is ononly durk1g moist (
The DTC can be set any time the ignition is in the environmental conditions (rain, 'snow, vehicle
RUN position and the EBCM detects an open or wash), inspect all the wheel speed sensor circuitry
a short to voltage. for signs of water intrusion. If the DTC is not
current,clear all DTCs and simulate the effects of
Action Taken When the DTC Sets water intrusion by using the following procedure:
• A malfunction DTC stores. 1. Spray the suspected area with a five percent
• The ABS!TCS disables. saltwater solution.
• The amber ABS!TCS indicator(s) turn on. Add two teaspoons of salt to twelve ounces
of water to make a five percent saltwater
" The Red BRAKE Warning indicator could turn on.
solution.
Conditions for Clearing the DTC 2. Test drive the vehicle over various road
• The condition responsible for setting the DTC no surfaces (bumps, turns, etc.) above
function is used. 3. If the DTC returns, replace the suspected
harness.
• 100 ignition cycles pass with no DTC(s) detected. O If an intermittent malfunction exists refer to
Diagnostic Aids Testing for Intermittent and Poor Connections in

• It is very important that a thorough inspection of Wiring Systems.
the wiring and connectors be performed. Failure Front Wheel Speed Sensor Resistance
to carefully and fully inspect wiring and connectors Use the following table that contains resistance values
may result in misdiagnosis, causing part for the front wheel speed sensors at varying sensor
replacement with reappearance of the malfunction. temperatures for use in diagnosis. The values are
• Thoroughly inspect any circuitry that may.be approximate and should be used as a guideline
causing the complaint for the following conditions: tor diagnosis Refer to ABS Diagnostic Specifications.
- Backed out terminals Test Description
- Improper mating The numbers below refer to step numbers on the
diagnostic table.
- Broken locks
6. This step checks for an open in the WSS or
- Improperly formed or damaged terminals WSS CKT.
- Poor terminal-to-wiring connections 13. Checks for a short to voltage in the WSS CKT.
- Physical damage to the wiring harness 15. Checks for a short to voltage in the WSS CKT.
DTC C0040 RF Wheel Speed Circuit Malfunction
Diagnostic
1 -
. System
2 -
4 -
5 Sensor Jumper Harness Replacement (Front Right). - -
connector C1 only.
6 4. Using J 39200 DMM, measure the resistance 800-1600 o
between terminals 4 and 5 of J 39700 if the vehicle is
equipped with Traction Control. If the vehicle is not
equipped with Traction Control then measure the
resistance between terminals 3 and 5 of J 39700.
column? Go to Step 13 Go to Step!
between terminals A and B.of the Wheel Speed
7 800-1600&1 .
Sensor Connector.
column? Go to Step B Go to Step 3
connector if the vehicle is equipped with Traction Control.
If the vehicle is not equipped with Traction Control
8 measure the resistance between terminal 3 of J 39700 and 0-50
terminal B of the WSS harness connector.
ls. the resistance within the range specified in the value(s)
the jumper harness, replace the jumper harness.
Replacement (Front Right).
10 connector. 0-50
Is the resistance within the range specified in the value(s) ·
)
DTC C0040 RF Wheel Speed Circuit Malfunction (cont'd)
the jumper harness, replace the jumper harness.
Replacement (Front Right).
engine off.
3. Using J 39200 DMM, measure the voltage at
13 terminal 4 of J 39700 if the vehicle is equipped with Above 1V
Traction Control. If the vehicle is not equipped with
Traction Control measure the voltage at terminal 3 of
J39700.
harness, replace the jumper harness. Refer to
(Front Right).
·.
Using J 39200 DMM, measure the voltage at terminal 5 (
of J 39700.
15 Above 1V
(Front Right).
Replace the EBCM. Refer to Electronic Brake Control Go to A
17 - System
-
Check-ABS
2. Using a scan tool clear the OTC.
3. Remove the scan tool from the DLC.
18 - Go to A
4. Carefully drive the vehicle above 12 Km/h (8 mph) for Diagnostic
DTC C0041 RF Wheel Speed Circuit Range/Performance
RF Wheel
Speed
0.8YEL 833
Sensor ~
@11 l2t:!J
0.8 LTBLU 872

B A C130
0.5 DKGRN 872 0.5TAN 833

3 5 C1 (ABS)
4 5 C1 (ABS/TCS)
'" - - - - - - - - - - - - ~
----------
- -. - -- - - - - , El.ectronic Brake
I ·High I Control Module
I Low I (EBCM)
I ~~ . I
I
Speed Sensor = Ji>
Signal I~
L------------------------J . 519701
Circuit Description - Broken locks

The speed sensor used on this vehicle is a multiple - Improperly' formed or damaged terminals
pole magnetic pickup. This sensor produces an - Poor terminaHo-wiring connections
AC signal that the EBCM uses the frequency from to - Physical damage to the wiring harness
calculate the wheel speed. • The following conditions may cause an intermittent
Conditions for Setting the DTC malfunction:
'!The DTC will set it one wheel speed = O and the -' A poor connection
other WSS are greater than 40 km/h (25 mph) for - Rubbed-through wire insulation
10 ms, or it the EBCM detects a short to ground. - A broken wire inside th.e insu.lation
• The DTC will set it during drive off, one wheel
" If the customer's comments reflect that the amber
=
speed 0, and the other WSS are greater than
ABS/TCS indicator is ononly during moist
12 km/h (7.5 mph).
environmental conditions (rain, snow, vehicle
Action Taken When the DTC Sets wash), inspect all the wheel speed sensor circuitry
• A malfunction DTC stores. for signs of water intrusion. If the OTC is not
• The ABS/TCS disables. current, clear all DTCs and simulate the effects of
• The amber ABS/TCS indicator(s) turn on.
• The Red BRAKE Warning indicator could turn on. 1. Spray the suspected area with a five percent
saltwater solution.
Conditions for Clearing the DTC Add two teaspoons of salt to twelve. ounces
• The condition responsible for setting the DTC no of water to make a five percent saltwater
longer exists and the scan tool Clear DTCs solution.
function is used.
• 1DO ignition cycles pass with no DTC(s) detected.
surfaces (bumps, turns, etc.) above 40 km/h
Important: After the DTC is cleared by ignition (25 mph) for at least 30 seconds.
cycle default, the vehicle must be driven above
3. lfthe DTC returns, replace the suspected
12 km/h (8 mph) for the ABS/TCS indicator(s) to
harness.
turn off. ·
• If an intermittent malfunction exists refer to
Diagr1ostic Aids Testing for Intermittent and Poor Connections in
" It is very important that a thorough inspection of Wiring Systems.
to carefully and fully inspect wiring and connectors
Front Wheel Speed Sensor Resistance
may result in misdiagnosis, causing part Use the following table that contains resistance values
) replacement with reappearance of the malfunction. for the front wheel speed sensors at varying sensor
temperatures for use in diagnosis. The values are
" Thoroughly inspect any circuitry that may be
causing the complaint for the following conditions: approximate and should be used as a guideline
- Backed out terminals for diagnosis. Refer to ABS Diagnostic Specifications.
- Improper mating
Test Description
The number(s) below refer to the step number(s) on
the diagnostic table. (
6. This step checks for the proper resistance in
the WSS.
7. This step checks for the proper WSS output.
DTC C0041 RF Wheel Speed Circuit Range/Performance
Diagnostic
1 - System
2 -
4 -
5 Sensor Jumper Harness Replacement (Front Right). - -
2. Using J 39200 DMM; measure the resistance
6 between terminals A and B of the WSS. 800-1600 Q
Is the resistance within .the range specified in the value(s) (
7 Above 100 mV
column? · Go to Step 8 Go to Step 3
8 OL (infinite)
connector C1 only.
9 between terminals 4 and 5 of J 39700 if the vehicle is OL (infinite)
equipped with Traction Control. If the vehicle is not
equipped with traction control measure the resistance
Is the resistance within the range specified in. the values
Repair short between CKT(s) 833 and 872, Refer to Wiring
Repairs. If a short between wheel speed sensor circuits is
•.' Rff!Rlqcement (Front Right).

DTC C0041 RF Wheel Speed Circuit Range/Performance (cont'd)
terminals 4 and 15 of J 39700 if the vehicle is equipped
with Traction Control. If the vehicle is not equipped with
11 traction control measure the resistance between OL (infinite)
Repair CKT 872 for a short to ground. Refer: to Wiring
Repairs. If a short to ground is found in the jumper
(Front Right).
13 OL (infinite)
(Front Right).
Is the repair complete? G.o to Step 16
15 - System
-
Check-ABS
) 1. Reconnect all previously disconnected components.
2. Using a scan tool clear the DTC.
16 - Goto A
4. Carefully drive vehicle above 12 Km/h (8 mph) for Diagnostic
several minutes. ..
System
Does the OTC reset as a current OTC? Go to Step2 Check-ABS
)
5"'.142 Antilock Brake System Brakes
DTC C0045 LR W.heel Speed Circuit Malf.unction
(
LR Wheel
Speed
0.8RED
885
C405C
C405B
o, o1
!Loe I
Sensor
@11
I
I
I
I
[S]N
0.8 BLK
B 884 c C1 0.5RED 885
0.5 BLK 884
A15 A14 C200D
C200A
0.5 BLK 884 0.5 RED 885

22 23 C1
r ,... - - - - - - - - - - - -
----------
- - ....,. - ,... - - - - - ., Electronic
Brake
I High~
·. .. ICoritrolModule
I Low · I (EBCM)
I .LRWheel • I .._
1 . . Speed S.ensor . -=- 1~ 111"4
L----------~-~----------J Signal
519704

The speed sensor used on this vehicle is a single malfunction:
point magnetic pickup. This sensor produces an - A poor connection
AC signal that the EBCM uses the frequency from to - Rubbetj-through wire insulation
Conditions for Setting the DTC ABSffCS indicator is on only during moist (
The DTC can be set any time the ignition is in the environrnental conditions. (rain, snow, vehicle
RUN position and the EBCM detects an open or wash), inspect all the w.hElel speed sensor circuitry
a short to voltage. for signs of water intrusion. 1.f the DTC is not
• The ABSff CS disables. saltwater solution.
• The amber ABSffCS indicator(s) turn on. Add two teaspoons of salt to twelve ounces
• The Red BRAKE Warning indicator turns on. of water to make a five percent saltwater
solution.
harness.
• 100 ignition cycles pass with no DTC(s) detected.
the wiring and connectors be performed. Failure Rear Wheel Speed Sensor Resistance
may result in misdiagnosis, causing part for the rear wheel speed sensors at varying sensor
replacement with reappearance of the malfunction. temperatures for use in diagnosis. The values
• Thoroughly inspect any circuitry that may be are approximate and should be used as a guideline
causing the complaint for the following conditions: for diagnosis. Refer to ABS Diagnostic Specifications.
- Broken locks diagnostic table.
DTC C0045 LR Wheel Speed Circuit Malfunction
Diagnostic
1 - System
'"
2 -
3 Replacement (With out Tractional Control). - -
4 -
Sensor Jumper Harness Replacement (Rear with Traction
5 Control). - -

6 connector C1 only. 2032-4266Q
4. Using J 39200 DMM. measure the resistance
between terminals A and B of the Wheel Speed 2032-4266Q
7
Sensor Connector.
column? · Go to Step 8 .Go to Step 3
8 connector. 0-5Q
9 - -
Wheel Speed Sensor Jumper Harness Replacement (Rear
with Traction Control).
Using J 39200 DMM, measure the. resistance between
10 connector. 0-5Q
Repair CKT 885 for an open or high resistanci. Refer to
11 Wheel Speed Sensor Jumper Harness Replacement (Rear - -
)
S.;144 Antilock Brake System Brakes
DTC C0045 LR Wheel Speed Circuit Malfunction (cont'd)
(
2. Turn the ignition switch to the RUN position,.
engine off.
\
Repairs. If a short to voltage is fourid in the jumper
harness, replace the jumper harness. Refer to Wheel
14 Speed Sensor Jumper Harness Replacement (Rear with - -
Traction Control).
Using J 39200 DMM, measure the voltage at terminal 23 ·
of J 39700.
15 Above 1V
16 Speed Sensor Jumper Harness Replacement (Rear with -
..
-
Traction Control).
Is the repair complete? Go to Step 18 (
17 - System
-
Check-ABS
2.Using a scan tool clear the OTC:
18 - Go to A
Does the OTC reset as a current OTC? Go toStep.2 Check-ABS
OTC C0046 LR Wheel Speed Circuit Range/Performance
C405C
LR Wheel O.SRED C405B
Speed 885 D, 01
Sensor
I
~
@11 0.8 BLK
L2w
B 884 C ~·· 0.5 RED 885

8f34
5 . A14 C2000
---------- C200A
'" -------------r-. :; _,- --fy. -

t
I
. 0.5 BU< 884 0.5 RED 885
. 22 ________ .?~ C1
High .
·. .
· L ..
· · · · ow .
.,Electronic.Brake
I Control Module
l(EBCM)
I LR Wheel .. .. I J.
I Speed Sensor ~ 1 ""-41. . .
L-----------------------J ~··
~~~
519704
Circuit Description ~ · Broken locks

The speed sensor used on this vehicle is a single - Improperly formed or damaged terrninals
point magnetic pickup. This sensor produces an - Poor terminal-to-wiring connectipns
AC signal that the EBCM uses the frequency from to
calculate the wheel speed. - Physical damage to the wiring harness
• The following. conditions may cause an intermittent
· Conditions for Setting the OTC malfunction:
! " The OTC will set if one wheel speed =O and the ,... A poor connectio.n
other WSS are greater than 40 Km/h (25 mph) for
1oms, or if the EBCM detects a short to ground. - Rubbed-through .wire insulation
.. The OTC will set if during arive off, one wheel - A broken wire inside the insulation
speed = O, and the other WSS are greater than • If the customer's comments reflect that. the amber
12 Km/h (7.5 mph). ABS/TCS indicat9r is·on only during moist
Action Taken When the OTC Sets environmental conditions (rain, snow, vehicle
.. A malfunction OTC stores. wash), inspect all the wheel speed sensor circuitry
• The ABS/TCS disables. for signs otwater intrusion. If the OTC is.not
current, clear all OTCs and simulate the effects of
.. The amber ABS/TCS indicator(s) turn on.
" The Red BRAKE Warning. indicator turns on.
1. Spray the suspected area'. with a five percent
Conditions for Clearing the DTC saltwater solution.
• The condition responsible for setting the OTC no
Add two teaspoons of salt to twelve ounces
longer exists and the scan tool Clear OTCs
of. water to make a five··percent.saltwater
function is used.
solution.
o 100 ignition cycles pass with no OTC(s) detected.
2. Test drive.the vehicle. over various road
Important: After the OTC is cleared by ignition surfaces (bumps, turns,, etc.) above
cycle default, the vehicle must be driven above 40 km/h (?5 mph) for at least 30 seconds.
12 Km/h (8 mph) for the ABS/TCS indicator(s) to
turn off. 3. If the OTC returns, replace the suspected
harness: ·
Diagnostic Aids ~ If an intermittent malfunction exists refer to
" It is very important that a thorough inspection of Testing for Intermittent andPoor Connections in
the wiring and connectors be performed. Failure Wiring Systems. ·
may result in misdiagnosis, causing part Rear Wheel Speed Sensor Resistance
) replacement with reappearance of the malfunction.
Use the following table that contains resistance values
• Thoroughly inspect any circuitry that may be for the rear wheel speed sensors at varying sensor
causing the complaint for the following conditions: temperatures for use in diagnosis. The values
- Backed out terminals are approximate and should be used as a guideline
- Improper mating for diagnosis. Refer to ABS Diagnostic Specifications.
5-146 Antilock Brake·System Brakes
Test Description
.the diagnostic table.
(
the WSS.
7, .This step checks for the proper WSS output.
DTC C0046 LR Wheel Speed Circuit
.
Range/Performance
Step Action . Value(s) Yes No
Diagnostic
1 - System
. '. '.
2 - Go to Step 4
Is physical damage of the WSS evident? Go to Step 3
Inspect the jumper harness for physical dama·ge.
4 -
Sensor Jumper Harness Replacem~nt (Rear with Traction
5 Control). · - -
Is the replacement complete? ·,,. Go to Step 16

1. Disconnect the WSS connector directl¥ at the WSS.
2. Using J 39200 DMM, measure the re,~istance
6 between terminals A and B of the WSS; 2032-42660 (
column? .. . . . G.o to Step 7 ·Ga to Step 3
1. With .the J 39200 DMM still connected to the WSS
2. Spin.the wheel.as fast as you can by_h1:1nd while Above 100 mV
7
monitoring the AC output. ·· ··
ls.the AC voltage within the range specified in the value(s)
column? · Go to Step 8 Go to Srep 3
8 OL (infinite)
column? Go to Step 9 Go to Srep 3
J 39700-530 cable adapter to thE3 EBCM harness
connector C1 only.
9 OL (infinite)
Repairs. If a between wheel speed sensor Circuits is found
in the jumper harness, replace the jumper harness. Refer
10 to Wheel Speed Sensor Jumper Harness Replacement - -
(Rear with Traction Control).
OTC C0046 LR Wheel Speed Circuit Range/Performance (cont'd)
11 OL (infinite)
:
Traction Control).
:
13 OL. (infinite)
:
Repairs. If a short to ground is found in the jumper :

Traction Control).
15 - System
-
Check-ABS
2. Using a scan tool clear the DTC.
16 - Go to A
4. Carefully drive vehicle above 12 Km/h (8 mph) for ·Diagnostic
: Does the DTC reset as a current DTC? Gq to Step 2 Check-ABS
.. :
)
DTC C0050 RR Wheel Speed Circuit Malfunction
(
C405C
RR Wheel O.SWHT C405B
Speed ~A 883 B,> 81
I
Sensor
{Qi II
I
I
I
I
I
I
0.8 BLK
I
I O.SWHT 883
} )
B 882 A A1
0.5 BRN 882
A10 A11 C200D
C200A
0.5 BRN 882 0.5 WHT 883

1 3 C1
'" - - - - - - - - - - - - - - - - - ""'. - - - - "'Electronic Brake
I H i g h ~ · I.Control Module
I Low I {EBCM)
I RRWheel · I A..
Speed Sensor .,,. P'&
I Signal
1~
~--------- --- --- .--.-J
519707
Circuit Description • T.he following conditions may cause an .intermittent

calculate the wheel speed. - A broken wire inside tt\e insulation
• If the customer's comments reflect that the amber (
Conditions for Setting the OTC ABS!TCS indicator is on only during moist
The OTC can be set any time the ignition is in the environmental conditions (rain, snow, vehicle
a short to voltage. for signs of water intrusion. If the OTC is not
current, clear all OTCs and simulate the effects of
Action Taken When the OTC Sets water intrusion by using the following procedure:
• A malfunction OTC stores. 1. Spray the suspected area with a five percent
• The ABS!TCS disables. saltwater solution.
• The amber ABS!TCS indicator(s) turn on. Add two teaspoons of salt to twelve ounces
• The Red BRAKE Warning indicator turns on.
solution.
Conditions for Clearing the OTC 2. Test drive the vehicle over various road
• The condition responsible for setting the OTC no surfaces (bumps, turns, etc.) above
longer exists and the scan tool Clear OTCs 40 km/h (25 mph) for at least 30 seconds.
function is used. 3. If the OTC returns, replace the suspected
harness.
• 100 ignition cycles pass with no OTC(s) detected.
Diagnostic Aids Testing tor Intermittent and Poor Connections in
may result in misdiagnosis, causing part for the rear wheel speed sensors at varying sensor
diagnostic table.
- Broken locks
DTC C0050 RR Wheel Speed Circuit Malfunction
Step Action Value(s} Yes No
Diagnostic
1 - System
2 -
Inspect the jumper harness for physical damag~.
4 -
Sensor Jumper Harness Replacement (Rear with Traction ,
5 Control). - -
1, Turn the ignition switch .to the OFF position.
J 39700s530. cable adapter to the EBCM harness
6 connector C1 only. 2032-A266Q
column? ' Go to Step 13 Go to Step 7
) 1. Disconnect the Wheel Speed Sensor.
between ter.minals A and B of the Wheel Speed 2032-4266Q
7
Sensor Connectqr.
8 connector. 0-5Q
Repair CKT 882 for an open or high resistance, Refer .to
10 connector. 0-5Q
) Is the repair complete? Go to Step 18
DTC C0050 RR Wheel Speed Circuit Malfunction (cont'd)
engine off.
Traction Control).
Using J 39200 DMM, measure the voltage at terminal 3 of
J39700.
15 Above 1V
Traction Control).
(
Go to Step 18
17 - System
-
Check-ABS .·
2.Using a scan tool clear the DTC.
18 - Go to A
4.Carefully drive the vehicle above 12 Km/h (8 mph) for Diagnostic .
(
DTC C0051 RR Wheel Speed Circuit Range/Performance
C405C
0.8 WHT C405 B
RR Wheel
Speed ~A 883 B t 81 !M;1
Sensor
@11 I
' 0.8 BLK

I
I O.SWHT 883
Ll!.I
>
A A1
0.5 BRN 882
A10
•-------------r---. ; ,- -1-1 •
I
I
I
High
RRWheel
Low
Electronic Brake
I Control Module
I (EBCM)
I A
speed Sensor ~ 1 .I~
I
L----------- Signal --------J..illlllfllllli
519707

The speed sensor used on this vehicle is a single - Improperly formed or damaged terminals
point magnetic pickup. This sensor produces an - Poor terminal-to-wiring connections
calculaie the wheel speed. - Physical damage to the wiring harness
• The following conditions may cause an intermittent
Conditions for Setting the OTC malfunction:
) =
• The OTC will set if one wheel speed 0 and the
- A poor connection
other WSS are greater than 40 km/h (25 mph) for
1Oms, or if the EBCM detects a short to ground. - Rubbed-through wire insulation
• The OTC will set if during drive off, one wheel - A broken wire inside the insulation
=
speed O, and the other WSS are greater than • If the customer's comments reflect that the amber
12km/h (7.5 mph). ABS/TCS indicator is on only during moist
Action Taken When the OTC Sets environmental conditions (rain, snow, vehicle
• A malfunction OTC stores. wash), inspect all the wheel speed sensor circuitry
• The ABS/TCS disables. for signs of water intrusion. If the DTC is not
• The amber ABS/TCS indicator(s) turn on.
Conditions for Clearing the OTC saltwater solution.
• The condition responsible for setting the OTC no
longer exists and the scan tool Clear OTCs
function is used.
solution.
• 100 ignition cycles pass with no OTC(s) detected.
Important: After the OTC is cleared by ignition surfaces (bumps, turns, etc.) above
cycle default, the vehicle must be driven above 40 km/h (25 mph) for at least 30 seconds.
turn off. · 3. If the DTC returns, replace the suspected
harness.
Diagnostic Aids • If an intermittent malfunction exists refer to
• It is very important that a thorough inspection of Testing for Intermittent and Poor Connections in
the wiring and connectors be performed. Failure Wiring Systems.
) replacement with· reappearance of the malfunction.
Test Description
the WSS.
DTC C0051 RR Wheel Speed Circuit. Range/Performance
Diagnostic
1 - System
2 -
Replace the WSS; Refer to Wheel Speed Sensor
4 -
Sensor Jumper Harness Replacement (Rear with Traction
5 Control). - -
Is the replacement complete? '
Go to Step 16
'
'
2. Using J 39200 DMM, measure the 'resistance
6 between terminals A and B of the WSS. 2032-4266Q (
7 Above 100 mV
.
8 OL (infinite)
connector C1 only.
9 OL (infinite)
Repairs. If a shqrt between wheel speed sensor circuits is
Replacement (Rear with Traction Control).
DTC C0051 RR Wheel Speed Circuit Range/Performance (cont'd)
)
11 OL (infinite)
Repair CKT 882 for a short to ground. Refer Wiring
Traction Control).
13 OL (infinite)
Is th.e reqistance within the range specified in the values
Traction Control).
15 - System
-
Check-ABS
1.
Reconnect all previously disconnected components.
2.
Using a scan tool clear the DTC.
) 16
3.
Remove the scan tool from the DLC.
- Go to A
. 4.
Carefully drive vehicle above 12 Km/h (8 mph) for Diagnostic ·
· several minutes. System
Does the OTC reset as a current DTC? Go to Step 2 Check-ABS
)
DTC C0055 Rear Wheel Speed Circuit Malfunction
C405C (
Rear
Wheel
0.5WHT
885
C405B
o: 01
~ c
Speed
Sensor
@ II
0.5 BLK
I
I
I
I
I
I
0.35 RED 885
E3:J
)
A 884 C C1 C200D
A14 C200A
r - ~ - - - - - - ·- - - - - - - - , Electronic Brake
I. High~ lcon.trolModule
I · Low I (EBCM)
I Rear Wheel I .._
I Speed Sensor -=- I .-,4
~----------------J
· Signal ~
. 519712

Conditions for Setting the DTC ABS indicator is on only during moist (
The DTC c.an be set any time the ignition is in the environmental conditions (rain, snow, vehicle .
a short to voltage. for signs of water intrusion. If the DTC is not
• The ABS disables. saltwater solution.
• The amber ABS indicator turns on. Add two teaspoons of salt to twelve ounces
• The Red BRAKE Warning indicator turns on. of water to make a five percent saltwater
solution.
harness.
may result in misdiagnosis, causing part for. the rear wheel speed sensors at varying sensor
DTC C0055 Rear Wheel Speed Circuit Malfunction
Diagnostic
1
System
Go to Step.2 Check-ABS
.. ....
Inspect the WSS for physical damage. ·.
2 -
Is physical damage of the WSS evident? Go to Step 3. Go to Step 4
3 Replacement (With out Tractional Control): - -
lrn~pect the jumper harness for physical damage.
4
Is physical damage of the jumper harness evident?
-
···..
Go to Step 5 Go to Step 6
Replace the jumper harness. Refer to Wheel Speed >
Sensor Jumper Harness Replacement (Rear with out

5 Traction Control). - -
6 connector C1 only. 763-:-15250
between terminals 22 and 23 of J 39700. . ' .·

) 1. Disconnect the Wheel Speed Sensor.
between terminals A and B of the Wheel Speed
7 763-15250
Sensor Connector.
column? · . .
.. Go toStep 8 Go to Step 3
8 connector. 0-50
9 - -
Wheel Speed Sensor Jumper Harness Replacement (Rear
with out Traction Control).
10 connector. 0-50
Wiring Repairs. If an open or high resistanc;e is found in
with out Traction Control).
'
) Go to Step 18
DTC C0055 Rear Wheel Speed Circuit Malfunction (cont'd)
-
.. Is the repair complete? .. Go to Step 18

2. Turn the ignition switch to. the RUN position,
engine off.
column? G6 to Step 14 Go to Step 15
out Traction Control}.
Is the repair complete? Go to. Step .18
of J 39700.
15 Above 1V
harness, replace the jumper harness. Refer to Wheel .
out. Traction Control).
(
Replace the EBCM. Refer to Wheel Speed Sensor Jumper Go to A
Harness Replacement (Rear with out Traction Control). Diagnostic
17 - System -
Check-ABS
1:
1.Reconnect all previously disconnected components. ·
18 - Go to A
several minutes. ·system
.··
(
DTC C0056 Rear Wheel Speed CKT Range/Performance
)
Rear
Wheel
0.5WHT
885
C405C
C4058
01I 01
!Loe I
Speed~
Sensor ~
II
0.35 RED 885
[SJ
0.5 BLK
A 884 C C1 0.35 BLK 884 C200D
A15 A14 C200A
.------r--; ;.,- -1--

I
I
I
.
··
High
Rear Wheel
.
---------- J
Low
'Electronic Brake
I Control Module
I (EBCM)
I A
I Speed Sensor -=- I l'.8'~
1. _ _ _ _ Signal _ _ _ _ _ _ _ _ _ _ _. Allllllii:!
519712

The speed sensor used on this vehicle is a single - Improperly formed or damaged terminals
point magnetic pickup. This sensor produces an - Poor terminal-to-wiring connections
calculate the wheel speed. - Physical damage to the wiring harness
\ Conditions for Setting the DTC malfunction:
) • The DTC will set if one wheel speed = O and the ·
other WSS are greater than 40 km/h (25 mph) for
- A poor connection
1O ms, or if the EBCM detects a short to ground. - Rubbed-through wire insulation
• The DTC will set if during drive off, one wheel - A broken wire inside the insulation
speed = 0, and the other WSS are greater than • If the customer's comments reflect that the amber
12 km/h (7.5 mph).
ABS indicator is on only during moist
Action Taken When the DTC Sets environmental conditions (rain, snow, vehicle
• A malfunction DTC stores. wash), inspect all the wheel speed sensor circuitry
• The ABS disables. for signs of water intrusion. If the DTC is not
· current, clear all DTCs and simulate the effects of
• The amber ABS indicator turns on.
Conditions for Clearing the DTC saltwater solution .
., The condition responsible for setting the DTC no
longer exists and the scan tool Clear DTCs
function is used.
solution.
Important: After the DTC is cleared by ignition surfaces (bumps, turns, etc.) above
cycle default, the vehicle must be driven above 40 km/h (25 mph) for at least 30 seconds.
turn off. 3. If the DTC returns, replace the suspected
harness.
Diagnostic Aids
• It is very important that a thorough inspection of Testing for Intermittent and Poor Connections in
the wiring and connectors be performed. Failure Wiring Systems.
) replacement with reappearance of the malfunction.
5~158 Antilock Brake System Brakes
Test Description
the diagnostic table.
(
the WSS.
DTC C0056 Rear Wheel Speed CKT Range/Performance .•

- Diagnostic
1
System
2 -
4 -
Replace the jumper harness: Refer to Wheel Speed
Sensor Jumper Harness Replacement (Rear with out
5 Traction Control). - -
Is the replacement complete? .· Go t9 Step 16
1. Disconnect the WSS connector directly at .the WSS.
6 between terminals A and B of the WSS. 763-1525 n (
select the mV AC scale. ' ;
2. Spin the rear wheel as fast as you can by hand while

7 Above 100 mV
8 OL (infinite)
Is the .resistance within the range specified in the value(s)
column? ... Go to Step 9 Go to Step 3
connector Ci only.
9 OL (infinite)
Repairs. If a short between wheel speed circuits is found
in the jumper harness, replace the jumper harness. Refer
10 to Wheel Speed Sensor Jumper Harness Replacement - -
(Rear with out Traction Control).
(
Brakes Antilock Brake System . 5.:159
DTC C0056 Rear Wheel Speed CKT Range/Performance (cont'd)
11 OL (infinite)
harness,. replace the jumper harness. Refer to. Wheel
12 Spef]d Sensor Jumper Harness Replacement (Rear with - -
out Traction Control).
13 OL (infinite)
a
Repair CKT 885 for short to ground. Refer to Wiring
out Traction Control).
15 - System
-
Check-ABS
) 2. Using a scan tool clear the OTC.
16 - Go.to A
4. Carefully drive vehicle above 12 Km/h (8 mph) for Diagnostic
)
DTC C0060 LF ABS Solenoid #1 Circuit. Malfunction
j
Power
(
Distribution
!c~;;:i~ics
Systems
1
0.8 PNK 739
30RN 440
14 8 C1
r- 1gniiio;;- -=-- =e-a'i'e~ f - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - , Electronic Brake
Positive Positive l I Control Module
(EBCM)
·~
Voltage Voltage I
,...,.._____.....,......, Solenoid Valve I .._
ill
Control Relay I .-,4
I Solenoid Valve Solenoid :

Relay Control . Valve Control
I
'·J
~-------------------------~----~--------J
I
I
.,,. ··
Solenoid Valve I
Ground
15 C1
:
I I
L------------------------------J Brake Pressure
Modulator Valve
(BPMV)
2 BLK 651
";" G101 (
519718
Circuit Description • ABS!fCS Indicators are turned on.

The Inlet valve solenoid circuits are supplied with • The Red BRAKE Warning Indicator turns on.
battery power when the ignition is in the run position.
The EBCM controls the valve functions by grounding · Conditions for Clearing the DTC
the circuit when necessary. • Condition for DTC is no longer present and scan
tool clear DTC function is used.
Conditions for Setting the OTC
• 100 ignition cycles pass with no DTC detec1ed.
The EBCM senses a discrepancy such as an open,
short to ground, or short to voltage in the circuit. Test Description
Action Taken When the OTC Sets The numbers below refer to step numbers on the
• A malfunction DTC is stored. Diagnostic Table.
• ABS!fCS disabled 2. This step determines if the DTC is current.
DTC C0060 LF ABS Solenoid #1 Circuit Malfunction
Diagnostic
1 - System
1. Tum the ignition switch to the OFF position.
2. Install a scan tool.
3. Turn the ignition switch to the RUN position, Go to A
2 engine off. -
Diagnostic
4. Using the scan tool run the Automated test. System
Does DTC C0060 reset as a current DTC? Go to Step 3 Check-ABS
3 - System
-
Check-ABS
DTC C0065 lF ABS Solenoid #2 Circuit Malfunction
Power
Distribution
~c:;~ics
Systems
~
1
0.8 PNK 739
3 ORN 440
14 8 C1
lg~o~ ;..;- ~~Tia~ f - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - "' Electronic Brake
r-
I
I
Positive
Voltage
Positive
Voltage
l I Control Module
I (EBCM)
I Solenoid Valve I ·4
ill
I Control Relay I II""
I I~
: Solenoid Valve Solenoid I
Relay Control Valve Control
I
~------------------------------~--------J
I
I
---.
Solenoid Valve
---.
I
Ground
15 C1
:
I I
L--------------------- --------J Brake Pressure
Modulator Valve
(BPMV)
2 BLK 651
) ...,. Gi01
519718
Circuit Description .. ABSffCS Indicators are turned on .

The Outlet valve solenoid circuits are supplied with .. The Red BRAKE Warning Indicator turns on.
battery power when. the ignition is in the RUN position.
The EBCM controls the valve functions by grounding Conditions for Clearing the DTC
the circuit when necessary. " Condition for OTC is no longer present and scan
tool clear OTC function is used.
Conditions for Setting the. DTC
• 100 ignition cycles pass with no OTC detected.
Action Taken When the DTC Sets The numbers below refer to step numbers on the
.. A malfunction OTC is stored . Diagnostic Table .
.. ABSffCS disabled 2. This step determines if the OTC is current.
DTC C0065 LF ABS Solenoid #2·Circuit Malfunction
Diagnostic
1 -
System
2 - Go to A
engine off.
•' Diagnostic
) Does DTC C0065 reset as a current OTC? Go to Step 3 Check-ABS
3 -
System -
Check-ABS
5-162 Antilock .Brake System Brakes
DTC C0070 RF ABS Solenoid #1 Circuit Malfunction
(
Power
Distribution
~c::~ics
Systems
j
3 ORN 440
14 1
0.8 PNK 739
8 C1
r 1gntt10;;- -;..;- ~~Tie-;: f - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - "' Electronic Brake
Positive Positive l I Control Module
Voltage Voltage I (EBCM)
_ _ _ _.......,.._ Solenoid Valve I
4
ill
Control Relay I P"4
I~

I
I ---1 :
r-----------~--------------~---~-----~~~J
I Solenoid Valve I 15 01
I I
~------------------------------J
Brake Pressure
Modulator Valve
{BPMV)
2 BLK 651
-;- G101 (
519718
Circuit Description • ABS/TCS Indicators are turned on.

The EBCM controls the valve functions bY grounding Conditions for Clearing the DTC
Conditions for Setting the DTC 0 100 ignition cycles pass with no DTC detected.
" A malfunction DTC is stored. Diagnostic Table.
" ABS/TCS disabled 2. This step determines if the DTC is current.
DTC C0070 RF ABS Solenoid· #1 Circuit Malfunction
Diagnostic
1 - System
2 engine off. -
Diagnostic
Does OTC C0070 reset as a current OTC? Go to Step 3 Check-ABS (
Replace the EBCM. Refer to Electronic Brake Control GotoA
3 - System -
Check-ABS
Power
Distribution
,
~c:;.:~ics
Systems
~
1"
I
lgririio;;
Positive
I
0.8 PNK 739
3 ORN 440
14 -------8
- Battery
Positive
Ci
f - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - . I. Electronic Brake
l Control Module
I Voltage Voltage I (EBCM)
I Solenoid Valve I A
ill
I ~~ I~
I I~
I
I ···i ···i Ground
I
I
~------------------------------~--------J
I 15 Ci Solenoid Valve I
I I
~------------------------------J Brake Pressure
Modulator Valve
(BPMV)
2 BLK 651
Gi01
519718

The Outlet valve solenoid circuits are supplied with • The Red BRAKE Warning Indicator turns on.
battery power when the ignition is in the RUN position.
the circuit when necessary. • Condition for OTC is no longer present and scan
Conditions for Setting the DTC
0 A malfunction OTC is stored. Diagnostic Table.
o ABS/TCS disabled 2. This step determines if the OTC is current.

-- Diagnostic
i
System
2 engine off. -
Diagnostic
) Does OTC C0075 reset as a current OTC? Go to Step 3 Check-ABS
Replace the EBCM. Refer to Electronic Brake Control (:lo to A
3 -
System -
Check-ABS
5., 164 Antilock Brake System Brakes
DTC cooao LR ABS Solenoid #1 Circuit Malfunction
Power
Distribution
~c~::ics
Systems
j [M;"1
u
(
:
3 ORN 440
14
.. lgniiio;;-'
Positive
I
0.8 PNK 739
8 C1
-------
- Battery
Positive
f ------------------------------
l
"'Ii
I
Electronic Brake
Control Module
I Solenoid Valve 1 4
ill
I Control Relay 1 IJlli'
I I~
I
I ···1 ···1 :
~----------~~--------------~---~-----~~~J
I Solenoid Valve I 15 C1
I
~-------------------------- ---J
Brake Pressure
Modulator Valve
(BPMV)
2 BLK 651
... Gi01 (
519718
Circuit Description O ABS/TCS Indicators are turned on.

The Inlet valve solenold circuits are supplied with • The Red BRAKE Warning Indicator turns on.
battery power when the ignition. is in the run position.
The EBCM controls the valve functions by grounding
Conditions for Clearing the DTC
the circuit when necessary. · ~ Condition for DTC is no longer present and scan
a 100 ignition cycles pass with no DTC detected.
.. A malfunction DTC is stored. Diagnostic Table .
" ABS/TCS disabled 2. This step determines if the DTC is current.
DTC C0080 LR ABS Solenoid #1 Circuit Malfunction

Was the Diagnostic System Check performed? · Go to A
Diagnostic
1 -
System
2 engine off.
-
Diagnostic
Does .DTC C0080 reset.as a current DTC? Go to Step 3 Check-ABS (
3 - System
-
Is the repair cqmplete?
Check-ABS
Power
Distribution
!c~:I'n~ics
Systems
j
F
I
14
jgnltio;;-
Positive
I
0.8 PNK 739
3 ORN 440
8 Ci
-:.. - ~~ft'a~ f - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -
Positive l "'Electronic Brake
: Control Module
I Vdtage Voltage (EBCM)
I Solenoid Valve I A
ill .
I Control Relay I I""'
I I~
: Solenoid Valve Solenoid :
~~ ·. . . ~~ I
: •---1
";- .
""1
-;- Ground
I
~---------- ----- -------------~------ .-J
I I
~-------------------------~----J Brake Pressure
Modulator Valve
(BPMV)
2 BLK 651
) ";- G101
519718
Circuit Description • ABSrrcs Indicators are turned on.

The Outlet valve solenoid. circuits are supplied with • The Red BRAKE Warning lndi.cator turns on.
battery power when the ignition .is in the RUN position.
The EBCM controls the valve functions by grounding Conditi<>ns for Clearing the DTC
Conditions for. Setting the DTC
" 100 ignition cycles pass with rio DTC detected.
The EBCM senses a discrepancy suc:h as an open,
short to ground, or short to voltage in the circ.uit Test Description
Action Taken When the DTC Sets The numbers below refer to step numbers o.n the
• ABSrrcs disabled 2. This step determines if the DTC is current.

Step Action Value(s) ·... Yes No
Diagnostic
1 - System
2 engine off. - Go to A
Diagnostic
Does OTC C0085 reset as a current OTC? Go to.Step.3 Check-ABS
3 -
System
-
Check'-ABS
DTC C0090 RR ABS Solenoid #1 Circuit Malfunction
Power (
Distribution
~c:;~ics
Systems
~
Positive
I
0.8 PNK 739
3 ORN 440
14 -------8 C1
... Jgrillio;;- - Battery
Positive
1 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - ., Electronic Brake
l I Control Module
I (EBCM)
·~
Voltage Voltage
.....,._ _ _ _ _......, Solenoid Valve I A
ill
Control Relay I .-
4

I
I " ···1 :
I- - - - - - - - - - - - ::.. - - - - - - - - - - - - - _"';;.., . - - .,. - - - - - ~0,;!!1£!._ J
I SolenoldValve I 15 C1
I I
b------------------------------J Brake Pressure
Modulator Valve
{BPMV)
2 BLK 651
G101 (
519718

Conditions fo.r Setting the DTC
• 100 ignition cycles pass with no DTC detected.
.. A malfunction OTC is stored. Diagnostic Table .
• ABS/TCS disabled 2. This step determines if the DTC is current.

Step Action .
Value(s) Yes No
r Diagnostic
- System
.3. Turn the ignition switch to the RUN position, Go to A
2 , engine off. -
Diagnostic
Does DTC C0090 reset as a current DTC? Go to Step 3 Check-ABS (
3 -
System
-
Check-ABS
Power
Distribution
~c;;:::lcs
S ems
j
30RN 440
14
.. ign1t10;;"
I
Positive
I 0.8 PNK 739
------- 8
- Battery f
Positive
C1
- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - ,I Electronic Brake
l Control Module
.I Voltage Voltage I (EBCM)
1 Solenoid Valve 1 ..t..
ill
1 Control Relay 1 Jiii'
I 1M6
I I
Solenoid Valve Solenoid
: Relay Control Valve Control :
I -=- •..• Ground I

~------------------------ -----~--------J
I I
~------------------------------J Brake Pressure
Modulator Valve
(BPMV)
2 BLK 651
) -;- G101
519718
Circuit Description .. ABS!TCS Indicators are turned on.

The Outlet valve solenoid circuits are supplied with " The Red BRAKE Warning Indicator turns on.
battery power when the ignition is in the RUN position.
The EBCM controls the valve functions by grounding Conditions for Clearing the OTC
the circuit when necessary. • Condition for OTC is no longer present and scan
Conditions for Setting the OTC
Action Taken When the OTC Sets The numbers below refer to step numbers on the
• A malfunction OTC is stored. Diagnostic Table.
• ABS!TCS disabled 2. This step determines if the OTC is current.
OTC C0095 RR ABS Solenoid #2 Circuit Malfunction

Diagnostic
1 - System
2 .. Install a scan tool.
2 engine off. - Go to A
Diagnostic
) Does OTC C0095 reset as a current OTC? Go to Step 3 Check-ABS
3 -
System
-
Check-ABS
5-168 Antilock Brake System Brakes.
OTC C0100 Rear ABS Solenoid #1 Circuit Malfunction
.
Power
Distribution
~ct;.Zi~lcs
Systems
j JM;1
L2w
(
1"'
14
Jgnttlo;;-
Positive
I
0.8 PNK 739
3 ORN 440
-------8 Ci
- Ba1tery
Positive
f - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - ..I Electronic Brake
l Control Module
Solenoid Valve 1 A
ill
Control Relay 1I ~

I
I ·--1 I
I
~------------------------------~--------J
I
-:
Solenoid Valve
-:- .
I
Ground
15 C1
I I
~------------------------------J Brake Pressure
Modulator Valve
(BPMV)
2 BLK 651
-: G101 (
519718
Circuit Description • ABS!TCS Indicators are turned on.

The Inlet valve solenoid circuit is supplied with battery • The Red BRAKE Warning Indicator turns on.
power when the ignition is in the run position. The
EBCM controls the valve functions by grounding the Conditions for Clearing the DTC
circuit when necessary. • Condition for DTC is no longer present and scan
• 100 ignition cycles pass with n6 DTC detected.
• ABS!TCS disabled 2. This step determines if the DTC is current.
DTC C0100 Rear ABS Solenoid #1 Circuit Malfunction

Diagnostic
1 - System
3. Turn the ignition switch to the RUN position, Go to A.
2 engine off. -
Diagnostic
Does OTC C0100 reset as a current OTC? . Go to Step 3 Check-ABS
Repace the EBCM. Refer to Electronic Brake Control Go to A
3 -
System
-
Check-ABS
Power
Distribution
~c:;;:i~ics
Systems
j·.
I"'
Positive
I
0.8 PNK 739
30RN 440
14 -------8 C1
19nii10;;- - Ba1tery
Positive
f - - . · - - - - - · ·· - . - - - - - - - - - - - - - - - - - - ..1Electronic Brake
. . , ·1 Control Modula
Voltage Voltage . · I (EBCM)
- - - - - - Solenoid Valve I 11,.
ill
Control Relay I Jlll"4
I~

I
~----------------~---------- --~---~----J
I
I 15 C1
-;-
Solenoid Valve
··:·
. I
Ground :
I I
~------------------------------J Brake Pressure
Modulator Valve
{BPMV)
2 BLK 651
) G101
519718

The Outlet valve solenoid circuit is supplied with • The Red BRAKE Warning Indicator turns on.
the circuit when necessary, • Condition for OTC is no longer present and scan .
short to ground, or short to voltage. in the circuit. Test Description
O A malfunction OTC is stored. Diagnostic Table.
• ABS/TCS disabled 2. This step determines if the OTC is current.
Step Action Value(s) Yes. No
Diagnostic
1 - System
2 - Go to A
engine off. Diagnostic
4. Using the scan' tool run .the Automated test. System
) Doe.s DTC C0105 reset as a current OTC? Go to Step 3 Check-ABS
Repace the. EBCM. Refer to Electronic Brake Control Go to A
3 - System -
Check-ABS
DTC C011 O Pump Motor Circuit Malfunction
!Hot At All Times! fHot In RUN, Bulb Test And START I

~ - - - - - - - ;
0
;r- - ~ Engine " - - - - - -p-.. ::r - ,I Engine
0 w~ w· ..
I L4 ABS BAT-1 Distribution I Wiring ABS IGN Distribution I 1nng
MaxiFuse® Schematics Harness MinlFuse <Bl Schematics Harness
I K4 40 A In Wiring I Junction 10 A in Wiring I Junction
~_ _ _____ ~~~_~Block 1 ... _ _ _ _ _ _8 !st~~ ~ Block 2
O.SPNK 739 Power
Distribution
3 RED 302 s1a1--- SChematics
In Wiring
o.s PNK 739 Systems
13 8 C1
r -eaiie;; - - - - - - - - - - - - - - - - - - - - - - - - Jgriitl;;;' - ~ - - - - - - - - , Electronic Brake
I Positive ' - - - - - - - - - - - . . . . . . - - - - - - - - Positive ·
1Control Module
I ~ I~
I ~~ I~
I Control I~
------ Relay
I .Pump I
I Motor I
I f ....• Relay I
• Control
t_2~:::-------------- T -$----=-1r~-~-~tc2-a~1:~
'"-----J
Brake Pressure
Modulator Valve
-=- G101
(BPMV)
.,.. G106
(
519720
Circuit Description Conditions for Clearing the DTC

The pump motor is an integral part of the BPMV, while • The. condition responsible for setting the DTC no
the pump motor relay is integral to the EBCM. The longer exists and the scan tool Clear DTCs
pump motor relay is not engaged during normal function is used.
system operation. When ABS or TCS operation is • 1oo ignition cycles pass with no DTCs detected.
required the EBCM activates the pump motor relay and
battery power is provided to the pump motor. Important: After the DTC is cleared using ignition
cycle default, the vehicle must .be driven above
Conditions for Setting the DTC 12 Km/h (8 mph) for the ABS!TCS indicator(s) to
• Pump motor voltage is not present 60 milliseconds turn off.
after activation of the pump motor relay.
Diagnostic Aids
• Pump motor voltage is present for more than
• It is very important that a thorough inspection of
2.5 seconds with no activation of the pump
motor relay. the wiring and connectors be performed. Failure
• Pump motor voltage is not present for may result in misdiagnosis, causing part
40 milliseconds after the purnp motor relay is replacement with reappearance of the malfunction.
commanded off.
• Thoroughly inspect any circuitry that may. be .
Action Taken When the DTC Sets causing the complaint for the following conditions:
• A malfunction DTC stores. - Backed out terminals
• The ABS!TCS disables. - Improper mating
" The amber ABS!TCS indicator(s) turn on. - Broken locks
• The Red BRAKE Warning indicator turns on. - Improperly formed or damaged terminals
- Poor terminal-to-wiring connections
- Physical damage to the wiring harness
• The following conditions may cause an intermittent Test Description
malfunction:
) - A poor connection
The numbers below refer to step numbers on the
diagnostic table.
- Rubbed-through wire insulation
4. This step checks for a short to ground in CKT 302.
- A broken wire inside the insulation
10. This step checks for an open in CKT 302.
Testing for Intermittent and Poor Connections in ·
Wiring Systems.
DTC C011 O Pump Motor Circuit Malfunction
Step Action Value{s) Yes No
·.
Was the· Diagnostic System Check performed? Go to A

Diagnostic
1 - System
Inspect the 40A ABS BATT 1 Maxifuse®, in the Underhood
2 Electrical Center 1. -
Is the fuse OK? Go to Step 7 Go to Step 3
1. Install a new 40A ABS BATT Maxifuse®.
2. Cycle the ignition switch from the OFF to RUN
position, engine OFF,
3 3. Using a scan tool in ABS!fCS Special Functions -
attempt to run the AUTOMATED test.
4. Recheck the 40A ABS BATT 1 Maxifuse® fuse. .
1. Tumthe Ignition switch to the OFF position.

) 2. Remove the 40A ABS BATT 1 Maxifuse®.
4. Connect the J 39700 Universal Pinout Box using the
4 J 39700-530 cable adapter to the EBCM harness OL (infinite)
connector only.
5. Using J 39200 DMI\II, measure the resistance
between termin;3.ls 13 and 15 of J 3Q700,
1. Disconnect the EBCM pump motor connector C2.

2. Connect a 10A fused jumper wire between the pump
motor connector C2 terminal 1 and battery voltage.
3; Connect a jumper wire between the pump motor
5 connector C2 terminal 2 and groLJnd. Only attempt to -
run the purryp motor for 5 seconds.
4. Disconnect the jumper wires.
5. Inspect the 1OA fuse in the jumper wire.
Replace the BPMV. Refer to Brake Pressure Modulator

6 Valve (BPMV) Replacement. - -
1. Turn the Ignition switch to the OFF position.
2. Disconnect the EBCM connector C1 .
3. Connect J. 39700 Universal Pinout Box using the
J 39700-530 cable adaptor to the EBCM harness
) 7 connector Cl only. 0-5.Q
4. Using J 39200. DMM, measur.e the resistance
column? Go to Step 9 Go to Step B
DTC C0110 Pump Motor Circuit Malfunction (cont'd)
8 Wiring Repairs. - -
.i
1. Install the fuse if removed.
2. Using J 39200 DMM, measure the voltage at the Go to Power
40A ABS BATT 1 Maxifuse® by probing between the Distribution
9 B+
fuse test terminals and a good ground. Schematics in
Is the voltage within the range specified in the value(s) Electrical
column? Go to Step 10 Diagnosis
of J 39700.
10 B+
'
Replace EBCM. Refer to Electronic Brake Control Goto A
11 - System
-
Check-ABS
Repair short to ground in CKT 302. Refer to Wiring
12 Repairs. - -
Repair open in CKT 302. Refer to Wiring Repairs.
13 - -
1. Disconnect the EBCM pump motor connector C2.
2. Connect a 1OA fused jumper wire between the pump
motor connector C2 terminal 1 and B+. (
3. Connect a jumper wire between the pump motor
14 connector C2 terminal 2 and ground. Only attempt to -
run the pump motor for 5 seconds.
4. Disconnect the jumper wires.
5. Inspect the 1OA fuse in the jumper wire.
1. Zero the J 39200 DMM leads.
15 between terminals 1 and 2 of the pump motor 0-4Q
connector C2.
2.Using a scan tool clear the DTC.
16 - Go to A
Does the OTC reset as a current DTC? Go to Step 2 Check-ABS
DTC C0121 Valve Relay Circuit Malfunction
iHot At All Times I !Honn RUN, Bulb Test And START I

.--
I
---------,E
. Power
.
I ~Qlne r - - - - - - P-;;-w; - ~ Engine
I L2 AB~ BAT-2. Distribution I W1nng A~~ IGN Distribution Wiring
MaxiFuse ® Schematics Harness M1rnFuse® Schematics I Harness ~
I
~ _
K2 50 A in Wiring
_ _____sy~e:::_s _ ~ Block 1
I Junction
.. _
10 A
_ ______
in Wiring I
Systems.:.. ...I
Junction
Block 2
Ltil
5 RED 1802
.. -
1
- - - - - - -
Power
- .... ., Engine
I w·.
I J11 ABSBAT-SOL Distribution mng
MlnlFuse ® Schematics I Harness 0.8 PNK 739
·, J10
I
1.-
_________
25 A in Wiring . I
Systems
...
I
Junction
Block 1
2 BLK 651
3 ORN 440
14 Ci 8 15 C1
r - a";tt;y - - - - - - - - - - - - - - - - - - - - - - 9
1 ntti;n- - ..,.. -G;u~ - "'Electronic Brake
Positive ' - - - - - - - - - - - ~ Positive Control Module
Voltage - - - - - - - - Solenoid Voltage (EBCM)
Valve Jt,
Control .1 ...~
Relay ~
Solenoid
-f Valve
...... Control
Solenoid
•....f Valve
.t
'~------------------,--
· -~~
-----------
.
--
Relay
I I Brake Pressure
Solenoid
Ii. _ _ _ _ _ _ _ _ _ _ _valve
_ ..,.. _ _ _ _ _ .sI
Modulator
(BPMV) Valve
) .,,. G101
519725
Circuit Description Diagnostic Aids

The solenoid valve relay supplies power to the • It is very important that a thorough inspection of
solenoid valve coils in the EBCM. The solenoid valve the wiring and connectors be performed. Failure
relay, located in the EBCM, is activated whenever to carefully and fully inspect wiring and connectors
the ignition switch is in the RUN position and no faults may result in misdiagnosis, causing part
are present. The solenoid valve relay remains replacement with reappearance of the malfunction.
O Thoroughly inspect any circuitry that may be
engaged until the ignition is turned OFF or a failure is
detected. causing the complaint for the following conditions:
- Backed out terminals
.Conditions for Setting the DTC - Improper mating
• DTC C0121 will set anytime the solenoid valve - Broken locks
relay is commanded on and the EBCM does - Improperly formed or damaged terminals
not see battery voltagE3 at the solenoid valves.
" DTC C0121 will set anytime the EBCM commands • The following conditions may cause an intermittent
the solenoid valve relay off and battery voltage is malfunction:
still present at the solenoid valves. -' A poor connection
Action Taken When the DTC Sets - A broken wire inside the insulation
• A malfunction DTC stores. • If an intermittent malfunction exists refer to
• The ABS/TCS disables. Testing for Intermittent and Poor Connections in
O The amber ABS/TCS indicator(s) turn on. Wiring SystE3ms.
• The solenoid valve relay is an integral part of the
• The Red BRAKE Warning indicator turns on. EBCM and is not serviced separately.
) Conditions for Clearing the DTC Test Description
• The condition responsible for setting the DTC no The numbers below refer to the step numbers on the
longer exists and the scan tool Clear DTCs diagnostic table.
function is used. 6. This step checks for a short to ground in CKT 440.
• 100 ignition cycles pass with no DTCs detected. 13. This step checks for an open in CKT 440.
DTC C0121 Vave
I Reav
I c·1rcu1t. MaIfunc1on
f
No
Step Action
Was the Diagnostic System Check performed?
Value(s) Yes
Goto A
(
Diagnostic
1 - System
Inspect the ABS BATI 2 Maxifuse in the Engine Wiring
2 Harness Junction Block 1. -·
1. Install a new ABS BATI 2 fuse. Go to A
2. Inspect the ABS BATI 2 fuse. Diagnostic
3 - System
Is the fuse OK?
Check-ABS Go to Step 9
lnspectthe ABS BATI Minifuse in the Engine Wiring
4 Harness Junction Block 1. -
1. Install a new ABS BATI fuse. Go to A
2. Inspect the ABS BATI fuse. Diagnostic
5
Is the fuse OK?
- System
Check-ABS Go to Step 6
2. Remove the ABS BATI Minifuse.
3. Disconnect the EBCM connector C1 .
6 J 39700-530 cable adapter to the EBCM harness OL (infinite)
connector only.
5. Using the J 39200 DMM, measure the resistance
between the J 39700 terminals 14 and 15.
Is the resistance within specifications? Go to Step 7 Go to Step 8
7
- System
-
Check-ABS (
Repair the short to ground in CKT 440. Refer to Wiring Go to A
Repairs. Diagnostic
8 - System
-
Is the circuit repair complete?
Check-ABS
Repairs. Diagnostic
9 - System
-
Check-ABS
Using the J 39200 DMM, probe between the Go to Power
ABS BATI 2 fuse test terminals and a good ground in Distribution
10 order to measure the voltage. B+ Schematics in
.ls the voltage within specifications? Electrical
Go to Step 11 Diagnosis
Using the J 39200 DMM, probe between the
ABS BATI Minifuse test terminals and a good ground
11 in order to measure the voltage. B+
Is the voltage within specifications? Go to Step 13 Go to Step 12
Repair the open or high resistance. in CKT 1802. Refer to Go to A
Wiring Repairs. Diagnostic
12
- System
-
Check-ABS
13 connector only. B+
4. Turn the ignition switch to the RUN position, engine off.
5. · Using the J 39200 DMM, measure the voltage at
terminal 14 of the J39700.
Repair the open or high resistance in CKT 440. Refer to Goto A
(
14
- System
-
Check-ABS
DTC C0161 ABS/TCS Brake Switch Circuit Malfunction
IHot At All Times i .

'"Power--3-
:. Distribution. H1
------.,1p
STOP/HAZARD I Fuse
JLoc I
I Block
Schematics
I in Wiring G1
Fuss 1
20 A I ~
._ _______ ------.1I
I Systems · · L..1il
O.SORN Exterior Ughts
Schematics in · ·
0.8 ORN 140 140 Lighting Systems
A C1
, -1'- , Stoplamp 0.8 LT BLU 20
1/ 1 Switch
I •-.A I (Closed with
1.. - .lY.1 pedal depressed)
B C1
0.8 LT BLU 20
8243 .--------.....i
0.8 LT BlU 20
A4 C200D
V8VING V6VINK
C200A.
Cruise Engine
PiOO 0;8 LT BLU Control Controls
$154..----,-,,'----'---li>- Schematics Schematics
20 in Cruise in Engine
0.8 LT BLU 20
1-:-.,
Control controls
s .c1 3.8L
' " ;0; ~ Electronic Brake
I Switch I Control Module
I Input I (EBCM)
:
I
. -:
·1~
:"
) .. __ ___ ..
I .;.· I
519727
Circuit Description " Thoroughly inspect any circl,lifry that may be

The Stoplamp Switch is a normally open switch, when causing the complaint for the following conditions:
the brake pedal is depressed the EBCM will sense · - Backed out terminals
battery voltage. This allows the EBCM to determine the
- Improper mating
state of. the brake lamps:
- Broken locks
- Improperly formed or damaged terminals
• EBCM detects batt~ry voltage at all times.
• EBCM never detects battery voltage from CKT 20.
• Both brake lamps are faulty. - Physical damage to the wiring harness
" The following. conditions may cause an intermittent
Action Taken When the OTC Sets
malfunction:
• DTC C0161 is set.
.- A poor connection
O
ABS and TCS remains active.
• The condition responsible for setting the DTC no
longer exists and the scan tool Clear DTCs .. If an intermittent malfunction exists refer to
function is used. Testing for Intermittent and Poor Connections in
Wiring Systems.
.. 100 ignition cycles pass with no DTCs detected,
Diagnostic Aids . Test Description
" It is very important that a thorough inspection of The numbers below refer to the step numbers on the
) the wiring and connectors be performed. Failure diagnostic table.
to carefully and fully inspect wiring and connectors 5. This step checks for voltage at the EBCM.
may result in misdiagnosis, causing part
replacement with reappearance of the malfunction. 11. This step checks the Stoplamp switch.
OTC C0161 ABS/TCS Brake Switch Circuit Malfunction
Diagnostic
1 - System
Observe the rear brake lamps.
2 -
Are the brake lamps off? Go to Step 4 Go to Step 3
Disconnect the Stoplamp Switch connector C1.
3 -
Are the brake lamps on? Go to Step 18 Go to Step 12
Press the brake pedal.
4 -
Do the brake lights come on? Go to Step 5 Go to Step 8
1. Turn the ignition switch .to the OFF position.
5 connector only. B+
4. Using .the J 39200 DMM, measure the voltage at the
J 39700 terminal 6 while an assistant presses the
brake pedal.
6 - System
-
Check-ABS
Repair the open or high resistance in CKT 20. Refer to Go to A
7
Wiring Repairs.
- Diagnostic
System
- (
Check-ABS
Check the STOP/HAZARD fuse in the 1/P Fuse Block.
8 -
1. Disconnect the Stoplamp Switch connector C1.
2. Using the J 39200 DMM, measure the voltage at the
9 B+
Stoplamp Switch harness connector terminal A.
Repair the open in CKT 140. Refer to Wiring Repairs. G.o to A
Is the circuit repair complete? Diagnostic
10 - System
-
Check-ABS
Connect a fused jumper wire between the Stoplamp
11 Switch harness connector terminals A .and B. -
Do the brake lamps come on? Go to Step 12 Go to Step 7
Adjust or repair the Stoplamp Switch as necessary. Go to A
Diagnostic
12 Is the repair complete? - System -
Check-ABS
1. Replace the STOP/HAZARD fuse. (Do not press the
brake pedal;)
13
2. Check the STOP/HAZARD fuse.
-
(
Brakes . Antilock Brake System 5-177
DTC C0161 ABSITCS Brake Switch Circuit Malfunction (cont'd)
Repairs. Diagnostic
14 -
System -
Check-ABS
1. Press the brake pedal. Go to A
2. Check the STOP/HAZARD fuse. -
Diagnostic
15
. System
Is the fuse OK? Check-ABS Go to Step 16
2. Disconnect the EBCM.
3. Replace the fuse.
16 -
4. Depress the brake pedal.
5. Check the STOP/HAZARD fuse.
Repairs. Diagnostic
17 - System
-
Check-ABS
Repair CKT 20 for a short to voltage. Refer to Wiring Go to A
Repairs. Diagnostic
18 - System
-
Check-ABS
)
5'."'178 Antilock Brake System Brakes
DTC C0166 TCS Priming Line Valve CKT Malfunction
(
Power
Distribution
~c:;::i~ics
Systems
~
1"
I
3 ORN 440
14
Jgnltio;;-
Positive
I
0.8 PNK 739
8 C1
-------
- Banery f
Positive
- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - .,I Electronic Brake
l Control Module
I ~~~ I•
ill
I ~~ I~
I I~
I
I ---.. ---1 I
I
r------------------------------~--------J
I
· . T
Solenoid Valve
T
I
~~
15 Ci
I I
~------------------------------J Brake Pressure
Modulator Valve
(BPMV)
2 BLK 651
..,,. G·101 (
519718
Circuit Description • ABSrrcs Indicators are turned on.

The TCS Prime valve solenoid circuits are supplied • The Red BRAKE Warning Indicator turns on.
with battery power when the ignition is in the RUN
position. The EBCM co.ntrols the valve functions by Conditions for Clearing the DTC
grounding the circuit when necessary. • Condition for DTC is no longer present and scan
The EBCM senses a discrepancy such as an open, .. 100 ignition cycles pass with no DTC detected.
" A malfunction DTC is stored. Diagnostic Table.
.. ABSff CS disabled 2. This step determines if the DTC is current.
DTC C0 166 TCS P nm
. .ma L'me VI
ave CKT MaIfunction
Diagnostic
1 -
System
2 engine off. -
Diagnostic
Does DTC C0166 reset as a current OTC? Go to Step 3 Check-ABS
Module (EBCM) Replacement. Diagnostic -
3 -
Is the repair complete? System
Check-ABS
DTC C0171 TCS Pilot Valve Circuit Malfunction
) Power
Distribution
!c~;::i~ics
Systems
j ~
L2w
14
'" l 9nitio;;-
I
Positive
I
0.8 PNK 739
3 ORN 440
8 C1
-;..:- ~~Tt'a~ f - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - ,I Electronic Brake
Positive l Control Module
I Solenoid Valve I A.
ill
I Control Relay I II"'
I I~
: Solenoid Valve Solenoid : . .
I
I ---. . ---.. . . . . Ground :
~------------------------------~--------J
I I
~------------------------------J Brake Pressure
Modulator Valve
(BPMV)
2 BLK 651
) .,... G101
519718

The Master Cylinder Isolation valve solenoid circuits • The Red BRAKE Warning Indicator turns on.
are supplied with battery power when the ignition is in
the RUN position. The· EBCM controls the valve · ·. Conditions for Clearing the DTC
functions by grounding the circuit when necessary. • Condition for DTC is no longer present and scan
Conditions for Setting the DTC • 100 ignition cycles pass with no DTC detected.
Action Taken When the DTC Sets The _numbers below refer to step numbers on the
• A malfunction OTC is stored. Diagnostic Table.
• ABS/TCS disabled 2. This step determines if the DTC is current.
DTC C0171 TCS Pilot Valve Circuit Malfunction
Step Action ·, Value(s) Yes No
Was the Diagn9stic System Check performed? Go to A
Diagnostic
1 - System
· 1. Turn the .ignition switch to the OFF position. ..
3. Tum the ignition switch to the RUN position,
2 engine 6ff: - Go to A
Diagnostic
4. Using the. scan tool run the Automated test. System·
) Does DTC C0171 reset as a current OTC?
Replace the EBCM. Refer to Electronic Brake Control
Go to Step 3
Go to A
Check-ABS
Module (EBCM) Replacement Diagnostic

3 -
System
-
Check-ABS
DTC C0181 Throttle Reduction Motor CKT Malfunction
(
r - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - , Accelerator
I I And Servo
I I Control ~
l__L·~,l~,, J__ J__~1~ J___ j~

I I Module (ASM) L2u
O.SWHT 560
221 560
0.8 WHT 491 o.a531
. 261 561
0.8 GRY
GRY 561
D C212 B D C211 F C212
1WHT 560 1 GRY 561 1 GRY 561

1WHT 560
5205
5204
2WHT 560
2GRY 561
?100
A B
Accelerator
Control And
Adjuster
(
519730

Identifies an adjuster assembly motor circuit that is Thoroughly inspect any circuitry that may be causing
shorted to ground, shorted to voltage, or an open the complaint for the following conditions:
circuit. This malfunction wiU not allow the adjuster - Backed out terminals ·
assembly motor to be .controlled at the commanded - Improper mating
current rate or will cause the driver circuit to allow - Broken locks
current directly to ground. - Improperly formed or damaged terminals
Conditions for Setting the DTC . - Physical damage to the wiring harness
DTC C0181 can set anytime the ignition switch is in The following conditions may cause an intermittent
the RUN position and the EBCM detects an open, malfunction:
short to ground, or a short to voltage. - A poor connection
Action Taken When the OTC Sets - Rubbed-through wire insulation
• A malfunction DTC stores
If an intermittent malfunction exists refer to Testing for
• The TCS disables Intermittent and Poor Connections in Wiring Systems.
• The amber TCS indicator turns on Test Description
Conditions for Clearing the DTC The number(s) below refer to the step number(s) on
• The condition responsible for setting the DTC no the diagnostic table.
longer exists and the scan tool Clear DTCs 4. This step checks for a short to ground.
function is used. 8. This step checks for an open.
• 100 ignition cycles pass .with no DTCs detected. 14. This step checks for a short to voltage. (
DTC C0181 Throttle Reduction· Motor CKT Malfunction
Diagnostic
1 - System
1. Tumthe ignition switch .to the OFF position.
2. Disconnect the Accelerator Control and Adjuster
connector.
3. Disconnect all cables from the Accelerator Control
and Adjuster.
4. Rotate Adjuster by hand fully, then release and allow
to return to the stop. Repeat this procedure 0.5:_10Q
2
three times.
5. Zero the leads on the J 39200 DMM.
.6 . Using J39200 OMM, measure the resistance
between the Accelerator Control and Adjuster
connector terminals A and 8.
..·
Is the resistance within the range specified in th.e value(s)
column? Go to Step .4 Go to Step 3
.
Replace the Accelerator Control and Adjuster. Refer to Go to A
Adjuster Assembly Replacement. Diagnostic
3 - System
-
Check-ABS
1. Disconnect the ASM harness connector.
2. Using J 39200 DMM measure the resistance between
4 the ASM harness connector terminals 22 and 28. OL (infinite)
Is the resistance wjthin the range specified in the value(s)
Repair CKT 560 for a short to ground. Refer to Wiring Go to A
Repairs. Diagnostic
5 -
System
-
Check-ABS
Using J 39200 DMM measure the resistance between the
ASM harness connector terminals 26 and 28.
6 OL (infinite)
Repairs. Diagnostic
7 - System
-
Check-ABS
Using the J 39200 DMM, measure the resistance between
the ASM harness connector terminal 22 and the
8 Accelerator Adjuster harness connector terminal A. 0-5Q
Repair CKT 560 for an open. Refer to Wiring Repairs. Go to A
Diagnostic
9 Is the repair complete? -
System
-
Check-ABS
)
DTC C0181 Throttle Reduction Motor CKT Malfunction (cont'd)
10 Accelerator Adjuster harness connector terminal A. 0-5Q
column? G.o to Step 11 Go to Step 9
11 Accelerator Adjuster harness connector terminal B. 0-5Q
Repair CKT 561 for an open. Refer to Wiring Repairs Go to A
Is the repair complete? Diagnostic
12 - System
-
Check-ABS
13 Accelerator Adjuster harness connector terminal B. 0-5Q
engine off.
14 2. Using the J 39200 DMM, measure the voltage at the Above 1V
ASM harness connector terminal 22.
15
Repairs.
- Diagnostic
-
(
Check-ABS
Using the J 39200 DMM, measure the voltage at the
ASM harness connector terminal 26.
16 Above 1V
column? ·. Go to.Step 17 Go to Step 18
Repairs. Diagnostic
17 - System
-
Check-ABS
Replace the ASM. Refer to Accelerator and Servo Control Go to A
Module (ASM) Replacement. Diagnostic
18 - System
-
Check-ABS
(
DTC C0182 Throttle Reduction Motor CKT Range Perf
)
r - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - , Accelerator
I I~~~
I I Control
~,1'~"'J ___ l__~1c~• _l ___ J~

I I Module (ASM)
[__l_
22I
0.8 WHT 560
D C212
49l o.53l
O.SWHT 560
B
8
GRY 561
D C211
I
26 561
0.8 GAY
F C212
1WHT 560 1 GRY 561 1 GRY 561

1 WHT 560
$205
8204
2WHT 560
2GRY 561
P100
A B
Ac.celerator
Control And
Adjuster
519730

The throttle position signal is used by the ASM to " Condition for OTC is no longer present and scan
control the actual throttle position that is requested by tool clear OTC function is used.
the EBCM. The EBCM compares the Delivered " 100 ignition cycles have passed with no DTCs
throttle position sensor value that is sent from the detected.
ASM to the throttle position sensor value sent from the
PCM over the Class 2 serial data line. Diagnostic Aids
Conditions for Setting the DTC If an intermittent malfunction exists refer to Testing for
Intermittent and Poor Connections in Wiring Systems.
DTC C0182 will set if the ASM delivers current greater
than 18 amps to the Accelerator Control and Adjuster Test Description
for more than three seconds without the cable The number(s) below refer to the step number(s) on
adjuster reaching its desired position. the diagnostic table.
Action Taken When the DTC Sets 4. This step checks if OTC C0181 is the cause for
• A malfunction OTC is stored. OTC C0182 for setting.
• The TCS is disabled. 5. This step checks if OTC C0182 is a current fault.
)
DTC C0182 Throttle Reduction Motor CKT Range Pert
Diagnostic
1 - System
Inspect all Accelerator Control and Adjuster cables and ..
linkages for any obvious problems that could cause
2 binding or sticking. -
Were any problems found? Go to Step 3 Go to Step 4

Repair as necessary. Go to A
Diagnostic
3 Is the repair complete? - System
-
Check-ABS
Is DTC C0181 also set as a current DTC? Go to
OTC C0181
4 - Throttle
Reduction Motor
CKT Malfunction Go to Step 5
1. Using a scan tool clear DTC C0182.
2. Raise the rear of the vehicle so that both rear wheel
are approximately 6 inches off the floor.
4. Using a scan tool in TCS Data List monitor the
Throttle Angle
5
5. Press the brake pedal.
-
6. Put vehicle in gear.
7. Release the brake pedal.
8. Depress and hold the Accelerator pedal between
Go to A (
Diagnostic
15 degrees and 45 degrees for at least four seconds. System
Did DTC C0182 reset as a current DTC? Go to Step 6 Check-ABS
Replace the Accelerator Control and Adjuster, Refer to Go to A .. · '
Adjuster Assembly Replacement. Diagnostic
6 - System
-
Check-ABS
(
DTC C0236 TCS RPM Signal Circuit Malfunction
)
.. - - - - - - - - - - - - - - - - - - , Electronic Brake
1
I
I
I
J
-=-
Spark Tachometer]
Ae1ard
Control
1
Control Module
I (EBCM)
lnpu1 I
I ~
~ -··t -------------------
_- - - - - - - - -"'" - - - ~ ~
19 11 C1
0.35 GRY/WHT 1687 0.35 WHT 121
K C101 G C105
0.35 GRY/WHT 1687 0.35WHT 121
~
I
I
I
--11 ------~--
53
-~.
_______________ _!V__G~~
TCS Spafk
(V8) 10
PWM out
C2
2-;;--- -
·
·
Tachometer j.M d I
. Output
~66~f.r~rain
I OUe
I (PCM)
I Retard Signal · 1 .. ,A
.. - - - - - - - - - - - .;... - - - - - - - - - .I ~ ·~
519733

The RPM signal circuit provides the EBCM with an Perform a thorough inspection of the wiring. Perform a
indication of engine RPM to help determine thorough inspection of the connectors. Failure to
TCS control methods and rates when a TCS event carefully and fully inspect the vviring. and the
takes place. connectors may result in misdiagnosis. Misdiagnosis
Conditions for Setting the DTC causes part replacemenrwith reappearance of
the malfunction. · ·
The EBCM does not receive an RPM input signal after
1 second, after the engine has been started. Test Description
Action Taken When the OTC Sets The number(s) below refer to the step number(s) on
• A malfunction DTC is stored. the diagnostic table.
• The TCS indicator is turned on. 2. If the instrument panel tachometer is working
• The TCS is disabled. ABS remains functional. properly, the cause of the malfunction is most
likely between 8120 and the EBCM, or the
Conditions for Clearing the DTC EBCM itself.
• The condition for DTC is no longer present and 10. At this point, the PCM is likely causing the
the scan tool Clear DTCs function is used.
malfunction. Refer to the appropriate
• 100 drive cycles have passed with no DTCs OBD system check.
detected.
)
OTC C0236 TCS RPM Signal Circuit Malfunction
. Step Action . Value(s) Yes No (
Diagnostic
1 - System
.
2. Vary the engine RPM with the throttle while observing
2 the 1/P tachometer. -
Does the 1/P tachometer work properly as the engine
RPM changes? Go to Step 3 Go to Step 4

2. Disconnect the PCM connector C2 from the PCM.
3. Disconnect the EBCM connector C1 from the EBCM.
4. Install the J 39700 Universal Breakout Box with the
3 J 39700-530 Cable Adapter to the EBCM harness only. 0-5Q
5. Use a J 39200 DMM to measure the resistance
between the PCM harness connector C2 terminal 10
and the J 39700 Universal Breakout Box terminal 11.
Is the resistance within the specified range? Go to Step9 Go to Step 11

2. Disconnect the PCM connector C2 from the PCM.
3. Disconnect the EBCM connector C1 from theEBCM.
4. Install the J 39700 Universal Breakout Box with the
4 J 39700-530 Cable Adapter to the EBCM harness only. 0-5Q
5. Use a J 39200 DMM to measure the resistance
between the PCM harness connector C2 terminal 10 (
and the J 39700 Universal Breakout Box terminal 11.
Is the resistance within the specified range? Go to Step5 Go to Step 12
Use a J 39200 DMM to measure the resistance between the

J 39700 Universal Breakout Box terminal 11 and
5 terminal 15. OL (Infinite)
Is the resistance within the specified range? Go toStep6 Go to Step 13
1. Turn the ignition switch to the RUN position

2. Use.a J 39200 DMM to measure the voltage between
6 the J 39700 Universal Breakout Box terminal 11 and 0-2 V
terminal 15.
Is the voltage within the specified range? Go to Step 7 Go to Step 14
1. lnspectthe PCM connector.for the following:

• Inspect for damage.
• Inspect for poor terminal contact.
• Inspect for corrosion.
2. Inspect the EBCM connector for the following:
• Inspect for damage.
7 • Inspect for poor terminal contact. -
• Inspect for corrosion ..
3. Ensure both the PCM connector and the EBCM
connector are properly retained when connected.
Are the following signs present on either connector:
• Is poor terminal contact present?
• Is corrosion present?
• Is damaged terminals present? Go to Step 15 Go toStepB
DTC C0236 TCS RPM Signal Circuit Malfunction (cont'd)
) 1. Reconnect all the connectors.
2. Using the scan tool clear the OTC.
3. Disconnect the scan tool from the DLC. - Go to A
8
Diagnostic
4. Start the engine. System
Did OTC C0236 reset? Go to Step 10 Check-ABS
9 - System
-
Check-ABS
Suspect PCM. Refer to A Powertrain On Board Go to A
Diagnostic (080) System Check in Engine Controls. Diagnostic
10 -
System
-
Check-ABS
Repair an open in CKT 121 between 8120 and _the Go to A
EBCM harness connector terminal 11. Refer to Wiring Diagnostic
11 Repairs. - -
System
Is the repair complete? Check-ABS
Repair an open in CKT 121 between 8120 and the Go to A
PCM harness connector C2 terminal 10. Refer to Wiring Diagnostic
12 Repairs. - -
System
Repair a short to ground in CKT 121. Refer to Wiring Go to A
Repairs. Diagnostic
13 - System_
-
Check-ABS
) Repair a short to voltage in CKT 121. Refer to Wiring Go to A
Repairs. Diagnostic
14 - System
-
Check-ABS
Replace all the terminals or replace the connectors that
exhibit signs of the following:
• That exhibit signs of poor terminal contact.
15 • That exhibit signs of corrosion. - -
Go to A
• That exhibit signs of damaged terminals.
Diagnostic
Refer to Connector Repairs in Electrical Diagnosis. System
)
DTC C0237 TCS Throttle Position Signal Malfunction
,~Il
,. - - - - - - - - - - - - - - ..,. - - - - - - - - ., Powertrain (
I TP
I Signal
I ~
sv
5V
Iw~.m
Reference
~
I Control
.rl~~
Ground I (PCM)
O _ I ..
.. - - - - - ----- - - - - - - ---- - .:. . . M
24 C2 8 60 C1
0.35 DK BLU 4170.35 GRY 596
. . . . . - - - - - - - - - - - 8118
0.35 DK BLU 417
.-----'l'-------s11a 0.35 BLK 452
0.35GRY 596
C . A
'"f-
I
-· - -•-!"'Throttle ·
• ·· I Position {TP)
0.35 DK BLU 417
I I Sensor
0.35GRY 596
'---------' B
0.35 BLK 452 ·
8119---------
0.35 BLK 452
B~fciii;~-~-~~:r~ ____ ,___ ~t5_B~+~h: .

E D K C100
0.35 DK
0.5 DK BLUI417 0.5 GRYI596 . 0.5 BLK1452
1 l 1
40 · . 41 43
~ - - - - - - - - '.'"" - - - - - - - - - - - - - - ~ Accelerator
1 TP TP Sensor sensor I And Servo
I Sensor . sv . Ground Control Module
I (ASM)
Signal Reference •
..
I _;;. _________________ ::::i_ ... _..1 . ~
552798

The throttle position signal is used by the ASM to • It is very important that a thorough inspection of
control the actual throttle position that is requested by the wiring and connectors be performed. Failure
the EBCM. to carefully and fully inspect wiring and connectors
Conditions for Setting the DTC may result in misdiagnosis, causing part
• OTC C0237 will set ·if the ASM is not receiving a
reference voltage. • If an intermittent malfunction exists refer to
., DTC C0237 will set if the reference signal is Inducing Intermittent Fault Conditions in Wiring
outside of a specified range. Systems.
Action Taken When the DTC Sets Test.Description

• A malfunction DTC is stored. The number(s) below refer to the step number(s) on
., The TCS is disabled. the diagnostic table .
• The amber TCS indicator will turn on. . 3. This step checks for an open in CKT 417.
Conditions for Clearing the OTC 5. This step checks for an open in CKT 596.
• Condition for DTC is no longer present and scan 7. This step checks for an open in CKT 452.
.. 100 ignition cycles have passed with no OTCs
detected.
DTC C0237 TCS Throttle Position Signal· Malfunction
Diagnostic
1 - System
Are any PCM TPS DTC(s) set? Go to A
Powertrain
On Board
2 - ·· Diagnostic (OBD)
System Check in
Engine Controls Go to Step 3
2. Disconnect the PCM connector C2.
3. Disconnect the TPS connector.
4. Disconnect the ASM connector.
3 0-50
5. Using the J 39200 DMM, measure the resistance
between terminal 40 of the ASM harness connector
and the TPS harness connector terminal C.
Repair CKT 417 for an open or high resistance. Refer to Go to A
4 - System
-
Check-ABS
terminal 41 of the ASM harness connector and the
5 TPS harness connector terminal A. 0-50
\ Is the resistance within the range specified in the value(s)
J
6 - System
-
Check-ABS
Using the J 39200 DMM, measure the. resistance between
terminal 43 of the ASM harness connector and the
7 TPS harness connector terininal B. 0-50
column? Go to Step 9 Go to Step B
Repair CKT 452 for an open or high resistance. Refer to .Go to A
Wiring· Repairs. Diagnostic
8 - System
-
Check-ABS
Replace the ASM. Refer to Accelerator and Servo Control Go to A
9 - System
-
Check-ABS
)
5-190 Antilock Brake·System Brakes
DTC C0238 TCS TP Sensor Comparison Malfunction
r- -
I
•
I
, ~
-
Signal .
-
TP Il
- - - - - - - -
!~~
5v
-
5V
..., - -
Reference
,.. - -. - - ..,.. -
~.m. ~,~~
Ground
l"1.
- .,
I (PCM}
Powertrain
I Control .
(
~ - - - -~24- C2
- - - - -8 -- --- -- - -- --- --- -- 6() .;; :: ~ ~
- ! C1 AOBO I .
0.35 DK BLU 4170.35 GRY 596

- - - - - - - - - - - - - 8118
0.35 DK BLU 417
---..Jl'\.----•S116 0.35BLK 452
0.35 GRY 596
C A
0.35 DK BLU 417

rf-
I
---
.
-;.,Throttle
• • Position (TP) I
I I Sensor
0.35 GAY 596.

1.-------J
B
0.35 BLK 452
s 11911111-------------.....,.....i
E
0.35 OK BL*~~~ j~-~
0.5 DK BL.UI417
-~~* _ _ _ _: ~~Jrt\go
D
0.5 GRYI.596
~
0.35 BLK 452
~:3_5,
0.5 BLKI452
K C100
40 41 43
~
I
-i-:-----1-~P:e:a~ - - - - - -i- :n:r- .,.:
Sensor 5V Ground I
:~~e:~~r.
Control Mooule
: Signal Reference . (ASM) ~
(
b-~-----------------~---~ 1
~
552798

The throttle position signal is used by the ASM to • It is very important that a thorough inspection of
control the actual throttle position that is requested by the wiring and connectors be performed. Failure
the EBCM. The EBCM compares the Delivered to carefully and fully inspect wirir:ig ,.?nc;I connectors
throttle position sensor value that is sent from the may result in misdiagnosis,. causing part
ASM to the throttle position sensor value sent from the replacement with reappearance of the malfunction.
PCM over the Class 2 serial data line.
.. If an intermittent malfunction .exists refer to
Conditions for SettingJhe DTC Testing for Intermittent and Poor Connections in
OTC C0238 will set if the EBCM detects a difference Wiring Systems.
between the PCM throttle position and the throttle
position sent from the ASM. Test Description
The number(s) below ,refer .to the step number(s) on
Action Taken When the· DTC Sets
.. A malfunction OTC is stored.
2. This step checks if the PCM detected a fault.
.. The TCS is disabled.
.. Condition for OTC is no longer present and scan
" 100 ignition cycles have passed with no DTCs
detected.
DTC C0238 TCS TP Sensor Comparison Malfunction
) Was the Diagnostic System Check performed? Go to A
-
Diagnostic
1
System
Are any PCM TPS DTCs set? Go to A
Powertrain
2 - On Board
Diagnostic (080)
System Check Go to Step 3
3. Disconnect the scan tool.
3 - Go to A
4. Turn the ignition switch to the RUN position, Diagnostic
engine off. System
Does OTC C0238 reset as a current OTC? Go to Step 4 Check-ABS
4 - -
Is the replacement complete? System
Check-ABS
)
DTC C0239 TCS Spark Retard Monitoring Malfunction
I
I
I
I
I
~
, . Spark
.,
----T
Tachometer
Retard
. Control
1
(.EBCM)
Input
11
"" - - - - - .... - - - - - - - - - - - - ., Electronic Brake
1 Control Module
- .
I
I
I ~
/;>
. .
(
I,, - -*---=-=---=---:.~-':"--=---=---=-
19 .
- - - - .,
tt C1
0.35 GRY/WHT 1687 0.35 WHT 121
K C101 G C105
0.35 GRY/WHT 1687 0.35 WHT 121
--r 1------~-
- (V8) 10
53 _______________ __0:,6)_~ C2
~
I PWM Out
~2~ - - - -
Tachometer
~ 6~~i~rain
iM d I
I Output I O Ue
I TCS Spark I (PCM)
I Retard Signal I. /;>
1..---------------------J~ (
519733

Spark Retard is simultaneously controlled by the • It is very important that a thorough inspection of
EBCM and the PCM. The PCM supplies a 12 volt pull the wiring and connectors be performed. Failure
up voltage. This voltage is monitored by the PCM, to carefully and fully inspect wiring and connectors
the EBCM requests spark retard by pulling the may result in misdiagnosis, causing part
voltage low. replacement with reappearance of the malfunction.
Conditions for Setting the DTC .. If an intermittent malfunction exists refer to
OTC C0239 can be set anytime when the EBCM Testing for Intermittent and Poor Connections in
senses a short to ground, a short to battery voltage, or Wiring Systems.
an open in CKT 1687.
Test Description
Action Taken When the DTC Sets The number(s) below refer to the step number(s) on
• A malfunction OTC is stored. the diagnostic table.
• The ABS/TCS is disabled.
2. This step checks for the pull up voltage from
• The Red BRAKE Warning indicator turn on. the PCM.
Conditions for Clearing the DTC 3. This step checks for a short to voltage.
• Condition for OTC is no longer present and scan 6. This step checks for a short to ground.
• 100 ignition cycles have passed with no DTCs
detected.
DTC C0239 TCS Spark Reta.rd Monitoring Malfunction
) Was the Diagnostic System Check performed? Go to A
-
Diagnostic
1
System
c
connector C1 only.
2 4. Turn the ignition switch to the RUN position, Above 10V
engine off.
2. Disconnect the PCM connector C2. I
3. Turn the igniUon switch to the RUN position,

engine off.
3 Above 1V
Repairs. Diagnostic
4 -
System
-
Check-ABS
) Replace the EBCM. Refer to Electronic Brake Control Go to A
5 -
System
-
Check-ABS
2. Disconnect the PCM connector. C2.
6 3. Using J 39200 DMM, measure the resistance OL (infinite)
Repairs. Diagnostic
7 -
System
-
Check-ABS
terminal 19 of J 39700 and terminal 53 of the
8 PCM connector C2. 0-5Q
Repair CKT 1687 for an open. Refer to Wiring Repairs. Go to A
Diagnostic
9 Is the repair complete? -
System
-
Check-ABS
Suspect the PCM. Refer to A Powertrain On Board Go to A
Diagnostic (080) System Check. Diagnostic
10 - -
Check-ABS
DTC C0240 PCM Traction Control Not Allowed
!HotAtAIITimesl IHotlnRUNI
r- · - -· - - - - -
I Power
- - - - - - - - - - , Engine
1
'" - - - - - - P;we-;- - ~ E~Qine
I Distribution L4 ABSBAT-2 I Wiring
ABSBAT-1 L2 •• H9 ABS IGN Distribution Winng Data Link
MlnlFuse ® Schematics I Harness Connector
I Schematics
K4 K2 MaxiFuselB> I Harn~SS
MaxiFuse®
In Wiring I Junction (DLC)
. I ~Y!~~~
I HS 10 A
...
so A
40 A
__________________ ..iBlock1I Junction
~ _ _ ____~~s- ~ Block 2 . 21
3 RED 302
'" Power
I
5 RED 1802
- - - - - - - - - - ,, En.gine
0.8 PNK 739
r--~--j-
I Data Link
1
Connector
Schematics In
1 Datalink .
0.35 PPL 1132
· G
.. .
·
I PIIce
,5
1
1
Pack
SP200
I Distribution j11 ABS BAT SOL I Wiring I Communications I
Schematics J MlnlFuse ® Harness
I in Wiring 1 25 A
1 Junction L - - - -, - - -· .I
I..Systems
_ _ _ _ _ _ _ _ _ _ JI Block 1
. . 0.35 LTBL~I1122
A3 C200D
3 ORN 440 C200A
2 BLK 651 0.35 LT BLU 1122
15
'" Ground
13 _____________1j
Battery - - - - - -
-----------------~
Battery - - - - - - - -
------------------------?~
Ignition - - - - - - - - · - - - -
J C1 .·
Serial ~Electronic
1 Positive Pos~lve Positive Data Brake
I Voltage Voltage Voltage Line I Control
I Class 2 I Module
I l~BC~
I I ~
L.------------------------------------------J~
G101 (
519691

The PCM monitors various parameters and will not • The condition for the DTC is no longer present
allow traction control operation if any parameter and the scan tool clear DTC function is used
falls below a specified value.
Conditions for Setting the.DTC detected
The PCM detects a malfunction and then causes
Test Description
TCS shut down until the malfunction has been
corrected The numbers below refer to the step numbers on the
diagnostic table.
4. This step checks if OTC C0240 resets.
• A DTC C0240 is stored
• The TCS is disabled
" The TRAC OFF indicator is turned on
• If the TCS is again allowed to function, the
indicator will be turned off but the DTC will
be stored
Brakes Antilock Brake System 5.;195
DTC C0240 PCM Traction Control Not Allowed
Diagnostic
1 - System
1. Turn the ignition switch to the RUN position with the Go to Diagnostic
engine off. Trouble
2. Using a Scan Tool, read the ABSffCS DTCs. Code (OTC)
2 - List/Type for the
Are any other DTCs set? appropriate
OTC table Go to Step3
3 Is DTC C0240 set as a current code? Go to Step5 Go to Step 4
1. Using the scan tool clear the OTC.
Go to A
4 3. Carefully drive the vehicle above 12 Km/h (8 mph) for - Diagnostic
Did OTC C0240 set as a current DTC? Go to Step 5 Check-ABS
Perform the Powertrain OBD System Check. Refer in Go to Powertrain
5 A Powertrain On Board Diagnostic (080) System Check. - Go to Control Module
Did the vehicle pass the OBD System Check? Diagnostic Aids Diagnosis
)
OTC C0241 PCM Indicated Requested Torque Malf
.. - - - - - - ..,. - - - - - - - ..,.. - - - - - - - - - - , Electronic Brake

(
I I Control Module
I
:
I
~
~Requested
.. Torque
!
.· . Delivered
Torque
_ - • ": Output _ _ _ _ _ _ _ _ _ _ _ Input _ _ _ _
i l(EBCM)
:
I
~
J,
~
0.35 ORN/B~:r~~--------~-~~-;:~/~~=1~~
I
.- -----r- 71 Q1
-R;qu";'st;i -
Torque
- - - -
9 C2
oeiwe~- - - - , Powertrain
- --.{'."'"
Torque I Co..nt. rol
I Input Output I Module
I . l(PCM)
I ~ I
I I~
. . ______________ .·. -- . - . ----J
I I
519744.

Traction Control is simultaneously controlled by the • It is very important that a thorough inspection of
EBCM and the ECM. The EBCM sends a requested the wiring and connectors be performed. Failure
torque message via a Pulse Width Modulated (PWM) to carefully and fully inspect wiring and connectors
signal to the ECM requesting a desired engine may result in misdiagnosis, causing part
torque level for proper Traction Control system replacement with reappearance of the malfunction.
operation. The PCM supplies the pull up voltage. • If an intermittent malfunction exists, refer to (
Conditions for Setting the DTC Checking Aftermarket Accessories in Wiring
Systems.
• If a defective requested torque signal is detected
by the PCM, a message is broadcasted back to • Possible causes for DTC C0241 to set:
the EBCM via class 2. - Open in the circuit 463.
• DTC C0241 can be set anytime when ignition - Circuit 463 shorted to ground or voltage.
voltage is present and the EBCM detects the - Communication problem.
first class 2 message of a defective requested
- Circuit 463 has a wiring problem,
torque signal from the PCM.
terminal corrosion, or poor connections.
Action Taken When the DTC Sets - PCM not receiving information from
• A malfunction DTC is stored. the EBCM.
• The TCS is disabled. Test Description
• The TRAC OFF indicator is turned on. The The numbers below refer to step numbers on the
ABS remains functional. diagnostic table.
Conditions for Clearing the DTC 4. This step checks for the proper requested torque
• Condition for DTC is no longer present and scan value received at the PCM. This value is in
tool clear DTC function is used. percent of torque.
• 100 ignition cycles have passed with no DTC(s) 5. This step checks for the proper requested torque
detected. value sent from the EBCM. This value is in
newton meters of torque.
7. This step checks for the presence of a pull-up
voltage from the PCM.
Brakes Antilock Brake System 5-1_97
DTC C0241 PCM Indicated Requested Torque Malf
)
-
Diagnostic
1
System
Check that ground, G101 and G106 is clean, tight and free
of damage. Refer to Power and Grounding Components in
2 Wiring Systems. -
Were any loose, damaged, or corroded grounds found? Go to Step 3 Go to Step 4

Repair ground as necessary. Refer to Wiring Repairs in Go to A
Wiring Systems. Diagnostic
3 - System
-
Check-ABS
. 1. Turn the ignition switch to the OFF position .

2. Install the scan tool.
4. Use the scan tool to select Engine 2 Data Display in
4 Powertrain. 80-95 %
5.. Using the. scan tool, observe the Traction Control
Desired Torque.
Is the desired torque within the range specified in the
value(s) column? Go to Step 5 Go to Step 7
1. Turn the engine off.
2. Turn the ignition .switch to the run position, engine off.
3. Using the scan tool, select ABSffCS Data Display.
5 ON·m
4. Observe the EBCM to PCM Requested Torque.
) Is the requested torque within the range specified in the
6 -
System
-
Check-ABS
2. Disconnect the EBCM connector.
3. Install J 39700 Universal Pinout Box using the
connector.
7 4. Turn the ignition switch to the RUN position, 4.5-5.5 V
engine off.
5. Using J 39200 DMM, measure the voltage between
engine off.
8 Greater than 1V
DTC C0241 PCM Indicated Requested Torque Malf (cont'd)
(
Repairs in Wiring Systems. Diagnostic
9 -
System
-
Check-ABS
10 between J 39700 terminals 27 and 15. OL (infinite)
11 - System
-
Check-ABS
12 between terminal 27 of J 39700 and the 0-2Q
PCM connector C2 terminal 71.
Diagnostic (080) System Check in Engine Controls. Diagnostic
13 - System
-
Is the Repair complete?
Check-ABS
Repair CKT 463 for an open. Refer to Wiring Repairs in Go to A
14 - System -
Check-ABS
(
DTC C0244 PWM Delivered Torque Malfunction
) I"' - - - - - - - - - - - - - - - - - - - - - - - - - "'Electronic Brake

I I Control Module
I l(EBCM)
I I J:. ~
~ Llil
: ~Requested
Torque _J:,.
{ Delivered
Torque
:
~----""' O u t p u t - - - - - - - - - - - Input----~
0.35 ORN/B~~r::.- -------:.~;~~~r:

71C1 9C2
~
I
-----r---~=:t;i -------~-~~~~~----~
Input Output
~~~:~rain
I Module
I I~~
I -=- I
I I J:..,
I I~
L-------------------------J
519744

Traction Control is simultaneously controlled by the • It is very important that a thorough inspection of
EBCM.and the PCM. The PCM sends a the wiring and connectors be performed. Failure
DELIVERED TORQUE message via a Pulse Width to carefully and fully inspect wiring and connectors
Modulated (PWM) signal to the EBCM confirming the may result in misdiagnosis, causing part
delivered torque level for proper Traction Control replacement with reappearance of the malfunction.
) system operation, The EBCM supplies the pull
up voltage.
Checking Aftermarket Accessories in Wiring
Conditions for Setting the DTC Systems.
• Possible causes for OTC C0244 to set:
DTC C0244 can be set anytime when ignition voltage
is present. A malfunction exists if the PWM signal - Open in CKT 464.
is out of range or no signal is received for a period - CKT 464 shorted to ground or voltage.
of 2 seconds. - Communication frequency problem.
Action Taken When the DTC Sets - Communication duty cycle problem.
- CKT 464 has a wiring problem,
• A malfunction DTC is stored.
terminal corrosion, or poor connections.
• The TCS is disabled. - EBCM not receiving information from
• The TRAC OFF indicator is turned on. The the PCM.
ABS remains functional.
Te$t Description
Conditions for Clearing the DTC The numbers below refer to step numbers on the
• Condition for DTC is no longer present and scan diagnostic table.
tool clear OTC function is used. 4. This step checks for proper torque value in N-m.
• 100 ignition cycles have passed with no DTC(s) 6. This step checks for the presence of a pull-up
detected. voltage from the EBCM.
DTC C0244 PWM Delivered Torque.Malfunction
(
Diagnostic
1 -
System
Check that grounds, G101 and G106 are clean, tight and
free of damage. Refer to Power and Grounding
2 Components in Wiring Systems. -
Were any loose, damaged, or corroded grounds found? Go to Step 3 Go to Step 4
Repair ground as necessary. Refer to Wiring Repairs in Goto A
3 - System
-
Check-ABS
2. Install the scan tool.
3. Turn the ignition switch to the ON position, engine off.
4 4. Using the scan tool, observe the PCM to EBCM O N-m
delivered torque.
Is the delivered torque within the range specified in the
5 - System
-
Check-ABS
3. Disconnect the EBCM connector. (
4. Install J 39700 Universal Pinout Box using the
6 connector and the EBCM connector. Battery Volts
5. Turn the ignition switch to the ON position, engine off.
2. Disconnect the J 39700-25 cable adapter from the
EBCM leaving the cable adapter connected to the
EBCM harness only.
7 3. Turn the ignition switch to the ON position, engine off. Greater than 1V
column? .· Go to Steps Go to. Step 11
8 - System
-
Check-ABS
9 between J 39700 terminals 9 and 15. OL (infinite)
DTC C0244 PWM Delivered Torque Malfunction (cont'd)
10 - System
-
Check-ABS
between terminal 9 of J 39700 and the
11 0-2Q
PCM connector C2 terminal 9.
Is the resistance within the range specified in the vallle(s)
column? Go to Step 12 Go. to Step 13
,'
Diagnostic (OBD) System Check. Diagnostic
12 - System
-
Is the Repair complete?
Check-ABS
Repair CKT 464 for an open. Refer to Wiring Repairs in Go to A
13 - System
-
Check-ABS
)
5·202 Antilock Brake System Brakes
DTC C0245 Wheel Speed Sensor Frequency Error
(
LF Wheel Speed
Sensor
RF Wheel Speed
Sensor
LR Wheel Speed
Sensor
(ABS/TCS)
RR Wheel Speed
Sensor.
(ABS/TCS)
!Loe I
~ N
B A
0.8
0.8 YEL 873
0.8
0.8 YEL 833
0.8BLK 884
0.8 RED 885 ·
Bl
0.8 BLK 882
A
0.8WHT 883
LTBLU 830
LT
A ____ _lf
B A C120 BLU 872
A. c
C1
D
01 A1
C405C
81 C405B
B A C130 0.5 0.5 BRN 882
RED 885 0.5 .,
0.5 BLK 884 WHT 883
A. A. A.
A15 A14 A10 A11 C200b
0.5 ---------- C200A
DK
GAN 872 0.5 BLK 884 0.5BLK 882
0.5
LTBLU 830 0.5 RED 885 O.SWHT 883 (
0.5TAN 833
0.5YEL 873
3 (ABS) 5 (ABS)
20 21 4 (ABSfTC) 5 (ABS/TCS) 22 23 3 C1
~-- H i g h ~ - - - H i g h ~ - - H l g h n - - Hlgh~~ECloe~t~oor~oBdrualkee
~ ~ ~ ~I
I (EBCM)
I
I
LF Wheel
Speed -=-
RF Wheel
Speed -=-
LR Wheel
Speed .,,.
RR Wheel
Speed .,,.
I >
I A"-J!A
Sensor Sensor Sensor Sensor ~
I Signal Signal Signal Signal I
L------------------------------------------J
519748
Circuit Description • The EBCM detects a deviation between the left

and right rear wheel speeds of greater than
The speed sensors used on the front of this vehicle
6 percent of the vehicle speed at greater than
are multiple pole and the rear uses a single pole
100 km/h (62 mph) on vehicles equipped
magnetic pickup. This sensor produces an AC signal
with TCS.
that the EBCM uses the frequency from to calculate
the wheel speed. " The EBCM detects a deviation between the left
and right front wheel speeds of greater than
Conditions for Setting the DTC 4 km/h plus 6 percent of the vehicle speed
• The EBCM detects a deviation between the left at greater than 100 km/h (62 mph).
and right rear wheel speeds of greater than This OTC will set when the EBCM cannot specifically
6 km/h (3.75 mph) at a vehicle speed of less than identify which wheel speed sensor is causing the
100 km/h (62 mph) on vehicles equipped malfunction. If the EBCM can identify the specific
with TCS. wheel speed sensor causing the malfunction,
• The EBCM detects a deviation between the left DTC C0245 will become a history DTC, and the DTC
and right front wheel speeds of greater than associated with the sensor (DTC C0036, OTC C0041,
10 km/h (6.25 mph) at a vehicle speed of less than DTC C0046, OTC C0051, or OTC C0056) will be
100 km/h (62 mph). set concurrent with DTC C0245.
Action Taken When the DTC Sets • If the customer's comments reflect that the amber
• A malfunction DTC stores. ABS/TCS indicator is on only during moist
) • The ABS/TCS disables.
environmental conditions (rain, snow, vehicle
wash), inspect all the wheel speed sensor circuitry
• The amber ABS/TCS indicator(s) turn on. for signs of water intrusion. If the DTC is not
• The Red BRAKE Warning indicator turn on. current, clear all DTCs and simulate the effects of
Conditions for Clearing the DTC 1. Spray the suspected area with a five percent
• The condition responsible for setting the DTC no saltwater solution.
longer exists and the scan tool Clear DTCs
function is used.
• 100 ignition cycles pass with no DTCs detected. solution.
Diagnostic Aids 2. Test drive the vehicle over various road
40 km/h (25 mph) for at least 30 seconds.
to carefully and fully inspect wiring and connectors 3. If the DTC returns, replace the suspected
may result in misdiagnosis, causing part harness.
replacement with reappearance of the malfunction. • If an intermittent malfunction exists refer to
• Thoroughly inspect any circuitry that may be Troubleshooting Procedure.s Cell 4 in Electrical
causing the complaint for the following conditions: Diagnosis for further diagnosis. ·
- Improperly formed or damaged terminals 2. If DTC C0245 is a history code, this step checks if
- Poor terminal-to-wiring connections a specific Wheel Speed Circuit Malfunction DTC
is set concurrently with DTC C0245. ·
7. This step checks if the wheel speed sensor
• The following conditions may cause an intermittent·
harness is routed in close proximity to the spark
malfunction:
plug wires.
- A poor connection
9. In this step, if the scan tool can record any
- Rubbed-through wire insulation erroneous wheel speed sensor signals, diagnose
- A broken wire inside the insulation that sensor(s) first.
)
DTC C0245 Wheel Speed Sensor Frequency Error
Step Action Value(s) Yes . No
Was the Diagnostic System· Check performed? Go to A (
Diagnostic
1 - System
. Go to Step 2 Check-.ABS
Is the following DTC(s) set concurrently with a history
I•
OTC C0245?
• OTC C0036 Goto OTC
2 • OTC C0041 - Diagnostic
• OTC C0046 Trouble
o OTC C0051 Code(DTC)
• OTC C0056 · Lisf/Type Go to Step 3
3 -
Is physical damage of the WSS evident? Go to Step 4. Go to Step 5
Replace the WSS.
4 - -
5
Is physical damage of the jumper harness evident?
Replace the jumper harness.
6 - -
Is the replacement complete? ·Goto Step 14
.·
Check for Proper routing of the wheel speed sensor
harness. Check that the wheel speeci sensor harness is
7 routed away from the spark plug wires. -
Is the wheel speed sensor harness properly routed? Go to Step 9 Go to Step 8
Reroute the wheel speed sensor harne~s away from the
8 spark plug wires. - -
Is the reroute complete? Go to Step 14
3. Set the scan tool to Snap Shot Auto Trigger mode
(
and monitor the wheelspeed sensors.
9
4. Carefully drive the vehicle above 12 Km/h (8 mph) for
-
several minutes
Did the scan tool trigger on any of the wheel speed
sensors? Go to Step 10 Go to Step 11
Note which wheel speed sensor triggered the scan tool.
Follow the appropriate Wheel Speed Sensor Malfunction Go to A
10 OTC table for the wheel speed sensor that triggered. Refer - Diagnostic -
to OTC Table. System
11 -
4. Carefully drive the vehicle above 12 Km/h (8 mph) for
several minutes.
Does the OTC reset as a current OTC? Go to Step 13 Go to Step 12
Malfunction is intermittent. Inspect all connectors and Go to A
harnesses for damage that may result in an open or high Diagnostic
System
13 - System
-
Check-ABS
3.Remove the scan tool from the DLC. Go to A
14 -
4.Carefully drive the vehicle above i2 Km/h (8 mph) for Diagnostic
Brakes Antjlock Brake System 5.:.205
DTC C0266 ADS Controller Malfunction
)
'" -R- -- -d - - - - - - - "'Accelerator
I equeste I S
I
TPS Position Delivered And ervo
I Control
Input TPS Position
I 12V Output I Module
,: ~
r -illJ1- PL...,JUL: (ASM)
PWM
1 - ·PWM , ..
0.35 ORN/BLK 463

L 37-]- - - - 35
. .
-I- --.. M .·
0.35
TAN/BLK 464
A C C212
---------
0.35 ORN/BLK 463
0.35.
TAN/BLK 464
------- P100
2 BLK 651
'" -----I-----i-----"'
1
I
15 27
_ n n_
-uu-
9 C1
_ n n_
-uu-
Electronic
1Brake And
IT t'
PWM . rac ,on
I PWM I Control
1
I . R~uested ~v I Module
I TPS Position Dehvere~. I (EBCM/EBTCM)
I Output TPS Position I
L - - - - - - - - - _!,n~t- - - - .I ..
M,
G101
213300
.Circuit Description Diagnostic Aids

This circuit monitors the Delivered Trottle Position • Thoroughly inspect the wiring and the connectors.
Input for proper operation. Failure to carefully and fully inspect the wiring
.Conditions for Setting the DT.C and the connectors can result in misdiagnosis .
Misdiagnosis may cause replacement of parts
OTC C0266 can set anytime the ignition is in the without repairing the malfunction.
RUN position and the EBCM does not recieve
a Delivered Throttle Positionlnput. • If an intermittent malfunction exists, refer to
Inducing Intermittent Fault Conditions in Electrical
Action Taken When the DT.C Sets Diagnosis,
• The TCS is disabled
Test Description
• The traction control indicator is turned on
The num.bers below refer to the step numbers on the
.Conditions for .Clearing the DT.C diagnostic table.
• The condition for the OTC is no longer present
3. This step checks for a good ground.
and the scan tool clear OTC function is used
• 100 ignition cycles have passed with no DTCs 5. Thi.s step checks for proper voltage.
detected
)
s~2os Anti lock Brake System Brakes
DTC C0266 ADS Controller Malfunction
Step Action ' Value(s) Yes No
(
Diagnostic
1 - System
1. Turn the ignition.switch to the OFF position.
2 3. Inspect the ASM harness connector and the -
connector for damage or corrosion.
Is there any evidence of damage or corrosion? Go to Step 7 Go to Step 3
.
the ASM harness connector terminal 28 and a good
3 ground. 0-5Q
.
4 ground. 0-5Q
Is the resistance within specifications? Go to Step5 Go to Step 8
1. Turn the ignition switch to the RUN position with the .
engine off.
5 2. Measure the voltage between the.ASM hamess B+
connector terminals 1 and 28.
6 - System
-
Check-ABS
(
Diagnostic
7 Are the repairs complete? - System
-
Check-ABS
Repair the open or high resistance in. CKT 151. Refer to Go to A
Wiring· Repairs. Diagnostic
8 - System
-
ls.the circuit repair complete?
Check-ABS
Replace the ASM .. Refer to Accelerator and.Servo Control Goto A
9 - System
-
Check-ABS
3. Install t~e J 39700 Univers.al Pinout Box using the
J39700-530 cable adapterto the EBCM harness
10 connector C1 only. OL (infinite)
4. Using J 39200DMM, measure the resistance
Is the resistance withih the range specified in the value(s)
Repairs. Diagnostic
11 - System
-
Check-ABS
Brakes Antilock Brake System s~201
DTC C0266 ADS Controller Malfunction (cont'd)
terminal 9 of J 39700 and terminal 35 of the..ASM harness
12 connector. 0-50
13 - System
-
Check-ABS
1. Turn the ignition swifoh to the RUN position,
engine off.
14 Above 1V
column?· · · Go to Step 15 Go to Step 9
Repair CKT 464 for a short to voltage Wiring Repairs. Go to A
Diagnostic
15 Is the circuit repair complete? - System
-
Check-ABS
·.
)
DTC C0550 ECU Malfunction
IHot At All Times! !Hot In RUN!

(
.. - - - - - - - - - - - - - - - .,, Engine. '" - - - - - - P-;;we-; - ~ Engine
I Power
Wiring Data Link
I
I Distribution L4 ABSBAT-1 L2 ABSBAT-2 I Wiring •• H9 ABS IGN Distribution
I Schematics K4 MaxiFuse® K2 MaxiFuse~ I Harness MlniFuse ® Schematics I Harness Connector
Junction I HS 10 A in Wiring I Junction (DLC)
..I InSystems
Wiring 40 A
______________ so A
----J~~1
~_ ~ Block 2
I
_ ____ s~~s- . 2.
.------j-
0.35 PPL 1132
3 RED 302 5 RED 1802 0.8 PNK 739 .G
I Data Link .,s
I PIi ce
connector . · ·· · Pack
I 1
'" - - - - - - - - - - .,, Engine
I Power Sche.matics in . .
I Data Link ·
. 1 SP 200
I Distribution J11 ABS BAT SOL I Wiring
Schematics
I 1n Wiring
I.. Systems
_ _ _ _ _
J
1
_
MlnlFuse ®
2s A
_ ___ J
I
Harness
1 Junction
Block 1
L-------
I Communications . I
.I
0.35 LT Blir11.22.
. A3 .C200D
30RN 440 C200A
2BLK 651 0.35 LT BLU 1122
15 13 . ____________1j _________________ ~ ________________________ ?~ ] C1
~ Ground Battery - - - - - - Battery - - - - - - - - Ignition - - - - - - - - - - - - - Serial ~Electronic
Positive F'osltive Positive Data Brake
I Class 2 I Module
I '(EBCM)
I I j;
L------------------------------------------J~
G101 (
519691

This DTC identifies a malfunction within the EBCM. • Condition for DTC is no longer present and scan
Conditions for Setting the DTC tool clear DTC function is used.
DTC C0550 is set when an internal EBCM malfunction • 100 ignition cycles pass with no DTCs detected.
exists.
• A malfunction DTC stores.
• The ABS!fCS disables.
• The amber ABS!fCS indicator(s) turn on.
• The Red BRAKE Warning indicator turn on.
DTC C0550 ECU Malfunction
Diagnostic
1 - System
2 Are any other DTC(s) present besides C0550? - Go to OTC Table Go to Step 3
3 - -
Is the replacement complete? System
Check-ABS (
DTC C0896 Device Voltage Range/Performance
) [fiof At All Times i IHot In RUN!
i--------------------.,E . '" - - - - - -P-;;w; - ~Engine
I Power 1 ~Qlne
I Distribution L4 ABS BAT-1 L2 ABS BAT-2 I Wtnng : H9 ABS IGN Distribution Wiring Data Link
I
1
I Schematics MaxiFuse® K2 MaxiFuse® I Harness MiniFuse ® schematics Harness Connector
4 Junction (DLC)
In Wiring K 4o A so A Junction I HS 10 A in Wiring I
...I~~
______________ I
-----'Block1 ~_ _ ____s~~s- ~Block2 2
.------j-
0.35 PPL 1132
3 RED 302 5 RED 1802 0.8 PNK 739 G
I Data Link .,s
I Price
.-------
I Power - ""' - - "' Engine
I
connector
Schematics in
I Data Link
I
I
Pack
SP 200
Distribu1ion J11 ABS BAT SOL: Wiring i Communications I
I
Schematics
I in Wiring J1
MlnlFuse
25 A
®
1
Junction
Harness 11.------- .a
I Systems ____ "'I Block 1
L.------
I
0.35 LT 8Lir1122
A3 C200D
3 ORN 440 C200A
2BLK 651 ·
rl
15
Ground
13 . - - - - - - - - - - - _i j
Battery - - · - - -
- - - - - - - -- - -- - - - - -
Battery - - - - - - - -
~ - - - - - - - - - - - - - - - - - 0.35 LT
Ignition - - - - - - - - - - - -
B~~
-
~ 122
Serial ~Electronic
Positive Positive Positive · Data Brake
I Class 2 I Module
I l(EBCM)
I . I ~
1-------------------------------------------J~
G10i
519691

The EBCM is required to operate within a specified .. The condition for the OTC is no longer present,
range of voltage to function properly. During ABS and the scan tool Clear DTCs function is used.
TCS operation, there are current requirements that • 100 ignition cycles have passed with no DTCs
will cause the voltage to drop. Because of this, voltage detected.
is monitored out of ABS/TCS control to indicate a Diagnostic Aids
good charging system condition, and also during • It is very important that a thorough inspection of
ABS/TCS control when voltage may drop significantly. the wiring and connectors be performed. Failure
The EBCM also monitors for high voltage conditions to carefully and fully inspect wiring and connectors
which could damage the EBCM. may result in misdiagnosis, causing part
• Thoroughly inspect any circuitry that may be
• The EBCM operating voltage falls below 9.4 volts causing the complaint for the following conditions:
out of ABS/TCS control, or 8.8 volts during - Backed out terminals
ABS/TCS control.
- Improper mating
" The EBCM operating voltage rises above - Broken locks
17.4 volts.
- Improperly formed or damaged terminals
.. The low voltage or the high voltage is detected for - Poor terminal-to-wiring connections
more than 500 milliseconds with the vehicle
speed above 6 km/h (3.6 mph).
Action Taken When the DTC Sets malfunction: ·
" A malfunction OTC is stored. - A poor connection
) .. The ABS and the Traction Control indicators are - Rubbed-through wire insulation
turned on. - A broken wire inside the insulation
" The ABS/TCS is disabled. • If an intermittent malfunction exists refer to
Inducing Intermittent Fault Conditions in Electrical
" The Red BRAKE Warning indicator turns on. Diagnosis for further diagnosis.
s~210 Antilock Brake System Bra!<es
Test Description
2. This step checks if the voltage is above the
maximum of the range.
4. This step checks if the voltage is below the
minimum of the range.
6. This step checks for the integrity of the ground
circuit.
DTC C0896 Device Voltage Range/Performance
Was a Diagnostic System Check performed? Go to A
Diagnostic
1 - System
1. Turn all the accessories off.
2 4. Use the scan tool to monitor the battery voltage while 0-17.4 V
running the engine at approximately 2000 RPM.
Is the monitored battery voltage within the
specified range? Go to Step 4 Go to Step 3
Use a J 39200 DMM to measure the voltage between the Go to Symptoms
battery positive terminal and ground. - Engine
3 0-17.4 V
Is the voltage within the specified range? Electrical in
Go to Step 5 Engine Electrical
Continue to monitor the battery voltage with the scan tool
while running the engine at approximately 2000 RPM.
4 0-9.4 V
Is the monitored battery voltage within the
specified range? Go to Step 6 Go to Step 5 (
2. Disconnect the scan tool if still connected. Go to A
5 - Diagnostic
3. Test drive the vehicle above 6 km/h (3.5 mph). System
Did OTC C0896 reset? Go to Step 10 Check-ABS.
1. Turn the. ignition switch to the OFF position.
3. Install the J 39700 Universal Pinout Box with the
J 39700-530 Cable· Adapter to the EBCM harness 0-5Q
6
connector C1 only.
4 . Use a J 39200 DMM to measure the resistance
. between the J 39700 terminal 15 and a good ground.
Is the resistance within the specified range? Go to Step 8 Go to Step i
·'
Repair open or high resistance in CKT 651. Refer to Go to A
7 - System -
Check-ABS
Go to Symptoms
2. Use a J 39200 DMM to measure the voltage between - Engine ·
8 Above 9.4 Volts
the J 39700 terminal 8 and 15. Electrical in
Is the voltage within the specified range? Go to Step 9 Engine Electricalt
2. Reconnect the EBCM connector C1.
3. Disconnect the scan tool if the scan tool is still -
9 Go to A
connected.
Diagnostic
4. Test drive the vehicle above 6 km/h (3.5 mph). System
Did OTC C0896 reset? Go to Step 10 Check-ABS
Replace the EBCM. Refer to Electronic Brake Control Go to A (
10 -
System
-
Check-ABS
OTC C0901 Device #2 Voltage low
I Hot In RUN, BULB TEST And START I

'" - HS
- - - - - - Power
- - - - .,I Engine Wiring
ABS IGN Distribution Harness
MiniFuse® Cell 10 I Junction
10 1
A
I
Block 2
---------J
P100
0.8 PNK 739

B C212
11
'" "i91;io';;" - - - - - - - - - - - - - - '."" ., Accelerator
I Positive I And Servo
I Voltage · I Control
1 .•Module
I 1
.. - - - - - - - - .... - - - - - - - - ,- ..
Ground Ground (ASM)
~ '
28 55 ~
1 BLK/WHT 151
1 BLK/WHT 151
8209------'
)
519750

• Thoroughly inspectthe wiring and the connectors.
This circuit monitors the voltage level available to the
Failure to carefully and fully.inspectthe wiring
ASM. If the voltage drops below 7.5 volts, full
and the connectors can re.suit in misdiagnosis.
performance of the traction control system cannot be Misdiagnosis may cause replacement of parts
guaranteed. without repairing the malfunction.
• Inspect for other low voltage conditions.
• Test the charging system. Refer to Symptoms -
DTC C0.901 can set anytime the ignition is in the Engine Electrical in Engine Electrical.
RUN position and ignition voltage is less than 7.5 volts • The following conditions are other possible causes
of low system voltage:
Action Taken When the DTC Sets - A charging system malfunction
- Excessive parasitic drain
•. The TCS is disabled
- A weak battery
~ The traction control indicator is turned on - A faulty system ground
• If an intermittent malfunction exists, refer to
Conditions for Clearing the DTC Inducing Intermittent Fault Conditions in Electrical
• The condition for the DTC is no longer present Diagnosis;
and the scan tool clear DTC function is used Test Description
The numbers below refer to the step numbers on the
diagnostic table.
detected
4. This step checks for a good ground.·
6. This step checks for proper voltage.
)
DTC C0901 Device #2 Voltage low
Diagnostic
1 - System
Check the Charging System. Refer to Symptoms - Engine Go to Symptoms
Electrical in Engine Electrical. - Engine
2 - Electrical in
Is the charging system OK?
Go to Step 3 Engine Electrical
3 3. Inspect the ASM harness connector and the -
connector for damage or corrosion.
Is there any evidence of damage or corrosion? Go to Step 7 Go to Step4
4 ground. 0-5Q
5 ground. 0-5 Q
·.
1. Turn the ignition switch to the RUN position with the
engine off.
6 2. Measure the voltage between the ASM harness More than 7.5 V Go to Battery
connector terminals 1 and 28. Charging in
Is the voltage within specifications? Go to Step 9 Engine Electrical
Diagnostic
7 Are the repairs complete? -
System
- (
Check-ABS
8 -
System
-
Check-ABS
Replace the EBCM. Referto Electronic Brake Control Goto A,
Module(EBCM) Replacement. Diagnostic
9 - · System -
Is the replacement complete? .
Check-ABS
Symptoms. Symptom list

Important: The following steps must be completed Refer to a symptom diagnostic procedure from the
before using the symptom tables, following Ii.st in order to diagnose the symptom:
1. Perform the A Diagnostic System Check - ABS • Traction Control System Off Indicator Always On
before using the Symptom Tables in order to
• Traction Control System Off Indicator Inoperative
verify that all of the following are true:
• There are no DTCs set. • Acceleration Slip Regulation Indicator Always 011
• The control module(s) can communicate via • Acceleration Slip Regulation Indicator Inoperative
the serial data link. • No Communication with EBCM
2. Review the system operation in order to familiarize
yourself with the system functions. Refer to ABS .. ABS.Indicator Always On
Description. • ABS Indicator Inoperative
Visual/Physical Inspection • Low Traction Indicator Always On
• Inspect for aftermarket devices which could affect • Low Traction Indicator Inoperative
the operation of the antilock brake system. Refer
to Checking Aftermarket Accessories.
• Inspect the easily accessible or visible system
(
• Inspect the master cylinder reservoir for the
proper fluid level.
Traction Control System Off Indicator Always On
T C200D
0.8 I A13 C200A
BU</ 451 I C200D !.-- ...
WHT I C4 C200B
J
I 0.35 LT BLU 1122
E C220 I 0.35 TAN/W. 33
I P100 0.35 BLK 451
Ground Brake
.P110 I Distribution Warning
I 0.35 $215 Schematics Schematic
0.8 1.BRNtWHT 1571 in Wiring In Hydraulic
Systems Brakes
BU</ 451 I 0.35 d.8 BLK 451
WHT I PPWWHT 1572 T
$110
3 BLK 451
I
I
;--1-1----
:
17
.
18 25
f"f - - S,-...'
Ci
Electronic
Data I Brake
"·---f res I
Control Module
E C220
P110
L
I
I
.1
3
BLK 451
. A Lamp 1 (EBCM) 0.8 BLK 451 I
I Logic "'" Control
1,, _ _ _ _ _ _ _ _ _ _ _ _ _ _ ... I ~
I
8110
.,,. G110 ~ i-;,...-_-_-_-_..1__;..J G110
519757

The TCS OFF Indicator is controlled by the EBCM by " It is very important that a thorough inspection of
sending class 2 messages to the Instrument Panel the wiring and connectors be performed. Failure
Cluster (IPC). It is turned on when the EBCM sets a to carefully and fully inspect wiring and connectors
OTC that turns on the TCS OFF indicator. It is may result in misdiagnosis, causing part
also turned on or off when the Control Switch is replacement with reappearance of the malfunction.
pressed. The Electronic Brake Control Module (EBCM) .. Thoroughly inspect any circuitry that may be
supplies 12 volts to the Traction Control Switch, causing the complaint for the following conditions:
1when the TCS switch is depressed the EBCM sees - Backed out terminals
the voltage go low, and that the TCS switch state has - Improper mating
changed. When the EBCM receives that a switch
- Broken locks
state has changed it turns on or off the Traction
Control and sends amessage to the IPC to turn on or - Improperly formed or damaged terminals
off the TCS OFF indicator depending on its - Poor terminal-to-wiring connections
previous state. · - Physical damage to the wiring harness
.. The following conditions may cause an intermittent Test Description
malfunction: The number(s) below refer to the step number(s) on (
- A poor connection the diagnostic table.
- Rubbed-through wire insulation 2. Checks if EBCM is receiving a Traction Control
Switch message from the switch.
3. Checks if the scan tool can turn on and off all the
• If an intermittent malfunction exists refer to indicator lamps in the instrument cluster.
Inducing Intermittent Fault Conditions in Wiring 5. Checks if the EBCM or Traction Control Switch is
Systems for further diagnosis. at fault.
Traction Control System Off Indicator Always On
DEFINITION: TCS Off indicator is on and traction control was not turned off. There are no DTC(s) set.
Diagnostic
1 - System
engine off.
2. Using a scan tool enter TCS Data List.
2 3. While monitoring the TCS On/Off switch status, press -
and release the TCS On/Off switch.
Does the switch status change from pressed to released
as the TCS switch is pressed and released? Go to Step 3 Go to Step 5
1. Using a scan tool in the instrument Pannel Cluster
Special Function.
2. Go to WOW Instrument Panel in Output Control.
3 3. In the WOW mode you can turn on or off the -
instrument panel indicators.
4. All indicators will turn ON when commanded on.
Does. the TCS OFF indicator turn on then off? Go to Step 9 Go to Step 4 (
1. Disconnect the Instrument Cluster and connect a Test
Light across the appropraiate power and ground
terminals.
2. Test Light OFF, repair open in power or ground
circuit to cluster.
4
3. Test Light ON, Check the connector for poor - -
connection to Cluster. Go to Step A
4. If OK, replace the Instrument Cluster IP Cluster Diagnostic
Replacement. System
Is the Instrument Cluster replacement complete? Check-ABS
1. Remove the Traction Control Switch and disconnect
the connector. Refer to
2. Using a scan tool in ABS/TC Data List read the
5 TCS Switch Status.
-
3. With the Traction Control Switch disconnected.
Does the TCS Switch status read released? Go to Step 6 Go to Step 7
Replace the Traction Control Switch. Refer to Traction Go to A
Control Switch Replacement (Chevrolet) Diagnostic .
6 - System -
Check-ABS
7 between the Traction Control Switch harness OL (Infinite) .
connector terminal E and a known good ground.
8 - System -
Check-ABS
Replace the EBCM. Refer to Electronic Brake Control Go to A .·
9 - System
-
Check-ABS
Traction Control System Off Indicator Inoperative
)
IHot In RUN I IHot In RUN, Bulb Test And START I
~ ~w;r;strlbu;on- - - - - - ~IP ~G; GAUGES - - ~IP
I
Schematics in GAUGES Fuse Fuse 9 Not used Fuse
I I I I
Wiring Systems Fuse 9 I Block H3 10 A Block
I 10A I H4 I
"'P:: --~-~ ;~~

Distribution
3
~ - ..
2
~
g~~n;~~r (DL~)- -
0.35 PPL 1132
~-5~~; ;9., Power Distribution
Traction Schematics
1
-+ - - 8206 G 8206 - + Schematics in
Control
Switch
~ -- - -- - - -- --
l
n Wiring
8
ystems
•1
B
-1.~ :
0.8 .PNK 39 .- - - - - -
I Data Link
~
- - - - - - , S 1.
I P ice
~~;i9ctor : :~c~ 00
Wiring Systems
F
I ISchematics
-...f I in Data Link I
"' - - - - - - 111:. - - - - - .1 I Communications I
F 0.35 E A ._ - - - - - - - - - - - .i
0 35
0.35 BRN/WHT 1571 J ·
~K~
BLK/ 451 0.35 GAY 1036
WHT Ground 0.35 0.35 LT BLU 1122 86 A3 Instrument
Distribution pp• "A'HT 1572 Cluster
S215 ..,. Schematics L./VV r - - - - - - - - - - - - - - - - - - - - - - ,
In Wiring I Solid ~ ~ I
Systems C200D I Class 2 Sta~e ~Chevrolet) Brake I
A3 C200A I Data Logic ASR Off I
v C200D I (Pontiac)
1
0.8
BLK/ 451 I
I
A13 C200A
C200D I .. __ TCS Off
I
WHT I C4 C200B ------------------ .I

815
I 0.35 LT BLU 1122
E C220 I 0.35 TAN/W:133
I P100 0.35 BLK 451
Ground Brake
) P110 I
I 0.35 S215 -.-ii
Distribution
Schematics
warning
Schematic
0.8 I BRN/WHT 1571 In Wiring in Hydraulic
0.35 Systems Brakes
BLK/ 451 I 0.8 BLK 451
;--11----J --
WHT I PPL/WHT 1572 T
I. 18 E C220
17 25 C1
I
8110 - - J Serial"'I Electronic P110 3
Data Brake
: •... -T Tcs I
Control Module BLK 451
3 BLK 451 . .t. Lamp
1 (EBCM) 0.8 BLK 451
I Logic = Control I
G110 '----------------'.
~ 8110 -----' G110
519757

The TCS OFF Indicator is controlled by the EBCM by • It is very important that a thorough inspection of
DTC that turns on the TCS OFF indicator. It is may result in misdiagnosis, causing part
also turned on or off when the Traction Control Switch replacement with reappearance of the malfunction.
is pressed. The Electronic Brake Control • Thoroughly inspect any circuitry that may be
Module (EBCM) supplies 12 volts to the Traction causing the complaint for the following conditions:
Control Switch, when the TCS switch is depressed - Backed out terminals
the EBCM sees the voltage go low, and that the - Improper mating
TCS switch state has changed. When the EBCM
- Broken locks
receives that a switch state has changed it turns on or
,). off the Traction Control and sends a message to - Improperly formed or damaged terminals
the IPC to turn on or off the TCS OFF indicator - Poor terminal-to-wiring connections
depending on its previous state. - Physical damage to the wiring harness
malfunction: The number(s) below refer to the step number(s) on (
- A poor connection the diagnostic table.
..., Rubbed-through wire insulation 2. Checks if EBCM is receiving a traction contlol
switch message from the switch.
• If an intermittent malfunction exists refer Inducing indicator lamps in the instrument cluster.
Intermittent Fault Conditions in Wiring System 5. Checks if the EBCM or Traction Control Sw~ch is
for further diagnosis. at fault.
Traction Control System Off lndica.tor Inoperative
DEFINITION: TCS Off indicator is Inoperative when attempting to disable traction control.

Diagnostic
1 - System
Go to Step 2. Check-ABS

engine off.
2. Using a scan tool enter TCS Data List.
and release the TCS On/Off switch.
as the TCS switch is pressed and released? Go to Step 3 Go to Step 5

Special Function.
2. Go to WOW Instrument Panel in Output Control. (
Does the TCS OFF indicator turn on then off? Go to Step 11 Go to Step 4
1. Disconnect Instrument Cluster and connect a test

light across the appropraiate power and ground
terminals.
circuit to Cluster.
4
3. Test Light ON, Check connector for poor connection
- -
to Cluster.
Go to Step A
Replacement. System
Is the instrument cluster replacement complete? Check-ABS
1. Remove the traction control switch and disconnect

the connector. Refer to Traction Control Switch
Replacement (Chevrolet)
2. Using a scan tool in ABS/TC Data List re.ad the
5 TCS Switch Status. -
3. Connect a jumper wire between te~minals E and F of .
the Traction Control Switch harness connector.

Does the TCS Switch status read pressed with the jumper
wire connected? Go toStep6 Go to Step 7
0
Replace the Traction Control Switch. Refer to Traction Go to A

Control Switch Replacement (Chevrolet). Diagnostic
6 - .System
-
Check-ABS
Brakes Antilock Brake System 5..;217
Traction Control System OfUndicator Inoperative (cont'd)
Step
) Action Value(s) Yes No
between the Traction Control Switch harness
7 o-5 n
connector terminal F and a known good ground ..
colu!Tlo? Go to Step 9 Go to Step 8
Repair CKT 451 for a open or high resistance. Refer to Go to A
Wiring Repairs in Wiring Systems. Diagnostic
8 - System
Check-ABS .
1. Disconnect the EBCM Connector C1
2. Install the J 39700 Uiversal Pinout box using the
J 39700-25 cable adapter to con_nector C1 only
9 3. Using DMM, measure the resistance between the o-5n
Traction Control Switch harness connector
terminal E and 17 of J 39700
4. Is the resistace within the range specified in the
10 -
System
-
Is the· repair complete?
Check-ABS
11 -
. System -
Check-ABS
)
)
5·218 Antilock Brake System Brakes
Acceleration Slip Regulation Indicator Always On
(
0.35 BLK 451

Ground
Distribution
8215 -..it Schematics (
0.8 in Wiring
Systems
BLK/ 451 0.8 BLK 451
WHT 'f
E C220
_ _ .J
8110 P110 3
BLK 451
3 BLK 451 0.8 BLK 451
G110 8110 - - - - .J G110
519757

The ASR OFF Indicator is controlled by the EBCM by • It is very important that a thorough inspection of
DTC that turns on the ASR OFF indicator. It is may result in misdiagnosis, causing part
also turned on or off when the Accelerator Slip replacement with reappearance of the malfunction.
Regulation (ASR) Switch is pressed. The Electronic O
Thoroughly inspect any circuitry that may be
Brake Control Module (EBCM) supplies 12 volts to the causing the complaint for the following conditions:
ASR Switch, when the ASR switch is depressed - Backed out terminals
the EBCM sees the voltage go low, and that the - Improper mating
ASR switch state has changed. When the EBCM
- Broken locks
off the ASR and sends a message to the IPC to - Improperly formed or damaged terminals
turn on or off the ASR OFF indicator depending on its - Poor terminal-to-wiring connections (
previous state. - Physical damage to the wiring harness
O The following conditions may cause an intermittent Test Description
malfunction:
) - A poor connection
The number(s) below refer to the step Ti!Umber(s) on
. - Rubbed-through wire insulation 2. Checks if EBCM is receiving a ASR Switch
..: A broken wire inside the insulation message from the switch.
• If an intermittent malfunction exists refer to 3. Checks if the scan tool can turn on and off all the
· Inducing Intermittent Fault Con.ditions in Wiring indicator lamps in the instrument cluster.
System for further diagnosis. 5. Checks if the EBCM or ASR Switch is at fault.
Acceleration Slip Regulation Indicator Always On
DEFINITION: ASR Off indicator is on and traction control was not turned off. There are no DTC(s) set.
Diagnostic
1 - System
engine off.
2: Using a scan tool enter TCS Data List.
.,2 3. While monitoring the ASR On/Off switch status, press -
· and release the ASR On/Off switch.
as the ASR switch is pressed and released? Go to Step 3 Go to Step 5
Special Function.
Does the ASR OFF indicator turn on then off? Go to Step 9 Go to Step 4
.1. Disconnect the instrument cluster and connect a Test
light across the appropraiate power and ground
terminals.
2. Test light OFF, repair open in power or ground circuit
to cluster.
4
3. Test light ON, check connector for poor connection to
- -
the cluster. Go to Step A
4. If OK, replace the instrument cluster IP Cluster Diagnostic
Replacement. System
1. Remove the ASR Switch and disconnect the
connector. Refer to Traction Control Switch
Replacement (Chevrolet).
5 2. Using a scan tool in ABS/TC Data List read the -
TCS Switch Status.
3. With the ASR Switch disconnected.
Does the TCS switch status read released? Go to Step 6 Go to Step 7
Replace the ASR Switch. Refer to Traction Control Switch Go to A
Replacement (Chevrolet). -
Diagnostic -
6
Is .the replacement complete? System
Check-ABS
between the ASR switch harness connector
7 OL (Infinite)
terminal E and a known good ground.
8
-
System
-
Check-ABS
9 - System
-
Check-ABS
Acceleration Slip Regulation Indicator Inoperative
(
~
L:.w
0.8
BU<! 451
WHT
0.35 BLK 451

Ground
Distribution (
$215 --<;I Schematics
0.8 in Wiring
Systems
BLK/ 451 0.8 BLK 451
WHT 'f
--rr-"--~'-'J"--"---=~
E C220
17 18 25 C1
8110 - -.I
~ =Onie
I Control Module
P110 3
BLK 451
3 BLK 451
: .. ··---f Tes
. .._ Lamp 1 (EBCM) 0.8 BLK 451
I Log,c -=- Control I
GiiO
L--------------.1 ~
" S110 ----.I G110
519757

The ASR OFF Indicator is controlled by the EBCM by • It is very important that a thorough inspection of
OTC that turns on the ASR OFF indicator. It is may result in misdiagnosis, causing part
also turned on or off when the Accelerator Slip replacement with reappearance of the malfunction.
Regulation (ASR) Switch is pressed. The Electronic • Thoroughly inspect any circuitry that may be
Brake Control Module (EBCM) supplies 12 volts to the causing the complaintfor the following conditions:
ASR Switch, when the ASR switch is depressed - Backed out terminals
t.he EBCM sees the voltage go low, and that the - Improper mating
ASR switch state has changed. When the EBCM
- Broken locks
off the ASR and sends a message to the IPC to - Improperly formed or damaged terminals
turn on or off the ASR OFF indicator depending on its - Poor terminal-to-wiring connections
(
previous state. - Physical damage to the wiring harness
Brakes Antilock Brake.System 5-221
malfunction: The nuniber(s) below refer to the step number(s) on
) - A poor connection the diagnostic table.
- Rubbed-through wire insulation 2. Checks if EBCM is receiving a ASR SVl'itch
- A broken wire inside the insulation message from the switch.
• If an intermittent malfunction exists refer to 3. Check if the scan too.I can turn on and off the
Inducing Intermittent Fault Conditions in Wiring indicator lamps in the instrument.cluster.
Systems for further diagnosis. 5. Checks if the EBCM or ASR Switch is at fault.
Acceleration Slip Regulation Indicator Inoperative
DEFINITION: ASR Off indicator is inoperative when attempting to disable traction control. There are no DTC(s) set.
Diagnostic
1 - System
Go toStep2 Check-ABS
engine off.
2. Using a SQan tool enter TCS Data List.
and release the ASR On/Off switch.
'•
Does the switch st.atus change from pressed to released

as the ASR switch is pressed and released? Go to Step 3 Go to Step 5
1. Using a scan to()I in the Instrument Pannel Cluster
Special Function.
) instrument panel indicators.
Does the ASR OFF indicator turn on then off? Go to Step 11 Go to Step 4
1. Disconnect instrument cluster and connect a test light
across the appropraiate power and ground terminals.
2. Test light OFF, repair open in power or ground circuit
to cluster.
4 3. Test light ON, check connector for poor connection to - -
Cluster.
Go to Step A
Replacement. System
1. Remove the ASR switch and disconnect the
connector. Refer to Traction Control Switch
Replacement (Chevrolet)
2. Using a scan tool in ABS/TC Data List read the
5 TCS switch status. -
3. Connect a jumper wire between terminals E and F of
the ASR Switch harness connector.
Does the TCS switch status read pressed with the jumper
wire connected? Go to Step 6 Go to Step 7
Replace the ASR switch. Refer to Traction Control Switch Go to A
Replacement (Chevrolet) Diagnostic
6 -
System
-
Check-ABS
Acceleration Slip Regulation Indicator Inoperative (cont'd)
Step Action
.·.
Value(s) Yes No (
2. Using J39200 DMM, measure the resistance
between the ASR switch harness connector 0-5 .Q
7
terminal F and a known good ground.
Is the resistance within the range specified in the. value(s)
column? Go to Step 9 Go.to Step 8
Repair CKT 451 for a open or high resistance. Refer to . Go to A
. Wiring Repairs in Wiring Systems. Diagnostic
8 - System
-
. Check-ABS
1. Disconnect the EBCM Connector C1
2. Install the J 39700 Universal Pinout box using the
J 39700-25 cable adapter to connector C1 only.
9.. 3. Using DMM, measure the resistance between the 0-5 .Q
ASR switch harness connector terminal E and 17
of J39700
4. Is the resistace within the range specified in the
Repair CKT 1571 for an open or high resistance. Refer to Goto A
10 - .· System ·· -
Check-ABS
Replace the EBCM. Refer to Electronic Brake Control Goto A
11 System
-
Check-ABS
. (
(
No Communication with EBCM
)
! Hot At All Times! !Hot In RUN!
..I Power
- - - - - - - - - - - - - - - - - - - .,I E"!QIne .. -
I
- - - - -P-owe-r - ... En.Qine
. 1r·1bui·
I DIS · . ion
L4
ABSBAT-1
L2
ABSBAT-2 I
Wiring I
H9 ABS IGN
<El)
Distribution
I
Wmng Data Link
scrematlcs MaxiFuse® K2 MaxlFuse® Harness MlnlFuse Schematics Harness Connector
I In Wiring K4 40A 50A 1 Junction I HS 10A In Wiring I Junction (DLC)
I Systems I I Systems I· Bl k ·
i.-------------- ____ .,Block1 a..;. _ _ _ _ _ _ _ _ ., oc :35PP~I1132
3 RED 302
r------
1Power
5 RED 1802
- - - - "' Engine
0.8 PNK 739
r-----j-
I Datalink
I
connector
~~~.
G
·. I p Iice
"'S
Pack
:.SP
,
I
Distribution
Schematics
I In Wiring
ABS BAT SOL I Wiring
MlnlFuse ®
25 A
: Harness
I
_______
e~~tcs in.. .
I..; Communications
.
· ...
I
200
Junction
I Systems ____ ...I Block 1
1.------ . 0.35 LT BL~I 1122
A3 C200D
3 ORN 440 . IC200A
2 BLK 651 0.35 LT BLU 1122
15 13 _____________1~ _________________ ~ ________________________ ?~ C1 .
'Gr.;nd ea~ry - - - - - - eati;ry- - - - - - - - - IQlritio;;- - - - - - - - .,.. - - - - - -s:;~1 "'Electronlc
I Positive Positive Positive · · Data I Brake
I Class 2 I Module
I '(EBCM)
I . I ~
L·- - - - - - - ._. - - - - - - - - - - - - - - - - - - - - .,.. - - - - - - - - .,.. - - - - J~
G101
519691

The Class 2 serial data line allows a.II the modules on • Thoroughly inspect the wiring and the connectors.
the line to transmit information to each other as Failure to carefully and fully inspect the wiring
needed. Each module is assigned an ID and all the and the connectors can result in misdiagnosis.
information sent out on the line is assigned a Misdiagnosis may cause replacement of parts
priority by which it is received. When the ignition without repairing the malfunction.
switch is turned to the run position each module begins
to send and receive informatioh. Each module on • If an intermittent malfunction exists, refer to
the Class 2 serial data line knows what information .it Inducing Intermittent Fault Conditions in wiring
needs to send out and what information it should system.
be receiving. What the modules do not know is which
module is supposed to send them the information.
This iniormation is only learned after the module has
received the information it needs along with the ID
of the module that sent the information. This
information is then remembered until the ignition .
switch is truned off.
No Communication with EBCM
Value(s) Yes No
Step Action (
DEFINITION: Scan tool can not communicate with the EBCM.
Was the Diagnostic System Check performed?. GotoA
Diagnostic
1 - System
Turn the Ignition switch to the RUN position with the Go to Scan Tool
engine off. Does Not
2 Can the scan tool communicate with other modules on the - Communicate
Class 2 serial data line, such as the PCM? w/Class 2
Go to Step 3 Data Line
Inspect the 1OA ABS IGN fuse in the Underhood Electrical
3 Center 2. -
Is the fuse OK? . Go to Step 4 Go to Step 6
1. Install the fuses if removed.
engine off.
4 3. Using J 39200 DMM, measure the voltage at the Battery Volts
10A ABS IGN fuse by probing between the fuse test Go to Testing for
terminals and a good ground. Short to Ground
Is the voltage within the range specified within the value(s) in Wiring
column?· Go to Step 5 Systems
5
J 39700-25 to the EBCM harness connector C1 only. 0-5Q
between J 39700 terminal 15 and a good ground.
1. Install a new 10A ABS IGN fuse.
2. Cycle the ignition switch from the OFF to RUN Go to A
(
6 position, engine off. - Diagnostic
3. Recheck the fuse. System
Is the fuse OK? Check-ABS Go to Step 7
2. Remove the 1OA ABS IGN fuse.
7 J 39700-25 to the EBCM harness connector C1 only. OL (infinite)
Repair CKT 739 for a short to ground. Refer to Wiring Goto A
Repairs. Diagnostic
8
- System -
Check-ABS
Repair CKT 651 or G101 for an open or high resistance. Go to A
Refer to Wiring Repairs. Qiagnostic
9 - System
-
Check-ABS
engine off. I
2. Using J 39200 DMM, measure the voltage between Battery Volts

10
J 39700 terminals 8 and 15.
Repair CKT 739 for an open. Refer to Wiring Repairs. Goto A
Is the repair complete? Diagnostic
11 - System
-
Check-ABS
12 - System
-
Check-ABS
Brakes Antjlock Brake System 5-225
ABS Indicator Always On
Data Link I Hot In RUN, Bulb Test And START I

Connector r - - - - - - - - ,... - - - , IP
(DLC) I G3 GAUGES Not used I
pp!21
Fuses Fuse
1 1
H3 10A Biock
0.35 1132 ~ _ _ _ _ _ _ _ _ _ _ _ H~ ~
~ l •.
5 39
Connector
Data - - -'Ii
Link (DLG)
I Schematics In
I. Data Link
. - J. ..· . .· . .- --. -.· --~
..
. .
.
.
Pack
Splice
1SP 200
o. PNK
S206 - - -+
Power Distribution
Schematics In
Wiring Systems
~ Communications _ _ _ ___ ·._ . . _ _ _ _ _ ~
J L
0.35 PNK 39
0.35 LT BLU 1122 0.35 GRY 1036
ft au~•
~ ~
Instrument
A3 C200D
C200A
86
r
I
---------------------------,
(!) (!) (!) (!) LOW ABS (Chevrolet) Brake
I
I Solid ~TRAC ~INOP ~ ASA Off ~
Class 2 State i - - - - ' · (Pontiac)
I ~ ~ ~Off
I
0.35 LT BLU 1122 I
~--- ------------------ -----J
~5 M
0.35 BU< 451
) P100 8215 ------,

0.8BLK 451 ! 0.35 TANJWHT 33
Ground.
E C220 Distribution
Schematics
In Wiring
25 Ci P110 Systems
r - - Serj;j - - , Electronic
I Data I Brake 0.8 BLK 451 'f
_ _ _ _ _ _ .J Brake
I I Control Module 8110 Warning
I l(EBCM) Schematics
in Hydraulic
I I /. 3BLK 451 Brakes
I I ~
~------..1~ .... G110
519763

The ln$trument Panel Cluster (IPC) turns the - Improperly formed or damaged terminals
ABS Indicator on during the IPC bulb check for - Poor terminal-to-wiring connections
approximately 3 seconds when the ignition switch is
turned to the ON position. If the EBCM sets a
Diagnostic Trouble Code (OTC) the EBCM sends a • The following conditions may cause an intermittent
class 2 message to the IPC to command the ABS malfunction:
Indicator on. - A poor connection
Diagnostic Aids - Rubbed-through wire insulation
" It is very important that a thorough inspection of - A broken wire inside the insulation
the wiring and connectors be performed. Failure .. If an intermittent malfunction exists refer to
to carefully and fully inspect wiring and connectors Inducing Intermittent Fault Conditions in Wiring
may result in misdiagnosis, causing part Systems.
) replacement with reappearance of the. malfunction .
.. Thoroughly inspect any circuitry that may be
causing the complaint for the following conditions:
- Improper mating
Test Description
The number(s) below refer to the step number(s) on (
indicator lamps in the instrument cluster.
4. Checks if the circuits going to the instrument
cluster or the cluster is at fault.
ABS Indicator Always On
DEFINITION: ABS indicator does not turn off after the Instrument Panel Cluster (IPC) bulb check and no
ABS/TCS DTC(s) set.
Diagnostic
1 - System
·.
1. Using a scan tool in the Instrument Panel Cluster
Special Functions.
All indicators will turn ON when commanded on.
Does the ABS indicator turn on then off? Go to Step 3 Go to Step 4
Replace the EBCM. Refer to Electronic Brake Control Goto A
3 - System
-
Check-ABS
(
terminals.
circuit to cluster
4
3. Test Light ON, check connector for poor connection - -
to cluster.
Goto A
Replacement System
Is the Instrument Cluster replacement complete? Check-ABS
(
Brakes Antitock Brake System 5-227
ABS Indicator Inoperative
Data Link fHot In RUN, Bulb Test And START I

Connector .. - - - - - - - - - - - - , 1p
(DlC) I G3 GAUGES Not used I
ppci21 1132
Fuse9 · Fuse
I H3 10A I Block
0.35 ~ __________ - H-:_ ~
~.D";;1a-;:1n';
I
- - -~
Conneator (DLC) -r.--..-. --.-.--.. -. ---.-.
- '. ~Splice
Pack
1 SP 200
0.5 PNK 39 Power Distribution
l
i Schematics in . . .. .. . . . I
S206 - - -ii- Schematics In
Wiring Systems
Daia Link . . ·
~Communications _ _ · ··- _ _ . . · ... _ _ · .. _ _ . ~
J L
0.35 PNK 39
0.35 LT BLU 1122 0.35 GRY 1036
It~ Instrument
A3 C2000
C200A
86
I"
I
---------------------------,
© (i) ©
A3
LOW ABS
~ Cluster
(Chevrolet)(!) Brake
I
I I
Solid ~ TRAC ~!NOP ~ ASR Off ~
I State .___..., (Pon1iac) I
I Class 2 I
Data Logic TCS Off
I I
0.35 LT BLU 1122 I I
&.---------~------------------J
815 A5
0.35 BLK 451

PiOO ·. $215 ------,
) 0.8 BLK 451 i 0.35 TAN/WHT 33
Ground
E C220 Distribution
Schematics
in Wiring
25 C1 P110 SySlems
r - - Seri7ii - - ., Electronic
I Data I Brake 0.8 BLK 451 f Brake
i I Control Module $110 -'-----.J Warning
I Schematics
. l(EBCM) in Hydrau6c
! .•. '.& 3BLK 451 Brakes
&.------J.
I ... I~
.... G110
519763

The Instrument Panel Cluster (!PC) turns the - Improperly formed or damaged terminals
ABS Indicator on during the IPC bulb check for - Poor terminal-to-wiring connections
approximately 3 seconds when the ignition switch is
Diagnostic Trouble Code (DTC) the EBCM sends a " The following conditions may cause an intermittent
class 2 message to the IPC to command the ABS malfunction:
Indicator on. - A poor connection
Diagnostic Aids - Rubbed-through wire insulation
0 It is very important that a thorough inspection of - A broken wire inside the insulation
the wiring and connectors be performed. Failure " If an intermittent malfunction exists refer to
to carefully and fully inspect wiring and connectors Inducing Intermittent Fault Conditions in Wiring
may result in misdiagnosis, causing part Systems.
O Thoroughly inspect any circuitry that may be
- Improper mating
Test Description
the· diagnostic table. (
2.: Checks if the scan tool can turn on and off all the
Cluster or the cluster is at fault.
ABS Indicator Inoperative
DEFINITION: ABS indicator does not turn ON during the Instrument Panel Cluster (IPC) bulb check and no
ABS/TCS DTC(s) set.
Diagnostic
1 - System
1. Using a scan tool in the lnstrumentPanel Cluster
Special Functions.
2 : 3. In the WOW mode you can turn on or off the -
Does the ABS Indicator turn on then off? Go to Step 3 Go to Step 4
3 - System
-
Check-ABS
(
terminals.
4 circuit to cluster. - -
3. Test Light ON, check connector for poor connection Go to A
to the cluster. Diagnostic
4. If OK, replace the Instrument Cluster IP Cluster System
Replacement. Check-ABS
Low Traction Indicator Always On
) Data Link !Hot In RUN, Bulb Test And START I
Connector '" - - - - - - - - - - - - , 1p
Fuse9 tuse
I-1. -..-.- -. ----.. -.---. -.~

I
2 I H3 iOA H4 I Block
0.35 pp~ 1132 L, _ _ _ _ _ _ _ _ _ _ _ _ _.
~ o:.1a:1n·';· -
I
Connee1or (OLC) oil
Schematics in
I Daia Link
~Communications _ _
- - -
------------
·
l · ·
.
·~
1
I
Splice
Pack
SP 200
0.5 PNK 39
8206 - - __,.
Power Distribution
Schematics in
Wiring Systems
J L
0.35 PNK .39
0.35 LT 8LU 1122 0.35 GRY 1036
AS C200D 86
,.
C200A I
I (!) LOW (!) ABS (1) (Chevrolet) ~ Brake
I Solid ~TRAC ~INOP ~ ASA Off \"1;/~
I
. Class 2 State 1---...., · (Pontiac)
Data Logic TCS Off
I
I
0.35 LT 8LU 1122
~--- ------------------------J
815 A5
0.35 BLK 451
P100 8215 -::--::-::--,
) 0.8 BLK 451 .l 0.35 TANJWHT 33
Ground
E C220 Distribution
Schematics
in Wiring
25 C1 P110 Systems
,. - - Seri;i - - "' Electronic
I Data I Brake 0.8 BLK 451 'f' Brake
I I Control Module 8110 -----,.-J Warning
I l(E8CM) Schematics
<' >
in Hydraulic
I . 3 8LK 451 Brakes
~ - - - - - :.. ~ irr., G110
519763

The Instrument Panel Cluster (IPC) turns the - Improperly formed or damaged terminals
LOW lRAC Indicator on during the IPC bulb check for - Poor terminal-to-wiring connections
approximately 3 seconds when the ignition switch is - Physical damage to the wiring harness
Diagnostic Trouble Code (OTC) the EBCM sends the • The following conditions may cause an intermittent
IPC the command to turn the LOW TRAC Indicator on. malfunction:
- A poor connection
Diagnostic Aids
.. It is very important that a thorough inspection of
to carefully and fully inspect wiring and connectors • If an intermittent malfunction exists refer to
may result in misdiagnosis, causing part Inducing Intermittent Fault Conditions in Electrical
replacement with reappearance of the malfunction. Diagnosis for further diagnosis.
" Thoroughly inspect any circuitry that may be
- Improper mating
Test Description
The number(s) below refer to the step number(s) on (
cluster or the cluster is at fault.
low Traction Indicator Always On
DEFINITION: LOW TRAC Indicator On without a low traction condition.
Diagnostic
1 - System
Special Functions.
Does the LOW TRAC Indicator turn on then off? Go to Step 3 Go to Step 4
3 - System
-
•.
Check-ABS
1. Disconnect the instrument cluster and connect a Test (
terminals.
circuit to cluster
4
3. Test Light ON, check connector for poor connection
- -
to cluster.
Go to A
Replacement System
(
Low Traction Indicator Inoperative
Data Link fHot In RUN, Bulb Test And STA@ fL:'l

Connector .. - - - - - - - - - - - - , 1p L.::'£.1
Fuses Fuse
I I
I
2 H3 10 A Block
~ - __ - _ _ _ _ _ _ _ H'!._ ~
-1--------. .---
0.35 pp~ 1132
~ oa1a Link ~ Splice

lI
- - - 0.5 PNK 39
Connector (DLC) .. - Pack Power Distribution
1~~~~~!cs In · . . :~~;:~:~s
I 1
SP 200 8206 - - -ii>
~Communications __ ------------~
J L
0.35 PNK 39
0.35 LT BLU 1122 0.35 GRY 1036
A3 C200D
C200A
~6 - - - - - - - - ~3- - - - - - - - - - - - ~ ~s~~;J~l I
{!) LOW {!) ABS a;"\ (Chevrolet) a;"\ Brake I
Solid ~TRAC ~!NOP "1:.'~ ASR Off l.:t;/~
State ,___ __, (Pontiac) I
Class2
Data Logic TCS Off I
0.35 LT BLU 1122

________________________ I
..I
L.-- -
615 A5
0.35 BLK 451
P100 8215 - - - - - - ,
) 0.8BLK 451 ..l 0.35 TAN/WHT 33
Ground
E C220 Distribution
Schematics
in Wiring
25 C1 P110 Systems
'" - - Serlai - - ., Electronic
I Data I Brake 0.8 BLK 451 'f Brake
I I Control Module 8110 ------.J Warning
I
I
l(EBCM)
I A 3BLK 45i In
Schematics
Hydraulic
Brakes
I IP~
I. - - - - - - .. .M .,,. G110
519763

The Instrument Panel Cluster (IPC) turns the - Improperly formed or damaged terminals
LOW TRAC Indicator on during the IPC bulb check for - Poor terminal-to-wiring connections
approximately 3 seconds when the ignition switch is - Physical damage to the wiring harness
Diagnostic Trouble Code (DTC) the EBCM sends the
O
The following conditions may cause an intermittent
IPC the command to turn the LOW TRAC Indicator on. malfunction:
- A poor connection
Diagnostic Aids
to carefully and fully inspect wiring and connectors • If an intermittent malfunction exists refer to
may result in misdiagnosis, causing part Inducing Intermittent Fault Conditions in Wiring
replacement with reappearance of the malfunction. System for further diagnosis.
• Thoroughly inspect any circuitry that may be
- Improper mating
Test Description
The number(s) below refer to the step nurnber(s) on
Cluster or the cluster is at fault.
low Traction Indicator Inoperative
_Step Action Value(s) Yes No a
DEFINITION: LOW TRAC Indicator never comes on.

Diagnostic
1 - System
Special Functions.
Does the LOW TRAC Indicator turn on then off? Go to Step 3 Go to Step 4
Replace the EBCM: Refer to Electronic Brake Control Go to A
3 - System
-
Check-ABS
Light across the Appropraiate power and ground
terminals.
(
4 circuit to cluster. - -
3. Test Light ON, check connector for poor connection Go to A
to the cluster. Diagnostic
4. If OK, replace the Instrument Cluster IP Cluster System
Replacement. Check-ABS
(
Repair Instructions
Electronic Brake Control Module (EBCM)
Replacement
Removal Procedure
Notice: To prevent equipment damage, never connect
or disconnect the wiring harness connection from
the EBCM with the ignition switch in the ON position. 4
2. Pull out lock tab from the EBCM harness
connector.
3. Disconnect the EBCM harness connector (6).
213428
4. Disconnect the pump motor connector (3) at the

bottom of the EBCM. 2
5. Remove the six EBCM to BPMV screws (2) and
discard.
Important: Be careful not to damage seal. Do not pry
apart using a tool.
Important: Care must be taken not to damage the
solenoid valves when the EBCM is removed from
the BPMV.
6. Separate the EBCM (1) from the BPMV (5) by
gently pulling apart until separated.
213438
s~234 Antilock Brake System Brakes
Important: Note the location and the orientation of the
wave spring in order to aid during installation.
7. If equipped with ABS. only, remove one wave (
1 spring (1) between the EBCM and BPMV and
discard.
255233
Important: Note the location and the orientation of the

wave spring in order to aid during instailation. ·
8. If equipped with ABS!TCS remove two wave ,
1 springs (1) between the EBCM and BPMV
and discard.
255236
lnstaUation Procedure
Important: Only the new wave spring(s) and screws
supplied with the new EBCM should be used.
1 1. Clean the BPMV gasket surface with alcohol
using a clean rag.
2. If equipped with ABS only, install one wave
spring (1) between the EBCM and BPMV.
Use location and orientation noted during removal.
· 255233
3. If equipped with ABSffCS, install two wave
springs (1) between the EBCM and BPMV. Use
) locations and orientation noted during removal.
255236

Notices.
4. Install the EBCM (1) to the BPMV (5).

Tighten
Tighten the top four mounting screws (2) to
2.9 N,m (26 lb in.). Tighten screws in an X pattern.
Tighten
\
I
) Tighten the bottom two mounting screws (2) to
2.9 N·m (26 lb. in.).
5. Connect the pump motor connector (3) to the
bottom of the EBCM.
213438
6. Connect the EBCM harness connector. Push in

lock tab.
engine off.
8. Perform the A Diagnostic System Check- ABS
213428
Accelerator and Servo Control
1 Module (ASM) Replacement
(
Removal Procedure
1. Disconnect the fasteners on the lower sound
insulator panel under the steering column.
2. Remove the lower sound insulator panel from the
vehicle.
3. Remove the left side kick panel on vehicles
4. Remove the bolt attaching the ASM bracket 10 the
upper 1/P.
5. Remove the push in retainer attaching the
ASM bracket to the side wall.
6. Remove the ASM bracket along with the
ASM from the mounting place (1,2).
7. Disconnect the ASM harness connector).
8. Remove the ASM to ASM bracket mounting
screws (3).
9. Remove the ASM and ASM bracket from the
vehicle (1,2).
213425
1 1. Install the ASM to the ASM mounting
bracket (1,2).
2. Install the ASM to ASM bracket screws (3).
3. Connect the ASM harness connector.
4. Install the ASM and ASM bracket in the
mounting place.
5. Install the push in retainer attaching the
ASM bracket to the side wall.
6. Install the bolt attaching the ASM bracket to the
upper 1/P.
7. Install the left side kick panel on vehicles equipped
with a manual transmission.
8. Install the lower sound insulator panel in the
vehicle.
9. Install the fasteners on the lower sound insulator
panel under the steering column.
213425
Brake Pressure Modulator Valve (BPMV)
Replacement
)
Removal Procedure
Caution: For safety reasons, the Brake Pressure
Modulator Valve (BPMV) must not be repaired, the
complete unit must be replaced. With the 4
exception of the EBCMIEBTCM, no screws may be
loosened. If screws are loosened, it will not be
possible to get the brake circuits leak-tight
and personal injury may result.
2. Disconnect the EBCM harness connector (6).
Important: Note the locations of the brake pipes in
order to aid in installation.
3. Disconnect the brake pipes from the BPMV. 3
213428
4. Remove the two nuts that connect the BPMV to

the BPMV bracket (3).
Notice: When removing the brake pressure modulator
valve, protect the vehicle exterior from possible
brake fluid spillage. Brake fluid can cause damage to
painted surfaces.
5. Remove the BPMV and EBCM as an assembly
from the vehicle (5).
255229
)
Important: If a new BPMV is being installed, remove (
the shipping plugs from the valve openings in the
compartment during the next step.
Important: Use the locations noted during remo\lal.
1. Install BPMV and EBCM as an assembly into the
BPMV bracket.(2).
2. Install the two BPMV bracket nuts (3).
Tighten
Tighten the two BPMV to BPMV bracket nuts to
12 N-m (8 lb ft.)
255229 (
Caution: Make sure brake pipes are correctly
connected to brake pressure modulator valve. If
brake pipes are switched by mistake, wheel lockup
will occur and personal injury may result. The
only two ways this condition can be detected are
by using a Scan Tool or by doing an Antilock stop.
4 3. Install the brake pipes on to the BPMV.
Tighten
Tighten the brake pipe fittings to 15 N-m (11 lb ft).
4. Connect the EBCM harness connector (6).
engine off.
6. Perform the A Diagnostic System Check - ABS
213428
Adjuster Assembly Replacement
Removal Procedure 4 1
Important: The adjuster assembly cables must always
be adjusted each time the adjuster assembly is
removed and/or replaced to ensure optimum system
performance. Refer to Cable Adjustment Procedure.
1. Remove the adjuster assembly splash cover.
2. Remove the cable cam cover.
3. Disconnect the adjuster assembly electrical
connector.
4. Remove the nuts attaching the adjuster assembly
to the bracket.
213434
5. Remove the cables from the adjuster assembly.
\
/
213407
1. Install the cables to the adjuster assembly.
(
6
213407 (
2. Install the adjuster assembly to the mounting
; bracket (3).
4
3. Install the adjuster assembly attaching nuts.
Tighten
Tighten the adjuster assembly attaching nuts to
25 N-m (18 lb ft).
4. Connect the adjuster assembly electrical
connector.
5. Adjust the adjuster assembly cables. Refer to
Cable Adjustment Procedure
6. Install the cable cam cover.
7. Install the adjuster assembly splash cover.
213434
Cable Adjustment Procedure
The throttle body, accelerator pedal, and cruise control
cables must be fully installed before making
adjustments. 1
1. Remove the throttle body lever cover.
2. Unlock the throttle body cable and· cruise control
cable adjuster (1).
3. Hold throttle body lever firmly at stop/idle position.
4. Pull the throttle body cable assembly just
rearward of the adjuster lock to remove slack
from cable.
important: Do not disturb cable after removing slack.
5. Lock the throttle body cable adjuster (1 ). 2
6. Hold throttle body lever firmly at stop/idle position.
7. Pull the cruise control cable assembly just
rearward of the adjuster lock to remove slack
from cable.
213432
Important: Do not disturb cable after removing slack.
8. Lock the throttle body cable adjuster (1 ).
Important: Cables should never be adjusted so tight
that tension from the cable will not allow the throttle
to close completely. If the cable is adjusted to tight, the
cable will prevent the engine from returning to idle
and will cause unstable idle quality.
Using a scan tool check the throttle angle. When the
accelerator is fully depressed the throttle angle
) should read 100 percent. When the accelerator is
released the throttle angle should read O percent. If
proper results are not obtained check cables for kihks
or damage and repeat procedure.
Wheel Speed Sensor Replacement (Front)

1. Refer to Wheel Bearing/Hub Replacement -
Front in Front Suspension.
2. Atter the replacement procedure is complete refer
to A Diagnostic System Check - ABS.
)
5-242 Antilock Brake. System Brakes
Wheel Speed Sensor Replacement
(With out Tractional Control)
(
Removal Procedure
1. Remove the wheel speed sensor connector.
2. Clean all dirt and debris from sensor
housing/sensor interface area.
3. Remove the Wheel Speed Sensor bolt (3).
4. Remove the Wheel Speed Sensor (4).
213402
1. Install the Wheel Speed Sensor (4).
2. Install the Wheel Speed Sensor mounting bolt (3):
Tighten
Tighten the bolt to 10 N-m (89 lb.in)
3. Install the wheel speed sensor connector.
213402
Wheel Speed Sensor Replacement

Removal Procedure
1. Remove the wheel speed sensor connector (2).
2. Clean all dirt and debris from sensor
housing/sensor interface area.
3. Remove the Wheel Speed Sensor attaching bolt.
4. Remove the Wheel Speed Sensor (1 ).
213413
1. Install the Wheel Speed Sensor (1 ).
) 2. Install the Wheel Speed Sensor attaching bolt.
Tighten
Tighten the bolt to 1o N·m (89 lb.in)
3. Install the wheel speed sensor connector (2).
213413
Wheel Speed Sensor Jumper Harness

Replacement (Front Right)
Removal Procedure
2. Remove the jumper harness from the
retaining clip.
3. Remove the grommet retainer at the inner fender.
4. Remove the harness cover from the right
slrut tower.
5. Remove the upper jumper harness connector.
6. Pull the grommet through inner fender pass-thru
and remove jumper harness.
213395
1. Route the new jumper harness through inner
fender pass-thru.
2. Install the upper jumper harness connector.
3. Install the harness cover on the right strut tower.
4. Install the grommet retainer at the inner fender.
5. Install the jumper harness from the retaining clip.
213395
Replacement (Front left)
Removal Procedure
(
2. Remove the jumper harness from the
retaining clip.
3. Remove the grommet retainer at the inner fender.
4. Remove the transmission cable retainer and
various harnesses from restraints at left strut
tower to access jumper harness connector.
5. Remove the upper jumper harness connector.
6. Pull the grommet through inner fender pass-thru
and remove jumper harness.
213395
1. Route the new jumper harness through inner
fender pass-thru.
2. Install the upper jumper harness connector.
3. Install the transmission cable retainer and various
harnesses to restraints that may have been
disconnected to access jumper harness.
4. Install the grommet retainer at the inner fender.
5. Install the jumper harness from the retaining clip. (
213395

Replacement (Rear with out Traction
Control)
Removal Procedure
2. Remove the rear wheel speed sensor jumper
harness grommet from retainer (1 ).
3. Remove the upper harness connector from rear
body pass-thru connector.
213402
1. Install the upper harness connector from rear
body pass-thru connector.
2. Install the rear wheel speed sensor jumper
harness grommet from retainer (1),
213402

Replacement (Rear with Traction Control)
Removal Procedure
1. Remove the wheel speed sensor connectors (2,3).
2. Remove the jumper harness grommet from.the
retainer.
3. Remove the upper jumper harness connector
from the rear body pass-thru connector.
213413
Installation. Procedure
1. Install the upper jumper harness connector from
the rear body pass-thru connector.
2. Install the jumper harness grommet to the
retainer.
3. Install the wheel speed sensor connectors (2,3).
213413
Wheel Speed Sensor Ring Replacement
(With out Traction Control)
(
The rear wheel speed sensor reluctor ring is located in
the differential case. If the reluctor ring is determined
to be damaged and must be replaced refer to
Differential case in Rear Axle.
Wheel Speed Sensor Ring Replacement

The rear wheel speed sensor reluctor rings are an
integral part of the rear axle shafts. If it has been
determined they must be replaced refer to Axle Shaft
in Rear Axle.
Traction Control Switch Replacement

2 (Pontiac)
Removal Procedure
1. Unsnap the front floor console accessory trim
plate (2).
2. Electrical connector from the traction control
switch (4).
3. Electrical connector from the convertible top
switch (3), if equipped.
4. Unsnap the traction control switch (1) from the
front floor console accessory trim plate (2).
(
'
380886
1. Traction control switch (1) to the front floor
console accessory trim plate (2).
2. Electrical connector to the convertible top
switch (3), if equipped.
3. Electrical connector to the traction control
switch (1).
4. Front floor console accessory trim plate (2).
380886
(
Traction Control Switch Replacement
) (Chevrolet) 1
Removal Procedure
1. Unsnap the 1/P accessory trim plate.
2. Disconnect the electrical connector from the fog
lamp switch (2),
traction control switch (1 ).
294806
4. Unsnap the traction control switch from the

1/P accessory trim plate.
367395
1. Install the traction control switch to the
IfP accessory trim plate.
2. Connect the electrical conector to the traction
control switch.
3. Traction control switch to the instrument panel
accessory trim plate (1).
367395
5.:.249 Antilock Brake System Brakes
4. Install the 1/P accessory trim plate.
1 (
294806

Service Precautions
ABS!TCS System Service Precautions
Observe the following general precautions during any
ABS/TCS service. Failure to adhere to these
precautions may result in ABS/TCS system damage. (
1. Unplug the EBCM/EBTCM harness connector
before performing electric welding procedures.
2. Carefully note the routing of the ABS/TCS wiring
and wiring components during removal. The
ABS/TCS components are extremely sensitive to
EMI (electromagnetic interference). Proper
mounting is critical during component service.
3. Do not use a quick charger for engine starting or
for battery charging with the battery still
connected. Brake failure or ABS/TCS component
damage may result.
4. Disconnect the battery with the ignition off.
5. Disconnect the EBCM/EBTCM connector with the
ignition off.
6. Do not attempt to repair the BPMV or any other
non serviceable ABS/TCS components where
noted in this section .. Many ABS/TCS components
are serviceable by component replacement only.
7. Do not hang th.e suspension components from the
WSS cables. The cables may be damaged.
8. Do not subject the EBCM/EBTCM to temperatures
of more than 85°C (184°F).
9. Do not use petroleum based fluids in the master
cylinder. Do not use any containers previously
used for petroleum based fluids. Petroleum causes
swelling and distortion of the rubber components
in the hydraulic brake system, resulting in
water entering the system and lowering the fluid
boiling point.
10. Inspect the ABS/TCS system after service using a
scan tool.
General System Description Use of Circuit Testing Tools
The purpose of the Bosch 5.3 Antilock Brake O
You should be familiar with the Digital
System (ABS) is to minimize wheel slip during heavy Multimeter (DMM) J 39200, and be familiar with
braking. The Bosch 5.3 performs this function by the meter controls and how to use them correctly.
monitoring the speed of each wheel and controlling
" You should be able to measure voltage, resistance
the brake fluid pressure to each wheel independently
and current.
during a braking event. This allows the driver to
retain directional stability and better steering capability. • You should know how to use jumper wires to
The Traction Control System (TCS) also monitors bypass components for testing circuits.
rear wheel speed. and compares the speed to Important: When measuring the resistance to ground
the speed of the front wheel. If excessive rear wheel of circuit or component, make sure to use a solid,
speed is detected in either rear wheels the TCS will be
unpainted chassis ground or the negative battery
activated.
terminal.
Abbreviations and Definitions
ABS Description
ABS: Antilock Brake System
ASM: Accelerator and Servo Control Module Brake Pressure Modulator Valve (BPMV)
B+: Battery Voltage The Brake Pressure Modulator Valve (BPMV) mounted
on the left side of the engine compartment, provides
BPMV: Brake Pressure Modulator Valve brake fluid modulation for each of the individual wheel
CKT: Circuit circuits as required during Antilock braking. During
DLC: Data Link Connector the Anti lock mode, the BPMV can maintain or reduce
brake fluid pressure independent of the pressure
DTC: Diagnostic Trouble Code
generated in the master cylinder. The BPMV does not
DMM: Digital Multimeter provide more pressure than is applied by the master
EBCM: Electronic Brake Control Module cylinder during braking.
EBD: Electronic Brakeforce Distribution The BPMV supplies Electronic Brakeforce
) EBTCM: Electronic Brake and Traction
Distribution (EBD). This function takes the place of the
proportioning valve(s).
Control Module
With the exception of the EBCM/EBTCM, the Brake
IPC: Instrument Panel Cluster Pressure Modulator Valve (BPMV) is an integral,
PCM: Powertrain Control Module non-serviceable component. The BPMV should never
TCS: Traction Control System be disassembled.
WSS: Wheel· Speed Sensor If the vehicle is not equipped with traction control the
BPMV uses a three circuit configuration with a
front-rear split. Individual circuits are provided for the
Basic Knowledge Required, left front and right front wheels, and the rear wheels
Before using this section, it is important that you have use one circuit.
a basic knowledge of the following items. Without If the vehicle is equipped with traction control the
this basic knowledge, it will be difficult to use BPMV uses a four circuit configuration with a front-rear
the diagnostic procedures contained in this section. split. Individual circuits are provided for the left front
If you need a review of basic electrical troubleshooting and right front wheels, and left rear and right rear
knowledge, Refer to General Electrical Diagnosis wheels.
Procedures in Wiring Systems. Additionally,
The BPMV consists of several other components
electrical/electronic courses are offered through which are described as follows:
General Motors Service Training.
Pump Motor
Basic Electrical Circuits
The BPMV contains a motor driven recirculation
e You should understand the basic theory of
electricity and know the meaning of voltage, pump. The pump serves two purposes: 1) During
current (amperes) and resistance (ohms). ABS Reduce Pressure events, it transfers fluid from
the brake calipers back to the master cylinder; and
" You should understand what happens in a circuit 2) During traction control, it transfers fluid from
with an open or shorted wire. the master cylinder reservoir to the rear brake calipers.
e You should be able to read and understand a The pump and motor are located within the BPMV
wiring diagram. and are not serviced separately.
ABS Valves The EBCM/EBTCM also controls the display of the
The ABS valves decrease or. maintain brake fluid ABS and traction control DTCs while in diagnostic (
pressure at the individual wheel circuits. If the vehicle mode. The EBCM/EBTCM continuously checks
is not equipped with traction control there are the speed of each wheel in order to determine if any
three Inlet, and three Outlet solenoid valves. If the wheel is beginning to slip. If a wheel slip tendency
vehicle is equipped with traction control there is detected, the EBCM/EBTCM commands the
are four Inlet, and four Outlet solenoid valves. The appropriate valve positions to modulate the brake fluid
solenoid valves maintain, increase, or decrease brake pressure in some or all of the hydraulic circuits.
fluid pressure to the individual wheel circuits. The This action prevents wheel slip and provides optimum
EBCM/EBTCM commands the valves to their correct braking. The EBCM/EBTCM continues to control
position during an antilock or traction event. During pressure in the individual hydraulic circuits until
antilock mode, the pressure in each hydraulic a slipping tendency is no longer present. The
circuit can be held or released by activating the EBCM/EBTCM continuously monitors the ABS/TCS for
appropriate valves. The normal state of the inlet valves proper operation. If an error is detected, the
is open, while the normal state of the Outlet valves EBCM/EBTCM can disable the ABS/TCS and turn on
is closed. This allows direct master cylinder pressure the ABS or TCS OFF Indicators in the IPC.
to the brakes during normal braking. The ABS Wheel Speed Sensors
valves are located within the BPMV and are not
serviced separately. A wheel speed sensor is located at each front wheel
bearing assembly. If the vehicle is equipped with
TCS Master Cylinder Isolation Valves traction control a wheel speed sensor i~ located at each
If the vehicle is equipped with Traction Control there is rear wheel bearing assembly. If the vehicle is not
one TCS Master Cylinder Isolation Valve within the equipped with traction control then a single rear wheel
BPMV. This valves isolates the master cylinder so the speed sensor is located in the differential housing. The
pump motor can build brake fluid pressure for the sensors use AC voltage in order to transmit wheel
rear brakes during a traction event. speed information to the EBCM/EBTCM. Passing a
toothed sensor ring past a stationary sensor causes the
TCS Prime Valves magnetic induction that generates the voltage. A pair of
If the vehicle is equipped with Traction Control there is wires carries the signal to the EBCM/EBTCM. The
one TCS prime valve within the BPMV. This valves wheel speed sensors are located in their respective
allow the pump to draw fluid from the master cylinder assemblies and are not adjustable. (
reservoir, through the compensating ports in the
master cylinder bore. Traction Control System ON/OFF Switch
Electronic Brake And Traction Control Module The Traction Control On/Off Switch is a momentary on
switch that allows the driver to shut off the TCS for
The EBCM/EBTCM performs the following primary personal or diagnostic reasons. Turning the switch to
functions: off places the TCS in the passive mode while
., Detects wheel slip tendencies maintaining ABS functions. With the TCS system on,
" Detects wheel speed differences pressing the switch disables the T.CS and the
TRACTION OFF indicator turns on.
" Controls the brake system while in the antilock or
traction control mode Stoplamp Switch
.. Controls the Electronic Brakeforce The stoplamp switch is an inputto the EBCM/EBTCM.
Distribution (EBD) The EBCM/EBTCM uses the stoplamp switch in
• Monitors the system for proper electrical operation order to tell when the brake pedal is being applied.
(
ABS Operation
ABS BPMV Hydraulic Flow
19 2
3 4
5 5
16
00 15
6
7
\
)
8
14 9
13
12
REAR AXLE FRONT LEFT FRONT RIGHT

215234
legend
(1) Master Cylinder (10) Right Front Rotor
(2) Front Brake Pipe (11) Left Front Outlet Valve
(3) Check Valve (12) Left Front Rotor
(4) Damping Chamber (13) Rear Rotors
(5) Pump (14) Rear Outlet Valve
(6) Pressure Accumulator (15) Rear Inlet Valve
(7) Right Front inlet Valve (16) Pressure Accumulator
(8) Left Front Inlet Valve (17) Damping Chamber
(9) Right Front Outlet Valve (18) Check Valve
ABSfTCS BPMV Hydraulic Flow
24 2
23
25
21
7
(
Rear Rear Front 10

Left Right Left
215251
Legend
(1) Master Cylinder (15) Left Rear Rotor
(2) Front Brake Pipes (16) Left Rear Outlet Valve
(3) Check Valve (17) Right Rear Inlet Valve
(4) Damping Chamber (18) Left Rear Inlet Valve
(5) Pump (19) Pressure Accumulator
(6) Pressure Accumulator (20) Check Valve
(7) Right Front Inlet Valve (21) Pump
(8) Left Front Inlet Valve (22) Check Valve
(9) Right Front Outlet Valve (23) Damping Chamber
(10) Right Front Rotor
(24) Isolation Valve
(11) Left Front Outlet Valve
(25) Prime Valve
(12) Left Front Rotor
(26) Internal Damper
(13) Right Rear Rotor
(27) Rear Brake Pipes
(14) Right Rear Outlet Valve
Antilock Brake System Traction Control
When wheel slip is noted during a brake application, Traction control will not have any effect on the
the ABS will enter Antilock mode. During Antilock operation of the vehicle until the control module
braking, hydraulic pressure in the individual wheel detects one or both of the rear wheels rotating faster
circuits is controlled to prevent any wheel from than the front wheels. At this time the Electronic
slipping. If the vehicle is equipped with traction control Brake and .Traction Control Module (EBCM) will
a separate hydraulic line and specific solenoid request the Powertrain Control Module (PCM) to retard
valves are provided for each wheel. If the vehicle is timing. If the EBCM continues to detect the rear
not equipped with traction control then both front wheel are rotating faster than the front it will request
wheels have a seperate hydraulic line and specific
the ASM to reduce the throttle angle. The last measure
solenoid valves, the rear wheels have only
taken to control the rear wheel is for the EBCM to
one hydraulic line controlled by one set of solenoid
valves. The ABS can decrease, hold, or increase apply the rear brakes, thus reducing torque to the rear
hydraulic pressure to each wheel brake. However, it wheels. Once the rear wheels begin to rotate at the
cannot increase hydraulic pressure above the same speed as the front wheels, the system will return
amount which is transmitted by the master cylinder full control to the driver. During Traction Control
during braking. mode, if the brake is applied to only one rear wheel,
most of the torque from the engine will be directed
During Antilock braking, a series of rapid pulsation's
will be felt in the brake pedal. These pulsation's to the other rear wheel which will improve the traction
are caused by the rapid changes in position of the of the vehicle.
individual solenoid valves as they respond to The braking is accomplished by closing the TCS Master
their desired wheel speed. This pedal pulsation is Cylinder Isolating Vaive, this isolates the master
present during Antilock braking and will stop when cylinder from the rest of the system. The TCS Prime
normal braking is resumed or when the vehicle comes valve opens to allow the pump to get brake fluid to build
to a s1op. A ticking or popping noise may also be pressure for braking. The drive wheel circuit solenoids
heard as the solenoid valves rapidly cycle. During are energized as needed to allow for pressure hold,
Antilock braking on dry pavement, the tires maY make pressure increase, or pressure decrease.
intermittent chirping noises as they approach
slipping. These noises and pedal pulsation's should b.e The TCS may be deactivated by the driver if desired.
In order to deactivate the TCS with the engine
) considered normal during Antilock operation.
running, depress the TCS On/Off switch. The system
Vehicles equipped with ABS may be stopped by will remain deactivated until the ignition switch is
applying normal force to the brake pedal. Brake pedal
cycled, or the S\{\/itch is pressed again.
operation during normal braking should be no
different than previous systems. Maintaining a constant Tires"With ABS/TCS
force on the pedal will provide the shortest stopping
The compact ,spare tire rotates faster than the others.
distance while maintaining vehicle stability.
The EBCM compensates for this faster rotation.
Pressure Hold Refer to Tires and Wheels in Suspension for
When the EBCM senses the wheel slip, the EBCM information on replacement tires.
closes the Inlet valve and keeps the Outlet valve Replacement Tires
closed in the BPMV in order to isolate the system. This
holds the pressure steady on the brake so that the The tire size is important for the performance of the
hydraulic pressure does not increase or decrease. ABS/TCS. The replacement tires should be the
same size load range and construction as the original
Pressure Decrease tires. Replace the tires in axle i;>ets and only with
If during the pressure hold mode the EBCM still tires of the same tire performance criteria specification
senses wheel slip, the EBCM will decrease the number. Use of any other tire size or type may
pressure to the brake. The Inlet valve is left closed seriously affect ABS/TCS operation. For information
and the Outlet valve is opened. The excess fluid on replacement tires for this vehicle, Refer to Tires and
is stored in the accumulator until the return pump can Wheels in Suspension.
return the fluid to the master cyclinder.
BRAKE Warning Indicator
Pressure Increase The red BRAKE Indicator in the instrument cluster will
If during the pressure hold or the pressure decrease illuminate to warn the driver of conditions in the
mode the EBCM senses that the wheel speed is brake system which may result in reduced braking
too fast, the EBCM will increase the pressure to the ability. The red BRAKE indicator will also illuminate
brake. The Inlet is opened and the Outlet valve is when the park brake is .applied. The BRAKE warning
closed. The increased pressure comes from the master Indicator will stay illuminated until the condition
cylinder and is related to the pressure applied to the has been repaired, or the park brake is released. Refer
brake pedal. to Brake System Testing in Hydraulic Brakes.
ABS Indicator TCS Off Indicator (Pontiac)
The ABS is located in the instrument cluster and will
illuminate if a malfunction in the ABS is detected by the
The TCS Off Indicator (Pontiac only) is located in the
instrument cluster and will illuminate if a malfunction
(
Electronic Brake and Traction Control Module (EBCM). in the traction control system is detected by the.
The ABS Indicator informs the driver that a condition Electronic Brake and Traction Control Module (EBCM).
exists which results in turning off the Antilock The TCS Off Indicator informs the driver that a
brake and traction control function if equipped. If only condition exists which results in turning off traction.
the ABS Indicator is on, normal braking with full Conditions for the TCS Off Indicator to turn on are as
power assist is available. If the BRAKE and Antilock follows:
Indicators are on, a problem may exist in the hydraulic 1. Traction control malfunction detected. As
brake system. Refer to Brake System Testing in previously described, the TCS Off Indicator turns
Hydraulic Brakes. Conditions for the Antilock Indicator on when a problem has been found in the
to turn on are as follows: traction control system. The TCS Off Indicator
1. ABS malfunction detected. As previously indicates that traction control has been disabled.
described, the ABS Indicator turns on when 2. Instrument Panel Cluster bulb check. When 1he
a problem has been found in the ABS. The ABS ignition is turned to RUN, the TCS Off Indicator
Indicator indicates that the ABS and TCS if will turn on for approximately three seconds
equipped have been disabled. and then turn off.
2. Instrument Panel Cluster bulb check. When the
ignition is turned to RUN, the ABS Indicator will low Trac Indicator
turn on for approximately three seconds and then The Low Trac Indicator is located in the instrument
turn off. cluster and will illuminate when the EBCM detects a
• Illumination of the BRAKE warning Indicator low traction condition. Conditions for the Low Trac
may indicate reduced braking ability. Indicator to turn on are as.follows:
" Illumination of the ABS Indicator without the 1. Instrument Panel Cluster bulb check. When 1he
BRAKE warning Indicator on indicates only ignition is turned to RUN, the ASR Indicator will
that Antilock braking is no longer available. turn on for approximately three seconds and
Power assisted braking without Antilock control then turn off.
is still available. 2. The EBCM detects an antilock braking condition.
" Refer to Brake System Testing in Hydraulic 3. The EBCM detects a traction control condition.
(
Brakes for diagnosis of any condition which
causes the BRAKE warning Indicator to
illuminate.
ASA Indicator (Chevrolet)
The ASR Indicator (Chevrolet only) is located in the
instrument cluster and will illuminate if a malfunction in
the traction control system is detected by the
Electronic Brake and Traction Control Module (EBCM).
The ASR Indicator informs the driver that a condition
exists which results in turning off traction. Conditions
for the ASR Indicator to turn on are as follows:
1. Traction control malfunction detected. As
previously described, the ASR Indicator turns on
when a problem has been found in the traction
control system. The ASR Indicator indicates that
traction control has been disabled.
2. Instrument Panel Cluster bulb check. When the
ignition is turned to RUN, the ASR Indicator will
turn on for approximately three seconds and
then turn off.
(
J 35616-A J 39700-530
Connector Test Adapter Kit Cable Adapter
8917 98824
J 39200 Tech 2
Digital Multimeter Scan Tool
39438
) J 39700
Universal Pinout Box
(
BLANK
(
INDEX 1
A Antenna Mast Replacement

Fixed .. ... ..... ... ..... ....... ... ... .... ..... . .. ... .. .... .. .. ... 8-348
) Abbreviations andTheir Meanings ..................... 0-22 Power .................................. ·........................ 8-349
A/C Refrigerant Pressure Sensor Replacement .... 1-72 Antenna Motor Replacement
A/C System Power .... .... .... ..... ... .... .... .. ..... ... .. .. .. ..... .. ... .. .. 8-350
Diagnosis Antenna Replacement
Noise ......................................................... 1-24 Fixed .................................... : ......... :............ 8-349
Accelerator and Servo Control Module (ASM) Antilock B.rake System
Replacement ............ .......... .... .... ... . 5-236 Adjuster Assembly Replacement ................... 5~239
Accelerator Controls Brake Pressure Modulator Valve
Ca.ble Replacement (5.7L) ... , ...•.. ,............... 6-1855 Replacement .. ... ... ..... .. .. .. ... ... .... .. .. . 5-237
Pedal Replacement (3.8L) ................. ,........ 6s1241, Cable Adjustment Procedure .. ,..... :............... 5-241
6-1244, 6-1245 Component Locations .. .. .. .. ... .. .... . .. .. .. .. .. .. ... .. 5-110
Pedal Replac:ement (5.7L) ................. ,........ 6-1857 Component Views .. .. ... ... .... .... .. . ... .. . .... ... ... .. . 5-114
Accumulator Replacement ............•..... ,.. : .......... 7 1-78 Connector End Views ................................... 5-122
Acid Rain' ...................... , ............ ,........·.......... 8-1139 Description
Actuator Replacement Abbreviations and Definitions .................... 5-249
Liftgate Lock . ...... ..... .............. .. ..... .. ...... ..... 8-11 06 ABS System ..... ...... .. .. ... ... .. ... . .. ... ... .... .. .. .. 5-249
Adjustment . . . . ABS System Operation ................. ,......... :. 5-251
Rack Bearing Pre load - Power .Steering ......... 2-35 Basic Knowledge Required ....................... 5-249
Temperature Control Cable (A/C - Manual) ....1-132 General ... ..... .... ...... .... .. ... .. .. .. .. .. .. ... .... .. .. .. 5-249
Adjustments Service Precautions .................................. 5~248
· Clutch Pre$sure Piate ............... : .................. 7-401 Diagnosis
Park/Neutral Position. Switch. ABS. Indicator Inoperative with
Automatic Transmission - 4L60-E ............. 7-309 No OTC Set .. ... .. .. ... .. ... .. .. .. ... .... ... .. . 5-227
Shift Cab.le ABS Indicator On No OTC Set .................. 5-225
Automatic Transmission - 4L60-E , ............ 7-303 ASR Indicator Inoperative with No
AIR OTC Set ....... .. .... .... . ... ... . .... .. ... .. .. .. . 5-220
Check Valve/Pipe Replacement ASR Indicator On with No OTC Set .......... 5-218
Bank 1 (5.7L) ... ,., .. , .............·.................... 6-1922 Diagnostic Starting Point ........................... 5-125
) ·Bank 2 (5.7L) ..... : ................ ;,.,; ....... ,..... ,. 6-1921 Diagnostic System Check .................... , .... 5-129
Diagnostic Traub.le Code (OTC) List/Type ... 5-127
Air Baffle Assemblies and Deflectors ·
Electromagnetic Interference .. . ... .. .... ... ... . .. 5-128
(Engine Cooling) ...... , ........... 6-661, 6-662
Enhanced Diagnostics ................ ,............. 5-.128
Air Cleaner
Initialization Sequence .............................. 5-128
· Assembly Replacement(5.7L) .... ,.... , .. ,....... 6-1929 Low Traction Indicator Inoperative ............. 5~231
Element Replacement (3.8L) ...................... 6-1298 Low Traction Indicator On All of the Time .... 5-229
Element Replacement (5. 7L) ,·· ..................... 6-1928 No Communication with EBCM ................. 5-223
Intake Duct Replacement (3.8L) ................. 6-1299 Scan Tool Data Definitions ....................... 5-126
Air Deflector Replacement Scan Tool Data List .. ... .... .. ... .. .. .. ... ... . .. .. ... 5-125
Radiator ....................................................... 8-871 Scan Tool Diagnostics .......... , ................... 5-125
Air Inlet Grille Panel Replacement ................... 8-871 Self-Diagnostics ........................................ 5-128
Air Outlet Replacement - Right [:)e~ogger Symptoms ................... , ............................ 5-212
(A/C , Manual) ................................ 1-138 JCS Indicator Inoperative with
Air/Wind Noise No OTC Set..................................... 5-215
Diagnm;is JCS Off Indicator On with No DTC Set ..... 5-213
Air Pressure Test .............. ,.: ..................... 8-783 Electronic Brake Control Module
Air/Wind Noise , .............................. : .......... 8-783 Replacement ......... , . ,............... ,. .. ... 5-233
Soap Suds or Bubble Test ....................... 8-783 GM SPO Group Numbers .............................. 5-97
·Tracing Powder or Chalk Test .................. 8-783 Schematic
ABS Schematic Icons . ... .... ... .. .. .. .... ... ... . .. ... 5-97
Alignment .
Schematics ... ...... ..... . .. .... .... ... ... .. ... .. .... .. .. . . .. .. 5-98
Checking Frame to Body Alignment ........... 8-1149
Special Tools , .............................................. 5-255
Alignment Checking · Specifications
Frame and Underbody ............................... 8-1149 ABS Diagnostic Specifications .................... 5-97
Aluminum Wheel . . Fastener Tightening .................................... 5-97
Hub Cap Replacement ... ,............................... 3-64 Wheel Speed Sensor
Porosity Repair ................ ,............................. 3-64 Jumper Harness Replacement ................. 5-243,
Refinishing ..................................................... 3-64 5-244, 5-245
Amplifier Replacement .......................... 8-338, 8-339 Ring Replacement .................................... 5-246
Antenna Wheel Speed Sensor Replacement ... 5-241 , 5-242
Schematic Anti-Theft Labeling ..... . ... ... .... .... .. .. .. .. .... ... .. .. .. ... 0-14
Power .. .. ... ...... ... ......... .... ...... ....... .... ........ . . 8~285 Arrows and Symbols, Description ........................ 0-4
Antenna Mast Cleaning ................................... 8-351 Ashtray Lamp Bulb Replacement ..................... 8-221
2 INDEX
Ashtray Replacement Automatic Transmission - 4L60-E (cont.)
Front Floor Console ..................................... 8-618 Diagnosis (cont.)
Ashtray/Lighter Replacement Engine .Coolant in Transmission :............... 7-272
Console ....................................................... 8-619 Engine Starts in Gear ............................... 7-287
Assist Rod Ball Stud Replacement Fluid Leak ................................................ 7-272
Hood ........................................ ; ...... .... ... .. ... 8-868 Flywheel/Torque Converter Vibration Test ... 7-270
Assist Rod Replacement Front Oil Leak .......................................... 7-287
Hood ........................................................... 8-867 Harsh Garage Shift ................................... 7-'283
Audible Warnings Harsh Shifts ............................................. 7-279
Diagnosis Inaccurate Shift Points ............................ :. 7-279
Key-in-Ignition Chime On with Line Pressure Check Procedure ............... 7-265
LF Door Closed ..... .. .... ... ..... .... .. .. ... 8-583 No 2-3 Shift or 2-3 Shift Slips, Rough
Key-in-Ignition Chime Always On .............. 8-582 or Hunting ...................................... 7:281
Key-in-Ignition Chime Inoperative .............. 8-582 No 3-4 Shift, Slips or Rough 3-4 Shift ...... 7-282
Lights On Chime Inoperative .................... 8-584 No Drive in All Ranges ............................. 7-287
Lights On Chime On with No Drive in Drive Range .......................... 7-287
Ignition in Run ................................ 8-584 No First or Second Gear/No Third or
Auto Trans Shift Lock Control .......................... 7-288 Fourth Gear .................................... 7-281
Circuit Description ........................................ 7-375 No Fourth Gear, or Slips in Fourth Gear .... 7-286
Schematics No Gear Selection .................................... 7-287
Column Mounted ........................................ 7-73 No Overrun Braking , Manual 3~2-1 .......... 7-283
Automatic Transmission No Park .................................................... 7-286
Shift Lock Control No Part Throttle or Delayed Downshifts .... 7-283
Component Views ..................................... 7-105 No Reverse or Slips in Reverse ............... 7-282
Automatic Transmission - 4L60-E No Second Gear, No Fourth Gear,
2:..4 Servo ..................................................... 7-321 and No Reverse Gear ................. ,.. 7-281
Accumulator Assembly, Spacer Plate, No Third Gear ........................................... 7-286
and Gaskets .... .... .... ... ... ..... .... ... . .... 7-349 No Torque Converter Clutch Apply ........... 7-283
Automatic Transmission Related No Torque Converter Clutch Release ....... 7~285
Connector End Views ..................... 7-109 Noise and Vibration Analysis ..................... 7-271
Brake Transmission Shift Interlock Oil Out the Vent ....................................... 7-286 (
Solenoid Replacement . ... .. .. .. ... ... .. . . 7-292 Oil Pressure High or Low ......................... 7-278
Case Extension Assembly Installation ........... 7-355 Powertrain On Board Diagnostic (OBD)
Component Location ...................................... 7-77 System Check -
Component Location Table ............................. 7-74 Automatic Transmission .................. 7-109
Control and Shift Solenoids Replacement ..... 7-342 Ratcheting Noise ...................................... 7-287
Description Road Test Procedure ............................... 7~265
Adapt Function ......................................... 7-375 Shift Lever Indicates Wrong Gear ............. 7-287
Definitions and Abbreviations .................... 7-372 Shift Solenoid Leak Test ........................... 7-275
Electrical Connector .................................. 7-379 Slip/Flare in Any Gear .............................. 7-286
Electronic Component ............................... 7-376 Slipping or Rough 1-2 Shift ...................... 7-280
Identification Information ......... ; ................. 7-374 Slips in 1st Gear ....................................... 7-279
Transmission General Information ............. 7-372 Symptom Diagnosis .................................. 7-276
Diagnosis Symptoms - A/T Shift Lock Control ........... 7-288
1st Gear Range Only - No Upshift ............ 7-279 Third Gear Only ........................................ 7-281
2nd /3rd Gears Only or Torque Converter Clutch Shudder ............. 7-285
1st/4th Gears Only ......................... 7-281 Torque Converter Clutch.(TCC)
2nd Gear Start .......................................... 7-286 Intermittent - OK Cold/Slips Hot ...... 7-286
2nd Gear Start Switch and Indicator Torque Converter Clutch (TCC) Slip -
Lamp Circuit Check ........................ 7-261 100 RPM Slip ................................. 7-285
3-2 Flare or Tie-Up .................................. , 7-281 Torque Converter Clutch (TCC) Slip
AT Oil Cooler Flushing and Flow Test ...... 7-275 with Stall/Stumbl.e ......•.................... 7-285
Case Porosity Repair .............................. ,. 7-275 Torque Converter Diagnosis Procedure ..... 7-268
Clutch Plate Diagnosis .............................. 7-271 Transmission Fluid Checking Procedure .... 7-263
Delay in Drive and Reverse ...................... 7-287 Transmission Overheats ............................ 7-278
Diagnostic Starting Point - Transmission Scan Tool
Automatic Transmission .................. 7-109 Data Definitions ................... 7-114, 7-117
Diagnostic Starting Point - Transmission Scan Tool Data List .... 7-111, 7-112
Automatic Transmission Shift Vibration in Reverse and
Lock Control System ...................... 7-111 Whining Noise in Park .................... 7-286
Diagnostic Trouble Code (OTC) List/Type ... 7-120 Do Not Use Air Tools ................................... 7-372
Diagnostic Trouble Code (OTC) El,ectronic Component Views .......................... 7-76
Type Definitions .............................. 7-120 Extension Housing Rear Oil Seal ................. 7-354
Drives in Neutral ............. :......................... 7-286 Filler Tube Replacement .................... 7-326, 7-328
INDEX 3
Automatic Transmission - 4L60-E (cont.) Battery (cont.)
Floor Shift Control Knob Replacement ......... 7-291 Load Test - Parasitic ................................. , .. 6-700
) Floor Shift Control Replacement .. :................ 7-305 Negative Cable Disconnect .......................... 6-722
Fluid/Filter Changing ............ , ....................... 7-311 Not Operating Properly ................................ 6-696
Flywheel to Torque Converter Bolts .............. 7-334 Replacement ................................................ 6~735
· lnline Harness Connector End View ............. 7-106 Terminal Check ........................................... 06-693
Internal Connector End Views ...................... 7-107 Tray and Hold-Down Retainer Description .... 6-782
Oil Cooler Line Replacement ....... : ... :.......... : 7-313 Tray Replacement ........................................ 6-738
Oil Pan Replacement ..... ...... ... ............ ......... 7-335 Visual Inspection .......................................... 6-693
Park Lock Cable Replacement .... ........ ......... 7-293 Battery Operation ... .. ... .... ... .. .. ... ...... .. . ... . ... ... .. . 6-781
Park/Neutral Position Switch Adjustment.. ..... 7-309 Battery Temperature vs Voltage Drop .............. 6-675
Park/Neutral Position· Switch Replacement ... 7-308 Battery Usage Specifications ........................... 6-67 4
Parts Cleaning and Inspection ......... ,........ 7-290 Belt, Drive, Replacement (3.8L) ..............•.......... 6-47
Pressure Regulator Replacement ....... , ......... 7-.324 Belt Reveal Molding Replacement ..... 8-1071, 8-1072
Replacement ., ................................... 7-359, 7-366 Blade Element Cleaning .................................. 8-269
Schematic Blower
Controls Schematic Diagrams ........ ,....... ,.... 7-68 Diagnosis
Schematic Icon Table ......................... , ....... 7-67 High Speed Inoperative (A/C - Manual) .... 1~122
Shift Cable Adjustment ,: ... :.................. :..... , .. 7-303 Inoperative at Any Speed (A/C - Manual) ..... 1.. 119
Shift Cable Replacement .......................... ,... 7-300 Operates at High Speed Only ·
Special Tools ...... ." ................ : .............. : ......... 7-380 (A/C - Manual) ............................... 1"121
Specifications Operates Continuously (A/C - Manual) ...... 1-123
· Component Resistance ...... .. ............. .......... 7-66 Operates in One Speed Only
Fastener Tightening .................................... 7-63 (A/C - Manual) ........................ : ...... 1-121
Fluid Capacity ............... : ...................... ;..... 7-64 Motor and Fan Assembly Replacement
General ............ ,,., ..... ·............................... ::·7-64 (A/C - Manual) ............................... 1°125
· Line Pressure ........................................ :.... 7-66 Resistor Replacement (A/C - Manual) .......... 1-124
Range Reference Table ..............................• 7-64 Blower Motor
Shift Solenoid Valve State and Gear Ratio .... 7-65 Controls Circuit Description (A/C - Manual) . .. .. 1-150
Shift Speed Table ....................................... 7-65 Diagnosis
TFP Manual Valve Position Switch Logic ... ; 7-66 Noise ................................................... -'· .... 1-21
TFT Sensor ............. :.................................. 7-63 Relay Replacement (Non-A/C) ....................... 1-"87
· Torque Converter Clutch PWM Solenoid, Body Control Module
TCC Solenoid, andWiring Harness ... 7-345 Description
Torque Converter Cover Circuit ....................................................... 8-544
Replacement ........................ 7-331, 7-333 Body Control Module Programming/RPO
Valve Body and Pressure Switch Configuration .................................. 8"543
Replacement ... ,.............................. 7-336 Body Control Module Replacement .................. 8"541
Vehicle Speed Sensor Replacement ............. 7-358 Body Control System ·
Vent Hose Replacement ........... '. ................... 7-320 Body Control Module Component Views ....... 8-530
Axle Replacement ·· .. Body Control Module Components ............... 8-527
· Rear Drive Axle ......................... ,................... 4-46 Body Control Module Connector End Views :; .. 8-531
Diagnosis ·
a Cannot Enter BCM Diagnostics ........ : .... ,... 8-539

· Clearing DTCs .......................................... 8-535
Diagnostic Starting Point -
Backup Lamp Bulb Replacenieht .......... 8-211, 8-212
Balancing Tires and Wheels ........... : .... : ............. 0-71 Body Control System ..... .. .. .. .... ... .. .. 8-534
Ball Joint Replacement, . ., . Displaying DTCs ....................................... 8-534
. Lower Front Suspension ................... 3-23 DTC List : ..... ,.. ... .. ..... .. ... ... ... .... .. .. ... ... ... .. .. 8-535
Ball Joint Replacement, . · Symptoms - Body Control System .. ... ... .. .. 8-539
Upper Front Suspension ..... , ........ ,.:;. 3-20 Schematics
Basecoat/Clearcoat Paint Systems ;................ 8-1135 Body Control Module ................................ 8-521
Battery ·. ··.. · · Body Control Module Schematic Icons ...... 8-520
.Battery Charge Low or Specifications
Completely Discharged ................... 6-719 GM SPO Group Numbers .... -'··· ................. 8-520
.· Cable Replacement ..... 6-723, 6-727, £:?~729; 6-732 Body Dimensions .. ... .. ..... .. ... ... .. ...... .. .. .. ... ... .. . 8-1142
Charging ......................... ,.,, ......... ,,: ...... , .... ,. 6-718 Body Front End
Common Causes of Failure ................. ,....... 6-692 Description
Description ................................. ,., ... ,............ 6-781 General ........................·............................ 8-877
Hqld Down Retainer Replac:emenr............... , 6-734 Specifications
. Hydrometer Displays .Dark. or Yellow Dot ...... 6-700 Fastener Tightening .................................. 8-849
'Hydrometer Displays Yellow Dot ........... :....... 6-694 GM SPO Group Numbers ..................... : .. , 8-850
Jump Starting
.. in Case of Emergency ........... 6-720 Body Measurements ............. 8-1150, 8-1158, 8-1167
4 INDEX
Body Rear End
Component Views ...................................... 8-1081
Cable Replacement
c (
Components . . .. ... ... .. . ..... .. .. .... .. ... ... ... .. .... ... . 8-1079
Connector End Views ................................. 8-1084 Accelerator Controls (5. 7L) ......................... 6-1855
Description ................................................. 8-1111 Hood Latch Release .................................... 8-863
Rear Compartment Lid Release Circuit ... 8-1111 Park Brake ···················:·'····················· 5-88, 5-90
Diagnosis Cage Nut Service, Damaged ......................... 8-1186
Diagnostic Starting Point - Camshaft Position Sensor
Body Rear End . .. ... .. .... ... .. .. .. .... ... . 8-1084 Replacement (3.8L) ................. ,..... 6-1294
Rear Lid Ajar Indicator Always On .......... 8-1088 Camshaft Position Sensor
Rear Lid Ajar Indicator Inoperative .......... 8-1089 Replacement (5.7L) ..................... ,. 6-1917
Symptoms - Body Rear End . .. .... .. ..... . ... . 8-1084 Cargo Area Front Trim Panel
Schematic Replacement . .... ..... .. ... .. ... 8-1 063, 8- i 064
Schematic Icons ................... , ................. 8-1076 Cargo Area Side Trim Panel Replacement ..... 8-1065
Specifications Carpet Replacement
Fastener Tightening ................................ 8-1075 Rear Center Trim Panel ................ 8-1067, 8-1068
GM SPO Group Numbers ....................... 8-1076 Cassette Player
Body Side Cleaning Tape Head and Capstan ................ 8-341
Door Molding Replacement .......................... 8-771 Cassette Player Care and Cleaning ................. 8-340
Brake Caliper Caster and Camber Adjustment, Front •.............. 3-11
Bracket Replacement ............................ 5-76, 5-77 Catalytic Converter Replacement ................... 6-1980
Inspection ...................................................... 5-69 Caution, Notice and Important, Definition of .. ,........ 3
Overhaul ............................. ,................. 5-70, 5-73 CD Changer Replacement
Replacement ......................................... 5-63, 5-66 Remote .. ..... ............. ... ... ...... ... . .... .... . 8-342, 8-344
Brake Master Cylinder Charging System
Description . ... . ... .. ... .. .. ... ... ... .. ... .. .... .. ... .. . ... . .. . . 5-52 Circuit Description ........................................ 6-783
Brake Pad Inspection ....................................... , 5-58 Operation ..................................................... 6-783
Brake Pads Replacement ......................... 5-58, 5-60 Charging System Description ......................... ;. 6-782
Brake Pedal Bracket Replacement .................... 5-32 Cleaning
Brake Pedal Replacement ............................ , .... 5-28 Fabric Trim ................................................ 8-1074
Brake Pedal Travel Glass Surfaces ........................................... 8-1074 (
Hydraulic Brakes ............................................ 5-20 Removal Of Specific Stains ........................ 8-1074
Brake Rotor Refinishing ............................ 5-79, 5-80 Cleaning Agents ............................................ 8-1074
Brake Rotor Replacement ........................ 5-77, 5-78 Cleaning Leather Trim ................................... 8-1074
Brake Warning System Cleaning the Headliner .................................. 8-1074
Schematics . ... ... . .... .. . .... .. .. ... .. .... .. .... . .... .... .. .. ... 5-7 Cleaning Vinyl Trim ....................................... 8-1073
BTSI Clearcoat Repair without Repainting .............. 8-1138
Diagnosis Clearcoat Thickness ...................................... 8-1140
Always On with Ignition in RUN ................ 7-289 Closeout/Insulator Panel Replacement
Bumper Replacement Left .............................................................. 8-589
Rear Suspension .. .. .. .. .. .. .. .... ... .. .. ... .... .. .... ... .. 3~44 Right ............................................................. 8-588
Bumpers Clutch
Air Deflector Replacement Actuator Cylinder Replacement .................... 7-395
Front Fascia ............................................. 8-830 Anticipate Switch Replacement ..................... 7-397
Description Clutch Pressure Plate Adjustment ................ 7A01
Bumper and Fascia ...................... ,........... 8-848 Clutch Pressure Plate and Clutch
Energy Absorber Replacement Driven Plate Replacement .... 7-399, 7-400
Front ........................................................ 8-837 Description
Rear .............................................. 8-845, 8-846 Clutch Driven Members ............................ 7-404
Fascia Grille Replacement Clutch Driving Members ............................ 7-404
Front Lower .............................................. 8-835 Clutch Operating Members ....................... 7-404
Fascia Replacement Hydraulic Clutch ....................................... 7-404
Front ........................ , .................... 8-831, 8-833 Hydraulic Clutch Fluid ............................... 7-404
Rear .............................................. 8-839, 8-842 Principal Components ............................... 7-404
Impact Bar Replacement
Diagnosis
Front ........................................................ 8-836
Actuator Fluid Leaks ................................. 7-388
Rear ......................................................... 8-847
License Bracket Replacement Does Not Disengage ................................ 7-382
Rear .......................................................... 8-838 Grabbing (Chattering) ............................... 7-384
License Pocket Cover Replacement Master Cylinder Fluid Leaks ..................... 7-388
Front ........................................................ 8-835 Noisy During Engagement ........................ 7-386
Specifications Pedal Hard to Push .................................. 7-387
Fastener Tightening .................................. 8-829 Pedal Spongy ........................................... 7-389
GM SPO Group Numbers ......................... 8-829 Pedal Squeaky ......................................... 7-390
INDEX 5
Clutch (cont.) Compressor Shaft Seal Removal .............. 1-43, 1-45
\
Diagnosis (cont.) Condenser Replacement ................................... 1-74
) Pedal Stays on Floor Console
(Clutch Disengaged) ....................... 7-386 Armrest Replacement
Pedal Sticks or Binds ......... ............. ..... ... . 7-389 Front Floor ............................................... 8-624
Pedal Travels to Floor Ashtray/Lighter Replacement ........................ 8-619
(Fluid in Master Cylinder) ............... 7-388 Bracket Replacement
Preliminary Checking Procedure ............... 7-382 Front Floor ............................................... 8-623
Rapid Driven Plate Wear .......................... 7-390 Coin Holder Replacement
Rattle (Trans Click) ................................... 7-385 Front Floor ............................................... 8-630
Release Bearing Noisy Cup Holder Replacement
w/ Clutch Engaged ......................... 7-385 Front Floor ............................................... 8-629
Slipping ......... ,.......................................... 7-383 Power Accessory Port Replacement
Spin Down Time ....................................... 7-382 Front Floor ............................................... 8-629
Unable to Select Gears ............................ 7-389 Replacement
Housing Replacement ...... ... .... ............... ...... 7-398 Front Floor ............................................... 8-621
Hydraulic Clutch Bleeding ............................ 7-391 Storage Bin Replacement ............................. 8-617
Master Cylinder Replacement ....................... 7-393 Trim Plate Replacement
Pedal Position Switch Replacement ............. 7-397 Front Floor .................................... 8~624; 8-628
Pedal Replacement ............ ,......................... 7-391 Console Compartment Door
Pilot Bearing Replacement ........................... 7-403 Latch Replacement ..................................... , 8-616
Release Bearing Replacement ..................... 7-402 Control Arm Bushings Replacement
Special Tools ............................................... 7-405 Rear Suspension ........................................... 3-46
Specifications Control Arm Replacement
Fastener Tightening .................................. 7-382 Rear Suspension
GM SPO Group Numbers ......................... 7-382 Lower ......................................................... 3-45
Sealers, Adhesives and Lubricants ........... 7-382 Control Arm Replacement, Lower .: .................... 3-31
Clutch Anticipate Switch Replacement (3.8L) .... 6-1297 Control Arm Replacement, Upper ...................... 3-29
Clutch Rotor and/or Bearing Install ........... 1-50, 1-52 Control Assembly Replacement
Clutch Rotor and/or Bearing Removal ...... 1-37, 1-38 (A/C - Manual) ............................... 1-126
) Coding Keys and Lock Cylinders ....................... 0-27
Coil Rear Suspension ....................................... 3-55
Control Module References ............................... 8-34
Conversion Table, English/Metric ., ....................... 0-3
Coil Spring Insulators Replacement Coolant
Rear Suspension .. .......... ...... .............. .. ......... 3-56 Description .............................................. :.... 6-66.9
Coil Spring Replacement Heater Description .......................... ,............ 6-670
Rear Suspension ........................................... 3-55 Recovery Pipe Replacement
Coin Holder Replacement (Engine Cooling) ............................. 6.-613
Front Floor Console . .......... ....... .. ........ ........ . 8-630 Recovery Reservoir Replacement
Collision Repair (Engine Cooling) ............................. 6-61 O
Radiator Support Recovery System Description ... ... .. ..... ..... ..... 6-669
Description ... .. ... ......... ....... .............. ... ..... 8-1220 Coolant Heater
Compact Disc Care and Cleaning ................... 8-346 Cord Replacement (Engine Cooling) ... 6-666, 6-667
Compressor Clutch Coil Install ...... ,.......... 1-53, 1-55 Coolant Heater Replacement
Compressor Clutch Coil Removal ............. 1-40, 1-41 (Engine Cooling) .................. 6-663, 6-664
Compressor Clutch Plate and Hub Cooling System Draining and Filling ..... 6-608, 6-609
Assembly Removal ........ •. ...... .. 1-35, 1-36 Courtesy Lamp Replacement
Compressor Clutch Plate/Hub Rear Quarter, ........................................... ,... 8-224
Assembly Replacement ........... 1-48, 1-49 Cover Replacement
Compressor Control Switches Install .................. 1-59 Trim Panel Opening ................................... 8-1091
Compressor Control Switches Removal ............. 1-47 Crankcase Ventilation System
Compressor Control Valve Assembly Install ....... 1-47 Inspection (3.8L) ........................... 6-1298
Compressor Control Valve Assembly Removal ... 1-42
Crankshaft Position Sensor
Replacement (3.8L) ....................... 6-1293
Replacement ........................ , .. 1-65, 1-68
Compressor Leak Testing .................... ,............. 1-60 Crankshaft Position Sensor
Compressor Mounting Bracket Replacement (5. 7L) ....................... 6-1915
Replacement ......................... : . 1-61 , 1-64 Crankshaft Position System Variation
Compressor Pressure Relief Valve Install .......... 1-59 Learn Procedure (3.8L) ................. 6-1234
Compressor Pressure Relief Valve Removal ...... 1-46 Crankshaft Position System Variation
Compressor Relay Replacement ........................ 1-71 Learn Procedure (5.7L) ................. 6-1840
Compressor Replacement ........................ 1-29, 1-32 Crossmember Brace Replacement
Compressor Sealing Washers Replacement ....... 1-65 Front .......................................................... 8-1176
Compressor Shaft Seal Install .... .... ....... ... 1-56, 1-57 Crossmember Replacement ........................... 8-1178
6 INDEX
Cruise Control Diagnostic Work Sheets ...................................... 0-5
Cable Adjustment .............................. 8-748, 8-749 Differential Carrier Replacement
Cable Replacement ........................... 8-737, 8-742 Rear Drive Axle ............................................. 4-28 (
Component Locations ................................... 8-716 Disc Brakes
Component Views ........................................ 8-717 Bra.ke Caliper
Connector End Views ................................... 8-721 Inspection ............................ , ...................... 5-69
Description Overhaul ........................................... 5-70, 5-73
System Circuit .......................................... 8-752 Replacement ..................................... 5-63, 5-66
System Description ................................... 8-751 Brake Rotor Replacement ..................... 5-77, 5-78
System Operation ..................................... 8-751 Burnishing Pads and Rotors .......................... 5-62
Diagnosis Description ..................................................... 5-82
Cruise Control Inoperative/ Diagnosis
Malfunctioning Using J 42958 Brake Rotor Lateral Runout Check ............. 5-57
Cruise Control Tester ..................... 8-727 Brake Rotor Thickness Variation Check ...... 5-57
Diagnostic Starting Point - Brake Rotor Tolerance ............................... 5-57
Cruise Control ................................ 8-722 Refinishing Brake Rotors ....................... 5-79, 5-80
Inoperative/Malfunctioning ......................... 8-723 Special Tools ................................................. 5-83
Symptoms - Cruise Control ....................... 8-722 Specifications
Module Replacement ................................... 8-731 Component ... ....... ... ...... ..... ... ... ... ... ...... .. ..... 5-56
Release Switch Adjustment .......................... 8-750 Fastener Tightening .................................... 5-56
Release Switch Replacement .. .... .... ..... .... .. .. 8-749 GM SPO Group Numbers ........................... 5-56
Schematic Dome and Reading Lamp Bulb Replacement ..... 8-221
Icons ........................................................ 8-713 Dome Lamp Replacement ............................... 8-226
Schematics .................................................. 8-714 Door Lamp Replacement ................................. 8-222
Special Tools ............................................... 8-753 Door Lock Switch Replacement ..•......... 8-912, 8-913
Specifications Door Locks
Fastener Tightening .................................. 8-713 Diagnosis
GM SPO Group Numbers ......................... 8-713 All Power Door Locks Inoperative ............. 8~895
Cup Holder Replacement Power Door Locks Switch Lock
Front Floor Console ..................................... 8-629 Function Inoperative - One ............. 8-897
Power Door Locks Switch Unlock
Function Inoperative ....................... 8-897
D One ...................................................... 8-897
Data Link Communications Door Opening Frame Replacement
Component Views . ... ... . .. .. ... .... .... ... ..... .... ... .. .. 8-20 Side .................................. 8-1204, 8-1205, 8,1208
Components ... .. .. ... .... .. .. . ... ..... .. ..... .. .. .... ... .. ... 8-18 Door Replacement
Connector End Views .................................... 8-21 Fuel Filler .................................................. 8-1095
Description Door Service ................................................. 8-1211
Circuit ........................................................ 8-34 Door Sill Plate Replacement .......................... 8-1067
Diagnosis Doors
Diagnostic Starting Point ............................. 8-22 Description
DTC List ... ... . ... ... .... .. . .. .. .... .... .... .. ..... ... ... .... 8-22 Power Door Locks Circuit ......................... 8-934
Scan Tool Does Not Communicate Power Mirrors Circuit ................................ 8-935
w/Class 2 Data Line .. .... ... ..... .... .. ... .. 8-31 Power Windows Circuit ............................. 8-934
Scan Tool Does Not Power Up .................. 8-30 Diagnosis
Schematic Icons ............................................ 8-15 Both Power Windows Inoperative .............. 8-905
Special Tools ................................................. 8-34 Diagnostic Starting Point - Doors .............. 8-894
Data Link Connector (DLC) Power Door Locks .................................... 8-896
Schematics . .. .. ... .. ... ... .. .. . ... ..... .... ... ... ...... .. .. ... 8-16 Do Not Lock ......................................... 8-896
Daytime Running Lamps Do Not Unlock ............ :......................... 8-896
Ambient Light Sensor Replacement .............. 8-220 Power Mirrors lnop in Up/Down
Control Module Replacement ....................... 8-177 Direction - One .................... 8-902, 8-904
Decimal and Metric Equivalents .......................... 0-3 Power Windows ........................................ 8s909
Definition of Caution, Notice and Important ............ 3 Express Function Inoperative ................. 8-909
Defogger Inoperative From LF Switch ................... 8-910
Right Air Outlet Replacement Power Windows Inoperative -
(A/C - Manual) ............................... 1-138 Right Front ..................................... 8-908
Description of Arrows and Symbols .... ... ..... ... ..... . 0-4 Power Windows Inoperative from
Diagnosis RF Switch ...................................... 8-910
Ball Stud Check . .. .. .. ... . .. . .. . .. ... ... .. .. ... .. .. .. .. .. .. . 3-17 Symptoms - Doors .................................... 8-894 (
Inoperative ................................................... 7-288 Door Handle Replacement
Inoperative - Both ........................................ 8-905 Inside ....................................................... 8-922
Strategy Based Diagnosis .............................. 0-32 Door Hinge Replacement .................. 8-920, 8-921
Tire Wear, Abnormal or Excessive ................... 3-4 Door Replacement ....................................... 8-919
INDEX 7
Doors (cont.) DTC C0045 . ...... ... ... ..... ... .... .. ..... .. .. .. .. .. .. ... .. . .. . 5-142
Door Seal Replacement .... ....... .. . ... .. .. .... .... .. 8-930 DTC C0046 ..... .... ... .. .. .... .. .... .... ... .. .. .. .. .. ... .. . .. .. 5-145
) Inside Handle Bezel Replacement ................ 8~915 DTC C0050 ... ..... ... .. ..... .. .. ... ... ..... . .. .. .. .. ... .. .. .. .. 5c148
Lock Actuator Replacement .......................... 8-925 DTC.C0051 ..................................................... 5-151
Lock Replacement ................................. :.. ;.. 8-924 DTC C0055 ................................................ ,.... 5-154
Lock Striker Adjustment ............................... 8-926 DTC C0056 ..................................................... 5-157
Mirror Face Replacement .................. 8-933, 8-934 DTC C0060 . ...... ... ... .. ... ... .... .. .... . ... .. .. .. .. .. ... . .. ... 5-160
Mirrors Replacement .................................... 8-932 DTC C0065 .....................................................,. 5-161
Power Door Systems Component Views ..... , 8-886 DTC C0070 ... .... . .. .... .... .. .. ... ... ... ... .. . .. .. .. ... .. .. .. .. 5-162
Power Door Systems Components ........... ;... 8-884 DTC C0075 ...................................................,. 5-163
Power Door Systems Connector End Views.. :., 8-890 DTC C0080 . .... .... ... ... ... .... .. .... ... ... .. .. .. .. .. .... .. . ... 5-164
Schematic DTC C0085 ,.. ..... ... ... ...... ... .. ... ..... .. .. . ... .. ... ... . .. . 5-165
Door Locks ................................... .... :....... 8:881 DTC ·C0090' .. ..... ... ... ..... ... .... .. ..... .. .. .. .. .. ... ... . .. .. 5-166
Outside Mirrors ............................... 8~882, 8-883 DTC C0095 . ..... .... ... .... .... ... ... .... ... .. .. .. .. .. ... .. .. . . 5-167
Power Door Systems Schematic. Icons ...... 8:.879 DTC C0100 ..................................................... 5-168
Power Windows ....................................... ,8-880 DTC C0105 ..................................................... 5-169
Special Tools ........................................... ;... 8~936 DTCC0110 ..................................................... 5-170
· Specifications . DTC C0121 .................................................... ; 5-173
Fastener Tightening .................................. 8-878 DTC'C0161 ······················································ 5-175
GM SPO Group Numbers ......................... 8-878 DTC C0166 ..................................................... 5-178
Striker Replacement ..................................... 8-926 DTC C0171 ..................................................... 5-179
Trim Panel Replacement DTC C0181 ..................................................... 5-180
Door ......................................................... 8-917 DTC C0182 ..................................................... 5-183
Water Deflector Replacement OTC· C0236 .... .... .... .. ...... ... .. .... ... ... .. .. .. .. ... . .. . ... 5-185
Door ......................................................... 8~918 DTC C0237 ..................................................... 5-188
Weatherstrip Replacement DTC C0238 . ..... .... ... .... ..... ... .. ..... ... .. .. .. .. ... ... .. .. . 5-190
Door ....................................................... ,.. 8,931 OTC C0239 ..... ... .... .... ..... ... .. .... ... ... . ... .. .. ... .. . ... 5-192
Window Regulator Motor Replacement ......... 8-928 DTC C0240 .. ..... ... ... ..... .... ... .. ..... .. ... . ... .. ... .. .. .. . 5-194
Window Regulator Replacement ................... 8-927 DTC C0241 ..................................................... 5:.195
Window Replacement ............................... ;... 8-928 DTC C.0244 ..................................................... 5-199
) Drain Channel. Replacement .......................... 8~1001
Drain Cock Replacement (Engine Cooling) ...... 6-652
DTC C0245 . ..... .... ... ... .. .... ... .. ..... ... .. .. .. ... .. ... .. .. . 5-202
DTC C0266 .... .... .... ... ..... ... ... .. .. ... .. .. .. .. .... .. .. ... . 5-205
Draining and Filling Cooling System DTC C0550 .. ..... ... ... ...... .. .... ... .... ... . ... .. ... .. .. .. .. . 5-208
(Engine Cooling) ................... 6-608, 6s609 DTC C0896 . ..... .... ... .... .... ... ... .... .. ... .. .. ... .. ... .. .. . 5-209
Drive. Belt Replacement - 3.8L ...................... , ... 6-47 DTC C0901 ..................................................... 5-21.1
DrumlRotor Imbalance ....................................... 0-50 DTC P0101 ..................................................... 6-857
DTC 12 ............................................................ B-536 DTC P0101 ................................................... 6-1411
DTC 21/31 ....................................................... 8~103 DTC P0102 ...................................................... 6-861
DTC 22/32 .. . ... .... ....... ... .... .. ..... ... ... ...... . 8-105, a~108 DTC P0102 ................................................... 6-1416
DTC 23/33 ·····················································" 8-759 DTC P0103 ......................................... 6-864, 6-1420
DTC 24/34 .......................................................... 9-8 DTC P0107 ......................................... 6-867, 6-1423
DTC 25/35 ........................................................ 8-687 DTC P0108 ......................................... 6-870, 6-1427
DTC 41 ..........................................................• 8-653 DTC P0112 ...................................................... 6-872
DTC 42 .. .. ... .. ....... .. ..... ..... ........ ... .. ... ...... ... ...... 8-654 DTC P0112 .................................................... 6-1431
DTC 43 . ... .. ... .. ...... .. ... .... .......... ............. .... •..... 8-655 DTC P0113 , ........................................ 6-874, 6-1434
DTC 44 ........................................................... 8-656 DTC P0117 ......................................... 6-877, 6-1438
DTC 45 .. ... ... .. .......... ... .. ........ .... ............. .... .... . 8-.657 DTC P0118 ......................................... 6-879, 6-1441
DTC 55 ........................................................... 8-538 DTC P0121 ................................................... 6-1445
DTC BOO 16 ....................................................... 9~38 DTC P0122 ................................................... 6-1449
DTC B0017 ..................................................~ ... ·; 9-41 DTC P0123 ................................................... 6-1453
DTC B0018 ....................................................... 9-44 DTC P0125 ......................................... 6-882, 6-1457
DTC 80022 ........................................................ 9~47 DTC P0131 ......................................... 6-885, 6-1460
DTC 80024 ....................................................... 9-50 DTC P0132 ......................................... 6-887, 6-1463
DTC 80026 ....................................................... 9-53 DTC P0133 ......................................... 6-890, 6-1467
DTC 80051 ....................................................... 9-56 DTC P0134 ......................................... 6-893, 6-1471
DTC 80053 ...................................................... , 9-57 DTC P0135 ......................................... 6-896, 6-1475
DTC 80670 ....................................................... 9..:58 DTC P0137 ......................................... 6-899, 6-1478
DTC B1000 ................................................ ,.... 8-5313 DTC P0138 ..................................................... 5..:902
DTC B·1000 ..................................................... 8-563 DTC P0138 ................................................... 6-1482
DTC 81001 ....................................................... 9-59 DTC P0140 ..................................................... 6-905
DTC C0035 .. .. ... ...... .... ..... ........ ........... ... ... ..... .. 5-130 DTC P0140 ................................................... 6-1486
DTC C0036 ..................................................... 5-133 DTC P0141 ..................................................... 6-908
DTC C0040 ·················································-'··· ·5-136 DTC P0141 ................................................... 6-1490
DTC C0041 ..................................................·... 5-139 DTC P0151 ......................................... 6-911, 6-1493
8 INDEX
OTC P0152 ..................................................... 6-913 OTC P0453 ................................................... 6-1013
OTC P0152 ................................................... 6-1496 OTC.P0453 ................................................... 6-1660 (
OTC P0153 ......................................... 6-916, 6-1500 OTC P0461 ................................................... 6-1665
OTC P0154 ..................................................... 6-919 OTC P0462 .................... ,.................. 6-1015, 6-1668
OTC P0154 ............................................... ; ... 6-1504 OTC P0463 ....................................... 6-1017, 6-1671
OTC P0155 ......................................... 6-922, 6-1508 OTC P0480 ....................................... 6-1020, 6°1675
OTC P0157 .................................................... 6-1511 OTC P0481 ................................................... 6-1023
OTC P0158 ................................................... 6-1515 OTCP0481 ................................................... 6-1678
OTC P0160 ................................................... 6-1519 OTC P0500 .... , .................................. 6-1026, 6-1681
OTC P0161 ................................................... 6-1523 OTC P0502 ................. , ...... ,........ , .... , .... 7-128, 7-131
OTC P0171 ......................................... 6-925, 6-1526 OTC P0503 ...... :. ................................... 7-134, 7-137
OTC P0172 ......................................... 6-928, 6-1529 OTC P0506 . . .. . . ... . . .. . ... . .. . . . . . . . .. .. . .. .. .. . .. .. . .. . . . . . 6-1028
OTC P0174 ......................................... 6-931, 6-1532 OTC.: P0506 . . .. . . .. . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-·1683
OTC P0175 ...................................................... 6~934 OTC P0507 . .. .. . ... . . .. . .. . . .. .. . .. . . .. . . . . . . .. . . . .. .. . .. .. .. 6-1030
OTC P0175 ................................................... 6-1535 OTC P0507 ..........,; ........................................ 6-1686
OTC P0200 . . . . . . . . . . . . . . ... . . . . .. . . . . . . . . . . . . . . . . .. . . . . . . . . . . 6-1538 OTC P0530 .................................................... 6-1689
OTC P0201 ..................................................... 6~937 OTC.P0530 ................................................... 6-1032
OTC P0202 .. .. . .. .. . . .. . .. . .. . . .. . . . . . . . . . . . . . .. . . . . . . . .. . . . . . . 6~940 OTC P0560 . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1035
OTC P0203 . . . . . . .. . . . . .. . .. .. . . .. . .. . . . . . . . .. . . . . . . . .. . . . . . . . . . 6-943 OTC ·po562 ..............................................·..... 6-·1692
OTC P0204 .. . . . . . . . . . . . .. .. . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . 6-946 OTC P0563 . . . . . . .. . . . .. . .. . . . ... . . . . .. . .. . .. .. .. . . . . .. . .. .. . . 6-1694
OTC P0205 .. . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . .. . . . . .. . 6-949 OTC P0567 . . . . . . .. . . . . . . .. . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6~1038
OTC P0206 . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ... . . . . . . . . 6-952 OTC P0568 . . . . . . .. . . . .. . .. . . . . . . . . . . . . . . . .. .•.. . . . .. . . . .. . . . . 6-1040
OTC P0218 ........................................... 7-122, 7-125 OTC P0571 ................................................... 6-1042
OTC P0230 . . . . . . . . . . . . .. . . . . . . . . . . .. . . . . .. . . . . . . . . . .. . . . . . .. . 6-1542 OTC P0601 ............................ ,.......... 6-1046, 6-1696
OTC P0230 . . . . . . . . . . .. .. . . . . . . . . . . . . . .. . . . . . . . . .. . . . . . . .. . .. . . . 6-955 OTC P0602 ....................................... 6-1047, 6-1697
OTC P0300 . . . . . . . . . . . ... . . . . . . .. . . .. . . . . .. . . . . . .. . . .. . . . . . . . . 6-1545 OTC P0604 .................................. ,....... : ........ 6-1047
OTC P0300 . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . .. 6-958 OTC P0604 . . . . . . .. . .. . . . . . . .. . . . . .. . . .. .. .. .. . . . . . .. .. .. .. . .. 6-1698
OTC P0325 . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-963, 6-1550 OTC P0606 ......•... : ........................................ 6-1048
OTC P0327 . . . . .. . .. . . .. . . . . . . . . . . . . . . . . . . . . •. . . .. .. 6-965, 6-1552 OTC P0608 .............. .-, ......................... ,......... 6-1699
OTC P0332 . . . . . . . . . . .. . . . . . . . . . . . . . . ... .. . . . . . . .. . . . . . . . . . . . . . . 6-968 OTC·P0620 ................................................... 6-1049
OTC P0332 . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . .. . . .. . . . . . . . . 6-1555 OTC P0645 ....................... : ......................... :. 6-1702 (
OTC P0335 ............................................. : . . . . . 6-1558 OTC P0650 .... ;: ................ :. ............... 6-1051, 6-1705
OTC P0336 ......................................... 6-971, 6~1562 OTC P0704 ....................................... , 6-1054, 6-1707
OTC P0341 . .. . . .. . .. . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . 6~97 4, 6-1565 OTC P0711 ....................................... : ... 7-141, 7-145
OTC P0342 . . .. . . . . . .. . . . . . . . . . . . .. . . .. . . . . . . . . . .. . . . . . . . . . . . . 6-1568 OTC P0712 ....................... : ....... ; ........... 7-149, 7-152
OTC P0343 ................................................. , . . 6-1572 OTC P0713 ........................................... 7-155, 7-159
OTC P0351 ................................................. :. 6-1576 OTC P0719 ........................................... 7-163, 7-166
OTC P0352 . . . . . . . . . . . . . .. . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . 6-1580 OTC P0724 ............................................. 7-169, 7-1T1
OTC P0353 . .. .. . .. .. . .. . .. .. .. . . . . . . .. . . .. . .. . . . . . . . . . . . . . . . . 6-1584 OTC P0740 ........................................... 7-173, 7-177
OTC P0354 ................................................... 6-1588 OTC P0742 ........................................... 7-181, 7-184
OTC P0355 .. . . . . . . . . . . . ... . . . . . .. . . . .. . . . . . . . . . . . .. . .. . . . . . . . 6-1592 OTC P0748 ........................................... 7-187, 7-191
OTC P0356 .. .. . .. . . . . . . . .. . . . . . . . . . . .. . . . . . . . . . . . . . . . .. . . . . . . 6-1596 OTC P0751 ........................................... 7-195, 7-198
OTC P0357 . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . 6-1600 OTC P0752 ..................................................... 7-200
OTC P035.8 .. . . .. . . .. . . . . . . . . . . . . . . . . . . . . .. . . . .. . .. . . . . . . . . . . . 6-1604 OTC P0753 ........................................... 7-202, 7-206
OTC P0401 ......................................... 6-978, 6-1608 OTC P0756 ..................................................... 7-213
OTC P0403 ................................................ : . . . . 6-980 OTC P0756 ..................................................... 7-2·10
OTC P0404 ................................................... 6-1610 OTC· P0757 ..................................................... 7-2t5
OTC P0404 .. . . . . . .. . . . . .. . . .. . .. .. .. .. . . .. . .. . .. .. . . . . . . . . . . . . . 6-983 OTC P0758 ........................................... 7-217, 7-221
OTC P0405 ................................................... 6-1613 OTC P0785 .. .. .. .. . . .. . . .. . .. .. .. .. . .. .. . .. .. .. . . .. .. 7-225, 7-229
OTC P0405 .. .. . . .. . .. . .. .. . . . . . . . . . .. . . . . . . . . . . . . . . . .. . . . . . . . . . 6s986 OTC P0801 .................................................. , 6-1710
OTC P0410 ................................................... 6-1617 OTC P0803 . . . . . . .. . . . .. . .. ... .. . . . . .. . . .. .. .. . . .. .. . . .. . . . .. . 6-1713
OTC P0412 ................................................... 6-1623 OTC P1106 .................................................... 6-1057
OTC P0418 ................................................... 6-1626 OTC P1107 .................................................... ·6-1059
OTC P0420 ......................................... 6-989, 6-1629 OTC P1111 .................................................... 6~1061
OTC P0430 ................................................... 6-1631 OTC P1111 .................................................... 6-1716
OTC P0440 . . . .. . .. .. .. ... . .. .. .. . .. .. .. .. .. . .. .. . . . 6-992, 6-1633 OTC P1112 .................................................... 6,1719
OTC P0442 ......................................... 6-997, 6-1639 OTC P1112 .................................................... 6-1063
OTC P0443 ................................ ,................ ,. 6-1001 OTCP1114 .................................................. ,. 6-1722
OTC P0443 .................................................... 6-1645 OTC P1114 .................................................... 6-1065
OTC P0446 .. . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1004, 6-1648 OTC P1115 ........................................ 6-1067, 6-1725
OTC P0449 ................................................... 6-1007 OTC P1120 .................................................... 6-1069
OTC P0449 . . . . . . . . . . . . . . . . . . . . . ... . . . . . . . . . . . . . .. . .. . . . . . . . . . 6-1652 OTC P1121 .................................................... 6-1728
OTC P0452 ................................................... 6-1010 OTC P1122 .................................................... 6-1731
OTC P0452 . . . . . . . . . . . . . . . . . . ... . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . 6-1655 OTC P1125 .................................................... 6-1073
INDEX 9
DTC P1133 ....................................... 6-1074, 6-1734
DTC P1134 .................................................... 6-1077
E
) DTC P1134 .................................................... 6-1737 Emblem Replacement
Front Bumper Fascia ................................... 8-770
DTC P1153 .................................................... 6-1740
End gate Latch Replacement . . ... .. .... ... .. . .. . .. .... 8-1105
DTC P1153 .................................................... 6-1080 Engine Compression Test ................................ 6-272
DTC P1154 .................................................... 6~1743 Engine Compression Test (3.8L) ........................ 6-23
DTC P1154 .................................................... 6-1083 Engine Controls - 3.8L
DTC P1220 ................................................... 6-1086 Component Views ........................................ 6-812
DTC P1221 ................................................... 6-1090 Components ... .... .. .... . .. ...... . . ... ... ... ... ... .. .. .. ... . 6-807
DTC P1258 ................................................... 6-1746 Connector End Views ... .. ... .. ... ... ... .. ... . .. . ... .. . . 6-818
DTC P1271 ................................................... 6-1093 Description
DTC P1272 ......................................... :......... 6-1094 Air Intake System ................................... 6-1322
DTC P1273 ................................................... 6-1095 Crankcase Ventilation System (3.8L) ....... 6-1321
DTC P1275 ................................................... 6-1096 Electric Engine Cooling Fan .................... 6-1305
Electronic Ignition System .................... ,.. 6-1314
DTC P1276 .. .. .. ... .. . ...... .. . .. .. .. .•... .... .. . ... ....... .. 6-1098
EVAP Control System (3.8L) ............. , ..... 6-1312
DTC P1280 ................................................... 6-1100 Exhaust Gas Recirculation · ·
DTC P1281 ................................................... 6-1102 System (3.8L) ............................... 6~1320
DTC P1285 ................................................... 6-1104 Fuel Metering Modes ofOperation .......... 6-1309
DTC P1286 ................................................... 6-1106 Fuel Metering System
DTC P1336 ....................................... 6-1108; 6-1747 Component (3.8L) ......................... 6-131 O
DTC P1351 ................................................... 6-1109 Fuel Supply Component .......................... 6-1306
DTC P1352 ................................................... 6-1111 Information Sensors/Switches .................. 6-1300
DTC P1361 ................................................... 6°1113 Knock Sensor System (3.8L) .................. 6-1318
DTC P1362 ................................................... 6-1116 Long Term Fuel Trim ............................ ,. 6~1312
DTC P1374 ............. , ..................................... 6-1119 Short Term Fuel Trim ............................. 6-1312
Throttle Actuator Control
DTC P1380 ......................... :............. 6-1122, 6-1750
System Description ....................... 6-1321
DTCP1381 ................................................... 6-1123 Diagnosis · ·
DTC P1381 ................................................... 6-1751 Alcohol/Contaminants-in-Fuel ................... 6-1226
DTC P1404 .............. ,................................ ,.,. 6-1752 Backfire ............................................... ,...6-11.85
DTCP1404 ................................................... 6-1125 Cranks but Does Not Run ........................ 6-847
DTC P1415 ........ ~ .......................................... 6-1756 Cruise Control .. . ... .. ... ..... ... . .... .. .. .. . .. .. .. . .. 6-1205
DTC P1416 .............................................. ,.... 6-1758 Cuts Out, Misses .................................... 6-l177
DTC P1441 ....................................... 6-1128, 6-1760 Data Link Connector .................................. 6-845
DTC P1514 ................................................... 6-1132 Detonation/Spark Knock ....................... ,. , 6-1175
DTC P1515 ................................................... 6-1134 Diagnostic Starting Point ................. , ....... :. 6-826
DTC P1516 ................................................... 6-1137 Diagnostic Trouble Code (OTC) List/Type ... 6-839
Diagnostic Trouble Code (DTC) Type
DTC P1517 ................................................... 6-1140
Definitions ....................................... 6-838
DTC P1518 ................................................... 6-1141 Dieseling, Run-On ................................... 6-1185
DTC P1519 ............................................. ::: ... 6-1144 Electric Cooling Fan ..... 6-1197, 6-1198; 6-1199,
DTC P1523 ................................................... 6-1145 6-1200, 6~1202
DTC P1546 ....................................... 6-1146, 6-1764 Engine Oil Level Sensor/Switch ...............6-1210
DTC P1571 ................................................... 6-1149 EV AP Control System ... . ... . .... .. . ... .. . .. ... ... 6-1228
DTC P1574 ................................................... 6-1151 Fuel Injector Balance Test ...................... 6-1217
DTC P1586 ................................................... 6-1154 Fuel Injector Balance Test with Tech 2 ... 6-1220
DTC P1626 ....................................... 6~1157, 6-1767 Fuel Injector Coil Test ............................ 6-1222
DTCP1629 ................................................... 6-1159 ECT Between 10-35 Degrees C ........... 6-1222
DTC P1635 ............................................. ;..... 6-1161 ECT Outside 10-35 Degrees C ........... : 6-1224
Fuel Pump Relay Circuit .................... , ...... 6-854
DTC P1635 ................................................... 6-1770
Fuel Quality ............................................ 6-1226
DTC P1637 ................................................... 6-1775 Fuel System ............................................. 6-856
DTC P1639 ................................................... 6-1778 Fuel System Pressure Test ..................... 6~1212
DTC P1639 ................................................... 6-1164 Fuel Tank Leak Check ........ , ............... : ... 6~1226
DTC P1689 ................................................... 6-1166 Hard Start ............................................... 6-1169
DTC P1810 ........................................... 7-233, 7-237 Hesitation, Sag, Stumble ......................... 6-1176
DTC P1860 ........................................... 7-241, 7-245 Inspection/Maintenance Status Reset ·
DTC P1870 ................................ ,........ ,. 7-249, 7-255 Procedures ................................... 6-1231
DTC U1000 and DTC U1255 ............. , ............... 8-23 Lack of Power, Sluggishness,
DTC U1001 - U1254 ......................................... 8-26 or Sponginess . .. . .. .. .. .. ... . .. . ... ... .. .. . 6-.1174
Manifold Absolute Pressure ·
DTC U1300 ................................... ,;.................. 8-28
Sensor Circuit ............................... 6-1194
DTC U1301 ....................................................... 8-29
10 INDEX
Engine Controls - 3.8L (cont.) Engine Controls - 5.7L (cont.)
Diagnosis (cont.) Diagnosis (cont.)
No Malfunction Indicator Lamp ..... ,....... :.... 6-843 Engine Oil Level Sensor/Switch .............. 6-1815
Poor Fuel Economy ................................ 6-1180 Engine Speed Output Circuit ................... 6-1829
Poor Fuel Fill Quality .............•................ 6-1181 Fuel Injector Balance Test with
Powertrain Control Module ...................... 6-1188 Special Tool ............................. ,:,. 6-1821
Powertrain Control Module Fuel Injector Balance Test with Tech 2 ... 6-1818
Controlled Air Conditioning ............ 6-1189 Fuel Injector Coil Test ...... , ...... , .............. 6-1824
Powertrain On Board Diagnostic ECT Between 10-35 Degrees C ........... 6-1824
System Check ............. :.. ..... .... .. .. ... 6-827 ECT Outside 10-35 Degrees C ...... .', .... 6-1826
Restricted Exhaust System Check . .. .. ... .. 6-1186 Fuel Pump Relay Circuit ..... ,.............. '. .... 6-1402
Rough, Unstable, or Incorrect Idle, Fuel System ............... ,......... , ................. 6-1406
Stalling .... .. .. ... .. .... .. .... .. ..... .. ... ... .. . 6-1183 Fuel Tank Leak Check ... , .................. '. ..... 6-1828
Scan Tool Data Definitions ....................... 6-832 Hard Start ................... :., ......................... 6-1783
Scan Tool Data List .. : ............................... 6-828 Hesitation, Sag, Stumble ....................... :: 6-1789
Service Bay Test .................. :................. 6-1231 Ignition Relay .. ,.................................... :.;'6~1399
Surges/Chuggles ................•.................... 6-1172 Inspection/Maintenance Status Reset
Symptoms .............................................. 5c1168 Procedures .................................. ; 6-1836
Emission Hose Routing Diagram .................. 6-788 Intermittent Condition .............................. 6-1781
Powertrain Control Module Lack of Power, Sluggishness, or ·
Connector End Views ......... , ........... 6-814 Sponginess ................. ,. ... .. ... .. ..... . 6-1785
Schematic PCM Controlled Air Conditioning ..... :....... 6-1946
Icons . .. .. . .. .. ... .... .. .. .. .... ... .... .. .. .. ... .... .. ... .... 6-790 PCM Controlled Generator ... , .................. 6-1810
Schematics ............................................... :.. 6-791 PNP Switch ........................... , ............ : ... ·6-1812
Special Tools .............................................. 6-1322 Poor Fuel Economy ..... " ..... ,.. , ............ , ... 6-1791
Specifications Poor Fuel Fill Quality ... :............... ,.... ,, .... 6-1793
Fastener Tightening ···············.'.·················· 6-786 Powertrain On Board Diagnostic
Fuel System ............................................. 6-787 System Check ..... ; ........................ 6-138.1
Temperature vs Resistance ...................... 6-786 ·Rough, Unstable, or Incorrect Idle,
Engine Controls - 5.7L Stalling ................................. , .. , .... 6-1795
Component Views .. .. ... .. .. .. .... .. .. . ... .. ... ... .. ... 6-1354 Scan Tool Data Definitions .. : .................. 6-1386
Components .. ... .... .. .. .. ... ... .... .. ... .... .... ... .. .... 6-1348 Scan Tool Data List .............................. ;. 6-1383
Connector End Views ................................. 6-1372 Service Bay Test .................................... 6-1836
Description Surges/Chuggles ......................... :.......... : 6-1784
Air Intake System ................................... 6-1967 Symptoms ................... ;: ... , ...... :.............. 6-1781
Crankcase Ventilation System ................. 6-1965 Vehicle Speed Output Circuit ., ................ 6-1$31
Electronic Ignition System ....................... 6-1958 Electronic Ignition System ........................ ::. 6-1833
Engine Cooling Fan- Electric ........... ,,_ ...... 6-1947 Emission Hose Routing Diagram ........... ,... , 6-1328
EV AP Control System ..................... ·........ 6-1954 Powertrain Control Module ·
Exhaust Gas Recirculation System .......... 6-1963 Connector End Views . ,................. 6-1368
Fuel Metering Modes of Operation .......... 6-1951 Repair
Fuel Metering System ·Component ... .. ... .. 6-1952 AIR Solenoid Valve Replacement .......... i. 6-1_926
Fuel Supply Component .......................... 6-1947 Heated Oxygen Sensor (H02S) . ·
Information Sensors/Switches .................. 6-1938 Replacement Bank 1 Sensor 1 ...... 6-1846
Knock Sensor System ............................. 6-1961 Heated Oxygen Sensor (H02S)
Long Term Fuel Trim .............................. 6-1954 Replacement Bank 1 Sensor 2 ...... 6-1847
Secondary Air Injection System ........•...... 6~1962 Heated Oxygen Sensor (H02S) ·
Short Term Fuel Trim ............................. 6-1953 Replacement Bank 2 Sensor 1 .. .. .. 6c1849
Speed Density System .. .. . .. . .. . ..... ... ... .. .... 6-1954 Heated Oxygen Sensor (H02S} · ·
Diagnosis · Replacement Bank 2 Sensor 2 .....'. 6-1851
A/C Refrigerant Pressure Sensor Circuit .... 6-1801 Schematic ·
A/C Request Circuit ................................ 6-1799 Icons ........................................ , . ... . .... .. .. . 6-·1328
Alcohol/Contaminants-in-Fuel ................... 6-1828 Schematics ................ ,............. , .. '. .... , ......... 6-1329
Backfire .................................................. 6.:1796 Secondary AIR Injection Shut Off ..
Cuts Out, Misses ............................... : ... : 6-1789 Valve Replacement, ................. "··· 6-1923
Detonation/Spark Knock .. .... ... .. .... .... .. .. .. . 6-1788 Special Tools ................................... ,..... : ...·. 6-1969
Diagnostic Starting Point ......................... 6-1380 Specifications
Diagnostic Trouble Code (DTC) Fastener Tightening ............ :: .................. 6-1325
List/Type ....................... , ............... 6c1391 Fuel System ........................................ : .. 6:1326
Diagnostic Trouble Code (OTC) . GM SPO Group Numbers .... :: ................. 6-1326
Type Definitions ,........................... 6-1390 Temperature vs Resistance ...... , .............. · 6-1325
Dieseling, Run-On ................................... 6-1796 Engine Coolant Temperature Sensor
Electric Cooling Fan ............................... 6-1803 Replacement (3.8L) ....................... 6-1235
Engine Cranks but Does Not Run ........... 6-1396
INDEX
Engine Coolant Temperature Sensor Engine Electrical (cont.)
Replacement (5.7L) ....................... 6-1841 Diagnosis (cont.)
Engine Coolant Temperature Sensor Battery Visual Inspection ........................... 6-693
Replacement Diagnostic Starting Point -
(Engine Cooling) .................. 6-650, 6-651 Engine Electrical ........................... ,. 6-686
Engine Cooling Engine Cranks/Cranks Slowly,
Component Views ........................................ 6-599 but Does Not Start ................ , .. .. .. .. 6-690
Components ...................... , .............. ,........... 6-598 Generator Assembly Check .. .. •... .. .. .. . .. .. ... 6-706
Connector End Views ... .... .......... .. ... .. .... ... .... 6-600 Generator Not Operating Properly ............. 6-704
Description Spark Plug Visual ..................................... 6-707
Air Baffles and Seals ................................ 6-673 Spark Plug Wire Harness ......................... 6-709
Coolant ....................................................·. 6-669 Starter Motor Noise ............................ ,..... 6-691
Coolant Heater .. .. .. ... .... .. .. ... ... ... .. .. ... .. .... .. 6-670 Starter No Load Test .............................. ,. 6-692
Coolant Recovery System ......................... 6-669 Starter Solenoid Clicks,
Cooling Fan Relay ............ ,....................... 6-672 Engine Does Not Crank .................. 6-688
Cooling System .............. ,......................... 6-669 Starter Solenoid Does Not Click .. .. . .... .. ... . 6-687
Electric Engine Cooling Fan ...................... 6-671 Symptoms - Engine Electrical ................... 6-686
Engine Coolant Temperature Sensor ........ 6-672 Generator Brace Replacement ..................... 6-763
Radiator Assembly ............................... , .... 6-670 Generator Bracket Replacement ....... 6-761, 6-762,
Radiator Filler/Pressure Cap Assembly ..... 6-671 6-763
Thermostat ............................................ ,.. 6-672 Generator Replacement .. .. ... .. ... .. .. . .. .. 6·764, 6-766
Throttle Body Coolant System .................. 6-670 Generator Splash Shield Replacement ......... 6-769
Water Pump ............................................. 6-672 Ground Strap Replacement ...................... ;... 6-759
Diagnosis Ignition Coil Module Replacement ..... ,.......... 6-777
Coolant Concentration Testing ............... , .. 6-604 Ignition Coil Replacement .................. 6-775, 6-776
Cooling System Leak Testing ........ : .......... 6-606 Schematic
Engine Fails To Reach Normal Starting and Charging Icons ..................... 6-676
Operating Temperature ................... 6-604 Schematics
Loss of Coolant ...... .. .. . .. ...... .... ... .. .... ... ... .. 6-602 Starting and Charging ..................... ,......... 6-677
Overheating .......................... , ................... 6-601 Spark Plug Replacement .................... :.. .. ..... 6-77 4
Pressure Cap Testing ............................... 6-608 Spark Plug Wire Harness
Thermostat ................................... ,........... 6-604 Replacement ............. 6-770, 6-772, 6-773
Schematic Special Tools .. .. ... .. .. .. .. .. .. .. .. . .. .. ... ... . .. .. . .. .. .. . 6-785
Cooling Fan ............................. , ............ ·.... 6-596 Specifications
Cooling System Icons .. .. .... ... .. . .. .. .. .. .. .. ... .. 6-595 Battery Temperature vs Voltage Drop ....... 6-675
Special Tools ............................................... 6-673 Battery Usage Table .: ............................... 6-674
Specifications Fastener Tightening .................................. 6-67 4
Engine Cooling System .............. ,.............. 6-594 Generator Usage .: .................... ,............... 6-675
Fastener Tightening .................................. 6-594 GM SPO Group Numbers ......................... 6-676
GM SPO Group Numbers ......................... 6-594 Spark Plug Usage Table ........................... 6-675
Engine Diagnosis Spark Plug Wire Resistance .................... , _6-676
Exhaust Leakage ...................... , ................ 6-1976 Starter Motor Usage Table ............... : ....... 6-675
Engine Electrical Starting and Charging Component Views ..... 6-682
Component Locations .. ..... ....... .. ... .. . .... ... .. .. .. 6-680 Starting and Charging
Description Connector End Views ..................... 6-686
Battery ...................................................... 6-781 Underhood Fuse Block (UBEC) .
Battery Operation ......................................- 6-781 Replacement ................... ,.. ... .... ... .. 6-741
Battery Tray and Hold-Down Retainer ....... 6-782 Engine Exhaust
Charging System ...................................... 6~782 Catalytic Converter Replacement............ ,... 6-1980
Charging System Circuit .. ...... .. .. ... .. .. .. ... ... 6-783 Converter Hanger Assembly
Charging System Operation ...................... 6-783 Replacement ....... 6-1991, 6-1992, 6-1993
Ignition System .............................. 6-783, 6-784 Converter Heat Shield Replacement ........... 6-1998
Ignition System Operation ......................... 6-784 Description
Starting System ........................................ 6-780 Catalytic Converter ............................... , . 6-2003
Starting System Circuit ............................. 6-780 Clamps .. ... .. .. .. .. ... ... ... ... . .. . ... •.. .. ... . ... .... ... 6,2003
Starting System Operation ........................ 6-780 Exhaust System ... .. .. .. .. ... .. ... .... .. .. .. ... .. . ... 6-2003
Diagnosis Hangers ............................ ,..................... 6°2003
Battery Common Causes of Failure .......... 6-692 Muffler .................................................... 6-2003
Battery Hydrometer Displays Dark or Diagnosis
Yellow Dot .. .. ..... .. .. .. .. .. ..... .... .. .. ... .. . 6-700 Exhaust Noise ........................................ 6-1975
Battery Hydrometer Displays Yellow Dot ... 6-694 Internal Muffler Rattles/Loss of Power ..... 6-1976
Battery Load Test - Parasitic .................... 6-700 Restricted Exhaust .. .. .. ... ... .. ... .. ... . .. .. ... ... . 6-197 4
Battery Not Operating Properly ...... ... ...... .. 6-696 Vibration or Rattling ................................ 6-197 4
Battery Terminal Check ............................. 6-693 Engine Mount Heat Shield Replacement .... 6-1997
12 INDEX
Engine Exhaust (cont.) Engine Mechanical - ;3.8L (cont.)
Exhaust Crossover Pipe Replacement ........ 6-1977 Description (cont.)
Exhaust Pipe and Muffler Heat Shields Lubrication .......·......................................... 6-242 (
Replacement .. ... .. ..... ... ... ... .... .. .. . ... 6-2000 Replacing Engine Gaskets ....... , ................ 6-243
Heat Shield Replacement ........................... 6-1999 Separating Parts ......... ,................ ,............ 6-244
Muffler Hangers Replacement ........ 6-1995, 6-1996 Service Precautions .................................. 6-244
Muffler Replacement .................................. 6-1986 Thread Repair ................................... ,., .... 6-218
Oxidation Catalytic Converter Tools and Equipment ................................ 6-245
Replacement .................... 6-.1983, 6-1985 Use of RTV and Anaerobic Sealer ....... , .... 6-243
Specifications Diagnosis
Exhaust System Clearances . ... ..... .. .... .. .. 6-1973 Base Engine Misfire ............... ; ..............•.... 6-21
Fastener Tightening ................................ 6-1972 Cylinder Leakage Test ................................ 6-31
GM SPO Group Numbers ....................... 6-1972 Drive Belt Tensioner ...........•............... , .. ... .. 6-42
System Inspection ......... , ......... , .................. 6-1976 Engine Compression Test ...... ,,,, ............... ,. 6-23
Engine ID and Partial VIN Location ..... , ...... 0-9, 0-10 Engine Noise ............................. ;....... 6-23, 6-25
Engine Mechanical - 3.8L Oil Consumption .,, .... , ........... ,........... , .. ,.... ,. 6-28
Balance Shaft Oil Leak .......... ,.................. :................. , ....... 6-29
Bearing and/or Bushing Installation ........... 6-216 Oil Pressure Diagnosis and Testing ......•. ,... 6-28
Bearing and/or Bushing Removal .............. 6-216 Symptoms - Drive Belt .......... , .................. ,. 6-31
Clean and Inspect .................................... 6-216 Disassembled Views .............. ,.............•....... ,. 6-43
Installation (Off-Vehicle) ............................ 6-223 Draining Fluids and Oil Filter Removal
Balance Shaft Removal (Off-Vehicle) ............ 6-183 (Off-Vehicle) .................................... 6-170
Camshaft Drive Belt
Bearing Installation (Off-Vehicle) ............... 6-203 Diagnosis ................................................. ,. 6-32
Bearing Removal (Off-Vehicle) .................. 6-201 Chirping Noise .................. ,.•........... , ..... ,. 6-32
Camshaft and Bearings Clean and Excessive Wear ,................... ,., ............. ,. 6-42
Inspect (Off-Vehicle) ....................... 6-202 Falls Off ............................ ,..................... 6-40
Installation (Off-Vehicle) ............................ 6-223 Rumbling .............. ,............... , ..•..•..; .......... 6-37
Removal (Off-Vehicle) .....,........ ,................. 6-183 Squeal ............... ,.......... ,....•...•. ,............... ,. 6-34
Replacement ......................... , .................. 6-121 Vibration .. ,................ ,........ ,...... ,, ......... .,, 6-38
Crankshaft Whine ......................................:.····:·'········· 6-36 (
Balancer Clean and Inspect ...................... 6-194 Idler Pulley Replacement ......... ,, ................. 6-49
Balancer Installation (Off-Vehicle) .............. 6-239 Replacement .............................................. 6-47
Balancer Removal (Off-Vehicle) ......... ,...... 6-170 Tensioner Installation (Off-Vehicle) ..... ,...... 6-238
Balancer Replacement .......... ,.. .. ... .. .. .. .. ... . 6-105 Tensioner Removal (Off-Vehicle) ............... 6-172
Crankshaft and Bearings Removal Tensioner Replacement ............................ ,, 6°48
(Off-Vehicle) ................................... 6-187 Engine Block
Crankshaft and Bearings Clean and Clean and Inspect (Off-Vehicle) .... ,........... 6-189
Inspect (Off-Vehicle) ....................... 6-192 Plug .Installation ........................................ 6-219
Crankshaft and Bearings Installation Plug Removal (Off-Vehicle) ...... ,................ 6-188
(Off-Vehicle) ................................... 6-219 Engine Flywheel
Front Cover Oil Seal Replacement ........... 6-108 Installation (Off-Vehicle) ·········,·······.··········· 6-239
Front Oil Seal Installation (Off-Vehicle) ..... 6-230 Engine Front Cover Clean and Inspect ... ,.... 6-215
Front Oil Seal Removal (Off-Vehicle) ........ 6-179 Engine Front Cover Installation
Rear Oil Seal and Housing Installation (Off-Vehicle) ............................ ,., ..... 6-229
(Off-Vehicle) .............. ,.................... 6-225 Engine Front Cover Removal (Off-Vehicle) ... 6-180
Rear Oil Seal and Housing Removal Engine Mount
(Off-Vehicle) ................................... 6-184 Bracket Replacement ..... ,............................. 6-59
Rear Oil Seal and Housing Replacement ..... 6-135 Inspection ................................................. ,. 6-50
Rear Oil Seal Installation (Off-Vehicle) ...... 6-226 Replacement ............................................ ,. ·5.51
Rear Oil Seal Removal (Off-Vehicle) ......... 6-184 Engine Replacement ....... ,............................ 6-137
Cylinder Boring and Honing ......................... 6-191 Engine Support Fixture .................................. 6-50
Cylinder Head Exhaust Manifold
Assemble ................................................. 6-21 O Clean and Inspect ............... ,.................... 6-214
Clean and Inspect .................................... 6-206 Installation (Off-Vehicle) ................. 6~232, 6-234
Disassemble .. ..... .. .. .... . ...... .... ..... .... .... .. ... . 6-205
Removal (Off-Vehicle) .................... 6-176, 6-177
Installation (Off-Vehicle) ............................ 6-231
Removal (Off-Vehicle) ............................... 6-179 Replacement ..................................... 6:82, 6-87
Replacement .................................. 6-123, 6-125 Flywheel
Description Replacement ............................................ 6-133 (
Cleanliness and Care ............................... 6-243 Flywheel Clean and Inspect ......................... 6-195
Components .. .... .... ..... .... ... .... .. ... .. .... .. . ..... 6-241 Flywheel Removal (Off-Vehicle) ......... 6-171, 6-172
Drive Belt System Description .............•..... 6-241 Front Cover Oil Seal Replacement ............... 6-108
Installation Precautions ............................. 6-245 Front Cover Replacement ... , ........................ 6-109
INDEX 13
Engine Mechanical - 3.8L (cont.) Engine Mechanical - 3.8L (cont.)
Intake Manifold Valve
Clean and Inspect .................................... 6-214 Lifter Removal (Off-Vehicle) ..... , .. ,............. 6-179
Installation (Off-Vehicle) ................. 6-234, 6-235 Rocker Arm and Push Rod Removal
Removal (Off-Vehicle) .................... 6-174, 6-175 (Off-Vehicle) .................... : .............. 6-178
Replacement ..................................... 6-68, 6-80 Rocker Arm CoverRemoval (Off-Vehicle) ... 6-178
Oil and Oil Filter Replacement ......... ,.......•... 6-168 Valve Guide Reaming/Valve and Seat .
Oil Filter Grinding ......................................... 6-208
Adapter and Valve Assembly Valve Lifter Installation (Off-Vehicle) ............. 6~230
Installation (Off-Vehicle) .................. 6-228 Valve Lifter Replacement ................ :.... , ........ 6-104
Adapter and Valve Assembly Va.Ive Lifters and Guides Clean and Inspect .... 6-205
Removal (Off-Vehicle) ..................... 6-181 Valve Rocker Arm and Push Rod ·
Adapter and Valve Assembly Installation (Off~Vehicle) ., .......... ,... ,. 6-231
Replacement .................... , ............. 6-116 •Valve Rocker Arm and Push Rod
Oil Level Indicator and Tube Installation · Replacement . ... ... .... .. ..... .. .. ... .... ... .. .. 6-99
(Off-Vehicle) .................................... 6-238 Valve Rocker Arm and Push Rods
Oil Level Indicator and Tube Removal Clean and Inspect .. , ... ,.u, ....... :....... 6-204
(Off-Vehicle) ................................... : 6-172 Valve Rocker Arm Cover Clean and
Oil Level Indicator and Tube Replacement ..... 6-68 Inspect ........................ ,.............. ,... 6-213
Oil Pan Valve Rocker Arm Cover Installation ·
Clean and Inspect .................................... 6-213 (Off-Vehicle) .................................... 6-232
Installation (Off-Vehicle) ............................ 6-222 Valve Rocker Arm Cover Replacement .... 6,93, 6-97
Removal (Off-Vehicle) ............................... 6-185 Valve Stem Oil Seal. and Valve Spring
Replacement ............................. , .... 6-101
Replacement ... .. ....... .. .. .... .............. .......... 6-127
Water Outlet Installation (Off-Vehicle) ............ 6-238
Oil Pump
Water Outlet Removal (Off-Vehicle) .............. 6-173
Clean and Inspect .................................... 6-211
Water Pump
Cover and Gear Set Installation
Clean and Inspect .................................... 6-215
(Off-Vehicle) ................................... 6-228
Cover and Gear Set Replacement ............ 6- i 16 Installation (Off-Vehicle) ............... :......... ,., 6~237
Pipe and Screen Assembly Installation ..... 6-222 Removal (Off-Vehicle) ..................... ,......... 6-173
Pipe and Screen Assembly Removal Engine Mechanical - 5.7L
(Off-Vehicle) ................................... 6-185 Balancer, Crankshaft, Replacement .............. 6-353
Pipe and Screen Assembly Replacement .... 6-133 Camshaft . ·
Oil Pump Cover and Gear Set Removal. Bearing Installation ....................... , ..: .... ,..•. 6-484
(Off-Vehicle) .................................... 6-181 Bearing Removal .............................. ,, ...... 6-479
Piston and Connecting Rod Assemble .......... 6-200 Camshaft and Bearings Clean and
Piston and Connecting Rod Disassemble ..... 6-195 Inspect ........................... :............... 6-481
Piston, Connecting Rod, and Bearing Installation (Off-Vehicle) ............................ 6-538
Installation ............. ,........................ 6-220 Removal (Off-Vehicle) .....................'.......... 6-446
Piston, Connecting Rod, and Bearing
Replacement ................. ,................... ··•·.... 6-382
Removal (Off-Vehicle) ..................... 6-186
Piston, Connecting Rod and Bearings Clutch Pilot Bearing Installation
(Off-Vehicle) ..... ,.............................. 6-575
. . Clean/Inspect ...................... ,........... 6-196
Clutch Pilot Bearing Removal (Off0 Vehicle) ... 6-421
Piston Selection ............................................6-198
· Crankshaft
Rear Oil Seal and Housing Replacement ..... 6-135
Balancer Clean and Inspect ...................... 6-467
Service Prior to Assembly .......... ,................. 6-218
Special Tools ................................................ 6-245 Balancer Installation (Off-Vehicle) .............. 6-577
Specifications .............. ,.............. ;..... . ............. 6-16 Balancer Removal (Off-Vehicle) .... , ........... 6-419
Fastener Tightening ............... ,.................... 6-15 Balancer Replacement .... ,........ , ................ 6-353
GM SPO Group Numbers ........................... 6-18 Crankshaft and Bearings Clean and
Sealers, Adhesives, and Lubricants ............ 6-19 Inspect .............................. ,: .. ;........ 6-458
Crankshaft and Bearings Installation
Timing Chain
(Off-Vehicle) ...................... :.. :...... ". 6-532
Timing Chain and Sprockets
Clean and Inspect ................ ,....... :. 6-203 Crankshaft and Bearings Removal
(Off-Vehicle) .............................. : .... 6-449
Timing Chain and Sprockets Installation
(Off-Vehicle) ................... : ... ;........... 6-227 Front Oil Seal Installation (OffNehicle) ., ... 6-548
Timing Chain and Sprockets Removal Front Oil Seal Replacement ...................... 6-356
(Off-Vehicle) .......... , .......... :.... ,... :;.,. 6-181 Rear Oil Seal Installation (Off-Vehicle) .,, ... 6-545
Timing Chain and Sprockets Rear Oil Seal Replacement ... , .................. 6-366
Replacement .................................. 6-120 Cylinder Boring and Honing (Off-Vehicle) ..... 6-456
14 INDEX
Engine Mechanical - 5.7L (cont.) Engine Mechanical - 5.7L. (cont.)
Cylinder Head Flywheel
Assemble . . .. .. ....... . ... .. .. ... .. ... .. .. .. .. .. .. ... .. .. . 6-497 Clean and Inspect .................................... 6-468
Clean and Inspect .................................... 6-491 Installation (Off-Vehicle) ............................ 6-576
Disassemble ... ..... .. ... .. ... .... .. ... .. ... ..... .. .. ... . 6-489 Removal (Off-Vehicle) ............................... 6-420
Installation (Off-Vehicle) ................. 6-553, 6-555 Replacement (5.7L) .................................. 6-384
Removal (Off-Vehicle) .................... 6-437, 6-438 Front Cover
Replacement .................................. 6-348, 6-350 Clean and Inspect .................................... 6-508
Description . Installation (Off-Vehicle) ............................ 6-546
Cleanliness and Care ............................... 6-585 Removal (Off-Vehicle) ............................... 6-442
Drive Belt System Description .. ... .... ... .. .. ... 6-582 Replacement ............................................ 6-357
Engine Components .. . ... . .. . ... . . ... ... .... .. ... .. . 6-580 Fuel Rail and Injectors Installation
Identification .. ...... .. ... .. .. ..... .. ... . .... ..... .. .. ... . 6-583 (Off-Vehicle) .................................... 6-568
Installation Precautions ............ :................ 6-587 Fuel Rail and Injectors Removal
Lubrication . .. .. ...... .. .. ... .. .... ... .. .. .... ..... .. .. . ... 6-584 (Off-Vehicle) ...................... ,............. 6-427
New Product Information .......................... 6-582 GM SPO Group Numbers ............................ 6-254
Replacing Engine Gaskets ........................ 6-585 Intake Manifold
Separating Parts ....................................... 6-587 Clean and Inspect .................................... 6-514
Thread Repair ........................... , .............. 6-520 Installation (Off-Vehicle) ............................ 6-564
Tools and Equipment ................................ 6-587 Removal (Off-Vehicle) ............................... 6-428
Use of RTV and Anaerobic Sealer .... ,. ... .. . 6-586 Replacement ............................................ 6-311
Diagnosis Oil and Oil Filter Change ............................. 6-416
Base Engine Misfire ....... ,.......................... 6-270 Oil Filter
Engine Compression Test ......................... 6-272 Oil Filter, Adapter, Pan Cover
Engine Noise ............................. , .............. 6-272 · Installation (Off-Vehicle) .................. 6-551
Oil Consumption ....................................... 6-276 Oil Filter, Adapter and Pan Cover
Oil Leak ......................... ,............. , ........... 6-276 Removal (Off-Vehicle) ..................... 6~439
Oil Pressure Diagnosis and Testing .......... 6-276 Oil Level Indicator and Tube
Symptoms - Drive Belt., ............................ 6-278 Installation (Off-Vehicle) ............................ 6-574
Valve Train ............................................... 6-274 Removal (Off-Vehicle) ............................... 6-422
Disassembled Views . .. .. .. .. .... ... . .. .. . .. .. .. .... .. .. 6-290 Replacement ............................................ 6-339 (
Draining Fluids and Oil Filter Removal Oil Pan
(Off-Vehicle) .................................... 6-417 Clean and Inspect ............... ,.................... 6-511
Drive Installation (Off-Vehicle) ........ ,.; ................. 6-548
Diagnosis ............................................ , .. ,. 6~284 Removal (Off-Vehicle) ............................... 6-440
Rumbling .......................... ,............. ,...... 6-284 Replacement ............................................ 6-370
Drive Belt Oil Pump
Diagnosis .................•............................... 6-279 Assemble ................................................. 6-505
Chirping Noise ...................................... 6-279 Clean and Inspect ........... ,........................ 6-503
Excessive Wear .................................... 6-289 Disassemble ............................................. 6-.501
Falls Off . .. .. .... ... .. ... .. .... .. .. .. . .... ... ... . ... ... . 6-287 Oil Pump, Pump Screen and Deflector
Squeal ................................................... 6-281 Installation (Off-Vehicle) .................. 6-541
Tensioner .............................................. 6-289 Oil Pump, Pump Screen and Deflector
Vibration .................................. ,. .... . ... ... . 6-285 Removal (Off-Vehicle) ..................... 6-444
Whine .. . .. ... ... .... .. ... . ... ..... .. . ... .... .... . ... ... . 6-283 Oil Pump, Pump Screen and Deflector
Engine Block Clean and Inspect Replacement .................................. 6-379
(Off-Vehicle) ..................................... 6-455 Piston and Connecting Rod Assemble .......... 6-476
Engine Block Plug Installation ....·.................. 6-529 Piston and Connecting Rod Disassemble ..... 6-468
Engine Block Plug Removal (Off-Vehicle) ..... 6-451 Piston, Connecting Rod, and Bearing
Engine Mount Installation (Off-Vehicle) .................. 6-535
Inspection ................................................. 6-302
Removal (Off-Vehicle) ..................... 6-447
Replacement .................................. , 6-303, 6-307 Piston, Connecting Rod and Bearings
Engine Set-Up and Testing .......................... 6-579 Clean/Inspect ............ 6-470, 6~472, 6-475
Engine Support Fixture ................................ 6-302 Piston Selection ........................................... 6-475
Engine Mechanical (5.7L) ........ , ............. 6-302 Rear Cover
Exhaust Manifold Clean and Inspect .................................... 6-508
Clean and Inspect .................................... 6-517 Installation (Off-Vehicle) ............................ 6-542
Rear Cover
Installation (Off-Vehicle) ................. 6-569, 6-571 Removal (Off-Vehicle) ............................... 6-443 (
Removal (Off-Vehicle) .................... 6-422, 6-424 Rear Cover
Replacement .................................. 6-342, 6-345 Replacement ............................................ 6-367
INDEX 15
Engine Mechanical - 5.7L (cont.) Engine Mount
Repair Replacement (3.8L) .............................. : ...... ,.. 6-51
) Drive Belt Idler Pulley Replacement - AIC .... 6-299 Replacement (5.7L) ........................... 6~303, 6-307
Drive Belt Idler Pulley Replacement - Engine Oil Level Sensor Replacement .... 8-631, 8-633
""' Accessory ............. ... ....... ....... ......... 6-299 Engine Oil and Oil Filter Change (5.7L) ........... 6-416
Drive Belt Replacement - AIC .. .. .. .. ... .. ..... . 6-298 Engine Oil and Oil Filter Replacement (3.8L) ... 6-168
Drive Belt Replacement - Accessory ......... 6-296 Engine Oil Life Monitor - Resetting ....... , ............ 0-39
Drive Belt Tensioner Replacement - A/C ... 6-301 Engine Oil Life Monitor Reset
Drive Belt Tensioner Replacement - Procedure (5.7L) ......................... ,. 6-1931
Accessory ................................ ,... .. . 6-300 Engine Replacement (3.8L) ............................. 6-137
Replacement .. ,....... :..................................... 6-385 Engine Replacement (5.7L) ............................. 6-385
Service Prior to Assembly ..... :............. ;........ 6-528 Engine Support Fixture (3.8L) .................. , ........ , .6~50
Special Tools ............. :................................. 6-588 English/Metric Conversion Table .......................... 0-3
Specifications Entertainment
· Engine Mechanical ................. '. ......... , ....... 6-251 Amplifier Replacement .............. ,.: ...... 8°338, 8-339
Fastener Tightening .... ,............................. 6-249 Antenna Mast Cleaning ................................ 8-351
Sealers, Adhesives, and Lubricants .......... 6-255 Antenna Mast Replacement
Thread Repair ........... ,........... ,.................. 6-257 Fixed ............................................... ·.... . .. .. 8-348
Throttle Body Installation (Off-Vehicle) .......... 6-568 Power . .... .. .... .... ... .. .. .. ... ... ... .. . ... ... .. .. .. . ... . .. 8-349
Throttle Body Removal (Off-Vehicle) ............. 6-426 Antenna Motor Replacement
Timing Chain Power .. .... ... ... ... ... .. .. ... . .. .. ... .. .. ... .. .. .. .. .. .. ... 8-350
Timing Chain and Sprockets Antenna Replacement
Clean and Inspect .......................... 6-485 Fixed . .... .. ... .... .... .. . .. ... ... .... .. . .. ... ... .. .. .. .. .. .. 8-349
Timing Chain and Sprockets Installation Cassette Player
(Off-Vehicle) ................................... 6-539 Cleaning Tape Head and Capstan ........ ,... 8-341
Timing Chain and Sprockets Removal Cassette Player Care and Cleaning ..............8-340
(Off-Vehicle) .............. ,....... ,... ,........ 6-445 CD Changer Replacement
Timing Chain and Sprockets ' Remote .. : ..................................... ,. 8-342, 8-344
Replacement ........................... ,...... 6-380 Compact Disc Care and Cleaning ................ 8-346
Valley Cover Component Locations ................. ,.. .. . . .. .. ... .. .. 8~286
) Clean and Inspect .................... ,............... 6-508 Component Views .............................. , .. .. . .. . . 8-288
Installation (Off-Vehicle) ........... '. ................ 6-562 Connector End Views ......................... : ......... 8-299
Removal (Off-Vehicle) ................... ,.... ,...... 6-432 Description
Replacement ............... ,., .... ,......................6-325 Cassette Tape Player Operation .............. 8-365,
Valve Guide ReamingNalve and · 8°366, 8-367
Seat Grinding ................................. 6-493 Compact Disc Player Operation ... :. 8~368, 8-370
Valve Lifter Power Antenna System ............................ 8-375
Installation (Off-Vehicle) ............. ,., ............ 6-552 Power Antenna System Circuit ... ,... ,, ......... 8-375
Removal (Off-Vehicle) ..................... : ... : ..... 6-438 Radio Controls Operation ... 8-360, 8~361, 8-362,
Replacement .............................. ,. ............ 6-352 . 8-364, 8-365
Valve Lifters and Guides Clean and Radio/Audio System ....................... 8-358, 8-359
Inspect ....................... ,....... .'........... 6-487 Radio/Audio System Circuit ....................... 8.~374
Valve Rocker Arm and Push Rod · Steering Wheel Controls System Circ.uit .... 8-375
Installation (Off-Vehicle) :: .......................... 6-557 Steering Wheel Controls
Removal (Off-Vehicle) ............................... 6-436 System Operation .............. :'. ........... 8-374
Replacement ..................... ,..... ...... ...... ..... 6-334 Theftlock Operation ...... :...... :: ........ :.... :...... 8-373
Valve Rocker Arm and Push Rods Diagnosis · . .
Clean and Inspect .................................... 6-486 Antenna Inoperative ....... ,.: ................. ,...... 8~310
Valve Rocker Arm Cover · Antenna Poor Reception ..... " ....... , ............ 8-311
Clean and Inspect ....... , ............................ 6s509 Compact Disc Inoperative ......................... 8-313
Installation (Off-Vehicle) ..... ,...... ,.... 6-559, 6-560 Diagnostic Starting Point -
Entertainment ..................... ,.. '......... 8-309
Removal (Off-Vehicle) .................... 6-433, 6"434
One or More Speakers . ..
Replacement., .............. : ........ ,........ 6-326, 6-332 Inoperative .... 8-321, 8-322, 8~324, 8-325,
Valve Stem Oil Seal and Valve 8-326, 8-327, 8-328, 8-329,
Spring Replacement ....................... 6-335 8-330, 8-331, 8-332
Vapor Vent Pipe Clean and Inspect ........... :. 6-519 Radio Display Inoperative,
Vapor Vent Pipe Installation (Off-Vehicle) ...... 6-563 No Sound from Speakers ,.. ... .. .. . .. .. 8-315
Vapor Vent Pipe Removal (Off-Vehicle) ........ 6-431 . Radio Display Inoperative,
Vapor Vent Pipe Replacement ...................... 6-324 Speakers Operative ........ ,................ 8-314
Water Pump Radio Illumination Inoperative with
Clean and Inspect ................................ ,... 6-519 Park Lamps On .............................. ~F315
Installation (Off-Vehicle) ............................ 6-569 Radio Memory Inoperative ........................ 8-314
Removal (Off-Vehicle) ............................... 6-426 Speaker General ...................................... 8-319
16 INDEX
Entertainment (cont.)
Diagnosis (cont.)
F
Speaker Noise .......................................... 8-319 Fan (
General ................................................. 8-319 Cooling Fan Relay Description ..................... 6-672
Speakers Inoperative - Subwoofer ............ 8-333 Cooling Fan Relay Replacement
Steering Wheel Controls Illumination (Engine Cooling) ............................. 6-633
Inoperative ...................................... 8-317 Electric Cooling Fan Replacement
Steering Wheel Controls Inoperative ......... 8~317 (Engine Cooling) ............................. 6-627
Symptoms - Entertainment ........................ 8-309 Electric Engine Cooling Fan Description ....... 6-671
Tape Player Inoperative ............................ 8-316 Electric Engine Cooling Fan Motor
Radio Replacement ........................... 8-334, 8-336 Replacement .................................. 6-633
Schematic Shroud Replacement (Engine Cooling) ......... 6-652
Icons ...................................•.................... 8-273 Fasteners ........................................................ ,. 0-17
Power Antenna ......................................... 8-285 Filter Replacement
Radio/Audio System ........... 8-274, 8-275, 8-277, In-Line Fuel (3.8L) ..................................... 6-1253
8-280, 8-282, 8-283 In-Line Fuel (5.7L) ..................................... 6-1869
Steering Wheel Controls ........................... 8-284 Finish Panel Replacement
Speaker Grille Replacement Upper Rear Trim ........................................ 8-1070
Rear .............................................. 8-356, 8-357 Floor Panel Reinforcement Replacement ....... 8-1175
Speaker Replacement .................................. 8-352 Fluid Capacities, Approximate ............................ 0-34
Front ........................................................ 8-353 Fluids and Lubricants, Recommended ............... 0-34
Rear ......................................................... 8-354 Flushing (Engine Cooling) ............................... 6-609
Special Tools ............................................... 8-375 Flywheel Replacement (3.8L) .......................... 6-133
Specifications Flywheel Replacement (5.7L) ........................ ;. 6-384
Fastener Tightening .................................. 8-272 Fog
Switch Replacement
GM SPO Group Numbers ......................... 8-272
Rear ......................................................... 8-174
Steering Wheel Control Switches Fog .Lamp .................................. 8-194, 8-196, 8-197
Replacement .................................. 8-346 Bulb Replacement
EVAP Front ........................................................ 8-198
Canister Purge Solenoid Valve Rear ...................................... , .......... ·........ 8-199 (
Replacement (5.7L) ....................... 6-1903 Relay Replacement ................................ , ..... 8-178
Canister Purge Valve Replacement (3.8L) ..... 6-1285 Replacement
Canister Replacement (3.8L) ...................... 6-1289 Rear ......................................................... 8-198
Canister Replacement (5. 7L) ...................... 6-1912 Switch Replacement
System Cleaning (3.8L) .............................. 6-1290 Front ............................................. 8-172, 8-173
System Cleaning (5.7L) .............................. 6-1914 Folding Top
System Hoses/Pipes Replacement (3.8L) ... 6-1288 Adjustment ................................................... 8-969
Arm Replacement .... ... .. ..... .. .... .. .. .. ... 8-992, 8-997
System Hoses/Pipes Replacement (5.7L) ... 6-1906
Bow Link Replacement ...................... 8-971 , 8-973
Vent Valve Replacement (3.8L) .................. 6-1286 Pivot Bracket Replacement ................. ,........ 8-988
Vent Valve Replacement (5.7L) .................. 6-1905 Side Front Weatherstrip Replacement ........ 8-1011
Evaporator Core Replacement .. ... ... ...... .. .... ... .... 1-79 Side Rail Assembly Replacement ................. 8-991
Evaporator Tube Replacement .......................... 1-69 Side Rail Link Replacement ......................... 8-980
Exhaust Gas Recirculation Side Rail Replacement .............................. , .. 8-974
Pipe Replacement (5.7L) ............................ 6-1927 Stowage Compartment Lid
System Cleaning (5.7L) .............................. 6-1928 Latch Replace .................. 8-1005, 8-1006
Valve Replacement (3.8L) .......................... 6-1296 Weatherstrip Retainer Replacement ............ 8-101 O
Folding Top Bow Replacement ... 8-952, 8-958, 8-964,
Valve Replacement (5. 7L) .......................... 6-1926
8-966, 8-968
Exhaust Manifold Replacement (3.8L) ...... 6-82, 6-87 Folding Top Cylinder Replacement .................. 8-950
Exhaust Manifold Replacement (5. 7L) ... 6-342, 6-345 Folding Top Pump with Motor Replacement ..... 8-949
Expansion (Orifice) Tube Filter Replacement ..... 1-70 Frame
Exterior Trim Floor Panel Reinforcement Replacement .... 8-1175
Description Frame and Underbody
Adhesive Retained Molding and Emblem .... 8-775 Description
Centerline ............................................... 8-1187
Molding/Nameplate Replacement ...... 8-765, 8-766,
Datum .................................................... 8-1187
8-767, 8-768, 8-769 General .................................................. 8-1187
Specifications
Diagnosis
GM SPO Group Numbers ......................... 8-764 Alignment Checking ................................ 8-1149
Washing and Waxing ................................... 8-774 Checking Frame to Body Alignment ........ 8-1149
Weld Stud Replacement ............................... 8-77 4 Special Tools .............................................. 8-1187
INDEX 17
Frame and Underbody (cont.) Fuel Tank
Specifications Draining Procedure (3.8L) .......................... 6-1254
) Asymmetrical Reference Points ............... 8-1148 Draining Procedure (5.7L) .....·.. ,................. , 6-1870
Body Dimensions ................................. ;.. 8-1142 Pressure Sensor, Replacement (3.8L) ......... 6-1262
Fastener Tightening ................................ 8-1141 Pressure Sensor Replacement (5.. 7L) ......... 6-1878
Symmetrical Reference Points ............... , 8~1148 .Pump Module Replacement (5.7L) ............. 6-1881
Frame Dimensions ........................................ 8-1146 Replacement (3.8L) ............................. ,., ..... 6-1255
Front Bumper Fascia Emblem Replacement .... 8-770 Replacement (5.7L) ...................... , ............. 6-1870
Front Fender Fuel Tank Pump Module Replacement (3.8L) ... 6-1268
Rear Molding Replacement. .... :.................... 8-771 Fuse Block Access Cover Replac:emenL........... 8-631
Front Oil Seal Replacement (5.7L) .................. 6-356 Fuse Block Replacement -
Front Suspension Underhoo<:l (UBEC) ..... ,... , .... ,........... 6-741
Component Locations ............... ,.................... 3-16
Description
General ...................................................... 3-40
G
Garnish Molding Replacement
Diagnosis
.Liftgate ....................................................... 8-1109
Ball Stud Check ......................................... 3. 17
Windshield Pillar ........................................ 8-1069
Special Tools ............................................., ... 3.-41 General Description, Suspension Diagn'osis ...... :.. 3-9
Specifications Generator
Fastener Tightening .................................... 3-15
Assembly Check ...................... , ... , ............... 6-706
GM SPO Group Numbers .... ;............... , ..... ; 3°,15
Brace Replacement ...... :.. ... .. ... ... .. ..... .. . ... .... . 6-763
Front Weatherstrip Replacement .................... 8~1012 Bracket Replacement ............. 6-761., 6-762; 6-763
Fuel Fill Limiter Vent Valve Replacement ....... ;6-1263
Not Operating Properly ........................... :.... 6-704
Fuel Filler Door
Replacement .. ... .. .. .. .. .. .. .. ... .. .. . ... ... .. .. 6-764, 6-766
Replacement . ... .. .... ......... ...... .... ................. 8-1095 Splash Shield Replacement ...... :., ................. 6-769
Fuel Filler Hose Replacement (5.7L) ............ ,. 6-1893 Usage Specifications ... :.... :...... ,.. .. ..... .. .... .. .. . 6-675
Fuel Filler Pocket Replacement .............. , .... ,. 8-1095 Glass Surface Cleaning ...................... : .......... 8-1074
Fuel Filler Tube Replacement .................·'. ...... 6-1265 GM SPO Group Numl:>ers
Fuel Filter Replacement, In-Line (3.8L) .......... 6-1253 Anti lock Brake System ........... , ... .. .. .... . .... .... ... 5-97
Fuel Filter Replacement, In-Line (5.7L) :......... 6-1869 Engine Mechanical (5. 7L) ............................. 6-254
) Fuel Hose/Pipes
Assembly Replacement (5.7L) .................... 6-1892 H
Replacement Hard Top . .
Chassis (3.8L) ........................................ 6~1272 Headlin.er Replacement ......... ,..... ,... , ... ,......... 8-948
Fuel Hose/Pipes Replacement Hazard Lamp · ·· · . ;
Chassis (5.7L) ............................................ 6-1886 Flasher Replacement ... :, .............................. 8-180
Engine Compartment (3.8L) ........................ 6-1278 Headlamp ··
Engine Compartment (5.7L) ......... ,.............. 6-1891 Aiming ........ : ..................... , ................. 8~191, 8-194
Fuel Injector Replacement (3,8L) ................... 6-1284 Bezel Replacement ., ........... , .......... ,..... , ..... ,. 8-190
Fuel Injector Replacement (5.7L) ................... 6-1901 .Bracket Replacement ........................ 8-869, 8-870
Fuel Level Sensor Replacement (3.8L) .......... 6-1271 Bulb Replacement ................ , ..... /.................. 8-186
Fuel Level Sensor Replacement (5.7L) .......... 6-1879 Door Module. Replacement ........ ,.................. 8-176
Fuel Pressure Connection Valve · Housing Panel Replacement ..... 1................. ,. 8-868
Replacement (5. 7L) .................... ,.. ff·t896 Leveling Switch Replacement······; .... ,........... 8-171
MotoriActuator Replacement .....,.. ,........ , ...... ;. 8-189
Fuel Pressure Regulator Replacement (3.8L) .... 6-1283
Opening Door Adjustment .............. : ......... ,... 8-188
Fuel Pressure Regulator Replacement (5.7L) ... 6-1,900 Opening Door Replacement ................... .".... , .8-186
Fuel Pressure Relief Procedure (3.8L) ...... ,.... ,6-1247 Repiacement .......... , ................... ,..... .' 8-18"1, 8-183
Fuel Pressure Relief Procedure (5.7L) ....... ,... 6-1863 Switch Replacement .......................... 8~169, 8~.170
Fuel Pulse Dampener Replacement (5.7L) ..... 6~1886 Headlamps · ·
Diagnosis
Fuel Pump Relay Replacement (3.8L) ........... 6-1285
Headlamps Always On -
Fuel Pump Strainer Replacement (3.8L) ........ 6-1270 · Low or High Beam ......... , .... ,8-133, 8-134,
Fuel Rail Assembly Replacement (3.8L) ......... 6-1281 8-135, 8-136
Fuel Rail Assembly Replacement (5.7L) .. ,... ,.. 6-1897 Headlight
Fuel Sender Assembly Replacement (5.7L) .... 6-1883 Door Schematics . ... .. . .. .. ... ... .. .. ... .... .... .... ... ... . 8-50
Fuel Sender Assembly Replacement (3.8L) .... 6-1267 Leveling Schematic .................... , ..... , ............. 8-51
Headlights .
Fuel Strainer Replacement (5. 7L) .................. 6-1880 Schematics ........... ,.. .. ... . ... .. ... .. ... ..... .... . 8-38; .8-39
Fuel System Cleaning (3.8L) ......................... 6~1280 Headlights - DRL Schematics .... ; ..... 8-40,. 8-41, 8-43
Fuel System Cleaning (5.7L) ........... , ... , .. ,...... 6-1895 Headliner Cleaning ........................................ 8-1074
18 INDEX
Headliner Replacement Hinge Replacement
Hard Top ..................................................... 8-948 Hood ....... .... .... . .. .... .. ....... .. .. .. .. .. . ... .. .. ... ... .. .. 8-855
Headrest Motor Replacement · Rear Compartment Lid ........................ ,... .. . 8-1101 (
Front Seat ..................................... 8-1052, 8-1053 Rear Lift Window ....................................... 8-1100
Heat Shield Replacement · Hood
Converter .. ... . ......... ... . .... .... ... ... .. ... .... .... .. .. . 6-1998 Adjustment ................................................... 8-851
Engine Mount .......................... , .. ... .... .... .. .. . 6-1997 Assist Rod Ball Stud Replacement ............... 8-868
Exhaust Pipe and Muffler ............ .'.............. 6-2000 Assist Rod Replacement .............................. 8-867
Heater Bumper Replacement ................................... 8-852
Core Description (Non-A/C) . ... .. . .... .. .. •... .. ... ... . 1-89 Close Out Filler Replacement ............. ,......... 8-855
Core Replacement (Non-A/C) .. . ... ... .... ... .. ... .. .. 1-88 Hinge Replacement ...................................... 8-855
Hose Assembly Replacement .. ... .. .... ... .. 1-83, 1-85 Latch Release Cable Replacement ............... 8-863
Heater Replacement - Latch Replacement
Engine (Block) Coolant ........ 6-663, 6-664 Primary ..................................................... 8-858
Description Secondary ................................................ 8-862
A/C System .. .. .. .. .... ... . .... .... .. ... ... .. .... .. .... .. .. 1-89 Replacement ................................................ 8-852
Accumulator ............................................... 1-93 Hood Rear Seal Replacement ......................... 8-872
Compressor .. ... .... .... .. ... .... .. .. .. .. .... .. ... 1-94, 1-95 Hook Replacement, Tow ................... 8-1182, 8-1184
Condenser ...... . .... .... .... . ... .... ... .. ... ... ... .. .... .. . 1-93 Horn Replacement ........................................... 8°672
Evaporator .. ... . .... .... ..... ... . .... .. ... ... ... ... .. ... .... 1-93 Horns
Expansion (Orifice) Tube ............................ t-93 Component Locations ................................... 8-667
Handling A/C Compressor .. ... ... .. ... ... .. ... ... .. 1-92 Connector End Views ................................... 8-668
Handling Compressor Oil ............................ 1-91 Description
Handling of Refrigerant Lines and Circuit ....................................................... 8-674
Fittings .........................................·.... 1-91 Operation ................................................. 8-67 4
Handling Refrigerant R-134a .................. , .... 1-91 Diagnosis
High Pressure Relief Valve ......................... 1-97 Diagnostic Starting Point - Horns .............. 8-668
Maintaining Chemical Stability ..................... 1-92 Horns Always On ..................................... 8-669
0-Ring/Flat Washer .................................... 1-97 Horns Inoperative ......................... ,........... 8-670
Refrigerant Oil Distribution . ... .. ... ... .. .. ... ... ... . 1-92 Symptoms - Horns .................................... 8-668
Refrigerant R-134a ..................................... 1-91 Relay Replacement ...................................... 8-673 (
Refrigeration System .. . ... .... .. .. .. .. ... .. .. ... ... .. . 1-90 Schematic
Relays and Sensors .. ..... .. .. .. .. .. .... .. ... .. ... ... . 1-97 Icons .. ... .. .. .. .. .. . .. . ......... ... .... ... ... ... .. .... ... .. . 8-665
Diagnosis Schematics .................................................. ·8-666
CCOT A/C System ........................................ 1-5 Specifications
Cold Drafts on Floor .......................... ;........ 1-27 Fastener Tightening .................................. 8-665
Cooling Insufficient, A/C System ................. :. 1-7 GM SPO Group Numbers ......................... 8-665
Cooling Insufficient, A/C System - Hose Routing Diagram
Pressure Zone A .............................. 1~10 Emission (5. 7L) .......................................... 6-1328
Cooling Insufficient, A/C System - Hose Routing Diagram, Emission (3.8L) .......... 6-788
Pressure Zone B ............. : ................ 1-13 Hose-Inlet, Replacement, Radiator ........ 6-614, 6-617
Cooling Insufficient, A/C System - Hose-Outlet, Replacement, Radiator ..... 6-620, 6~623
Pressure Zone C .. .... .. ... ... ... .. ... .. ... .. . 1-16 Hub Cap
Cooling Insufficient, A/C System - Aluminum Wheel Hub Cap Replacement ........ 3-64
Pressure Zone D .............................. 1-18 Hub/Wheel Bearing Replacement, Front ., .......... 3-24
Defrosting Insufficient .... : ............................. 1-21 HVAC - Manual
Heating Insufficient ........................... :......... 1-21 Air Distributor Duct Replacement .................. i-137
Odor ................................................ ,..... :.... 1-27 Air Outlet Replacement - Floor ..................... 1-188
Odor Correction . .... . ... ..... ... .... .. .. .. . ... .. ... .. .. .. .. . 1-28 Air Outlet Replacement - Right Defogger ..... 1-138
Refrigerant Recovery and Recharging ... .... .. .. . 1-28 Air Outlet Replacement - Side Window ........ 1-139
Special Tools ................................................. 1::97 Blower Control Schematic .............. ,............. 1-103
Specifications Blower Motor and Fan Assembly
Fastener Tightening ...................................... 1-3 Replacement .................................. 1-125
Fitting and Line Tightening ........................... 1-3 Blower Motor Resistor Replacement ... .... ... .. . 1-124
GM SPO Group Numbers ............................ 1-4 Component Locations ......................... .:........ 1-106
Refrigerant Oil Distribution ............................ 1-4 Component Views ................................... :.... 1-108
System Capacities ....... :.. .. .. .. ... ... .. ... .. ... .. .. ... . 1-3 Compressor Control Schematic .. ... .. .. .. .. .. .. .. . 1-104
Heating and Ventilation (Non-A/C) Connector End Views ................................... 1-113
Description Control Assembly Replacement . .. .. .. .. .. .. .. .. . .. 1-126
Heater Core ...... .... .... .... ... ... ... .. ... .. ... .. ... .... . 1-89 Control Blower Switch Replacement .. .. .. ... .. .. 1-_129 (
High Mounted Stop Lamp Control Lamp Bulb Replacement .. .. .. .. .. .. .... .. 1-128
Replacement ....................... 8-204, 8-206, Control Lamp Bulb Wiring Harness
8-208, 8-210 Replacement .... .... .. ... .. ... . .. . .... . ... ... . 1-128
Hinge Pillar Trim Replacement ....................... 8-1062 Control Selector Switch Replacement .... ... .... 1-130
INDEX 19
HVAC - Manual (cont.) Hydraulic Brakes (cont.)
) Control Vacuum Harness Replacement ........ 1-142 Specifications .
Control Vacuum Valve Replacement ..... :: ...... 1-130 Brake System ...... ,, ....................................... 5-5
Defroster Valve Actuator Replacement .......... · 1-136 Fastener Tightening .......... :...... :.-................... 5-5
Description System Bleeding .... ,............... , .... : 5-44, 5:-46 1 5-47
Air Distribution System ...... ....... ..... .... ....... 1°144 . System Flushing ................... , ........... ,; ........... 5-47
Blower Controls Circuit ................ :............ F150 ·. Vacuum Brake Booster Hose Replacement .... 5-50
Blower Motor ... ........... .... .......... ... ............. 1-145 Vacuum Brake Booster Replacement ............. 5-48
Blower Motor Resistor ............. ; ............ , ... 1-145
Control Assembly ........................... 1-145, H47
Vacuum Hose Harness ............................. 1-149 I
Diagnosis Identification, Vehicle· .................... ,.,: ......... :......·... 0-5
A Diagnostic System Check ...................... 1-115 Idle Air Cont.rel Valve Replacement (5.7L) ...... 6-1854
AJC Compressor Clutch Does Not Idle Learn Procedure(5.7L) ........................... 6-1840
Disengage ........ ...... ....... .... ............. 1-118 Ignition Coil Replacement ............, ........ 6-775, 6-776
AJC Compressor Clutch Does Not Ignition Coil Module Replacement '. ..... ,............ , .6-777
Engage ..................................... :..... 1-116 Ignition Coil(s) Replacement (3.8L) ................ 6-1293
Air Delivery Improper ................................. 1-123 Ignition Control Module Replacement (3.8L) .... 6-1292
Diagnostic Starting Point ........................ , .. 1-115 Ignition Key Lock Cylinder Test ............ :, .. ; ...... 8-700
Symptoms ................................................ 1-115 Ignition System ·
Inside Air Valve Actuator Replacement ........ : 1-134 Description ............ '. .................. ,, . .. ... .. 6~ 783,< 6-784
Mode Valve Actuator Replacement , ...... ,. ..... . 1-136 Operation ................................. ,.......... :........ 6-784
Schematic Icons ........ :.... .. ............ .. .. ... ... .. .... 1-102 Important, Cauticm_,and Notice, Definition of ,,., ... , ... 3
Specifications Instrument Cluste'r · ·· · ·
Fastener Tightening .................................. 1-101 Description . . .
GM SPO Group Numbers ......................... 1-101 Circuit .................... •.......... ,: ........ :.. : .. :., .. :... 8-641
Temperature Control Cable Adjustment ......... 1-132 Gauge Operation . ... ...... ... .... .. . .......... 8-637
Temperature Control Cable Replacement .... ; 1~131 General .............................................. : ... : ..8-636
Vacuum Actuator Replacement ............ , ........ 1~135 Indicator Operation ......................... , ......... 8-638
Vacuum Hose Harness Replacement Instrument Panel
(A/C - Manual) ......................... ,..... 1-141 Carrier Replacement ................ , ..... ,... , ......... 8-601
Vacuum Tank Replacement (A/C- Manual) ..... 1-140 Cluster Replacement ............... ,., ............... ,.. 8-615
HVAC Control Lamp Replacement ..... , ............. 8-224 Compartment Door Lock Cylinder
Hydraulic Brake System Replacement ....... .... .. .. .. .... .. .. ... .. .. .. 8-599
Component Views ............................................ 5-9 Compartment Lamp Replacement ....... ,.. . ... .. 8-223
Components ......................................... ·: ......... , 5-8 Compartment Lat.ch Replacement .. .. .. .. .. .. ... .. 8-598
Connector End Views .. .. .. .. .. .. .. .... ..... .... .... .... . 5-11 Compartment Striker Replacement ,.. , . ,... ,, .... B:596
Schematic Icons ....................................... :...... 5-6 Description ............... ·............ : .....•·:················· 8_-635
Hydraulic Brakes Odometer Repair Label ..... ,................... ,... 8-636
Brake Hose Inspection ............................... ,... 5-38 Storage Compartment··ooo.t Replacement.: ... 8°597
Description Upper Trim Pad Replacement ...................... 8~599
Brake Fluid and Brake Fluid Handling .. :..... 5-53 Instrument Panel Compartment Lamp ·
Brake Warning System ............................... 5-54 Inoperative .. ... .. •.... . .... . .•. •. ... · ............ 8-149
Brake Warning System Circuit .................... 5-54 Instrument Panel, Gauges. and Console .
Master Cylinder ..................... :.. ... ....... .... .. .. 5-52 Audible Warnings Component Locations ., ..... 8-581
Vacuum Brake Booster .. .. ...... .. . .. .. .. ... . ... .... . 5-53 Description · ·
Diagnosis Audible Warnings ....................... '. .............. 8-643
Brake Fluid Leaks ...................................... 5-20 Audible Warnings Circuit ................ '. .. ,..,., .. 8-644
Brake Pedal Travel ..................................... 5-20 Console ................,.... ,.. ;.................... : ...... : .. 8~644
Brake System Testing ................................ 5-20 Diagnosis
Brake Warning Indicator Always On ........... 5-17 CHANGE ENGINE OIL Indicator
Brake Warning Indicator Inoperative ..... : ..... 5-18 Always On ........ :......... , ... ·; ........ : ..•... , 8-572
Diagnostic Starting Point - CHANGE ENQINE QIL ,indicat9r,. .•. . ..
Hydraulic Brakes .... , .... ; .................... 5-11 Inoperative ..... :.. :......... ,,:, .. :,., ....... ·.... 8-572
Diagnostic System Check ............... :.. :........ 5~11 CHECK GAGES lndibator Always On ....... 8-573
Master Cylinder .......................................... 5-21 CHECK GAGES Indicator Inoperative .. ::, .• 8-574
Symptoms - Hydraulic Brakes ............... ,..... 5~16 Diagnostic Starting Point O lr1stn.:iment
Front Brake Hose Replacement ......... :...... ..... 5-39 Panel, Gauges and Console ........... 8~561
GM SPO Group Numbers ................................ 5-5 OTC List ............................................... .'... 8-561
ISO Flares Replacement ..... ..... ... .... ............ ... 5-36 Engine Coolant Temperature Gauge
Pipe Replacement ...... ... ...... ........ ... ............. ... 5°36 Always Cold ...... :.... '. ....•..... : .......... ::, 8-564
Rear Brake Hose Replacement .... 5-40, 5-41, 5-43 Engine Coolant Temperature Gauge
Special Tools ................................................. 5-55 Always Hot ........ : ............................ 8°564
20 INDEX
Instrument Panel, Gauges and Console (cont.)
Diagnosis (cont.)
J (
Engine Oil Pressure Gauge Jacking and Lifting ............................................ 0~30
Always High ........................ 8-565, 8-566
Engine Oil Pressure Gauge
Always Low ... ... ... .. ... .... ... .... .. .... ... .. 8-567
K
Key Coding and Lock Cylinders ........................ 0-27
Engine Oil Pressure Gauge Inaccurate Keyless Entry
or Inoperative ................................. 8-567 Component Location .................................... 8-650
Fuel Gauge Always Indicates Empty ......... 8-568 Description
Fuel Gauge Always Indicates Full ............. 8-569 Keyless Entry System Operation ................ 8-662
Instrument Cluster Diagnostic Remote Keyless Entry System ............. , .... 8-662
Remote Keyless Entry System Circuit ..... ,.. 8-663
System Check .. ... .. ... .. .. .. ..... .. ... .... .. 8-562
Diagnosis
Low Engine Oil Level Indicator Courtesy Lamps Inoperative with
Always On ... ... ... ... .... ... .... .. .. .... .... .. . 8-57 4 Transmitter ..................................... 8-658
Low Engine Oil Level Indicator Diagnostic Starting Point -
Inoperative ...................................... 8-575 Keyless Entry ..... ,...... , .................... 8-652
Odometer Inoperative ............................... 8-569 Diagnostic System Check ... , ........ ,..........•. 8-652
OTC List ......................,. ............... ,,. ....... ,... .8-652
Odometer Inoperative - Trip ...................... 8-570
Remote Keyless Entry System
REDUCED ENGINE POWER Indicator Does Not Change Modes ............... 8~(358
Always On .. .... ... ... ... ... ... .... .. .... ... .. .. 8-576 Remote Keyless Entry System
REDUCED ENGINE POWER Indicator Inoperative .................................. ,." 8-659
Inoperative ...................................... 8-576 Symptoms - Key less Entry ......................,.. 8-658
Speedometer and/or Odometer Schematic
Inoperative ...................................... 8-570 Icons ............................... :.... , ....................8-646
Schematics ...................................•............,.. 8~647
Speedometer Inaccurate
Special Tools ...................................... , ........ 8-664
(J 38522 Available) ......................... 8-577 Specifications
Speedometer Inaccurate GM SPO Group Numbers ......................... 8-646 (
(J 38522 Unavailable) ..................... 8-578 Keyless Entry Transmitter Programming/
Symptoms - Instrument Panel, Synchronization .................... , ......... 8-661
Gauges and Console ... .. .... ... ... ... .. .. 8-563 Knee Bolster
Tachometer Inoperative ............................ 8-571 Deflector Replacement ....................... , ......... 8-590
Replacement
Volt Gauge Inaccurate or Inoperative ........ 8-571 Left .... .. . .... .. .. .. .... . .... .. ... ... ... . ... .... ... . ... ..... •. 8-590
Instrument Cluster Component Locations ..... 8-551 Knock Sensor Replacement (3.8L) .................. 6-1295
Instrument Cluster Component Views ........... 8-553 Knock Sensor Replacement (5.7L) .................. 6:1.9.18
Instrument Cluster Connector End Views ..... 8-560
Schematic
Audible Warnings ...................................... 8-580 L
Audible Warnings Schematic Icons ........... 8-579 Label
Anti-Theft Labeling ......................................... 0-14
Instrument Cluster Schematic Icons .......... 8-546
Service Parts ID .......................... ,.·................ 0-14
Schematics Label, Vehicle Certification .................................. 0-8
Instrument Cluster .................................... 8-547 Labels
Analog ................................................ :. 8-547 Replacement, How to Obtain ......................... 0-17
Special Tools ............................................... 8-645 Latch Replacement
Specifications Endgate ..............................·...................... ·. 8-1105
Fastener Tightening .................................. 8-545 Hood Primary ............................................... 8-858
Hood Secondary ................................. ,........ 8-862
Left ................................................................. 8-590
Instrument Panel Service Precautions .............. 8-585 License Lamp Replacement .......... ,....... 8-212, 8-214
Intake Air Temperature Sensor Lift Off Panel
Replacement (~.8L) ....................... 6-1240 Adjustment ..................................... ,........... 8~.1009
Intake Air Temperc1ture Sensor Weatherstrip Replacement .......................... 8-1015
Replacement (5.7L) ....................... 6-1853 Lift Panel Strut Replacement
Interior Trim Rear .......................................................... 8s tl02
(
Specifications Lift Window Panel Adjustment
Fastener Tightening ................................ 8-1061 Rear .......................................................... 8-1096
GM SPO Group Numbers ....................... 8-'1061 Lift Window Panel Hinge Replacement
Rear .......................................................... 8-1100
INDEX 21
Lift Window Panel Opening Weatherstrip Lighting Systems (cont.)
Replacement Diagnosis (cont.)
) Rear .. ... ..... .. ... .. .. ... .. ... .. ... .... . ..... .. .... ..... .. .. . 8-1110 Headlamps Inoperative In Low Light
Lift Window Panel Replacement Conditions ...................................... 8-142
Rear .. .. .. ..... ... ... .. ... ........ ..... .. ...... ..... ..... ... .. 8-i 097 Headlamps, Parklamps, DRL On with
Liftgate Garnish Molding Replacement ........... 8-1109 Park Brake Applied ......................... 8-143
Liftgate Lock Actuator Replacement ............... 8-1106 Headlight Doors Inoperative - One Door .... 8-145
Liftgate Lock Cylinder Replacement ............... 8-1 i 04 Headlight Leveling Inoperative .·... ,............. 8-147
Liftgate Trim Panel Replacement ................... 8-1091 Headlight Leveling Inoperative -
Lifting and Jacking . .. .... .. .... .. ......... ..... ............. .. 0-30 Actuator Switch Illuminated ............. 8-148
Lift-Out Panels Headlight Leveling Inoperative O
Mounting Hardware Replacement .. . 8-1003, 8-1004 One Actuator .................................. 8-146
Lighting Systems High Beam Indicator Always On ............... 8-148
Component Locations .................................... ·8-72 High Beam Indicator Inoperative ............... 8-149
Component Views . ......... ........... ..... ............... . 8-80 Instrument Panel Compartment Lamp
Connector End Views .................................... 8-95 Inoperative ...................................... •8-149
Description .. .... .. .. ... ......... .......... .... .. ............. 8-229 Instrument Panel Lamp
Backup Lights Circuit ................................ 8-237 Inoperative - One ........................... 8~151
Daytime Running Lamps Circuit .... 8-232, 8-233, Instrument Panel Lamps Do Not Dim ........ 8-150
. 8-234 Instrument Panel Lamps Inoperative ......... 8~150
Exterior Lights Circuit ..................... 8-235, 8-236 Park Lamps Inoperative ............................ 8-152
Fog Lights Circuit .... ,................................ 8-234 Left ....•...... " -'· ..... '" .... .... .. ... .. .... .. .. ... .. .... . 8-152
Headlight Doors Circuit ............................. 8-234 Right .............•....................................... 8-153
Headlight Leveling Circuit ......................... 8-234 Park/Turn Lamps Inoperative - Front ......... 8-154
Headlights Circuit ...................................... 8-232 Park/Turn Lamps Inoperative - One Front .... 8-154
Interior Lights Circuit ................................. 8-237 Position Lamps Inoperative ....................... 8-155
Interior Lights Dimming Circuit .................. 8-238 Left ....................................................... 8-155
Diagnosis Side Marker Lamp Inoperative .................. 8-156
Backup Lamp Inoperative - One ............... 8-114 One Lamp .............. -'· ............................. 8-156
Backup Lamps Always On .. ..... ..... ... .. ....... 8-i 12 Stop Lamps Always On ... .. ... ... .... .. ... .. ... ... 8-159
) Backup Lamps Inoperative ........................ 8-113 Center High Mounted ............................ 8-158
Courtesy Lamps Always On ................. :.... 8-1 i 5 Stop Lamps Inoperative ............................ 8-156
Courtesy Lamps are Inoperative with All ................................................ ; ........ 8-156
IP Dimmer Switch ........................... 8-117 CHMSL Operates ................................... 8-158
Courtesy Lamps Inoperative .. ..... .............. 8-116 One ...................................................... 8-157
Courtesy Lamps Inoperative with Symptoms - Lighting Systems .............. , .... 8-111
Doors Ajar ... ..... ........ ... .... .............. . 8-118 Tail Lamps Inoperative ............................. 8-159
Courtesy Lamps Inoperative with Let Rear .............................•.................. 8-159
Rear Compartrnent Lid Open ... ...... . 8~ 120 Right Rear ............................................ 8-160
Courtesy/Reading Lamps Always On ........ 8-121 Turn Lamps Always On .................... ,....... 8-165
Courtesy/Reading Lamps Inoperative ........ 8-121 Turn Signal and Hazard Lamps
Courtesy/Reading Lamps Inoperative Inoperative ................ : ..................... 8-163
with Lamp Switch .. ...... ...... ............. 8-118 Turn Signal Indicator Always On - Left ..... 8-165
Daytime Running Lamps Inoperative ......... 8-122 Turn Signal Indicator Always On - Right ... 8-166
Diagnostic Starting Point - Turn Signal Indicator Inoperative ............... 8-166
Lighting Systems .......... .... .............. 8-102 Left ....................................................... ·8-166
Diagnostic System Check ......................... 8-102 Turn Signal Inoperative ............................. 8-161
OTC List ..•.. ;, .. ~ ......................................... 8-102 Left Front ............................................... 8-161
Exterior Lamps Inoperative - All ................ 8-123 Turn Signal Lamp Inoperative ................... 8-163
Fog Lamp Indicator Inoperative ...... 8-131, 8-132 Left Rear ................................................ 8-163
Fog Lamp Switch Illumination Lamp Right Front ............................................ 8-162
Inoperative ...................................... 8-130 Right Rear ........................... :................ 8-164
Turn Signal Lamps Inoperative ... :............. 8-160
Fog Lamps Always On .. .. .. . ... . ...... .. ... ....... 8-124
VF Display Inoperative .... ,......................... 8-168
Fog Lamps Inoperative - All .......... 8-125, 8-126,
Radio ............... , .................................... 8-168
8-127
VF Displays Do Not Change with
Fog Lights Inoperative - One ................... 8-129 · Park Lamps On .............................. 8-167
Hazard Lamps Inoperative ........................ 8-132 Schematic
Headlamp Door(s) Inoperative ................... 8-144 Backup Lights ............................................. 8~66
Headlamps Inoperative " High Beam ......... 8-139 Exterior Lights ................. 8-52, 8~55, 8-58, 8-62
Headlamps Inoperative - Fog Lights ....................... 8-45, 8-46, 8-48, 8-49
Low and High Beams ..................... 8-14"1 Headlight Doors ............... :.......................... 8-50
Headlamps Inoperative - Low Beams ........ 8-137 Headlight Leveling .... ,.............. ,: ................. 8°51
Headlamps Inoperative - One Lamp .......... 8-140 Headlights ......................................... 8-38, 8-39
22 INDEX
Lighting Systems (cont.) Manual Transmission - M49 (cont.)
Schematic (cont.) Specifications (
Headlights - Daytime Running Lamps ........ 8-66, Fastener Tightening ...................................... 7-5
8-41, 8-43 GM SPO Group Numbers ............................ 7-5
Icons .......................................................... 8-37 Lubrication ................................................... 7-5
Interior Lights ............................................. 8-67 Support and Mount Assembly ........................ 7-15
Interior Lights Dimming ............................... 8-69 Vehicle Speed Sensor .................................... 7-21
Special Tools ............................................... 8-238 Manual Transmission - MM6
Specifications Backup Lamp Switch Replacement ................ 7,49
Bulb Usage ................................................ 8-36 Control Lever Handle Assembly ..................... 7-47
Fastener Tightening .................................... 8-35 Description ..................................................... 7s61
GM SPO Group Numbers ........................... 8-36 Diagnosis
Turn Signal Indicators Inoperative Clunk on Acceleration or Deceleration ........ 7-40
Right .. ,..................................................... 8-167 Gear Clash When Shifting Gears ................ 7-35
Lock Actuator Replacement Oil Leak ..................................................... 7-40
Liftgate . . .. . .. .. .. .. .. . .. .. .. .. .. . .. ... .. .. .. .. .. .. . .. .. .. . .. . 8-1106 Transmission Does Not Shift into
Lock Cylinder Replacement One Gear ......................................... 7-38
Liftgate . ... .. .. .. ... . ... .. . ... .. .. .. .. .. .. . .. .. .. . .. .. .. . .. . .. 8-1104 Transmission Jumps Out of Gear ............... 7-37
Lock Cylinders and Key Coding ........................ 0-27 Transmission Locked in One Gear .............. 7-39
Lock Striker Replacement Transmission Noisy .................................... 7-35
Rear Compartment ..................................... 8-1107 Transmission Shifts Hard ............................ 7-33
Lubricants and Fluids Recommended ................ 0-34 Transmission Shifts Hard into Reverse .... ,., 7-34
Luggage Screen Support Replacement .......... 8-1069 Fluid Level Check ............................ ,............. 7-41
Lumbar Bladder Replacement ........................ 8-1049 Gear Select/Skip Shift Solenoid
Lumbar Motor Replacement ........................... 8-1047 Replacement .................................... 7-52
Mainshaft Rear Oil Seal ................................. 7-48
Oil Drain and Fill ........................................... 7-53
M Replacement .... .... .... ..... ........ .. .. ... ... .... ... ....... . 7-54
Maintenance and Lubrication Reverse Lockout Solenoid Replacement ........ 7-51
Explanation of Scheduled Services ................ 0-37 Shift Control Assembly Replacement .............. 7-44
Maintenance Items ......................................... 0-35 Shift Control Boot Replacement ..................... 7-45 (
Maintenance Schedule ................................... 0-35 Shift Control Closeout Boot Replacement ....... 7-46
Owner Checks and Services .......................... 0-39 Shift Control Knob Replacement .................... 7-47
Periodic Maintenance Inspections ................... 0-41 Special Tools ............................. , ................... 7-62
Maintenance Items ............................................ 0-35 Specifications
Maintenance Schedule ...................................... 0-35 Fastener Tightening Specifications .............. 7-32
Manifold Absolute Pressure Sensor GM SPO Group Numbers ........... ,............... 7-32
Replacement (3.8L) ....................... 6-1237 Lubrication .................................................. 7-32
Manifold Absolute Pressure Sensor Vehicle Speed Sensor Replacement ............... 7-49
Replacement (5.7L) ....................... 6-1844 Vent Tube Replacement ................................. 7-53
Manual Transmission - M49 Marker Lamp
Backup Lamp Switch ..................................... 7-19 Replacement
Description ..................................................... 7-30 Side .. .. ... .. .. .. .. .. ... . .... .. .. .. .. . .. . .. .. . .. .. .. .. .. .. .. . 8-200
Diagnosis Mass Air Flow Sensor Replacement (3.8L) .... 6-1236
Gear Clash When Shifting Gears ................. 7-7 Mass Air Flow Sensor Replacement (5.7L) .. ,. 6-1842
Transmission Does Not Shift into Master Cylinder
One Gear ........................................... 7-9 Bench Bleeding ............................................. 5-25
Transmission Jumps Out Of Gear ................ 7-9 Fluid Level Sensor Replacement .................... 5-26
Replacement .................................................. 5-24
Transmission Locked in One Gear .............. 7-11
Reservoir Filling ............................................. 5-22
Transmission Noisy ...................................... 7-8 Reservoir Replacement .................................. 5-23
Transmission Shifts Hard .............................. 7-6 Meanings of Abbreviations ................................. 0-22
Fluid Level Check .......................................... 7-12 Mirror Face Replacement ..................... 8-933, 8-934
Mainshaft Rear Oil Seal .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. . 7-18 Mirror Replacement
Oil Drain and Fill ........................................... 7-22 Door ........ ......... .... .............. ... .. ... .... ... ... .. ..... 8-932
Replacement . .. .. ... .. .... .. .. ... ... ..... .. ... .... ..... .. .. ... 7-23 Mirrors
Shift Control Diagnosis
Power Mirrors Inoperative .................. ,...... 8-898
Knob Replacement .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. . 7-18
One ...................................................... 8-899
Shift Control Assembly ................................... 7-13 Power Mirrors Inoperative in Left and (
Shift Control Boot Assembly .. .. .. .. .. .. .. .. .. .. .. .. .. . 7-14 Right Direction ........................... ,.... 8-901
Shift Control Closeout Boot Replacement ....... 7-17 One ............................................ 8-901, 8-902
Special Tools ................................................. 7-31 Power Mirror Switch Replacement ................ 8-914
INDEX 23
Molding Replacement Park Brake
Belt Reveal ................................... 8-1071, 8-1072 Actuator Replacement .. ... ... .. ... ... ... .. ... .. ... ... .... 5-94
) Body Side Door ........................................... 8-771 Backing Plate Replacement ........................... 5-94
Front Fender Rear ....................................... 8-771 Brake Drum Inspection .................................. 5-93
Liftgate Garnish .......................................... 8-1109 Cable Replacement .. .. ... .. .... ... .. ... .. .... .. .. 5-88, 5-90
Rear Quarter . ... ... .. ... ..... .... .. .......... .... ........ ... 8-772 Description
Rocker Panel ............................................... 8-773 System . .. .. .. .... ... ... .. ... .. ... .... .. .. ... .... .. .. .... ... .. 5-96
Windshield Pillar Garnish ........................... 8-1069 Lever Replacement .. .. ... .. ... .... .. .. ... .... .. .. .... ... .. 5-86
Mount, Engine, Replacement (5.7L) ...... 6-303, 6-307 Shoe Adjustment ............................. :.............. 5-86
Shoe Replacement .. .. ... .. ... ... ... .. ... .... .. .. ... .... .. 5-85
Mount, Engine, Inspection (5.7L) ..................... 6-302
Special Tools ................................................. 5-96
Specifications
N Fastener Tightening .................................... 5-84
GM SPO Group Numbers ..............•............ 5-84
Noise Diagnosis Park/Turn Signal Lamp Bulb Replacement ....... 8-204
Doors ................................................ 8-791, 8-792 Park/Turn Signal Lamp Replacement ... 8-201, 8-202,
Front of Vehicle ................................. 8-785, 8-786 8-203
Instrument Panel .................... 8-786, 8-787, 8-788 PCM Replacement/Programming (5.7L) ......... 6-1837
Rear of Vehicle ........... 8-795, 8-796, 8-797, 8-798 Pedal Replacement
Roof ....................................... 8-792, 8-793, 8-794 Accelerator Controls (3.8L) ........... 6-1241, 6-1244,
Seat .................................................. 8-789, 8-790 6-1245
Under Vehicle ................................... 8-798, 8-799 Accelerator Controls (5. 7L) ......................... 6-1857
Notice, Caution and Important, Definition of ........... 3 Pinion Seals and Bearing Annulus
Replacement .................................. ; . 2-45
Plastic Panel Information and Repair
0 Description
Handling Precautions For Plastic ............. 8-1131
Oil Consumption Diagnosis (3.8L) ..................... 6-28
How to Identify Plastic Parts ................... 8-1130
Ordering Information, Special Tools ..................... 0-5 Plastic Identification and Refinishing
Oxygen Sensor Replacement, Heated (3.8L) .... 6-1238 Systems .. .. .. ... ... ... .. ... .. .... ... ... ... .... 8-1130
) p
Plastic Repair Precautions ...... .-............... 8~ 1132
Specifications
Repair Materials - Flexible Plastic Part ... 8-1112
Paint Gauges ................................................ 8-1140 Repair Materials - Rigid Plastic Part ....... 8-1112
Paint/Coatings Plastic Panels .. .. ... ... ... . .. ... ... ... .. ... ... .... ... .. .... .. 8-1113
Anti~Corrosion Treatment and Repair .......... 8-1135 Plastic Repair Instructions ............................. 8-1113
Basecoat/Clearcoat Paint Systems ............. 8-1135 Plate Replacement
Clearcoat Repair without Repainting ........... 8-1138 Door Sill ..................................................... 8-1067
Environmental Fallout Power Door Lock Switch Replacement ... 8-912, 8-913
Acid Rain ................................................ 8-1139 Power Folding Top
Paint Identification ...................................... 8-1138 Bow Replacement ................. 8-952, 8-958, 8-964,
Specifications 8-966, 8-968
Circuit Description ...................................... 8-1019
Clearcoat Repair - 3M Products .............. 8-1133
Cylinder Replacement .................................. 8-950
Clearcoat Repair - Meguiar Products ...... 8-1134
Inoperative ................................................... 8-946
Painting Operation ................................................... 8-1017
Clearcoat Thickness ................................... 8-1140 Pump with Motor Replacement .................... 8-949
Rail Dust Damage Repair .......................... 8-1140 Schematics .. .. ..... ... .. .. ... ... .. ... .. ... .... .. .... .... ... . 8-939
Panel, Plastic ................................................ 8-1113 Power Mirror Switch Replacement ................... 8-914
Panel Reinforcement Power Mirrors
Quarter ..................................... ,.... 8-1213, 8-1216 Diagnosis
Panel Repair · Inoperative ..................................•............. 8-898
Backing Patch Fabrication .......................... 8-1123 One ....................................................... 8-899
Gouge or Puncture .................................... 8-1114 Inoperative in Left and Right Direction ...... 8-901
Panel Replacement One ............................................ 8-901, 8-902
Power Steering
Air Inlet Grille .............................................. 8-871
Bleeding the System ...................................... 2-14
Complete ..... .. ... ... . ........ ... ..... ... ....... ........ ... 8-1122 Checking and Adding Fluid ............................ 2-13
Front Side .................................................... 8-874 Control Valve Replacement ................ ,.. 2-24, 2-25
Partial ....................................... ,...... ....... .. . 8-1118 Cooler Pipe Replacement . .. .. ... ... .... .. .... .... ... .. 2-29
Rear End ...................................... 8-1107, 8-1108 Description
Rocker ....................................................... 8-1201 Gear ........................................................... 2-48
Upper Rear Trim Finish .............................. 8-1070 Pump ......................................................... 2-47
.Wheelhouse ................................................. 8-876 Seal Replacement Recommendations ... ... .. . 2-48
24 INDEX
Power Steering (cont.) Power Windows (cont.)
Diagnosis s.witch Replacement .......................... 8-911, 8-912 (
Excessive Wheel Kickback or Loose Powertrain Control Module
Steering ............................................ 2-10 Air Conditioning Control Diagnosis (3.8L) ... 6,·1189
Foaming, Milky-Appearing PS Fluid, Connector End Views (3.8L) ........................ 6-814
Low in Level .................................... 2-12 Connecto_r End Views (5.7L) ....... ,............... 6-.1368
Gear and Pump Leaks ................................. 2-7 Controlled Air Conditioning
Groan Noise in Steering Pump ................... 2-13 Description (3.8L) , ........................ 6~1305
Growl Noise in Steering Pump .............. , .... 2~13 Controlled Generator Description (3.8L) ..... , 6-1306
Hissing Noise in Steering Gear ......... ,.......... 2-7 Controlled Warning Lamps
Increase in Effort While Turning .................. 2°10 Description (3.8L) ......................... 6-1304
Low Oil Pressure Due to Steering Gear ..... 2-12 Description (3.8L) ....................................... 6-1300
Low Oil Pressure Due to Steering Pump .... 2-12
Description (5.7L) ....................................... 6-1932
Poor Return of Steering Wheel ................... 2-11
Diagnosis (3.8L) ......................................... 6-1188
Rattle Noise .in Rack and Pinion ................... 2-7
Replacement/Programming (3.8L) ............... 6-.1232
Seal Replacement Rec.ommendations ........... 2s9
Powertrain Control Module Idle Learn
Steering Effort Hard in Both Directions ....... 2-11
Steering Wheel Kickback ...... , ............... ,., ... 2-11 Procedure (5.7L) ........................... 5:1840
System Test Procedure .......... : ....... ;;: ........... 2-9 Pressure Relief Valve Replacement ............... B-1109
Too Much Play in Steering ......................... 2-11 Programming Additional Keys -
Vehicle Leads to One Side or the Other ..... 2-12 Theft Deterrent ............................... 8-705
Wander or Poor Steering Stability ................ 2-12 Programming/Replacement
Wheel Surges or Jerks While Turning ........ 2-11 Powertrain Control Module (3.8L) ............... 6.-1232
Whine Noise in Steering Pump ................... 2-13 Programming/RPO Configuration of the
Flushing the System ...................................... 2-28 Body Control Module ...................... 8-543
Gear Replacement ................................ 2~32, 2-34 Programming/Synchronization
Pulley Replacement ................................. , ..... 2-20 Key less Entry Transmitter ............................. 8-66.1
Pump Front Bracket Replacement .................. 2-26 Propeller Shaft
Pump Rear Bracket Replace .......................... 2-27 Description ................................................ :;· ... ·4-18
Pump Replacement ........................... , ... 2-21, 2-22 Center Bearing ........................................... 4-19
Rack and Pinion Phasing ...................................................... 4-19 (
Boot Replacement ............................ , ......... 2~35 Universal Joint ............................................ 4-19
Steering Gear Cylinder Pipe Assemblies/
0-Ring Seals - Off Vehicle ............... 2-43 Diagnosis .. ..... ...... ... .. ..... ... .. . ... ... .. . ... .... .. .. . .. .. .. 4-4
Rack Bearing Pre load .................................... 2-35 Leak at Front Slip Yoke ............................... 4~5
Remote Fluid Reservoir Bracket Noise ........................................................... 4-7
Replacement .................................... 2-19 Knock or Clunk Noise ............................ .' .. 4-7
Remote Fluid Reservoir Replacement ............ 2-18 Ping, Snap, or Click Noise ........................ 4-6
Reservoir Replacement .................................. 2-24 Scraping Noise ...... .... .... .. .. ..... . .. .. .... ... .. .. .. . 4-7
Return Hose Replacement ............................. 2-30 Roughness or Vibration ................................ 4-5
Special Tools ................................................. 2-48
Shudder on Acceleration at Low Speed ........ 4-7
Specifications
Fastener Tightening ...................................... 2-3 Propeller Shaft Replacement, One-Piece .......... 4-8
Fluid Specifications ...... , ................................ 2-3 Propeller Shaft Replacement, Two-Piece ........ 4-10
GM SPO Group Numbers ............................ 2-3 Special Tools ................................................. 4-20
Tie Rod Replacement - Inner ......................... 2-41 Specifications
Tie Rod. Replacement - Outer O Off Vehicle .... 2-38 Fastener Tightening ......................... ,............ 4-3
Power Steering Gear GM SPO Group Numbers ............ : ............... 4-3
Runout Specifications ................................... 4-3.
Disassembled View ...................................... 2-4
Universal Joint and Slip Yoke Replacement ... 4-14
Power Steering Pump
Propeller Shaft Balancing Weight Amounts ....., .. 0-42
Disassembled View ............................... 2-5, 2-6 Propeller Shaft Runout Specifications ................ 0-42
Power Windows .............................................. 8-905 Pump, Fuel, Module Replacement (5.7L) ...... , 6-1881
Diagnosis
Inoperative ................................................ 8-906
Left Front .............................................. 8-906
Q
Inoperative from LF Switch ....................... 8-91 O Quarter Panel Replacement .............. 8-1213, 8-1216
Inoperative from RF Switch ....................... 8-910 Quick Connect Fitting Service (
Inoperative RF from LF Switch ................. 8-907 Metal Collar (3.8L) ..................................... 6-1248
Inoperative Right Front ............................. 8-908 Metal Collar (5.7L) ..................................... 6-1864
Power Windows Inoperative ...................... 8-906 Plastic Collar (3.8L) .................................... 6-1250
Left Front ......... ,.................................... 8-906 Pla?tic Collar (5.7L) .................................... 6-1866
INDEX 25
R Rear Drive Axle (cont.)
Specifications
Radiator Fastener Tightening .................................... 4-21
) Air Baffle Assemblies and Deflectors ... 6-661, 6-662 GM SPO Group Numbers ........................... 4-22
Air Deflector Replacement ............................ 8-871 Pinion Bearing and Differential Bearing
Assembly Description ................................... 6-670 Pre load ... ... ... ... .. ... .... ... .. .. .. .. . ... .. .. .. . . 4-22
Cleaning (Engine Cooling) .. ,......................... 6-61 o Rear Axle .................................................·.. 4-21
Filler/Pressure Cap Assembly Description ..... 6-671 Rear Axle Usage .. .. . ... .. .. .. .. .. .. .. .. .. .. .. .. .. .. . •.. 4-22
Inlet Hose Replacement
Rear End Panel Replacement .. .. .. .. .. . 8-1107, 8-1108
(Engine Cooling) ................. , 6-614, 6-617
Rear Lift Window
Outlet Hose Replacement
Replacement ................................................ 8-819
. (Engine Cooling) .................. 6-620, 6-623 Rear Quarter ··
Replacement (Engine Cooling) ..................... 6-654
Molding Replacement ................................... 8-772
Support Replacement (Engine Cooling) ........ 6-658
Rear Suspension
R.adiator Support Description . .... .... ......... .. ..... 8-1220
Special Tools ................................................. 3-60
Radio Replacement .. ..... .. .... .. ...... .... ... .. 8-334, 8-336
Specifications
Radio/Audio
Fastener Tightening .................................... 3-43
'system s.chemat.ics ............... 8-274, 8-275 8-277
GM SPO Group Numbers ........................... 3-43
8-280, 8-282, 8-283
Rail Replacement Rear Window
Side ........................................................... 8-1201 Defogger Braided Lead Wire ............ , ........... 8-825
Upper ...... :................................................. 8-1188 Reveal Molding Replacement ....................... 8-809
Rail Sectioning Rearview Mirror
>Lower ...... :..................................... 8-1196 8-1198 Replacement ................................................ 8-811
RAP ' Support Replacement ................................... 8-813
Diagnosis Rear11iew Mirror Lamp Replacement ................ 8-225
Diagnostic System Check ...... ... .. .. .. .. ... ... .. 8-758 Relay
Rear Compartment Lamp Replacement . ........ .. 8~228 Cooling Fan Relay Description ..................... 6-672
Fuel Pump Relay Replacement (3.8L) ........ 6-1285
Rear Compartment Lid Hinge Replacement ... 8-1101
Horn Relay Replacement ... .. .. .. .. .. .. .. .. .. .. .. .. .. 8-673
) Rear Comp~=;:;~~~~t~~-~~-~:~'.~~~ ................ 8 _1107 Theft Deterrent Relay Replacement .............. 8-702
Relay Replacement
Rear Compartment Lid Release Inoperative ... 8-1085
Starter Motor ................................................ 6-710
Rear Compartment Lid Replacement ............. 8-1099
Release Systems
Rear Compartment Lid Switch Replacement .. .. 8-1090
Schematics ... .... ... ... . ..... ... ... .. ... .. ... . .... . ... . .. . 8-1077
Rear Crankshaft Oil Seal Replacement (5.7L) .... 6-366 Replacement
Rear Drive Axle Fr~nt ...................................... 8-194, 8-196, 8-197
Axle Housing Inspection ................................. 4-40 Retained Accessory Power
Axle Replacement ... ... .. .... ........ .. ... .. .. ..... .. ...... 4-46 Component Locations ................................... 8-756
Axle Shaft Replacement ................................. 4-26 Description
Backlash Adjustment ...................................... 4-42 Circuit ....................................................... 8-763
Bearings Inspection ........................................ 4-41 Diagnosis
Description ..................................................... 4-52 Diagnostic Starting Point - Retained
Diagnosis Accessory Power .. .. ... .. .. ... .. ... ... . .. .. . 8-758
Noise Diagnosis ........................................ , 4-23 OTC List ................................................... B- 758
Differential Carrier Replacement ..................... 4-28 RAP Inoperative ....................................... 8"761
Differential Inspection ..................................... 4-41 RAP On after Timeout .............................. 8-761
Drive Pinion Assemble ................................... 4-34
Symptoms - Retained Accessory Power .... 8-761
Drive Pinion Disassemble .............................. 4-30
Schematic
Gear Tooth Contact Pattern Check ................. 4743
Icons . .. ... ... .. .. .. ... .. .... .... ... .. .. ... ... . .. .... . .. ... . . 8-754
Housing Cover and Gasket Replacement ....... 4-25
Inspection Before Disassembly ....................... 4-40 Schematics ...................................... :........... 8-755
Lu.bricant Level Check ................................... 4-25 Rocker Panel
Oil Seal and/or. Bearing Replacement ............ 4-36 Molding Replacement ................................... 8-773
Pinion and Ring Gear Inspection ................... 4-48 Rocker Panel Replacement ........................... 8-1201
Pinion Depth Adjustment ................................ 4-32 Roof
Pinion.Flange Replacement .... , ...................... 4-47 Description
Pinion Oil Seal Replacement ......................... 4-38 Power Folding Top Circuit ....................... 8-1019
Rear Axle Assemble ....................................... 4-36 Power Folding Top Operation ................. 8-1017
Rear Axle Disassemble .................................. 4-29 D~noo~ .
Side'Bearing Preload Adjustment ................... 4-41 Diagnostic Starting Point - Roof .. .. .. .. .. .. .. .. 8-946
Special Tools ................................................. 4-53 Symptoms - Roof ............................. :.. ... .. 8-946
26 INDEX
Roof (cont.) Seat Belt Retractor Replacement
Power Roof Systems Component Left Front .............................................. 9-17, 9-18
. Locations................. ,..... ,... ,.,.: ...... ,..... 8-941 Rear .. ..... .. . ....... . .. ... ....... .. ....... .. .. .. .. .. .. .. 9-22, 9-24 (
Power Roof Systems Component .Views ....... ·8-942 Right Front ........................................... 9-19, 9-21
Power Roof Systems · ·· · Seat,Belts
Connector End \/iews ............. :....... 8-945 Components .............................................. ,..... 9-5
Specifications . . Connector End Views ...................................... 9-5
Fastener Tightening .......................... ,....... 8-937 Description
GM SPO Group Numbers .... ,........ '. ........... 8-938 Seat Belt System ....................................... 9-27
Roof Outer Replacement ..........................•.... 8-1213
System Circuit ............................................ 9-28
Rotor/Drum Imbalance ....................................... 0-50
Diagnosis
RPO Code List ............................ , ......... ,,, ........ 0-15
Diagnostic Starting Point - Seat Belts ........... 9-6
Diagnostic System Check .... ... .. .. . ... ... .......... . 9-6
Schematic Icons
s Diagnostic Trouble Code (DTC) List/Type ..... 9-6
Fasten Safety Belt Chime Always On ......... 9-12
Data Link Communications ............................. 8-15 Fasten Safety Belt Chime Inoperative ......... 9-12
Schematics . Fasten. Safety Belt Indicator Always Qn ...... 9-10
Audible Warnings .......•..... , ...... , ..................... 8-580 Fasten Safety Belt Indicator Inoperative ...... 9-10
Backup Lights .............. :............................ ,; ... 8-66 Operational and Functional Checks .............. 9-6
Body Control Module ....................... ,........... 8-521 Seat Belt Service Precautions .................... 9-13
Cruise Control ................ ,................... ;.:.: ..... 8-714 Symptoms - Seat Belts .............................. , 9-10
Data Link Connector (DLC) ..................... , ... ,.. , 8-16 Schematic
Defogger ................................................. ,..... 8-802 Icons ............................................................ 9-3
·Door Locks ............................. , ....... , ............ 8-881 Schematics .. .... ... .. ....... .. ..... .. .. . .. ... . .. ... .... .. ....... 9-4
Engine Controls (3.8L) ............................... ,. 6-791 Specifications
Engine Controls (5.7L) ............................... 6-1329 Fastener Tightening ...................................... 9-3
Exterior Lights ..................... 8-52; 8-55, 8°58, 8-62 GM SPO Group Numbers ...................... , ..... 9s3
Fog Lights ... ·.:, .................... 8-45, 8-46; 8s48, 8-49 Seats
Ground Distribution ....... :: ......... :, ........ ,.: .. ,.... 3:.421 Adjuster Mechanism Replacement
Headlight Doors ............................................. 8-50 · Power ......................................·........ ..,..... 8-1050 (
Headlight Leveling ................ : ..... ,.................. 8~51 Description
Headlights .......................................... ,.. 8-38, 8-39 Front Seats .. , .......................................... 8-1059
Headlights - Daytime Power Lumbar Circuit ............................. 8-1060
Running Lamps .............. 8~40, 8-41, 8-43 Power Seat Systems Circuit .................... 8-1059
Horns ..................................................... ,:,.·.. 8-666
Rear Seats ............................................. 8-1060
Instrument Cluster ·
Diagnosis
Analog .......................................... .c, •••• , ..... 8-547
'Diagnostic Starting Point - Seats ............ 8-1029
Interior Lights ...............................................,,. 8-67
Lumbar Support ...................................... 8-1033
Interior Lights Dimming ............................. :"·· 8,69
Does Not Move In or Out .................... 8-1033
Keyless Entry .............................................. : 8-647
Lumber Support .......................................... 8-1022 Lumbar Support Inoperative ., .................. 8-1032
Outside Mirrors ............................ , .... 8-882, 8-883 Power Seat Adjuster Does Not Move
Power Distribution ............................ :........... 8-402 Vertically ....................................... 8-1029
Power Folding Top .................................... : .. 8s939 Power Seat Inoperative ........................... 8-1030
Power .Seats .................................. ,.. : .. :..... 8~1021 Power Seat Inoperative in One Direction ... 8-1031
Power Windows ................ ,.......................... 8°880 Symptoms - Seats .................................. 8-1029
Release Systems .. ,......... :..... :, ................... 8-.1077 Headrest Replacement
Retained Accessory Power ....................... : ... 8-755 · Front Seat .................................. 8-1052, 8-1053
·SIR ........................................': ................. :.,.:. 9-30 Lumbar Bladder Replacement .................... 8-1049
Theft Deterrent .......................... :...'............... 8-676 Lumbar Replacement ................................. 8-1047
Seal Replacement . · Power Recliner Replacement
Hood Rear ............... : ................................... 8-872 Front Seat ..................................... : ........ 8-1043
Seat .Back Latch Replacement Power Seat Systems Component Views ..... 8-1025
Rear Folding ................................ :............. 8-1057 Power Seat Systems Components ............. 8-1024
Seat Back Latch Striker Replacement . . . Power Seat Systems
R F Id" ,... .. ·. Connector End Views ................... 8-1025
. ear o mg .................................. ,............. 8-1058
Seat Belt Schematic ·
Child Restraint Belt Tether Location .... ~. 9~25, 9-26 Power Seat Systems Schematic Icons .... 8-1020 (
Seat Belt Buckle Replacement · Schematics
·Left Front ....................................................... 9-14 Lumbar Support ...................................... 8-1022
Right Front .............................................·....... 9-15 Power Seats ........................................... 8-1021
INDEX 27
Seats (cont.) SIR (cont.)
Seat Back Inflatable Restraint Steering Wheel
) Hinge/Recliner Mechanism
Replacement ....... .. .... ..... .. ... ... .. ..... 8-1042
Module Coil Replacement .. .. .. .... . .. .. .. 9-75
Inflatable Restraint Steering Wheel
Front ................................................... 8-1042 Module Replacement .. ... .. .. .. .. .. ... .. .. .. 9-74
Seat Back Recliner Mechanism Replacement Inflater Module Handling, Shipping, and
Front ...................................................... 8-1046 Scrapping ......................................... 9-79
Seat Back Replacement Repairs and Inspections Required After
Front ...................................................... 8-1040 an Accident ... .. ... .. .. .... ... .. .. .. ... . ... ... . .. 9-78
Seat Cushion Cover Replacement Schematics .... ... ... .... ... .. .. ... ... ... ... . .. . .. .. .. ... .. .. .. 9-30
Front ...................................................... 8-1039 Icons .......................................................... 9-29
Seat Cushion Trim Cover and Pad Service Precautions ....................................... 9-64
Replacement .......................... ;...... 8-1039 Special Tools ................................................. 9-99
Seat Replacement Specifications
Bucket . .. ... ... ... .. ...... ............ .. .. ... 8-1034, 8-1035 Fastener Tightening . .. ... .. .. .... ... .. .. .. .. ... .. .. ... . 9-29
Front Bucket .............................. 8-1036, 8-1037 GM SPO Group Numbers ........................... 9-29
Shoulder Restraint Guide Replacement Solenoid
· Rear Seat ............................................... 8-1056 Brake Transmission Shift Interlock
Special Tools .............................................. 8-1060 Solenoid Replacement
Specifications · Automatic Transmission (4L60-E) .............. 7~292
Fastener Tightening ................................ 8-1020 Control and Shift Solenoids Replacement
GM SPO Group Numbers ....................... 8-1020 Automatic Transmission - 4L60-E . ... .. .. ... .. 7-342
Secondary Air Injection Spare Tire Replacement
Pump Relay Replacement (5.7L) ................ 6-1922 Compact . .. ..... .. .. ... ... ... .. ... .. ... .... .. .. .. .. .... .. .. .. ... 3-68
Pump Replacement (5.7L) .......................... 6-1919 Spark Plug
Service Parts ID Label . ........ ..... .... ............ ....... . 0-14 Replacement .... ... .. .... ... .. ... . .. ... .. .. .. ... .. .. ... .. ... 6-77 4
Service Port Valve Core Replacement ............... 1-72 Usage ............................. : .... ;....................... 6-675
Shelf Trim Panel Replacement Visual Diagnosis . .. .... ... .. .. ... .... .. .. .... . .. ... .. .. ... 6-707
Rear .......................................................... 8-1073 Wire Harness Diagnosis ................. : ............. 6-709
Shock Absorber Speaker Grille Replacement
Replacement - Front ...................................... 3-33 Rear ................................................. 8-356, 8-357
Replacement - Rear ....................................... 3-54 Speaker Replacement . ... ... .. ... .... .. .. .. ... .. .. .... . ... 8-352
Shoulder Belt Replacement Front ............................................................ 8-353
Rear .............................................................. 9-15 Rear ............................................................ 8-354
Side Marker Lamp Replacement . ..... .... ... ......... 8-227 Special Tools
Side Weatherstrip Retainer Antilock Brake System . .. .. .... .. ... .. .. ... .. ... ... .. . • 5-255
Protector and Seal ........................ 8-1016 Automatic Transmission (4L60-E) ................. 7-380
SIR Clutch .. .. ... .. ... .. .. ... .. .... .. ... .. .... .. ... .. ... . ... ... .. .. . 7-405
Component Views .. .... ............. .... ........... ........ 9-32 Cruise Control .. .. ... .. ... ... .. ... ... ... ... .. ... . .... .. .. .. . 8-753
Components .................................................. 9-31 Disc Brakes ... .... .. .. .... ... .. ... .. .... ... .. .. .. ... ... . ... .. . 5-83
Connector End Views .. ............ ... ..... ....... ....... 9-33 Doors .. ... ... ..... .... .. ... ... ... .. ... ... ... ... .. .. .. ... ... . ... . 8-936
· Description Engine Controls (3.8L) ...................... ,........ 6-1322
Special Tools ............................................. 9-98 Engine Controls (5.7L) ............................... 6-1969
System Component Description and Engine Cooling .. ... .. .... .. ... ... ... .. ... .. .. .. ... ... . ... . 6-673
Definitions ........................................ 9-95 Engine Electrical . .. ... ... .. ... .. .... .. .... . .. ... ... ... . ... 6-785
System Operation ....................... ,................9-94 Engine Mechanical (3.8L) .. . .. . .... .. .. ... .. ... ... . ... 6-245
· Diagnosis Engine Mechanical (5.7L) ............................. 6-588
A Diagnostic System Check ....................... 9-36 Entertainment . .. .. ... .. .... .. ... .. ... ... ... .. ... .. .. ... .. .. . 8-375
AIR BAG Warning Lamp Circuit Frame and Underbody ............................... 8-1187
Malfunction ....................................... 9-61 Front Suspension .. ... .... . ... .. ... ... ... .. .. .. .... .. .. ... .. 3-41
Diagnostic Starting Point ............................. 9-34 General Information ....................................... 0-33
OTC List . .. ... ... .. ..... ....... .... ..... .... ..... .. .......... 9-37 Heating and Ventilation .................................. 1-97
Scan Tool Data Definitions ......................... 9-35 Hydraulic Brakes .. ... .. .... .. ... ... ... ... .. .. .. .... .. .. .. .. . 5-55
Scan Tool Data List ...... ..... ... ........... ........ .. 9-34 Instrument Panel, Gauges and Console ....... 8-645
Symptoms . .. .... .. ..... ....... ... ..... ........ ... ........ . . 9-60 Keyless Entry ... .. ... .. .... .. ... .. ... ... ... .. .. .. ... ... .. ... 8-664
·Disabling the SIR System .............................. 9-64 Lighting Systems . .. ... ... .. ... .. ... ... ... .. .. ... . .. .. .. ... 8-238
Enabling the SIR System ............................... 9-66 Park Brake .... .... .. .... .. ... ... .. ... ... ... .. .. .. .... .. . ... .. . 5-96
General Service Instructions .......................... 9-68 Power Steering .. .. ... .. .... .. ... ... ... ... .. .. .. ... ... .. .. . .. 2-48
Inflatable Restraint Instrument Panel Propeller Shaft . ... . .... .. ... .. ... .. .... ... .. .. .. .. .. .. . ... .. . 4-20
Inflater Module Replacement ..........•. 9-72 Rear Drive Axle . ... ... .. ... .. ... .. .... ... .. .. .. .... .. .. .. ... 4-53
Inflatable Restraint Sensing and Rear Suspension .. ... .. ... ... .. ... ... ... .. .. .. .... .. .. .. ... 3-60
Diagnostic Module Replacement ., ..... 9-69 Seats .. .... ..... .... ... .. ... ... ... .. ... ... .. ... .. .. .... .. ... . . 8-1060
28 INDEX
Special Tools (cont.) Specifications (cont.)
SIR ............................ .-........................... ,........ 9-99 Fastener Tightening (cont.)
Stationary Windows .............. :, ...................... 8-828 SIR ............................................................ 9-29 (
Steering Wheel and Column - Tilt .................. 2-98 Stationary Windows .................................. 8-801
Theft Deterrent ......... ,.. : ... : .............. ,............. 8-712 Steering Wheel/Column - Tilt ...................... 2-50
Wheel Alignment .... , .......... >,, ... .', ..... i: ... ,........ ,.: 3-14 Tires and Wheels ....................................... 3-61
Wipers/Washer Systems·············"················ 8-271 Wheel Alignment ........................................ 3-10
Special Tools Ordering Information ..: ..... ........... .. : 0-5 Wipers/Washer System , ............................ 8-239
Specifications Fluid Capacity
ABS Diagnostic Specifications Automatic Transmission .............................. 7-64
Anti lock Brake System ................................ 5-97 4L60-E .................................................... 7-64
Approximate Fluid Capacities .......... , .............. 0-34 Fluid Specifications
Battery Temperature vs Voltage Drop ........... 6-675 Power Steering ............................................. 2-3
Battery Usage ............................................. , 6~67 4 Frame Dimensions ..................................... 8-1146
Body Dimensions .................................. ,.... 8°1142 Fuel System
Brake System Engine Controls (3.8L) .............................. 6-787
Hydraulic Brakes .......................................... 5-5 Engine Controls (5.7L) ............................ 6-1326
Components General
Disc Brakes .......:.................... .-.:.................. 5-56 Automatic Transmission (4L60-E) ................ 7-64
Engine Cooling System Generator Usage ......................................... 6-675
Engine Cooling ..•.... , ............... ,: ................ 6-594 GM SPO Group Numbers
Engine Mechanica.l(3.8L) .... :, ....... .' ................. 6-16 Body Control System ................................ 8-520
Engine Mechanical (5.7L) .. :, ........... , ..... , ....... 6-251 Body Front End ........................................ 8-850
Exhaust System Clearances ....................... 6-1973 Body Rear End .... ......... .......... .. •.. .. ...... ... 8-1076
Fastener Tightening Bumpers ................................................... 8-829
3.8L ........•.......................................... :....... 6-15 Clutch ....................................................... 7-382
5.7L .......................................................... 6-249 Cruise Control .......................................... 8-713
Anti lock Brake System ................................ 5-97 Disc Brakes ............ ·.................................... 5-56
A\.ltomatic Transmission .... , .... : .. ;................. 7~63 Doors ....................................................... 8-878
4L60-E ...............................:· ...................... 7-63 Engine Controls (5.7L) ............................ 6-1326
Body Front End ........................................ 8-849 Engine Cooling ......................................... 6-594
Body Rear End ......•................................ 8-1075 Engine Electrical ....................................... 6-676
(
Bumpers ................................................... 8:829 Engine Exhaust ...................................... 6-1972
Clutch ....................................................... 7-382 Engine Mechanical (3.8L) ........................... 6-18
Cruise Control .......................................... 8-713 Entertainment ........................................... 8-272
Disc Brakes ................................................ 5-56 Exterior Trim ............................................. 8-764
Doors ...................... ,................ ,, ............... 8-878 Front Suspension ....................................... 3-15
Engine Control (3.8L) ............................... 6-786 Heating and Ventilation ................................ 1°4
Engine Controls (5.7L) ............................ 6-1325 Horns ....................................................... 8-665
Engine Cooling ......................................... 6-594 HVAC - Manual ........................................ 1-101
Engine Electrical ....................................... 6-674 Hydraulic Brakes .......................................... 5-5
Engine Exhaust ........................; ............ ,. 6~1972 Instrument Panel, Gauges and Console .... 8-546
Entertainment ............................ , .............. 8-272 Interior Trim ............................................ 8-1061
Frame and Underbody ........................... , 8-1141 Keyless Entry ........................................... 8-646
Front Suspension ....................................... 3-15 Lighting Systems ........................................ 8-36
Heater and Ventilation .................... , ............. 1-3 Manual Transmission (M49) .......................... 7-5
Horns ............................ .-.......................... 8-665 Manual Transmission (MM6) ....................... 7-32
HVAC - Manual ...................................... ,. 1-101 Park Brake ................................................. 5-84
Hydraulic Brakes ......................•................... 5-5 Power Steering ............................................. 2-3
Instrument Panel, Gauges and Console .... 8-545 Propeller Shaft ............................................. 4-3
Interior Trim ............................................ 8-1061 Rear Drive Axle ............ .......... .. .. .... ........ ... . 4-22
Lighting Systems ........................................ 8-35 Rear Suspension ........................................ 3-43
Manual Transmission .................................... 7-5 Roof ......................................................... 8-938
M49 ......................... ~, ... .-: .................... , ..... 7-5 Seat Belts ... ..... .... ....... ......... .. .. .. ... .. ...... ....... 9-3
MM6 ............................•.....................·., ... 7-32 Seats ...................................................... 8-1020
Park Brake ...............•......... ,................... ;: .. 5-84 SIR ............................................................. 9-29
Power Steering ........................................... ,. 2-3 Stationary Windows .................................. 8-801
Propeller Shaft ............................................. 4-3 Steering Wheel/Column - Tilt ...................... 2-50
Rear Drive Axle .......................................... 4-21 Theft Deterrent ......................................... 8-675 (
Rear Suspension ........................ , .........•.... ·. 3°43 Tires and Wheels ....................................... 3-61
Roof .................................................. , ...... 8-937 Lubrication
\
·seat Belts .. ..... .... ... ..... ... .. .. .... ..... ... .. .... .. ...... 9-3 Manual Transmission (M49) .......................... 7-5
Seats ...................................................... 8-1020 Manual Transmission (MM6) ....................... 7-32
INDEX 29
Specifications (cont.) Starting System
Pinion Bearing and Differential Bearing Preload Circuit Description ........................................ 6-780
) Rear Drive Axle .......................................... 4-22 Description ................................................... 6-780
Propeller Shaft Balancing Weight Amounts ..... 0-42 Operation .. ... .... ... ... .... .... ..... ...... .. ..... .. .. .. .. . .. . 6-780
Propeller Shaft Runout ................................... 0-42 Stationary Windows
Range Reference Table Bus Bar Lead Terminal Repair ...................... 8-825
Automatic Transmission (4L60-E) ................ 7-64 Component Locations ................................... 8-803
Rear Axle Usage ........................................... 4-22 Component Views ........................................ 8-804
Recommended Fluids and Lubricants ............. 0-34 Description
Runout Specifications Adhesive Service Kit Description ............... 8-826
Propeller Shaft ............................................. 4-3 Extended Method Description ................... 8-826
Sealers, Adhesives, and Lubricants General ... ..... .. ... .... ... .... ....... .. .... .... ... . .. . .. .. 8-826
Clutch .........................................•............. 7-382 Rear Window Defogger ............................. 8-827
Engine Mechanical (3.8L) ........................... 6-19 Rear Window Defogger Circuit .................. 8-827
Engine Mechanical (5.7L) ......................... 6-255 Rear Window Defogger Operation ............. 8-827
Shift Solenoid Valve State and Gear Ratio Reveal Molding ......................................... 8-827
Automatic Transmission (4L60-E) ................ 7-65 Short Method Description .......................... 8-826
Shift Speed Table Diagnosis
Automatic Transmission (4L60-E) ................ 7-65 Defogger Always On - Rear ..................... 8-805
Spark Plug Usage ........................................ 6-675 Defogger Grid Lines ................................. 8-807
Spark Plug Wire Resistance ......................... 6-676 Defogger Inoperative - Rear ..................... 8-806
Starter Motor Diagnostic Starting Point -
Usage ...................................................... 6-675 Stationary Windows ........................ 8-805
Temperature vs Resistance Symptoms - Stationary Windows ............... 8-805
Engine Controls (3.8L) .............................. 6-786 Schematics
Engine Controls (5. 7L) ............................ 6-1325 Defogger ...... ,. ... .... ... .... ..... .... .... .... ... .. .. .. . . 8-802
TFP Manual Valve Position Switch Logic Special Tools ............................................... 8-828
Automatic Transmission (4L60-E) ................ 7-66 Specifications
Thread Repair Fastener Tightening .................................. 8-801
Engine Mechanical (5.7L) ......................... 6-257
Window Cleaning ......................................... 8-824
Tire and Wheel Runout ............. : ............. ,...... ,0-42 Window Polishing ......................................... 8-823
Tire Inflation Pressure .................................... 0-34 Steering Knuckle Replacement .......................... 3-25
Tires and Wheels ........................................... 3-61 Steering Wheel and Column - Tilt
Wheel Alignment ............................................ 3-10 Column
Spoiler Replacement Replacement ... ... ... ... ...... ..... .... .... .... .. .. . .. ... . 2-68
Rear ................................. 8-1092, 8-1093, 8-1094 Description
Spring Insulators Replacement CoH Ignition Lock System ............. ;.................... 2-97
Rear Suspension ........................................... 3-56 Steering Wheel and Column ....................... 2-96
Spring Replacement .......................................... 3-55 Diagnosis
Squeaks and Rattles Hazard Switch Does Not Stay On ............•. 2-58
Description Hazard Warning Cannot Be Turned Off ...... 2-58
Noise ..... ... .. ..... .... ... ... ... ... ..... .. .... .......... .... 8-800 High Lock Effort ......................................... 2-55
Diagnosis ... .. ... .... ...... ........ .... ..... ..... .... .. ..... .. 8-785 High Lock Effort Between the
Stabilizer Shaft Off Lock Positions ...... .. ... ..... ... .. . ... . .. 2-54
Link Replacement .......................................... 3-20 High Steering Shaft Effort ........................... 2-55
Replacement .................................................. 3-19 Housing Scraping Bowl ............................. ,. 2-56
Stabilizer Shaft Link Replacement Ignition Switch Cannot Be Set Correctly ..... 2-58
Rear Suspension . .. .... ........ ...... ............... ...... . 3-53 Ignition Switch Does Not Turn .................... 2-58
·Stabilizer Shaft Replacement Ignition Switch Electrical System
Rear Suspension ...... . .... .. ... ....... ............... ..... 3-50 Does Not Operate ............................ 2-58
Stain Removal ... .... ... .... ......... ...... .............. .... 8-107 4 Key Cannot Be Removed in the
Starter Motor Off Lock Position .... .. ... .... .... .... . .. .. . ... 2-54
Diagnosis Lock System Does Not Lock . .. .. ... ..... . .. .. .. .. 2-54
Solenoid Clicks, Lock System Does Not Unlock ................... 2-54
Engine Does Not Crank .................. 6-688 Lock Cylinder Can Be Removed
Solenoid Does Not Click ........................... 6-687 Without Depressing Retainer ............ 2-54
No Load Test . ... .. ...... ......... ... ..... .... ..... .. .... ... 6-692 Loose Steering Wheel .............................•.. 2-56
Noise Diagnosis ........................................... 6-691 Loose Steering Wheel
Pinion Clearance Check ............................... 6-716 (Every Other Tilt Position) ................ 2-56
.Relay Replacement ...................................... 6-710 Looseness In Steering Column ................... 2-56
Replacement ..................................... 6-711, 6-713 Noise in Steering Column ........................... 2-55
Shield Replacement ..................................... 6-717 Noise When Tilting Steering Column .......... 2-57
30 INDEX
Steering Wheel and Column - Tilt (cont.) Steering Wheel and Column - Tilt (cont.)
Diagnosis (cont.) Turn Signal and Multifunction Switch Assembly·
Steering Wheel Does Not Lock in Assemble - Off Vehicle .. '. .................... 2-73
Turn Signal and Multifunction Switch Assembly·
(
Any Tilt Position ............................... 2-58
Steering Wh.eel Not Returning to Disassemble - Off Vehicle .................. 2-72
Top Tilt Position ................... ,..... ,..... 2-56 Turn Signal Cancel Cam, Upper Bearing Inner.
Turn Signal Difficult to Operate .... ,.............. 2-57 Race Assemble - Off Vehicle .......... : ... 2-83
Turn Signal Does Not Cancel ..................... 2-57 Turn Signal Cancel Cam, Upper Bearing Inner
Turn Signal Does Not Indicate Race Disassemble - Off Vehicle .......... 2-82
Lane Change ....... : ........................... 2-57 Visual Identification
Turn Signal Does Not Stay in Disassembled View .. .. .. .. .. ... .. .. .. .. .. .. .. .. .. .. ... 2-52
Turn Position .................................... 2-57 Steering Wheel Control Switches
Dimmer Switch Assembly - Assemble - Replacement .................................. 8-346
Off Vehicle ....................................... 2-76 Steering Wheel Controls Schematic ........;......... 8-284
Dimmer Switch Assembly - Disassemble - Stop Lamp Replacement
Off Vehicle ....................................... 2-75 High Mounted .............. 8-204, 8-206, 8-208, 8-210
Hazard Warning Switch Replacement - Stoplamp Switch
On Vehicle ....................................... 2-62 Adjustment ........................................ , ............ 5-51
Horn Switch Replacement - Replacement ......•........................ , .................. 5-50
On Vehicle .............................. 2-63, 2-64 Strategy Based Diagnosis ................................. 0-32
Ignition Switch Assembly - Assemble - Striker Replacement
Off Vehicle ............ , .......... ,.. ... .. . ... .. .. 2-75 Rear Compartment Lid Lock .. .. .. .. .. .. .. .. .. .. .. . 8-1107
Ignition Switch Assembly·- Disassemble - Strut Replacement
Off Vehicle ....................................... 2-74 Rear Lift Panel ... .. .. .. .. ... .. .. ... .. .. .. .. .. .. .. .. .. .. .. 8-1102
Ignition Switch Replacement - On Vehicle ...... 2-59 Rear Lift Window Panel .. .. .. .. .. .. .. .. .. .. ... .. .. .. 8-1103
Inflatable Restraint Coil Centering - Struts o.r Shock Absorbers
Off Vehicle .................................. , .... 2-93 Diagnosis
Inflatable Restraint Steering Wheel Module Bench Test .................................................. 3-8
Coil - Assemble - Off Vehicle ........... 2-71 Leak ........ :....·........................................ ,....... 3-8
Inflatable Restraint Steering Wheel Module Noisy ........................................................... 3-8
Coil - Disassemble - Off Vehicle ....... 2-70 On-Vehicle Testing ....................................... 3-8
Intermediate Steering Shaft Replacement ....... 2-66 Weak· ........................................................... 3-7 (
Lock Cylinder Set - Assemble ........................ 2-78 Sunshade Panel Replacement ....................... 8-1002
Lock Cylinder Set - Disassemble· ................... 2-78 Suspension
Lock Housing Assembly - Assemble - Description
Off Vehicle ....................................... 2-88 General ........................................................ 3-9
Lock Housing Assembly - Disassemble - Diagnosis
Off Vehicle ....................................... 2-87 Abnormal or Excessive Tire Wear ......., ........ 3-4
Pivot and Pulse Switch Assembly - Struts or Shock Absorber Bench Test ... .. .. ... 3-8
Assemble - Off Vehicle ..................... 2-77 Struts or Shock Absorbers Leak ................... 3-8
Pivot and Pulse Switch Assembly - Struts or Shock Absorbers Noisy .................. 3-8
Disassemble - Off Vehicle ................ 2-77 Struts or Shock Absorbers On-Vehicle
· Special Tools ............................................... ,.. 2-98 Testing ......................................... ,..... 3-8
Specifications · Struts or Shock Absorbers Wec:1.k .................. 3-7
Fastener Tightening .................................... 2-50 Trim Height .................................................. 3-4
GM SPO Group Numbers ........................... 2-50 Front
Steering Column Accident Damage - Description ................................................. 3-40
Off Vehicle .... ,.................................. 2-94 General ................................................... 3-40
Steering Column Housing - Assemble c Rear
Off Vehicle ....................................... 2-85 Description .. .... .... .... .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. ... 3-59
Steering Column Housing - Disassemble - General ........................ : .......................... 3-59
Off Vehicle ....................................... 2-84 Switch
Steering Shaft, Lower Bearing, Jacket , Clutch Anticipate Switch Replacement .. ,....... 7-397
Assemble - Off Vehicle ..................... 2-91 Clutch Pedal Position Switch
Steering Shaft, Lower Bearing, Jacket - . Replacement .......................... :....... 7-397
Disassemble - Off Vehicle ................ 2-89 Cruise Release Switch Adjustment ............... 8-750
Steering Wheel Control Sw.itch Assembly Cruise Release Switch Replacement ............ 8-749
Replacement .. ... ... .. .. ... .. ... .. .. .. .. ... .. .. . 2-.64 Engine· Oil Pressure Switch
Steering Wheel Replacement ......................... 2-6~ Replacement .. .. .. .. .. . .. .. ... . .. ... 8-586, 8-587
Tilt Lever Replacement - On Vehicle .............. 2-62 Fog Lamp Switch Replacement
Front ............................. :............... 8-172, 8-173
(
Tilt Spring - Assemble .................................... 2-81
Tilt Spring - Disassemble .. •, ............................ 2-79 Rear ......................................................... 8-174
Turn Sign Multifunction Signal Lever Hazard Warning Switch Replacement -
Replacement - On Vehicle ................ 2-60 On Vehicle (Tilt) ............................... 2-62
INDEX 31
Switch (cont.) Theft Deterrent (cont.)
Headlamp Leveling Switch Replacement ...... 8-171 Diagnosis (cont.)
) Headlamp Switch Replacement ......... 8-169, 8-170 Lights Inoperative in CDT Alarm Mode ..... 8-691
Horn Switch Replacement - SECURITY Indicator Inoperative ............... 8-693
On Vehicle (Tilt Column) .......... 2-63, 2-64 Security Indicator LED Inoperative ............ 8-697
Ignition Switch Replacement (Tilt Column) ...... 2-59 SECURITY Indicator Off,
IP Compartment Lamp Switch Replacement ... 8-585 Engine Does Not Crank ................. , 8-694
Park/Neutral Position Switch Adjustment SECURITY Indicator On, Engine Starts .... 8-696
Automatic - 4L60-E ................................... 7-309 Shock Sensor Inoperative ......................... 8-698
Park/NeutraL Position Switc.h Replacement Symptoms - Theft Deterrent .. ... .. .... .. ... .. .. .. 8-689
Automatic 4L60-E ..................................... 7-308 System Feature Customization
Power Door Lock Switch Inoperative ................... , .................. 8~698
Replacement ........................ 8-912, 8-913 Feature Customization ................ , ................ 8-705
Power Mirror Switch Replacement ........ ,....... 8-914 Programming Additional Keys ..... :................. 8-705
Power Window Switch Replacement ... 8-911, 8-912 Programming Replacement Keys,
Rear Compartment Lid Switch Ignition Cylinder, or
Replacement ................ : ... ,............ 8-1090 Powertrain Control Module . •.. ... ... . ... 8-705
Steering Wheel Control Switch Assembly Relay Replacement ........... , .. .. ... .. ... .... .. ... .. ... 8-702
Replacement (Tilt Column) ................ 2-64 Schematic
Steering Wheel Control Switches Icons ... .... ... .. .. ... .... . ... ... .. .... .. .. ... .... ... ... .. . .. 8-675
Replacement .. ........ ......... .... ....... .... 8-346 Schematics ........................ , .. ... .. ... ..... .. .. ... . .. 8-676
Stoplamp Switch Adjustment .......................... 5-51 Shock Sensor Replacement ... ... .. .. ..... .. ... .. ... 8-703
Stoplamp Switch Replacement ....................... 5-50 Special Tools .......•........•.............................•. 8-712
Torque Converter Clutch PWM Solenoid, Specifications
TCC Solenoid, and Wiring Harness GM SPO Group Numbers ......................... 8-675
Automatic Transmission - 4L60-E ............. 7-345 Thermal Bypass Pipes
Valve Body and Pressure Switch Replacement Replacement (Engine Cooling) . .. ... .... .. .. ... .. .. 6-639
Automatic - 4L60-E ................................... 7-336 Thermostat ·
Switches Description . ... ... .. .... ... .. ... ... .. . .. ... .. ... .... .. ... ... .. 6-672
Traction Control Switch Housing Replacement
) Replacement ... ,.................... 5-246, 5-247 (Engine Cooling) . .. .... .. .. ... .... 6-634, 6-637
Replacement (Engine Cooling) . ... .. .... 6~638, 6-639
Thread Inserts ................................................... 0-21
T Throttle Body
Tail Lamp Bulb Replacement ........................... 8-218 Assembly Replacement (5.7L) ...... , ............. 6-1857
Tail Lamp Replacement ........................ 8~215, 8-216 Cleaning Procedure (5.7) ........................... 6-1863
Temperature Control Cable Coolant System Description .. ... .. ... .... ... . .... .. . 6-670
Adjustment (A/C- Manual) ........................... 1-132 Throttle Body Air Inlet Screen
Temperature Sensor Description - Replacement (3.8L) ....................... 6~1246
Engine Coolant ............................... 6-672 Throttle Body Assembly Replacement (3.8L) .... 6-1245
Theft Deterrent Throttle Body Heater
Component Locations .. ...... ...... ............ ...... .. . 8-680 Inlet Hose Replacement (Engine Cooling) .... 6~625
Component Views .... ... ...... ...... ......... .. ....... ... 8-682 Outlet Hose Replacement (Engine Cooling) .. .. 6~626
Connector End Views .. ...... ....... ........ .. ....... ... 8-685 ihrottlePosition Sensor Replacement (5.7L) .... 6-1853
Description Thrust Angle Adjustment, Rear .......................... 3-12
Content Theft Deterrent . ....... ............ ........ 8-708 Tire
Content Theft Deterrent Circuit ................. 8-71 O Chain Usage Description . ... ... .. .. ... ..... ... .. .. ... .. 3-71
Content Theft Deterrent Operation ... ......... 8-708 Description ..................................................... 3~70
Vehicle Theft Deterrent ............................. 8-710 Inflation Description ........................................ 3-70
Vehicle Theft Deterrent Circuit .................. 8-712 Mounting and Dismounting ............................. 3-68
Vehicle Theft Deterrent Operation ............. 8-711 Placard Description ............................... , ... ... .. 3-72
Diagnosis Replacement
Content Theft Deterrent Alarm Mode Compact Spare .......................................... 3-68
Always On .. .. ...... .... .. ... ......... .... .. .... 8-689 Rotation ........................... : .............................. 3-69
Tire and Wheel Runout Specifications ..... .. .. .. .. .. 0~42
Content Theft Deterrent Alarm Mode
Tire and Wheel Inspection - ·
Inoperative ...................................... 8-690
· Vibration Diagnosis . ... .. . ..... .... .. ... .. .... 0-44
Diagnostic Starting Point - Tire Inflation Pressure Specifications ................. 0-34
Theft Deterrent ............................... 8-686 Tire Placard .. .... .... .... ... .. .. .. ... .. .. .. .. ... ..... ... .. ... ... ... 0-9
Diagnostic System Check ......................... 8-686 Tire Repair ........................................................ 3-68
DTC List .... ...... . .... .. ...... .... ..... .... .... .... ... .... 8-686 Tire Wear
Horn Inoperative in CDT Alarm Mode ....... 8-691 Abnormal or Excessive . .. ... .... .. .. ... .... .... .. ... .. .... 3-4
Ignition Key Lock Cylinder Test ................ 8-700 Tires and Wheel Balancing .. .... .. .. .. ... ..... .. .... . .... . 0-71
32 INDEX
Tires and Wheels Trim Replacement
Description ....................................... ,............. 3-70 Hinge Pillar ................................... ,............ 8-1062
. Aluminum Whe.els ...................... ,............. , .. 3-72 Turn Signal (
Chain Usage ............. ,................................ 3-71 Flasher Replacement ................ ,....... 8-179, 8-180
Inflation ................ ,..................... ,............·.• ; 3-70 Turn Signal Lamp Bulb Replacement
P-Metric Sized Tires ................................... 3-71 Rear ......................... ,........................ 8-219, 8-220
Replacement Wheels .......... ,............ , .......... 3-72
Tire Placard ....................................... , ........ 3-72
Diagnosis
u
Underbody Inspection .................................... 8-1185
Radial Tire Lead/Pull Correction .... ,, ........... 3-63
Upper Rear Trim Finish Panel Replacement ..... 8-'1070
Wheel Mounting Surface Check., ................ 3-62
.Specifications ............................. , •..... .... .. ..... ... 3-61
Fastener Tightening ............. ,, ......... ,........... 3-61 v
GM SPO Group Numbers ...•.................•..... 3-61 Vacuum Brake Booster
Wheel Removal and Installation ..................... 3-66 Hose Replacement .... ,..... ........ . •. .. .. .. .. .... .. .. ... 5-50
Toe Adjustment, Front ............... ,: ....... ,.............. 3-12 Replacement .. .... ....... ..... ... ....... . . .. .. ... ... .... ... .. . 5-48
Torque Arm Replacement Vacuum Brake Booster Operation Description .... 5-53
Rear Suspension .................. ,........................ 3°47 Vacuum Hose Harness.
Tow Hook Replacement .................... 8-1182, 8-1.184 Replacement (A/C - Manual)., ......... ,............ 1-141
Track Bar Replacement Vacuum Tank Replacement (A/C - Manual) ..... 1-140
Rear Suspension ............ , ............................ ,. 3-57 Valve Replacement
Traction Control Switch Replacement .... 5s246, 5-247 Pressure Relief .......................................... 8-1109
Training Information .......... , ....... , ........................ , 0-5 Vapor Vent Pipe
Transmission - MM6 Clean and Inspect (5.7L) ..............•............... 6-519
Support and Mount Assembly ............. ,.......... 7-42 Vapor Vent Pipe Replacement (5.7L) ............... 6-324
Transmission Floor Shift Control Indicator Vehicle Certification Label ..... ,............................. 0-8
Lamp Replacement .................. : ., .... 8-226 Vehicle l.dentification ............................................ 0-5
Transmission ID and Partial VIN Location ......... 0-12 Vehicle Speed Sensor
Transmission Support Replacement ............... 8-1173 Manual Transmission (M49) ........................... 7-21
Transmission Usage .......................................... 0-13 Vehicle Speed Sensor Replacement
Transmitter Automatic Transmission - 4L60-E ................. 7-358 (
Battery Replacement Manual Transmission (MM6) .......................... 7-49
Key less Entry .......... , ............ , ..... , .....•....... 8-660 Vibration
Special Tools ................................................. 0-86
.. Programming/Synchronization
Vibration Diagnosis
Keyless Entry ........................................... 8-661 Balancing Tires and Wheels ........................... 0~71
Trim Cleaning Basic Terms ................................................... 0-73
Fabric ........................................................ 8-1074 Classifying the Vibration ................................. 0-47
.Leather .................................... , .................. 8-1074 Diagnosing First-Order Driveline Vibration ...... 0-51
Vi"nyl ........... ,................. ,............................. ,. 8-1073 Diagnosing Second-Order Driveline
Trim Height Diagnosis .................... :..................... 3-4 Vibration ........................................... 0-61
Trim Height Specifications .................................. , 3-3 Diagnostic Information and Proc.edures .......... 0-43
Trim Panel. Carpet Replacement . Driveline Vibration Analysis ............. : .............. 0~51
Rear Center ...................•.... , ......... 8-1067, 8~1068 El.ectronic Vibration Analyzer ........... , .............. 0-81
Trim Panel Opening Cover. Replacement ....... 8-1091 Engine Related Vibration ................................ 0-67
Trim Panel Replacement Matching Frequency to Component RPM ., ..... 0-48
Cargo Area Front ........................... 8-1063, 8-1064 Reed Tachometer ........................................... 0-81
Cargo Area Side .. . .. .... . .... ... ... .. ... ... . .. .... .. ... 8-1065 Road Test ...................................................... 0-45
Liftgate ................................................ ,...... ·8-1091 Rotor/Drum Imbalance ................................... 0-50
Shelf Systematic Approach ............ :......................... 0-43
Tire and Wheel Inspection .................... : ........ 0~44
Rear ........... , ........................................... 8-1073
Tire and Wheel Vibration ............................... 0-70
Trim Plate Bezel Replacement
Types of Road Test Procedures ..................... 0-45
IP Cluster .......................................... 8-594., 8-595 Vibrations That Can Be Felt . ... . .. ... .. ..... .. ...... .. 0-4 7
Trim Plate Replacement · Vibrations That Make Noise ........................... 0-48
IP Accessory ......................•.............. 8-592, 8-594 VIN Derivative ..................................................... 0-7
IP Accessory Left ......... , ... ,........................... 8-591 VIN, Partial, Location and Engine ID .......... 0-9, 0-10
(
INDEX 33
w Wheels
Aluminum Wheels Description ........................ 3-72
) Washer Replacement Wheels Description ................... 3-72
Pump Replacement ......................... ,............ 8-254 Windnoise ·
Solvent Container Replacement ........ , .......... 8-252 Exterior ........................................................ 8-784
Water Pump Interior ......................................................... 8-784
.Clean and Inspect ..... ;.................................. 6-519 Window Regulator Motor Replacement ............ 8-928
Description .............·.............................. ,....... 6-672 Window Regulator Replacement ....... ,.............. 8-927
Replacement (Engine Cooling) .......... 6-640, 6-642 Window Replacement
Waterleaks Door ............................................................ 8-928
Body Waterleak Repair ..... ,.......................... 8-780 Windows
Diagnosis Diagnosis
Air Hose Test ..................................... ,..... 8-778 Power Windows Inoperative ...................... 8-907
Body Waterleak Repair ............................. 8-776 RF from LF Switch ................................ 8-907
Dust Leaks ............................................... 8-779 Power Window Switch Replacement ... 8-911, 8-912
Localized Testing (Spot Testing) .......... ,.... 8-777 Windshield
Test Preparation ............................. ,: ........ 8-776 Reveal Molding Replacement ....................... 8-808
Water Hose Test ...................................... 8-778 Side Garnish Molding Replacement ... 8-810, 8-811
Generalized Testing ...... ,............. ;................. 8-777 Windshield Glass Cleaning .............................. 8-269
Specifications Windshield Replacement ................................. 8-814
Recommended Materials Wiper
(Waterleak Repair) .......................... 8-776 Arm Blade Replacement .............................. 8-256
Stationary Window Waterleak Repair ............ 8-782 Arm Replacement ........................................ 8-255
Weatherstrip Waterleak Repair ...................... 8-781 Blade Element Cleaning ............................... 8-269
Weather Retainer Replacement Blade Element Replacement ............. : . .. ... .... 8-257
Folding Top ................................................ 8-1010 Chatter Repair ............................................. 8-269
Weatherstrip Replacement .Motor Cover Replacement .. ... .. ... .. .. .... . .. ... ... . 8-258
Door ............................................. ,.............. 8-931 Motor Replacement .. ... .. .... .. .. .. ... .. .. .... . .. .. .... . 8-259
Folding Top Side Front ...... , .............. , ......... 8-1011 Transmission Replacement ........................... 8-264
Rear Lift Window Panel Opening ............... 8-1110 Wipers/Washer Systems
) Wheel Component Locations ... . . .. .. ... . .. . .. .. .... .. .. .. ... .. 8-241
Removal and Installation ................................ 3-66 Component Views .... .. ... .... ... .. .. ... .. ..... . .. .. ... .. 8-242
Wheel Alignment Connector End Views . ... ... .. .. ... .. .. .. .. . .. . .. ... ... . 8-243
Description
Description
System Operation . .. ... .. .. . .. .. .. . .. .. .... .. .. .. .... . 8-270
Camber .... .. .. .. .. . . .. .. ..... .. .. .. . .. . .. .. .. .. . . .. .. .. . .. .. 3-13 Windshield Wipers/Washer System ........... 8-270
Caster .. ... .. .. .. .. .. ... .. .. .. .. ... .. .. .. ... .... .. .. .. . .. . .. .. 3-13 Diagnosis
Toe ............................................................ 3-14 System Check ... . .. .. .. .... .. . .. ... ... .. .. .. ... .. . .... . 8-244
Diagnosis Washers Inoperative ................................. 8-249
Preliminary Alignment Inspection ................ 3-10 Wiper Arm Tip Pressure Check,
Front Caster and Camber Adjustment ............ 3-11 Blade Element Check .. .. .. . .. .. .. .. .. .. .. 8-251
Wiper Blade Do Not Park with
Front Toe Adjustment ..................................... 3-12
Switch Off .. . .. .. .. ... .. .. . .. .. .. . .. .. .. . . .. .. . .. 8-248
Measuring ...................................................... 3-11 Wiper High Mode Inoperative,
Rear Thrust Angle Adjustment ........................ 3-12 Low Mode Operates ....................... 8-246
Special Tools ................................................. 3-14 Wipers Always On .................................... 8-247
Specifications ....... .... ..... ..... ........ .. .................. 3-1 O Wipers Delay Mode Inoperative ................ 8-245
Fastener Tightening .................................... 3-1 O Wipers Inoperative .................................... 8-244
Wheel Bearing/Hub Replacement - Front ........... 3-24 All Modes .. . .. . .. . .. . .. .. .. .. . .. ... .. .. .. . . .. . .. .. .. .. . 8-244
Wheel Hub Bolt Replacement ............................ 3-18 Wipers Mist, Delay, and Low Modes
Inoperative ...................................... 8-246
Wheelhouse
Schematics
Panel Replacement ...................................... 8-876 Pulse . .. .. .. .. . .... .. .. . .. .. . .. .... . .. .. ... ... .. . .. . . .. .. .. .. 8-240
Wheelhouse Replacement Special Tools ............................................... 8-271
Front ............................................. 8-1191, 8-1193 Specifications
Rear .......................................................... 8-1218 Fastener Tightening .................................. 8-239
34 INDEX
Wiring Systems Wiring Systems (cont.)
Description Diagnosis (cont.)
Harness Routing Views ............................. 8-481 Splicing Copper Wire Using Splice Clips ... 8-384 (
lnline Harness Connector End Views ........ 8-461 Splicing Copper Wire Using Splice
Diagnosis Sleeves .............................. ,........... 8-393
Checking Aftermarket Accessories ,........... 8-384 Splicing In line Harness Diodes .................. 8-395
Circuit Protection ...................................... 8-390 Splicing Twisted or Shielded Cable ........... 8-394
Circuit Breakers ..................................... 8-390 Terminal Position Assurance Locks ........... 8-398
Fuses .................................. : ................. 8-390 Testing for Continuity ............................. ,.. 8-386
Fusible Links ......................................... 8-391 Testing for Electrical lntermittents ............. 8-389
Circuit Testing .......................................... 8-384 Testing for Poor Connections .................... 8-387
Connector Position Assurance Locks .; ... , .. 8~398 Testing for Short to Ground ...................... 8-387
Connector Repairs ......... , .......................... 8-398 Testing for Short to Voltage ...................... 8-387
Electrical Symbols .................................... 8-380 Troubleshooting with a Digital
Flat Wire Repairs ..................................... 8:398 Multimeter ....................................... 8-385
General Electrical Diagnosis Procedures ... 8,384 Troubleshooting with a Test Light ............. 8-385
H02S Wiring Repairs ...................... , ........ 8-395 Using Connector Test Adapters ................ 8-384
Inducing Intermittent Fault Condition ......... 8-388 Using Fused Jumper Wires ....................... 8-385
Measuring Frequency ............................... 8-386 Weather Pack Connectors ........................ 8-400
Measuring Voltage .................................... 8-386 Where to Find Electrical Schematics ......... 8-376
Measuring Voltage Drop ........................... 8:.386 Wiring Repairs .......................................... 8-390
Passenger Car Zoning .............................. 8~379 Electrical Center Identification ...................... 8-454
Probing Electrical Connectors ................... 8-384 Power and Grounding Component Views ..... 8-449
Power and Grounding Components .............. 8-436
Pull to Seat Connectors ............................ 8-399 Power and Grounding
Push to Seat Connectors .......................... 8~398 Connector End Views ..................... 8-460
Repairing Connector Terminals ................. 8-401 Schematics
Repairing Damaged Wire Insulation .......... 8-391 Ground Distribution ................................... 8-421
Scan Tool Snapshot Procedure ................ 8-389 Power Distribution .. .. .. .. .. ... .. .. ... . .. .. .. .. .. .. .. .. 8-402
SIR Wiring Repairs ........................... ,....... 8-396 Work Sheets, Diagnostic .............. ,...................... 0-5
(
(
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' I
2000 Chevrolet Camaro
and Pontiac Firebird
Service anual
Volume 2
This manual provides information on the diagnosis, the service procedures, the adjustments,
and the specifications for the 2000 Chevrolet Camara and Pontiac Firebird.
Information on transmission unit repair (overhaul) can be found in the 2000 Transmission/
Transaxle/Transfer Case Unit Repair Manual (TURM) available separately. The TURMmanual
contains information on automatic and manual transmissions, including the fluid flow and circuit
description information.
The technicians who understand the material in this manual and in the appropriate Dealer Service
Bulletins better serve the vehicle owners.
When this manual refers to a brand name, a part number, or a specific tool, you may use an
equivalent product in place of the recommended item. All information, illustrations, and
specifications in this manual are based on the latest product information available at thetime of
pubHcation approval. General Motors rese.rves the right to make changes at any time without
notice. ·
t TABLE OF CONTENTS
Volume 1 Volume 3
Preface ................................................................ 1 Preface ................................................................ 1
Cautions and Notices .... .. ... .. ...... ... .... ... ... .... ..... .. 3 Cautions and Notices . ... .... ... ..... .. .... .. ... ... ...... ... .. 3
General Information ....................................... 0-1 Transmissionrrransaxle ................................ 7-1
General Information ......................................... 0-3 Manual Transmission - M49 ............................ 7-5
Maintenance and Lubrication ......................... 0-34 Manual Transmission - MM6 ......................... 7-32
Vibration Diagnosis and Correction ... ... .... .... .. 0-42 Automatic Transmission - 4L60-E .................. 7-63
HVAC ................................................................ 1-1 Clutch ......................................................... 7-382
Heating, Ventilation and Air Conditioning ......... 1-3 Body and Accessories .................................. 8-1
HVAC Systems - Manual ............................. 1-101 Data Link Communications ............................ 8-15
Steering ............................................................ 2-1 Lighting Systems ........................................... 8-35
Power Steering System ................................... 2-3 Wipers/Washer Systems .............................. 8-239
Steering Wheel and Column - Tilt ................. 2-50 Entertainment ... .. ... ..... ... ... .... .... .... ... .. ... ...... . 8-272
Suspension ...................................................... 3-1 Wiring Systems ........................................... 8-376
Suspension General Diagnosis ... ... .... ..... ... ..... . 3-3 Body Control System .... ... ... .... .... .... .. ... ..... ... 8-520
Wheel Alignment · ........................................... 3-10 Instrument Panel, Gauges and Console ....... 8-545
Front Suspension .......................................... 3-15 Keyless Entry .. ... .. .... ..... ... .. .. ... ..... ... .. ... ...... . 8-646
Rear Suspension ........................................... 3-43 Horns .. ... ... ..... ... .. ... ...... ... ... .... .... .... .. ... ... ..... 8-665
( Tires and Wheels .......................................... 3-61 Theft Deterrent ............................................ 8-675
Driveline/Axle .................................................. 4-1 Cruise Control ............................................. 8-713
Propeller Shaft ... ... .... .... ... .. .... ..... .... .... .... .... .... 4-3 Retained Accessory Power .......................... 8-754
Rear Drive Axle ............................................ 4-21 Exterior Trim ............................................... 8-764
Brakes .. ,........................................................... 5-1 Waterleaks ... .... ... .. ...... ... ... .... .... .... ... .. .. ....... 8-776
Hydraulic Brakes ............................................. 5-5 Air/Wind Noise ............................................ 8-783
Disc Brakes .. .... .... .. .. ... .... .. ..... ..... ... ... ... .... .... 5-56 Squeaks and Rattles . .... ... .... ... ..... ... . ... ... ... .. 8-785
Park Brake . ... .... .. .... .... .... .. ... ....... ... .. .... .... .... . 5-84 Stationary Windows ..................................... 8-801
Anti lock Brake System .................................. 5-97 Bumpers ..................................................... 8-829
INDEX ....................................................... INDEX-1 Body Front End _........................................... 8-849
Doors .. ... ... ...... .. ... ... ...... ... .... .... ... ... .. ... ..... ... 8-878
Roof ............................................................ 8-937
Volume 2
Seats .... .. ..... .... ... .. ....... ... .. ..... .... ... .. ... .. ..... 8-1 020
Preface ................................................................ 1 Interior Trim .............................................. 8-1061
Cautions and Notices .. .... .. .... ...... ... ... .... ... ...... .. .. 3 Body Rear End ......................................... 8-1075
Engine .............................................................. 6-1 Plastic Panel Information and Repair ......... 8-1112
Engine Mechanical - 3.8L .............................. 6-15 Paint/Coatings ........................................... 8-1133
Engine Mechanical - 5.7L ............................ 6-249 Frame and Underbody ............................... 8-1141
Engine Cooling ............................................ 6-594 Collision Repair ......................................... 8-1188
Engine Electrical ......................................... 6-674
Engine Controls - 3.8L ................................ 6-786 Restraints ......................................................... 9-1
En,gine Controls - 5.7L .............................. 6-1325 Seat Belts ..... .... .. ... ...... ... ... .... .... .. ... . ... ... ...... .. . 9-3
Engine Exhaust .... .. ...... .. .. .... ..... ... .... ... .... .. 6-1972 SIR ............................................................... 9-29
( I INDEX ....................................................... INDEX-1 INDEX ....................................................... INDEX-1

Engine Table of Contents 6-1
) Section 6
Engine
Engine Mechanical - 3:al ............................. 6-15 Crankshaft Front Cover Oil Seal
Specifications ........ ,.......................................6-15 Replacement ........................................... 6-108
Fastener Tightening Specifications ........ T .... 6-15 Engine Front Cover Replacement ................ 6-109
•· Engine Mechanical .. Specifications ,.······:··,·······6-16 Oil Pump Cover and Gear Set
GM SPO Group Numbers ..................... : ....... 6-19 Replacement ................ , .................. , ....... 6-116
Sealers, Adhesives, and l,.ubricants ............... 6-20 Oil Filter Adapter and Valve Assembly
Diagnostic Information and Procedures ...... :6-21 Replacement ...... : .......... :.......................... 6-116
Base Engine Misfire Diagnosis ..................... 6-21 Timing Chain and Sprockets
Replacement ........... ,................................ 6-120
Engine Compression Test ., .. :.......................6-23
Camshaft Replacement· .............................. 6-121
Engine Noise Diagnosis (Base, Engine) ....... :6-23
Cylinder Head Replacement(Left) .............. 6-123
Engine Noise Diagnosis (Valve Train) ...... , ... 6-25
Oil Consumption:Diagnosis .......................... 6-28 Cylinder Head Replacement (Right) ........... 6-125
Oil Pan Replacement .................. , .............. 6-127
Oil Pressure Diagnosis and Testing .... ; ........ 6-28
Oil Leak Diagnosis' ..................... ;.............. , .. 6-29 Oil Pump Pipe and Screen Assembly
Replacement ............ , .............................. 6-133
Gylinder Leakage Test .. ,.............................. 6-31
Engine Flywheel Replacement .................... 6-133
Symptoms - Drive Belt ........ ;.....•...... :.......•... 6-31
Crankshaft Rear Oil Seal and Housing
Drive Belt Chirping Diagnosis'·· ............... , ..... 6-32
Replacement ....... , ................................... 6-135
Drive Belt Squeal Diagnosis ..................... ; ... 6-34
) Drive Belt Whine Diagnosis ............... ; .......... 6-36
Engine Replacement. ..................................6-137
Engine Oil and Oil Filter Replacement ....... 6-168
Drive Belt Rumbling Diagnosis ................ , .... 6-37
Draining Fluids and OH Filter Removal ....... 6-170
.Dri\(e Belt Vibration Diagnosis .................. ,.. :6-38
Crankshaft
. .Balancer . . Removal .................... 6-170
Drive .Belt Falls. Off Diagnosis ... , .. ,.. ,:, .... ,..... 6-40
Engine Flywheel Removal
Drive B~lt ,Excessive. Wear Diagnosis ........... 6-42 (Manual Transmission) ................ ;........... 6-171
Drive Belt Tensioner Diagnosis ... ,... , ........... ,6-42 Engine Flywheel Removal
Disassembled Views ....................................6-43 (Automatic Transmission) ........................ 6-172
Repair Instructions .......... ,............. ,................ 6-47 Drive Belt Tensioner Removal .................... 6-172
Drive Belt Replacement .· ............................... 6-47 Oil Level Indicator and Tube Removal ....... 6-172
Drive Belt Tensioner. Replacement ............... 6-48 Water Outlet Removal ................................ 6-173
Drive Belt Idler F'l.llley Replacement .............. 6-49 Water Pump Removal ............... :................ 6-173
Engine Mount Inspection ......... ·.· .................... 6-50 Intake Manifold Removal (Upper) ............ ,.. 6-174
Engine· Support Fixture .................................6~50 Intake Manifold Removal (Lower) ............... 6-175
Engine Mount Replacement ......................... 6-51 Exhaust Manifold Removal. (Left Side) ........ 6-176
Engine Mount Bracket Replacement ............. 6-59 Exhaust Manifold Removal (Right Side) ..... 6-177
Oil Level Indicator and Tube Replacement ... 6-68 Valve Rocker Arm Cover Removal
Intake Manifold Replacement (Upper) ........... 6-68 (Left Side) .,, .. ,.,........................................ 6-178
Intake Manifold Replacement (Lower) ........... 6-80 Valve. Rocker Arm Cover Removal
Exhaust Manifold Replacement (Left) .......... :6-82 (Right Side) ......................... :............. , ..... 6-178
Exhaust Manifold Replacement (Right) .........• 6-87 V.alve Rocker Arm and Push Rod
Valve .Rocker Arm Cover Removal ................................................. 6-178
Replacement (Left) ................. ,.,.,, ....... ;, ... 6-93 Cylinder Head Removal ............... ,............. 6-179
Valve Rocker Arm Cover Valve Lifter Removal .................................. 6-179
Replacement (Right) ................ ,................ 6-97 Crankshaft Front Oil .Seal Removal ........ , ... 6-179
Valve Rocker Arm and Push Rod Engine Front Cover Removal ...................... 6-180
Replacement ......................... ,.................. 6-99 Oil Filter Adapter Removal ......................... 6-181
) Valve Stem Oil Seal and Valve Spring Oil Pump Cover and Gear Set Removal .... 6-181
Replacement .: .. ,.... ,...... , .. :, ............. .:........ 6-101 Timing Chain and Sprockets
Valve. Lifter Replacement .: .. ,................. ,., .. 6-104 Removal (VIN K) .................................... 6-181
Crankshaft Bal.ancer Replacement ....... ,...... 6-105 · Camshaft Removal ...................................... 6-183
6-2 Table of Contents Engine
Balance Shaft Removal .............................. 6-183 Piston, Connecting Rod, and Bearing
Crankshaft Rear Oil Seal Removal ............. 6-184 Installation ..............................................6-220
Crankshaft Rear Oil Seal and Housing Oil Pump Pipe and Screen Assembly
Removal .................................................6-184 Installation .............................................. 6-222
Oil Pan Removal ........................................6-185 Oil Pan Installation .....................................6-222
Oil Pump Pipe and Screen Assembly Camshaft Installation .............................. : ... 6-223
Removal .................................................6-185 Balance Shaft Installation ........................... 6-223
Piston, Connecting Rod, and Bearing Crankshaft Rear Oil Seal and Housing
Removal .................................................6-186 Installation ..............................................6-225
Crankshaft and Bearings Removal ............. 6-187 Crankshaft Rear Oil Seal Installation .......... 6-226
Engine Block Plug Removal ....................... 6-188 Timing Chain and Sprockets
Engine Block Clean and Inspect ................ 6-189 Installation (VIN K) ................................. 6-227
Cylinder Boring and Honing ....................... 6-191 Oil Pump Cover and Gear Set
Crankshaft and Bearings Clean and Installation ..............................................6-228
Inspect ...................................................6-192 Oil Filter Adapter Installation ................. ; .... 6-228
Crankshaft Balancer Clean and Inspect ...... 6-194 Engine Front Cover Installation .................. 6-229
Engine Flywheel Clean and Inspect
Crankshaft Front Oil Seal Installation ..•...... 6-230
(Automatic Transmission) ........................ 6-195
Engine Flywheel Clean and Inspect Valve Lifter Installation ............................... 6-230
(Manual Transmission) ............. , .............. 6-195 Cylinder Head Installation ........................... 6-231
Piston and Connecting Rod Disass.emble ... 6-195 Valve Rocker Arm and Push Rod
Piston, Connecting Rod, and Bearings Installation ..............................................6-231
Clean and Inspect ................................... 6-196 Valve Rocker Arm Cover Installation
Piston Selection ........... : ............................. 6-198 (Left Side} .. , .......................................... '..6-232
Piston and Connecting Rod Assemble ........ 6-200 Valve Rocker Arm Cover Installation
Camshaft Bearing Removal ......................... 6-201 (Right Side) .............................................6-232
Camshaft and Bearings Clean and Exhaust Manifold Installation (Left Side) , .... 6-232
Inspect .....................................................6-202 Exhaust Manifold Installation
Camshaft Bearing Installation ..................... 6-203 (Right Side) ............................................6-234
Timing Chain and Sprockets Clean and Intake Manifold Installation (Lower) ............6-234
Inspect (VIN K) .... , .................................. 6-203 Intake Manifold Installation (Upper) ............6-235
Valve Rocker Arm and Push Rods Water Pump Installation .............................6-237
Clean and Inspect .................................. 6-204
Water Outlet Installation ............................. 6-238
Valve Lifters and Guides Clean and
Inspect ........................ , .......................... 6-205 Oil Level Indicator and Tube Installation ..... 6-238
Cylinder Head Disassemble ....................... 6-205 Drive Belt Tensioner Installation ................. 6-238
Cylinder Head Clean and Inspect ............... 6-206 Engine Flywheel Installation
Valve Guide ReamingNalve and Seat (Automatic Transmission) ........................ 6:239
Grinding ................................................. :6-208 Engine Flywheel Installation
Cylinder Head Assemble ...................... , ..... 6-210 (Manual Transmission) ............................. 6~239
Oil Pump Clean and Inspect ...................... 6-211 Crankshaft Balancer Installation .................. 6-239
Valve Rocker Arm Cover Clean Description and Operation .......................... 6-241
and Inspect ......................................... ; .. 6-213 Engine Component Description ........... , ..... ,6-241
Oil Pan Clean and Inspect ......................... 6-213 Drive Belt System Description .................... 6-241
Intake Manifold Clean and Inspect Lubrication Description ............................... 6-242
(Upper) ...................................................6-214
Cleanliness and Care ................................. 6-243
Intake Manifold Clean a.nd Inspect
(Lower) ...................................................6-214 Replacing Engine Gaskets ......................... 6-243
Exhaust Manifold Clean and Inspect .......... 6-214 Use of RTV and Anaerobic Sealer .............6-243
Water Pump Clean and Inspect ............. :, .. 6-215 Separating Parts ........................................6-244
Engine Front Cover Clean and Inspect ...... 6-215 Service Precautions ................................... 6-244
Balance Shaft Clean and Inspect ............... 6-216 Installation Precautions ............................... 6-245
Balance Shaft Bearing and/or Bushing Tools and Equipment .................................6-245
Removal ..................................................6-216 Special Tools and Equipment .....................6-245
Balance Shaft Bearing and/or Bushing
Installation ..............................................6-216 Engine Mechanical - 5.7L ....... ,...................6-249
Thread Repair ............................................6-218 Specifications ....................... :......................6-249 (
Service Prior to Assembly .......................... 6-218 Fastener Tightening Specifications ............. 6-249
Engine Block Plug Installation ...•................ 6-219 Engine Mechanical Specifications ............... 6-251
Crankshaft and Bearings Installation ...........6-219 GM SPO Group Numbers .......................... 6-254
Sealers, Adhesives, and Lubricants ............ 6-256 Oil Pump, Pump Screen and Deflector
Thread Repair Specifications ...................... 6-257 Replacement ........................................... 6-379
) Diagnostic Information and Procedures ..... 6-270
Base Engine Misfire Diagnosis ................... 6-270
Replacement ...........................................6-380
Engine Compression Test .......................... 6-272 Camshaft Replacement ............................. ;6-382
Engine Noise Diagnosis ... ;.............. :, ......... 6-272 Engine Flywheel Replacement ................ ;; .. 6-384
Valve Train Diagnosis ................................ 6-274 Engine Replacement .......................... , ....... 6-385
Oil Consumption Diagnosis .................... ,... 6-276 Engine Oil and Oil Filter Change ............... 6-416
Oil Pressure Diagnosis and Testing ........... 6-276 Draining Fluids and Oil Filter Removal ....... 6-417
. Oil Leak Diagnosis .....................................6-277 Crankshaft Balancer Removal .................... 6-419
Symptoms. - Drive Belt ..... ;.........................6-278 Engine Flywheel Removal .......................... 6-420
Drive Belt Chirping Diagnosis ..................... 6-279 Clutch Pilot Bearing Removal ..................... 6-421
Drive Belt Squeal Diagnosis .......................6-281 Oil Level Indicator and Tube Removal ....... 6-422
Drive Belt Whine Diagnosis ........................ 6-283 Exhaust Manifold Removal (Left Side) ........ 6-422
Drive Belt Rumbling Diagnosis ............ ,...... 6-284 Exhaust Manifold Removal (Right Side) ..... 6-424
. Drive Belt Vibration Diagnosis .................... 6-285 Water Pump Removal ................................ 6-426
Drive Belt Falls Off Diagnosis ..... ,.............. 6-287 Throttle Body Removal.; ....... ,...................... 6-426
Drive Belt Excessive Wear Diagnosis ......... 6-289 Fuel Rail and Injectors Removal ................ 6-427
. Dri_ve Belt Tensioner Diagnosis .................. 6-289 Intake Manifold Removal ............................ 6-428
· Visual Identification ......................................6-290 Vapor Vent Pipe Removal .......................... 6-431
Qisassembled Views .... ,.............................. 6-290 Engine Valley Cover Removal .................... 6-432
· Repair Instructions ......................................6-296 Valve Rocker Arm Cover Removal
Drive Belt Replacement - Accessory .......... 6-296 (Left Side) ................................. : ... , ........ 6-433
Drive Belt Replacement - A/C ..................... 6-298 Valve Rocker Arm Cover Removal
Drive. Be.It Idler Pulley Replacement , (Right Side) ........................................... :6-434
Acce_ssory ........ : ......................................6-299 Valve Rocker Arm and Push Rod
Drive Belt Idler Pulley · ' Removal .... :............................................6-436
Replacement - A/C ................................. :6-299 Cylinder Head Removal (Left Side) ............ 6-437
Drive Belt Tensioner Replacement· - Cylinder Head Removal (Right Side) .......... 6-438
) Accessory ... ,... : ............ ,.. : . ,..................... 6-300 Valve Lifter Removal ..................................6-438
Drive Belt Tensioner Replacement O A/C ..... 6-301 Oil Filter, Adapter and Pan Cover
Engine Mount Inspection .................... :....... 6-302 Removal .................................................6-439
Engine Support Fixture .................. ,........ :.. 6-302 Oil Pan Removal ................................ ,....... 6-440
Engine Mount Replacement (Left) ..............6-303 Engine Front Cover Removal ..................... 6-442
Engine Mount Replacement (Right) ............6-307 Engine Rear Cover Removal ...................... 6-443
Intake Manifold Replace,ment ., ................... 6-311 Oil Pump, Pump Screen and Deflector
Vapor Vent Pipe Replacement .................... 6-324 Removal .... ,.... ,.......................................6-444
Engine Valley Cover Replacement ............. 6-325 Timing Chain and Sprockets Removal ........ 6-445
Valve Rocker Arm Cover . Camshaft Removal .....................................6-446
Replacement (Left) ................................. 6-326 Piston, Connecting Rod, and Bearing
Valve Rocker Arm Cover · Removal .............................................. :.. 6-447
Replacement (Right) ·............................... 6-332 Crankshaft and Bearings Removal ............. 6-449
Valve Rocker Arm and Push Rod Engine Block Plug Removal ....................... 6-451
Replacement ... :, ......... ,............................ 6-334 Engine Block Clean and Inspect ................ 6-455
Valve Stem Oil Seal a:nd Valve Spring·· Cylinder Boring and Honing ....................... 6-456
Replacement ............ , .......................,... ,.,.6-335 Crankshaft and Bearings Clean and
Oil Level Indicator and Tube Inspect ............ '.......................................6-458
· · Replacement ...........................................6-339 Crankshaft Balancer Clean .and Inspect ...... 6-467
Exhaust Manifold Replacement (Left) ......... 6-342 Engine Flywheel Clean and Inspect ........... 6-468
Exhaust Manifold Replacen:,ent (Right) ....... 6-345 Piston and Connecting Rod
Cylinder Head Replacement (Left) .............. 6-348 Disassemble ..... : ...................................... 6-468
Cylinder Head Replacement (Right) ,......... :6-350 Piston, Connecting Rod, and Bearings
Valve Lifter Replacement :.......................... 6-352 Clean and lnspect(Piston and Pin) ........ 6-470
Crankshaft Balancer Replacement .............. 6-353 Piston, Connecting Rod, and Bearings
Clean· and Inspect
Crankshaft Front Oil Seal Replacement ...... 6-356 (Connecting Rod and Bearings) .............. 6-472
Engine Front Cover Replacement ............... 6-357 Piston, Connecting Rod, and Bearings
Crankshaft Rear Oil Seal Replacement ...... 6-366 Clean and Inspect
Engine Rear Cover Replacement ............... 6-367 (Measuring Piston Ring End Gap) .......... 6-475
Oil Pan Replacement .............. ,., ................ 6-370 . Piston Selection ......................................... 6-475
Piston and Connecting Rod Assemble ........ 6-476 Throttle Body Installation ....................... ,, .... 6-568
· Camshaft Bearing Removal ........................ 6-479 Water Pump Installation ...................... ,...... 6-569
Camshaft and Bearings Clean and Exhaust Manifold Installation (Left Side) ..... 6-569
Inspect ................................................... 6-481 Exhaust Manifold Installation
Camshaft Bearing Installation ..................... 6-484 (Right Side) .......................... ,.................6-571
Timing Chain and Sprockets Clean and Oil Level Indicator and Tube Installation ..... 6-574
Inspect ...................................................6-485 Clutch Pilot Bearing Installation .................. 6-575
Valve Rocker Arm and Push Rods Engine Flywheel Installation ....................... 6-576
Clean and Inspect .................................. 6-486 Crankshaft Balancer Installation .................. 6-577
Valve Lifters and Guides Clean and Engine Set-Up and Testing ......................... 6-579
Inspect ..................................... , ...... , ...... 6-487 Description and Operation .......................... 6-580
Cylinder Head Disassemble ....................... 6-489 Engine Component Description ................. ,6-580
Cylinder Head Clean and Inspect .............. ,6-491 Drive Belt System Description .................... 6-582
Valve Guide ReamingNalve and Seat New Product Information ............................ 6-582
Grinding ...... , ........................................... 6-493 Engine Identification ............................. :..... 6-583
Cylinder Head Assemble ............................ 6-497 Lubrication .................................................6-584
Oil Pump Disassemble ............................... 6-501 Cleanliness and Care .................................6-585
Oil Pump Clean and Inspect ...................... 6-503
Replacing Engine Gaskets ........ ,.......... : ..... 6-585
Oil Pump Assemble ................................... 6-505
Use of RTV and Anaerobic Sealer .............6-586
Engine Front Cover Clean and Inspect ...... 6-508
Engine Rear Cover Clean and Inspect ....... 6-508 Separating Parts ........................................ 6-587
Engine Valley Cover Clean and Inspect ..... 6-508 Installation Precautions ............................... 6-587
Valve Rocker Arm Cover Clean and Tools and Equipment .................................. 6-587
Inspect ................................................... 6-509 Special Tools and Equipment ........ , ............6-588
Oil Pan Clean and Inspect ......................... 6-511
Engine Cooling .............................................6-594
Intake Manifold Clean and Inspect ............. 6-514
Exhaust Manifold Clean and Inspect .......... 6-517 Specifications ..............................................6-594
Vapor Vent Pipe Clean and Inspect ........... 6-519 Fastener Tightening Specifications ...... , ...... 6-594
Water Pump Clean and Inspect ................. 6-519 Engine Cooling System Specifications ........ 6-594
Thread Repair ............................................6-520 GM SPO Group Numbers ........................... 6-595 (
Service Prior to Assembly .......................... 6-528 Schematic and Routing Diagrams ............ ,.6-595
Engine Block Plug Installation .................... 6-529 Cooling System Schematic Icons ............... 6-595
Crankshaft and Bearings Installation ........... 6-532 Cooling Fan Schematics ............................ 6-596
Piston, Connecting Rod, and Bearing Component Locator .....................................6-598
Installation .............................................. 6-535 Cooling System Components ..................... 6-598
Camshaft Installation .................................. 6-538
Cooling System Component Views ............. 6-599
Timing Chain and Sprockets Installation ..... 6-539
Cooling System Connector End Views ....... 6-600
Oil Pump, Pump Screen and Deflector
Installation ..............................................6-541 Diagnostic Information and Procedures ..... 6-601
Engine Rear Cover Installation ................... 6-542 Engine Overheating .................................... 6-601
Crankshaft Rear Oil Seal Installation .......... 6-545 Loss of Coolant .........................................6-602
Engine Front Cover Installation .................. 6-546 Thermostat Diagnosis ............. ,................... 6-604
Crankshaft Front Oil Seal Installation ......... 6-548 Engine Fails To Reach Normal
Oil Pan Installation ..................................... 6-548 Operating Temperature ........................ ,... 6-604
Oil Filter, Adapter, Pan Cover Coolant Concentration Testing ................ :'.,.6-604
Installation ..............................................6-551 Cooling System Leak Testing ..................... 6-606
Valve Lifter Installation ............................... 6-552 Pressure Cap Testing ................. :............ :.6-608
Cylinder Head Installation (Left Side) ......... 6-553 Repair Instructions .......................................6-608
Cylinder Head Installation (Right Side) ....... 6-555 Draining and Filling Cooling
Valve Rocker Arm and Push Rod System (3.8 L) ........................................ 6-608
Installation ....................... , ...................... 6-557 Draining and Filling Cooling
Valve Rocker Arm Cover Installation System (5.7 L) ........................................6-609
(Left Side) · .............................................. 6-559 Flushing ..................................................... 6-609
Valve Rocker Arm Cover Installation Radiator Cleaning ...................................... 6-61 O
(Right Side) ......................................... ,.. 6-560 Coolant Recovery Reservoir
Engine Valley Cover Installation ................. 6-562 Replacement ...........................................6·61 O
Vapor Vent Pipe Installation ....................... 6-563 Coolant Recovery Pipe Replacement ......... 6-613
Intake Manifold Installation ......................... 6-564 Radiator Hose Replacement -
Fuel Rail and Injectors Installation .............. 6-568 Inlet (3.8 L) ............................................ 6-614
Radiator Hos.e Replacement - Engine Electrical ..........................................6-674
Inlet (5.7 L) ........ , ................................... 6-617 Specifications ..............................................6-67 4
) Radiator Hose Replacement - Fastener Tightening Specifications ............. 6-67 4
Outlet (3.8 L) .................................. , ....... 6-620 Battery Usage ............................................ 6-675
Radi.ator Hose Replacement - Battery Temperature vs Voltage Drop ........ 6-675
· Outlet (5.7 L) ..........................................6-623 Starter Motor Usage ............................ .'...... 6-675
Throttle Body Heater Hose Generator Usage .......................................6~675
Replacement - Inlet (5.7 L) ..................... 6-625 Spark Plug Usage ......................................6-675
Throttle Body Heater Hose Spark Plug Wire Resistance ....................... 6-676
Replacement " Outlet (5. 7 L) .................. 6-626
GM SPO Group Numbers .......................... 6-676
Cooling Fan Replacement - Electric ........... 6-627
Schematic and Routing Diagrams .............. 6-676
Cooling Fan Motor Replacement -
Engine Electrical Schematic Icons .............. 6-676
Electric ......................... ,..........,............... 6-633
Starting and Charging Schematics .............. 6-677
Cooling Fan Relay Replacement ................. 6-633
Component Locator ..................................... 6-680
Thermostat Housing
Replacement (3.8 L) ................................ 6-634 Engine Electrical Components .................... 6-680
. Thermostat Housing Engine Electrical Component Views ........... 6-682
Replacement (5.7 L) ............................... 6-637 Engine Electrical Connector End Views ...... 6-686
Thermostat Replacement (3.8 L) ....... : ........ 6-638 Diagnostic Information and Procedures ..... 6-686
thermostat Replacement (5.7 L) ................. 6-639 A Diagnostic Starting Point - Engine
The.rmostat Bypass Pipes Electrical .................................................6-686
Replacement (3;8 L) ............................... 6-639 Symptoms - Engine Electrical ..................... 6-686
Water Pump Replacement (3.8 L) .............. 6-640 Starter Solenoid Does Not Click ................. 6-687
Water Pump Replacement (5.7 L) .............. 6-642 Starter Solenoid Clicks, Engine Does
Engine Coolant Temperature Sensor Not Crank .............................. ,................ 6-689
Replacement(3.8 L) ., ............................. 6-650 Engine Cranks/Cranks Slowly, but Does
Engine Coolant Temperature Sensor Not Start ................................................ :6-690
Replacement (5.7 L) ............................... 6-651 Starter Motor Noise Diagnosis .................... 6-691
Drain Cock Replacement ............................ 6-652 Starter No Load Test ................................. 6-692
) Fan Shroud Replacement ........................... 6-652 Battery Common Causes of Failure ............ 6-692
Radiator Replacement ................................6-654 Battery Check ............................................ 6-693
Radiator Support Replacement ................... 6-658 Battery Terminal Check .............................. 6-694
Radiator Air Baffle Assemblies and Battery Hydrometer Displays Yellow Dot .... 6-695
Deflectors (Lower) ..................................6-661 Battery Not Operating Properly ... , ............... 6-696
Radiator Air Baffle Assemblies and Battery Hydrometer Displays Dark or
Deflectors (Upper) ....................... , ..........6-662 Yellow Dot ..............................................6-700
Coolant Heater Replacement (3.8 L) .......... 6-663 Battery Electrical Drain/Parasitic
Coolant Heater Replacement (5.7 L) ..........6-664 Load Test ...............................................6-700
Coolant Heater Cord Generator Not Operating Properly .............. 6-704
Replacement (3:8 L) ...............................6-666 Generator Assembly Check ........................ 6-706
Coolant Heater Cord Spar k Pl ug V1suaID'1agnos1s . ..............
. . 6-707
·.· ......
Replacement (5.7 L) ............................... 6-667 Spark Plug Wires Not Operating ·
· Description and Operation ..........................6-669 Properly ..................................................6-709
Cooling System Description ........................ 6-669 Repair Instructions ......................................6- 71 o
Coolant Description ....................................6-669 Starter Motor Relay Replacement ............... 6-71 O
Coolant Recovery System Description ........ 6-669 Starter Motor Replacement (3.8 L) ............. 6-711
Throttle Body Coolant System Starter Motor Replacement (5. 7 L) .............. 6-713
Description· .............................................6-670 Starter Pinion Clearance Check ................. 6-716
Coolant. Heater Description ......................... 6-670 Starter Shield Replacement (3.8 L) ............ 6-717
. Radiator Assembly Description ............. ,..... 6-670 Starter Shield Replacement (5. 7 L) ............ 6-717
Pressure Cap Description ........................... 6-671 Battery Charging ........................................6-718
Engine Cooling Fan Description - Battery Charge Low or Completely
l::lectric ...................................................6-671 Discharged .............................................6-719
Cooling Fan Relay Description ................... 6-672 Jump Starting in Case of Emergency ......... 6-720
Water Pump Description ............................ 6-672 Battery Negative Cable Disconnect/
Thermostat Description .... ,.......... , ............... 6-672 Connect Procedure .................................6-722
Engine CoolantTemperature Sensor Battery Cable Replacement
Description .............................................6-672 (3.8 L Positive) .................................. ,: ... 6-723
Air Baffles and Seals Description ............... 6-673 Battery Cable Replacement
Special Tools and Equipment ..................... 6-673 (3.8 L Negative) .................................... :.6-727
Battery Cable Replacement Diagnostic Information and Procedures ..... 6·826
(5.7 L Positive) .......................................6-729 A Diagnostic Starting Point ........................ 6·826
Battery Cable Replacement A Powertrain On Board ·
(5.7 L Negative) ................................•..... 6-732 Diagnostic (OBD) System Check ............. 6·827
Battery Hold Down Retainer Scan Tool Data List ·.................. : ... : ... :........ 6·828
Replacement ...........................................6-734 · Scan Tool Data Definitions ........ : ......... ,... : .. 6·832
Battery Replacement ..................... , ........• :.. 6-735 Diagnostic Trouble Code (OTC) Type '
Battery Tray Replacement .......................... 6-738 Definitions ........................ : ...................... 6·838
Underhood Fuse Block Replacement ...... ,... 6-741 Diagnostic Trouble Code (OTC) List/Type ... 6·839
Ground Strap Replacement .......... :·:·····:···:.6-759 Malfunction Indicator Lamp (MIL) ·
Generator Bracket Replacement (3.8 L) ... ,.6-761 Inoperative .................. : .......................... :6-843
Generator Bracket Replacement Data Link Connector Diagnosis ............... , .. 6·845
(5.7 L Front) ........ , .................................. 6-762 Engine Cranks but Does Not Run ............... 6·847
Generator Bracket Replacement .. . Fuel Pump Electrical Circuit Diagnosis ....... 13.·854
(5.7 L Rear) ................................ , .... '. ..... 6~763 Fuel System Diagnosis ........... : ........... ,, ..... 6·856
Generator Brace Replacement ................. : .. 6-763 DTC P0101 Mass Air Flow (MAF) .
Generator Replacement (3.8 L) ............ ,..... 6-764 Sensor Performance ·······:,··········,···········6·857
Generator Replacement (5.7 L) ... ,,, ............ 6-766 DTC P0102 Mass Air Flow (MAF)
Generator Splash Shield Replacement ........ 6-769 Sensor Circuit Low Frequency ....... .'..........6·861
Spark Plug Wire Harness Replacement DTC P0103 Mass Air Flow (MAF) . ' .
(3.8 L Right Bank) ,................................. 6-770 Sensor Circuit Higll Frequency ... ,......... ,.6·864
Spark· Plug Wire Harness Replacement DTC P0107 Manifold Absolute '
(3.8 L Left Bank) ....................... , ............ 6-772 Pressure (MAP) Sensor Circuit Low
. Spark Plug Wire Harness · Voltage ................................................ ,.. 6-867
Replacement (5.7 L) ................................ 6-773 DTC P0108 Manifold Absolute
Spark Plug Replacement ........................ :: .. 6-774 Pressure (MAP) Sensor Circuit High
Ignition Coil Replacement (3.8 L) ................ 6-775 Voltage ............... , .................. , ...........•.. :.6·870
Ignition Coil Replacement (5.7 L) ....... , ....... 6-776 DTC P0112 Intake Air Temperature (IAT) ·
Ignition Coil Module , Sensor Circuit Low Voltage ................. : ... 6·872
Replacement (3.8 L) ... ,.............. :........ ,... 6~777 DTC P0113 Intake Air (
Description and Operation ................... ,...... 6-780 Temperature (IAT) Sensor Circuit
Starting System Description .....................•. 6-780 High Voltage .................................•.........6-874
Starting System Operation ......................... 6-780 DTC P0117 Engine Coolant
Temperature (ECT) Sensor Circuit
Starting System Circuit Description ...... ,...... 6-780
Low Voltage ......................•.....................6·877
Battery Description ..................................... 6-781
DTC P0118 Engine Coolant
Battery Operation ................................ ;...... 6-781 Temperature (ECT) Sensor Circuit
Battery Tray and Hold-Down Retainer High Voltage ......................... , .... :......... : .. 6-879
Description .............. :..................... :., ... ,... 6-782 DTC P0125 Engine Coolant
Charging System Description ................... ,.6-782 Temperature (ECT) Excessive . Time
Charging System Operation .............. ,........ 6-783 to Closed Loop Fuel Control : .......... ._., .... 6·882
Charging System Circuit Description ... :.:, .... 6-783 OTC P0131 H02S Circuit Low Voltage
Ignition System Description (3.8 L) ...........·.. 6-783 Bank 1 Sensor 1 ............ , ......................... 6-885
Ignition System Description (5.7 L) ...... ,...•.. 6-784 DTC P0132 H02S Circuit High Voltage
Ignition System Operation .......................... 6-784 Bank 1 Sensor 1 ................ ,.................... 6·887
Special Tools and Equipment ..................... 6-785 DTC P0133 H02S Slow Response
Bank 1 Sensor 1 ......................................6·890
Engine Controls - 3.8L ................................6-786
DTC P0134 H02S Circuit Insufficient
Specifications ..............................................6-786 Activity Bank 1 Sensor 1 ................. ,....... 6·893
Temperature vs Resistance ...............•........ 6-786 DTC P0135 H02S Heater Performance
Fastener Tightening Specifications ............. 6-786 Bank 1 Sensor 1 ······:·: ... : ................'......• :6·896
Fuel System Specifications ...................... ,.. 6-787 DTC P0137 H02S Circuit Low Voltage
Schematic and Routing Diagrams .............. 6, 788 Bank 1 Sensor 2 .............. ,., ...... :............. 6·899
Emission Hose Routing Diagram ................ 6-788 DTC P0138 H02S. Circuit High Voltage
. Engine Controls Schematic Icons ............... 6-790 Bank 1 Sensor 2 ................................... :.. 6·902
Engine Controls Schematics .. , .................... 6-791 DTC P0140 H02S Circuit Insufficient
Component Locator .................................,.·.. 6-807 Activity Bank 1 Sensor 2 ............ :.... :....... 6·905 (
Engine Controls Components .................. :.. 60807 DTC P0141 H02S Heater Performance
Engine Controls Component Views ............ 6-812 Bank 1 Sensor 2 .....................................6-908
PCM Connector End Views ........... : ............ 6-814 DTC P0151 H02S Circuit Low Voltage
Engine Controls Connector End Views ....... 6-818 Bank 2 Sensor 1 .......................... ,.......... 6-911
DTC P0152 H02S Circuit High Voltage DTC P0452 Fuel Tank Pressure Sensor
Bank 2 Sensor 1 .....................................6-913 Circuit Low Voltage ..................... ; ......... 6-1010
DTC P0153 H02S Slow Response DTC P0453 Fuel Tank Pressure Sensor
Bank 2 Sensor t .............................. ,...... 6-916 Circuit High Voltage .............................. 6-1013
DTC P0154 H02S Circuit Insufficient DTC P0462 Fuel Level Sensor Circuit
Activity Bank 2 Sensor 1 ......................... 6-919 Low Voltage ...................................•..... 6-1015
DTC P0155 H02S Heater Performance DTC P0463 Fuel Level Sensor Circuit
Bank 2 Sensor 1 .............................. ;...... 6-922 High Voltage ......................................... 6-1017
DTC P0171 Fuel Trim System Lean DTC P0480 Cooling Fan Relay 1
Bank 1 ............................................ ;....... 6-925 Control Circuit .......................................6-1020
..DTC P0172 Fuel Trim System Rich DTC P0481 Cooling Fan Relay 2 and 3
Bank 1 .•..................................................6-928 Control Circuit .......................................6-1023
DTC P0174 Fuel Trim System Lean DTC P0500 Vehicle Speed
Bank 2 ........................... :........................6-931 Sensor (VSS) Circuit ............................. 6-1026
DTC P0175 Fuel Trim System Rich DTC P0506 Idle Speed Low ..................... 6-1028
Bank 2 ...•................................................6-934 DTC P0507 Idle Speed High .................... 6-1030
DTC P0201 Injector 1 Control Circuit .......... 6-937 DTC P0530 Air Conditioning (A/C)
DTC P0202 Injector 2 Control Circuit ..........6-940 Refrigerant Pressure Sensor Circuit ...... 6-1032
DTC P0203 Injector 3 Control Circuit .......... 6-943 DTC P0560 System Voltage ..................... 6-1035
DTC P0204 Injector 4 Control Circuit .......... 6-946 DTC P0567 Cruise Control Resume
DTC P0205 Injector 5 Control Circuit .......... 6-949 Switch Circuit ................ : ....................... 6-1038
DTC P0206 Injector 6 Control Circuit .......... 6-952 DTC P0568 Cruise Control Set Switch
DTC P0230 Fuel Pump Relay Control Circuit ....................................................6-1040
Circuit .....................................................6-955 DTC P0571 Cruise Control Brake
DTC P0300 Engine Misfire Detected ..........6-958 Switch Circuit ........................................ 6-1042
DTC P0325 Knock Sensor (KS) Circuit ....... 6-963 DTC P0601 Control Module Read Only
DTC P0327 Knock Sensor (KS) Circuit Memory (ROM) .....................................6-1046
Bank 1 ....................................................6-965 DTC P0602 Control Module Not
DTC P0332 Knock Sensor (KS) Circuit Programmed ......................................... 6-1047
) Bank 2 ....................................................6-968 DTC P0604 Control Module Random
Access Memory (RAM) .......................... 6-1047
DTC P0336 Crankshaft Position (CKP)
Sensor Circuit .........................................6-971 DTC P0606 Control Module Internal
DTC P0341 Camshaft Position (CMP) Performance .........................................6-1048
Sensor Performance ............................... 6-974 DTC P0620 Generator Performance ......... 6-1049
DTC P0401 Exhaust Gas DTC P0650 Malfunction Indicator
.Recirculation (EGR) Flow Insufficient ....... 6-978 Lamp (MIL) Control Circuit .................... 6-1051
DTC P0403 Exhaust Gas OTC P0704 Clutch Switch Circuit ............. 6-1054
Recirculation (EGR) Solenoid Control DTC P1106 Manifold Absolute
Circuit ...................•.................................6-980 Pressure (MAP) Sensor Circuit
DTC P0404 Exhaust Gas Intermittent High Voltage ....................... 6-1057
Recirculation (EGR) Open Position DTC P1107 Manifold Absolute
Performance ...........................................6-983 Pressure (MAP) Sensor Circuit
DTC P0405 Exhaust Gas Intermittent Low Voltage ...... : ................ 6-1059
Recirculation (EGR) Position Sensor OTC P1111 Intake Air
Circuit Low Voltage ..................................6-986 Temperature (IAT) Sensor Circuit
DJ"C P0420 Cataly_st System Low _ Intermittent High Voltage ....................... 6-1061
Efficiency ................................................6-989 DTC P1112 Intake Air
DTC P0440 Evaporative Temperature (IAT) Sensor Circuit
Emission (EVAP) System ..... ,.................. 6-992 Intermittent Low Voltage ....................... 6-1063
DTC P0442 Evaporative DTC P1114 Engine Coolant
Emission (EVAP) System Small Leak Temperature (ECT) Sensor Circuit
Detected .................................................6-997 Intermittent. Low Voltage ....................... 6-1065
DTC P0443 Evaporative DTC P1115 Engine Coolant
Emission (EVAP) Purge Solenoid Temperature (ECT) Sensor Circuit
Control Circuit .......................................6-1001 Intermittent High Voltage ........................ 6-1067
DTC P0446 Evaporative DTC P1120 Throttle Position (TP)
Emission (EVAP) Vent System · Sensor 1 Circuit .................................... 6-1069
Performance .........................................6~ 1004 DTC P1125 Accelerator Pedal
DTC P0449 Evaporative Position (APP) System .......................... 6-1073
Emission (EVAP) Vent Solenoid DTC P1133 H02S Insufficient Switching
Control Circuit ...................................... :6-1007 Bank 1 Sensor 1 ................................... 6-1074
DTC P1134 H02S Transition Time OTC P1518 Throttle Actuator
Ratio Bank 1 Sensor 1 ..... ; .................... 6-1077 Control (TAC) Module Serial Data
OTC P1153 H02S Insufficient Switching Circuit ............................ ;...................... 6-1141
Bank 2 Sensor 1 ...................................6-1080 DTC P1519 Throttle Actuator
OTC P 1154 H02S Transition Time Control (TAC) Module Internal Circuit .... 6-1144
Ratio Bank 2 Sensor 1 .............•............ 6-1083 DTC P1523 Throttle Closed Position ·
OTC P1220 Throttle .Position (TP) Performance ......................................... 6-1145
Sensor 2 Circuit ....................................6-1086 DTC P1546 Air Conditioning (A/C) •
OTC P1221 Throttle Position (TP) Clutch Relay Control Circuit ..... : ............ 6,1146
Sensor 1- 2 Correlation ......................... 6-1090 DTC P1571 Traction Control Torque
OTC P1271 Accelerator Pedal Request Circuit ................ ,.................... 6-1149
Position (APP) Sensor 1-2 Correlation ... 6-1093 DTC P1574 Stoplamp Switch Circuit _ ......... 6-1151
OTC P1272 Accelerator Pedal OTC P1586 Cruise Control Brake
Position (APP) Sensor 2-3 Correlation ... 6-1094 Switch 2 Circuit .................................... 6-1154
OTC P1273 Accelerator Pedal OTC P1626 Theft Deterrent Fuel Enable
Position (APP) Sensor 1-3 Correlation ... 6-1095 Signal Lost ...........................................6-1157
OTC P1275 Accelerator Pedal DTC P1629 Theft Deterrent Fuel Enable
Position (APP) Sensor 1 Circuit ............. 6-1096 Signal Not Received ............................ :6-1159
DTC P1276 Accelerator Pedal DTCP1635 5 Volt Reference 1 Circuit ,.... 6-1161
Position (APP) SensorJ Performance ... 6-1098 DTCP1639 5 Volt Reference 2 Circuit .... $1164
OTC P 1280 Accelerator Pedal DTC P1689 Traction Control Delivered
Position (APP) Sensor 2 Circuit ............. 6-1100 · Torque Output Circuit ..•................. ; ....... 6~1166
OTC P1281 Accelerator Pedal Symptoms ........ ;........................................6-1168
Position (APP) Sensor 2 Performance ... 6-1102 Hard Start ................................................6-1170
OTC P1285 Accelerator Pedal Surges/Chuggles ...................... , ............... 6~1172
Position (APP) Sensor 3 Circuit ............. 6-1104 Lack of Power, Sluggishness, or
DTC P1286 Accelerator Pedal Sponginess ........................ , ....... ,........... 6-1174
Position (APP) Sensor 3 Performance .,.6-1106 Detonation/Spark Knock ........................... 6-1176
OTC P1336 Crankshaft Position (CKP) Hesitation, Sag, ·stumble .... :... : .................. 6-1176 (_
System Variation Not Learned ............... 6-1108 Cuts Out, Misses .................................... :.6-1178 .
OTC P1351 Ignition Coil Control Circuit Poor Fuel Economy ......... : ....................... 6-1180
High Voltage ......................... :............... 6-1109 Poor Fuel Fill Quality .•.... , ... ;........... , ........ 6-1182
OTC P1352 Ignition Bypass Circuit High Rough, Unstable, or Incorrect Idle and
Voltage ......................................,........... 6-1111 Stalling ..................... :................. ,......... 6-1183
OTC P1361 Ignition Control (IC) ·Circuit Dieseling, Run-On .................................... 6-1185
Low Voltage .......................................... 6-1113 Backfire ....................................................6-1185
OTC P1362 Ignition Bypass Circuit Low Restricted Exhaust System Check ., .......... 6-1187
Voltage .................................•...............6-1116 Powertrain Control Module Diagnosis ........ 6-1188
DTC P1374 Crankshaft Position (CKP) · PCM Controlled A/C ·Circuit· Diagnosis ...... 6-1189
High to Low Resolution Frequency MAP Sensor Circuit Diagnosis ..... , ............ 6-1194
Correlation ............................................6-1119 Electric Cooling Fan Diagnosis
OTC P1380 Misfire Detected - Rough (Description) ..........•.... ,.... , .................... 6-1197
Road Data Not Available ......... : ............ 6-1122 Electric Cooling Fan Diagnosis
OTC P1381 Misfire Detected ~ No (Functional Check) ... :....... ,....•.. ,............ 6-1198
Communication with Brake Control Electric Cooling Fan Diagnosis ·
Module ................................. ,............... 6-1123 (Table 1) ............................................... 6-1199
OTC P1404 Exhaust Gas Electric Cooling Fan Diagnosis
Recirculation (EGR) Closed Position . (Table 2) ..............................................6-1200
Performance .................... , .................... 6-1125 · Electric Cooling Fan Diagnosis .
(Table 3) ......................................... :.... 6-1202
DTC P1441 Evaporative
Emission (EVAP) System Flow During Cruise Control Diagnosis ............................6-1205
Non-Purge ............................................6~1128 Engine Oil Level Sensor/Switch
OTC P1514 Throttle Body Performance .... 6-1132 Diagnosis , .................................... ,,, ...... 6~1210
OTC P1515 Control Module Throttle Fuel System Pressure Test ...................... 6-1212
Actuator Position Performance .:: ........... 6-1134 Fuel Injector Balance Test .•...................... 6-1217
OTC P1516 Throttle Actuator Fuel Injector Balance Test with Tech 2 .... 6-1220 (
Control (TAC) Module Throttle Fuel lnj Coil Test - ECT Between
Actuator Position Performance .............. 6-1137 10-35 Degrees C (50°95 Degrees F) ..... 6-1222
OTC P1517 Throttle Actuator Fuel lnj Coil Test - ECT Outside
Control (TAC) Module Performance ....... 6-1140 10-35 Degrees C (50-95 Degrees F) ..... 6-1224
Fuel Tank Leak Check ............................. 6-1226 Crankshaft Position (CKP) Sensor
Alcohol/Contaminants-in-Fuel Diagnosis .... 6-1226 Replacement .........................................6-1293
) Fuel Quality Diagnosis ................ ,............ 6-1226 Camshaft Position (CMP) Sensor
EVAP Control System Diagnosis .............. 6-1228 Replacement .........................................6-1294
Inspection/Maintenance Status Reset Knock Sensor (KS) Replacement .............. 6-1295
Procedures ..... : .....................................6-1231 EGR Valve Replacement .......................... 6-1296
Service Bay Test ..................................... ,6-1231 Clutch Anticipate Switch Replacement ...... 6-1297
Repair Instructions ....................................6-1232 Crankcase Ventilation System
PCM Replacement/Programming .............. 6-1232 Inspection ............................................. 6-1298
CKP System Variation Learn Procedure ... 6-1234 Air Cleaner Element Replacement ............ 6-1298
ECT Sensor Replacement ........................6-1235 Air Cleaner Intake Duct Replacement ....... 6-1299
MAF Sensor Replacement ........................ 6-1236 Description and Operation ........................ 6-1300
MAP Sensor Replacement ....................... 6-1237 Powertrain Control Module Description ..... 6-1300
Heated Oxygen Sensor (H02S) Information Sensors/Switches
Replacement ........................ ,................ 6-1238 Description ...........•................................6-1300
IAT Sensor Replacement ......................... 6-1240 PCM Controlled Warning Lamps
Accelerator Controls Pedal Description ............................................6° 1304
Replacement PCM Controlled Air Conditioning
(TAC Module and Bracket Assembly) .... 6-1241 Description ... ,... , ....... ,...... , ..... ,............... 6-1305
Accelerator Controls Pedal Replacement Engine Cooling Fan Description -
(Bracket and Rod Assembly) ................ 6-1244 Electric ..................................................6-1305
Accelerator Controls Pedal PCM Controlled Generator Description ..... 6-1306
Replacement (Pad, Spring and Pin) ...... 6-1245 Fuel Supply Component Description ......... 6-1306
Throttle Body Assembly Replacement ...... 6-1245 Fuel Metering Modes of Operation ........... 6-1309
Throttle Body Air Inlet Screen Fuel Metering System Component
Replacement ......................................... 6-1246 Description ............................................ 6-131 O
Fuel Pressure Relief. Procedure ................ 6-1247 Short Term Fuel Trim Description ............. 6-1312
Quick Connect Fitting(s) Service Long Term Fuel Trim Description ............. 6-1312
(Metal Collar) .................................. ,..... 6-1248 EVAP Control System Operation
) Quick Connect Fitting(s) Service Description ............................................ 6-1312
(Plastic Collar) ............................... : ...... 6-1250 Electronic Ignition (El) System ·
In-Line Fuel Filter Replacement ................ 6-1253 Description ............................................6-1314
Fuel Tank Draining Procedure ................. $·1254 Knock Sensor (KS) System Description .... 6-1318
Fuel Tank Replacement ........................... 6-1255 EGR System Descrip~ion ....... : .................. 6-1320
Fuel Tank Pressure Sensor Throttle Actuator Control System
Replacement .........................................6-1262 ·Description ............................................ 6-1321
Fill Limiter Vent Valve Replacement ......... 6~1263 Crankcase Ventilation System
Filler Tube Replacement .......................... 6-1265 Description ............................................6-1321
Fuel Sender Assembly Replacement ........ 6-1267 Air Intake System Description ................... 6-1322
Fuel Tank Pump Module Replacement ..... 6-1268 Special Tools and Equipment ................... 6-1322
Fuel Pump Strainer Replacement ............. 6-1270 Engine Controls - 5.7L .............................. 6-1325
Fuel Level Sensor Replacement ............... 6-1271 Specifications ............................................ 6-1325
Fuel Hose/Pipes Replacement · Temperature vs Resistance .......... ,........... 6-1325
(Chassis) ..............................................6-1272
Fastener Tightening Specifications ............ 6-1325
Fuel Hose/Pipes Replacement
Fuel System Specifications ....................... 6-1326
(Engine Compartment) ...... :................... 6-1278
GM SPO Group Num.bers .... ,................... 6-1327
Fuel System Cleaning .............................. 6-1280
Schematic and Routing Diagrams ............ 6-1328
Fuel Rail Assembly Replacement ............. 6-1281
Emission Hose Routing Diagram ............... 6-1328
Fuel Pressure Regulator Replacement ...... 6-1283
Engine Controls Schematic Icons ............. 6-1328
Fuel Injector Replacement ........................ 6-1284
Engine Controls Schematics ...................... 6-1329
Fuel Pump Relay Replacement ................ 6-1285
Component Locator .............. ;.................... 6-1348
EVAP Canister Purge Valve
Replacement ... : ..................................... 6-1285 Engine Controls. Components ................... 6-1348
EVAP Vent Valve Replacement ......... , ...... 6-1286 Engine Controls Component Views ........... 6-1354
EV AP System Hoses/Pipes PCM Connector End Views ...................... 6-1368
Replacement ......................................... 6-1288 Engine Controls Connector End Views ..... 6-1372
EV AP Canister Replacement .................... 6-1289 Diagnostic Information and Procedures ... 6-1380
EVAP System Cleaning ............................ 6-1290 A Diagnostic Starting Point ....................... 6-1380
Ignition Control Module Replacement ....... 6-1292 A Powertrain On Board
Ignition Coil(s) Replacement ..................... 6-1293 Diagnostic (OBD) System Check ........... 6-1381
Scan Tool Data List ................................. 6-1383 OTC P0151 H02S Circuit Low Voltage
Scan Tool Data Definitions ................ ,...... 6-1386 Bank 2 Sensor 1 ................................... 6~1493
Diagnostic Trouble Code (OTC) Type OTC P0152 H02S Circuit High Voltage
Definitions .............................................6-1390 Bank 2 Sensor 1 ................................... 6-1496
Diagnostic Trouble Code (OTC) OTC P0153 H02S Slow Response
List/Type .... ,......... ,................................ 6-1391 Bank 2 Sensor 1 ................................... 6-1500
Engine Cranks but Does Not Run ............ 6-1396 OTC P0154 H02S Circuit Insufficient
Ignition Relay Diagnosis ........... , ............... 601399 Activity Bank 2 Sensor 1 ....................... 6-1504
Fuel Pump Electrical Circuit Diagnosis ..... 6-1402 OTC P0155 H02S Heater Performance
Fuel System Diagnosis ............................. 6-1406 Bank 2 Sensor 1 ................................... 6-1508
OTC P0101 Mass Air Flow (MAF) OTC P0157 H02S Circuit Low Voltage
Sensor Performance ; ............................ 6-1411 .Bank 2 Sensor 2 ................................... 6.~1511
OTC P0102 Mass Air Flow (MAF) OTC P0158 H02S Circuit High Voltage
Sensor Circuit Low Frequency .............. 6-1416 Bank 2 Sensor 2 .................................... 6-1515
OTC P0103 Mass Air Flow (MAF) OTC P0160 H02S Circuit Insufficient
Sensor Circuit High Frequency .............. 6-1420 Activity Bank 2 Sensor 2 ....................... 6-1519
OTC P0107 Manifold Absolute OTC P0161 H02S Heater Performance
Pressure (MAP) Sensor Ci.rcuit Low Bank 2 Sensor 2 ................................ ,.. 6-1523
Voltage ................................................. 6-1423 OTC P0171 Fuel Trim System Lean
OTC P0108 Manifold Absolute Bank 1 .................................................. 6-1526
Pressure (MAP) Sensor Circuit High OTC P0172 Fuel. Trim System Rich
Voltage ....................... , ......................... 6-1427 Bank 1 .................................................:6-1529
OTC P0112 Intake Air OTC P0174 Fuel Trim System Lean
Temperature (IAT) Sensor CircuiLLow Bank 2 ....... ·........................................... 6-1532
Voltage .................................................. 6-1431 OTC P0175 Fuel Trim System Rich
OTC P0113 Intake Air. Bank 2 .................................................. 6-1535
Temperature (IAT) Sensor Circuit OTC P0200 Injector Control Circuit ........... 6-)538
High Voltage ......................................... 6-1434 OTC P0230 Fuel Pump Relay Control
OTC P0117 Engine Coolant Circuit ................................................... 6-1542
Temperature (ECT) Sensor Circuit
Low Voltage ......................................... 6-1438
OTC P0300 Engine Misfire Detected ......... 6-1545 (
OTC P0325 Knock Sensor Module
OTC P0118 Engine Coolant Performance ......................................... 6-1550
Temperature (ECT) Sensor Circuit OTC P0327 Knock Sensor (KS) 1
High Voltage ......................................... 6-1441 .Circuit ...................................................6-1552
OTC P0121 TP Sensor Circuit OTC P0332 Knock Sensor (KS) 2
Insufficient Activity .................................6-1445 Circuit ...................................................6-1555
OTC P0122 Throttle Position (TP)
OTC P0335 Crankshaft Position (CKP)
Sensor Circuit Low Voltage ................... 6-1449
Sensor Circuit .................................•..... 6-1558
Sensor Circuit High Voltage .................. 6-1453 OTC P0336 Crankshaft Position (CKP)
Sensor Performance ....................... ,..... 6-1562
OTC P0125 Engine Coolant
Temperature (ECT) Excessive Time OTC P0341 Camshaft Position (CMP)
to Closed Loop Fuel Control ................. 6-1457 Sensor Performance ................. ;........... 6-1565
OTC P0131 H02S Circuit Low Voltage OTC P0342 Camshaft Position (CMP)
Bank 1 Sensor 1 ...................................6-1460 Sensor Circuit Low Voltage ........•.·... ,.... :6-1568
OTC P0132 H02S Circuit High Voltage OTC P0343 Camshaft Position (CMP)
Bank 1 Sensor 1 ...................................6-.1463 . Sensor Circuit High Voltage ................ ,.6-1572
OTC P0133 H02S Slow Response OTC P0351 Ignition Coil 1 Control
Bank 1 Sensor 1 ...................................6-1467 Circuit ...................................................6°1576
OTC P0134 H02S Circuit Insufficient OTC P0352 Ignition Coil 2 Control
Activity Bank 1 · Sensor 1 ....................... 6-1471 Circuit ...................................................6-1580
OTC P0135 H02S Heater Performance OTC P0353 Ignition Coil 3 Control
Bank 1 Sensor 1 ................................... 6-1475 Circuit .....................................·.. ,........... 6-1584
OTC P0137 H02S Circuit Low Voltage OTC P0354 Ignition Coil 4 Control
Bank 1 Sensor 2 ................................... 6-1478 Circuit ...................................................671588
OTC P0138 H02S Circuit High Voltage OTC P0355 Ignition Coil 5 Control
Bank 1 Sensor 2 ......... ;......................... 6-1482 Circuit ............................................ i ...... 6-1592 (
OTC P0140 H02S Circuit Insufficient OTC P0356 Ignition Coil 6 Control
Activity Bank 1 Sensor 2 ....................... 6-1486 Circuit ................................................... 6-1596
OTC P0141 H02S Heater Performance OTC P0357 Ignition Coil 7 Control
Bank 1 Sensor 2 ...................................6- i 490 Circuit ................................................... 6-1600
OTC P0358 Ignition Coil 8 Control DTC P0602 Control Module Not
Circuit ............ ;......................................6-1604 Programmed ......................................... 6-1697
) OTC P0401 Exhaust Gas OTC P0604 Control Module Random
Recirculation (EGR) Flow Insufficient ..... 6-1608 Access Memory (RAM) .......................... 6-1698
OTC P0404 Exhaust Gas DTC P0608 Vehicle Speed Output
Recirculation (EGR) Open Position Circuit ................................................... 6-1699
Performance ......................................... 6-1610 DTC P0645 Air Conditioning (A/C)
OTC P0405 Exhaust Gas Clutch Relay Control Circuit .................. 6-1702
Recirculation (EGR) Position Sensor DTC P0650 Malfunction Indicator
Circuit Low Voltage ............................... 6-1613 Lamp (MIL) Control Circuit .................... 6-1705
OTC P0410 Secondary Air DTC P0704 Clutch Switch Circuit ............. 6-1707
Injection (AIR) System ........................... 6-1617 OTC P0801 Reverse Inhibit Solenoid
DTC P0412 Secondary. Air Control Circuit .........................................6-1710
Injection (AIR) Solenoid. Control OTC P0803 Skip Shift Solenoid Control
Circuit ...................................................6-1623 Circuit .............................................·...... 6-1713
DTC P0418 Secondary Air OTC P1111 Intake Air
Injection (AIR) Pump Relay Control Temperature (IAT) Sensor Circuit
Circuit .................................................... 6-1626 Intermittent High Voltage ...... ,........ ,....... 6-1716
DTC P0420 Catalyst System Low OTC P1112 Intake Air
Efficiency Bank 1 .............. ,................... 6-1629 Temperature (IAT) Sensor. Circuit
DTC P0430 ·Catalyst System Low Intermittent Low Voltage ....................... 6-1719
Efficiency Bank 2.................................... 6-1631 OTC P1114 Engine Coolant
DTC P0440 Evaporative Temperature (ECT) Sensor Circuit
Emission (EV AP) System ...................... 6-1633 Intermittent Low Voltage ....................... 6-1722
DTC P0442 Evaporative OTC P1115 Engine Coolant
Emission (EVAP) System Small. Leak Temperature (ECT) Sensor Circuit
Detected ...............................................6-1639 Intermittent High Voltage ....................... 6-1725
DTC P0443 Evaporative OTC P1121 Throttle Position (TP)
Emission (EV AP) Purge Solenoid Sensor Circuit Intermittent High
Voltage ......... ,................... , ................... 6-1728
) Control Circuit ....................................... 6-1645
DTC P0446 Evaporative
Emission (EVAP) Vent System Sensor Circuit Intermittent Low
Performance .......................................... 6-1648 Voltage .................................................6-1731
DTC P0449 Evaporative DTC P1133 H02S Insufficient Switching
Emission (EVAP) Vent Solenoid Bank 1 Sensor 1 ................................... 6-1734
Control Circuit ....................................... 6-1652 OTC P1134 H02S Transition Time
DTC P0452 Fuel Tank Pressure Sensor Ratio Bank 1 Sensor 1 .......................... 6-1737
Circuit Low Voltage ............................... 6-1655 OTC P1153 H02S Insufficient Switching
DTC P0453 Fuel Tank Pressure Sensor Bank 2 Sensor 1 ................................... 6-1740
Circuit High Voltage .............................. 6-1660 OTC P1154 H02S Transition Time
Ratio Bank 2 Sensor 1 .......................... 6-17 43
DTG P0461 Fuel Level Sensor
Performance .........................................6-1665 OTC P1258 Engine Coolant
DTC P0462 Fuel Level Sensor Circuit Overtemperature - Protection Mode
Active .................................................... 6-17 46
Low Voltage ......................................... 6-1668
OTC P1336 Crankshaft Position (CKP)
DTC P0463 Fuel Level Sensor Circuit
System Variation Not Learned .............. 6-1747
High Voltage ......................................... 6-1671
DTC P0480 Cooling Fan Relay 1 OTC P1380 Misfire Detected - Rough
Road Data Not Available ...................... 6-1750
Control Circuit ....................................... 6-1675
OTC P1381 Misfire Detected - No
DTC P0481 Cooling Fan Relay 2 and 3
Communication with Brake Control
Control Circuit ....................................... 6-1678
Module ...................... : .......................... 6-1751
DTC P0500 Vehicle Speed
OTC P1404 Exhaust Gas
Sensor (VSS) Circuit .............................. 6-1681
Recirculation (EGR) Closed Position
DTC P0506 Idle Speed Low ..................... 6-1683 Performance .... :....................................6-1752
DTC P0507 Idle Speed High .................... 6-1686 OTC P1415 Secondary Air
DTC P0530 Air Conditioning (A/C) Injection (AIR) System Bank 1 ............... 6-1756
Refrigerant Pressure Sensor Circuit ...... 6-1689 OTC P1416 Secondary Air
DTC P0562 System Voltage Low ...... ;....... 6-1692 Injection (AIR) System Bank 2 ............... 6-1758
DTC P0563 System Voltage High ............. 6-1694 OTC P1441 Evaporative
DTC P0601 Control Module Read Only Emission (EV AP) System Flow During
Memory (ROM) ..................................... 6-1696 Non-Purge ............................................ 6-1760
OTC P1539 Air Conditioning (A/C) Heated Oxygen Sensor (H02S)
Clutch Feedback Circuit High Voltage ... 6-1762 Replacement Bank 2 Sensor 1 .............. 6-1849
DTC P1546 Air Conditioning (A/C) Heated Oxygen Sensor (H02S)
Clutch Feedback Circuit Low Voltage .... 6-1764 Replacement Bank 2 Sensor 2 .............. 6-1851
OTC P1626 Theft Deterrent Fuel Enable TP Sensor Replacement .......................... 6-1853
Signal Lost ........................................... 6-1767 IAT Sensor Replacement ......................... 6-1853
OTC P1635 5 Volt Reference 1 Circuit ..... 6-1770 IAC Valve Replacement ........................... 6-1854
DTC P1637 Generator Accelerator Controls Cable
L-Terminal Circuit ... ;................................ 6-1775 Replacement .........................................6-1855
OTC P1639 5 Volt Reference 2 Circuit ..... 6-1778 Accelerator Controls Pedal
Symptoms ................................................ 6-1781 Replacement ......................................... 6-1857
Intermittent Conditions ........... , .................. 6-1782 Throttle Body Assembly Replacement ...... 6-1857
Hard Start ................................................ 6-1783 Throttle Body Cleaning Procedure ............ 6-1863
Surges/Chuggles ...................................... 6-1784 Fuel Pressure Relief Procedure ................ 6-1863
Lack of Power, Sluggishness, or Quick Connect Fitting(s) Service
Sponginess ........................... ; ............... 6° 1786 (Metal Collar) .................•.... ,................. 6-1864
Detonation/Spark Knock ........................... 6-1788 Quick Connect Fitting(s) Service
Hesitation, Sag, Stumble ......................... :6-1789 (Plastic Collar) ......................·................ 6-1866
Cuts Out, Misses ..................................... 6-1790 In-Line Fuel Filter Replacement ................ 6-1869
Poor Fuel Economy ., ...... : ........................ 6-1791 Fuel Tank Draining Procedure .................. 6-1870
Poor Fuel Fill Quality ... ·.· .......................... 6-1794 Fuel Tank Replacement ........................... 6-1870
Rough, Unstable, or Incorrect Idle and Fuel Tank Pressure Sensor
Stalling .................. :.............................. 6-1795 Replacement .........................................6-1878
Dieseling, Run-On ..... ,.............................. 6-1796 Fuel Level Sensor Replacement ........ ,...... 6-1879
Backfire ....................................................6-1797 Fuel Strainer Replacement ............ , .......... 6-1880
A/C Request Circuit Diagnosis .................. 6-1799 Fuel Tank Pump Module Replacement ..... 6-1881
A/C Refrigerant Pressure Sensor Circuit Fuel Sender Assembly Replacement ........ 6-1883
Diagnosis , ............................................. 6-1801 Fuel Pulse Dampener Replacement ......... 6-1886
Electric Cooling Fan Diagnosis ................. 6-1803 Fuel Hose/Pipes Replacement
PCM Controlled Generator Diagnosis .. ,.... 6-1810 (Chassis) ...............................................6-1886 \
PNP Switch Diagriosis ... ,................... , ...... 6-1812 Fuel Hose/Pipes Replacement
Engine Oil Level Sensor/Switch (Engine Compartment) .......................... 6-1891
Diagnosis ..............................................6-1815 Fuel Hose/Pipes Assembly
Fuel Injector Balance Test with .Tech 2 .... 6-1818 Replacement (Rear) ............................... 6-1892
Fuel Injector Balance Test with Special Fuel Filler Hose Replacement .................. 6-1893
Tool .................................................; ..... 6-1821 Fuel System Cleaning .............................. 6-1895
Fuel lnj Coil Test - ECT Between Fuel Pressure Connection Valve
10-35 Degrees C (50-95 Degrees F) ..... 6-1824 Replacement .... ,····: ............................... 6-1896
Fuel lnj Coil Test - ECT Outside Fuel Rail Assembly Replacement ............. 6-1897
10-35 Degrees C (50-95 Degrees F) .. , .. 6-1826 Fuel Pressure Regulator Replacement ...... 6-1900
Fuel Tank Leak Check ., ................ , ......... :6-1828
Fuel Injector Replacement ........................6-1901
Alcohol/Contaminantssin-Fuel Diagnosis .... 6-1828
EVAP Canister Purge Solenoid Valve
Engine Speed Output Circuit Diagnosis .... 6-1829
Replacement .........................................6-1903
Vehicle Speed Output Circuit Diagnosis ... 6-1831
EVAP Vent Valve Replacement ................ 6-1905
Electronic Ignition (El) System
Diagnosis .............................................. 6-1833 EVAP System Hoses/Pipes
Inspection/Maintenance Status Reset Replacement .........................................6-1906
Procedures ........................................... 6-1836 EVAP Canister Replacement .................... 6-1912
Service Bay Test .......................................6-1836 EVAP System Cleaning ............................ 6-1914
Repair Instructions .......................... ,......... 6-1837 Crankshaft Position (CKP) Sensor
PCM Replacement/Programming .............. 6-1837 Replacement .........................................6-1915
CKP System Variation Learn Procedure ... 6-1840 Camshaft Position (CMP) Sensor
PCM Idle Learn Procedure ....................... 6-1840 Replacement .........................................6-1917
ECT Sensor Replacement ........................ 6-1841 Knock Sensor (KS) Replacement .............. 6-1918
MAF Sensor Replacement ........................ 6-1842 Secondary AIR Injection Pump
MAP Sensor Replacement ....................... 6-1844 Replacement ......................................... 6-1919
Heated Oxygen Sensor (H02S} AIR Check Valve/Pipe Replacement -
Replacement Bank 1 Sensor 1 .............. 6-1846 Bank 2 .................................................6-1921
Heated Oxygen Sensor (H02S} AIR Check Valve/Pipe Replacement -
Replacement Bank 1 Sensor 2 .............. 6-1847 Bank 1 .................................................6-1922
Secondary Air Injection Pump Relay Engine Exhaust ..........................................6-1972
Replacement ......................................... 6-1922 Specifications ............................................ 6-1972
) Secondary AIR Injection Shut Off Valve
Replacement ......................................... 6-1923
Fastener Tightening Specifications ............ 6-1972
GM SPO Group Numbers ........................ 6-1972
AIR Solenoid Valve Replacement ............. 6-1926 Exhaust System Clearances ..................... 6-1973
EGR Valve Replacement .......................... 6-1926 Diagnostic information and Procedures ... 6-1974
EGR Pipe Replacement ........................... 6-1927 Vibration or Rattling ................................. 6-197 4
EGR System Cleaning ............................. 6-1928 Restricted Exhaust ................................... 6-1974
Air Cleaner Element Replacement ............ 6-1928 Exhaust Noise ..........................................6-1975
Air Cleaner Assembly Replacement .......... 6-1929 Internal Muffler Rattles/Loss of Power ...... 6-1976
Engine Oil Life Monitor Reset Exhaust Leakage ..................................... 6-1976
Procedure .............................................6-1931 Repair Instructions .................................... 6-1976
Description and Operation ........................ 6-1932 Exhaust System Inspection ...................... 6-1976
Powertrain Control Module Description ..... 6-1932 Exhaust Crossover Pipe
Information Sensors/Switches Replacement (5.7 L) ............................. 6-1977
Description ............................................ 6-1938 Catalytic Converter
PCM Controlled Air Conditioning Replacement (3.8 L) ............................. 6-1980
Description ............................................6-1946 Oxidation Catalytic Converter
Engine Cooling Fan Description - Replacement (5. 7 L Left) ...................... 6-1983
Electric .................................................6-1947 Oxidation Catalytic Converter
Fuel Supply Component Description ......... 6-1947 Replacement (5.7 L Right) .................... 6-1985
Fuel Metering Modes of Operation ........... 6-1951 Muffler Replacement ................................. 6-1986
Fuel Metering System Component Converter Hanger Assembly
Description ............................................6-1952 Replacement (3.8 L Automatic) ............. 6-1991
Short Term Fuel Trim Description ............. 6-1953 Converter Hanger Assembly
Long Term Fuel Trim Description ............. 6-1954 Replacement (3.8 L Manual) ................. 6-1992
Speed Density System Description ........... 6-1954 Converter Hanger Assembly
EV AP Control System Operation Replacement (5.7 L) ............................. 6-1993
Description ............................................ 6-1954 Exhaust Muffler Hangers
Electronic Ignition (El) System Replacement (3.8 L) ............................. 6-1995
Description ............................................6-1958 Exhaust Muffler Hangers
Knock Sensor (KS) System Description .... 6-1961 Replacement (5.7 L) ............................. 6-1996
Secondary AIR Injection System Engine Mount Heat Shield
Description ............................................6-1962 Replacement (5.7 L) ............................. 6-1997
EGR System Description .......................... 6-1963 Converter Heat Shield Replacement ......... 6-1998
Crankcase Ventilation System Exhaust Heat Shield Replacement ........... 6-1999
Description ............................................ 6-1965 Exhaust Pipe and Muffler Heat Shields
Air Intake System Description ................... 6-1967 Replacement .........................................6-2000
Special Tools and Equipment ................... 6-1969 Description and Operation ........................ 6-2003
Exhaust System Description ..................... 6-2003
Catalytic Converter Description ................. 6-2003
Muffler Description ................................... 6-2003
Hangers Description ................................. 6-2003
Clamps Description .................................. 6-2003
BLANK
Engine Engine Mechanical - 3.8L 6-15
Engine Mechanical - 3.8L

)
Specifications
Specifications
... Application .. Metric English
Accelerator Control Cable Bracket Bolt 10N:m 891bin
Balance Shaft Gear Bolt 22 + 70° N,m 16 +70° lb ft
Balance Shaft Retainer Bolt 30N·m 22 lb ft
Camshaft Position Sensor Bolt 10N·m 891bin
Camshaft Sprocket Bolt 100-+ 90° N,m 74 + 90° lb ft
Camshaft Thrust Plate Bolt 15 N·m 11. lb ft
Connecting Rod Cap B.olt ... 27+ 50° N·m 20 + 50° lb ft
Crankshaft Balancer Bolt .. 150 + 114° N·m 111+114°lbft
Crankshaft Main Bearing Cap Bolt 40 .+ 110° N·m 30 + 11 0° lb ft
Crankshaft Main Bearing Cap Bolt (Side) . 15 + 45° N,m 1t + 45° lb ft
Crankshaft Position Sensor Stud 30N·m 22 lb ft
Crankshaft Rear Oil Seal Housing Bolt 15 + 50° N·m 11 + 50° lb ft
Cylinder Head Bolt 50 + 120° N,m 37 + 120° lb ft
Drive Belt Tensioner Bracket Bolt 50N·m 37 lb ft
EGR Valve Adapter Nut .. 50N·m 37 lb ft
EGR Valve Nut . 29N·m 21 lb ft
EGR Valve Outlet Pipe Bolt/Nut (Except Upper Intake Manifold) 29N·m 21 lb ft
) EGR Valve Wiring Harness Heat Shield Bolt/Nut 10 N·m 891bin
Engine Block Coolant Drain Plug .18 N·m 13 lb ft
Engine Coolant Temperature Sensor 25N·m 18 lb ft
Engine Flywheel Bolt (New) 15 + 50° N,m 11 + 50° lb ft
Engine Front Cover Bolt/Stud 20 + 40° N,m 15 + 40° lb ft
Engine Lift Bracket Bolt/Nut/Stud 30N·m 22 lb ft
Engine Mount Bracket Bolt 102 N·m 75 lb ft
Engine Mount Nut, Lower 43N·m 32 lb ft
Engine Mount Nut, Upper 47N·m 35 lb ft
Engine Mount Strut Bolt 48N·m 35 lb ft
Engine Mount Strut Bracket Bolt at Engine, Left 50N·m 37 lb ft
Engine Mount Strut Bracket Bolt at Engine, Right 50N·m 37 lb ft
Engine Mount Strut Bracket Bolt at Upper Radiator Support 28N·m 21 lb ft
Engine Mount Strut Nut 48N·m 35 lb ft
Engine Oil Gallery Plug 30N·m 22 lb ft
Exhaust Manifold Nut 23N·m 17 lb ft
Exhaust Manifold Bolt/Stud 23N·m 17 lb ft
Fuel Injector Rail Assembly Nut 9N·m 801bin
Fuel Injector Rail Stud 25N·m 18 lb ft
Fuel Injector Sight Shield Bracket Nut 30N·m 22 lb ft
Generator Brace Bracket Bolt 50N·m 37 lb ft
Heated Oxygen Sensor 42N·m 31 lb ft
ICM Bracket Stud 30N·m 22 lb ft
ICM Assembly Bolt/Nut 50N·m 37 lb ft
Lower Intake Manifold Bolt 15 N·m 11 lb ft
MAP Sensor Bracket Bolt 30N·m 22 lb ft
6-16 Engine Mechanical - 3.8l Engine
Fastener Tightening Specifications (cont'd)
Specifications
Application Metric .English
MAP Sensor Bolt 3N-m 271bin
Oil Cooler Adapter Connector 50N·m 37 lb ft
Oil Filter Adapter Bolt 15 N-m· + 50° 11 lb ft+ 50°
Oil Level Indicator Tube Nut 19 N-m 14 lb ft
Oil Pan Bolt 14N·m 1251bin
Oil Pan Drain Plug 30N-m 22 lb ft
Oil Pump Cover Screw 11 N·m 981bin
Oil Pump Screen Bolt 15 N-m 11 lb ft
Power Brake Booster Heat Shield Nut 20N·m 15 lb ft
Side Main Cap Bolt 15 + 45° N·m 11 + 45° lb ft
Starter Motor Heat Shield Bolt 30N·m 22 lb ft
Throttle Body Bolt/Nut 10N·m 891bin
Throttle Body Support Bolt 10N·m 891bin
Timing Chain Dampener Bolt 22N·m 16 lb ft
.
Upper Intake Manifold Bolt Refer to Procedure
Valve Lifter Guide Retainer Bolt 30N·m 22 lb ft
Valve Rocker Arm Bolt ·. 15 + 90° N-m 11 + 90° lb ft
Valve Rocker Arm Cover Bolt 10 N·m 891bin
Water Outlet Bolt 27N·m 20 lb ft •.
Water Pump Bolt 15 + 80° N·m 11 + .80° lb ft

Water Pump Pulley Bolt 13 N·m 1_16 lb in .
(
Engine Mechanical Specifications
Specification
General Data
Engine Type 90° V-6
Displacement 231 cu in
Liter (VIN) 3.8L (K)
RPO L36 .·
Bore 96.52 mm 3.8 in

Stroke 86.36 mm 3.4 in
Compression Ratio 9.4:1 . .
Firing Order 1-6-5-4-3-2
Lubrication System
Oil Capacity with Oil Filter Change 4.25 L 4.5 qt
Oil Capacity without Oil Filter Change 3.75 L 4 qt
Oil Pressure @ Operating Temperature (1850 RPM) Using
10W-30 Oil. 414 kPa 60 psi min
Oil Filter Type Throw Away Element and Can

Gear Pocket Depth 11.71-11.75 mm 0.461-0.4625 in
Gear Pocket Diameter 89.10-89.20 mm ·· 3.508~3.512 in
Inner Gear Tip Clearance 0.152 mm 0.006 in
Outer Gear Diameter Clearance 0.203-0.381 mm 0.008-0.015 in
End Clearance 0.025-0.089 mm 0.001-0.0035 in (
Valve-to~Bore Clearance 0.038-0.076 mm 0.0015-0.003 in
Engine Engine Mechanical - 3.8l 6-17
Engine Mechanical Specifications (cont'd)
Specification
Type of Lubrication
Main Bearings '
Pressure
Connecting Rods Pressure
Piston Pins Splash
Balance Shaft Bearing - Front Splash
Balance Shaft Bushing - Rear Pressure
Camshaft Bearings . Pressure
Timing Chain Splash
Cvlinder Walls Splash
Oil Pump Type -
'
. Ge rotor
Oil Pressure Sending Unit Electrical
"
Oil Intake Stationary
Oil Filter System Full Flow
Cylinder Bore
Diameter 96.5 mm 3.8 in
Out-Of-Round Maximum 0.0254 mm 0.001 in
Taper 0.0254 mm 0.001 in
Pis1on
Used Piston Clearance (41 mm from Top of Piston) 0.050-0.091 mm 0.0020-0.0036 in
New Piston Clearance (41 mm from Top of Piston) 0.010-0.051 mm 0.0004-0.0020 in
Pis1on Ring Groove Depth
Top Compression 4.019-4.146 mm 0.158-0.163 in
2nd Compression 4.214-4.341 mm 0.0166°0.171 in
Oil Control 3.814-3.941 mm 0.150-0.155 in
Piston Ring End Gap
2nd Compression 0.58-0.84 mm 0.023-0.033 in
Oil Control 0.254-0.762 mm 0.010-0.030 in
Piston Ring Side Clearance
',
2nd Compression 0.033-0.079 mm 0.0013-0.0031 in

Oil Control 0.023-0.201 mm 0.0009-0.0079 in
Piston Ring Width
Top Compression 1.176-1.197 mm 0.0463-0.0471
2nd Compression 1.476-1.497 mm 0.0581-0.0589
Oil Control 1.854-2.007 mm 0.073-0.079
Piston Pin
Diameter 21.9950-22.0000 mm 0.8659-0.8661 in
Clearance in Piston 0.0020-0.0130 mm o.,0000,8-0.00051, in
Fit-ln·Rod (Clearance) 0.0066-0.0217 _mm 0.0003-0.0009 in
Crankshaft
,,
Main Journal Diameter-All 63.470-63.495 mm 2.4988-2.4998 in ,,
Rod Journal Diameter-All 57.1170-57.1475 mm, 2.2487-2.2499 in
Main Journal Taper-Maximum 0.00889 mm 0.00035in
Rod Journal Taper-Maximum 0.00889 mm 0.00035 in
Main Journal Out-of-Round-Maximum 0.00635 mm 0.00025 in
Rod Journal Out-of-Round-Maximum 0.00508 mm 0.00020 in
Specification
Main Bearing To Journal Clearance 1 0.0178-0.0406 mm 0.0007-0.0016 in
Main Bearing To Journal Clearance 2, 3, and 4 0.0229-0.0457 mm 0.0009-0.0018 in
Rod Bearing Clearance 0.0127-0.0660 mm 0.0005-0:0026 in
Crankshaft End Play 0.076-0.276 mm 0.003-0.011 in;
Connecting Rod
Rod Side Clearance 0.102-0.508 mm 0;004-0.0200 in
Connecting Rod Large End Bore ID 60.295-60.312 mm 2.37378-2.3745 in
..
Camshaft . ;
Journal Diameter 47.655-46.858 mm 1.8462-1.. 8448 in

Bearing Inside Diameter 1 and 4 46.970-46.934 mm 1.8428-1.8492 in -. .
Bearing Inside Diameter 2 and 3 46.977-46.942 mm 1.8481-1.8495 in
Bearing-to-Journal Clearance 0.041-0.119 mm 0.0016-0.0047 in
Intake Maximum Lobe Lift 6.55 mm ·. 0.258 in
Exhaust Maximum Lobe Lift 6.48 mm 0.255 in.
Balance Shaft
End Play 0.0-0.171 mm 0.0-0.0067 in
Rear Journal Diameter 38.085-38.105 mm 1.4994-1 .5002 in·, .
Radial Play-Front, Bearing Clearance 0.0-0.026 mm 0.0-0.0010 in
Rear Bearing To Journal Clearance 0.0127-0.109 mm 0.0005-0.0043 in
Drive Gear Lash 0.050-0.125 mm 0.002-0.0049 in
Bearing Bore Diameter-Front 51.973-51.999 mm 2.0462-2.0472 in
Bearing Bore Diameter-Rear, In Block 47.584-47.612 mm 1.8735-1.8745 in (
Bearing Inside Diameter-Rear 38.118-38.194 mm 1.5007-1.5037ih
Valve System
Lifter Hydraulic
Rocker Arm Ratio 1.6:1
Face Angle 45°
..
Seat Angle 45°
Minimum Margin 0.635 mm 0.025 in
Seat Runout-Maximum 0.050 mm 0.002 in
Seat Width-Intake 1.53-2.03 mm 0.060~0.080 in
Seat Width-Exhaust 2.29-2.79 mm 0.090-0.110.in.
Stem Height-All 49.15-50.17 mm 1.935-1.975 in
Stem Clearance-All 0.038-0.089 mm 0.0015-0.0032 in
Valve Spring
Free Length 49.78 mm 1.960 in
334N@
Load-Closed . -75 lb@ 1.72 in
43.69 mm
Load-Open 1014 N @ 32.4 mm 228 lb @ 1.277 in
.
Installed Height 42.93-44.45 mm 1.690-1 .720 in
Approximate Number of Active Coils 4.48 .
Approximate Number of Total Coils 6.60

Flywheel
Runout~Maximum 0.38 mm 0.015 in
(
) Automatic Transmission Engine Flywheel 0.666
Camshaft Bearing 0.539
Camshaft Timing Chain 0.724
Connecting Rod 0.603
Connecting Rod Bearing Kit 0.616
Crankshaft Balancer 0.659
Crankshaft Bearing Kit 0.096
Cylinder Head· 0.269
Cylinder Head Gasket N.S.
..
EGR Valve Gasket 3.680
Engine Block·. N.S.
Engine Camshaft 0.519
Engine Cooling Manifold 1.097
Engine Cooling Manifold Gasket 1.097
Engine Cooling Thermostat 1.246
Engine Crankshaft 0.646
. Engine Front Cover 0.206
.
Engine Front Cover Gasket 0.207
Exhaust Manifold 3.601
Exhaust Manifold Gasket 3.270
Intake Manifold
Intake Manifold Gasket
3.265
N.S.
'
) Oil Filter 1.836
Oil Filter Adapter 1.840
Oil Filter Adapter Gasket 1.840
Oil Level Indicator 1.516
Oil Level Indicator Tube 1.516
Oil Pan Kit with Gasket 1.429
Oil Pan Reinforcement 1.426
Oil Pump Screen 1.656
Oil Pump Screen Gasket 1.657
Oil Pump Cover 1.723
Piston with Pin 0.629
Piston with Ring Kit 0.643
Spark Plug 2.270
Throttle Body 3.335
Throttle Body Gasket 3.336
Valve Lifter 0.459
Valve Lifter Guide 0.439
Valve Pushrod 0.426
Valve Rocker Arm Cover 0.386
Valve Rocker Arm Cover Gasket 0.423
Valve Spring 0.303
Water Pump Gasket 1.079
Water Pump Kit 1.069
Water Pump with Gasket 1.069
6-20 Engine Mechanical - 3.8l Engine,
Sealers, Adhesives, and lubricants
Accelerator Control Cable Bracket Bolt Threads Thread lock 12345382
Coolant Temperature Sensor Threads Sealant 12346004 .
Crankshaft Position Sensor Bolt/Stud Threads Thread lock 12345382
Crankshaft Side Main Bolt Threads Thread lock 12345493 ·
Engine Block Coolant Drain Plug Threads Sealant 12346004
Engine Block Oil Gallery Plug Threads Sealant 12346004
Engine Front Cover Bolt Threads Sealant , 12346004 ·.
Engine Oil Oil-10W-30 1234561.6

Engine Oil Supplement Lubricant .1052368
Exhaust Manifold Bolt and Stud Threads Thread lock 12345493
Intake Manifold Bolt Threads (Lower) Thread lock 12345382.
Intake Manifold Coolant Pipe Sealant 12345493
Intake Manifold to Engine Block Mating Surface Sealant 12346286·
Knock Sensor Threads Sealant 12346004
Oil Filter Bypass Hole Plug Threads Sealant ·12346004
Oil Pan Bolt Threads Threadlock 12345382 ·.
Oil Pressure Switch Threads Sealant 12346004 .
Piston and Piston Pin Oil-10W-30 12345616

Rear Crankshaft Main Bearing Cap Sealant 1052942 .
Valve Lifter and Camshaft Prelube Lubricant 12345501
Valve Rocker Arm Cover Bolt Threads Thread lock 12345382
Valve Rocker Arm Bolt Threads Thread lock 12345493
(
'
(
Base Engine Misfire Diagnosis
Checks Action
Engine performance diagnosis procedures are covered in Engine Controls and should be consulted for diagnosis of any
Driveability, Emissions, or Malfunctioning Indicator Lamp (MIL) concerns.
The following diagnosis covers common concerns and possible causes.
When the proper diagnosis is made, the concern should be corrected by adjustment, repair or replacement as required.
Refer to the appropriate section of the service manual for each specific procedure.
This diagnostic table will assist in engine misfire diagnosis due to a mechanical concern such as a faulty engine camshaft,
worn or damaged bearings or bent valve pushrod.
This tap le ll'lill not isolate. a crossed fuel injector wire, faulty fuel injector or any other driveability component failure that may
cause a misfire. ·
The Powertrain On-Board Diagnostic ~ystem checks must be performed first.
. When using this. table to make a Base Engine Misfire diagnosis, begin with the preliminary information below and then
proceed to the specific category.
Preliminary 1. Perform OTC P0300 before proceeding with Base Engine Misfire Diagnosis
information .
. OTC P0300 will assist in determining which cylinder or cylinders are misfiring.
2. Perform a visual inspection of the following:
• A loose or improperly installed engine flywheel or crankshaft balancer
• Worn, damaged or misaligned accessory drive system components
3. Listen to the engine for any abnormal internal engine noises.
4. Inspect the engine for acceptable oil pressure.
5. Verify if the engine has excessive oil consumption.
6. Verify if the engine has excessive coolant consumption.
7. Perform a compression test on the engine.
Intake Manifold Leaks An intake manifold that has a vacuum leak may cause a misfire.
Inspect for t.he following:
• Improperly installed or damaged vacuum hoses
• Faulty .or improperly installed lower intake manifold and/or gaskets
• c.racked or damaged lower intake manifold
• Improperly installed MAP sensor
The sealing grommet of the MAP sensor should not be torn or damaged
• Improperly installed throttle body or damaged gasket
• Warped intake manifold
• Warped or damaged cylinder head sealing surface
Coolant Consumption Coolant consumption may or may not cause the engine to overheat.
Inspect for the following:
• External coolant leaks
• Faulty cylinder head gasket
• Warped cylinder head
• Cracked cylinder head
• Damaged engine block
6-22 Engine Mechanical - 3~8L Engine
Base Engine Misfire Diagnosis (cont'd)
Checks Action
Oil Consumption O.il consumption may or may not cause the engine to misfire.
1.. Remove the spark plugs and inspect for an oil fouled spark plug.
2. Perform a cylinder compression test.
3. If the compression test indicates worn valves or valve guides, inspect the
following:
O Worn, brittle, or improperly installed valve stem oil seals
• Worn valve guides

• Worn valve stems
• Worn or burnt valves or valve seats
4.' If the compr,ession test indicates worn or damaged piston rings, inspect the
following: · ·
0
.Broken or improperly seated piston rings
• Excessive piston ring end gap
• Excessive cylinder bore wear or taper
• Cylinder damage
• Piston damage
Abnormal Internal Engine Noises 1. Start the engine and deter.mine i.f the noise is timed to the engine camshaft
speed or the crankshaft speed.
2. Using a timing light, two knocks per flash is the crankshaft speed and
one knock per flash is the engine camshaft speed.
3. If the noise is timed to the engine camshaft speed, inspect the following:
• Missing or loose valve train components
• Worn or loose valve. r9cker arms
• Worn or bent valve pushrods
• .·Faulty valve springs
· • Bent or burnt valves (
• Worn engine camshaft lobes
• Worn or damaged camshaft timing chain and/or sprockets
Important: A slight COLD kno'ck or piston slapping noise could be considered
normal if not present after the engine has reached normal operating temperatures .
.4. If the knock is timed to the crankshaft speed, inspect the following:
• Worn crankshaft or connecting rod bearings
• Piston or cylinder damage
• Worn piston or piston pin
• Faulty connecting rod
• ·Excessive carbon build-up on the top of the piston
No Abnormal Internal Engine Noise 1. Inspect for a worn or improperly installed camshaft timing chain and/or
sprockets.
2. Remove the valve rocker arm cover on the side of the engine with the cylinder
that is misfiring.
3. Inspect for the following:
• Loose valve rocker arm studs
• Bent valve push rods
• Faulty valve springs
• Faulty valve lifters (bleeding down)
• Worn or improperly seated valves
• Worn engine camshaft lobes
(
Engine Compression Test • Compare the sounds in other engines to ensure
the noise is not a normal condition.
1. Charge the battery if the battery is not fully
charged. • Remember, engine noise is generally
synchronized to either engine speed (caused by
2. Disable the ignition system.
the crankshaft, connecting rods or pistons) or .
3 . .Disable the fuel injection system. one-half engine speed (valve train noise). Try to
4. Remove all the spark plugs. determine the rate at which the noise is occurring.
•5. Turn the ignition to the ON position. Main Bearing Noise
·6 .. Depress• the acceierator pedal to position the • Damaged or worn main bearing noise is revealed
throttle plate 'wide open. by dull thuds or knocks which happen on every
7. Start with the compression gauge at zero and engine revolution. This noise is loudest when the
· crank the engine through four compression engine is under heavy load.
strokes (four puffs). · • Excessive crankshaft end play is indicated by an
8. Check the compression for each cylinder. Record intermittent rap or knock sharper than a worn
the readings. main bearing.
9. if a cylinder has low compression, inject • The following are causes of main bearing noise:
approximately 15 ml (one tp.blespoon) of engine - Low oil pump pressure
oil into the combustion chamber through the spark
- Thin, diluted, or dirty oil and/or filter
plug hole. Recheck the compression and record
the reading. - Excessive main bearing clearance
10. The minimum compression in any one cylinder - Excessive crankshaft end play
should not be less than 70 percent of the highest - Out-of-round crankshaft journals
cylinder. No cylinder should r.ead less than·. - Loose c.rankshaft pulley
690 kPa (100 psi). For example, if the highest
pressure in any one cylinder is - Loose flywheel or torque converter
1 035 kPa (150 psi), the lowest allowable pressure Loose main bearing cap
for any other cylinder would be 725 kPa (105 psi). - Belt pilling
(1 035 x 70% = 725) (150x 70% = 105).
• Normal :_ Compression builds up quickly and
Connecting Rod Bearing Noise
) evenly to the' specified compression for each A damaged or worn connecting rod bearing will
cylinder. produce a knock under all speeds. During the early
stages of wear, connecting rod noise may be confused
• Piston Rings Leaking -,,-- Compression is low
with piston slap or loose piston pins. Connecting rod
on the first strpke. Then comP,ression build~
knock noise increases in volume with engine
1,1p with the following strokes but dol3s not
speed and is at its lou.dest on deceleration.
reach. normal. Compression improves
considerably when you add oiL · The following are causes of connecting rod
bearing noise:
• Valves Leaking - Compression is low on the .
first stroke. Compression usually does not ~ Excessive bearing clearance
build up on the following strokes. Compression • Worn crankshaft connecting rod journal
does not improve much when you add oil. • Thin, diluted, or dirty oil and/or filter
• If two adjacent cylinders have low·er than • Low oil pressure
normal compression, and injecting oil intothe
cylinders does not increase the compression, • Crankshaft connecting rod journals out-of-round
the cause may be a head· gasket leaking • Misaligned connecting rod
between the cylinders. • Connecting rod bolts not properly torqued
• The wrong bearing inserts or misaligned
Eng1ine Noise Diagnosis (Base Engine) bearing half
Notice: Some engine noise is.Characteristic to
the design. Compare the sounds in other engines in
order to make sure that you are not trying to correct a
normal condition.
• There are four steps to diagnosing engine noise.
· They include:·· ·
- The type of noise
- Under which operating conditions it exists
- At what rate in the engine
- At what location in the engine
6-24 Engine Mechanical - 3.8L Engine
Timing Gear or Chain and Sprocket Noise Rattle (Balance Shatt)
Engines designed with timing gears, or tho.se equipped Balance shaft rattle sounds like a tinny, cha~ery rattle
with a timing chain and sprockets, can produce or a knocking noise that seems to come from the
different noise. The most common noise is a high top rear of the engine. This noise is most pronounced
frequency, light-knocking sound. This sound will when the engine is hot, and is not affected by
generally be the same in intensity whether the engine engine load. An example would be dirt lodged in the
is idling, operating at high speeds, or under load: root between two gear teeth. Each time the root
The following are causes of timing gear or chain and between two balance shaft gear teeth meshes with a
sprocket noise: cam gear.tooth, the balance shaft is momenJarily
forced upward. This pivots the shaft through the front
• Worn timing chain and/or gears bearing, causing a downward force on the rear ·
• Misaligned gears bearing that eventually wears the rear bearirig; causing
• Excessive backlash a rattle. The following are other factors that contribute
• A damaged tooth to balance shaft bearing rattle: · ·
• Gear or sprocket loose on the shaft • A tight link on the timing chain
• Too much end play in the camshaft or crankshaft • Damaged, broken, or dirty teeth on the balance
shaft gears '
Loose or improperly seated camshaft timing gears are
usually loudest when warm. They are speed sensitive • Aworn timing chain tensioner
only. They are not load sensitive.· • Misaligned rear balance shaft bushing
Cam gear noise will usually be evident at a warm idle Flywheel Noise
in neutral and sounds much like a loose timing chain.
Notice: 9onverter bolts that are too. long may dimple
Piston Noise the torque converter clutch apply surface and ·
Piston pin, piston, and connecting rod noise are hard cause a shudder condition.
to separate. A loose piston pin, for example, causes A loose or cracked flywheel will produce an irregular
a sharp double knock usually heard when the engine is thud or.click. To test for a loose.or cracked_flywheel,
idling, or during sudden acceleration then deceleration operate the vehicle at approximately 32 km/h (20 mph)
of the engine. A piston pin that has been improperly and shut off the engine. If a thud is heard, the
fitted will emit a light ticking noise that is more flywheel may be loose or damaged. This type of thud
noticeable with no load on the engine. Excessive is loudest on deceleration. Loose torque (
piston-to-cylinder bore clearance.will caus~ a piston converter-to-flywheel or flywheel-to~crankshaft bolts
slap noise. The noise is similar to a metallic knock, as will resemble a bearing knock. This concjitiori produces
if the piston were slapping.the cyiinder waH during several raps during quick acceleration on a
its stroke. As with most engine noise, understanding free-running engine. Depending on the idle
the cause of the noise will help you imagirie what smoothness, when the transaxle is in gear, the noise
the noise sounds like. An indication of pistqn slap is a may or may not appear. Check the torque ·
decrease in noise as the engine warms up. When converter-to-flywheel and the flywheeHo-crankshaft
the engine is cold, the piston-to-bore clearance bolts before attempting to investigate any
is greater and piston slap will be louder. The following bearing-related knock.
are causes of piston noise:
Knocks Cold and Continues for 2 to 3 Minutes
• Worn or loose piston pin orbushing
Cold engine knock usually disappears when the
• Improper pin fit specific cyHnder secondary ignition circuit. is grounded
• Excessive piston~to-cylinder .bore clearance out. Cold engine piston knock which disappears in
• Lack of lubrication 1.5 minutes sho.uld be considered acceptable.
• Carbon deposits on top of the piston striking the • Engine flywheel contacting the transmission
cylinder head converter cover - reposition the transmission
converter cover.
• Worn or broken piston ring land
• Loose or broken crankshaft balancer or the drive
• Broken or cracked piston
pulleys - tighten or replace the crankshaft
• Misaligned connecting rods balancer or the drive pulleys as· necessary.
• Worn or damaged rings • Excessive piston-to-bore clearance - replace the
• Excessive ring land clearance piston. ·
• Insufficient ring-end gap clearance • Bent connecting rod - replace the connecting rod.
• Piston 180 degrees out of position
• Incorrect skirt profiles
(
Knocks at Idle Hot • The flywheel is cracked - replace the flywheel.
O Excessive crankshaft main bearing clearance
• Inspect the drive belt for wear. Check the tension
and/or replace as necessary. - replace the crankshaft main bearings as
• Inspect the A/C compressor or generator bearing. necessary.
Replace or repair as necessary. • Excessive connecting rod bearing clearance -
• Inspect the valve train. Replace the parts as replace the connecting rod bearings as
necessary. necessary.
• Inspect for improper oil viscosity. Install the proper light Knock Hot in light Load Condition
viscosity oil for the expected temperature. Refer Light knock hot may be caused by one or. more of the
to Maintenance and Lubrication for the engine
oi1I specifications,
• Loose torque converter bolts - tighten the torque
• Inspect for excessive piston pin clearance.
converter bolts.
Replace the piston and the pin as necessary.
• Leak at the exhaust manifold - tighten the bolts
" Inspect the connecting rod alignment. Check and
and replace the exhaust manifold gasket if
replace the connecting rods as necessary.
necessary.
• Inspect for insufficient piston-to-bore clearance.
Hone the bore and fit the new piston. • Excessive connecting rod bearing clearance -
replace the connecting rod bearings as
• Inspect the crankshaft balancer for. looseness. necessary.
Tighten and/or replace the worn parts.
• Detonation or spark knock, refer to Engine
• Ensure that the piston pin is not offset to .the Controls.
wrong side. Properly install the pistdn. ·
• Ensure that the camshaft drive gear backlash is Engine Noise Diagnosis (Valve Train)
not excessive. The knock will also be heard on
a cold engine. A light tapping at one-half engine speed, or any
varying frequency, can indicate a valve train problem.
Knocks on Start-Up but Only Lasts a These tapping noises increase with the engine
Few Seconds speed. Warm up the engine before attempting to judge
The following conditio.ns may produce engine knocks the valve train noise. This will bring all of the engine
) on initial start-up, but only last a few seconds: components to a normal state of expansion. Run
• Improper oil viscosity the engine at various speeds and listen for engine
noise with the hood closed.
- Install the proper oil viscosity for the
expected temperatur~s. Caution: The following procedure is not
- Refer to Maintenance and Lubrication. recommended. on engines with stainless steel
• Lifter bleed down - clean, test, and replace the
exhaust manifolds because manifold temperature
lifter as necessary.
will exceed the flash point of the oil causing a
fire with possible personal injury.
- When the engine is off, some valves will be
open. Spring pressure against the lifters will If the valve mechanism is abnormally noisy, remove
tend to bleed th~ liftElr dolJYn.Hepair the the valve rocker arm covers and use a stethoscope to
lifter only if the problem is consistent. determine which valve train components are causing
the noise. The causes of the valve noise include
- Engines operated for only short periods the following conditions:
between start-ups may have lifter noise that
lasts for a few seconds. This is a normal • Broken or.weak valve springs
condition. • Sticking or warped valves
• Excessive crankshaft end play - replace the • Bent push rods
crankshaft thrust bearing.
• Dirty, stuck, or worn valve lifters
" Excessive front main bearing clearance - rep.lace
the worn parts. · • Damaged or improperly machined camshaft lobes
• Timing chain tensioner malfunction - clean, • Insufficient or poor oil supply to the valve train
inspect and, replace the timing chain tensioner, if (low oil pressure)
required. • Excessive valve stem-to-guide clearance
Heavy Knock Hot in Heavy Load Condition • Worn valve guides
• Broken crankshaft balancer or pulley hub - • Worn push rods
replace the parts as necessary.
• Worn valve rocker arms
• loose torque converter bolts - tighten the bolts.
• Broken valve rocker arm bolt
• The drive belt is too tight or nicked - replace
the drive belt as necessary. • Loose or worn valve rocker arm attachments
• The exhaust system is grounded - reposition the • Missing or improperly positioned lifter guides (roller
exhaust system components as necessary. lifter engines)
6-26 Engine Mechanical - 3.SL Engine
Momentary Noise on Engine Startup
DEFINITION: Momentary noise when the engine is started, usually cold
This condition is normal. Oil drains from the valve lifters
which hold the valves open when the engine is not
1 running. The valve lifter needs a few seconds to fill with oil -
after you start the engine. Repair as No correction is
Does the noise.continue after a few seconds? required needed
Intermittent Noise on Idle Only

DEFINITION: Intermittent noise on idle that disappears when engine speed increases
··.
1. Disassemble the valve lifters.
2. Check the valve lifters for any dirt. Check the valve
1
lifters for a pitted or damaged check ball.
-
ReplaCe the
Are the valve lifters dirty or damaged? . valve lifter System OK
Noise at Idle
Step I . Action I Value(s) I Yes I No
1
I
DEFINITION: Noise at idle or with hot oil that quiets at higher engine speeds or with .cold oil
Inspect the lifter for a high leakdown rate.
Does the lifter have a high leakdown rate? I -
I Replace the
faulty.lifter I No correction is
needed
Noise at High Vehicle Speeds

DEFINITION: Noise at.high RPM only .
Check for a high engine oil level. An oil level above the . (
FULL mark allows the crankshaft counterweights to churn
the oil into a foam. When the foam is pumped into the
1 lifters, the lifters become noisy since a solid column of oil -
)
ensures the proper operation. Drain the oil to
Is th.e oil level too high? the proper level Go to Step 2
Check for a low engine oil level. An oi.1 level below the
ADD mark allows the oil pump to pump .air a.t high speeds.
2 This causes noisy valve lifters. -
Add oil a.s
Is the oil level too low? required Go to Step 3
Check the oil pan. Repair as
3 -
Is the oil pan bent against the oil pump pickup? · required Go to Step 4
Check the oil pump screen. Repair as
4 -
Is the oil pump screen bent or loose? required System OK
(
Engine Engine Mechanical -. 3.8L 6-27
Noise at Idle, louder at High Engine Speed
DEFINITION: Noise at idle that gets louder as the engine speed increases, up to 1500 RPM
This noise is not connected with lifter malfunction. The
noise becomes noticeable at 10 to 15 mph LOW range, or
30 to 35 mph DRIVE range. The noise is described as a
ticking sound. At idle, the sound may be entirely gone or
appear as a light ticking noise in one or more of the
valves. This noise is caused by one or more of the
following:
1 -
• .A badly worn or sclJffed valve tip and rocker arm pad
• Excessive valve stem-to-guide dearance
• Excessive valve seat runout
• An off-square valve spring
• Excessive valve face runout Repair as
Are any components damaged or worn excessively? necessary Go to Step 2
The noise may be an off-square valve spring. Eliminate
this noise by rotating the valv.e spring .and the valve.
1. Crank the engine u.ntil the noisy valve is off its seat.
2. Rotate the spring. This Will a.lso rotate the valve. -
2
3. Repeat until the valve is quiet.
4. If correction is obtained, check for an off-square valve
spring. Replace the
Is the valve spring off-square more than 1.6 mm (1/16 in)? valve spring System OK
.
Noise at any Engine Speed
DEFINITION: Noise at all engine RPM '
Check for excessive valve lash. To check for valve lash,
turn the engine so the piston in the cylinder is on TDC of
thefiring stroke. If valve lash is present, the push rod
1 moves freely up and down with the valve rocker arm held -
against the valve. Repair as
Is the valve lash. excessive? required Go to Step 2
Check for aworn push rod upper end ball. Replace the push
2 Is the push rod upper end ball worn? - rod and valve
rocker arm Go to Step 3
a.
Check for bent push rod.
- Replace the
3
Is the push rod bent? push rod Go to Step 4
Check the lubrication system feed to the push rod and for Replace the
4 a properly lubricated push rod. - push rod and
Are the· push .rod and feed system properly lubricated? Go to Step 5 valve rocker arm
Check for a loose or damaged valve rocker arm. Replace the
5 -
Is the valve rocker arm loose or damaged? valve rocker arm Go to Step 6
If the push rod or the valve rocker arm does not need to
be replaced, this indicates trouble in the valve lifter or the Replace the Replace the
6 camshaft. -
camshaft and valve lifters as
Is the camshaft worn or damaged? valve lifters necessary
Oil Consumption Diagnosis • Excessive bearing clearance - replace the
bearings.
An engine that has excessive oil consumption uses
0.9L (1 qt) of oil, or more, within 2,000 mi (3 20.0 km). • Cracked, porous, or plugged oil galleries -,- repair
The following list indicates the conditions and or replace the engine block. · ·
corrections of excessive oil consumption: • The gallery plugs are missing or improperly
• An improperly read oil level indicator (dipstick) installed - install or repair as necessary ..
- Inspect the oil level while the vehicle is • The pressure. regulator valve is: stuck.'
parked on a level surface. - Check the pressure regulator valve for
- Allow adequate drain-down time. sticking in the bore.
• Improper oil viscosity - Check the bore for scoring and burrs.
- Use the recommended SAE viscosity for • The camshaft is worn or poorly machined -
prevailing temperatures. replace the camshaft. ·
- Refer to Maintenance and Lubrication for the • Worn valve guides·--'- repair as needed.
proper oil viscosity specifications.
• Continuous high-speed driving Oil Pressure Testing
• Severe hauling, such as a trailer. This causes Tools ,Required
decreased oil mileage.
J 25087-C Oil Pressure Test Kit
• A malfunctioning crankcase ventilation system
If the ve.hicle has low oil pressure perform the
• External oil leaks following tests.
- Tighten the bolts, as needed.
1. Check the oil level..
- Replace the gaskets and seals, as needed.
2. Raise the vehicle and remove the oil filter.
• Worn or.omitted valve guides and/or valve
stem seals 3. As$emble the plunger valve in tbe large hole of
J 25087-C base and the hose in the small hole
- Ream the guides. of J 25087-C base. Connect the gauge to the end
- Install oversized service valves ancl/or new of the hose.
valve stem seals.
4. Insert the flat side of the rubber plug in the
• Broken or worn piston rings bypass valve without depressing the bypass valve
• Improperly installed or unseated piston rings itself. ·
• Improperly installed or improperly fitted piston 5. Install J 25087-C on the filter mounting pad.
• Plugged cylinder head gasket oil drain holes
• Damaged intake gaskets
Oil Pressure Diagnosis and Testing J 25087-C

Low or No Oil Pressure
The following can cause low or no oil pressure:
• Low oil level - fill to the full mark on the oil level
indicator.
• Slow idle speed
• Incorrect or malfunctioning oil pressure switch -,-
replace the oil pressure switch.
• Incorrect or malfunctioning oil pressure gauge-,-
replace the oil pressure gauge.
• Improper oil viscosity or diluted oil
- Install oil of proper viscosity for expected
temperature.
- Install new oil if it is diluted.
566977
• The oil pump is worn or dirty - clean or replace
the oil pump. 6. Start the engine and check the overall oil
pressure, the oil pressure switch, and for
• The oil filter is plugged - replace the oil filter.
noisy lifters. The engine should be at operating
• The oil pickup screen is loose or plugged - temperature before checking the oil pressure. The (
replace the oil pickup screen. oil pressure should be approximately
• A hole in the oil pickup tube - replace the oil 414kPa (60 psi) at 1850 rpm using
pickup tube. 1OW30 engine oil.
7. It adequate oil pressure is indicated, check the oil adequate reading at this time indicates a good
pressure switch. pump and the previous low pressure was due to
8. If a low reading is indicated, press the valve on worn bearings, etc. A low reading while pressing
the tester base to isolate the oil pump and/or its the valve would indicate a faulty ,pump.
components from the lubricating system. An
Oil Leak Diagnosis
Important: You can repair most fluid leaks by first visually locating the leak, repairing or replacing the component, or by
resealing the gasket surface. Once the leak is identified, determine the cause of the leak. Repair the cause ofJhe. leak as
well as the leak itself.
1. Operate the vehicle until it reaches normal operating
temperature.
2. Park the vehicle on a level surface, over a large
1 sheet of paper or other clean surface. -
3. Wait (15 minutes).
4. Check for drippings.
Are drippings present? Go toStep2 System OK
Can you identify the type of fluid and the approximate
2 -
location of the leak? Go to Step 10 ·Go to Step 3
1. Visually inspect the suspected area. Use a small
.
mirror to assist in looking at hard to see areas.
2. Check for leaks.at the following locations: .
• Sealing surfaces
3 -
• Fittings
• Cracked or damaged components
) location of the leak? Go to Step 10 Go to Step 4
1. Completely clean the entire engine and surrounding
components.
2. Operate the vehicle for several kilometers (miles) at
normal operating temperature and at varying speeds.
4. sheet of paper or other clean surface. -
5. Identify the type of fluid, and the approximate location
of the leak.
location of the leak? Go to Step 10 Go to Step 5
2. Check for leaks at the following locations:
5 -
• Fittings
components.
2. Apply an aerosol-type powder (baby powder, foot
powder, etc.) to the suspected area.
6 normal operating temperature and at varying speeds. -
of the leak, from the discolorations in the powder
surface.
Oil Leak Diagnosis (cont'd)
7 -
• Fittings
Can yOu identify the type of fluid and the approximate
Use J 28428-E in order to identify the type of fluid, and the
approximate location of the leak. Refer to the
8 manufacturer's instructions when using the tool. -
9 -
. • Fittings
location of the leak? Go to Step 10 System OK
1. Inspect the engine for mechanical damage. Special
attention should be shown to the following areas:
• Higher than recommended fluid levels
• Higher than recommended fluid pressures
• Plugged or malfunctioning fluid filters or pressure
bypass valves (
• Plugged or malfunctioning engine ventilation
system
10 • Improperly tightened or damaged fasteners -
• Cracked or porous components
• Improper sealants or gaskets where required
• Improper sealant or gasket installation
• Damaged or worn gaskets or seals
• Damaged or worn sealing surfaces
2. Inspect the engine for customer modifications.
Is there mechanical damage, or customer modifications to
the engine? Go to Step .11 System OK
Repair or replace all damaged or modified components.
11 -
Does the engine still leak oil?. Go to Step 1 · System OK
(
Cylinder leakage Test • Remove the suspect cylinder head and
inspect. Refer to Cylinder Head Clean
) Tools Required and Inspect.
J 35667-A Cylinder Leakdown Tester 9. If air is heard from the crankcase system at the
With the use of air pressure, a cylinder leakage test crankcase (oil filler tube), perform the following
will aid in the diagnosis. The cylinder leakage test may procedure:
be used in conjunction with the engine compression • Remove the piston from the suspect cylinder.
test, to isolate the cause of leaking cylinders. • Inspect the piston and connecting rod
assembly. Refer to Piston, Connecting Rod,
Caution: Refer to Battery Disconnect Caution in and Bearings Clean and Inspect.
• Inspect the engine block. Refer to Engine
1. Remove the battery ground (negative) cable. Block Clean and Inspect.
2. Remove the spark plugs. Refer to Ignition System. 10. If bubbles are found in the radiator, perform the
following procedure: ·
3. Install the J 35667-A.
• Remove both cylinder heads and inspect.
Refer to Cylinder Head Clean and Inspect.
• Inspect the engine block. Refer to Engine Block
Clean and Inspect.
11 . Remove the J 35667-A.
12. Install the spark plugs. Refer to Ignition System.
13. Install the battery ground (negative) cable. Refer to
Battery.
Symptoms - Drive Belt

Important: Review the drive belt system operation in
order to familiarize yourself with the system
functions. Refer to Drive Belt System Description.
Visual/Physical Inspection
• Inspect for aftermarket devices which could affect
the operation of the drive belts. ·
309966 which could cause the symptom.
4. Measure each cylinder on the compression • Inspect the drive belt for excessive wear,
stroke, with both valves closed. shredding, or missing sections.
Important: It may be necessary to hold the crankshaft " Inspect the drive belt for contamination of
balancer bolt, to prevent piston movement. excessive dirt, oil, coolant or other substances
that may affect the drive belt operation.
5. Apply air pressure, using the J 35667-A. Refer to
the manufacturer's instructions. Intermittent
6. Record the cylinder leakage readings for each • Drive belt symptoms may be from intermittent
cylinder. failure of an accessory drive component.
Important: • Drive belt symptoms may occur from changes in
load of the accessory drive components.
• Normal cylinder leakage is from 12 to 18 percent.
• Ambient temperatures, moisture, or engine
" Make a note of any cylinder with more leakage operating temperature can affect the drive
than the other cylinders. belt operation .
.. Any cylinder with 30 percent leakage or more
requires service. Symptom List
7. Inspect the four primary areas, to properly Refer to a symptom diagnostic procedure from the
diagnose a leaking cylinder. following list in order to diagnose the symptom:
• Drive Belt Chirping Diagnosis
8. If air is heard from the intake or exhaust system,
perform the following procedure: • Drive Belt Squeal Diagnosis
" Remove the valve rocker arm cover of the • Drive Belt Whine Diagnosis
suspect cylinder head. • Drive Belt Rumbling Diagnosis
- Ensure that both valves are closed. • Drive Belt Vibration Diagnosis
- Inspect the cylinder head for a broken valve • Drive Belt Faffs Off Diagnosis
spring. • Drive Belt Excessive Wear Diagnosis
Drive Belt Chirping Diagnosis
Diagnostic Aids 6. Misalignment of the pulleys may be caused from
The symptom may be intermittent due to moisture on improper mounting of the accessory drive
the drive belt or the pulleys. It may be necessary component, incorrect installation of the accessory
to spray a small amount of water on the drive belt ih drive component pulley, or the pulley may be
order to duplicate the customers concern. If spraying bent inward or outward from a previous repair.
water on the drive belt duplicates the symptom, Test for a misaligned pulley using a straight edge
cleaning the belt pulleys may be .the probable solution. in the pulley grooves across two or three pulleys.
If a misaligned pulley is found, refer to that
A loose or improper installation of a body component, accessory drive component for the proper
a suspension component, or other item(s) on the installation procedure for that pulley.
vehicle may cause the chirping noise.
10. Inspection of the fasteners can eliminate the
Test Description possibility that a wrong bolt, nut, spacer, or washer
The number(s) below refer to the step number(s) on was installed.
the diagnostic table. 12. Inspecting the pulleys for being bent should
2. The noise may not be engine related. This step is include inspecting for dents or other damage to
to verify that the engine is making the noise. If the pulleys that would prevent the drive belt ·
the engine is not making the noise do not proceed from not seating properly in all of the pulley
further with this table. grooves or on the smooth surface of a pulley when
the back side of the belt is used to drive the
3. Th.e noise may be an internal engine noise. pulley.
Remove the drive belt and operate the engine for
a brief period, this will verify if the chirping 14. Replacing the drive belt when it is not damaged or
noise is related to the drive belt. With the drive there is not excessive pilling will only be a
belt(s) removed the water pump may not operate temporary repair.
and the engine may overheat. Also DTCs may
set when the engine is operated with the drive belt
removed.
4. Inspect all drive belt pulleys for pilling. Pilling .is
the small balls or pills or it may be strings in (
the drive belt grooves from the accumulation of
rubber dust.
Step Action Yes No .
Notice: Refer to Belt Dressing Notice in Cautions and Notices.
DEFINITION: The following items are indications of chirping:
• A high pitched noise that is heard once per revolution of the drive belt or a pulley.
• Chirping may occur on cold damp startup conditions.and will subside once the vehicle reaches normaloperating
temperature.
Did you review the Symptoms - Drive Belt diagnostic information and Go to Symptoms ~
1
perform th.e necessary inspections? Go to Step .2 · Drive Belt .·.
Verify that there is a chirping.noise. Goto
2
Does the engine make the chirping noise? Go to Step.3 Diagnostic Aids:
1. Remove the drive belt. .·
Go to Engine Noise
3 2. Operate the engine for no longer than 30 to 40 seconds. Diagnosis (Base
Does the chirping noise. still exist? .. Engine) Go tp. Step 4
Inspect for severe belt pilling exceeding 1/3 of the belt groove depth. c
4 ;
Does the belt grooves have pilling? Go to Step 5 Go to. Step 6
Clean the drive belt pulleys with a suitable wire brush.
5
Were the drive belt pulleys cleaned? Go toStep 15 Go toStep 6
Inspect for a misalignment of the pulleys.
6
Are any. of the pulleys misaligned? Go to Step 7 Go to Step 8
Replace and/or repair any misaligned pulleys.
7
Were the misaligned pulleys repaired and/or replaced? Go to Step 15 Goto Step 8
Inspect for bent and/or cracked brackets. (
.,
8
Were there any bent and/or cracked brackets? GotoStep9 Go to Step 10
Replace any bent and/or cracked brackets. Refer to Drive Belt
9 Tensioner Replacement.
) Were the bent and/or cracked brackets replaced? Go to Step 15 Go to Step 10
Inspect for improper, missing and/or loose fasteners.
10
Were there any improper, missing and/or loose fasteners? Go to Step 11 Go to Step 12
Replace any improper and/or missing fasteners.
11 Tighten any loose fasteners. Refer to Fastener Tightening

Specifications.
Inspect for a bent pulley.
12
Was a bent pulley found? Go to Step 13 Go to Step 14
Replace the bent pulley.
13
Was the bent pulley replaced? Go to Step 15 Go to Step 14
Replace the drive belt. Refer to Drive Belt Replacement. Go to
14
Was the drive belt replaced? Go to Step 15 Diagnostic Aids
Run the engine in order to verify the repair.
15
Does the drive belt still chirp? Go to Step 3 System OK
Drive Belt Squeal Diagnosis
Diagnostic Aids Test the accessory drive components with the
A loose or improper installation of a body component, engine operating by varying the load on the
a suspension component, or other items on the components to verify that the components operate .
vehicle may cause the squeal noise.· properly,
If the noise is intermittent, verify that the accessory 5. This test is to verify that the drive beltterisioner
.drive components are not the cause, by varying their operates properly. If the drive belt tensioner is
loads makirig sure they are operating to their not operating properly, proper belt tension may not
maximum capacity. An overcharged A/C system, a be achieved to keep the drive belt from slipping
'power steering system restriction, or incorrect fluid, or which could cause a belt squeal noise.
a failing generator are suggested items to inspect.
6. This test is to verify that the drive belt is not to
Test Description long, which would prevent the drive belt
The number(s) below refer to the step number(s) on tensioner from operating properly. Also if an
the diagnostic table. incorrect length drive belt were installed, it may
2. The noise may not be engine related. This step is not be routed properly and may be turning
to verify that the engine is making the noise. If an accessory drive component in the wrong
the engine is not making the noise do not proceed direction.
further w.ith this table 7. Misalignment of the pulleys may be caused from
3. The noise may be an internal engine noise. improper mounting of the accessory drive
Remove the drive belt and operate the engine for component, incorrect installation of the accessory
a brief period, th.is will verify that the squeal drive component pulley, or the pulley is bent
noise is the drive belt or an accessory drive inward or outward from a previous repair .. Tesl for
component. With the drive belt removed the water a misaligned pulley using a straight edge iri the
pump may not operate and the engine may pulley grooves across two or three pulleys. If
overheat. Also DTCs may set when the engine is a misaligned pulley is found refer to that accessory
operated with the drive belt removed. .drive component for the proper installatio.n
procedure for that pulley.
4. This test is to verify that an accessory drive
component does not have a seized bearing. With 8. This test is to. verify that the pulleys are the (
the drive belt removed test the bearings in the co.rrect diameter or width. Using a known. good
accessory drive components for smooth operation. vehicle compare the pulley sizes. ·
(
Step Action Yes No
DEFINITION: The following items are indications of drive belt squeal:
• A loud screeching noise that is caused. by .a slipping drive belt (this is unu.sual for a drive belt with multipie ribs)
• The noise occurs when a heavy load is applied to the drive belt, such as an air conditioning compress9r engagement
snapping the throttle, or slipping on a seized pulley or a faulty accessory drive.component.
Did you review the Symptoms - Drive Belt diagnostic information and Go to Symptoms -
1
perform the necessary inspections? · . GotoStep2 . Drive Belt. ..·
Verify that there is a squeal noise. Go to
2
Does the engine make the squeal noise? Go to Step 3 Diagnostic Aids
Go to Engine Noise
3 2. Operate the engine for no longer than 30 to 40 seconds. Diagnosis (Base ..
Does the squeal noise still exist? · Engine) G.o to Step' 4
Inspect for an accessory drive component seized bearing or a faulty
4 accessory drive component.
Did you find and correct the condition? Go to Step 9 .Go to Step 5
Inspect the drive belt tensioner for proper operation. Refer to Drive
5 Belt Tensioner Diagnosis.
'
Did.you find.and correct thE:J condition? Goto Step 9 .. Go to Step 6
Check for the correct drive belt length. Refer.to Drivf?. BfJlt
6 Replacement.
Did you find and correct the condition?· Gcrto Step 9 · Go· to Step 7
'Inspect for misalignment of a pulley.
7
Did you find and correct the condition? Go tc:> Step 9 Go to Step 8
Inspect for the correct pulley size. Go to
8 '
) Did you find and correct the condition? Go to Step 9. Diagnostic Aids
9
Does the drive belt still squeal? Go. toStep3 System OK
6-36 Engine Mechanical - 3;8L Engine
Drive Belt Whine Diagnosis
Diagnostic Aids water pump may not operate and the engine may
The drive belt will not cause the whine noise. overheat. Also DTCs may set when the engine
' is operated with the drive belt removed.
If the whine noise is intermittent, verify the accessory
drive components are not the cause, by varying 4. The inspection should include checking the drive
their loads making sure they are operating to their belt tensioner and the drive belt idler pulley
maximum capacity. An overcharged A/C system, bearings. The drive belt may have to be installed
a power steering system restriction or incorrect fluid, and the accessory drive components operated
or a failing generator are suggested items to inspect. separately by varying their loads. Refer to
Test Description the suspected accessory drive component for the
proper inspection and replacement procedure.
The number(s) below refer to the step nurriber(s) on
3. This test is to verify that the noise is being caused
by the drive belt or the accessory drive
components. With the drive belt removed the
Step Action Yes No
DEFINITION: A high pitched continuous noise that may be caused by an accessory drive component failed bearing.
Did you review the Symptoms - Drive Belt diagnostic information and Go to. Symptoms -
1
perform the necessary inspections? Go to Step2 Drive Belt
Verify that there is a\rvhine noise. Goto
2
Does the engine make the whine noise? Go to Step 3 Diagnostic Aids
1 . Remove the drive belt.
Go to Engine Noise
Does tt,e whine noise still exist? Engine) Go to Step4 (
Inspect for a failed accessory drive component bearing. Go to
4
Did you find and repair the condition?. Go to Step 5 Diagnostic Aids
5
Does the drive belt still whine? Go to Step 3 System OK
(
Drive Belt Rumbling Diagnosis
Diagnostic Aids 3. This test is to verify that the drive belt is causing
Vibration when the engine is operating may cause a the rumbling noise. The rumbling noise may be
body component or another part of the vehicle to confused with an internal engine noise due to the
produce rumbling noise. similarity in the description. Remoye only
one drive belt at a time if the vehicle has multiple
The drive belt may have a condition that can not be
seen or felt. Sometimes replacing the drive belt may be drive belts. With the drive belt removed the
the only repair for the symptom. water pump may not be operate and the engine
may overheat. Also DTCs may set when the
If replacing the drive belt, and completing the engine is operated with the drive belt removed.
diagnostic table, the noise is only heard when the
drive belt is installed, there may be an accessory drive 4. Inspect the drive belt to ensure that the drive belt
component failure. Varying the load on the accessory is not the cause of the noise. Small cracks
drive components may aid in identifying which across the ribs of the drive belt will not cause the
accessory drive component is causing the rumbling noise. Belt separation is identified by
rumbling noise. the plys of the drive belt separating, this may be
Test Description seen at the edge of the belt or felt as lump a
in the belt.
the diagnostic table. 5. Small am9unts of pilling is normal condition and
· acceptable. When the pllling is severe the drive
2. This test is to verify that the symptom is present
belt does not have a smooth surface for
during diagnosing. Other vehicle components
may cause a similar symptom. proper operation.

Step Action Yes No
DEFINITION:
• A low pitch tapping, knocking, or thumping noise heard at or just above idle.
) • Heard once per revolution of the drive belt or a pulley.
• Rumbling may be caused from:
- Pilling, the accumulation of rubber dust that forms small balls (pills} or strings in the drive belt pulley groove
- The separation of the drive belt
- A damaged drive belt
1
Verify that there is a rumbling noise. Go to
2
Does the engine make the rumbling noise? Go to Step 3 Diagnostic Aids
1 . Remove the drive belt.
Go to Engine Noise
Does the rumbling noise still exist? Engine) Go to Step 4
Inspect the drive belt for damage, separation, or sections of
4 missing ribs.
Did you find any of these conditions? Go to Step 7 Go to Step 5
Inspect for severe pilling of more than 1/3 of the drive belt pulley
5 grooves.
Did you find severe pilling? Go to Step 6 Go to Step 7
1. Clean the drive belt pulleys using a suitable wire brush.
6 2. Reinstall the drive belt. Refer to Drive Belt Replacement
Install a new drive belt. Refer to Drive Belt Replacement
7 -
Run the engine in order to verify the repair. Go to
8
Does the drive belt still rumble? Diagnostic Aids System OK
Drive Belt Vibration Diagnosis
Diagnostic Aids 4. The drive belt may cause a vibration. With the
The accessory drive components may have ah affect drive belt removed inspect the condition of
on engine vibration. An overcharged A/G system,·· the drive belt.
a power steering system restriction, or incorrect fluid, 6. Inspection of the fasteners can eliminate the
or an extra load placed on the generator are some possibility that a wrong bolt, nut, spacer, or washer
systems that should be inspected. To help identify an was installed.
intermittentor an improper condition; vary the loads 8. This step should only be performed if the cooling
on the accessory drive components. fan is driven. by the drive belt. Inspect the engine
Test Descr'iption · cooling fan for bent, twisted,. loose, or cracked
blades. Inspect the fan clutch for smooth
The number(s) below refer to the step number(s) on operation. Inspect for a ben.t fan shaft or bent
the diagnostic table. · ·
mounting flange.
2. This testis to verify thal the symptom is present 9. This step should only be performed if the water
during diagnosing. o.ther vehicle components pump is driven by the drive belt. Inspect the ·
may cause a similar sympto!ll such as the exhaust water pump shaft for being bent. Also inspect the
system, or the drivetrain. water pump bearings for smooth operation and
3. This test is to verify that t.he drive belt or accessqry · excessive play. Compare the water pump
drive components may be causing the vibration. with a known good water pump.
With the drive belt removed the water pump 1o. Accessory drive component brackets that are
may not operate and the engine may overheat. bent, cracked, or loose may put extra strain
Also DTCs may set when the engine is operated on that accessory component causing it to vibrate.
with the drive belt removed.
(
Step Action Yes No
DEFINITION: T~e following items are indications of drive belt vibration:
;
• The vibration is engine-speed related.
• The vibration may be sensitive to accessory load.
1
Verify that the vibration is engine related. Go to
2
Does the engine make the vibration? Go to Step 3 Diagnostic Aids
1 . Remove the drive belt. Go to Engine
2 .. Operate the engine for no longer than 30 to 40 seconds. Related Vibration in
3
Vibration and
Does the engine still make the vibration? Diagnosis Go to Step4
Inspect the drive belt for wear, damage, debris build-up and missing
4 drive belt ribs.
Did you find any of these conditions? Go to Step5 Go to Step 6
;
Install a new drive belt. Refer to Drive Belt Replacement.
5
-
Inspect for improper, missing or loose fasteners.
6
Did you find any of these conditions? Go to Step 7 Go to StepB
Tighten any loose fasteners. Refer to Fastener Tightening
Specifications.
7
Replace improper or missing fasteners.
-
Inspect for damaged fan blades or bent fan clutch shaft, if the fan is
belt driven. Refer to Cooling Fan Motor Replacement - Electric in
8 Engine Cooling.
Did you find and correct the condition? Go to Step 11 Go to Step 9
) Inspect for a bent water pump shaft, if the water pump is belt driven.
9 Refer to Water Pump Replacement (3.8 L) in Engine Cooling.
Inspect for bent or cracked brackets. Go to
10
Did you find and correct the condition? Go to Step 11 Diagnostic Aids
11
Does the drive belt still vibrate? Go to Step 3 System OK
Drive Belt Falls Off Diagnosis
Diagnostic Aids drive component pulley, or the pulley being bent .
If the drive belt repeatedly falls off the drive belt inward or outward from a previous repair. Test
pulleys, this may be caused by pulley misalignment. for a misaligned pulley using a straight edge in the
pulley grooves across two or three pulleys. If a
An extra load that is quickly applied on released by an
accessory drive component may cause the drive misaligned pulley is foundrefer to that accessory
belt to fall off the pulleys. Verify that.the accessory drive component for the proper installation
drive components operate properly. procedure of that pulley.
If the drive belt is the incor.rect length, the drive belt 5. Inspect the pulleys for dents, bends or other
tensioner may not maintain the proper tension on damage. Damage to the pulleys that would
the drive belt. prevent the drive belt from seating properly in the
pulley grooves. Damage would also prevent
Test Description proper alignment of the drive belt pulley, when the
The number(s) below refer to the step number(s) on smooth surface of the drive belt is required to
the diagnostic table. drive the pulley.
2. This inspection is to verify the c.ondition of the 6. Accessory drive component brackets that are .bent
drive belt. Damage may have occurred to the drive or cracked will let the drive belt fall off.
belt when the drive belt fell off the pulley. The
drive belt may of been damaged in which 7. Inspection of the fasteners can eliminate the
case caused the drive belt to fall off the pulley. possibility that a wrong bolt, nut, spacer, or washer
Inspect the drive be.It tor cuts, tears, sections was installed. Missing, loose, or the incorrect
of ribs missing, or damaged belt plys. fasteners may cause pulley misalignment from the
4. Misalignment of the pulleys may be caused from bracket moving under load. Over tightening of
improper mounting of the accessory drive the fasteners may cause misalignment of
component, incorrect iristallatiori of the accessory the accessory component bracket.
(
Step Action Yes No
DEFINITION: The drive be.It falls off the pulleys or may not ride correctly .on the puUeys. '
1
Inspect for a damaged drive belt.
2
Did you find the condition? Go to Step 3 Goto Step 4
Install a new drive belt. Refer to Drive Belt Replacement.
3
Does the drive belt continue to fall off? Go to Step 4 System OK
Inspect for misalignment of the pulleys.
4
Did you find and repair the condition? Go to Step 12 Go to Step 5.
Inspect for a bent or dented pulley.
5
Did you find and repair the condition? Go to Step 12 Go to Step 6
Inspect for a bent or a cracked bracket.
6 .
Did you find and repair the condition? Go to Step 12 Go to Step 7
7
Did you find loose or missing fasteners? Go to Step 8 Go to Step 9
Specifications.
8
Replace improper or missing fasteners. !
Test the drive belt tensioner for operating correctly. Refer to Drive
Does the drive belt tensioner operate correctly? Go to Step 11 Go to Step 10
Replace the drive belt tensioner. Refer to Drive Belt Tensioner
) 10 Replacement.
Inspect for failed drive belt idler and drive belt tensioner pulley
11 bearings. Go to
Did you find and repair the condition? Go to Step 12 Diagnostic Aids
12 -
Does the drive belt still fall off? System OK
Drive Belt Excessive Wear Diagnosis
Diagnostic Aids 3. The installation of a drive belt that is to wide or to
Excessive wear on a drive belt is usually caused by narrow will cause wear on the drive belt. The
an incorrect installation or the wrong drive belt for the drive belt ribs should match all of the grooves on
application. all of the pulleys.
Minor misalignment of the drive belt pulleys will not 4. This inspection is to verify the drive belt is not
cause excessive wear, but will probably cause contacting any parts of the engine or body
the drive belt to make a noise or to fall off the while the engine is operating. There should be
pulley (s). sufficient clearance when the drive belt accessory
Excessive misalignment of the drive belt pulleys will drive components load varies. The drive belt
cause excessive wear and may also make the should not come in contact with an engine or a
drive belt fall off the pulley. body component when snapping the throttle.
Test Description
2. The inspection is to verify the drive belt(s) is
correctly installed over all of the drive belt pulleys.
Wear on the drive belt may be caused by
mis-positioning the drive belt by one groove on a
pulley.
Step Action Yes No
DEFINITION: Wear at the outside ribs of the drive belt due to an incorrectly installed drive belt.
1
Inspect the drive belt(s) for the proper installation. Refer to Drive Belt
(
2 Replacement.
Did you find this condition? Go to Step 5 Go to Step 3
Inspect for the proper drive belt.
3
Inspect for the drive belt rubbing against a bracket, hose, or wiring
4 harness. Go to
Replace the drive belt. Refer to Drive Belt Replacement.
5 -
6 -
Is there still excessive drive belt wear? System OK
Drive Belt Tensioner Diagnosis 3. Move the drive belt tensioner through it's full
travel.
Important: When the engine is operating, the belt
tensioner arm will move. Do not replace the belt " The movement should feel smooth
tensioner because of movement in the belt • There should be no binding.
tensioner arm.
• The tensioner should return freely.
Notice: Allowing the drive belt tensioner to snap into
4. If any binding is observed, replace the drive belt
the free position may result in damage to the
tensioner. tensioner. Refer to Drive Belt Tensioner
Replacement.
1. Remove the drive belt. Refer to Drive Belt
Replacement. 5. Install the drive belt. Refer to Drive Belt
Replacement.
2. Position a hex-head socket on the drive belt
tensioner arm and rotate the arm (
counterclockwise.
Engine Engine Mechanical - 3.8L 5.;43
Disassembled Views
Cylinder Head and Components
54
52~~
53 v 55
2
3
45
11
43 13
19
41
) 22
35 34
31 29 28
32
589348
legend
(1) Engine Lift Rear Bracket (17) Intake Valve
(2) Generator Brace Bracket (18) Exhaust Manifold Gasket (Left)
(3) Generator Brace Bolt (19) Exhaust Manifold (Left)
(4) Valve Lifter Guide (20) Exhaust Manifold Nut
(5) Valve Rocker Arm Bolts (21) Exhaust Manifold Stud
(6) Valve Rocker Arm (22) Exhaust Manifold Heat Shield
(7) Valve Rocker Arm Retainer (23) Exhaust Manifold Heat Shield Nut
(8) Pushrod (24) Exhaust Manifold Heat Shield Nut
(9) Valve Lifter (25) EGR Valve Outlet Pipe
(10) Valve Stem Keys (26} EGR Valve Outlet Pipe Bolt
(11) Valve Stem Cap (27) EGR Va.Ive Outlet Pipe Nut
(12) Valve Stem Spring (28) Heated Oxygen Sen~or
(13) Valve Seal (29) Engine Lift Front Bracket
(14) Spark Plug (30} EGR Valve Adapter Studs
(15) Cylinder Head (31) EGR Valve Adapter Bolt
(16) Cylinder Head Gasket (32) EGR Valve Adapter
(33) EGR Valve Adapter Nuts (45) Exhaust Manifold Gasket (Right)
(34) Drive Belt Tensioner (46) Intake Manifold Seal
(35) Drive Belt Tensioner Bolt (47) Lower Intake Manifold Gasket
(36) EGR Valve Gasket (48) Cylinder Head Gasket
(37) EGR Valve (49) Cylinder Head
(38) EGR Valve Nuts (50) Valve Rocker Arm Cover Gasket
(39) Engine Block (51) Valve Rocker Arm Cover
(40) Exhaust Manifold Heat Shield (52) Oil Fill Cap
(41) Exhaust Manifold Heat Shield Nut (53) Oil Fill Cap Seal
(42) Exhaust Manifold Nut (54) Oil Fill Tube
(43) Exhaust Manifold Stud Oil Fill Tube Seal
(55)
(44) Exhaust Manifold (Right}
Crankshaft and Components
34 35 4
33
27
31
, },.
~~
\
30
29
~~
~)~ 26 (
22 23 24 25
21@)~
I~,,~
~ 18
19
20
17
42447
Legend
(1) Crankshaft Balancer Key (13) Oil Pan Drain Plug Gasket
(2) Crankshaft Upper Bearing (14) Oil Pan Gasket
(3) Crankshaft Rear Oil Seal (15) Engine Oil Pan
(4) Engine Flywheel (16) Oil Pan Bolt
(5) Flywheel Bolt (17) Engine Oil Level Sensor
(6) Engine Crankshaft (18) Crankshaft Position Sensor Shield
(7) Crankshaft Main Bearing Cap (19) Crankshaft Balancer
(8) Side Main Bearing Bolt (20} Crankshaft Balancer Washer
(9) Crankshaft Main Bearing Cap Bolt (21) Crankshaft Balancer Bolt
(10) Crankshaft Lower Bearing (22} Camshaft Position Sensor Bolt
(11) Crankshaft Main Bearing Cap (23} Camshaft Position Sensor
(12) Oil Pan Drain Plug (24) Crankshaft Position Sensor
(25) Oil Pump Gear Set (31) Water Pump Pulley
(26) Oil Pump Cover (32) Water Pump
(27) Oil Pump Cover Bolt (33) Water Pump Gasket
(28) Crankshaft Front Oil Seal (34) Engine Front Cover
(29) Water Pump Bolt (35) Engine Front Cover Gasket
(30) Water Pump Pulley Bolt
Intake Manifolds and Components
403765
Legend
(1) Fuel Injector Rail Nuts (10) Upper Intake Manifold Gasket
(2) Fuel Injector Rail (11) Lower Intake Manifold
(3) Water Outlet Bolts (12) Coolant Temperature Sensor
(4) Water Outlet (13) Lower Intake Manifold Bolt
(5) Water Outlet Gasket (14) Throttle Body
(6) Thermostat (15) Throttle Body Gasket
(7) Thermostat Gasket (16) Upper Intake Manifold
(8) ICM Bracket Bolt (17) Upper Intake. Manifold Bolt
(9) ICM Bracket (18) Vacuum Source Manifold
Piston and Components
43 44
p~38
42 I _1 ~
41~40 39~
/ -~
37 7 6 ~8
36
35 9
32 -o~ i~ ~ ~
28 ~ , ;~...._
23
~J
22
~ . · "a I,) ·o0· ~

13
10
31
1 16
11
18- 12
17
(
42456
Legend
(1) Piston Pin Retainer Clip {23) Oil Pressure Relief Valve ·
(2) Piston Rings {24) Oil Filter Adapter Gasket
(3) Piston {25) Oil Filter Adapter
(4) Connecting Rod (26) Oil Filter Adapter Bolt
(5) Connecting Rod Bearings (27) Camshaft Thrust Plate
(6) Connecting Rod Cap (28) Camshaft Thrust Plate Bolt
(7) Connecting Rod Cap Bolt (29) Timing Chain Dampener
(8) Crankshaft Rear Oil Seal Housing Bolt (30) Crankshaft Sprocket
(9) Crankshaft Rear Oil Seal Housing {31) Camshaft Sprocket Bolt
(10) Crankshaft Rear Oil Seal Housing Gasket {32) Timing Chain
(11) Oil Level Indicator {33) Camshaft Position Sensor Magnet
(12) Oil Level Indicator Tube (34) Balance Shaft Drive Gear
{13) Cylinder Head Location Hole Pin (35) Camshaft Key
{14) ESC Knock Sensor (36) Camshaft
{15) Engine Block (37) Camshaft Bearings
(16) Oil Pump Screen Gasket (38) Balance Shaft Bushing
(17) Oil Pump Screen (39) Balance Shaft
(18) Oil Pump Screen Bolt (40) Balance Shaft Gear
(19) Engine Block Core Hole. Plug (41) Balance Shaft Gear Bolt
(20) Engine Front Cover Pin (42) Balance Shaft Gear Pin
(21) Engine Block Oil Gallery Plug (43) Balance Shaft Retainer Bolt (
(22) Oil Pressure Relief Valve Spring (44) Balance Shaft Retainer
Repair Instructions
! Drive Belt Replacement
Removal Procedure
. 1. Position a hex-head socket on the belt tensioner
pulley bolt.
2. Rotate the drive belt tensioner (2) clockwise to
relieve the tension on tfle drive belt (1 ).
3. Remove the drive belt (1) from the tensioner (2)
and pulleys.
4. Clean and inspect the belt surfaces of all the
pulleys.
41363
1. Route the drive belt (1) around the pulleys.
2. Position a hex-head socket on the belt tensioner
pulley bolt.
relieve the tension.
) 4. Install the drive belt (1) onto the drive belt
tensioner (2).
5. Inspect the drive belt (1) to ensure that the belt is
properly aligned into the grooves of the pulleys.
41363
Drive Belt Tensioner Replacement
Removal Procedure
Filling Cooling System (3.8 L) in Engine Cooling.
Replacement.
3. Rem.ave the generator. Refer to Generator
Replacement (3.8 L) in Engine Electrical.
4. Remove the heater hoses from the drive belt
tensioner.
282933
5. Remove the drive belt tensioner bolts (3).

Important: The drive belt tensioner (2) must be
rotated if it is difficult to remove. Pulling the
tensioner (2) from the top may damage the engine
front cover. If necessary, break the plastic thermostat
bypass upper pipe (1) to allow rotation of the drive
belt tensioner (2), replace the pipe during installation.
6. Remove the drive belt tensioner (2).
7. Remove the thermostat bypass pipes (1, 4) from (
the tensioner (2), if necessary.
441249
1. Install the thermostat bypass pipes (1, 4) to the
tensioner, if necessary.
2. Install the drive belt tensioner (2) to the engine.
Notices.
3. Install the drive belt tensioner bolts (3).
Tighten
Tighten the drive belt tensioner bolts (3) to
50 N·m (37 lb ft).
441249
4. Install the heater hoses to the drive belt tensioner.
5. Install the generator. Refer to Generator
Replacement (3.8 L} in Engine Electrical.
6. Install the drive belt. Refer to Drive Belt
Repla<Jement.
7. Refill the engine coolant. Refer to Draining and
Filling Cooling System (3.8 L} in Engine Cooling.
282933
Drive Belt Idler Pulley Replacement

Removal Procedure
Belt Replacement. 1
2. Remove the drive belt idler pulley bolt(1 ).
3. Remove the drive belt idler pulley (2).
500350
1. Install the drive belt idler pulley (2).
Notices. 1
2. Install the drive belt idler pulley bolt (1 ).
Tighten
Tighten the drive belt idler pulley bolt (1) to
50 N·m (37 lb ft).
Belt Replacement.
500350
Engine Mount Inspection
Notice: Broken or deteriorated mounts can cause
misalignment and destruction of certain drive
train components; When a single mount breaks, the
remaining mounts are subjected to abnormally ,
high stresses:
Notice: When raising or supporting the engine for any
reason, do not use a jack under the oil pan, any
sheet metal, or the crankshaft pulley. Lifting the engine
in an unapproved manner may cause component
damage.
1. Measure the engine movement at the engine
mounts in order to check for damage to the
rubber portions of the mount.
1.1. Apply the park brake.
1.3. Firmly apply the primary brakes.
1.4. Have an assistant stand to the side of the
vehicle to observe for engine movement.
1.5. Slightly load the engine in reverse and
drive. If the engine moves more than
24 mm (0.945 in) from the at rest position;
in either direction, check the engine
mount attachment.
2. If the engine mount attac.hment is within
specifications, replace the engine mount.
3. Replace the engine mount also if any of the ··
following conditions exist: (
• Heat check cracks cover the hard rubber
surface.
• The rubber cushion is separated from the .·
metal plate of the mount. .
• There is a split through the rubber cushion.
4. If the mount is loose, lowerthe engine and tighten
the bolts or the nuts to the engine frame or the
bracket Refer to Fastener Tightening
Specifications.
Engine Support Fixtur~

Tools Required
• J 28467-90A Engine Support Adapters
• J 41044 Engine Support Fixture Adapters
• J 28467-8 Universal Engine Support Fixture
1. Remove two strut mounting nuts from the left and
right side strut towers.
2. Attach the engine support fixture adapters
J 28467-90A to the strut tower studs.
3. Install the engine support fixture adapters
J 28467-90A J 41044-1 and J 41044-2 onto the fixture adapters
J 28467-90A on each strut tower.
4. Secure with the wings nuts provided.
(
578405
Engine Engine Mechanical - 3.8L 6;.51
5. Place the cross bar J 28467-3 into the engine
support adapters J 41044-1 and J 41044-2.
J 28467-50 J28467-8 or-8A
) 6. Install the quick release pins.
7. Thread the lift hooks J 28467-50 and J 28467-8
J 28467-34 (2)
or (8A) into the support hook brackets J 28467-6A.
8. Place the support hook brackets J 28467-6A over
the cross bar J 28467-3 and connect the hooks to
the engine lift brackets.
9. Tighten the large wing nuts J 28467-34.
578415
Engine Mount Replacement

Removal Procedure
reason, do not use a jack under the oil pan,
/
crankshaft balancer, or any sheet metal. Due to small
clearances 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. Jacking against the 2 ./
crankshaft balancer may also cause oil seal and/or
crankshaft bearing damage. Always use a J 28467-A
(Universal Support Fixture) along with J 41044
(Engine Support Adapters) when raising or supporting
the engine.
1. Remove the generator. Refer to Generator
2. Remove the ignition control module. Refer to
Ignition Coil Module Replacement (3.8 L) in
Engine Electrical. 50513

Information.
4. Remove the 3-way catalytic converter. Refer to
Catalytic Converter Replacement (3.8 L) in
Engine Exhaust.
5. Remove the right side engine mount through bolt
nut (2).
6. Remove the .left side engine mount through bolt
nut (1 ). ·
7. Install the engine support fixture to the engine.
Refer to Engine Support Fixture.
8. Raise the engine slightly in order to relieve
tension on the through bolts.
50520
9. Remove the trar1smission oil cooler pipe bracket

bolt and bracket.
46662
10. Remove the air conditionjng compressor bolts.
282953
11. Remove the air conditioning compressor rear
bolts (2, 3).
1
) 12. Position the A/C compressor forward of the
bracket in order to remove the engine mount
through bolt without recovering the refrigerant.
365440
13. Remove the right engine mount through bolt (1).
50513
14. Remove the left engine mount through bolt (2).

15. Raise the engine enough to remove the engine
mounts and engine mount brackets.
50520
16. Remove the right engine mount bolts (1) and the
right engine mount (2).
49837
17. Remove the left engine mount bolts (1) and the
left engine mount (2).
50525
18. Remove the right engine mount bracket

bolts (1, 2) and the right engine mount bracket (3).
(
4 3
50517
19. Remove the positive cable from the engine
mount stud.
) 0 Remove the battery positive cable nut (2).
• Remove the harness clamp from the stud.
• Remove the RF (Radio Frequency)
ground strap.
211604
20. Remove the left engine mount bracket bolts (3).

21. Remove the left engine mount bracket stud (2)
and the engine mount bracket (1 ).
22. Visually Inspect the rubber portions of the engine
mount for damage.
50546
1. Install the left engine mount bracket (1) and
stud (2) to the engine block.
Notices.
2. Install the left engine mount bracket bolts (3).
Tighten
• Tighten the engine mount bracket bolts (3) to
100 N-m (74 lb ft).
e Tighten the engine mount bracket stud (2) to
87 N,m (64 lb ft).
50546
3. Install the positive cable to the engine mount
bracket stud.
• Install the RF (Radio Frequency) ground strap.
• Install the harness clamp to the stud.
• Install the battery positive cable nut (2).
Tighten
Tighten the battery positive cable nut (2) to
25 N·m (18 lb ft).
211604
4. Install the right engine mount bracket (3) and

bolts (1, 2) to the engine block.
Tighten
• Tighten the two engine mount bracket bolts
(10 to 100 N-m (74 lb ft).
• Tighten the engine mount bracket bolt (2) to
50 N-m (37 lb ft).
50517
5. Install the left engine mount (2) and bolts (1) to

the crossmember.
Tighten
Tighten the left engine mount bolts (1) to
58 N·m (43 lb ft).
50525
6. Install the right engine mount (2) and bolts (1) to
the crossmember.
Tighten
Tighten the right engine mount bolts (2) to
58 N-m (43 lb ft).
7. Lower the engine until the mount bracket and
mount through holes line up together.
8. Remove the engine support fixture.
49837
9. Install the left engine mount through bolt (2).
50520
10. Install the right engine mount through bolt (1 ).
50513
11 . Position the A/C compressor rearward to the
bracket.
1
12. Install the air conditioning compressor rear
bolts (2, 3).
Tighten
Tighten the air conditioning compressor rear
bolts (2, 3) to 30 N·m (22 lb ft).
365440
13. Install the air conditioning compressor bolts.

Tighten
Tighten the air conditioning compressor bolts to
50 N-m (37 lb ft).
282953
14. Install the transmission oil cooler pipe bracket

and bolt. ·
Tighten
Tighten the oil cooler pipe bracket to
17 N·m (13 lb ft).
46662
Engine Engine Mechanical - 3.SL 6-59
15. Install the left side engine mount through bolt
nut (1).
1 Tighten
Tighten the engine mount through bolt nut (1) to
80 N-m (59 lb ft).
50520
16. Install the right side engine mount through bolt

nut (2).
Tighten
80 N·m (59 lb ft).
)
17.
18.
19.
Install the 3-way catalytic converter. Refer to
Engine Exhaust.
Lower the vehicle.
Install the ignition control module. Refer to Ignition
Coil Module Replacement (3.8 L) in Engine
7
2 I
Electrical.
~
50513
Engine Mount Bracket Replacement

Removal Procedure
reason, do not use a jack under the oil pan, crankshaft
balancer, or any sheet metal. Due to small clearances
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.
Jacking against the crankshaft balancer may also cause
oil seal and/or crankshaft bearing damage. Always use
a J 28467-A (Universal Support Fixture) along with
J 41044 (Engine Support Adapters) when raising or
supporting the engine.
) Replacement (3.8 L) in Engine Electrical.
~
Engine Electrical.
50513
Information.
4. Remove the 3-way catalytic converter. Refer to \
Engine Exhaust.
5. Remove the right side engine mount through bolt
nut (2).
6. Remove the left side engine mount through bolt
nut (1 ).
7. Install the engine support fixture. Refer to Engine
Support Fixture.
~ 8. Raise the engine slightly in order to relieve

tension on the through bolts.
50520
9. Remove the transmission oil cooler pipe bracket (

bolt and bracket. ,
46662
10. Remove the air conditioning compressor bolts.
282953
11. Remove the air conditioning compressor rear

bolts (2, 3).
1
12. Position the A/C compressor forward of the
bracket in order to remove the engine mount
through bolt without recovering the refrigerant.
13. Raise the engine slightly in order to relieve tension
on the through bolts.
365440
14. Remove the right engine mount through bolt (1 ).
2
/ I
50513
15. Remove the left engine mount through bolt (2).
16. Raise the engine enough to remove the engine
mounts and engine mount brackets.
50520
17. Remove the right engine mount bolts (1) and the
right engine mount (2).
49837
18. Remove the left engine mount bolts (1) and the
left engine mount (2).
50525
bolts (1, 2) and the right engine mount bracket (3).
4 3
50517
20. Remove the positive cable from the engine

mount stud.
• Remove the battery positive cable nut (2).
• Remove the RF (Radio Frequency)
ground strap.
211604

and the engine mount bracket (1 ).
23. Visually Inspect the rubber portions of the engine
mount for damage.
50546
stud (2) to the engine block.
Notices.
2. Install the left engine mount bracket bolts (3).
Tighten
• Tighten the engine mount bracket bolts (3) to
100 N-m (74 lb ft).
• Tighten the engine mount bracket stud (2) to
87 N-m (64 lb ft).
50546
3. Install the positive. cable to the engine mount

bracket stud.
• 1.nstall the RF (Radio Frequency) ground strap.
• Install the battery positive cable nut (2).
Tighten
Tighten the battery positive cable nut (2) to
25 N-m (i 8 lb ft).
211604
4. Install the right engine mount bracket (3) and

bolts (1, 2) to the engine block.
Tighten
• Tighten the two engine mount bracket bolts
(10 to 100 N-m (74 lb ft).
• Tighten the engine mount bracket bolt (2) to
50 N-m (37 lb ft).
4 3
50517
Engine Engine Mechanical - 3.8L 6~65
5. Install the left engine mount (2) and bolts (1) to
the crossmember.
Tighten
Tighten the left engine mount bolts (1) to
58 N-m (43 lb ft).
50525
6. Install the right engine mount (2) and bolts (1) to

the crossmember.
Tighten
Tighten the right engine mount bolts (2) to
58 N·m (43 lb ft).
7. Lower the engine until the mount bracket and
mount through holes line up together.
49837
9. Install the left engine mount through bolt (2).
50520
1O. Install the right engine mount through bolt (1 ).
50513
11 . Position the A/C compressor rearward to the

bracket.
1
12. Install the air conditioning compressor rear
bolts (2, 3).
Tighten
Tighten the air conditioning compressor rear
bolts (2, 3) to 30 N·m (22 lb ft).
365440
13. Install the air conditioning compressor bolts.

Tighten
Tighten the air conditioning compressor bolts to
50 N·m (37 lb ft).
282953
14. Install the transmission oil cooler pipe bracket
and bolt.
) Tighten
Tighten the oil cooler pipe bracket to
17 N·m (13 lb ft).
46662
15. Install the left side engine mount through bolt

nut (1).
Tighten
80 N-m (59 lb ft).
50520
16. Install the right side engine mount through bolt

nut (2).
Tighten
Tighten the engine mount through bolt nut· (2) to
80 N·m (59 lb ft).
17. Install the 3-way catalytic converter. Refer to
Engine Exhaust.
19. Install the ignition control module. Refer to Ignition
Electrical.
50513
Oil Level Indicator and Tube Replacement
Removal Procedure
1. Remove the oil level indicator from the
indicator tube.
2. Remove the oil level indicator tube nut.
3. Remove the oil level indicator tube from the
engine block.
554751
1. Replace the 0-ring seal if necessary.
2. Install the oil level indicator tube to the
engine block.
Notices.
3. Install the oil level indicator tube nut.
Tighten
Tighten the oil level indicator tube nut to
19 N·m (14 lb ft).
4. Install the oil level indicator to the indicator tube.
554751
Intake Manifold Replacement (Upper)

Removal Procedure
Tools Required
J 37088-A Fuel Line Quick Connect Separator
2. Disconnect the intake air temperature (IAT) sensor
electrical connector.
208554
Engine Engine Mechanical ~ 3.8L 6-69
3. Remove the air intake duct.
4. Remove the drive belt tensioner. Refer to Drive
Belt Tensioner Replacement.
554755
5. Disconnect the fuel injector electrical

connectors (1) from the fuel injectors.
6. Disconnect the manifold absolute pressure (MAP)
sensor electrical connector (2).
439410
7. Disconnect the engine harness vacuum tube (1)

from the vacuum port.
439411
8. Remove the fuel pressure regulator tube (2) from
the following components: .
• Manifold vacuum source (1)
• Fuel pressure regulator valve (3)
439396
9. Remove the manifold vacuum source screws (2).

10. Remove the manifold vacuum source (1) from the
upper intake manifold.
441250
11. Disconnect the fuel. injector electrical

connectors (1) from the fuel injectors.
12. Disconnect the evaporative emission (EVAP)
canister purge valve switch electrical
connector (2).
13. Relieve the fuel pressure. Refer to Fuel Pressure
Relief Procedure in Engine Controls - 3.8 L.
439467
14. Disconnect the fuel lines (1) from the fuel rail
using J 37088-A.
\ 15. Disconnect the fuel vapor line (4) from the EVAP
canister purge valve (5).
439396
16. Remove the EVAP canister purge valve bolts (1).

17. Remove the EVAP canister purge valve (2) from
the upper intake manifold.
Engine Electrical.
439395
19. Reposition the brake booster hose clamp.

20. Remove the brake bo.oster hose (2) from the
upper intake manifold fitting (1 ),
439407
21. Remove the captured secondary lock from the
connector.
22. Disconnect the electronic throttle control (ETC)
electrical connector (1 ).
439418
23. Disconnect the following electrical connectors:

5 • Mass airflow (MAF) sensor (1)
• Engine coolant temperature (ECT) sensor (2)
4 24. Remove the engine harness rosebud clip (3) from
the throttle body.
25. Remove the engine harness clamp bolt (5) and
harness clamp (4).
26. Reposition the engine wiring harness.
27. Remove the thermostat housing. Refer to
(
Thermostat Housing Replacement (3.8 L) in
3 Engine Cooling.
28. Disconnect the wiring harness rosebud clips from
the fuel rail.
1
29. Reposition the wiring harness.
439428
30. Remove the fuel rail nuts (1 ).

Important: Clean ariy dirt ouf of.the injector bores
with compressed air.
31. Remove the fuel rail (2) from the upper intake
manifold.
441253
32. Remove the throttle body bolt (1) and nuts (2).
33. Remove the throttle body (3) and gasket (4).
439449
34. Remove the upper intake manifold bolts (1, 3, 4).

35. Remove the upper intake manifold (2).
441255
36. Remove the upperintake manifold gasket (1).

37. Clean the upper and lower intake manifold sealing
surfaces.
439503
6-74 Engine Mechanical - 3.8l
38. Remove the lower . Engine
seals (3.' 4) , 1"f necessary.
intake manifold O-nng$
.
439510
Installation Proc
· ed ure
1. seal
Install(3new lowe r .intake manifold O .
' 4) , i"f removed. -nng
439510
2. Install the upper m

. take man 1"f0 Id gasket (1 ).
439503
3. Install the upper intake manifold (2) onto the lower
intake manifold.
Notices.
4. Install the upper intake manifold bolts (1, 3, 4).
Tighten
• Tighten the upper intake manifold bolt (3) to
15 N-m (11 lb ft).
• Tighten the nine upper intake manifold
bolts (4) to 10 N-m (89 lb in).
• Tighten the two upper intake manifold bolts (1)
to 30 N-m (22 lb ft).
441255
5. Install the throttle body (3) and gasket (4).

6. Install the throttle body bolt (1) and nuts (2).
Tighten
• Tighten the throttle body nuts (2) to
1O N-m (89 lb in).
• Tighten the throttle body bolt (1) to
10 N,m (89 lb in).
439449
7. Install the fuel rail (2) to the upper intake manifold.

8. Install the fuel rail nuts (1 ).
Tighten
Tighten the fuel rail nuts (1) to 8.5 N·m (75 lb in).
9. Position the wiring harness.
10. Connect the wiring harness rosebud clips from the
fuel rail.
11. Install the thermostat housing. Refer to Thermostat
Housing Replacement (3.8 L) in Engine Cooling.
12. Position the engine wiring harness.
441253
13. Install the engine harness clamp (4) and harness
clamp bolt (5).
Tighten
Tighten the harness clamp bolt (5) to
6 N-m (53 lb in).
14. Install the engine harness rosebud clip .(3) to the
throttle body.
15. Connect the following electrical connectors:
• MAF sensor (1)
• ECT sensor (2)
439428
16. Connect the ETC electrical connector (1 ).

17. Install the captured secondary lock from the
connector.
439418
18. Install the brake booster hose (2) to the upper

intake manifold fitting (1 ).
19. Position the brake booster hose clamp.
20. Install the ignition control module. Referto Ignition
Electrical.
439407
Engine Engine Mechanical a 3.8l 6a77
21. Install the EVAP canister purge valve (2) to the
) 22. Install the EVAP canister purge valve bolts (t).
Tighten
Tighten the EVAP canister purge valve bolts (1)
to 10 N-m (89 lb in).
439395
23. Connect the fuel vapor line (4) to the EVAP

canister purge valve (5).
24. Connect the fuel lines (1) to the fuel rail.
439398
25. Connect the EVAP canister purge valve switch

electrical connector (2).
26. Connect the fuel injector electrical connectors (1)
to the fuel injectors.
439467
27. Install the manifold vacuum source (1) to the
28. Install the manifold vacuum source screws (2). \
Tighten
Tighten the manifold vacuum source screws (2) to
10 N-m (89 lb in).
441250
29. Install the fuel pressure regulator tube (2) to the

" Manifoldvacuum source (1)
• Fuel pressure regulator valve (3)
439396
30. Connect the engine harness vacuum tube (1) to

the vacuum port.
439411
31. Connect the MAP sensor electrical connector (2).
32. Connect the fuel injector electrical connectors (1)
to the fuel injectors.
33. Install the drive belt tensioner. Refer to Drive Belt
Tensioner Replacement.
439410
34. Install the air intake duct.
554755
35. Connect the IAT sensor electrical connector.

208554
Intake Manifold Replacement (lower)
Removal Procedure
1. Remove the upper,intake manifold. Refer to
Intake Manifold Replacement (Upper).
2. Remove the coolant temperature sensor.
349800
3. Remove the 0-ring seals (3, 4), if necessary.

4. Remove the lower intake manifold bolts (1 ).
5. Remove the lower intake manifold (2).
439510
6. Remove the lower intake manifold seals (1).

2 1 7. Remove the lower intake manifold gaskets (2).
439530
1. Install the lower intake manifold gaskets (2). 2
2. Install the lower intake manifold seals (1 ).
Apply silicone sealer GM P/N 12345366 or
equivalent to the ends for the manifold seals (2).
439530
3. Install the lower intake manifold (2).

4. Apply thread lock compound GM P/N 12345493
or equivalent to the bolt threads before installing.
and Notices.
5. Install the lower intake manifold bolts (1 ).
2
Tighten
Tighten the lower manifold bolts (1) to
) 15 N·m (11 lb ft).
439510
6. Remove the coolant temperature sensor.

Tighten
Tighten the coolant temperature sensor to
25 N·m (18 lb ft).
7. Remove the upper intake manifold. Refer to
Intake Manifold Replacement (Upper).
349800
Exhaust Manifold Replacement (Left)
Removal Procedure
Information.
Engine Exhaust.
3. Disconnect the connector position
assurance (CPA) retainer.
4. Disconnect the wiring harness connector (1) from
the oxygen sensor.
5. Remove the oxygen sensor connector from the
spark plug wire harness bracket.
439775
6. Remove the oxygen sensor from the exhaust

manifold.
577702
7. Disconnect the numbers 1, 3 and 5 spark plug

wires from the spark plugs.
211645
8. Remove the numbers 3 and 5 spark plugs from
the cylinder head.
14824
9. Remove the two rear exhaust manifold studs and

nut from the exhaust manifold.
613220
11. Remove the number 1 spark plug from the

cylinder head.
14824
6-84 Engine Mechanical ~ 3.8L Engine
12. Remove the exhaust manifold heat shield nuts.
13. Remove the exhaust manifold heat shields from
the exhaust manifold.
613198
14. Remove the exhaust manifold studs and nut from

the exhaust manifold.
15. Remove the exhaust manifold and gasket from
the cylinder head.
16. Remove the heat shield studs from the exhaust
manifold, if necessary.
613220
1. Install the heat shield studs to the exhaust
2. Install the exhaust manifold gasket and manifold
to the cylinder head studs.
Notices.
3. Install the front two exhaust manifold studs and
nut to the exhaust manifold.
Tighten
" Tighten the two front exhaust manifold studs to
15 N-m (11 lb ft).
O
Tighten the exhaust manifold nut to
18 N-m (13 lb ft).
(
613220
4. Install the exhaust manifold heat shields to the
exhaust manifold.
5. Install the exhaust manifold heat shield nuts.
Tighten
Tighten the exhaust manifold heat shield nuts to
10 N-m (89 lb in).
613198
6. Install the number 1 spark plug to the

cylinder head.
Tighten
Tighten the number 1 spark plug to
27 N-m (20 lb ft).
Information.
14824
8. Install the two rear exhaust manifold studs and

Tighten
• Tighten the two rear exhaust manifold studs to
15 N·m (11 lb ft).
• Tighten the exhaust manifold nut to
18 N-m (13 lb ft).
613220
9. Install the numbers 3 and 5 spark plugs to the
cylinder head.
Tighten
Tighten the numbers 3 and 5 spark plugs to
27 N-m (20 lb ft).
14824
10. Connect the numbers 1, 3 and 5 spark plug wires

to the spark plugs.
211645
11. Install the oxygen sensor to the exhaust manifold.

Tighten
Tighten the oxygen sensor to 42 N-m (31 lb ft).
577702
Engine Engine Mechanical Q 3.8l 6;..87
i 2. Install the oxygen sensor connector to the spark
plug wire harness brackeL
13. Connect the wire harness connector (1) to the
oxygen sensor connector.
14. Connect the CPA retainer.
Engine Exhaust.
439775
Exhaust Manifold Replacement (Right)

Removal Procedure
i . Raise and suitably support the vehicle. Refer to
Information.
Engine Exhaust.
) 3. Disconnect the connector position
assurance (CPA) retainer.
4. Disconnect the oxygen sensor electrical
connector (3) from the harness.
439410
5. Remove the oxygen sensor connector rosebud

from the engine lift bracket.
6. Remove the oxygen sensor from the exhaust
manifold.
577706
7. Disconnect the numbers 4 and 6 spark plug wires
from the spark plugs.
211642
8. Remove the number 6 spark plug from the

cylinder head.
14824
9. Remove the two rear exhaust manifold studs and

'
613225
11. Disconnect the number 2 spark pluQwire from the
spark plug.
211642
12. Remove the numbers 2 and 4 spark plugs from

the cylinder head.
14824
13. Remove the exhaust mrmifold heat' shjeld nuts.

14. Remove the exhaust ~anifold heat shields fr~m
the exhaust manifold. ,>
'
~
'
613223
6~90 Engine Mechanical - 3.8L Engine
15. Remove the two front exhaust manifold studs and
16. Remove the right exhaust manifold and gasket
from the cylinder head.
17. Remove the heat shield studs from the exhaust
613225
1. Install the heat shield stud to the exhaust manifold,
if necessary.
2. Install the right exhaust manifold gasket and
manifold to the cylinder head studs.
Notices.
3. Install the two front exhaust manifold studs and I
nuts to the exhaust manifold. \
Tighten
• Tighten the two front exhaust manifold studs to
15 N·m (11 lb ft).
• Tighten the exhaust manifold nuts to
18 N·m (13 lb ft).
613225
4. Install the exhaust manifold heat shields to the

exhaust manifold.
5. Install the exhaust manifold heat shield nut.
Tighten
Tighten the exhaust manifold heat shield nuts to
1O N-m (89 lb in).
'
~
'
613223
6. Install the numbers 2 and 4 spark plugs to the
cylinder head. ·
Tighten
Tighten the numbers 2 and 4 spark plugs to
27 N-m (20 lb ft).
14824
7. Connect the number 2 spark plug wire to the

spark plug.
Information.
211642
9. Install the two rear exhaust manifold studs and

Tighten
• Tighten the two rear exhaust manifold studs to
15 N-m (11 lb ft).
• Tighten the exhaust manifold nut to
18 N-m (13 lb ft).
613225
6-92 Engine Meclumical - 3.8L Engine
10. Install the number 6 spark plug to the ·
cylinder head.
Tighten
Tighten the number 6 spark plug to
27 N·m (20 lb ft}.
14824
11. Connect the numbers 4 and. 6 spark plug wires to

the spark plugs.
211642
12. Install the oxygen :sensor to the exhaust manifold.

Tighten
Tighten the exhaust manifold to 42 N-m (31 lb ft}.
13. Connect the oxygen sensor electrical conneclor
rosebud to the engine lift bracket.
577706
14. Connect the oxygen sensor electrical
connector (3) to the wiring harness.
15. Connect the CPA retainer.
Engine Exhaust.
439410
Valve Rocker Arm Cover

Replacement (Left)
Removal Procedure
Engine Electrical.
2. Remove the exhaust gas recirculation (EGR)
) valve outlet pipe bolt from the upper intake
manifold.
3. Remove the EGR valve outlet pipe nut from the
EGR valve adapter.
4. Remove the EGR valve outlet pipe.
577700
5. Disconnect the EGR valve electrical connector.
221704
6. Remove the EGR valve adapter nuts (2}.
7. Remove the EGR valve adapter bolt (1 ).
8. Remove the EGR valve adapter from the cylinder (
head studs.
9. Remove the oil level indicator tube. Refer to Oil
Level Indicator and Tube Replacement.
2
577696
10. Remove the engine lift bracket from the cylinder

head studs.
11. Remove the top ignition control module
bracket bolt.
Information.
13. Remove the rear ignition control module
bracket bolts.
15. Remove the ignition control module bracket.
577690
16. Loosen the valve rocker arm cover bolts.

1 17. Remove the valve rocker arm cover (1).
18. Clean the following items:
• Valve rocker arm cover
• Cylinder head gasket surface
• Valve rocker arm cover bolts
37442
Engine Engine Mechan.ical - 3.8L 6-95
1. Apply thread lock adhesive GM P/N 12345493 or
equivalent, to the valve rocker arm cover bolt
threads.
Notices.
2. Install the valve rocker arm cover (1 ).
3. Tighten the valve rocker arm cover bolts.
Tighten
Tighten the valve rocker arm cover bolts to
10 N·m (89 lb in).
4. Install the ignition control module bracket.
Information.
6. Install the rear ignition control module
bracket bolts.
Tighten 37442
Tighten the rear ignition control module bracket

bolts to 50 N·m (37 lb ft).
8. Install the top ignition control module bracket bolt.
Tighten
Tighten the top ignition control module bracket
9. Install the engine lift bracket to the cylinder
) head studs.
10. Install the oil level indicator tube. Refer to Oil
Level Indicator and Tube Replacement.
577690
11. Install the EGR valve adapter to the cylinder
head studs.
12. Install the EGR valve adapter bolt (1).
13. Install the EGR valve adapter nuts (2).
Tighten
• Tighten the EGR valve adapter nuts (2) to
50 N-m (37 lb ft).
" Tighten the EGR valve adapter bolt (1) to
25 N-m (18 lb ft).
2
577696
14. Connect the EGR valve electrical connector.
221704
15. Install the EGR valve outlet pipe.

16. Install the EGR valve outlet pipe nut to the
EGR valve adapter.
17. Install the EGR valve outlet pipe bolt to the upper
intake manifold.
Tighten
• Tighten the EGP valve outlet pipe nut to
29 N-m (21 lb ft 1 •
O Tighten the EGR valve outlet pipe bolt to
29 N·m (21 lb ft).

18. Install the ignition control module. Refer to Ignition
Electrical.
577700
Replacement (Right)
Removal Procedure
2. Remove the spark plug wires from the 1,3 and
5 spark plugs.
3. Remove the spark plug wiring harness from the
clip and reposition the harness.
Information.
52978
5. Remove the rear engine left bracket bolt (1) and

stud (2).
6. Remove the rear engine lift bracket (3).
52977
8. Loosen the valve rocker arm cover bolts.

9. Remove the valve rocker arm cover.
35819
6-98 Engine Mechanical - .3.8L Engine
10. Remove the oil fill tube cap, if necessary.
i 1. Remove the oil fill tube, if necessary.
To remove the fill tube press the tangs inside the \
tube in and twist the tube.
12. Clean the following ite.ms:
0 Valve rocker arm cover
" Cylinder head gasket surface
~ Valve rocker arm cover bolts.
577684
i. Install the oil fill tube to the valve rocker arm·
cover, if .removed.
2. Install the oil fill tube cap, if removed.
577684

equivalent to the valve rocker arm cover b.olt
threads.
4. Install the valve rocker arm cover.
Notices.
5. Tighten the valve rocker arm cover bolts.
Tighten
1O N·m (89 lb in).
Information.
35819
7. Install the rear engine lift bracket (3).
8. Install the rear engine lift bracket stud (2) and
bolt (1 ).
Tighten
Tighten the rear engine lift bracket stud (2) and
bolt (1) to 50 N-m (37 lb in).
52977
10. Install the spark plug wiring harness to the clip.

11. Install the spark plug wires to the 1,3 and
5 spark plugs.
52978
Valve Rocker Arm and Push Rod

Replacement
Removal Procedure
1. Remove the valve rocker arm covers. Refer to
Valve Rocker Arm Cover Replacement (Left) or
Valve Rocker Arm Cover Replacement (Right).
2. Remove the valve rocker arm bolts (1 ).
3. Remove the valve rocker arms (2).
554762
4. Remove the valve rocker arm retainer (1 ).
439870
5. Remove the pushrods (1 ).
439864
1 Tools Required
J 36660-A Torque Angle Meter
Important: Reinstall the rocker arms and pushrods in
the same locations from which they were removed.
Important: When installing valve rocker arms
and pushrods, coat the bearing surfaces with prelube
GM P/N 12345501 or equivalent. Install these
components in the locations from which they were
removed.
1. Install the pushrods (1 ).
439864
2. Install the valve rocker arm retainer (1 ).
439870
3. Install the valve rocker arms (2).

equivalent to the rocker arm bolt threads before
installing.
Notices.
5. Install the valve rocker arm bolts (1).
Tighten
) Tighten the valve rocker arm bolts to
15 N-m (11 lb ft). Use the J 36660-A in order to
torque the bolts an additional 90 degrees.
6. Install the valve rocker arm covers. Refer to Valve
Rocker Arm Cover Replacement (Right) or Valve
Rocker Arm Cover Replacement (Left).
554762
Valve Stem Oil Seal and Valve Spring

Replacement
Removal Procedure
Tools Required
• J 23590 Spark Plug Port Adapter
• J 38606 Valve Spring Compressor
1. Remove the valve rocker arm and push rod. Refer
to Valve Rocker Arm and Push Rod
Replacement.
2. Remove the spark plug. Refer to Spark Plug
Replacement in Engine Electrical.
Important: Rotate the engine so that the piston in the
cylinder being worked on is at top dead center (TDC)
before removing the valve keys. This will eliminate the
) possibility of the valve accidentally falling inside the
cylinder.
3. Install the J 23590 to the spark plug port and
apply compressed air in order to hold the
valves closed.
190565
4. Install the J 38606 on the valve spring.
J 38606
190566
5. Compress the valve spring using the J 38606.

6. Remove the valve keys.
7. Remove the valve spring ahd cap.
J 38606
190527
8. Remove the valve stem oil seal.

9. Inspect the valve spring for bent, cracked or
broken parts. Replace it if damaged. Refer to
Cylinder Head Clean and Inspect.
190567
Tools Required
~428~
e J 42863 Valve Seal Installer

" J 23590 Spark Plug Port Adapter
Important: The color of the replacement seal rnay not
be the same color as the original seal. Install the
seals in their correct location based on GM part and
package description. Ensure that the seal is fully
seated on the valve guide.
1. Place the valve stem oil seal over the valve stem
so the seal begins to contact the valve guide.
Important: Use hand pressure only when installing
the valve seal using J 42863. Using to much force may
cause damage to the oil seal and possibly lead to
excessive oil consumption.
2. Using J 41512 push the valve stem oil seal over
the vavle guide. 40071
3. Install the J 38606 on the valve spring.
J 38606
)
154517
4. Compress the valve spring using the J 38606.
J 38606
190527
5. Using install the valve spring and the valve cap.
6. Install the valve keys.
7. Release the valve spring.
J 38606 8. Ensure that the valve keys are seated.
190566
10. Disconnect the air pressure, and remove

the J 23590.
11. Install the spark plug. Refer to Spark Plug
Replacement in Engine Electrical.
12. Install the push rod and valve rocker arm. Refer
Replacement.
190565
Valve Lifter Replacement

Removal Procedure
1. Remove the lower intake manifold. Refer to Intake
Manifold Replacement (Lower).
2. Remove the valve rocker arms and the pushrods.
Refer to Valve Rocker Arm and Push Rod
Replacement.
3. Loosen the valve lifter guide bolts.
4. Remove the valve lifter guide.
5. Remove the valve lifters.
41374
i. Coat the valve lifters with prelube, GM
I P/N 12345501 or equivalent prior to installation.
2. Install the valve lifters.
3. Install the valve lifter guide.
Notices.
4. Tighten the valve lifter guide bolts.
Tighten
Tighten the valve lifter guide bolts to
30 N-m (22 lb ft).
5. Install the valve rocker arms and pushrods. Refer
Replacement.
6. Install the lower intake manifold. Refer to Intake
41374
Crankshaft Balancer Replacement

Removal Procedure
Tools Required
• J 38197 Crankshaft Balancer Puller
" J 37096 Flywheel Holding Tool
1 . Remove the drive belt. Refer to Drive Belt
Replacement.
) 2. Raise and suitably support the vehicle. Refer to
Information.
3. Remove the starter motor. Refer to Starter Motor
4. If equipped with the M49 manual transmission
remove the following components:
5. Remove the transmission brace bolts (2, 3).
6. Remove the transmission brace (1 ).
349561
7. Remove the flywheel housing inspection cover

bolts (2).
1
8. Remove the flywheel housing inspection cover (3).
9. If equipped with the 4L60-E automatic
transmission remove the torque converter cover.
Refer to Torque Converter Cover Replacement
(3.8 L) in Automatic Transmission - 4L60-E.
349560
10. Use J 37096 in order to hold the flywheel.
309963
11. Remove the crankshaft balancer bolt (1) from the

balancer (2).
12. Remove the key (3) from the crankshaft.
1
440746
13. Remove the crankshaft balancer using

the J 38197.
13.1. Invert J 38197-2 so the leg of the tool is
facing away from the crankshaft balancer.
13.2. Install the silver bolts J 38197-4 to the
crankshaft balancer.
13.3. Remove J 38197-1, J 38197-2, and
J 38197-4 from the crankshaft balancer.
313955
Tools Required
l J 36660-A Torque Angle Meter 1
1. Lubricate the seal surface of the crankshaft
balancer with engine oil.
2. Install the crankshaft balancer (2).
3. Align the key slot in the balancer (2) to the key
slot in the crankshaft.
4. Install the key (3)
Notices.
5. Install the crankshaft balancer bolt (1 ).
Tighten
Tighten the crankshaft balancer bolt (1) to
150 N·m (111 lb ft). Use the J 36660-A to torque
the crankshaft balancer bolt (1) an additional
114 degrees.
440746
7. If equipped with the 4L60-E automatic
transmission install the torque converter cover.
Refer to Torque Converter Cover Replacement
(3.8 L) in Automatic Transmission - 4L60-E.
8. If equipped with the M49 manual transmission
install the following components:
9. Install the flywheel housing inspection cover (3).
10. Install the flywheel housing inspection cover 1
bolts (2).
)
Tighten
Tighten the flywheel housing inspection cover
349560
11. Install the transmission brace (1 ),
12. Install the transmission brace bolts (2, 3).
Tighten \
a Tighten the brace bolts. (3) to the engine block
to 28 N-m (21 lb ft).
• Tighten the brace bolts (2) to the transmission
to 50 N-m (37 lb ft).
13. Install the starter motor. Refer to Staner Motor
15. Install the drive belt. Refer to Drive Belt
Replacement.
16. Perform the crankshaft position (CKP)
system variation learn procedure. Refer to CKP
System Variation Learn Procedure in Engine
Controls - 3.8 L.
349561
Crankshaft Front Cover Oil Seal

Replacement .
Removal Procedure
1. Remove the crankshaft balancer. Refer to
Crankshaft Balancer Replacement.
2. Use a screwdriver to pry outthe crankshaft front
oil seal. Use. care in order to avoid damage to the
seal bore or seal contact surfaces.
50499
Tools Required
J 35354 Seal Installer
1. Install the crankshaft front oil seal. Use the
J 35354 and a soft faced hammer.
3. Coat the outside seal surface of the crankshaft
balancer with lubricant GM P/N 12377985 or
equivalent.
4. Install the crankshaft balancer. Refer to Crankshaft
Balancer Replacement.
50499
Engine Front Cover Replacement
Removal Procedure
1. Drain the engine oil.
3. Disconnect the intake air temperature (IAT) sensor
208554

5. Loosen the coolant pump pulley bolts.
Belt Tensioner Replacement.
7. Remove the power steering pump. Refer to Power
Steering Pump Replacement (VB) in Power
Steering System.
) Lifting and Jacking the Vehicle in General
Information.
554755
10. Disconnect the crankshaft position sensor

11. Remove the crankshaft position sensor shield.
440841
6-11 O Engine Mechanical - 3.8l Engine
12. Remove the crankshaft position sensor studs,
i 3.Remove the crankshaft position sensor.
14. Remove the oil pan to front cover bolts.
15. Loosen the oil pan bolts, to drop the oil pan
slightly in order to add clearance for the front
cover installation.
554767
17. Remove the coolant pump pulley bolts.

18. Remove the coolant pump pulley.
221711
i 9. Remove the radiator outlet hose from the

front cover.
221689
Engine Engine Mechanical - 3.8L Sm 111
20. Remove the engine front cover studs and bolts (1 ).
21. Remove the engine front cover (2).
50504
22. Remove the engine front cover gasket from the

engine block.
440843
23. Remove the coolant pump bolts (1 ).

24. Remove the coolant pump (2).
25. Remove the coolant pump gasket (3) from the
front cover (4).
11687
26. If replacing the front cover (1 ), disassemble the
1
.. Oil pump gear set (2)
G Camshaft sensor (3)
" Oil filter adapter (5) and gasket
" Oil pressure relief valve (6) and spring
27. Remove the crankshaft front oil seal (4).
28. Clean the engine front cover and engine block
surfaces.
4 3
445496
Installation Procedure .
1 Tools Required
s J 36660-A Torque Angle Meter
O J 35354 Seal Installer
1. If replacing the front cover (1 ), assemble the
following parts:
e Oil pump gear set (2)
~ Camshaft sensor (3)
• Oil filter adapter (5) and a new gasket

0
Oil pressure relief valve (6) and spring
2. Install a new crankshaft front oil seal (4)
4 3
445496
3. Install the coolant pump gaskElt (3) to the front

cover (4).
4. lnstallt~e,coolqnt pump (2).
Notices,
5. :Install .the coolant pump bolts (1 ).
Tighten··
Tighten the coolant pump bolts (1) to
15 N·m (11 lb ft). Use the J 36660-A to torque the
coolant pump bolts (1) an additional 80 degrees.
11687
6. Install a new engine front cover gasket to the
engine block.
440843
7. Install the engine front cover (2).
50504
8. Apply sealant GM P/N 12346004 or equivalent to

the engine front cover bolts (1) and stud (2).
9. Install the engine front cover bolts (1) and stud (2).
Tighten
Tighten the front cover bolts (1) and stud (2) to
20 N-m (15 lb ft). Use the J 36660-A to torque the
front cover bolts (1) and stud (2) an additional·
40 degrees. ·
445603
10. Install the radiator outlet hose. to the front cover.
221689
11. Install the coolant pump pulley.

12. Install the coolant pump pulley bolts.
Tighten
Tighten the coolant pump pulley bolts to
13 N·m (115 lb in).
Information.
14. Install the oil pan to front cover bolts. (
Tighten
Tighten the oil pan bolts to 14 N·m (10 lb ft).
221711
15. Install the crankshaft position sensor. .

the crankshaft position· sensor studs.
17. Install the crankshaft position sensor studs.
Tighten
Tighten the crankshaft position sensor studs to
20 N-m (15 lb ft). Use the J 36660-A to torque the
crankshaft position sensor studs an additional
40 degrees.
554767
Engine Engine Mechanical~ 3.8l 6-115
18. Install the crankshaft position sensor shield.
19. Connect the crankshaft position sensor electrical
connector.
22. Install the power steering pump. Refer to Power
Steering Pump Replacement (VB) in Power
Steering System.
Tensioner Replacement.
440841
554755

26. Refill the engine oil.
208554
Oil Pump Cover and Gear Set
Replacement
Removal Procedure
1. Remove the engine front cover. Refer to Engine
Front Cover Replacement.
2. Remove the oil pump cover attaching screws.
3. Remove the oil pump cover.
4. Remove the oil pump gear set.
5. Inspect the oil pump gear set and housing. Refer
to Oil Pump Clean and Inspect.
153600
1. Lubricate the oil pump gear set with
petroleum jelly.
2. Install the oil pump gear set.
3. Pack the oil pump cavity with petroleum jelly.
4. Install the oil pump cover.
Notices.
5. Install the oil pump cover screws.
Tighten
Tighten the oil pump cover screws to
11 N-m (98 lb in).
6. Install the engine front cover. Refer to Engine
153600
Oil Filter Adapter and Valve Assembly

1 2 Replacement
Removal Procedure
Replacement.
2. Remove the engine ground strap bolt (1) and
ground strap (2).
3. Disconnect the air conditioning compressor
electrical connector (3).
Information.
6. Remove the air conditioning compressor mounting
bracket. Refer to Compressor Mounting Bracket
Replacement (3.8 L) in Heating, Ventilation and Air
Conditioning.
445688
Engine Mee hanical - 3.8L 6-117
Engine
7 Disconnect the oil pressure
sensor electrical
· connector (2).
a. Remove the oil pressure sensor.
9. Remove the engine oil filter.
---------4444(0847
10. Remove the oil filter adapter bolts (3).
11. Remove the oil filter adapter (2) and gasket (1).
12. Remove the pressure relief valve (4) and
spring (5).
13. Clean the parts in a suitable solvent. Dry the parts.
14. Clean all of the gasket sealing surfaces.
15. Inspect the following areas:
• The oil pressure relief valve (4) and the valve
bore for burrs
O The spring (5) for loss of tension, replace the
spring if you are in doubt.
440844
Tools Required
1. Install the pressure relief valve (4) and spring (5).
2. Install the oil filter adapter (2) and gasket (1 ).
and Notices.
3. Install the oil filter adapter bolts (3). (
Tighten
Tighten the oil filter adapter bolts (3) to
15 N·m (11 lb ft). Use the J 36660-A to torque the
oil filter adapter bolts (3) an additional 50 degrees.
440844
4. Install a new oil filter.

Tighten
Tighten the oil filter to 30 N·m (22 lb ft).
440847
Engine Eng .me Mechanical - 3.8 L 6-119
5. Install the oil press ure sensor.
Tighten the oil. pressure sensor to

Tighten
16 N-m (12 lb ft).
440848
6 oil pressure .se nsor electrical .

. Connect the mounting
connector (2).condilloning compre~~~~g Bracket .
7. Install the a;:r to CompiessC?r M~entilation and Air
bracket. Re . L) in Heating, .
. . Replace"!ent .113•8 . .·
Conditioning.
8. Lowe r the vehicle.
440853
. co mpressor electrical
h air conditioning
9 Connect t e It (1)
. connector (3). d strap (2) and bo .
10. Install the en gine groun
Tighten the engine

Tighten . ground strap bolt to
25 N,m (18 lb ft). R fer to Drive Belt

11 lnsta II the drive belt. e
· Replacement. .
· e 011 ·
12. Ref I·11 the engin
3
6-120 Engine Mechanical - .3.8l Engine
Timing Chain and .Sprockets Replacement
Removal Procedure
4 Front Cover Replacement.
2. Align the timing marks (2) on the sprockets (1, 3)
so that they are as close together as possible.
3. Remove the timing chain dampener.
4. Remove the camshaft sprocket bolt.
550171
5. Remove .the timing chain (1) and camshaft

sprocket (2).
Important: If the crankshaft sprocket does not come
off easily, a light .blow on the edge of .the sprocket
(with a pla$tiC mallet) should dislodge the sprocket.
6. Remove the crankshaft sprocket (3).
7. Clean the timing chain.
8. Clean the sprockets.
9. Inspect all the components for wear or damage.
10. If the balance shaft timing has been disturbed. (
Refer to Balance Shaft Removal and Balance
Shaft Installation.
11. Use the following steps if the pistons have been
moved in the engine:
11.1. Turn the crankshaft in order to set the
number one piston is at top dead center.
11.2. With the sprocket installed, turn the
camshaft in order to have the timing
mark straight down.
550172
Tools Required
J 36660-ATorque Angle Meter
1. Install the timing chain (1) onto the
sprockets (2, 3) with the timing marks in their
closest together position.
2. Install the timing chain (1) and sprockets (2, 3).
Notices.
3. Install the camshaft sprocket bolt.
Tighten
Tighten the camshaft sprocket bolt to
100 N-m (74 lb ft). Use the J 36660-A to torque
the camshaft sprocket bolt an additional (
90 degrees.
4. Install the timing chain dampener.
550172
5. Install the timing chain dampener bolt.
Tighten
Tighten the dampener bolt to 22 N-m (i 6 lb ft).
Important: Rotate the engine two revolutions and
check the timing marks. Ensure the marks are aligned.
Camshaft Replacement
Removal Procedure
1 . Recover the refrigerant. Refer to Refrigerant
Recovery and Recharging in Heating, Ventilation
2. Remove the radiator with the A/C condenser.
Refer to Radiator Replacement in Engine
Cooling.
3. Remove the valve lifters. Refer to Valve Lifter
Replacement.
4. Remove the timing chain and sprockets. Refer to
Timing Chain and Sprockets Replacement. ·
5. Remove t11e balance shaft gear (2) from the
camshaft (1).
441129
} 6. Remove the camshaft thrust plate baits.

7. Remove the camshaft thrust plate.
8. Remove the camshaft key.
Notice: All camshaft journals are the same diameter,
so care must be used in removing or installing the
camshaft to avoid damage to the camshaft bearings.
9. Use the following procedure to remove the
camshaft:
9.1. Install three 5/16-18 x 4 in bolts in the
camshaft bolt holes.
9.2. Carefully rotate and pull the camshaft out.
10. Inspect the camshaft and bearings. Refer to
Camshaft and Bearings Clean and Inspect.
35815
1. Coat the camshaft with prelube GM P/N 12345501
or equivalent before installation. (
2. Install the camshaft.
3. Install the camshaft key.
4. Install the camshaft thrust plate.
Notices.
5. Install the camshaft thrust plate bolts.
Tighten
Tighten the camshaft thrust plate bolts to
15 N·m (11 lb ft).
35815
6. Install the balance shaft drive gear (2) to the

camshaft ·(1) .
441129
7. Align the timing marks (2) on the balance shaft.

gear (1) and the balance shaft drive gear (3).
8. Install the timing chain and sprockets. Refer to
Timing Chain and Sprockets Replacement.
9. Install the valve lifters. Refer to Valve Lifter
Replacement.
10. Install the radiator with the A/C condenser. Refer
to Radiator Replacement in Engine Cooling.
11. Charge the A/C system. Refer to Refrigerant
441151
Cylinder Head Replacement (Left)
Removal Procedure
3. Remove the right exhaust manifold. Refer to
Exhaust Manifold Replacement (Left) in Engine
Exhaust.
4. Remove the valve rocker arms and pushrods.
Replacement.
5. Remove the cylinder head bolts (1 ).
6. Remove the left cylinder head (2).
441261
7. Remove the left cylinder head gasket (1).

8. Disassemble the cylinder head. Refer to Cylinder
Head Disassemble.
441262
Tools Required
Important: The arrow on the gasket must point to the
front of the engine. Failure to install the gasket
properly will cause gasket failure and possible engine
failure.
1. Assemble the cylinder head. Refer to Cylinder
Head Assemble.
2. Install a new left cylinder head gasket (1) to the
aHgnment pins (2).
441262
3. Install the left cylinder head (2).
441261

Notices.
4. Torque the cylinder head bolts following the given
sequence.
5. Install the cylinder head bolts.
Tighten
Tighten the cylinder head bolts to 50 N-m (37 lb ft)
in sequence shown. Use the J 36660-A to
torque the cylinder head bolts an additional
120 degrees.
@ to Valve Rocker Arm and Push Rod
Replacement.
® ® ® 7. Install the left exhaust manifold. Refer to Exhaust
Manifold Replacement (Left) in Engine Exhaust.
38826
10. Change the engine oil and filter. Refer to Engine
Oil and Oil Filter Replacement.
(
Cylinder Head Replacement (Right)
Removal Procedure
3. Remove the right exhaust manifold. Refer to
Exhaust Manifold Replacement (Right).
4. Remove the valve rocker arms and the pushrods.
Replacement.
5. Remove the cylinder head bolts (1 ).
6. Remove the right cylinder head (3).
441261
7. Remove the right cylinder head gasket (3).

8. Disassemble the cylinder head. Refer to Cylinder
Head Disassemble.
441262
Tools Required
Important: The arrow on the gasket must point to the
front of the engine. Failure to install the gasket
properly will cause gasket failure and possible engine
damage.
1. Install the new right cylinder head gasket (3) to
the alignment pins (2).
441262
s~12s Engine Mechanical - 3.SL Engine
2. Install the right cylinder head (3).
441261

Notices.
3. Tighten the cylinder head bolts following the given
sequence.
Tighten
in sequence shown. Use the J 36660-A to
torque the cylinder head bolts an additional
120 degrees. (
4. Install the pushrods and the valve rocker arms.
@ Replacement
5. Install the right exhaust manifold. Refer to
® ® Exhaust Manifold Replacement (Right) in Engine
Exhaust.
38826
8. Change the engine oil and Jilter. Refer to.Engine
Oil Pan Replacement
Removal Procedure
Information.
4. Remove the right side engine mount (2) to cradle
bolts (1 ).
49837
5. Remove the left side engine mount (2) to cradle

bolts (1 ).
50525
6. Remove the right and left side shock absorber

lower mounting bolts.
220629
7. Remove the intermediate steering shaft bolt from
the rack and pinion.
8. Support the engine cradle with appropriate (
equipment.
220630
9. Disconnect the oil level sensor electrical

connector ( 1) .
440880
Notice: Remove the oil level sensor, located in the oil

pan, before the oil pan is removed. The sensor may
be damaged if the oil pan is removed first.
10. Remove the oil level sensor from the oil pan.
441263
12. Remove the front crossmember bolts.
i 220632
13. Remove the oil pan bolts (1 ).

14. Remove the oil pan (2).
Lower the rear of the oil pan while rotating the
pan outward.
441269
15. Remove the oil pan gasket.

16. Clean the oil pan gasket mating surface.
441265
1. Install the oil pan gasket.
441265
2. Install the oil pan (2).

Notices. · ·
3. Install the oil pan bolts (1 ).
Tighten
Tighten the oil pan bolts to 14 N-m (10 lb ft).
441269
4. Install the front crossmember bolts.

Tighten
.. Tighten the upper four crossmember bolts to
125 N·m (92 lb ft). ..
" Tighten the lower two crossmember bolts to
145 N-m (107 lb ft).
5. Install the starter motor. Refer to Starter Motor
I
(
~ 220632
6. Install the oil level sensor to the oil pan.
Tighten
Tighten the oil level sensor to 20 N-m (15 lb ft).
441263
7. Connect the oil level sensor electrical

connector (1 ).
8. Remove the equipment used to support the
engine cradle.
440880
9. Install the intemediate steering shaft from the rack

and pinion.
Tighten
Tighten the intermediate shaft bolt to
47 N·m (35 lb ft).
220630
10. Install the right and left side shock absorber lower
mounting bolts.
Tighten (
Tighten the shock bolts to 65 N·m (48 lb ft).
220629
11. Install the left side engine mount (2) to cradle

bolts (1 ).
Tighten
Tighten the left side engine mount to cradle
50525
12. Install the right side engine mount (2) to cradle

bolts (1 ).
Tighten
Tighten the right side engine mount to cradle
15. Change the engine oil and filter. Refer to Engine
49837
Oil Pump Pipe and Screen Assembly
J Replacement
Removal Procedure
1. Remove the oil pan. Refer to Oil Pan
Replacement.
2. Remove the oil pump screen attaching bolts (2).
3. Remove the oil pump screen (1 ).
4. Remove the oil pump screen gasket (3).
5. Clean the screen and housing with solvent and
blow dry with compressed air.
6. Clean the gasket mating surfaces on the pipe
flange and cylinder block.
441270
1. Install the oil pump screen gasket (3).
2. Install the oil pump screen (1 ).
Notices.
3. Install the oil pump screen bolts (2).
Tighten
Tighten the oil pump screen bolts (2) to
15 N·m (11 lb ft).
4. Install the oil pan. Refer to Refer to Oil Pan
Replacement.
441270
Engine Flywheel Replacement

Removal Procedure
Tools Required
J 37096 Flywheel Holding Tool
1. If equipped with a manual transmission remove
the clutch pressure plate and driven disc. Refer
to Clutch Pressure Plate arid Clutch Driven
Plate (3.8 L) in Clutch.
2. Remove the automatic transmission, if equipped.
Refer to Transmission Replacement (3.8 L) in
automatic Transmission - 4L60-E.
3. Use the J 37096 to hold the flywheel to loosen the
flywheel bolts.
309963
6·134 Engine Mechanical - 3.8L Engine
4. If equipped with the manual transmission, remove
4.1. Remove the flywheel bolts (1 ). (
4.2. Remove the flywheel (2).
441112
5. If equipped with the automatic transmission,

remove the following components:
5.1. Remove the flywheel bolts (1 ).
5.2. Remove the flywheel (2).
441271
Tools Required
• J 36660-A Torque Angle Meter
• J 37096 Flywheel Holding Tool
1. If equipped with the automatic transmission, install
1.1. Install the flywheel (2).
1.2. Install the flywheel bolts (1) finger tight.
441271
2. If Elquipped with the manual transmission, install
2.1. Install the flywheel (2).
2.2. Install the flywheel bolts (1) finger tight.
. 441112
3. Use the. J 37096 to hold the flywheel when

ti,ghtening the flywheel bolts.
Notices.
4. Tighten the flywheel bolts.
Tighten
Tighten the flywheel bolts to 15 N-m (11 lb ft). Use
the J 36660-A to torque the flywheel bolts an
) additional 50 degrees.
5. Install the .automatic transmission, if equipped.
Refer to Transmission Replacement (3.8 L) in
automatic Transmission - 4L60-E.
6. If equipped with a manual transmission install the
clutch pressure plate and driven disc. Refer to
Clutch Pressure Plate and Clutch Driven Plate
(3.8 L) in Clutch.
309963

Replacement
Removal Procedure
1. Drain the engine coolant .from the cooling system.
Refer to Draining and Filling Cooling System
(3.8 L) in Engine Cooling. · ·
2. Remove the engine flywheel. Refer to Engine
Flywheel Replacement.
3. Loosen all of the oil pan bolts.
4. Remove the crankshaft rear oil seal housing bolts.
5. Remove the crankshaft rear oil seal housing.
6. Remove the rear oil seal housing gasket.
) Important: Make sure not to damage the crankshaft
OD surface with any tool.
7. Remove the oil seal from the housing.
153604
8. Clean the gasket surfaces of the oil seal housing
and the engine block.
9. Inspect the ID of the. oil seal housing bore. (
Replace the crankshaft rear oil seal housing
as required.
10. Inspect the crankshaft for nicks or burrs on the
surface that contacts the seal.
11. Repair or replace the crankshaft as required.
Tools Required
• J 41349 Crankshaft Rear Oil Seal Housing
Aligning Tool
Notice: Do not use sealers or adhesives on rear main
oil seal housing gasket. Use of sealers or adhesives
on this gasket may cause oil leaks.
1. Install the crankshaft rear oil seal housing gasket
over the bolts for alignment.
Important: The plastic inserts in the crankshaft rear
oil seal housing are used .to aid assembly only.
The inserts are not required for ser:vice.
2. Finger tighten the crankshaft rear oil seal
housing bolts.
153604
3. Apply engine oil to both sides of the J 41349.

(
Notice: Sealability of the rear mai.n oil seal depends
on the correct alignment of the rear main oil seal
J 41349 housing and the oil pan. Incorrect alignment
may cause oil leaks.
4. Install the J 41349 over the crankshaft. Twist the
tool to aid in sliding the tool over the crankshaft.
5. Raise the oil pan and finger tighten the oil
pan bolts.
Notices.
6. Tighten the crankshaft rear oil seal housing bolts.
Tighten
Tighten the crankshaft rear oil seal housing bolts
to 15 N·m (11 lb ft). Use the J 36660-A to
torque the crankshaft rear oil sea.I housing bolt an
additional 50 degrees.
153603
8. Tighten the oil pan bolts.
Tighten
Tighten the oil pan bolts to 14 N-m (10 lb ft).
9. Remove th.e engine flywheel. Refer to Engine
Flywheel Replacement.
Filling Cooling System {3.8 L) in Engine Cooling. (
Engine Engine Mechanical~ 3.8L 6-137
Engine Replacement
I Removal Procedure
Tools Required
• J 37088-A Fuel Line Disconnect Tool Set
O J 39580 Universal Engine Support Table
• J 21366 Converter Holding Strap

2. Disconnect the positive battery cable.
211587

sensor electrical connector.
208554

5. Recover the refrigerant. Refer to Refrigerant ·
6. Relieve the fuel pressure. Refer to Fuel Pressure
Relief Procedure in Engine Controls - 3.8 L.
Information.
9. Remove the front wheels. Refer to Tire and
Wheels.
11 . Remove the 3-way catalytic converter. Refer to
Engine Exhaust.
554755
12. Drain the transmission fluid, if equipped with a
13. Remove the propeller shaft. Refer to Propeller (
14. Remove the torque arm. Refer to Torque
Arm Replacement in Rear Suspension.
15. On vehicles equipped with a automatic
transmission, unsnap the transmission range
selector lever cable from the range selector lever
at the transmission.
208264
16. Remove the retainer from the range selector

lever cable. (
.ml
I
341079
(
17. Remove the range selector lever cable from the
cable bracket.
208276
18. On vehicles equipped with a manual transmission,

disconnect the clutch actuator cylinder line from
the actuator cylinder using J 36221.
19. Remove the left side front air deflector. Refer to
in Bumpers.
20. Remove the stabilizer bar bracket bolts.
21. Remove the stabilizer bar brackets.
43255
22. Remove the steering gear coupling shield.

23. Remove the intermediate steering shaft bolt and
shaft from the rack.
220630
6-140 Engine Mechanical- .3.8L Engine
24. Remove the wiring harness ground bolt and RF
(Radio Frequency) ground strap and cruise
control ground lead from the front rail. (
25. Disconnect the knock sensor electrical connectors.
346034
26. Disconnect the wheel· speed sensors electrical

connectors.
\ (
346036

and condenser hose nut at the condenser.
569444
29. Remove the front fuel pipe heat shield nuts {1 ).
30. Remove the front fuel pipe heat shield (2).
31. Disconnect the brake lines from the brake
pipe clip.
7cP
173551
33; Remove the engine wiring harness ground

bolt (1 ).
1 2
34. Remove the engine ground.
445688

282936
37. Remove the heater hoses from the drive belt
tensioner.
(
282933
38. Using J 37088-A disconnect the following pipes:

• The fuel feed (1) from the fuel rail
.. The fuel return (2) from the fuel rail
39. Disconnect the EVAP pipe (6) at the engine.
215517
40. Remove the capture secondary lock from the

41. Disconnect the electronic throttle control (ETC)
42. Remove the forward lamp harness branch from
the wire harness clip.
439418
43. Remove the inlet hose from the water outlet.
221680
44. Remove the outlet hose from the water pump.
221689
45. Remove the brake booster vacuum hose (2) from

the intake manifold fitting (1 ).
46. Remove the front two brake pipes from the brake
modulator.
439407
47. Disconnect the captured secondary locks.
48. Disconnect the forward lamp harness from the
engine harness. (
\
49. Disconnect the engine harness vacuum tube from
the bottom of the vacuum check valve.
346047

connectors.
51. · Remove the PCM from the vehicle.
52. Remove the right side insulator panel. Refer to
53. Remove the hinge pillar trim panel. Refer to Trim
Replacement - Hinge Pillar in Interior Trim.
(
346043
54. Disconnect the engine wiring harness from the

instrument panel wiring harness.
346039
55. Remove the engine wire harness through the front
of dash. Place the harness on top of the engine.
J 56. Remove the floor shift control, if equipped. Refer
to Floor Shift Control Replacement in Automatic
Transmission - 4L60-E.
57. Remove the transmission control, if equipped.
Refer to Shift Control Assembly Replacement in
Manual Transmission - M49.
Information.
346041

60. Remove the cotter pins and nuts from the left and
right upper ball joints.
61. Using J 39549 separate the upper control arms
from the steering knuckles.
62. Support both steering knuckles.
63. Position J 39580 below the engine.
) 64. Lower the vehicle.
65. Lay the engine wire harness on top of the engine.
220629
~ 220632
67. Remove the transmission support bolts.
68. Raise the vehicle and remove the engine and
transmission fromthe vehicle. (
69. Secure the crossmember to the J 39580.
208587
70. Position a hex-head socket on the belt tensioner,

pulley bolt.
relieve the tension on the drive belt (1 ).
72. Remove the drive belt (1) from the tensioner (2)
and pulleys.
41363
73. Remove the A/C compressor.rear bolts (2, 3).

74. Remove the A/C compressor rear bracket
stud (1 ).
75. Remove the A/C compressor rear bracket.
365440
282953
78. Remove the drive belt tensioner bolts.

79. Remove the drive belt tensioner.
35804
80. Remove the power steering pump nuts (3).

81. Reposition the power steering pump to 1
crossmember.
290569
5.;14s Engine Mechanical - 3.SL Engine
---- \ --
82. Disconnect the generator electrical connector.
211637
83. Remove the positive cable nut from the generator

terminal.
84. Remove the generator from the engine.
85. Install a lifting devise to the engine.
43670

bolts (1, 2) and the right engine mount bra,c~et (3).
4 3
50517
and the left engine mount bracket (1 ).
89. With the aide of an assistant, raise the engine
and transmission from the crossmember.
50546
90. If equipped with the automatic transmis$ion ·

remove the following:
91. Right side transmission support brace
bolts (1, 2, 3).
92. Right side transmission support but (6). 1
93. Right side transmission support (4).
208574
94. Left side transmission support brace bolts (3, 5).

95. Left side transmission support nut (1 ). 1
96. Left side transmission support (4).
97. Remove the torque converter cover (2).
5 4
208577
6-150 Engine Mechanical - 3.8L. Engine
98. Remove the flywheel to torque converter bolts.
208580
99. If equipped with the manual transmission remove

the following:
100. Right side transmission support bolts (3, 4).
448855
102. Left side transmission support bolts (2, 3).

103. Left side transmission support (1 ).
104. Disconnect the electrical connectors from.the
transmission.
349561
105. For the automatic transmission, remove the
transmission to engine bolts and nut.
) 106. Separate the transmission from the engine.
107. Attach the J 21366 to the transmission.
208594
108. For the manual transmission, remove,t~e

flywheel housing to engine bolts (l, 2) and
nuts (3).
109. Separate the flywheel housing from the engine.
441492
11 O. For the manual transmission, remove the

pressure plate bolts (1 ).
111. Remove the pressure plate (2) an.d the clutch
disc (6) from the flywheel (5).
7 6
441865
112. For the automatic transmission, remove the
flywheel bolts (1) and flywheel (2).
(
441271
113. For the manual transmission, remove the

flywheel bolts (1) and flywheel (2).
114. Install the engine to a engine stand.
441112
Tool.s Required
• J 39580 Universal Engine Support Table
1. Install engine lifting devise and remove engine
from the stand.
Notices.
2. For the manual transmission, install the
flywheel (2) and flywheel bolts (1 ).
Tighten
Tighten the flywheel bolts (1) to 15 N·m (11 lb ft).
Use the J 36660-A to torque the flywheel bolts
an additional 50 degrees.
441112
3. For the automatic transmission, install the
flywheel (2) and flywheel bolts (1 ).
Tighten
Tighten the flywheel bolts (1) to 15 N-m (i 1 lb ft).
Use J 36660-A to torque the flywheel bolts an
additional 50 degrees.
441271
4. For the manual transmission; install the clutch

disc (6) and pressure plate (2) to the flywheel (5).
2 3
5. Install the pressure plate bolts (1).
Tighten
Tighten the pressure plate bolts (1) to
20 N-m (15 lb ft). Use J 36660-A to torque the
pressure plate bolts (1) an additional 45 degrees.
6. Align the flywheel housing to the engine.
)
7 6
441865
7. For the manual transmission, install the flywheel,··

housing to engine bolts (1, 2) and nuts. (3). . J
Tighten
Tighten the flywheel housing to engine bolts (1, 2)
and nuts (3) to 95 N·m. (70 lb ft).
8. If equipped with a automatic transmission remove
the J 21366 from the transmiss'ion. ·
441492
9. For the automatic transmission, install the
transmission to engine bolts and nut.
Tighten (
Tighten the transmission to engine bolts and nut
to 95 N-m (70 lb ft).
10. Connect the electrical connectors to the
transmission.
208594
11. If equipped with the manual transmission install

the following:
12. Left side transmission support (1 ).
13. Left side transmission support brace bolts (2, 3).
Tighten
• Tighten the left side transmission support
brace bolts (2) to 50 N-m (37 lb ft).
• Tighten the left side transmission support (-
brace bolts (3) to 28 N-m (21 lb ft).
349561
14. Right side transmission support (1 ).

15. Right side transmission support brace bolts (3, 4).
Tighten
Tighten the right side transmission support brace
bolts (3, 4) to 50 N-m (37 lb ft).
448855
16. If equipped with the automatic transmission install
the following:
17. Install the torque converter to flywheel bolts.
Tighten
Tighten the torque converter to flywheel bolts to
63 N·m (47 lb ft).
208580
18. Install the torque converter cover (2).

19. Left side transmission support (4). 1
20. Left side transmission support bolts (3, 5).
21. Left side transmission support nut (1 ).
Tighten
bolts (3) to 8.5 N-m (75 lb in).
) O Tighten the left side transmission support

nut (1) to 80 N-m (59 lb ft).
5 4
208577

23. Right side transmission support brace
bolts (1, 2, 3).
24. Right side transmission support nut (6).
1
Tighten
• Tighten the right side transmission support
brace bolts (1) to 8.5 N-m (75 lb in).
bolts (2, 3) to 50 N-m (37 lb ft).
nut (6) to 80 N-m (59 lb ft).
25. With the aide of an assistant, lower the engine
and transmission to the crossmember.
208574
6-156 Engine Mechanical - 3~8l Engine
mount bracket stud (2).
27. Install the left engine mount bracket bolts (3). (
Tighten
• Tighten the left engine mount bracket bolt (3)
to 100 N·m (74 lb ft).
• Tighten the left engine mount bracket stud (2)
to 87 N-m (64 lb ft).
50546
28. Install the right engine mount bracket (3) and the
engine mount bracket bolts (1, 2).
Tighten
• Tighten the two right engine mount bracket
bolts (1) to 100 N,m (74 lb ft).
• Tighten the right engine mount bracket bolt (2)
to 50 N-m (37 lb ft).
29. Remove the lifting devise from the engine.
(
4 3
50517
30. Install the generator to the engine.

31. Install the positive cable nutto the generator
terminal.
Tighten
Tighten the positive cable nut to generator
terminal to 22 N·m (16 lb ft).
43670
32. Connect the generator electrical connector.
211637
33. Install the power steering pump.

34. Install the power steering pump nuts (3). 1
Tighten
Tighten the power steering nuts (3) to
30 N-m (22 lb ft).
3 2
290569
35. Install the drive belt tensioner.

36. Install the drive belt tensioner bolts.
Tighten
Tighten the drive belt tensioner bolts to
50 N·m (37 lb ft).
35804
Tighten (
50 N·m (37 lb ft).
282953
39. Install the A/C compressor rear bracket.

1 40. Install the A/C compressor rear bracket stud (1 ).
Tighten
• Tighten the A/C compressor rear bra.cket ·.
stud (1) to 50 N,m (37 lb ft).
O
Tighten the A/C compressor rear bolts (2, 3) to
30 N·m (22 lb ft). (
365440
42. Route the drive belt (1) around the pulleys.

pulley bolts.
relieve the tension on the drive belt (1 ).
45. Install the drive belt (1) onto the tensioner (2).
46. Remove the crossmember to J 39580 security
straps.
47. Lower the vehicle and install the engine and
transmission to the vehicle.
48. Align the crossmember to the vehicle body.
41363
49. Install the.front crossmember bolts
Tighten
• Tighten the upper four cradle bolts to
125 N-m (92 lb ft).
• Tighten the lower two cradle bolts to
145 N-m (107 lb ft).
i 220632
50. Install the transmission support bolts.

Tighten
Tighten the transmission support bolts to
57 N-m (42 lb ft).
Information.
52. Remove the J 39580 from below the vehicle.
) 53. Remove the supports from both steering knuckles.
54. Connect the ball stud to the steering knuckle.
208587
55. Install the nuts and cotter pins to the left pnd right
upper ball joints.
Tighten
Tighten the upper ball joint nuts. to
53 N-m (39 lb ft).
56. lnstal the right and left side shock absorber lower
mounting bolts.
Tighten
Tighten the shock bolts to 65 N·m (48 lb ft).
58. Install the transmission control, if equipped. Refer
to Shift Control Assembly Replacement in Manual
Transmission - M49.
59. Install the floor shift control, if equipped. Refer to
Floor Shift Control Replacement in Automatic
220629
60. Install the engine wire harness through the front
of dash.
(
346041
61. Connect the engine wiring harness to the

62. Install the hinge pillar trim panel. Refer to Trim
63. Install the right side insulator panel. Refer to
Closeout/Insulator Panel Replacement - Right
346039
64. Install the PCM to the vehicle.

65. Connect the PCM connectors.
346043
66. Connect the engine harness vacuum tube to the
bottom of the vacuum check valve.
) 67. Connect the forward lamp harness to the engine
harness.
68. Connect the captured secondary locks.
69. Install the front two brake pipes to the brake
modulator.
346047
70. Install the brake booster vacuum hose (2) to the

intake manifold fitting (1 ).
439407
71. Install the outlet hose to the water pump.
221689
6-,162 Engine Mechanical - 3.8l Eng in~
72. Install the inlet hose to the water outlet.
221680
73. Install the forward lamp harness branch to the

wire harness clip.
74. Connect the electronic throttle control (ETC)
75. Install the capture secondary lock to the electrical
connector.
439418
76. Connect the EVAP pipe (6) at the engine.

77. Connect the fuel return pipe (2) to the fuel rail.
78. Connect the fuel feed pipe (1) to the fuel rail.
215517
79. Install the heater hoses to the drive belt tensioner.
282933

bolt at the accumulator
Tighten
Tighten A/C compressor and condenser hose bolt
at the accumulator to 48 N-m (36 lb ft).
569444
82. Install the engine ground.

83. Install the engine wiring harness ground bolt (1) to 1 2
25 N-m (18 lb ft).
Information.
85. Connect the brake lines to the brake pipe clip.
445688
86. Install the front fuel pipe heat shield (2).
87. Install the front fuel pipe heat shield nuts (1).
Tighten
(
Tighten the front fuel pipe heat shield nuts (1) to
5 N-m (44 lb in).
7~
173551

Tighten
nut at the condenser to 16 N-m (12 lb ft).
365450

hose bolt.
Tighten
365423
92. Connect the wheel speed sensors electrical
connectors.
I 93. Connect the knock sensors electrical connectors.
346036
94. Install the RF ground strap, cruise control lead

and wiring harness ground bolt to the front rail.
Ti,ghten
Tighten the wiring harness ground bolt to
12 N-m (106 lb in).
346034
95. Install the intermediate steering shaft and bolt to

the rack.
Tighten
47 N-m (35 lb ft).
96. Install the steering gear coupling shield.
97. Install the stabilizer bar brackets.
98. Install the stabilizer bar bracket bolts.
Tighten
Tighten the stabilizer bar bracket bolts to
55 N·m (41 lb ft).
99. Install the left side front air deflector. Refer to Air
Deflector Replacement - Front Bumper Fascia in
Bumpers.
I
220630
100. On vehicles equipped with a manual
transmission, connect the clutch actuator
cylinder line to the actuator cylinder.
(
43255

transmission, install the range selector lever
cable to the cable bracket.
208276
102. Install the retainer to the range selector

lever cable.
~I
341079
Engine Engine Mechanical - 3.8L 6.;.167
103. Snap the transmission range selector lever cable
to the range selector lever at the transmission.
) 104. Install the torque arm. Refer to Torque Arm
Replacement in Rear Suspension. ·
105. Install the propeller shaft. Refer to Propeller
Shaft Replacement - One.Piece or Propeller
Shaft Replacement - Two Piece in ·
Propeller Shaft.
Engine Exhaust.
107. Install the front wheels. Refer to Tire and Wheel
208264
554755

208554
6-168 Engine Mechanical. - 3.8L Engine
111. Connect the positive battery cable.
Replacement (3.8 L) in Engine ElectricaL (
113. Refill the engine a.ii.
114. Refill the transmission .fluid.
115. Refill the engine co9lant. Refer to Draining and
Recovery and.RechargingJn Heating, Ventilation
and Air Conditioning. · ·
System Bleeding (Manual Bleeding) or ·
Hydraulic Brake System Bleeding (Pressure
Bleeding) in Hydraulic Brakes.
118. Bleed the clutch hydraulic system. Refer to
Hydraulic Clutch Bleeding in Clutch.
119. Perform the crankshaft postion (CKP)
211587 Controls - 3.8 L.
Engine Oil and Oil Filter Replacement

Removal Procedure
1. Raise and suitably support the vehicle .. Refer to
Information.
2. Position the oil drain pan under the engine oil
drain plug.
3. Remove the engine oil drain plug.
4. Clean and'inspect the engine oil drain plug,
(
replace if necessary.
5. Clean and inspect the engine oil drain plug
sealing surface on the. oil pan, replace the oil pan
if necessary.
190564
6. Remove the .oil filter.

7. Clean and inspect the oil filter sealing area on the
oil filter adapter, replace .if necessary. Refer to Oil
Filter Adapter Removal.
440847
1. Ughtly oil the replacement oil filter gasket with
clean engine oil.
Notices.
2. Install a new engine oil filter.
Tighten
Tighten the engine oil filter to 30 N-m (22 lb ft).
440847
3. Install the engine oil drain plug.

Tighten
Tighten the engine oil drain plug to
30 N·m (22 lb ft).
4. Remove the oil drain pan.
6. Fill the engine with new engine oil.
)
8. Inspect for oil leaks after engine start up.
9. Turn off the engine and allow the oil a few minutes
to drain back into the oil pan.
10. Remove the oil level indicator from the oil
indicator tube.
11. Clean off the indicator end of the oil level indicator
with a clean paper towel or cloth.
12. Install the oil level indicator into the oil level
indicator tube until the oil level indicator handle
contacts the top of the oil level indicator tube. 190564
13. Again, remove the oil level indicator from the oil
level indicator tube keeping the tip of the oil level
indicator down.
14. Check the level of the engine oil on the oil level
indicator.
15. If needed add or drain the engine oil to the
correct level.
Draining Fluids and Oil Filter Removal
Draining the Engine
1. Remove the oil drain plug.
(
3. Remove the oil filter.
192725
4. Remove the coolant drain plugs.

5. Drain the coolant.
'I
211914
Crankshaft Balancer Removal

Tools Required
• J 37096 Flywheel Holding Tool
• J 38197 Crankshaft Balancer Puller
1. Use J 37096 to hold the flywheel.
309963
2. Remove the crankshaft balancer bolt.
192730
3. Use J 38197to remove the crankshaft balancer.

Important: Do not separate the crankshaft pulley from
the crankshaft balancer. Service the crankshaft .
pulley and the crankshaft balancer as an assembly.
3.1. Invert J 38197-2 so the leg of the tool is
facing away from the crankshaft balancer.
3.2. Install the silver screws J 38197-4 to the
crankshaft balancer.
3.3. Turn J 38197-1 to remove the crankshaft
balancer from the crankshaft. J 38197
3.4. Remove J 38197-1, J 38197-2, and
J 38197-4 from the crankshaft balancer.
313955
Engine Flywheel Removal (Manual

Transmission)
1. Remove the flywheel bolts. Discard the bolts.
2. Remove the flywheel.
3. Inspect the flywheel for damage. If the flywheel is
damaged, replace the flywheel.
4. Inspect the crankshaft and flywheel mating
surfaces for burrs. If necessary, replace the
flywheel.
192727
(Automatic Transmission)
1. Remove the flywheel bolts. Discard the bolts. (
2. Remove the flywheel.
3. Inspect the flywheel for damage. If the flywheel is
damaged, replace the flywheel.
4. Inspect the crankshaft and flywheel mating
surfaces for burrs. If necessary, replace the
flywheel.
36665
Drive Belt Tensioner Removal

313973
Oil level Indicator and Tube Removal

1. Remove the oil level indicator bolt.
2. Remove the oil level indicator.
36615
Water Outlet Removal
1. Remove the water outlet bolts.
2. Remove the water outlet.
3. Remove the water outlet gasket.
4. Remove the thermostat.
36621
Water Pump Removal

1. Remove tHe water pump pulley bolts.
2. Remove the water pump pulley.
313967
3. Remove the water pump bolts.

4. Remove the water pump.
5. Remove the water pump gasket.
36600
Intake Manifold Removal (Upper)
1. Remove the right spark plug wires.
2. Remove the manifold vacuum source. (
3. Remove the EGR outlet pipe bolt and nut.
4. Remove the EGR outlet pipe from the intake
manifold.
36609
Notice: The two bo.lts which .fasten the lower intake·

manifold to the. cylinder head are .accessible only after
the upper intake is removed. The bolts are located
in the right front and left rear corners of the lower
intake manifold. Remove the upper intake manifold to
service the lower intake.
5. Remove the throttle body nuts and bolt.
6. Remove the throttle body.
7. Remove the throttle body gasket. (
36624
8. Remove the fuel injectior rail nuts.

9. Remove the fuel injector .rail.
36631
10. Remove the upper intake manifold bolts.
11 . Remove the upper intake manifold.
J 12. Remove the upper intake manifold gasket.
36634
Intake Manifold Removal (lower)

1. Remove the ignition control module and bracket.
2. Remove the generator bracket.
566980
3. Remove the lower intake manifold bolts.

Notice: The two bolts which fasten the lower intake
manifold to the cylinder head are accessible only after
the upper intake is removed. The bolts are located
in the right front and left rear corners of the lower
intake manifold. Remove the upper intake manifold to
service the lower intake.
4. Remove the lower intake manifold.
5. Remove the lower intake manifold gasket.
50046
6-176 Engine Mechanical - 3.8l E11gine
Exhaust Manifold Removal (left Side)
i. Remove the exhaust manifold heat shield nuts.
2. Remove the exhaust manifold heat shield. (
589352
Important: When removing th.e EGR inlet tube from

the le_ft exhaust manifold, inspect the pipe for leaks
during installation. Replace the EGR adapter if
the pipe leaks.
3. Remove the EGR inlet pipe bolt and nuts.
4. Remove the EGR inlet pipe from the exhaust
manifold.
589355
5. Remove the engine lift hook.
.566982
6. Remove the exhaust manifold nuts.
7. Remove the exhaust manifold.
) 8. Remove the exhaust manifold gasket.
589361
Exhaust Manifold Removal (Right Side)

1. Remove the exhaust manifold heat shield nuts.
2. Remove the exhaust manifold heat shield.
589365
3. Remove the exhaust manifold nuts.

4. Remove the exhaust manifold.
5. Remove the exhaust manifold gasket.
589366
6-178 Engine Mechanical - 3.8L Eng in~
Valve Rocker Arm Cover Removal ··
(Left Side)
1. Remove the valve rocker arm cover bolts. (
35819
1
Valve Rocker Arm Cover Removal
(Right Side)
1. Remove the valve rocker arm cover bolts.
63414
Valve Rocker: Arm and Push Rod Removal

1. Remove the valve rocker a'rm bolts.
2. Remove the valve rocker arm.
3. Remove the push rods. ·
35840
Engine Engine Mechanical .. 3.8L 6-179
Cylinder Head Removal
1. Remove the cylinder head bolts.
2. Discard the cylinder head bolts.
3. Remove the cylinder head.
4. Remove the cylinder head gasket.
35842
Valve Lifter Removal

1. Remove the valve guide retainer bolts.
2. Remove the valve guide retainers.
3. Remove the valve lifters.
41374
Crankshaft Front Oil Seal Removal

lmponant: Do not damage the seal bore odhe
contact surfaces.
Use a screwdriver to pry out the crankshaft front
oil seal.
26135
Engine Front Cover Removal
1. Remove the crankshaft position sensor shield;
(
35844
2. Remove the crankshaft position sensor studs.

3. Remove the crankshaft position sensor.
4. Remove the. bolts connecting the oil pan to the
engine front cover.
36589
5. Remove the engine front cover bolts and stud.

6. Remove the engine front cover.
7. Remove the engine front cover gasket.
345236
Oil Filter Adapter Removal
1. Remove the oil filter adapter bolts from the engine
front cover.
2. Remove the oil filter adapter.
3. Remove the oil filter adapter gasket.
4. Remove the oil pressure relief valve.
5. Remove the oil pressure relief valve spring.
36655
Oil Pump Cover and Gear Set Removal

1. Remove the oil pump cover screws.
3. Remove the oil pump gears.
26160

Removal (VIN K)
1. Align the timing marks on the sprockets.
192708
2. Remove the timing chain dampener.
154523
3. Remove the camshaft sprocket bolt.·

4. Remove the camshaft sprocket.
5. Remove the timing chain.
6. Remove the crankshaft sprocket.
7. Remove the crankshaft balancer key.
192716
8. Remove the balance shaft drive gear.
154519
Camshaft Removal
) 1. Remove the camshaft thrust plate screws.
2. Remove the camshaft thrust plate.
3. Remove the camshaft. Carefully rotate and pull
the camshaft out of the camshaft bearings.
35815
Balance Shaft Removal

Tools Required
J 6125-18 Slide Hammer
1. Remove the balance shaft driven gear bolt.
2. Remove the balance shaft driven gear.
154521
3. Remove the balance shaft retainer bolts.

4. Remove the balance shaft retainer.
42237
6·184 Engine Mechanical .. 3.8L Engine
5. Use J 6125-18 to remove the balance shaft
J 6125-18
36705
Crankshaft Rear Oil Seal Removal

Important: Do not damage the crankshaft or the
crankshaft rear oil seal housing.
Pry the crankshaf(rear oil seal out with a screwdriver.
26129

Removal
1. Remove the crankshaft rear oil seal housing bolts.
The bolts may remain in the crankshaft rear oil
seal housing.
2. Remove the crankshaft rear oil seal housing.
26125
Oil Pan Removal
Notice: Remove the oil level sensor, located in the oil
pan, before the oil pan is removed. The sensor
may be damaged if the oil pan is removed first.
1. Remove the oil level sensor.
35861
2. Remove the oil pan bolts.

3. Remove the oil pan.
4. Remove the oil pan gasket.
44775

Removal
1. Remove the oil pump pipe and screen
assembly bolts.
2. Remove the oil pump pipe and screen assembly.
3. Remove the oil pump pipe and screen assembly
gasket.
4. Use solvent to clean the oil pump pipe and
screen.
26202
Removal
(
Tools Required
• J 41507 Connecting Rod Assembly Guide
• J 24270 Cylinder Ridge Reamer
1. Mark the connecting rod cap and the connecting
rod for proper installation.
Notice: If there is a pronounced ridge at the top of the
piston travel, the ridge must be removed with a
ridge reamer before the piston and connecting rod
assembly are removed. Applying force may break the
piston rings or damage the piston.
2. Use the J 24270 to remove the cylinder bore
ring ridge.
J 24270 2.1. Turn the crankshaft until the piston is at the
bottom of the stroke.
2.2. Cover the piston with a cloth.
11497
2.3. Remove the cylinder ring ridge.
2.4. Turn the crankshaft until the piston is at the
top of the stroke.
2.5. Remove the cloth.
2.6. Remove the metal shavings from the
cylinder and piston.
3. Remove the connecting rod bolts.
4. Remove the connecting rod cap.
38153
(
5. Install J 41507to the connecting rod. Hand
tighten the tool to the connecting rod.
6. Use hand pressure on J 41507 to push the
connecting rod towards the top of the cylinder.
Important: Mark the piston with the number of the
cylinder from which it was removed. Mark the piston as
to what is the front for proper reassembly.
7. Remove the piston, the connecting rod, and the
connecting rod bearings.
38180
Crankshaft and Bearings Removal

Tools Required
• J 6125-18 Slide Hammer
• J 41348 Main Bearing Cap Puller
Important: This engine has side bolts on all of the
main caps except the rear cap. These bolts must be
removed to service the caps.
1. Remove the crankshaft main bearing cap
side bolts.
2. Remove the crankshaft main bearing cap bolts.
35863
Notice: Main bearing caps are press fit. Remove the

caps carefully for service. J 41348 has been designed
to work with J 6125-B in order to prevent damage J 6125-18
to the bearing and cap. J 41348 MUST be installed
properly into the bolt holes of the caps and J 6125-B
attached to J 41348 in order to properly remove
the main cap without damaging the bearing or the
cap. Any deviation from this procedure may cause
damage to the cap and the bearing and may result in
future engine damage.
Notices.
3. Install J 41348 into the crankshaft main bearing
cap bolt holes.
Tighten
Tighten the bolts on J 41348 to 12 N-m (100 lb in).
4. Install J 6125-18 to J 41348.
5. Use J 6125-18 to remove the crankshaft main
bearing caps.
36704
6. Remove the crankshaft.
7. Remove the upper main bearings from the
engine block. (
35863
Engine Block Plug Removal
1
I
1. Remove the threaded coolant jacket plugs.
589370
2. Remove the remaining plugs using the following

procedure.
2.1. Obtain a suitable self-threading screw.
2.2. Drill a hole into the plug.
2.3. Install the self-threading screw.
2A. Use the screw to pry out the plug.
26198
Engine Block Clean and Inspect
I Tools Required
e J 8087 Cylinder Bore Checking Gauge
" J 8001 Dial Indicator Set

1. Clean the sealing material from the gasket mating
surfaces.
2. Boil the engine block in caustic solution.
3. Flush the engine block with clean water or steam.
4. Clean the oil passages.
5. Clean the blind holes.
6. Spray the cylinder bores and the machined
surfaces with engine oil.
7. Inspect the threaded holes. Clean the holes with a
tap. If necessary, drill out the holes and install
thread inserts. Refer to Thread Repair.
8. Use a straight edge and a feeler gage to check
the deck surface for flatness. Carefully machine 5272
minor irregularities. Replace the block if more than
0.254 mm (0.010 in) must be removed.
9. Inspect the oil pan rail for nicks. Inspect the front
cover attaching area for nicks. Use a flat mill file
to remove any nicks.
10. Inspect the mating surfaces of the
transmission case.
Notice: A broken flywheel may result if the
transmission case mating surface is not flat.
11. Use the following procedure to measure the
engine block flange runout at the six mounting bolt
hole bosses:
11.1. Temporarily install the crankshaft. Measure
the crankshaft flange runout.
11 .2. Hold the gauge plate flat against the
crankshaft flange.
11.3. Place J 8001 on the transmission mounting
bolt hole boss. Set the indicator to 0.
11 .4. Record the readings obtained from all of
the bolt hole bosses. The measurements
should not vary more than 0.254 mm
(0.010 in).
1 i .5. Recheck the crankshaft flange runout if
the readings vary more than 0.254 mm 38648
(0.010 in).
12. Inspect the crankshaft main bearing bores. Use
J 8087 to measure the bearing bore concentricity
and alignment at the following locations: (
0 " The camshaft
" The crankshaft
Important: Recondition the engine block with the
crankshaft main bearing caps and the crankshaft main
bearing cap side bolts installed and tightened to
specification ..
13. Ensure that the crankshaft main bearing caps are
installed correctly. The arrows should point toward
the front of the engine.
14. Replace the engine block if the bores are ou1 of
specification.
38663
15. Use J 8087 to inspect the cylinder bores. Inspect

for the following items:
J 8087 "Wear
" Taper
( " Run-out
.. Ridging
Important: If the bore is worn beyond the limits, refit
the bore with oversized pistons. Select the smallest (
available oversize piston. Refer to Piston Selection.
16. Leave sufficient material to allow honing when
fitting the piston.
38662
Engine Engine Mechanical.., 3.SL 6-191
Cylinder Boring and Honing 3. Make full strokes in the cylinder to eliminate taper.
Repeatedly check the measurement at the top,
Boring Procedure the middle, and the bottom of the cylinder bore.
1. Before honing or boring, measure all of the new Notice: Handle the pistons with care. Do not force the
pistons. Select the smallest piston for the piston
pistons through the cylinder until you hone the
fitting. Slightly varied pistons in a set may provide
cylinder to the correct size. The piston can be distorted
correction, if the first piston is too loosely fitted.
through careless handling.
2. Before using any type of boring bar, file th.e top of
the engine block to remove any dirt or burrs. If the Important: The finish marks should be clean but not
cylinder block is not straight, the boring bar may sharp. The finish marks should be free from
be tilted, causing the bored cylinder wall to
imbedded particles and torn or folded metal.
have incorrect right angles to the crankshaft.
3. Carefully follow the instructions fumished by the 4. When finish honing a cylinder bore to fit a piston,
manufacturer regarding use of equipment. move the hone up and down at a sufficient speed
to obtain a fine and uniform surface finish in a
4. Install all crankshaft main bearing caps to
cross hatch pattern.
specification when boring cylinders. Cover or tape
the crankshaft bearings and other internal parts 5. Determine the finish hone cylinder measurement
to protect these parts during the boring or honing by measuring the piston to be installed, and by
operation. adding the average of the clearance specification.
5. Leave 0.03 mm (0.001 in) on the diameter for Measure the block and the piston at normal
finish honing when performing the final cut with room temperature.
a boring bar. Carefully perform the honing 6. True up the refinished cylinder bores. Final hone
and boring operation to maintain the specified each cylinder bore to remove all stone or
clearances between pistons, rings, and cutter marks.
cylinder bores.
7. After final honing and before the piston is checked
Honing Procedure for fit, clean the bores with hot water and
1. Follow the manufacturer's recommendations for detergent. Scrub the bores with a stiff bristle
use, cleaning, and lubrication when honing the brush and rinse the bores thoroughly with
) cylinders. Use only clean, sharp stones of hot water. Do not allow any abrasive material to
the proper grade for the amount of material to be remain in the cylinder bores. This abrasive
removed. Dull, dirty stones cut unevenly and material will wear the new rings, the cylinder
generate excessive heat. When using coarse or bores, and the bearings lubricated by the
medium-grade stones, leave sufficient metal so all contaminated oil. After washing dry the bore.
stone marks may be removed with the fine
stones used for finishing to provide the proper 8. Permanently mark the piston for the cylinder to
clearance. which the piston has been fitted.
2. During the honing operation, thoroughly clean the 9. Apply clean engine oil to each bore to prevent
cylinder bore. Check for the correct piston fit. rusting.
6-192 Engine Mechanical. - 3.SL Engine
Crankshaft and Bearings .Clean and
Inspect
Tools Required
(
• J 8087 Cylinder Bore Checking Gauge
1. Cle.an the crankshaft of the following elements:
• Oil
• Sludge
• Carbon
2. Inspect the rankshaft oil passages for obstructions.
3. Inspect the crankshaft keyway for nicks or wear.
4. Inspect the crankshaft threads.
Important: If cracks, severe gouges or burned spots
are found, the crankshaft must be replaced. Slight
roughness may be removed with a fine polishing cloth
soaked in clean engine oil. Burrs may be removed
with a fine oil stone.
5. Inspect the crankshaft bearing journals and the
26122
crankshaft thrust surfaces for the following
conditions:
• Cracks
• Chips
· • Gouges
• Roughness
• Grooves
• Overheating (discoloration)
6. Inspect the corresponding crankshaft bearings for (
embedded foreign material and determine the
source.
Important: Note the location of the crankshaft main
bearing high· spots. If they are not in. line, the
crankshaft is bent and must be replaced.
7. Inspect the crankshaft bearings for uneven
side-to-side wear. This may indicate a bent
crankshaft or a tapered bearing journal.
Important: The crankshaft bearings are of the
precision insert type. The crankshaft bearings are
available in standard and various undersizes.
Notice: Do not scrape, shim, or file bearing inserts. If
the bearing surface of the insert is touched with
bare fingers, the skin oil and acids will etch the bearing
surface.
0 0 8. Inspect the outer surfaces of the crankshaft

bearings for the following conditions:
. • Wear - surface wear indicates either movement
of the insert or high spots in the surrounding
material (spot wear).
• Overheating or discoloration
0 0 • Looseness or rotation indicated by flattened
tangs and wear grooves
9. Inspect the thrust surfaces of the main thrust
bearing for the following conditions:
• Wear (
50027
• Grooving (Grooves are caused by irregularities
of the crankshaft thrust surface.)
Engine Engine Mechanical;. 3.8L 6-193
Important: If crankshaft bearing failure is due to other
than normal wear, investigate the cause. Inspect the
crankshaft or connecting rod bearing bores.
10. Using the J 8087 inspect the connectJng rod
bearing bores or crankshaft main bearing
bores using the following procedure:
10.1. Tighten the bearing cap to specification.
10.2. Measure the bearing bore using J 8087 for
taper and out-of~round.
10.3. No taper or out-of-round should exist.
() /
38663
Bearing Selection
Measure the bearing clearance to determine the
correct replacement bearing insert size. There are
two methods to measure bearing clearance. Method A
gives more reliable results and is preferred.
• f\ilethod A yields measurement from which the
bearing clearance can be computed.
" Method B yields the bearing clearance directly.
l\ilethod B does not give any indication of
bearing run-out.
Method A
Important: Do not mix inserts of different nominal.size
in the same bearing bore.
1. Measure the crankshaft bearing journal diameter

with a micrometer in several places, 90 degrees
apart. Average the measurements.
2. Measure the crankshaft bearing journal taper and
run out. 5265
3. Install the crankshaft bearing inserts. Tighten the

bearing cap bolts to specification.
4. Measure the connecting rod inside diameter in the
same direction as the length of the rod with an
inside micrometer.
5. Measure the crankshaft main bearing inside
diameter with an inside micrometer.
6. Select a set of bearing inserts that will produce
the desired clearance.
7. If the specified clearances cannot be met, the
crankshaft journals must be reconditioned and
undersized bearing inserts installed.
6·494 Engine Mechanical~ 3.8L Engine
Method B
Important: Do not mix inserts of different nominal size (
in the same bearing bore.
1. Clean the. used bearing inserts.
2. Install the used bearing inserts.
3. Place a piece of gaging plastic across the entire
t>E:laring width.
4. Install the bearing caps .
.o Notice: In order to prevent the possibility of cylinder
block or crankshaft bearing cap damage, the
crankshaft bearing caps are tapped into the cylinder
block cavity using a brass, lead, or a leather mallet
before the attaching bolts are installed. Do not
use attaching bolts to pull the crankshaft bearing caps
into the seats. Failure to use this process may
damage a cylinder block or a bearing cap.
5. Install the bearing cap bolts to specification.
4981 Important: Do not rotate the crankshaft.
6. Remove the bearing cap, leaving the gagirig .
plastic in place. It does not matter whether the
gaging plastic adheres to the journal or to
the bearing cap.
7. Measure the gaging plastic at .its widest point with
the scale printed on the gaging plastic package.
8. Remove the gaging plastic.
9. Selectaset of bearing inserts that will produce
the desired clearance.
(
Crankshaft Balancer Clean and Inspect
• Inspect the crankshaft balancer for damage.
• Inspect the outside of the crankshaft balancer
mounting shaft for grooves.
• ReplacE:l the cra11kshaft balancer if grooves are
. present and appear to be causing an oil leak.
313962
(
(Automatic Transmission)
• Clean the flywheel.
• Inspect the engine flywheel for damage and
cracks.
• Inspect the engine flywheel ring gear for
damaged teeth.
• Replace the flywheel if any damage is found.
187014

• Clean the flywheel.
• Inspect the engine flywheel for damage and
cracks.
• Inspect the engine flywheel ring gear for
damaged teeth.
• Replace the flywheel if any damage is found.
427582
Piston and Connecting Rod Disassemble

Caution: Handle the piston carefully. Worn piston
rings are sharp and may cause bodily injury.
1. Remove the piston rings. Use a suitable tool to
. expand the rings. Piston rings must not be
reused.
4977
Important: Two retainers hold the. piston pins in
place. Reuse the retainers if they are n9t damaged.
Ensure the piston pin is not damaged. ·
(
2. Remove the piston pin retaining clips.
3. Remove the piston pin.
~
~-q/
/
35866
Piston, Connecting Rod, and Bearings

Clean and Inspect
Caution: Bodily injury may occur if the carburetor
cleaning fluidis exposed to the skin orif the
fumes are inhaled.
~
1. Clean the piston and connecting rod in solvent.
~-q/ Caution: Wear safety glasses in order to avoid eye

damage.
2. Dry the components with compressed air.
(
/ 3. Clean the piston ring grooves with a suitable ring
groove cleaning tool.
4. Clean the piston oil lubrication holes and slots.
35866
5. Inspect the piston for the following conditions:

• Eroded areas (1) on top of the piston
• Scuffed or damaged skirt (2)
• Damage to the pin bore (3)
• Cracks in the piston ring· 1ands, the piston skirt,
or the pin bosses ·
• Piston ring grooves for nicks, burrs, or other
warpage which may cause the piston ring
to bind.
6. Inspect the piston for scoring, wear or other
damage.
2
156168
7. To determine the piston-to bore clearance, use a
micrometer and measure the piston pin.
4976
8. To determine the piston pin-to bore clearance,

use an inside micrometer and measure the piston
pin bore.
9. To determine the piston pin-to-bore clearance,
subtract the piston pin diameter from the piston
pin bore diameter.
4975
10. Inspect the connecting rod for an out-of-round

bearing bore.
156167
11. Inspect the connecting rod for twisting.
156169
12. Inspect the connecting rod cap bolts for stretch

(compare to known good bolt). (1) is a stretched
bolt, (2) is a new or good bolt.
1
~~«b\--~~~{({~((~({(-l{(_~~(~(((~l©
2 (
~~)~l~____.....((~(((~[((~((~[~~(~((~WD
187037
Piston Selection
1. Measure the pston diameter. Remove the piston
pin to measure the piston for size and taper.
2. Replace the piston with a standard or an oversized
piston if the piston is damaged.
Important: Cosider both the piston condition and the
cylinder bore condition when fitting the pistons.
Production and service pistons have the same nominal
weight. Production and service pistons can be
intermixed without affecting the engine balance. If
necessary, fit used pistons to any cylinder of the
engine. Ensure that the pistons are in good condition.
3. Measure the cylinder bore. If the cylinder bore
is worn beyond specifications, rebore the
cylinder bore. Use the following procedure to (
hone the cylinder bore to the correct size:
3.1. Select a piston.
3.2. Hone the cylinder bore to obtain the
recommended clearance.
4988
3.3. Scrub the cylinder bore and the piston with
soap and water. Remove all foreign
material. Dry the cylinder bore. Rub clean
) engine oil into the cylinder bore.
4. Use the following procedure to measure
piston-to-cylinder bore clearance:
4.1. Measure the cylinder bore with a
telescoping gauge. If the cylinder bore is
damaged, rebore or hone the cylinder bore
to size.
4.2. Subtract the piston diameter from the
cylinder bore diameter to determine the
piston-to-bore clearance.
4.3. Compare the piston-to-bore clearance with
the specifications to determine if the
clearance is within the acceptable range.
5. If the used piston is not within the acceptable
clearance range, check the service piston sizes
to determine if a new piston can be selected.
Service pistons are available in standard
and 0.508 mm (0.020 in) oversize.
6. 11 the cylinder bore needs reconditioning, measure
the new piston diameter and hone the cylinder
4987
bore to the correct clearance.
7. Select a new piston. Mark the piston to identify
the corresponding cylinder.
8. Select a set of new piston rings.
')
9. Place each ring, one at a time, into the
corresponding cylinder. <O
10. Place the piston for that cylinder, upside down
(top of the piston pushing on the ring). Push the c:::,
~
ring down to the bottom of the ring travel.
11. Remove the piston.
(Q)
~
(_j
4967
6.;.200 Engine Mechanical- 3.SL Engine
12. Measure the ring gap.
13. If the ring gap is not within an acceptable
specification range, increase the ring gap. Do this (
by filing any excess material from the ends of
the ring:
4968
14. Measure the piston ring side clearance

(compression rings).
Notice: Do norcut the ring groove with a. file or a
rough edged tool. Good performance and durability
depends on the straightness and smoothness of
the ring groove.
15. Use the following procedure to measure piston
compression ring side clearance:
15.1. Roll the piston ring around the groove. (
15.2. Measure the side clearance.
15.3. If the ring is too tight, check for nicks
or burrs.
Use emery cloth to remove burrs.
15.4. Determine if the ring is within
specifications. If necessary, replace
the ring.
22934
Piston and Connecting Rod Assemble

1. Coat the piston pin with oil.
2. Install one piston pin retainer into the retaining
-~ groove.
3. Install the connecting rod and piston pin. The
connecting rod can be installed in either
direction. Push the piston pin in until it bottoms
against the installed piston pin retainer.
4. Install the second piston pin retainer.
5. Ensure the piston pin moves freely.
Important: To provide an effective compression seal,
the ring gaps must be staggered.
35866
Notice: Use a piston ring expander to install the
piston rings. The rings may be damaged if expanded
more than necessary.
I
6. Install the following components of the bottom ring
assembly (oil control ring):
6.1 . The expander
6.2. The lower oil control ring
6.3. The upper oil control ring
4977
7. Install the middle ring (compression ring) with the

manufacturer's mark facing up.
8. Install the top ring (compression ring).
4967
Camshaft Bearing Removal
Q
~ i
Tools Required
J 33049 Camshaft Bearing Remover/Installer
1. Select the expander assembly and driving washer. tJ @)
E;I
2. Assemble J 33049.
00 @)
DJJ (IDO)
(ID 0)
@(@
@(®
(ID@
622704
3. Drive out the camshaft bearings.
35815
Camshaft and Bearings Clean and Inspect

Tools Required
J 7872 Magnetic Base Indicator Set
1. Measure the camshaft journals with a micrometer.
If the camshaft journals are not within
specifications, replace the camshaft. Refer to
Engine Mechanical Specifications.
(
35212
2. Measure the camshaft runout using J 7872.

2.1. Mount the camshaft in V-blocks between
centers.
2.2. Use J 7872fo check the intermediate
camshaft journal.
3. If the runout exceeds specifications, the camshaft
is bent and should be replaced. Refer to Engine
Mechanical Specifications.
35211
Engine Engine Mechanical - 3~8L 6-203
Camshaft Bearing Installation
Tools Required
J 33049 Camshaft Bearing Installer
1. Select the camshaft bearings.
35815
2. Use the following procedure to install the camshaft
~
~-l
bearings:
2. i. Assemble J 33049 according to the
manufacturer's instructions.
2.2. Place the bearing on the tool. @)
Notice: Severe engine damage may result if the oil
holes are not correctly aligned.
00 @)
JJD @O)
2.3. Index the bearing oil holes with the engine
block oil passages.
@O)
((ID(®
~)COD
®@
622704
Timing Chain and Sprockets Clean and

Inspect (VIN K)
1. Inspect the timing chain and sprockets for
damage.
2. Inspect the timing chain for overall in and out
movement. Movement should not exceed
25 mm (1 in).
3. Inspect the sprockets for wear.
192708
Valve Rocker Arm and Push Rods Clean
and Inspect
Important: Parts that are too be reused must be
(
marked, sorted, and organized for assembly.
• Mark, sort, and organize the components for
assembly.
Caution: Bodily injury may occur if the carburetor
cleaning fluid is exposed to the skin or if the
fumes are inhaled.
3 Caution: Wear safety glasses in order to avoid eye
damage.
• Clean the components with cleaning solvent.
• Dry the components with compressed air.
1 • Inspect the valve rocker components for the
2 following:
• Valve rocker arm valve pushrod socket contact
surface (1)
635934
The contact surface must be smooth with no
scoring or excessive wear.
• Valve rocker arm roller pivot for binding. or
damage (2)
• Valve rocker arm valve stem contact
surface (3)
The contact surface should be smooth with no ·
• Inspect the valve pushrods for the following:
• Restriction of the oil passage (1) (
• Wear or scoring of the end contact surfaces (2)
The end contact surfaces must be smooth with
no scoring or excessive wear.
• Shaft for bends (3)
Roll the valve pushrod on a flat surface to
determine if the valve pushrod is bent.
488857
(
Inspect
1. Keep the valve lifters in order so they can be
installed in their original position.
Important: When new valve lifters are installed, coat
the valve lifters with camshaft and lifter prelube
GM P/N 1052365 (or equivalent).
2. Inspect the following areas of the valve lifters:
• The retaining clip (1)
• The push rod socket for wear (2)
• The valve lifter body for wear and scuffing (3)
• The valve lifter bore for wear 3
• The valve lifter roller assembly for wear (4)
• The valve lifter roller pin for damage (5)
• The oil hole for plugging (6)
3. Inspect the valve lifter guides for cracks or
damage.
178485
Cylinder Head Disassemble

Tools Required
J 38606 Valye Spring Compressor
Important: During disassembly, ensure the valve train
components are kept together and identified so they
can be reinstalled in their original locations and
with the same mating surfaces as when removed.
) 1. Use J 38606 to compress the valve spring.
187057
2. Remove the valve keys.

3. Remove the valve cap and spring.
4. Remove the valve stem oil seal by prying up on
the bottom.
42226
6·206 Engine Mechanical • 3.8L Engine
Cylinder Head Clean and Inspect
Tools Required
J 9666 Valve Spring Tester (
1. Inspect the cylinder head gasket and the mating
surfaces for leaks, corrosion, and blowby.
2. If the gasket failed, determine the cause. Gasket
failure is caused by the following conditions:
• Improper installation
• A loose or warped cylinder head
• Missing dowel pins
3. Clean the cylinder head of all foreign material. Do
not use a motorized wire brush on any gasket
sealing surface.
4. Clean the threaded holes.
5. Inspect the cylinder head for cracks typically
between the valve seats and inside of the
exhaust ports.
26157
Important: Do not attempt to weld the cylinder head.
If the cylinder head is damaged, replace the
cylinder head.
6. Inspect the cylinder head deck for corrosion.
7. Inspect the following locations for flatness:
• The cylinder head deck
• The intake manifold mating surface
• The exhaust manifold mating surface
8. Recondition the surfaces by parallel grinding.
Replace the cylinder head if more than 0.254 mm (
(0.010 in) is removed.
36712
(
9. Measure the height from the deck surface to the
cast pads. Do this to determine if the cylinder
head has sufficient deck surface thickness
to resurface.
New cylinder heads measure from
1.372-1.676 mm (0.054-0.066 in). If the cylinder
head does not meet the minimum thickness
after resurfacing, replace the cylinder head.
10. Inspect all of the threaded holes for damage.
Repair the threaded holes, if necessary.
11. Inspect the valve seating surfaces.
12. Inspect the cooling jacket plugs.
13. Inspect the valve guides for wear. Clean the valve
guides.
14. Inspect the valve seats for excessive wear and
hot spots.
36714
15. Inspect the valve springs expanded height.

16. Inspect the valve spring ends. If the valve spring
ends are not parallel, the valve spring is bent.
Replace the bent valve spring.
63468
17. Using the J 9666 test the valve spring load. If the
valve spring load js below specification, replace
the valve spring.
18. Inspect the valve spring seating surface of the
valve spring retainers for wear or gouging. If the
seating surface is damaged, replace the valve
spring retainers.
19. Use the following procedure to measure the valve
seat concentricity:
19.1. Lift the valve off its seat.
19.2. Apply a dab of blue dye to the valve face.
19.3. Seat and rotate the valve.
The blue dye traces transferred to the valve
seat are an indication of concentricity of
the valve seat.
4960
run out:
20:L Clean off the blue dye. (
20.2. Apply blue dye to the valve seat.
20.3. Seat and rotate the valve.
The traces of blue dye transferred to the
valve indicates valve runout.
20.4. Recondition the valve seat or valve face, if
needed.
Valve Guide ReamingNalve and Seat

Grinding
Tools Required
J 8001 Dial Indicator Set
1. Recondition the valve seats by grinding. Use an
oscillating type valve seat grinder. Follow the
grinder manufacturer's instructions. If the valve
seat is too wide after grinding, use a 20 degree
stone or a 70 degree stone in order to narrow the
valve seat. The 20 degree stone will lower the
seat. The 70 degree stone will raise the seat.
Replace or recondition the valves if the seats are
reconditioned.
2. After grinding the valves, measure the valve
margin. Replace the valve if less than the
minimum recommended specification.
Notice: Clean the valve guides before reaming.
4955
Packing of chips or carbon may result in the reamer
jamming into the valve guide or broken reamer flutes.
(
3. Clean any foreign material from the valves.
Use a wire brush to remove carbon. Do not
scratch the valve stem. Soak the valves in
carburetor cleaning fluid to remove varnish.
4. Use a suitable tool to clean the valve guides.
5. Follow the grinder manufacturer's instructions.
Ensure that the new surface is perpendicular to
the valve stem.
6. Inspect the valve key grooves for chipped or worn
1 2 lands (5). Replace the valve if the valve key
groove is damaged.
7. Inspect the valve stem tip for wear (6).
Recondition the valve stem tip by grinding.
8. lnspectthe valve stem for burrs and
scratches (4). Use an oil stone to remove burrs
and minor scratches.
9. Inspect the valve stem for straightness (3). Use
3 V blocks to inspect the valve head for bending or
distortion. Replace any bent or distorted valves.
10. Inspect the valve face for grooving (1, 2). If the
4 groove is so deep that refacing the valve face
would result in a knife edge, replace the valve.
5
6 (
156174
11. Inspect the valve face for burning, pitting, or
cracking (1, 2, 3, 4). If pieces of the valve face
are broken off, inspect the corresponding
piston and cylinder head area for damage.
3 2
156173
12. Measure the valve movement:

12.1. Insert the valve into the guide.
12.2. Lift the valve 2 mm (1/8 in) off of the seat.
12.3. Move the valve from side to side.
12.4. Use J 8001 to measure the amount of
movement.
40076
Important: Clean the valve guide before reaming to

avoid breaking the reamer flutes. Do not push down
on the reamer.
13. Ream the valve guides for oversize valves if the
clearance exceeds the specifications.
14. Ream the valve guide bores for the oversize
valves.
15. Recondition the valve seats after reaming the
valve guide bores or installing the new valve
guides.
40073
6-210. Engine Mechanical - 3.SL Engine
16. Inspect the valve stem for straightness. Use
V blocks to inspect the valve head for bending or
distortion. Replace any bent or distorted valves.
• It is essential that the valve guide bores (
are free of carbon or dirt to ensure the proper
centering of the pilot in the guide.
The valve seats should be concentric to within
0.05 mm (0.031 in) total indicator reading.
• Reface pitted valves on a valve refacing
machine to ensure the correct relationship
between the valve head and the valve stem.
Replace the valve if the valve stem is
warped (2), or if the valve stem shows signs of
excessive wear.
Inspect the valve key area (1) for damage and
carbon build up.
Replace the valve if the edge of the head is
less than 0.79 mm (0.031 in) thick after
156172
grinding.
• Use the manufacturer's recommendations of
equipment for the proper results.
Cylinder Head Assemble

~428~ Tools Required
• J 42863 Valve Seal Installer
1. Install the valves. The valves are available in
standard size and 0.015 in oversize.
Be sure to use oversize valve seals if oversize
(
valves are used.
Important: Use hand pressure only when installing
the valve seal using J 42863. Using to much force may
cause damage to the oil seal and possibly lead to
excessive oil consumption.
2. Place the valve stem oil seal over the valve stem
so the seal begins to contact the valve guide.
3. Use J 42863 to push the valve stem oil seal over
the valve guide.
40071
(
4. Use J38606 to install the valve spring and the
valve cap.
5. Install the valve keys.
stem height:
6.1. Place the valve in the guide. Hold the valve
in the closed position.
6.2. Use a valve stem height gauge to measure J 38606
the valve stem height.
6.3. The measurement should be
49-50 mm (1.93-1.97 in).
154517
Important: Grinding the valves increases the valve

stem height and the valve spring installed height. Add
shims to correct the valve spring installed height.
spring installed height:
7.1. Place the valve in the valve guide.
7.2. Install the valve spring cap and the valve
cap keys.
) 7.3. Seat the valve spring retainer by pulling up.
7.4. Use a steel machinists' rule to measure
the distance from the spring seat to the
bottom of the valve spring cap.
7.5. The measurement should be
42-44 mm (1.69-1.75 in).
If the measurement is not within
specifications add shims under the valve
spring.
40072
Oil Pump Clean and Inspect

1. Use a suitable solvent to clean the oil pump.
2. Remove all old gasket material from the engine
front cover and from the engine block.
3. Inspect the oil pump cover and the engine front
cover for the following damage:
• Cracks
• Scoring
• Porous or damaged casting
" Damaged threads
• Excessive wear
4. Inspect the pressure regulator valve for the
1ollowing damage:
• Scoring
• Sticking in the bore
• Burrs
• Foreign material
26160
5. Inspect the pressure regulator spring for loss of
tension or bending. Replace the pressure
regulator spring if damaged. (
6. Inspect the oil pump gears for the following
conditions:
• Chipping
• Galling
• Scoring
• Excessive wear
7. Measure the inner oil pump gear tip clearance.
38819
(
8. Measure the outer oil pump gear diameter
clearance.
38820
9. Measure the oil pump gear end clearance.
10. Measure the pressure regulator valve-to-bore
clearance.
36663
Valve Rocker Arm Cover Clean

and Inspect
• Clean the valve rocker arm cover mating surface.
• Clean the valve rocker arm cover. Remove all
the sludge and th~ oil deposits.
• Inspect the valve rocker arm cover for damage.
Replace the valve rocker arm cover if any
damage is found.
187054
Oil Pan Clean and Inspect

• Clean the oil pan mating surface.
• Clean the oil pan. Remove all the sludge and the
oil deposits.
• Inspect the threads for the oil level sensor and the
engine oil drain plug.
• Inspect the oil pan for dents or distortion.
• Repair or replace the oil pan as necessary.
35861
Intake Manifold Clean and Inspect (Upper)
• Clean the upper intake manifold mating surfaces.
• Clean the upper intake manifold. (
• Inspect the upper intake manifold for damage.
• Replace the upper intake manifold as necessary.
403785
Intake Manifold Clean and Inspect (lower)

• Clean the lower intake manifold mating surfaces.
• Clean the lower intake manifold.
• Inspect the threaded holes for damage.
• Inspect the lower intake manifold for damage or
nicks in the mating surfaces.
• Replace or repair the lower intake .manifold as
necessary. (
187073
Exhaust Manifold Clean and Inspect

1. Clean the exhaust manifold mating surfaces.
2. Clean the exhaust manifold.
3. Inspect the exhaust manifold mating surfaces for
damage.
589373
4. Inspect the exhaust manifold flange for
straightness, using a straight edge and a
feeler guage.
5. If the exhaust manifold flange is warped more
than 0.05 mm (0.002 in) replace the exhaust
manifold.
589375
Water Pump Clean and Inspect

• Oean the water pump mating surface.
• Clean the water pump.
• Inspect the water pump shaft for looseness.
• Inspect the water pump vanes for damage.
• Inspect the water pump mating surfaces for nicks.
• Repair or replace the water pump as necessary.
187022
Engine Front Cover Clean and Inspect

• Clean the engine front cover mating surface.
" Clean the engine front cover.
• Inspect the engine front cover threaded holes.
• Inspect the engine front cover for damage.
O Inspect the engine front cover mating surfaces
for nicks.
• Repair or replace the engine front cover as
necessary.
345236
6.;216 Engine Mechanical - 3.8l Engine
Balance Shaft Clean and Inspect
1. Clean the balance shaft.
2. Inspect the balance shaft bearing/bushing journals (
for excessive wear.
3. Inspect the balance shaft driven gear and the
balance shaft drive gear for nicks and burrs.
4. Inspect the balance shaft retainer for damage.
5. Inspect the balance shaft threads for damage.
6. Repair or replace the balance shaft components
as necessary.
388909

Removal
Tools Required
J 36995Balance Shaft Bearing Remover/Installer
1. Use J 36995 to remove the balance shaft bearing.
2. Use J 36995 to remove the balance shaft
bushing. It may take a considerable amount
of force to loosen the bushing from the block bore.
J 36995
36706

Installation
Tools Required
• J 21465-13 Drive Handle Extension
• J 36995 Balance Shaft Bearing Remover/Installer
1. Dip the balance shaft bushing in clean engine oil.
Important: The J 36995 installs the balance shaft
bushing to the correct depth. The balance sl1aft
bushing is properly installed when J 36995 fully
contacts the balance shaft bore or the engine
block/transaxle mounting flange.
2. Use the balance shaft bushing installers to install
the balance shaft bushing.
J 36995 3. Remove J 36995.
36707
4. Dip the balance shaft bearing into clean engine oil.
5. Use J 21465-13 and J 36995 to install the balance J 36995
I shaft bearing into the engine block.
J 21465-13
622251
Thread Repair
General purpose thread repair kits are available
commercially. (
4963
8. Screw the thread insert onto the mandrel of the

thread insert installer. Engage the tang of the
thread insert onto the end of the mandrel.
4962
Important: The thread insert should be flush to 1 turn
Caution: Refer to Safety Glasses Caution in below the surface.
Cautions and Notices. 9. Lubricate the thread insert with clean engine oil
(except when installing in aluminum) and install
Important: Refer to the thread repair kit the thread insert.
manufacturer's instructions regarding the size of the 10. If the tang of the thread insert does not break off
drill and which tap to use. when backing out the thread insert installer, break
off the tang using a drift punch.
(
Always avoid any buildup of chips. Back out the tap
every few turns and remove the chips. Service Prior to Assembly
Dirt will cause premature wear of the rebuilt engine.
1. Determine the size, the pitch, and the depth of the Clean all of the components. Use the proper tools
damaged thread. in order to measure components when inspecting for
2. Adjust the stop collars on the cutting tool as excessive wear. Repair or replace the components
needed. Tap the stop collars to the required depth. that are not within the manufacturers specification.
3. Drill out the damaged thread. When components are reinstalled into an engine,
return the components to their original location,
4. Remove the chips. position, and direction. During assembly, lubricate all
5. Apply clean engine oil to the top thread. of the moving parts with clean engine oil or engine
assembly lubricant (unless otherwise specified). This ·
6. Use the tap in order to cut new thread. will provide initial lubrication when the engine is.
7. Clean the thread. first started.
(
Engine Block Plug Installation
Notices.
1. Install the threaded oil jacket plugs.
Tighten
1
I
Tighten the oil jacket plugs to 30 N-m (22 lb ft).
589370
2. Install the remaining oil gallery plugs using GM

P/N 12346004 sealant or equivalent.
26198

Tools Required
1. Install the upper crankshaft main bearings.
2. Install the crankshaft. Lubricate the crankshaft to
crankshaft main bearing contact areas with engine
oil or engine assembly lubricant.
Notice: In order to prevent the possibility of cylinder
block or crankshaft bearing cap damage, the
crankshaft bearing caps are tapped into the cylinder
block cavity using a brass, lead, or a leather mallet
before the attaching bolts are installed. Do not
use attaching bolts to pull the crankshaft bearing caps
into the seats. Failure to use this process may
damage a cylinder block or a bearing cap.
3. Install the lower crankshaft main bearings into the
main bearing caps.
35863
6-220 Engine Mechani.cal - 3.8l Engine
4. Install the crankshaft main bearing caps. Us13
GM P/N 1052942 sealer at the number ·
4 crankshaft main bearing cap to the engine block (
surtace. ·
Notice: Refer to Permanently Stretching Bolt Notice in
Notices.
5. Install the crankshaft main bearing cap bolts. Start
the crankshaft main bearing cap bolts by hand.
Ensure the bottom of the crankshaft main bearing
cap is parallel to the bottom of the channel.
Tighten
• Tighten the crankshaft main bearing cap bolts
in equal increments. Do not completely
tighten one bolt at a time to prevent the cap
from being cocked.
• Tighten the bolts to 70 N-m (52 lb ft) to fully
26153 seat the crankshaft main bearing caps.
Loosen the bolts 360 degrees
counterclockwise,
O Tighten the bolts to 20 N-m (15 lb ft), then
40 degrees (30 lb ft).

" Use J 36660-A to tighten the bolts in steps:
35 degrees + 35 degrees + 40 degrees for
a total of 110 degrees.
6. Install the side main bolts. Apply
GM P/N 12345493 or equivalent to the side
main bolts.
Tighten
(
Tighten the side crankshaft main bearing cap
bolts to 15 N·m (11 lb ft). Use J 36660-A to tighten
the bolts an additional 45 degrees.

Installation
Tools Required
" J 8037 Piston Ring Compressor
• J 41507 Connecting Rod Guide
1. Position the crankshaft so the connecting rod
journal is opposite th.e piston and connecting
rod assembly being install.ed. This .will aid in 1he
installation of the connEicting rod assembly.
2. Lubri.cate ·the cylinder wall with engine oiL
3. Install the connecting rod bearing inserts.
4. Lubricate the connecting rod .bearingjnsert surtace
with engine oi.1.
5. Install J 4.15.07 to the connecting md; Hand
tighten the tool,to the connecting rod.
38180
6. Install JB037to the piston.
(
Engine Engine Mechanical - 3;8l 6-,221
Notice: Guide the lower connecting rod end carefully
to avoid damaging the crankshaft journal.
7. Use J 8037 to compress the piston rings for
installation of the piston and connecting rod
assembly.
8. Install the piston and connecting rod assembly
into the engine.
Important: Ensure the arrow on top of the piston or J 8037
the markings made during removal face towards
the front of the engine or are in the same location as
when removed.
9. Use J41507to pull the connecting rod into place.
10. Remove J 41507.
5159
11. Install the connecting rod bearing cap.

Notices.
12. Install the connecting rod bearing cap bolts.
Tighten
Tighten the connecting rod bearing cap bolts to
27 N-m (20 lb ft) + 50 degrees using J 36660-A.
13. Pry the connecting rod back and forth and check
for binding. If necessary loosen and retighten the
connecting rod bearing cap.
38153
14. Measure the connecting rod side clearance.
5163
Installation
1. Install the oil pump pipe and screen assembly (
gasket.
Important: The oil pan gasket must be installed
before the oil pump pipe and screen assembly.
2. Install the oil pan gasket.
3. Install the oil pump pipe and screen assembly.
Notices.
4. Install the oil pump pipe and screen
assembly bolts.
Tighten
Tighten the bolts to 15 N-m (11 lb ft).
26202
Oil Pan Installation

1. Install the oil pan gasket to the oil pan flange.
2. Install the oil pan.
3. Clean the oil pan bolts.
4. Apply one drop of GM P/N 12345382 to each bolt.
Notices.
5. Install the oil pan bolts. (
Tighten
Tighten the bolts to 14 N·m (125 lb in).
44775
Notice: Install the oil level sensor, located in the oil

pan, after the oil pan is installed. The sensor may be
damaged if the oil level sensor is installed first.
6. Install the oil level sensor.
Tighten
Tighten the oil level sensor to 20 N·m (15 lb ft).
35861
Camshaft Installation
1. Coat the camshaft with prelube GM P/N 12345507
or equivalent.
2. Install the camshaft.
3. Install the camshaft thrust plate.
Notices.
4. Install the camshaft thrust plate bolts.
Tighten
35815
Balance Shaft Installation ·

J 36996
Tools Required
" J 8001 Dial Indicator
• J 21465-13 Drive Handle Extension
• J 36996 Balance Shaft Installer
1. Use J 21465-13 and J 36996 to install the balance
shaft into the engine block.
J 21465-13
566836
2. Install the balance shaft bearing retainer.

Notices.
3. Install the balance shaft bearing retainer bolts.
Tighten
Tighten the balance shaft retainer bolts to
30 N·m (22 lb ft). .
42237
4. Install the balance shaft driven gear.
Cautions and Notices. (
5. Install the balance shaft driven gear bolt.
Tighten
Tighten the balance shaft driven gear bolt to
22 N-m (16 lb ft). Use J 36660-A to tighten the bolt
an additional 70 degrees.
154521,
6. Using J 8001 measure the balance shaft end play.

End play must not exceed 0.028 mm (0.008 in).
38470
7. Using J 8001 measure the balance shaft radial

play at the rear. Radial play must be between
0.0127-0.119 mm (0.0005-0.0047 in).
J 8001
8. Install the balance shaft drive gear.
9. Install the camshaft sprocket.
10. Turn the camshaft so the timing mark on the
camshaft sprocket is straight down.
11 . Remove the camshaft sprocket and balance shaft
drive gear.
12. Turn the balance shaft so the timing mark on the
balance shaft driven gear points straight down.
13. Install the balance shaft drive gear.
14. Align the marks on the balance shaft driven gear
and the balance shaft drive gear. Do this by (
turning the balance shaft.
38472
Engine Engine Mechanical - 3.8L 6"'.225
15. Turn the crankshaft so the number one piston is
at top dead center,
) 16. Install the timing chain.
17. Install the camshaft sprocket.
18. Using J 8001 measure the gear lash at
four places. Measure every quarter turn. Gear
lash must be between 0.050-0.127 mm
(0.002-0.005 in). · '
38477

Installation
Tools Required
• J41349 Crankshaft Rear Oil Seal Aligning Tool
1. Clean the gasket from the crankshaft rear oil seal
housing.
2. Clean the crankshaft rear oil seal housing.
3. Inspect the crankshaft rear oil seal housing for
damage.
Notice: Do not use sealers or adhesives on rear main
oil seal housing gasket. Use of sealers or adhesives
on this gasket may cause oil leaks.
4. Install the crankshaft rear oil seal housing gasket
over the bolts for alignment.
Important: The plastic inserts in the crankshaft rear
oil seal housing are used to aid assembly only. 26125
The inserts are not required for service.
5. Install the crankshaft rear oil seal housing. Hand
tighten the crankshaft rear oil seal housing bolts.
Notice: Sealability of the rear main oil seal depends
on the correct alignment of the rear main oil seal
housing and the oil pan. Incorrect alignment
may cause oil leaks.
6. Apply engine oil to both sides of J 41349.
7. Install J 41349 over the crankshaft. Twist the tool
to aid in sliding the tool over the crankshaft.
8. Place a straight edge on the engine block oil pan (
flange and the crankshaft rear oil seal housing
flange. Use a feeler gage to ensure there is
no more than 0.10 mm (0.004 in) step on each
side. Rotate the crankshaft rear oil seal housing to
make the step equal on each side. Replace 1he
crankshaft rear oil seal housing if the rotation does
not make the step equal.
Notices.
9. Tighten the crankshaft rear oil seal housing bolts.
Tighten
Tighten the crankshaft rear oil seal housing bolts
to 15 N-m (11 lb ft). Use J 36660-A to tighten
the bolts an additional 50 degrees.
10. Remove J 41349.
44779 11. Recheck the step height on each side to ensure
the crankshaft rear oil seal housing did not move.
If the step height is beyond specification,
reinstall the crankshaft rear oil seal housing and
measure the step again. Replace the crankshaft
rear oil seal housing if the clearance is still beyond
specification.
Crankshaft Rear Oil Seal Installation

Tools Required
J 38196 Crankshaft Rear Oil Seal Installer (
1. Apply engine oil to the inside diameter and tile
outside diameter of the crankshaft rear oil seal.
2. Slide the crankshaft rear oil seal over the mandrel
until the back bottoms squarely against the collar
of the tool.
26129
(
3. Use the following procedure to install the seal:
\ Notice: Refer to Fastener Notice in Cautions and
I Notices. J 38196
3.1 . Attach J 38196 to the crankshaft by hand or
tighten attaching screws to 5 N-m (54 lb in).
3.2. Turn the T handle of J 38196 so the collar
pushes the crankshaft rear oil seal into the
bore. Turn the handle until the tool is
bottomed out. Ensure the crankshaft rear oil
seal is seated properly.
3.3. Loosen the T handle of J 38196 until it
comes to a stop.
3.4. Remove the attaching screws.
37747

(VINK)
Tools Required
1. Install the crankshaft balancer key into the
crankshaft keyway.
The crankshaft balancer key should be parallel to
the crankshaft or with a slight incline.
2. Install the timing chain on the sprockets. Align the
timing marks.
192708
3. Install the timing chain, the crankshaft sprocket,

and the camshaft sprocket.
Notices.
4. Install the camshaft sprocket bolt.
Tighten
Tighten the camshaft sprocket bolt to
100 N·m (74 lb ft). Use J 36660-A to tighten the
camshaft sprocket bolt an additional 90 degrees.
192716
5. Install the timing chain dampener.
Tighten
Tighten the timing chain dampener bolt to (
22 N·m (16 lb ft).
154523
Oil Pump Cover and Gear Set Installation

1. Lubricate the oil pump gears with petroleum jelly.
2. Install the oil pump gears.
3. Pack the oil pump cavity with petroleum jelly.
Notices.
5. Install the oil pump cover screws. (
Tighten
Tighten the screws to 11 N-m (98 lb in).
Oil Filter Adapter Installation

1. Install the oil pressure relief valve spring into the
engine front cover.
2. Install the oil pressure relief valve into the engine
front cover.
3. Install a new oil filter adapter gasket.
4. Install the oil filter adapter.
Notices.
5. Install the oil filter adapter bolts.
Tighten
Tighten the oil filter adapter bolts to
15 N·m + 50° (11 lb ft+ 50°).
(
36655
Engine Front Cover Installation
! Tools Required
1. Install the engine front cover gasket.
2. Install the engine front cover.
Align the cogs on the crankshaft sprocket with the
cogs on the oil pump in the engine front cover.
the engine front cover bolt threads.
Notices.
4. Install the engine front cover bolts.
Tighten
Tighten the engine front cover bolts to
20 N-m (15 lb ft). Use J 36660-A to tighten the
engine front cover bolts an additional 40 degrees.
5. Install the oil pan to engine front cover bolts. 345236
Tighten
Tighten the oil pan bolts to 14 N-m (125 lb in).
6. Install the oil filter.
Tighten
the crankshaft position sensor stud threads.
8. Install the crankshaft position sensor.
Tighten
Tighten the crankshaft position sensor studs to
30 N-m (22 lb ft).
36589
9. Install the crankshaft position sensor shield ..
35844
Crankshaft Front Oil Seal Installation

Tools Required
J 35354 Seal Installer
1. Coat the inside diameter of the crankshaft front oil
seal with lubricant GM P/N 10522497 or
equivalent.
2. Use J 35354 and a soft faced hammer to install
the crankshaft front oil seal. (
3. Remove J 35354.
J 35354
36662
Valve lifter Installation

1. Dip the valve lifters in prelube GM P/N 12345501
or equivalent.
2. Install the valve lifters.
3. Install the valve lifter guides.
Notices.
4. Install the valve lifter guide bolts.
Tighten
Tighten the valve lifter guide bolts to
30 N-m (22 lb ft).
41374
Cylinder Head Installation
I Tools Required
1. Install the cylinder head gasket. Ensure the
arrows point towards the front of the
engine. The left cylinder head gasket has .the
letter L stamped next to the arrow.
2. Install the cylinder head.
35842

Notices.
3. Install new cylinder head bolts.

Tighten
in sequence. Using J 36660-A rotate each
cylinder head bolt an additional 120 degrees.
@
~
® @ ®
38826

Installation
Tools Required
J 36660-ATorque Angle Meter
1. Install the push rods.
2. Install the push rod guide plates.
3. Install the valve rocker arms.
4. Apply GM P/N 12345493 threadlocker or
equivalent to the valve rocker arm bolt threads.
Notices.
) 5. Install the valve rocker arm bolts.

Tighten
Tighten the valve rocker arm bolts to
15 N·m (11 lb ft) + 90 degrees using J 36660-A.
35840
s. 232 Engine Mechanical - 3.SL Engine
Valve Rocker Arm Cover Installation
(Left Side)
(
equivalent to threads.·.
Notices.
3. Install the valve rocker arm cover bolts.
Tighten
10 N-m (89 lb in).
35819

(Right Side)
equivalent to.the threads.
Notices.
3. Install the valve rocker arm cover bolts. (
Tighten
10 N-m (89 lb in).
63414
Exhaust Manifold ln.stallation (Left Side)

1. Install the exhaust manifold gasket to the
cylinder head,
2. Install the exhaust manifold to the cylinder head.
Notices.
3. Install the exhaust manifold nuts.
Tighten
Tighten the nuts 23 N,m (17 lb ft).
589361
4. Install the exhaust manifold heat shield.
Tighten
• Tighten the two end nuts to 23 N-m (17 lb ft).
• Tighten the bottom nut to 10 N·m (89 lb in).
589352
6. Install the engine lift hook.
566982
Important: Inspect the .EGR inlet pipe for leaks.

Replace the EGR adapter if the pipe leaks.
7. Install the EGR inlet pipe to the exhaust manifold.

8. Install the EGR inlet pipe bolt and nuts.
Tighten
Tighten the nuts to 50 N·m (36 lb ft) and the bolt
to 25 N-m (18 lb ft).
589355
6;..234 Engine Mechanical - 3.8L Engine
Exhaust Manifold Installation (Right Side)
1. Install the exhaust m~nlfold ga.sket tb the
cylinder head.
2. Install the exhaust manifold to the cylinder head.
Notices.
3. Install the exhaust manifold nuts.
Tighten
Tighten the nuts to 23 N·m (17 lb ft).
589366
4. Install the exhaust manifold heat shield.

Tighten
• Tighten the two end heat shield nuts to
23 N·m (17 lb ft).
• Tighten the bottom nut to 10 N-m (89 lb in).
589365
Intake Manifold Installation (Lower)

1. Install the lower intake manifold gasket.
2. Install the lower intake manifold.
equivalent on the threads.
50046
Notices.
) 4. Install the lower intake manifold bolts.
Tighten
Tighten the bolts in sequence to 15 N·m (11 lb ft).
50288
5. Install the generator bracket.

6. Install the ignition control module bracket.
Tighten
Tighten the ignition control module bracket bolts
to 50 N·m (37 lb ft).
7. Install the ignition control module and nuts.
Tighten
) Tighten the ignition control module nuts to
30 N·m (22 lb ft).
566980
Intake Manifold Installation (Upper)

1. Install the upper intake manifold gasket.
2. Install the upper intake manifold.
3. Install the water outlet.
403782
Notice: Refer to. Fastener Notice in Cautions and
Notices.
4. Install the upper intake manifold bolts.

(
Tighten
• Tighten the vertical bolts in sequence to
15 N·m (11 lb ft).
• Tighten the two water outlet bolts in sequence
to 27 N-m (20 lb ft) ..
• Tighten the side bolts in sequence to
30 N-m (22 lb ft).
403789
5. Install the fuel injector rail.

6. Install the fuel injector rail nuts.
Tighten
Tighten the fuel injector rail nuts to
9 N·m (80 lb in).
403779
7. Install the throttle body gasket.

8. Install the throttle body.
9. Install the throttle body nuts and bolt.
Tighten
Tighten the throttle body nuts and bolt to
10 N-m (89 lb in).
403776
10. Install the EGR outlet pipe to the intake manifold,
Tighten
Tighten the EGR outlet pipe bolt. and nut to
29 N·m (21 lb ft).
11. Install the m1:1nifold vacuum source.
12. Install the rear generator mounting bracket
and bolts.
Tighten
. Tighten the bolts to 50 N-m (37 lb ft).
403772
Water Pump installation

Tools Required
J 36660-ATo'rque Angle Meter
1. Install. the water pump gasket.
2. Install the water pump.
) Notices.
· 3. Install the water pump bolts.
Tighten
Tighten the water pump bolts to 15 N·m (11 Jb ft).
Use J 36660-A to tighten the bolt an additional
80 degrees.
187022
4. Install the water pump pulley.

5. Install the water purnp pulley bolts.
Tighten
Tighten the water pump pulley bolts to
13 N·m (116 lb in),.
313967
Water Outlet Installation
1. Install the thermostat.
(
2. Install the water outlet gasket.
Notices.
4. Install the water outlet bolts.
Tighten
Tighten the water outlet bolts to 27 N-m (20 lb ft).
36621
Oil Level Indicator and Tube Installation

1. Install the oil level indicator tube.
• Lubricate the 0-ring with engine oil and make
sure it is in place. ·
• Make sure the assembly is fully seated in the
engine block.
Notices. (
2. Install the oil level indicator tube bolt.
Tighten
Tighten the bolt to 1O N·m (89 lb in).
36615
Drive Belt Tensioner Installation

2. Install the heater water bypass inlet pipe to the
lower intake manifold and to the tensioner.
Notices.
3. Install the tensioner bolts.
Tighten
313973
Engine Engine Mechanical - 3.8L a..239
Engine Flywheel Installation
J (Automatic Transmission)
Tools Required ·
1. Install the flywheel.
Notices.
2. Install the new flywheel bolts.
·. Tighten
Tighten the bolts to 15 N·m (11 lb ft). Use the
J 36660-A to tighten the bolts an additional
50 degrees.
36665
Engine Flywheel ~nstallation

Tools Required
1. Install the flywheel.
Notices. .
)
2. Install the new flywheel bolts.
Tighten
Tighten the bolts to 15 N-m (11 lb ft). Use
J 36660-A to tighten the bolts an aaditional
50 degrees.
192727
Crankshaft Balancer Installation

Tools Required
.. J 37096 Flywheel Holding Tool
.. J 36660-A Torque Angle Meter
1. Lubricate the seal surface of the crankshaft
balancer with engine oil.
2. Install the crankshaft balancer.
3. Use J 37096 to hold the flywheel.
309963
6~240 Engine Mechanical - 3;8L Engine
(
Notices.
4. Install the crankshaft balancer bolt.
Tighten
Tighten the crankshaft balancer bolt to
150 N·m (111 lb ft). Use J 36660-A to tighten the
crankshaft balancer bolt an additional
114 degrees.
192730
(
) Engine Component Description The plunger and the valve lifter body then raise as a
unit, pushing up the push rod to open the valve.
Engine Construction The force of the valve spring which is exerted on the
Starting at the front of the engine, the cylinders of the plunger through the valve rocker arm and push
left bank are numbered 1-3-5 and the cylinders of rod, causes a slight amount of leakage between the
the right bank are numbered 2-4-6. The crankshaft is plunger and the valve lifter body. This leakage allows a
supported in the engine block by four bearings. The slow escape of trapped oil in the base of the valve
crankshaft is counterbalanced by the flywheel, lifter body. As the valve lifter .rolls down the other side
the crankshaft balancer, and the weights cast into the of the camshaft lobe and reaches the base circle or
crankshaft. Additional counterbalancing is obtained valve closed position, the plunger sprir::ig quickly moves
from the balance shaft which rides in the engine block the plunger back (up) to its original position. This
above the camshaft and is driven by the camshaft. movement causes the check ball to open against the
All 3800 engines are even-firing, the cylinders ball spring, and any oil inside the plunger is drawn
fire at equal 120 degree intervals of crankshaft rotation. into the base of the valve lifter. This restores the valve
The location of the crankshaft journals has been lifter to the zero lash.
offset by 30 degrees to fire the cylinders at 120 degree
intervals of crankshaft rotation. The camshaft lobes Drive Belt System Description
and timing also reflect the 120 degree intervals.
The drive belt system consists of the following
The even firing crankshaft provides an equal interval
Components:
of 120 degrees between ignition of each of the
cylinders throughout the firing order. The firing order is • The drive belt
1-6-5-4-3-2. The aluminum alloy pistons have • The drive belt tensioner
slipper skirts and are cam turned. Four drilled holes or • The drive belt idler pulley
casted slots in the oil ring grooves permit drain • The crankshaft balancer pulley
back of the oil collected by the oil ring. The camshaft
is supported by four bearings in the engine block • The accessory driv.e component mounting
and is driven by the crankshaft through sprockets and brackets
a timing chain. The cylinder heads are cast iron · • The accessory drive components
) and incorporate integral valve stem guides. Right and - The power steering pump, if belt driven
1 left cylinder heads are identical and are - The generator
interchangeable, but it is good practice to reinstall the
cylinder heads on the side from which they are - The A/C compressor, if equipped
removed. The intake manifold is bolted to the inner - The engine cooling fan, if belt driven
faces of both cylinder heads so it connects with - The water pump, if belt driven
all inle1 ports. - The vacuum pump, if equipped
Each exhaust and intake valve has a valve spring to - The air compressor, if equipped
insure positive seating throughout the operating speed
The drive belt system may use one belt or two belts.
range. The valve rocker arms for each bank of the
The drive belt is thin so that it can bend backwards
cylinders pivot on pedestals bolted to the cylinder
and has several ribs to match the grooves in the
head. Hydraulic roller valve lifters and tubular push
pulleys. There also may be a V-belt style belt used to
rods are used to operate overhead rocker arms
drive certain accessory drive components. The
and valves of both banks of the cylinders from a single
drive belts are made of different types of rubbers
camshaft. This system requires no lash adjustment
(chloroprene or EPDM) and have different layers or
at the 1ime of assembly or service.
plys containing either fiber cloth or cords for
In addition to its normal function of a cam follower, reinforcement.
each valve lifter also serves as an automatic adjuster
Both sides of the drive belt may be used to drive the
which maintains zero lash in the valve train under
different accessory drive components. When the
all operating conditions. By eliminating all lash in the
back side of the drive belt is used to drive a pulley,
valve train and also providing a cushion of oil to absorb
the pulley is smooth.
operating shocks, the valve lifter promotes quiet
valve operation. It also eliminates the need for periodic The drive. belt is pulled by the crankshaft balancer
valve adjustment to compensate for wear of parts: pulley across the accessory drive component pulleys.
Oil is supplied to the valve lifter through a hole in the The spring loaded drive belt tensioner keeps
side of the valve lifter body which indexes with a constant tension on the drive belt to prevent the drive
groove and a hole. in the valve lifter plunger. Oil is then belt from slipping. The drive belt tensioner arm will
metered past the oil metering valve in the valve move when loads are applied to the drive belt by the
\ lifter, through the push rods to the valve rocker arms. accessory drive components and the crankshaft.
) When the valve lifter begins to move up the The drive belt system may have an idler pulley, which
e;amshaft lobe, the check ball is held against its seat is used to add wrap to the adjacent pulleys. Some
in the plunger by the check ball spring which traps the systems use an idler pulley in place of an accessory
oil in the base of the valve lifter body below·the drive component when the vehicle is not equipped with
plunger. the accessory.
lubrication Description
(
44529
The engine lubrication system is of the force-feed oil pressure relief valve in the oil filter adapter. Oil is.
type. The oil is supplied under full pressure to drawn into the pump through the screen and pipe
the crankshaft, connecting rods, valve lifters, camshaft, assembly, and a passage in the crankcase, connecting
and rear balance shaft bearing. A controlled volume to the passages in the engine front cover. Oil is ·
of oil is supplied to the valve rocker arms and discharged from the oil pump to the oil filter adapter.
push rods. All other moving parts are lubricated by The oil filter adapter consists of an oil filter bypass
gravity flow or splash. The engine oil is stored in the valve and a nipple for installation of an oil filter. The
lower crankcase (oil pan) which is filled through a spring-loaded oil pressure relief valve, located in.
filler opening in the valve rocker arm cover. A the engine front cover, limits the oil pressure. The oil
removable oil level indicator, on the left side of the filter bypass valve opens when the oil filter is .
engine block, is provided to check the oil level. The oil restricted to approximately 68.95 kPa (10 psi) of
pump is located in the engine front cover and is pressure difference between the oil filter inlet and
driven by the crankshaft. It is a gerotor-style pump discharge. The oil will then bypass the oil filter
which is a combination of a gear and a rotor pump. It and channel unfiltered oil directly to the main oil
is connected by a passage in the cylinder block to galleries of the engine. A full-flow oil filter is externally (
an oil screen and pipe assembly. The screen is mounted to the oil filter adapter on the lower right
submerged in the oil supply and has ample vol.ume for front side of the engine. If the filter element becomes
all operating conditions. If the screen becomes restricted, not allowing engine oil to pass through,
clogged, oil may be drawn into the system through the a spring-loaded bypass valve opens.
The main oil galleries run the full length of the engine Important: Do not use any other method or technique
block and cut into the valve lifter guide holes to in order to remove the gasket material from a
) supply oil at full pressure to the valve lifters. Holes, components.
drilled from the crankshaft bearings to the main
Do not use the following items in order to clean the
oil gallery, intersect the camshaft bearing bores to gasket surfaces:
supply oil to the cam bearings.
• Abrasive pads
Oil is transfered from the crankshaft bearings to the
connecting rod bearings through holes drilled in • Sand paper
the crankshaft. Pistons, piston pins, and cylinder walls • Power tools
are lubricated by oil splash from the crankshaft and These methods of cleaning may damage the
connecting rods. component.
Each valve rocker arm and valve is supplied with oil
through the tubular push rod. The oil comes from Abrasive pads also produce a fine grit that the oil filter
the inside of the valve lifter passing around the cannot remove from the oil. Tflis grit is abrasive
metering valve and through a hole in the push rod and may cause internal engine damage.
seat. Oil from the push rod passes through a hole in 3. Remove all of the gasket and the sealing material
the push rod seat, and emerges on top of the push rod from the qomponent using a plastic or a wood
seat boss. scraper. Do not gouge or scrape the sealing
surfaces.
Cleanliness and Care
Important: Do not allow the sealant to enter any blind·
An automobile engine is a combination of many of the threaded holes. The sealant may cause the following
following surfaces: · conditions: ·
• Machined • Prevent you from properly seating the bolt
• Honed • Ca.use damage when you tighten the bolt
• Polished
4. When assembling components, use only the
• Lapped sealant 'specified inthe service procedure.
The tolerances of these surfaces are measured in the · Ensure that the sealing surfaces are clean and
ten-thous.andths of an inch. When you service any free of debris or oil. Wheri applying sealant
internal engine part, clean.liness and care are . · to a component, apply a bead size as specified in
) important. Apply a liberal coating of engine oi.1 to the the service procedure.
friction areas during assembly in order to protect 5. Tighten the bolts to the specifications.
and lubricate the surfaces on initial operation.
Throughout this section, practice proper cleaning and
protection procedures to the machined surfaces Use of RTV and .Anaerobic Sealer
and to the friction areas. The following 2 types of sealer are commonly used i.n
Notice: Engine damage may result if an abrasive engines:
paper, pad, or motorized wire brush is used to clean • The RTV sealer
any engine gasket surfaces.
• The anaerobic gasket eliminator sealer
Whenever you remove the valve train components,
Follow the service procedure instructions. Use the
keep the components in order. Follow this procedure in
correct sealer in the proper place in order to prevent
order to install the components in the same locations
oil leaks. Do not interchange the 2 types of sealers.
and with the same mating surfaces as when
Use th.e sealer recommended in the service procedure.
removed.
Caution: Refer to Battery Disconnect Caution in Applying RTV Sealer
Cautions and Notices. • Do not. use the room temperature
Disconnect the negative battery cables before you' vulcanizing (RTV) sealant in areas where extreme
perform any major work on the engine. For more · temperatures are expected. These areas include
information on the disconnection of the battery, refer the following locations:
to Engine Electrical. - The exhaust manifold
Replacing Engine Gaskets - The head gasket
1. Do not reuse any gasket unless otherwise - The other surfaceswhere gasket eliminator
specified. Reusable gaskets will be identified in the is specified
service procedure. Do not apply sealant to any • Use a rubber mallet in order to separate the
gasket or sealing surface unless called out in the components sealed with RTV sealant. Bump the
service procedure. part sideways in order to shear the RTV sealer.
) 2. Use a rubber mallet in order to separate Perform the bumping at the bends or the
components. Bump the part sideways in order to reinforced areas in order to prevent distortion of
loosen the components. Perform the bumping the components. The RTV sealant is weaker
at the bends or at the reinforced areas in order to in shear (lateral) strength than in tensile (vertical)
prevent the distortion of components. strength.
Important: Do not use any other method or technique • Apply a continuous bead of the gasket elimina.tor
in order to remove the gasket material from a to 1 flange. Clean and dry any surfaces that you
component. will reseal. (
• Do not use the following items in order to clean Important: Anaerobic sealed joints that are partially
the gasket surfaces: torqued and allowed to cure more than 5 minutes may
- Abrasive pads result in incorrect shimming and sealing of the joint.
- Sand Paper • Do not allow the sealer to enter the blind
- Power tools threaded holes. The sealer may cause the
These methods of cleaning may damage the part
- Prevent you from properly seating the bolt
Abrasive pads also produce a fine grit that the oil filter
cannot remove from the oil. This grit is abrasive - Cause damage when you tighten the bolt
and may cause internal engine damag~. • Spread the sealer evenly in order to get a uniform
• Remove all of the gasket material from the coating on the sealing surface.
component using a plastic or a wood scraper. Use • Tighten the bolts to the specifications.
Loctite® brand gasket remover P/N 4MA or the
• Remove the excess sealer from the outside of
equivalent. Follow all of the safety
the joint.
recommendations and the directions that are on
the container.
Separating Parts
Important: Do not allow the sealer to enter the blind
threaded holes. The sealer may cause the following The components of an internal combustion engine
conditions: develop wear patterns with their mating components.
During disassembly of the engine, parts should be
- Prevent you from properly seating the bolt
separated and kept in order so they may be reinstalled
- Cause damage when you tighten the bolt in the same location from which they were removed.
• Apply the RTV sealant to a clean surface. Use a
bead size as specified in the procedure. Apply Service. Precautions
the bead to the inside of any bolt holes.
• Assemble the components while the RTV sealant Important: Follow the engine service information
below. This information is important in order to prevent
is still wet (within 3 minutes). Do not wait for the
RTV sealant to skin over. damage and in contributing to reliable engine (
performance.
Important: Do not overtigliten the bolts.
In order to avoid damage to the engine oil pan, use a
• Tighten the bolts to specifications. block of wood between the jack and the oil pan.
Applying Anaerobic Sealer Ensure that the block of wood extends past the
complete width of the oil pan. Due to the small
The anaerobic gasket eliminator hardens in the clearance between the oil pan and the oil pump
absence of air. This type of sealer is used where screen, jacking against the oil pan may cause the oil
2 rigid parts (such as castings) are assembled pan to bend against the pump screen. This condition
together. When 2 rigid parts are disassembled and no results in a damaged oil pick-up unit.
sealer or gasket is readily noticeable, the parts
were probably assembled using a gasket eliminator. Caution: Refer to Fastener Notice in Cautions and
Notices.
Important: Do not use any other method or technique When working on the engine, remember that the
in order to remove the gasket material from a 12-volt electrical system is capable of causing short
component. circuits. When performing any work where electrical
Do not use the following items in order to clean the terminals may possibly be grounded, disconnec1
gasket surfaces: the ground cable of the battery at the battery.
• Abrasive pads Any time you remove the air cleaner, cover the intake
• Sand paper opening. This procedure protects against the
accidental entrance of foreign material. Foreign
• Power tools material may follow the intake passage into the
These methods of cleaning may damage the part. cylinder. This condition causes extensive damage
Abrasive pads also produce a fine grit that the oil filter when you start the engine.
cannot remove from the oil. This grit is abrasive In the mechanical procedures described in this
and may cause internal engine damage. section, generally no references will be made to the
• Remove all of the gasket material from the removal of optional equipment such as the power
component using a plastic or a wood scraper. Use steering pump, the air conditioning compressor, etc. (
Loctite® brand gasket remover P/N 4MA or the If you need to remove any optional equipment in order
equivalent. Follow all of the safety to perform other service, refer to the appropriate
recommendations and the directions that are on section of this service manual for the specific
the container. information.
Installation Precautions Special Tools and Equipment
Caution: Before removing or installing any Illustration Tool Number/Description
) electrical unit, or when a tool or equipment could
easily come in contact with "live" or "hot all
the times" 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 J 6125-18
ignition switch must be in the OFF or LOCK Slide Hammer
position.
Notice: The following information on engine service
should be noted carefully, as it is important in
preventing damage and contributing to reliable engine 4865
performance.
When raising or supporting the engine tor 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 the
oil pan to be bent against the oil pump screen resulting J 7872
in a damaged oil pump screen or oil pump pipe. Magnetic Base Indicator Set
Any time the throttle body or air induction tube is
removed, the intake opening should be covered. This
will protect against the accidental entrance of
foreign material which could follow the intake passage 2014
into the cylinder and cause extensive damage when
the engine is started.
Tools and Equipment

Work in a clean and well-lit area. Have the following J 8001
) components available before you begin to work: Dial Indicator Set
• A suitable parts cleaning tank
• A compressed air supply
• Trays, in order to keep the parts and the fasteners
organized 2014
• An adequate set of hand tools

An approved engine repair stand will prevent personal
injury or damage to the engine components. The
special tools are designed in order to quickly
and safely accomplish the operations tor which the J 8037
tools are intended. Using the tools will minimize Universal Piston Ring
possible damage to the engine components. Precision Compressor
measuring tools are required for the inspection of
certain critical components. Torque wrenches
are needed for the correct assembly of various parts.
J 8087
Cylinder Bore
Checking Gauge
5110
)
J 8520 J 25087-C
Dial Indicator Adapter Oil Pressure Test Kit
3408 60304
J 9666 J 28428~E
Valve Spring Tester High Intensity Black Light
5112
62292
J 21465-13
J 28467-B
Drive Handle Extension
Engine Support Fixture
(
3400
190562
~
J 23590
Spark Plug Port Adapter
~ ~ J 28467-90A
~ ~
Engine Support Adapters
3400 ~ 367798
J 24270 J 33049
Cylinder Ridge Reamer Camshaft Bearing
Remover/Installer Set
3412
5118
(
Engine Engine Mechanical·- 3.8L 6-247
Illustration Tool Number/Description Illustration . Tool Number/Description
J37088-A
J -35354
Fuel Line Quick Connect
Seal Installer
Seperator
37773 13542
J 36660 J 37096.
Torque Angle Meter Flywheel Holding Tool
3413 37623
J 38196
J 35667-A
Crankshaft Rear Oil Seal
Cylinder Leakdown Tester
Installer
)
62295 38068
J 36995
J 38197
Balance Shaft Bearing Crankshaft Balancer Puller
Remover/Installer
38285 13547
J 36996 J 38606
Balance Shaft Installer Valve Spring Compressor
3411 49850
J 41044 J 41507
Engine Support Adapters Connecting Rod Guide
220634 38090
J 41348 J42863
Main Bearing Cap Puller Valve Seal Installer
38515 223541
J 41349
Housing Alignment Tool
(
49848
(
Engine Mechanical - 5.7L

Specifications
Specification
Accelerator Control Cable Bracket Bolts 10 N,m 891bin
Air Conditioning Compressor Bolts 50N·m 37 lb ft
. Air Conditioning Compressor Bracket Bolts 50N·m 37 lb ft
Air Conditioning Idler Pulley Bolt 50 N,m 37 lb ft
Air Conditioning Tensioner Bolt 25N·m 18 lb ft
Air Injection Reaction (AIR) Pipe-to-Exhaust Manifold Bolts 20N·m 15 lb ft
Camshaft Retainer Bolts 25N·m .18 lb ft
Camshaft Sensor Bolt 25N·m. · 18 lb ft
·.
Camshaft Sprocket Bolts 35 N,m 26 lb ft
.·
Catalytic Converter Nut 25N·m 18 lb ft
Connecting Rod Bolts - First Design (First Pass) 20N·m 15 lb ft
Connecting Rod Bolts - First Design (Final Pass) . 60degrees
Connecting Rod Bolts - Second Design (First Pass) 20N·m
'"•'
. 15 lb ft
Connecting Rod Bolts - Second Design (Final Pass) 75 degrees
Coolant Temperature Gauge Sensor 20N·m 15 lb ft
Crankshaft Balancer Bolt (Installation Pass-to Ensure the Balancer is
330 N:m.
' 240 lb ft
Completely Installed)
Crankshaft Balancer Bolt (First Pass-Install a NEW Bolt After the
Installation Pass and Tighten as Described in the First and Final 50N·m .. 37 lb ft
Passes)
Crankshaft Balancer Bolt (Final Pass) 140 degrees
Crankshaft Bearing Cap Bolts (Inner Bolts-First Pass in Sequence) 20N·m 15 lb ft
Crankshaft Bearing Cap Bolts (Inner Bolts-Final Pass in Sequence) 80 degrees
Crankshaft Bearing Cap Side Bolts 25N·m 18 lb ft
Crankshaft Bearing Cap Studs (Outer Studs-First Pass in Sequence) 20N·m 15 lb ft
Crankshaft Bearing Cap Studs (Outer Studs-Final Pass in Sequence) 53 degrees
Crankshaft Oil Deflector Nuts 25N·m 18 lb ft
. Crankshaft Position Sensor Bolt 25N·m 18 lb ft
Cylinder Head Bolts (First Pass all M11 Bolts in Sequence) 30N·m 22 lb ft
Cylinder Head Bolts (Second Pass all M11 Bolts in Sequence) 90 degrees
Cylinder Head Bolts (Final Pass all M11 Bolts in Sequence-Excluding
90 degrees
the Medium Length Bolts at the Front and Rear of Each Cylinder Head)
Cylinder Head Bolts (Final Pass M11 Medium Length Bolts at the Front
50 degrees
and Rear of Each Cylinder Head in Sequence)
Cylinder Head Bolts (MB Inner Bolts in Sequence) 30N·m 22 lb ft
Cylinder Head Coolant Plug 20 N-m 15 lb ft
Cylinder Head Core Hole Plug 20N·m 15 lb ft
Drive Belt Idler Pulley Bolt 50N·m 37 lb ft
Drive Belt Tensioner Bolts 50N·m 37 lbft
Engine Block Coolant Drain Plugs 60N·m 44 lb ft
Engine Block Heater 40N·m 30 lb ft
Engine Block Oil Gallery Plugs 60N·m 44 lb ft
Engine Coolant Air Bleed Pipe Bolts and Studs 12 N·m 1061bin
Engine Crossmember Bolts (Large) 145 N·m 107 lb ft
Specification
Application Metric
.·
English
..
(
Engine Crossmember Bolts (Small) 125 N-m 92 lb ft
Engine Flywheel Bolts (First Pass) ·. 20N-m 15 lb ft
Engine Flywheel Bolts (Second Pass) 50 N-m 37 lb ft
Engine Flywheel Bolts (Final Pass) 100N-m 74 lb ft
Engine Flywheel-to-Torque Converter Bolts 60N-m 44 lb ft
Engine Front Cover Bolts 25N-m 18 lb ft.
Engine Moµnt Heat Shield Nuts 10 N-m 891bin
Engine Mount Stud-to-Engine Block. .. 50N-m 37 lb ft
Engine Mount Through Bolts 95N-m 70 lb ft
Engine Mount Through Bolt Nuts 80 N-m 59 lb ft
Engine Mourit-to-Engine Block Bolts 50N-m 37 lb ft
Engine Rear Cover Bolts 25N-m 18 lb ft
Engine Service Lift Bracket M10 Bolts 50N-m 37 lb ft
Engine Service Lift Bracket M8 Bolt 25 N-m 18 lb ft
Engine Valley Cover Bolts 25N-m 18 lb ft
Engine Wire Harness Clip Bolt 50N-m 37 lb ft
Engine Wire Harness Ground Strap Bolt 50 N-m 37 lb ft
Exhaust Gas Recirculation (EGR) Valve Bolts (First Pass) 10 N-m 891bin
EGR Valve Bolts (Final Pass) 30 N-m 22 lb ft
EGR Valve Pipe-to-Cylinder Head Bolts 50N-m 37 lb ft
EGR Valve Pipe-to-Exhaust Manifold Bolts 30 N-m . 22 lb ft
EGR Valve Pipe-to-Intake Manifold Bolt 10 N;m 891bin
Exhaust Manifold Bolts (First Pass) 15 N-m 11 lb ft
(
Exhaust Manifold Bolts (Final Pass) 25 N-m :J8 lb ft
Exhaust Manifold Heat Shield·Bolts 9N·m 801bin
Exhaust Manifold Pipe Nuts 35N-m 26 lb ft
Front Shock-to-Engine Crossmember Bolts 65N-m 48 lb ft
Fuel Injection Fuel Rail Bolts 10 N-m 891bin
Generator Bracket Bolts 50N-m 37 lb ft
Generator Rear Bracket-to-Engine Block Bolt 25N-m 18 lb ft
Generator Rear Bracket-to-Generator Bolt 25N-m 18 lb ft
Ground Strap Bolt (at Rear of Cylinder Head) 50N-m 37 lb ft
Ignition Coil-to-Bracket Bolts 12 N-m 106 lb in··
..
Ignition Coil Bracket-to-Valve Rocker Arm Cover Bolts 12 N-m 106 lb in
Intake Manifold Bolts (First Pass in Sequence) 5N-m 441bin
Intake Manifold Bolts (Final Pass in Sequence) 10 N-m 89lbin
Knock Sensors 20N-m 15 lb ft
Oil Filter 30N-m 22 lb ft
Oil Filter· Fitting 55N-m 40 lb ft
Oil Level Indicator Tube Bolt 25N-m 18 lb ft
Oil Level Sensor 13 N-m 115 lb in
Oil Pan Baffle Bolts 12 N-m i061bin
Oil Pan Closeout Cover Bolt (Left Side) 12 N-m 106 lb in
Oil Pan Closeout Cover Bolt (Right Side) 12 N-m 106 lb in
Oil Pan Cover Bolts 12 N-m 106 lbin
(
Oil Pan Drain Plug 25N-m 18 lb ft
Oil Pan M8 Bolts (Oil Pan-to-Engine Block and Oil Pan-to-Front Cover) 25N-m 18 lb ft
Engine Engine Mechanical- 5.7L 6-251
Specification
) Application Metric English
Oil Pan M6 Bolts (Oil Pan-to-Rear Cover) 12 N·m 1061bin
Oil Pressure Sensor 20N·m 15 lb ft
Oil Pump-to-Engine Block Bolts 25N·m 1.8 lb ft
Oil Pump Cover Bolts 12 N·m 1061bin
Oil Pump Relief Valve Plug 12.N·m 1061bin
Oil Pump Screen Nuts 25N-m 18 lb ft
Oil Pump Screen-to-Oil Pump Bolt 12 N-m 1061bin
Oxygen Sensor 42N·m 31 lb ft
Positive Crankcase Ventilation (PCV) System Strap Nut (at Right Front
12 N·m 1061!:? in
Vapor Vent Pipe Stud)
Power Steering Pump Bolts 25N·m 18 lb ft
Power Steering Pump Bracket Bolts 25N·m 18 lb ft
Spark Plugs (Cylinder Heads-New) 20N·m 15 lb ft
Spark Plugs (all Subsequent Installations) 15 N-m 1 {lb ft
Throttle Body Bolts 12 N-m 1061bin
Transmission Housing Bolt 50N·m 37 lb ft
Valve Lifter Guide Bolts 12 N·m 1061bin
Valve Rocker Arm Bolts 30 N-m 22 lb ft
Valve Rocker Arm Cover Bolts 12 N-m 1061bin
Water Inlet Housing Bolts 15 N:m 11 lb ft
Water Pump Bolts (First Pass) 15 N-m 11 lb ft
) Water Pump Bolts (Final Pass) 30N·m 22 lb ft
Water Pump Cover Bolts 15 N-m 11 lb ft
Engine Mechanical Specifications

Specification
General Data
Engine Type VB
Displacement 5.7L-5665 cc 346 C.ID
Bore 99.0 mm 3.898 in
Stroke 92.0 mm 3.622 in
Compression Ratio 10.1:1
Firing Order 1-8-7-2-6-5-4-3
Spark Plug Gap · ·1.524 mm 0.06 in
Lubrication System
Oil Capacity (without Oil Filter Change) 4.7 Liters 5.0 Quarts
Oil Capacity (with Oil Filter Change) 5.2 Liters · 5.5 Quarts
41 kPa at 1,000 6 psig at 1,000
el'.lgine RPM engine RPM
Oil Pressure (Minimum-Hot) 124 kPa at 2,000 18 psig at 2,000
engine RPM engine RPM·
165 kPa at 4,ooo 24 psig at 4,000
engine RPM engine RPM
Oil Type 5W~30
Camshaft
Camshaft End Play 0.025-0.305 mm 0.001-0.012 in
Camshaft Journal Diameter 54.99-55.04 mm 2.164-2.166 in
6-252 Engine Mechanical- 5.7L Engine
Specification
Application Metric English (
Camshaft Journal Diameter Out-of-Round 0.025 mm 0.001 in
Camshaft Lobe Lift (Intake) 7.43 mm 0.292 in
Camshaft Lobe Lift (Exhaust) 7.43 mm 0.292 in
Camshaft Runout (Measured at the Intermediate Journals) 0.05 mm 0.002 in
Connecting Rod
Connecting .Rod Bearing Bore Diameter 56.505-56.525 mm 2.224-2.225 in
Connecting Rod Bearing Bore Out~of-Round (Production) 0.004 mm 0.00015 in
Connecting Rod Bearing Bore Out~of-Round (Service Limit) 0.008 mm 0.0003 in
Connecting Rod Bearing Clearance (Production) 0.015-0.063 mm 0.0006-0.00248 in
Connecting Rod Bearing Clearance (Service Limit) 0.015-0.076 mm 0.0006-0.003 in
Connecting Rod Side Clearance 0.11-0.51 mm 0.00433-0.02 in
Crankshaft
Crankshaft Bearing Clearance (Production) 0.018-0.054 mm 0.0007-0.00212 in
Crankshaft Connecting Rod Journal Diameter (Production) 53.318-53.338 mm 2.0991-2.0999 in
Crankshaft Connecting Rod Journal Diameter (Service Limit) 53.308 mm 2.0987 in
0.005 mm (Maximum 0.0002 in (Maximum for
Crankshaft Connecting Rod Journal Taper (Production) for 1/2 of the Journal 1/2 of the Journal
., Length) Length)
Crankshaft Connecting Rod JournalTaper (Service Limit) 0.02 mm (Maximum) 0.00078 in (Maximum)
Crankshaft Connecting Rod Journal Out-of-Round (Production) 0.005 mm 0.002 in
Crankshaft Connecting Rod Journal Out-of-Round (Service Limit) 0.01 mm 0.00039 in
Crankshaft End Play 0.04-0.2 mm 0.0015-0.0078 in
Crankshaft Main Journal Diameter (Production) 64.993-:65.007 mm 2.558-2.559 in ..
(
Crankshaft Main Journal Diameter (Service Limit) 64.993 mm (Minimum) 2.558 in (Minimum) ·
Crankshaft Main Journal Out-of-Round (Production) 0.003 mm 0.000118 in
Crankshaft Main Journal .Out-of-Round (Service. Limit) 0.008 mm 0.00031 in
. Crankshaft Main Journal Taper (Production) O.D1 mm 0.00039 in
Crankshaft Main Journal Taper (Service Limit) 0.02 mm 0.00078 in
Crankshaft Reluctor Ring Runout (Measured 1.0 mm (0.04 in) Below
0.25 mm 0.01 in
the Tooth Diameter)
Crankshaft Runout (at Rear Flange) 0.05 mm (Maximum) 0.002 in (Maximum)
CrankshaftThrust Wall Runout 0.025 mm 0.001 in
Crankshaft Thrust Wall Width (Production) 26.14-26.22 mm 1.029-1.032 in
Crankshaft Thrust Wall Width (Service) 26.2 mm (Maximum) 1.0315 in (Maximum)
Cylinder Bore
Cylinder Bore Diameter 99.0-99.018 mm 3.897-3.898 in
Cylinder Bore Taper Thrust Side 0.018 mm (Maximum) 0.0007 in (Maximum)
Cylinder Head
Cylinder Head Engine Block Deck Flatness (Measured within a
0.08 mm 0.003 in
152.4 mm (6.0 in) area)
Cylinder Head Engine Block.Deck Flatness. (Measuring the Overall
0.1 mm 0.004 in
Length of the Cylinder Head) ·•
Cylinder Head Exhaust Manifold Deck Flatness 0.22 mm 0.008 in
Cylinder Head Intake Manifold Deck Flatness 0.22 mm 0.008 in
Cylinder Head Height (Measured from the Cylinder Head Deck to the
Valve Rocker Arm Cover Seal Surface)
120.2 mm (Minimum) 4.732 in (Minimum) (
Engine Block
Camshaft Bearing Bore Diameter 55.063-55.088 mm 2.168-2.169 in
Specification
) Application Metric English
Engine Block Cylinder Head Deck Surface Flatness (Measured within a
0.08 mm 0.003 in
152.4 mm (6.0 in) area)
Engine Block Cylinder Head Deck Surface Flatness (Measuring the
0.22 mm 0.008 in
Overall Length of the Block Deck)
Engine Block .Cylinder Head Deck Height (Measuring from the
234.57-234.82 mm 9.23ff-9.245 in
Centerline of Crankshaft to the Deck Face)
Main Bearing Bore Diameter (Production) 69.871-69.889 mm 2.75....:2.751 in
Main Bearing Bore Out-of-Round 0.5mm 0.02 in
Valve Lifter Bore Diameter (Production) 21.417-21.443 mm 0.843-0.844 in
Intake Manifold
ln1ake Manifold Cylinder Head Deck Flatness (Measured at Gasket
0.5mm 0.02 in
Sealing Surfaces)
Oil Pan and Front/Rear Cover Alignment
.
Oil Pan to Rear of Engine Block Alignment (at Transmission 0.0-0.25 mm
0.0-0.01 in (Maximum)
Bellhousing Mounting Surface) (Maximum)
Front Cover Alignment (at Oil Pan Surface) 0.0-0.5 mm 0.0-0.02 in
Rear Cover Alignment (at Oil Pan Surface) 0.0-0.5 mm 0.0-0.02 in
Piston
Piston Outside Diameter (at Size Point) 98.964-98.982 mm 3.8962-3.8969 mm
Piston Out-of-Round (Service Limit) 0.018 mm .. 0.0007 in
Piston to Bo.re Clearance (Production) 0.018-0.054 mm o.0007....:0.00212 in
0.018-'-0.054 mm 0.0007-0.00212 i.n
Piston to Bore Clearance (Service Limit)
(Maximum) (Maximum)
Piston Pin
Piston Pin Clearance to Piston Bore (Production) 0.01-0.02 mm 0.0004-0.00078 in
0.01-0.02 mm 0.0004-0.00078 in
Piston Pin Clearance to Piston Bore (Service Limit)
(Maximum) (Maximum)
Piston Pin Diameter 23.997-24.0 mm 0.9447-0.9448 in
0.02-0.043 mm 0.00078-0.00169 in
Piston Pin Fit in Connecting Rod
(Interference) (Interference)
Piston Rings '
Piston Compression Ring End Gap (Production-Top) (Measured in
0.23-0.38 mm 0.009-0.0149 in
Cylinder Bore)
Piston Compression Ring End Gap (Production-2nd ) (Measured in
0.44-0.64 mm 0.0173-0.0251 in
Cylinder Bore)
Piston Oil Ring .End Gap (Production) (Measured in Cylinder Bore) 0.18-0.69 mm 0.007-0.0271 in
Piston Compression Ring End Gap (Service-Top) (Measured in 0.23-0.38 mm 0.009-0.0149 in
Cylinder Bore) (Maximum) (Maximum)
Piston Compression Ring End Gap (Service-2nd ) (Measured in 0.44-0.64 mm 0.0173-0.0251 in
Piston Oil Ring End Gap (Service Limit) (Measured in 0.18-0.69 mm 0.007-0.0271 in
Piston Compression Ring Groove Clearance (Production-Top) 0.04-0.085 mm 0.00157-0.003346 in
Piston Compression Ring Groove Clearance (Production-2nd ) 0.04-0.08 mm 0.00157-0.003149 in
Piston Oil Ring Groove Clearance (Production) 0.01-0.22 mm 0.0004-0.00866 in
0.04-0.085 mm 0.00157-0.003346 in
Piston Compression Ring Groove Clearance (Service-Top)
(Maximum) (Maximum)
) 0;04-0.08 mm 0.00157-0.003149 in
Piston Compression Ring Groove Clearance (Service-2nd )
(Maximum) (Maximum)
0.01-0.22 mm 0.0004-0.00866 in
Piston Oil Ring Groove Clearance (Service Limit)
(Maximum) (Maximum)
6-254 Engine .Mechanical -·5.7L Engine
Specification
Application Metric English (
Valve System
Valve Face Angle 45 degrees
Valve Guide Installed Height (Measured from the Cylinder Head
17.32 mm 0.682 in
Spring Seat Surface to the Top of the Valve Guide)
Valve Lash Net Lash-No Adjustment
Valve Lift (Exhaust) 12.15 mm 0.479 in
Valve Lift (Intake) 11.99 mm 0.472 in
Valve Lifter Hydraulic Roller
Valve Margin 1.25 mm (Minimum) 0.05 in (Minimum)
Valve Rocker Arm Ratio 1.70:1
Valve Seat Angle 46 degrees
Valve Seat Runout 0.05 mm (Maximum) 0.002 in (Maximum)
Valve Seat Width (Exhaust) 1.78 mm 0.07 in
Valve Seat Width (Intake) 1.02 mm 0.04 in
Valve Spring Free Length 52.9 mm 2.08 in
Valve Spring Installed Height (Exhaust) 45.75 mm 1.8 in
Valve Spring Installed Height (Intake) 45.75 mm 1.8 in
Valve Spring Pressure (Closed) 340 N at 45.75 mm 76 lb at 1.8 in
Valve Spring Pressure (Open)· 980 N at 33.55 mm 220 lb at 1.32 in
Valve Stem Clearance (Production-Exhaust) 0.025-0.066 mm 0.001-0.0026 in
Valve Stem Clearance (Production-Intake) 0.025-0.066 mm 0.001-0.0026 in
Valve Stem Clearance (Service-Exhaust) 0.093 mm (Maximum) 0.0037 in (Maximum)
Valve Stem Clearance (Service_;lntake) 0.093 mm (Maximum) 0.0037 in (Maximum) (
Valve Stem Diameter (Production)· 7.955-7.976 mm 0.313-0.314 in
Valve Stem Diameter (Service) 7.95 mm (Minimum) 0.313 in (Minimum)
Valve .Stem Oil Seal Installed Height (Measured from the Valve Spring
18.1-19.1 mm 0.712-0.752 in
Shim to Top Edge of Seal Body)

Camshaft -. ,, .. 0.519
Camshaft Bearing 0.539
.Camshaft Timing Chain 0.724
Connecting Rod 0.603
Connecting Rod Bearing Kit 0.616
Coolant Radiator 1.219
Crankshaft 0.646
Crankshaft Balancer 0.659
.. Crankshaft Bearing Kit 0.096
· Crankshaft Transmission Pilot Bearing 0.649
Crankshaft Oil Defl~ctor 1.430
Crankshaft .Front Oil Seal 0.213
Crankshaft Rear Oil Seal 0.137
Cylinder Head 0.269
Cylinder Head Gasket 0.289
Engine Block N.S.
(
Engine Coolant Air Bleed Pipe 0.1097
Engine Coolant Air Bleed Pipe Gasket 0.1097
GM SPO Group Numbers (cont'd)
Engine Cooling Thermostat 1.246
·.
Engine Front Cover 0.206
Engine Front Cover Gasket 0.207
Engine Flywheel (Automatic Transmission) 0.666
Engine Flywheel (Manual Transmission) 0.666
Engine Rear Cover 0.137
Engine Rear Cover Gasket 0.137
Exhaust Manifold 3.601
Exhaust Manifold Gasket 3.27
Ignition Coil 2.17
Intake Manifold 3.265
Intake Manifold Gasket 3.270
Oil Filter 1.836
Oil Level Indicator 1.. 516
Oil Level Indicator Tube 1.516
Oil Pan 1.426
Oil Pan Gasket 1.429
Oil Pump 1.652
Oil Pump Screen 1.656
Oil Pan Cover 1.426
Oil Pan Cover Gasket 1.429
Piston with Pin 0.629
Piston with Ring Kit 0.643
Radiator Fan Shroud 1.277
Spark Plug 2.270
Sta1ier Motor 2.041
Throttle Body 3.335
Throttle Body Gasket 3.336
Valley Cover 3.265
Valley Cover Gasket 3.270
Valve Lifter 0.459
Valve Lifter Guide 0.439
Valve Pushrod 0.426
Valve Rocker Arm 0.333
Valve Rocker Arm Cover 0.386
Valve Rocker Arm Cover Gasket 0.423
Valve Rocker Arm Support 0.429
Valve Spring 0.303
Valve Spring Shim 0.303
Valve Stem Oil Seal 0.308
Water Pump Gasket 1.079
Water Pump with Gasket 1.069
Sealers, Adhesives, and lubricants
Coolant Sensor Threads Sealant 12346004 (
Cylinder Head Core Hole Plugs Thread lock 12345382
Cylinder Head Expansion Plugs Thread lock 12345382
Cylinder Head M8 Bolt Threads Thread lock 12345382
Engine Block Front Oil Gallery Plug Thread lock 12345382
: Engine Block Plug Sealing Washers Sealant 12346004
-
Engine Flywheel Bolt Threads Thread lock 12345382
Engine Oil (FN Car) 5W-30 Oil 12345610
Engine Oil (Y Car) 5W-30 Synthetic Oil 12345885
Engine Oil Supplement Lubricant 12345795
Exhaust Manifold Bolt Threads Thread lock 12345493
Fuel Rail Bolt Threads Thread lock 12345382
Ignition Coil and Bracket Assembly Bolts Threadlock 12345382
Intake Manifold Bolt Threads Thread lock 12345382
Oil Pan Surface at Front .and Rear Covers Sealant 12378190
Oil Pressure Sensor Threads Sealant 12346004
(
Thread Repair Specifications
Engine Block-Front View
64583
Engine Block-Front View

.. Drill Depth Tap Depth
Thread Counterbore (Maximum) (Maximum)
Hole, ·Size • Insert Drill Tool Tap Driver mm (in) mm (in)
M8
J 42385-210 J 42385-208 J 42385-209
1-6
xJ.25
I
·.. J 42385-206
.
J 42385-207
.
22.5 (0.885) 17.5 (0.688)
M10
J 42385:215 J 42385-211 J 42385-212 J 42385:213 J 42385-214 25.0 (0.984) 19.5 (0.767)
.7 ....... .x 1.5 .·•
M10
8 J 42385-215 J 42385-211 J 42385-212 J 42385-213 J 42385-214 32.5 (1.28) 25.0 (0.984)
:. x. 1..5 .• ,.· :
MB J 42385-208 J 42385-209
9 J42385-210 J 42385-206 J 42385-207 22.5 (0.885) 17.5 (0.688)
. x 1.25
M10
10 J42385-215 J42385-211 J 42385-212 J 42385-213 J 42385-214 Thru Thru
. x 1.5
Ml}
1H3 J 42385-210 ·J 42385-206 J 42385-207 J 42385-208 J 42385-209 22.5 (0.885) 17.5 (0.688)
x i.25
M8
14 J 42385-210 J 42385-206 J 42385-207 J 42385-208 J 42385-209 Thru 18.0 (0.708)
x 1.25
MB
15 J 42385-210 J 42385-206 J 42385-207 J 42385-208 J 42385-209 22.5 (0.885) 17.5 (0.688)
x 1.25
M8
16 J 42385-210 J 42385-206 J 42385-207 J 42385-208 J 42385-209 Thru 18.0 (0.708)
x 1.25
M8
17-27 J 42385-210 J 42385-206 J 42385-207 J 42385-208 J 42385-209 22.5 (0.885) 17.5 (0.688)
x 1.25
Engine Block-Rear View
3 (
15
12 11 10 7 6 (
64590
Engine Block-Rear View

Drill Depth Tap Depth
Hole Size Insert Drill Tool Tap Driver mm (in) mm (in)
M10
1 J 42385-215 J 42385-211 J 42385-212 J 42385-213 J 42385-214 27.0 (1.06) 21.5 (0.846)
x 1.5
MB
2-4 J 42385-210 J 42385-206 J 42385-207 J 42385-208 J 42385-209 22.5 (0.885) 17.5 (0.688)
x 1.25
M10
5-6
x 1.5 J 42385-215 J 42385-211 J 42385-212 J 42385-213 J 42385-214 27.0 (1.06) 21.5 (0.846)
MB 17.5 (0.688) .•
7-13
x 1.25 J 42385-210 J 42385-206 J 42385-207 J 42385-208 J 42385-209 22.5 (0.885)
M10
14-16 J 42385-215 J 42385-211 J 42385-212 J 42385-213 J 42385-214 27.0 (1.06) 21.5 (0.846)
x 1.5
.. 17-18 MB
J 42385-210 J 42385-206 J 42385-207 J 42385-208 J 42385-209 22.5 (0.885) 17.5 (0.688)
x 1.25
Engine Engine Mechanical -5.7L 6-259
Engine Block-Left Side View
20 19 i8 17 16 15 14 13 12
64602
Engine Block-Left Side View

'
·... Thread Counterbore (Maximum) (Maximum)
MS
1 J 42385-210 J 42385-206 J 42385-207 J 42385-208 J 42385-209 26.5 (1.04) 19.0 (0.784)
x 1.25
' .
M11
. 2-3 J42385-108 J 42385-105 - J 42385-106 J 42385-107 124.0 (4.88) 115.0 (4.52)
x 2.0
..
MB
4 · x 1.25 J 42385-210 J 42385-206 J 42385-207 J 42385-208 J 42385-209 26.5 (1.04) 19.0 (0.784)
..
5 M6 x 1.0 J 42385-205 J 42385-201 J 42385-202 J 42385-203 J 42385-204 22.5 (0.885) 16.0 (0.629)
M11
6-7
x2.0 J 42385-108 J 42385-105 - J 42385-106 J 42385-107 124.0 (4.88) 115.0 (4.52)
MS
8 J 42385-210 J 42385-206 J 42385-207 J 42385-208 J 42385-209 26.5 (1.04) 19.0 (0.784)
x 1.25
9 .. rv,11. J 42385-108 J 42385-105 - J 42385-106 J 42385-107 69.0 (2.72) 60.0 (2.36)
x 2.0
M11
10
x 2.0 J 42385-108 J 42385-105 - J 42385-106 J 42385-107 124.0 (4.88) 115.0 (4.52)
M16
11
x 1.5 - - - - - - -
M10
12-17 J 42385-215 J 42385-211 J 42385-212 J 42385-213 J 42385-214 29.0 (1.14) 23.0 (0.905)
x 1.5
M28
18
x 1.25
- - - - - - -
Engine Block-left Side View (cont'd)
(
MS
19'.""20 J 42385-210 J 42385-206 J 42385-207 J 42385-208 J 42385-209 21.0 (0.826) 16.0 (0.629)
x 1.25
M16
21
x 1.5
- - - - - - -
M10
22 J 42385-215 J 42385-211 J 42385-212 J 42385-213 J 42385-214 27.0 (1.06) 21.5 (0.846)
x 1.5
M11
23 J 42385-108 J 42385-105 - J 42385-106 J 42385-107 124.0 (4.88) 115.0 (4.52)
x 2.0
M11
24
x 2.0
J 42385-108 J 42385-105 - J 42385-106 J 42385-107 69.0 (2.72) 60.0 (2.36)
MS
25 J 42385-210 J 42385-206 J 42385-207 J 42385-208 J 42385-209 26.5 (1.04) 19.0 (0.784)
x 1.25
M11
26-27
x 2.0
J 42385-108 J 42385-105 - J 42385-106 J 42385-107 124.0 (4.88) 115.0 (4.52)
28 M6 x 1.0 J 42385-205 J 42385-201 J 42385-202 J 42385-203 J 42385-204 22.5 (0.885) 16.0 (0.629)
MS
29 J42385-210 J 42385-206 J 42385-207 J 42385-208 J 42385-209 26.5 (1.04) 19.0 (0.784)
x 1.25
• Bolt holes 2, 3, 6, 7, 10, 23, 26, and 27 have a 85 mm (3.34 in) counterbore included in the 124.0 mm (4.88 in)
drill depth.
• Bolt holes 9 and 24 have a 30 mm (1.18 in) counterbore included in the 69.0 mm (2. 72 in) drill depth. Use sleeve
J 42385-315 with the drill and tap.
(
Engine Block-Right Side View
22 .
~~
) 21 18 14
64579
Engine Block-Right Side View

MB
1 J 42385-210 J 42385-206 J 42385-207 J 42385-208 J 42385-209 26.5 (1.04) 19.0 (0.784)
x 1.25
M11
2-3 J 42385-108 J 42385-105 - J 42385-106 J 42385-107 124.0 (4.88) 115.0 (4.52)
x 2.0
MB
4 J 42385-210 J 42385-206 J 42385-207 J 42385-208 J 42385-209 26.5 (1.04) 19.0 (0.784)
x 1.25
5 M6 x 1.0 J 42385-205 J 42385-201 J 42385-202 J 42385-203 J 42385-204 22.5 (0.885) 15.0 (0.590)
Mi1
6-7
x 2.0 J 42385-108 J 42385-105 - J 42385-106 J 42385-107 124.0 (4.88) 115.0 (4.52)
MB
8 J 42385-210 J 42385-206 J 42385-207 J 42385-208 J 42385-209 26.5 (1.04) 19.0 (0.784)
x 1.25
M11
9
x 2.0 J 42385-108 J 42385-105 - J 42385-106 J 42385-107 69.0 (2.72) 60.0 (2.36)
M11
10 J 42385-108 J 42385-105 - J 42385-106 J 42385-107 124.0 (4.88) 115.0 (4.52)
x 2.0
M10
11-14 J 42385-215 J 42385-21-1 J 42385-212 J 42385-213 J 42385-214 27.0 (1.06) 21.5 (0.846)
x 1.5
M10
15-19 J 42385-215 J 42385-211 J 42385-212 J 42385-213 J 42385-214 29.0 (1.14) 23.0 (0.905)
x 1.5
M16
20
x 1.5
- --- - -- - - -
-
Engine Block-Right Side View (cont'd)
Thread Counterbore (Maximum) (Maximum) (
M8
21 J 42385-210 J 42385-206 J 42385-207 J 42385-208 J 42385-209 22.5 (0.885) 17 .5 (0.688)
x 1.25
M11
22
x 2.0
J 42385-108 J 42385-105 - J 42385-106 J 42385-107 124.0 (4.88) 115.0 (4.52)
M11
23 J 42385-108 J 42385-105 - J 42385-106 J 42385-107 69.0 (2.72) 60.0 (2.36)
x 2.0
M8
24 J 42385-210 J 42385-206 J 42385-207 J 42385-208 J 42385-209 26.5 (1.04) 19.0 (0.784)
x 1.25
M11
25-26
x 2.0
J 42385-108 J 42385-105 - J 42385-106 J 42385-107 124.0 (4.88} 115.0 (4.52)
27 M6 x 1.0 J 42385-205 J 42385-201 J 42385-202 J 42385-203 J 42385-204 22.5 (0,885) 15.0 (0.590)
M8
28
x 1.25
J 42385-210 J 42385-206 J 42385-207 J 42385-208 J 42385-209 26.5 (1.04) 19.0(0.784)
• Bolt holes 2, 3, 6, 7, 10, 22, 25, and 26 have a 85 mm (3.34 in) counterbore included in the 124.0 mm (4.88 in) '
drill depth.
• Bolt holes 9 and 23 have a 30 mm (1.18 in) counterbore included in the 69.0 mm (2.72 in) drill depth. Use sleeve
(
Engi,ne Block-Bottom View
25 24 23 22 21 20 19 18 17 16 15
64655
Engine Block-Bottom View

M10
1 J 42385-104 J 42385-101 - J 42385-102 J 42385-103 31.0 (1.22) 25.5 (1.0)
x 2.0
M10
2 x 2.0
J 42385-104 J 42385-101 - J 42385-102 J 42385-103 53.5 (2.10) 44.0 (1.73)
M8
3 J 42385-210 J 42385-206 J42385-207 J 42385-208 J 42385-209 22.5 (0.885) 17.5 (0.688)
x 1.25
M10 J 42385~ ·103
4 J 42385-104 J 42385-101 - J 42385-102 31.0 (1.22) 25.5 (1.0)
x 2:0
M10
5 J 42385-104 J 42385-101 - J 42385-102 J 42385-103 53.5 (2.10) 44.0 (1.73)
x 2.0 ..
M16
6
x 1.5 - - - - - - -
7 N/A - - - - - - -
M8
8 J 42385-210 J 42385-206 J 42385-207 J 42385-208 J 42385-209 22.5 (0.885) 17.5 (0.688)
x 1.25
M10
9
x 2.0
J 42385-104 J 42385-101 - J 42385-102 J 42385-103 31.0 (1.22) 25.5 (1.0)
M10
10-11
x 2.0
J 42385-104 J 42385-101 - J 42385-102 J 42385-103 53.5 (2.10) 44.0 (1.73)
M10
12
x 2.0
J 42385-104 J 42385-101 - J 42385-102 J 42385-103 31.0 (1.22) 25.5 (1.0)
Engine Block-Bottom View (cont'd)
Thread Counterbore (Maximum) (Maximum) (
M10
13-14
x 1.5
J 42385-215 J 42385-101 - J 42385-213 J 42385-214 42.5 (1.67) 37.0 (1.45)
M8
15 J 42385-210 J 42385-206 J 42385-207 J 42385-208 J 42385-209 22.5 (0.885) 17.5 (0.588)
x 1.25
..
M16
16
x 1.5
- - - - - - -
..
M10
17
x 2.0
J 42385-104 J 42385-101 - J 42385-102 J 42385-103 53.5 (2.10) 44.0 (1.73)
M10
18
x 2.0
J 42385-104 J 42385-101 - J 42385-102 J 42385-103 31.0 (1.22) 25.5 (1.0)
19
MB .J 42385-210 J 42385-206 J 42385-207 J 42385-208 J 42385-209 22.5 (0.885) 17.5 (0.588)
x 1.25
M10
20
x 2.0
J 42385-104 J 42385-101 - J 42385-102 J 42385-103 53.5 (2.10) 44:o (1.73)
M10
21
x 2.0
J 42385-104 J 42385-101 - J 42385-102 J 42385-103 31.0 (1.22) 25.5 (1.0)
MB .
22 J 42385-210 J 42385-206 J 42385-207 J 42385-208 J 42385-209 · 22.5 (0.885) 17.5 (0.688)
x.1.25
M10
23
x 2.0
J 42385-104 J 42385-101 - J.42385-102 J 42385-103 31.0 (1.22) 25.5 (1.0)
M10
24
x 2.0
J 42385-104 J 42385-101 - J 42385-.1 02 J 42385-103 53.5 (2.10) 44.0 (1.73)
25-26
MB J 42385-210 J 42385-206 J 42385-207 J 42385-208 J 42385-209 22.5 (0.885) 17.5 (0.688)
x 1.25 (
M10
27
x 2.0
J 42385-104 J 42385-101 - J 42385-102 J 42385-103 31.0 (1.22) 25.5 (1.0)
M10
·-
28-29
x 2.0
J 42385-104 J 42385-101 - J 42385-102 J 42385-103 53.5 (2.10) 44.0 (1.73)
M10
30
x2.0 J 42385-104 J 42385-101 - J 42385-102 J 42385-103 31.0 (1.22) 25.5 (lO)
31
MB J 42385-210 J 42385-206 J 42385-207 J 42385-208 J 42385-209 22.5 (0.885) 17.5 (0.688) ·.
x 1.25
M28
32
x 1.25
- - - - - - -
33
MB J 42385-210 J 42385-206 J 42385-207 J 42385-208 J 42385-209 22.5 (0.885) 17.5 (0.688)
x 1.25
M10
34
x 2;0
J.42385-104 J 42385-101 - J.42385-102 J 42385-103 53.5 (2.10) 44.0 (1.73)
M10
35
x 2.0
J 42385-104 J 42385-101 - J 42385-102 J 42385-103 31.0 (1.22) 25 . 5(1.0)
I>
M8
36 J 42385-210 J 42385-206 J 42385-207 J 42385-208 J 42385-209 22.5 (0.885) 17.5 (0.688)
x 1.25
• Bolt holes 2, 5, 10, 11, 18, 21, 24, 28, 29, and 34 have a 20.5 mm (0.807 in) counterbore included in the. 53.5 mm
(2.1 O in) drill depth.
O Bolt holes 1, 4, 9, 12, 17, 20, 23, 27, 30, and 35 have a 1.5 mm (0.059 in) counterbore included in the 31.0 mm (1.22 in)
drill depth. Use sleeve J 42385-316 with the drill and tap.
O Bolt holes 13 and 14 have a 11.5 mm (0.452 in) counterbore included in the 42.5 mm (1.67 in) drill depth. Use sleeve
.
(
Engine Block-Top View
) 14 i 2
) 10 9 8 7
64573
Engine Block-Top View

·-··
M8
1-4 J 42385-210 J 42385-206 J 42385-207 J 42385-208 J 42385-209 26.5 (1.04) 19.0 (0.784)
x 1.25
M16
5
x 1.5
- - - - - - -
M8
6-7 J 42385-210 J 42385-206 J 42385-207 J 42385-208 J 42385-209 26.5 (1.04) 19.0 (0.784)
x 1.25
M10
8 J 42385-216 J 42385-211 J 42385-212 J 42385-213 J 42385-214 22.5 (0.885) 17.0 (0.669)
xi .5
M8
-
9-10 J 42385-210 J 42385-206 J 42385-207 J 42385-208 J 42385-209 26.5 (1.04) 19.0 (0.784)
x i.25
M10
11 J 42385-216 J 42385-211 J 42385-212 J 42385-213 J 42385-214 22.5 (0.885) 17.0 (0.669)
x 1.5
-· 12-14 M8
-- --
,J 42385-210 J 42385-206 J 42385-207 J 42385-208 J 42385-209 26.5 (1.04) 19.0 (0.784)
x 1.25
~----·- ,~--.......----·
Cylinder Head-Top View
11 12
8 7 6
260168
Cylinder Head-Top View

MB
1-5 J 42385-210 J 42385-206 J 42385-207 J 42385-208 J 42385-209 26.5 (1.04) 19.0 (0.784)
x 1.25
6-9 M6 x 1.0 J 42385-205 J 42385-201 J 42385-202 J 42385-203 J 42385-204 20.05 (0.789} 16.05 (0.632}
(
MB
10-12 J 42385-210 J 42385-206 J 42385-207 J 42385-208 J 42385-209 26.5 (i .04} 19.0 (0.784)
x 1.25
(
Cylinder Head-End View
)
6)D v1
0 oe2
·. :J .
5
?-
4
~·
3
64503
Cylinder Head-End View

Hole Size Insert Drill Tool Tap Driver ·...· mm (in) mm (in)
M10
1
x 1.5 J 42385-215 J 42385-211 J 42385-212 J 42385-213 J 42385-214 w.o (1.10) 20.0 (0.787)
) 2 - NIA - - - - - -
M10
3 J 42385-215 J 42385-211 J 42385-212 J 42385-213 J 42385-214 '28.0 (1.10) 20.0 (0.787)
x 1.5
4 NIA - - - - - - -
M10
5-6 J 42385-215 J 42385-211 J 42385-212 J 42385-213 J 42385-214 28.0 (1.10) 20.0 (0.787)
x 1.5
6-268 Engine Mechanical - 5.. 7l Engine
Cylinder Head-Exhaust Manifold Deck View
64555
Cylinder Head-Exhaust Manifold Deck View

M10
1-2 J42385-215 J 42385-211 J 42385-212 J 42385-213 J 42385-214 28.0 (1.10) 20.0 (0.787)
x 1.5
MB
(
3 J 42385-210 J 42385-206 J 42385-207 J 42385-208 J 42385-209 21.0 (0.826) 16.0 (0.629)
x 1.25
M14
4
x 1.25 - - - - - - -
MB
5 J 42385-210 J 42385-206 J 42385-207 J 42385-208 J 42385-209 21.0 (0.826) 16.0 (0.629)
x 1.25
M14
6
x 1.25
- - - - - - -
MB
7-8 J 42385-210 J 42385-206 J 42385-207 J 42385-208 J 42385-209 21.0 (0.826) 16.0 (0.629)
x 1.25
M14
9
x 1.25
- - - - - - -
MB
10 J 42385-210 J 42385-206 J 42385-207 J 42385-208 J 42385-209 21.0 (0.826) 16.0 (0.629)
x 1.25
--- ~
M14
11
x 1.25 - - - - - - -
MB
12 J 42385-210 J 42385-206 J 42385-207 J 42385-208 J 42385-209 21.0 (0.826) 16.0 (0.629)
x 1.25
M12
--
13
x 1.5
- - - - - - -
·- f---,-~----
M10
14-15 J 42385-215 J 42385-211 J 42385-212 J 42385-213 J 42385-214 28.0 (1.10) 20.0 (0.787)
x 1.5
·-
(
Engine Engine Mechanical.- 5.7l 6-269
Cylinder Head-Intake Manifold Deck View
7 1 2
4 3
64557
-Cylinder Head-.lntake Manifold Deck View Drill Depth Tap Depth

1-2 M6 x 1.0 J 42385-205 J 42385-201 J 42385-202 J 42385-203 J 42385-204 Thru Thru
3-4 M6 x 1.0 J 42385-205 J 42385-201 J 42385-202 J 42385.-203 J 42385-204 22.5 (0.885) 15.0 (0.688)
5-7 M6 x 1.0 J 42385-205 J 42385-201 J.42385-202 J 42385-203 J 42385-204 Thru Thru
6-270 Engine Mechanical - S.7L Engine
Base Engine Misfire Diagnosis (
Checks Action
Engine performance diagnosis procedures are covered in Engine Controls and should be consulted for diagnosis of any
Driveability, Emissions, or Malfunctioning Indicator Lamp (MIL) concerns.
The following diagnosis covers common concerns and possible causes.
When the proper diagnosis is made, the concern should be corrected by adjustment, repair or replacement as required.
Refer to the appropriate section of the service manual for each specific procedure.
This diagnostic table will assist in engine misfire diagnosis due to a mechanical concern such as a faulty camshaft, worn or
damaged bearings or bent pushrod.
This table will not isolate a crossed injector wire, faulty injector or any other driveability component failure that may cause a
misfire.
The Powertrain On-Board Diagnostic System checks must be performed first.
When using this table to make a Base Engine Misfire diagnosis, begin with the preliminary information below and then
proceed to the specific category.
Preliminary 1. Perform OTC P0300 before proceeding with Base Engine Misfire Diagnosis
information.
OTC P0300 will assist in determining which cylinder or cylinders are misfiring.
2. Perform a visual inspection for the following:
• A loose or improperly installed engine flywheel or crankshaft balancer
• Worn, damaged, or misaligned accessory drive system components
3. Listen to the engine for any abnormal internal engine noises.
4. Inspect the engine for acceptable oil pressure.
Refer to Oil Pressure Diagnosis and Testing.
5. Verify if the engine has excessive oil consumption.
6. Verify if the engine has coolant consumption.
7. Perform a compression test on the engine. (
Refer to Engine Compression Test.
Intake Manifold Leaks An intake manifold that has a vacuum leak may cause a misfire.
• Improperly installed or damaged vacuum hoses
• Faulty or improperly installed intake manifold and/or gaskets
• Loose Exhaust Gas Recirculaton (EGR) valve pipe or damaged or missing
0-ring seal
• Cracked or damaged intake manifold
Inspect the areas between the intake runners.
• Improperly installed or damaged Manifold Absolute Pressure (MAP) sensor
housing (located at the rear of the intake manifold)
• Improperly installed or damaged MAP sensor housing 0-ring seal
• Improperly installed MAP sensor or vacuum hoses
The sealing grommet of the MAP sensor should not be torn or damaged.
O Improperly installed throttle body or damaged gasket
• A loose EGR valve pipe assembly or damaged or missing 0-ring seal

• Warped intake manifold
• Warped or damaged cylinder head sealing surface
Coolant Consumption Coolant consumption may or may not cause the engine to overheat.
• External coolant leaks
• Faulty cylinder head gasket
• Warped cylinder head
• Cracked cylinder head
• Damaged engine block
(
Engine Engine Mechanical - 5.7L s~211
Base Engine Misfire Diagnosis (cont'd)
Checks Action
Oil Consumption 1. Oil consumption may or may not cause the engine to misfire.
2. Remove the spark plugs and inspect for an oil fouled spark plug.
3. Perform a cylinder compression test.
Refer to Engine Compression Test.
4. If the compression test indicates worn valves or valve guides, inspect for the
following:
• Worn valve guides
• Worn valve stems
• Worn or burnt valves or valve. seats
• Worn, brittle, or improperly installed valve stem oil seals
5. 1.f the compression test indicates worn or damaged piston rings, inspect the
following: ·
• Broken or improperly seated piston rings
• Excessive piston ring end gap
• Excessive cylinder bore wear or taper
·• Cylinder damage
• Piston damage
Abnormal Internal Engine Noises 1. With the engine running try and determine if the noise is timed to camshaft
speed or crankshaft speed.
2 .. Using a timing light, two knocks per flash is crankshaft speed and one knock
per flash is camshaft speed.
3. If the noise is timed to camshaft speed, inspect the following:
• Missing or loose valve train components
• Worn or loose valve rocker arms
• Worn or bent pushrods
) • Faulty. valve springs
O Bent or burnt valves
• Worn camshaft lobes

O Worn or damaged timing chain and/or sprockets
Important: A slight .COLD knock or piston slapping noise could be considered

normal if not present after the engine has reached normal operating temperatures.
4. If the knock.is timed to crankshaft speed, inspect the following:
• Worn crankshaft main or connecting rod bearings
• Piston or cylinder damage
O Worn piston or piston pin
• Damaged or faulty connecting rod

• .Excessive carbon build-up on the top of the piston
No Abnormal Internal Engine Noise 1. Inspect for a worn or improperly installed timing chain and/or sprockets.
2. Remove the valve rocker arm cover on the side of the engine with the cylinder
that is misfiring.
• Loose valve rocker arm bolts
• Bent push rods
• Faulty valve springs
• Faulty valve lifters (bleeding down)
• Worn or improperly seated valves
• Worn camshaft lobes
Engine Compression Test 9. The minimum compression in any one cylinder
should not be less than 70 percent of the highest
1. Charge the battery if the battery is not fully cylinder. No cylinder should read less than
charged. · 690 kPa (100 psi). For example, if the highest
(
pressure in any one cylinder is 1035 kPa (150 psi),
the lowest allowable pressure for any other
3. Disable the fuel injection system. cylinderwould be 725 kPa (105 psi).
(1035 x 70% =725) (150 x 70% = 105).
4. Remove all the spark plugs.
•. No.rmal - Compression builds up quickly and
· 5. Block the throttle plate wide open. evenly to the specified compression for each
cylinder.
6. Start with the compression gauge at zero, and
crank the engine through four compression • Piston Rings Leaking - Compression is low
on the first.stroke. Compression then builds
strokes (four puffs).
· up with the following strokes but does not
. 7. Make the compression check for each cylinder. reach normal. Compression improves
Record the reading. considerably when you add oil.
• Valves Leaking - Compression is low on the
8. If a cylinder has low compression, inject firststroke: Compression usually does not
approximately 15 ml (one tablespoon) of engine build up on the following strokes. Compression
oil into the combustion chamber through the spark does not improve much when you add oil.
plug hole. ' " lftvito adjacent cylinders have lower than
Recheck the compression and record the reading. normal compression and injecting oil into
the cylinders does not increase the
cornpression, the cause may be a head gasket
· leaking between the cylinders.
Engine Noise Diagnosis
Symptom Cause
There are four steps to diagnosing engine noise. You must determine the following:
• The type of noise
For example, is the noise a light rattle/tapping or a low rumble/knocking?
(
• The exact operating condition under which the noise exists.
Note factors such as the ambient temperature, the amount of engine warm-up time, the engine temperature, engine
RPMs, and other specifics.
• At what rate the noise. occurs, and at what location in the engine .
Remember, engine noi~es are generally synchronized to either engine speed (crankshaft, flywheel, connecting rods,
balancer, or pistons and related components) or one-half engine speed (valve train noise such as rocker arms, valve
lifters, and timing chain). Try to determine the rate at which the noise is occurring,
• Compare the engine .sounds to other engines and make sure you are not trying to correct a normal condition.
Noise on Start-Up but Only Lasts a O Improper oil viscosity. Install the recommended oil viscosity. for the expected
Few Seconds temperatures.
• Incorrect oil filter without the anti-drainback feature
• Worn or dirty valve lifters
• Excessive piston to bore clearance
• Excessive piston pin to piston clearance
• Excessive crankshaft bearing clearance
Knocks Cold and Continues for • Loose or broken crankshaft balancer or accessory drive components
1 to 2 Minutes • Excessive piston to bore clearance
A cold piston knock which disappears in 1.5 minutes should be considered
acceptable.
• A cold engine knock usually disappears when the specific cylinders secondary
ignition circuit is grounded out.
Intermittent Noise on Idle, • Improper oil viscosity. Install the recommended oil viscosity for the expected
Disappearing When Engine Speed is temperatures.
Increased • Lower than specified oil pressure
Install an oil pressure gauge and measure the engine oil pressure.
(
• Dirty or worn valve lifter
Engine Noise Diagnosis (cont'd)
Symptom Cause
Valve Train Noise (Rattle/Tapping) The following conditions may cause valve train noise:
• Lower than specified oil pressure
• Worn or faulty oil pump
• Loose oil pump-to-engine block bolts
• Loose valve rocker arm attachments
• Worn valve rocker arm bearings
• Worn valve rocker arm and/or pushrod
• Broken valve spring
• Sticking valves
• Worn, dirty, or faulty valve lifters
• Worn camshaft lifter lobes
• Worn valve guides or valve stems
• Bent, broken, or damaged timing chain sprocket teeth
Knocks at Idle Hot The following conditions may cause a knocking noise:
(Rumble/Knocking) • Malfunctioning accessory drive system components
• Loose or broken crankshaft balancer
• Loose prop shaft hub or clamp (Corvette only)
• Detonation or spark knock
Check for proper operation of the cooling, knock, and ignition control
components.
Refer to diagnostic information. in Engine Controls.
• Excessive connecting rod bearing clearance
• Excessive piston pin to bore clearance
• Bent connecting rod
• Excessive crankshaft main or thrust bearing clearance
• Loose torque converter bolts
• Cracked or damaged flywheel
• Exhaust leak at the manifold
Exhaust System Noise and/or · Exhaust system noise and/or leakage may be caused by the following conditions:
Leakage • Improperly installed or misaligned exhaust system components
• A cracked or broken exhaust manifold
• Damaged or worn gaskets and/or seals
• Burned or rusted out exhaust system components
• A broken or loose exhaust clamp and/or bracket
6·274 Engine Mechanical- 5.7L Engine
Valve Train Diagnosis
Symptom Cause
• A light tapping noise at one-half engine speed, or any varying frequency, may indicate a valve train problem. (
• These tapping noises will typically increase with engine speed.
• Before attempting to diagnose valve train noise, check for the proper oil level and thoroughly warm up the engine.
By doing this you will bring all engine components to a normal state of expansion.
• While sitting in the drivers seat, run the engine at various speeds and listen for any abnormal engine noise.
• Whenever Valve Lifter Diagnosis is necessary, always. use a listening device such as and engine stethoscope, or
listening ears J 39565. These tools will help to isolate any lifter noise and identify noises that could be mis-diagnosed as
lifter noise.
A light tapping noise similar to valve • Fuel injectors
train noise may be caused by the • Evaporative emission (EVAP) purge solenoid
following components: O
Detonation
O
Loose heat shields
The Causes of Valve Train Noise . • Poor oil quality caused by water contamination, aeration, or fuel dilution
May Include the Following Conditions: • Low engine oil pressure
• Worn or faulty oil pump
• A loose or plugged oil pump screen
0 Loose valve rocker arm attac.hments (causing excessive valve lash)
• Worn or damaged valve rocker .arm bearings
• Worn valve rocker ar.m and/or pushrod
O Broken valve spring
• Sticking valves
• Valve lifters worn, dirty, or faulty
• Broken valve lifter guide
• Camshaft valve lifter lobes worn
• Worn valve guides or valve stems
• Worn, damaged, or missing valve keys
(
• Bent pushrods
• Excessive play in the camsha~ timing chain
• Bent, broken, or damaged timing chc:1in sprocket teeth
(
Diagnostic Table
DEFINITION: A light tapping noise at one half engine speed, or any varying frequency.
1 Is there valve train noise? - Go to Step 2 System OK
Check for a high engine oil level. A engine with the oil
level above the FULL mark allows the crankshaft
counterweights to churn the oil into foam. When foamy oil
2 is pumped into the lifters, the lifters become noisy. A solid - Drain the oil to
column of oil ensures proper lifter operation. the proper level.
Is the oil level too high? System OK Go to Step 3
Check for a low engine oil level. A engine with the oil level
below the ADD mark may allow the oil pump to pump air Add oil as
3 at high engine RPMs. - required.
Is the oil level too low? System OK Go to Step 4
Check for proper engine oil pressure. Refer to Engine
Mechanical Specifications and Oil Pressure Diagnosis and
4 Testing. -
Is the engine oil pressure within specifications? Go to Step 7 Go to Step 5
1. Check the oil pump screen for damage or a loose fit
to the oil pump.
2. Inspect for a missing or damaged oil pump screen
5 -
0-ring seal. Repair as
Is the oil pump screen loose or is the screen or 0-ring required.
seal damaged? System OK Go to Step 6
Check for a damaged oil pump or loose mounting bolts
Repair as
6 Refer to Oil Pump Clean and Inspect - required.
Is the oil pump damaged or are the fasteners loose? System OK Go to Step 10
Remove and inspect the valve lifters, guides, rocker arms,
and pushrods. Refer to Valve Rocker Arm and Push Rods Replace the
7 Clean and Inspect and Valve Lifters and Guides Clean and - components as
Inspect. required.
Are components worn or damaged? System OK Go to Step B
Perform a camshaft lobe lift test. Refer to Camshaft and Replace the
camshaft and
8 Bearings Clean and Inspect - Camshaft is OK valve lifters.
Is the test within Engine Mechanical Specifications ? Go to Step 9 System OK
Remove the engine front cover and inspect the timing
chain and sprockets for excessive wear or damage.
Refer to Timing Chain and Sprockets Clean and Inspect
9 Important: Pushrod engines are designed so that a timing -
chain more than one tooth improperly positioned will cause Replace the
valve interference with the piston. components as
Are the components worn or damaged, or improperly required.
positioned? System OK Go to Step 10
Perform a complete disassembly of the engine and inspect Replace the
all components. components as
10 - required. -
Are the components worn or damaged?
System OK
6-276 Engine·Mechanical - 5.7l Engine
Oil Consumption Diagnosis
Checks Causes
Excessive oil consumption (not due to leaks) is the use of 0.95 liters (1.0 qt) or more of engine oil within 2414 kilometers
(1,500 miles),
(
Preliminary The causes of excessive oil consumption may include the following conditions:
• External oil leaks
Refer to oil leak diagnosis.
• Incorrect oil level or improper reading of the oil level indicator
With the vehicle on a level surface, run the engine for a few minutes, allow
adequate drain down time (2-3 minutes) and check for the correct engine
oil level.
• Improper oil viscosity
Refer to the vehicle owners manual and use the recommended SAE grade and
viscosity for the prevailing temperatures.
• Continuous high speed driving and/or severe usage
• Crankcase ventilation system restrictions or malfunctioning components
• Worn valve guides and/or valve stems
Refer to Cylinder Head Clean and Inspect.
• Worn or improperly installed valve stem oil seals
• Piston rings broken, worn, not seated properly
Allow adequate time for the rings to seat.
Replace worn piston rings as necessary.
• Piston and rings improperly installed or miss-fitted to the cylinder bore
Oil Pressure Diagnosis and Testing 4. Listen for a noisy valve train or a knocking noise.
5. lnspct for the following:
Tools Required " Oil diluted by water or glycol (anti freeze)
• J 21867 Pressure Gauge and Hose Assembly • Foamy oil
• J 42907 Oil Pressure Testing Tool 6. Remove the oil filter and install the J 42907. (
7. Install J 21867 or equivalent to the J 42907.
8. Run the engine and measure the engine oil
pressure.
9. Compare the readings. to Engine Mechanical
Specifications.
10. If the engine oil pressure is below specifications,
inspect the engine for one or more of the following:
.. Oil pump worn or dirty
Refer to Oil Pump Clean and. Inspect.
0 Oil pump-to-engine block bolts .loose
Refer to Oil Pump, Pump Screen and Deflector

Installation.
" Oil pump screen loose, plugged, or damaged
O Oil pump screen 0-ring seal missing· or
damaged
" Malfunctioning oil pump pressure
regulator valve
" Excessive bearing clearance
.. Cracked, porous, or restricted oil galleries
416607 • Oil gallery plugs missing or incorrectly installed
1. With the vehicle on a level surface, run the Refer to Engine Block Plug Installation.
vehicle for a few minutes, allow adequate .. Broken valve lifters
drain down time (2-3 minutes) and measure for a Repair as necessary
low oil level. i 1. If the oil pressure reading on the J 21867 or
2. If required, add the recommended grade engine equivalent is within specifications, inspect for
oil and fill the crankcase until the oil level the following:
measures full on the oil level indicator. 0
Plugged or incorrect oil filter and/or (
3. Run the engine briefly (10-15) seconds and verify malfunctioning oil bypass valve
low or no oil pressure on the vehicle gauge .. Malfunctioning oil pressure gauge or sensor
or light. Repair as necessary
Oil Leak Diagnosis
Important: You can repair most fluid leaks by first visually locating the leak, repairing or replacing the component, or by
resealing the gasket surface. Once the leak is identified, determine the cause of the leak. Repair the cause of the leak as
well as the leak itself.
1. Operate the vehicle until it reaches normal operating
temperature.
4. Check for drippings.
Are drippings present? Go to Step2 System OK
2 location of the leak?
3
• Fittings
-
components.
normal operating temperature and at varying speeds.
) 5. Identify the type of fluid, and the approximate location
of the leak.
5 -
• Fittings
location of the .leak? Go to Step 10 Go to Step 6
components.
2. Apply an aerosol-type powder (baby powder, foot
powder, etc.) to the suspected area.
6 normal operating temperature and at varying speeds. -
of the leak, from the discolorations in the powder
surface.
7 -
• Fittings
6-278 Engine Mechanical - 5~7l Engine
Oil Leak Diagnosis (cont'd)
Step Action : Value(s) Yes No
Use. J 28428-E in order to identify the type of fluid, and the (
approximate l9cation .of the leak. Refer to the
8 manufacturer's instructio.ns when using the tool. -
Can you identify the type offluid and the approximate ,,·,
location of the leak? Go to Step 10 Go to Step9
9 -
• Fittings
• Cracked or damaged components ·•

location of the leak? Go to Step 10 System. OK
..
1. Inspect the engine for mechanical damage. Special
attention should be shown to the following areas:
• Higher than recommended fluid levels
• Higher than recommended fluid pressures
• Plugged or malfunctioning .fluid filters or pressure
bypass valves · · ..
• Plugged or malfunctioning engine ventilation
system ·
10 • Improperly tightened or damagi:3d fasteners -
• Cracked or porous components
• Improper sealants or gaskets where required
• Improper sealant or gasket installation
• Damaged or worn gaskets or seals .. ,·,
• Damaged or worn sealing surfaces
2. Inspect the engine for customer modifications. (
Is there mechanical damage, or customer modifications to
the engine? Go to Step 11 System OK
Repair or replace all damaged or modified components.
11 -
Does the engine still leak oil? G.o to Step 1 System OK
Symptoms - Drive Belt Intermittent

• Drive belt symptoms may be from intermittent
Important: Review the drive belt system operation in
failure of an accessory drive component.
order to familiarize yourself with the system
functions. Refer to Drive Belt System Description. .. Drive belt symptoms may occur from changes in
load of the accessory drive components.
" Ambient temperatures, moisture, or engine
• Inspect for aftermarket devices which could affect operating temperature can affect the drive
the operation of the drive belts. belt operation.
Symptom list
which could cause the symptom. Refer to a symptom diagnostic procedure from the
following list in order to diagnose the symptom:
• Inspect the drive belt for excessive wear,
shredding, or missing sections. • Drive Belt Chirping Diagnosis
• Inspect the drive belt for contamination of O Drive Belt Squeal Diagnosis
excessive dirt, oil, coolant or ot_her substances O Drive Belt Whine Diagnosis
that may affect the drive belt operation. O Drive Belt Rumbling Diagnosis
.. Drive Belt Vibration Diagnosis

• Drive Belt Falls Off Diagnosis
• Drive Belt Excessive Wear Diagnosis
(
Diagnostic Aids 6. Misalignment of the pulleys may be caused from
The symptom may be intermittent due to moisture on improper mounting of the accessory drive
the drive belt(s) or the pulleys. It may be necessary component, incorrect installation of the accessory
to spray a small amount of water on the drive belt(s) in drive component pulley, or the pulley may be
order to duplicate the customers concern. If spraying bent inward or outward from a previous repair.
water on the drive belt(s) duplicates the symptom, Test for a misaligned pulley using a straight edge
cleaning the belt pulleys may be the probable solution. in the puUey grooves across two or three pulleys.
If a misaligned pulley is found refer to that
A loose or improper installation of a body component, accessory drive component for the proper
a suspension component, or other item(s) on the installation procedure for that pulley.
vehicle may cause the chirping noise.
Test Description possibility that a wrong bolt, nut, spacer, or washer
The number(s) below refer to the step number(s) on was installed.
the diagnostic table. 12. Inspecting the pulleys for being bent should
2. The noise may not be engine related. This step is include inspecting for a dents or other damage to
to verify that the engine is making the noise. If the pulleys that would prevent the drive belt(s)
the engine is not making the noise do not proceed from not seating properly in all of the pulley
further with this table. grooves or on the smooth surface of a pulley when
the back side of the belt is used to drive the
3. The noise may be an internal engine noise. pulley.
Remove the drive belt(s) and operate the engine
for a brief period, this will verify if the chirping 14. Replacing the drive belt(s) when it is not damaged
noise is related to the drive belt(s). With the drive or there is not excessive pilling will only be a
belt(s) remove the water pump may not be temporary repair.
operate and the engine may overheat. Also DTCs
may set when the engine is operated with the
drive belt(s) removed.
4. Inspect all drive belt pulleys for pilling. Pilling is
the small balls or pills or it may be strings in
) the drive belt grooves from the accumulation of
rubber dust.
Step Action Yes No
Notice: Refer to Belt Dressing Notice in Cautions and Notices. (
DEFINITION: The following items are indications of chirping:
• A high pitched noise that is heard once per revolution of the drive belt or a pulley.
• Chirping may occur on cold damp startup conditio.ns and will subside once the vehicle reaches normal operating
temperature.
1
perform the necessary inspections? Go to Step 2 Drive Belt
Verify t.hat there is a chirping noise. Go to
2
Does the engine make the ch\rping noise? Goto Step 3 .· Diagnostic Aids
3 2. Operate the engine for no longer than 30 to 40 seconds. Go to Engine Noise
Does the chirping noise still. exist? Diagnosis Go to Step4
Inspect for sel,'.ere pilling exceeding 1/3 of the belt groove depth.
4
Does the belt grooves have pilling? Go to Step 5 Go to 8tep6
Clean the drive belt pulleys with a suitable wire brush.
5
Were the drive belt pulleys cleaned? Go toStep 15 Go toStep6
Inspect for a misalignment of the pulleys.
6
Are any of the pulleys misi:\ligned? Go to Step7 Go to Steps
'
Replace and/or repair any misaligned pulleys.
7
Were the misaligned pulleys repaired and/or replaced? Go to Step 1.5 Go to.Steps
Inspect for bent and/or cracked brackets.
8
Did you find any bent and/or cracked brackets? Go to Step 9 Go to Step 10
Replace any bent and/or cracked brackets.
9
Were the bent and/or cracked brackets replaced? Go to Step 15 Go to Step 10
10
Inspect for improper, missing and/or loose fasteners. c
(
Were there any improper, missing and/or loose fasteners? Go to Step 11 Go to Step 12
Replace any improper and/or missing fasteners.
11 Tighten any loose fasteners. Refer to Fastener Tightening
Specifications.
Inspect for a bent pulley.
12
Did you find the condition? Go to Step 13 Go to Step 14
Replace the bent pulley.
13
Was the bent pulley replaced? Go to Step 15 Go to Step 14
Replace the drive belt(s). Refer to Drive Belt Replacement -
Accesso,y or Drive Belt Replacement - A/C. Go to
Was the drive belt(s) replaced? Go to Step 15 Diagnostic Aids
15
Does the drive belt still chirp? Go to Step 3 System OK
(
Diagnostic Aids the accessory drive components for smooth . .
A loose or improper installation of a body component, operation. Test the accessory drive components
a suspension component, or other items on the with the engine operating by varying the load ·
vehicle may cause the squeal noise. bn the components to verify that the components
operate properly. ·
If the noise is intermittent, verify that the accessory
drive components are not the cause, by varying their 5, This test is to verify that the drive belt(s) tensioner
loads making sure they are operating to their operates properJy. If the drive belt tensioner is not
maximum capacity. An overcharged A/C system, a operating properly; proper belt tension may not
power steering system restriction, or incorrect fluid, or be achieved to keep the drive belt from slipping
a failing generator are suggested items to inspect which could cause a belt squeal noise.
Test Description 6. This test is to verify that the drive belt(s) is not to
The number(s) below refer to the step number(s) on long, which would prevent the drive belt tensioner
the diagnostic table. from operating properly. Also if an incorrect
2. The noise may not be engine related. This step is length drive belt(s) were installed, it may not be
to verify that the engine is making the noise. If routed properly and may be turning an accessory
the engine is not making the noise do not proceed drive component in the wrong direction. ··
further with this table. 7. Misalignment·of the pulle!ys may be.caused from
3. The noise may be an internal engine noise. improper mounting of the accessory drive
Remove the drive belt(s) and operate the engine component, incorrect .installation of the accessory
for a brief period, this will verify that the squeal drive component pulley, or the pulley is bent
noise is the drive belt(s) or an accessory inward or outward from a previous repair. Test for
drive component. With the drive belt(s) removed a misaligned pulley using a straight edge in the
the water pump may not operate and the pulley grooves across two or three pulleys. If
engine may overheat. Also DTCs may set when a misaligned pulley is found refer to that accessory
the engine is operated with the drive belt(s) drive c;omponent for the proper installation
removed. procedure for that pulley ..
4. This test is to verify that a:n accessory drive 8.. This test is to verify _that the pulleys are the ·
component does not have a seized bearing. With correct diameter or width. Using a known good
the drive belt(s) removed test the bearings in vehicle to compare the pulley sizes.
Step Action Yes No
Notice:. Refer to Belt Dressing Notice in Cautions and Notices. (
DEFINITION: The.following items.are indications of.drive belt squeal:
• .A loud screec~ing nois.e that is caused bya slipping drive belt {this is unusual for a .drive belt with multiple ribs)
• The noise occurs when a heavy load is applied to the drive belt, such as an air conditioning compressor engagement
snapping the throttle, or slipping on a seized pulley or a faulty accessory drive component.
Did you. review the. Symptoms - Drive Belt diagnostic information and Go to Symptoms -
1
perform the necessary inspections? . Go to Step2 Drive Belt
Verify that there )s a squeal rioise. Go to
2
Doesthe engine make the squeal noise? Go to Step 3 Diagnostic Aids
1.. Remove the.drive belt(s).
3 2.. Operate the engine for no longer than 30 to 40 seconds. Go to Engine Noise
Does the squeal noise still exist? Diagnosis Go to Step4
Inspect for an accessory drive component seized bearing or a faulty
4 acGessory drive component.
Did you firid and correct the condition? Go to Step 9 Go to Steps
lnspectthe drive belt tensioner for proper operation. Refer to Drive
Did. you find and correct the condition? Go to Step 9 Go to Step6
Check for the correct drive belt length. Refer to Drive Belt
6 Replacement - Accessory or Drive· Belt Replacement - A!C.
Inspect for misalignment of a pulley.
7
Did you find and correct the condition?. Go to Step 9 Go to StepB
Inspect for the correct pulley size. Go to
8
Did you find. and .correct the condition? Go to Step 9 Diagnostic Aids
(
9
Does the drive belt still squeal? Go to Step 3 System OK
Diagnostic Aids water pump may not operate and the engine may
The drive belt(s) will not cause the whine noise. overheat. Also DTCs may set when the engine
is operated with the drive belt(s) removed.
If the whine noise is intermittent, verify that the
accessory drive components are not the cause, by 4. The inspection should include checking the drive
varying their loads making sure they are operating to belt tensioner and the drive belt idler pulley
their maximum capacity. An overcharged A/C bearings. The drive belt(s) may have to be
system, a power steering system restriction, or installed and the accessory drive components
incorrect fluid, or a failing generator are suggested operated separately by varying their loads. Refer
items to inspect. to the suspected accessory drive component
Test Description for the proper inspection and replacement
procedure.
3. This test is to verify that the noise is being caused
by the drive belt(s) or the accessory drive
components. With the drive belt(s) removed the
Step Action Yes No
DEFINITION: A high pitched continuous noise that may be caused by an accessory drive component failed bearing.
Did you review the Symptoms · Drive Belt diagnostic information and Go to Symptoms -
1
Verify that there is a whine noise. Go to
2
Does the engine make the whine noise? Go to Step 3 Diagnostic Aids
1. Remove the drive belt(s).
3 2. Operate the engine for no longer than 30 to 40 seconds.
) Does the whine noise still exist?
Go to Engine Noise
Diagnosis Go to Step4
Inspect for a failed accessory drive component bearing. Goto
4
Did you find and repair the condition? Go to Step5 Diagnostic Aids
5
Does the drive belt still whine?
-
System OK
Engine
Diagnostic Aids 3. This test is to verify that the drive belt(s) is
Vibrationwhen the' engine is operating may cause a causing the rumbling noise. The rumbling noise (
body component or another part of the vehicle to may be confused with an internal engine
produce a rumbling no.ise. · noise due to the similarity in the description.
Remove only one drive belt at a time if the vehicle
The drive belt(s) may have a condJtion that can not be
seen or felt. So.metimes replacing the drive qelt(s) has multiple drive belts. With the drive belt(s)
may be.the only repair forth.e symptom. removed the water pump may not operate and the
engine may overheat. Also DTCs may set when
If after replacing the drive belt(s) and completing the the engine is operating with the drive belt(s)
diagnostic table, the noise is only heard with the removed.
drive belt(s) installed; there may be an accessory drive
component failure. Varying the load on the accessory 4. Inspect the drive belt(s) to ensure that the drive
drive components may aid in identifying which belt is not the cause of the noise. Small cracks
accessory drive component is causing the across the ribs of the drive belt will not cause the
rumbling noise. rumbling noise. Belt separation is identifi'3d by
the plys of the drive belt separating, this may be
Test Description seen at the edge of the belt or felt as a lump
The number(s) below refer to the step number(s) on in the belt.
the diagnostic table. 5. Small amounts of pilling is a normal condition and
2. Thi.s test is to verify that the symptom is present acceptable. When the pilling is severe the drive
during diagnosing. Other vehicle components belt does not have a smooth surface for
may cause a similar symptom. proper operation.
Step Action Yes No
Notice: R~fer. tq Belt Ores.sing Notice in Cautions and Notices.
DEFINITION:
• A low pitch tapping, knocking, or thumping noise heard at or just above idle.
• Heard once per revolution of the drive belt or a pulley. (
• Rumbling may be caused. from:
- Pilling, the accumulation of rubber dust that forms small balls (pills) or strings in the drive belt pulley groove
..:.. The sepa.ration of the drive belt
- A damaged drive belt
-
.;
[)id yOu review the Symptoms - Drive Belt diagnostic information and Go to Symptoms -
1
perform the necessary inspections? Go to Step 2 Drive Belt
Verify that there is a rumbling noise. Go to
2
Does the engine make the rumbling noise? Go to Step 3 Diagnostic Aids
1. Remove the drive belt(s).
3 2. Operate the engine for no longer than 30 to 40 seconds. Go to Engine Noise
Does the rumbling noise still exist? Diagnosis Go to Step4
-
Inspect the drive belt(s) for damage, separation, or sections of
4 missing ribs.
Did you find any of these conditions? Go to Step 7 Go to Step 5
Inspect for severe pilling of more than 1/3 of the drive belt pulley
5 grooves.
Did you find severe pilling? Go to Step 6 Go to Step 7
1. Clean the drive belt pulleys using a suitable wire brush.
2. Reinstall the drive belt. Refer to Drive Belt Replacement -
6
Accessory or Drive Belt Replacement - AIC.
Install a new drive belt. Refer to Drive Belt Replacement - Accessory
7 or Drive Belt Replacement - A/C. -
Run the engine in order to verify the repair. Go to
8
does the drive belt still rumble? Diagnostic Aids System OK
Drive Belt Vibration Diagnosis 4. The drive belt(s) may cause a vibration. With the
drive belt(s) removed inspect the condition of
Diagnostic Aids the drive belt.
The accessory drive components may have an affect
on engine vibration. An overcharged A/C system,
possibility that a wrong bolt, nut, spacer, or washer
a power steering system restriction, or incorrect fluid,
was installed.
or an extra load placed on the generator are some
systems that should be inspected. To help identify an 8. This step should only be performed if the cooling
intermittent or an improper condition, vary the loads fan is driven by the drive belt. Inspect the engine
on the accessory drive components. · cooling .fan for bent, twisted, loose, or .cracked
Test Description blades. Inspect the fan clutch for smo.oth
operation. Inspect for a bent fan shaft or a bent
The number(s) below refer to the step number(s) on mounting flange.
9. This step should only be performed if the water
2. This test is to verify that the symptom is present
pump is driven by the drive belt Inspect the
during diagnosing. Other vehicle components
water pump shaft for being bent Also inspect the
may cause a similar symptom such as the exhaust
system, or the drivetrain. water pump bearings for smooth operation and
excessive play .. Compare the water pump
3. This test is to verify that the drive belt(s) or with a known, good water pump.
accessory drive components may be causing the
vibration. With the drive belt{s) removed the 10. Accessory drive component brackets that are
water pump may not operate and the engine may bent, cracked, or loose may put an extra strain on
overheat. Also DTCs may set when the engine that accessory component causing it to vibrate.
is operated with the drive belt(s) removed.
)
Step Action Yes No
DEFINITION: The following items are indications of drive belt vibration:
• The vibration is engine-speed related.
• The vibration may be sensitive to accessory load.
Did you review the Symptoms -Drive Belt diagnostic information and Go to Symptoms -
1
Verify that the vibration is engine related. Go to
2
Does the engine make the vibration? Go to Step 3 Diagnostic Aids
1. Remove the drive belt (s). Go to Engine
2. Operate the engine for no longer t.han 30 to 40 seconds. Related Vibration in
3
Vibration and
Does the engine still make the. vibration? Diagnosis Go to Step4
Inspect the drive belt for wear, damage, debris build-up and missing
4 drive belt ribs.
Did you find any of these conditions? Go to Step 5 Go to Step6
Install a new drive belt. Refer to Drive Belt Replacement - Access01y
6
Did you find any of these conditions? Go to Step 7 Go to StepB
7 Tighten any loose fasteners. Refer to Fastener Tightening -
Specifications.
Inspect for damaged fan blades or a bent fan clutch shaft, if the fan
8 is belt driven.
Inspect for a bent water pump shaft, if the water pump is belt driven.
9 Refer to Water Pump Replacement (5. 7 L) in Engine Cooling.
Inspect for bent or cracked brackets. Go to
10
Did you find and correct the condition? Go to Step 11 Diagnostic Aids
11 -
Does the drive belt still vibrate? System OK
Diagnostic Aids drive component pulley, or the pulley is bent
I If the drive belt(s) repeatedly falls off the drive belt inward or outward from a previous repair. Test for
pulleys, this may be caused by pulley misalignment. a misaligned pulley using a straight edge in the
pulley grooves across two or three pulleys. If
An extra load that is quickly applied or released by an
a misaligned pulley is.found refer to that accessory
accessory drive component may cause. the drive
belt(s) to fall off the pulleys. Verify that the accessory· drive component for the proper installation
procedure of that pulley. ·
drive components operate properly:
If the drive belt(s) is the incorrect length, the drive belt 5. Inspect the pulleys for dents, bends or other
tensioner may not maintain the proper tension on damage. Damage to the pulleys would prevent the
the drive belt. drive belt(s) from seating properly in the pulley
grooves. Damage would also prevent proper
Test Description alignment of the drive belt to pulley, when
The number(s) below refer to the step number(s) on the smooth surface of the drive belt is required to
the diagnostic table. · · drivethe pulley.
2. This inspection is to verify the condition of the 6. Accessory drive component brackets that .are bent
drive belt(s). Damage may have occurred to or cracked will allow the drive belt(s) to fall off the
the drive belt when the drive belt(s) fell off the pulley.
pulley. The drive belt(s) may have been damaged 7. Inspection of the fasteners can eliminate the
in which case caused the drive belt to fall off possibility that a wrong bolt, nut, spacer, or washer
the pulley. Inspect the drive belt(s) for cuts, tears, was installed. Missing, loose, or incorrect
sections of ribs missing, or damaged belt plys. fasteners may cause pulley misalignment from the
4. Misalignment of the pulleys may be caused from bracket moving under load. Over tightening of
improper mounting of the accessory drive the fasteners may also cause misalignment of the
component, incorrect installation of the accessory · accessory component bracket.
)
Step Action Yes No
Notice: Refer to Belt Dressing Notice in Cautions and Notices. (
DEFINITION: The drive belt falls off the pulleys or may not ride correctly on the pulleys.
1
Inspect for a damaged drive belt.
2
Did you find the condition? Go to Step 3 Go to Step4
Install a new drive belt. Refer to Drive Belt Replacement - Accessory
3 or Drive Belt. Replacement - A/C.
Inspect for misalignment of the pulleys.
4
Did you find and repair the condition? Go to Step 12 Go to Step5
Inspect for a bent or dented pulley.
5
Inspect for a bent or a cracked bracket.
6
7
Did you find loose or missing fasteners? Go to Step 8 Go to Step9
Specifications.
8
Does the drive belt continue to fall off? Go to Step9 System OK
Test the drive belt tensioner for operating correctly. Refer to Drive
Does the drive belt tensioner operate correctly? Go to Step 11 Go to Step 10
Replace the drive belt tensioner. Refer to Drive Belt Replacement - (
10 Accessory or Drive Belt Replacement - A/C.
Inspect for failed drive belt idler and drive belt tensioner pulley
11 bearings. Go to
12 -
Does the drive blet still fall off? System OK
) Diagnostic Aids 3. The installation of a drive belt that is to wide or to
Excessive wear on a drive belt(s) is usually caused by narrow will cause wear on the drive belt(s). The
incorrect installation or the wrong drive belt(s) for drive belt ribs should match all of the grooves
the application. on the pulleys.
Minor misalignment of the drive belt pulleys will not 4. This inspection is to verify the drive belt(s) is not
cause excessive wear, but will probably cause contacting any parts of the engine or body while
the drive belt(s) to make a noise or to fall off the the engine is operating. There should be sufficient
pulley(s). clearance when the drive belt accessory drive
Excessive misalignment of the drive belt pulleys will components load varies. The drive belt(s) should
cause excessive wear and may also make the not come in contact with an engine or a body
drive belt(s) fall off the pulley(s). component when snapping the throttle.
Test Description
The number(s) below refer to the step .number(s) on
the diagnostic .table. ·
2. The inspection is to verify that the drive belt(s) is
correctly installed over all of the drive belt
pulleys. Wear on the drive belt(s) may be caused
by mis-positioning the drive belt(s) by one groove
on a pulley.
Step Action Yes ·. No
Notir:e: Refer to BeltDressing Notice in Cautions and Notices.
DEFINITION: Wear at the outside ribs of the drive belt(s) due to an incorrectly installed drive belt(s).
Did you review the Symptoms - Drive Belt diagnostic information and Go tci Symptoms -
1
) Inspect the drive belt(s) for the proper installation. Refer to Drive Belt :
2 Replacement - Accesso,y or Drive. Belt Replacement - AIC.

Inspect for the proper drive belt.
3.
Did you. find this condition? Go to Step 5 Go to Step 4
Inspect for the drive belt rubbing against a bracket, hose, or wiring
4 harness. Go to
Did you find and repair the .condition? Go to Step 6 Diagnostic Aids
Replace the drive belt. Refer to Drive Belt Replacement - Accesso,y
6
Is there still excessive drive belt wear?
-
System OK
Drive Belt Tensioner Diagnosis 3. Move the belt tensioner through it's full travel.
• The movement should feel smooth.
Important: When the engine is operating, the belt
tensioner arm will move. Do not replace the. belt • There should be no binding.
tensioner because of movement in the belt • The belt tensioner should return freely.
tensioner arm. 4. If any binding is observed, replace the drive belt
tensioner. Refer to Drive Belt Tensioner
Notice: Allowing the drive belt tensioner to snap into Replacement - Accessory or Drive· Belt Tensioner
the free positio.n may result in damage to the Replacement - AIC. ·
tensioner. 5. Install the drive belt. Refer .to Drive Belt
Replacement - Accessory or Drive· Belt
1. Remove the drive belt. Refer to Drive Belt Replacement - AIC.
Replacement - Accessory or Drive Belt
Replacement - AIC.
pulley bolt.
6-290 Engine Mechanical - s~7L Engine
Disassembled Views (
Intake Manifold/Upper Engine
21~
17
12
363236
Legend
(1)Fuel Rail (with Injectors) (12) Valley Cover
(2)Fuel Rail Bolt (13) Valley Cover Bolt
(3)Fuel Rail Stop Bracket (14) Knock Sensor Oil Seal
(4)Intake Manifold Gasket (15) Knock Sensor
(5)Manifold Absolute Pressure (MAP) Sensor (16) Knock Sensor Wire Harness
(6)Intake Manifold Bolt (17) Engine Coolant Air Bleed Hose
(7)Intake Manifold (18) Engine Coolant Air Bleed Pipe Stud
(8)Throttle Body Gasket (19) Engine Coolant Air Bleed Pipe
(9)Throttle Body (20) Engine Coolant Air Bleed Pipe Gasket (
(1 O)Throttle Body Bolt (21) Engine Coolant Air Bleed Pipe Bolt
(11) Valley Cover Gasket
Cylinder Head/Upper Engine
26
eJ
10
24 ---11
14
23
~19
21 '--20 16
490779
Legend
(1) Valve Rocker Arm Cover Bolt (15) Exhaust Manifold (with Heat Shield)
(2) Valve Rocker Arm Cover Bolt Grommet (16) Exhaust Manifold Bolts
(3) Valve Rocker Arm Cover (17) Push rod
(4) Cylinder Head Bolt (Short) (18) Coolant Temperature Gauge Sensor
(5) Cylinder Head Bolt (Medium) (19) Valve Rocker Arm Bolt
(6) Cylinder Head (20) Valve Rocker Arm
(7) Cylinder Head Bolt (Long) (21) Valve Rocker Arm Pivot Support
(8) Valve Stem Keys (22) Cylinder Head Gasket
(9) Valve Spring Cap (23) Valve Rocker Arm Cover Gasket
(10) Valve Spring (24) Oil Fill Tube
(11) Valve Stem Oil Seal (25) Oil Fill Tube Cap
(12) Valve Spring Shim
) (26) Ignition Coil and Bracket Assembly
(13) Valve
(27) Ignition Coil and Bracket Assembly Bolt
(14) Exhaust Manifold Gasket
lower Front of Engine
;>--4 (
r30 29
7
22
~ (
15 14
~
16
18 17 11
19
309874
Legend
(1) Oil Level Indicator Tube Bolt (17) Engine Front Cover
(2) Oil Level Indicator Tube (18) Crankshaft Front Oil Seal
(3) Oil Level Indicator Tube 0-ring Seal (19) Crankshaft Balancer
(4) Valve Lifter Guide Bolt (20) Crankshaft Balancer Bolt
(5) Valve Lifter Guide (21) Engine Front Cover Bolt
(6) Valve Lifter (22} Camshaft Sprocket Bolt
(7) Engine Block (23} Camshaft Sprocket Locating Pin
(8) Crankshaft Rear Oil Seal (24) Camshaft Sprocket
(9) Engine Rear Cover Bolt (25) Camshaft Retainer Bolt
(10) Engine Rear Cover (26) Camshaft Retainer
(11) Engine Rear Cover Gasket (27) Camshaft
(12) Crankshaft Sprocket (28) Camshaft Bearings
(13) Timing Chain (29) Water Pump
(14) Oil Pump Assembly (30) Water Pump Bolt (
(15) Oil Pump Assembly Bolt (31) Water Pump Gask~ts
(16) Engine Front Cover Gasket (32) Oil Level Indicator
lower Engine Assembly
26
24 t---21
27 t:J--22 20 19
178454
Legend
(1) Camshaft Position Sensor Bolt (17) Oil Pan Cover
(2) Camshaft Position Sensor (18) Oil Pan Cover Bolt
(3) Oil Pressure Sensor (19) Oil Pan Closeout Cover Bolt (Left Side)
(4) Engine Block (20) Oil Pan Closeout Cover (Left Side)
(5) Piston Rings (21) Oil Filter Adapter
(6) Piston and Connecting Rod Assembly (22) Oil Filter
(7) Connecting Rod Bearings (23) Oil Level Sensor
(8) Connecting Rod Cap (24) Oil Pan Closeout Cover (Right Side)
(9) Connecting Rod Bolt (25) Oil Pan Closeout Cover Bolt (Right Side)
(10) Crankshaft Oil Deflector (26) Crankshaft Bearing Cap Side Bolt
(11) Engine Flywheel (Manual Transmission) (27) Crankshaft Bearing Caps
(12) Engine Flywheel (Automatic Transmission) (28) Crankshaft Bearing Cap Studs
(13) Engine Flywheel Bolt (29) Crankshaft Bearing Cap Bolts
(14) Oil Pan Gasket (30) Crankshaft Bearing
(15) Oil Pan (31) Crankshaft Thrust Bearing
(16) Oil Pan Cover Gasket (32) Crankshaft
(33) Crankshaft Sprocket Key (37) Oil Pump Screen
(34) Engine Block Front Oil Gallery Plug (38) Oil Pump Screen Nut
(35) Clutch Pilot Bearing (39) Oil Pump Screen 0-Ring (
(36) Oil Pump Screen Bolt
Cylinder Head Assembly (Aluminum)
64108
legend
(1) Cylinder Head
(2) Valve Stem Keys
(3) Valve Spring Cap
(4) Valve Spring
(5) Valve Stem Oil Seal
(6) Valve Spring Shim
(7) Valve Guide
(8) Cylinder Head Expansion Plugs
(9) Exhaust Valve Seat
(10) Exhaust Valve
(11) Intake Valve Seat
(12) Intake Valve
(
Engine Engine Mechanical~ 5.7L 6-295
Oil Pump Assembly
64190
Legend
(1) Driven Gear (5) Plug
(2) Oil Pump Housing (6) Drive Gear
(3) Pressure Relief Valve (7) Cover Bolt
(4) Pressure Relief Valve Spring (8) Cover
)
Repair Instructions
Drive Belt Replacement - Accessory (

Removal Procedure
2. Disconnect the mass airflow (MAF) sensor
208553
3. Remove the air intake duct from the throttle body

and the air cleaner box.
208569
4. Position a hex-head socket on the belt
tensioner bolt.
5. Rotate the drive belt tensioner clockwise to relieve
the tension on the drive belt.
6. Remove the drive belt from the tensioner and
pulleys.
7. Clean and inspect the belt surfaces of all the
pulleys.
551461
1. Route the drive belt around the pulleys.
2. Position a hex-head socket on the belt
tensioner bolt.
3. Rotate the drive belt tensioner clockwise to relieve
the tension.
4. Install the drive belt onto the drive belt tensioner.
5. Inspect the drive belt to ensure that the belt is
) properly aligned into the grooves of the pulleys.
551461
6. Install the air intake duct to the throttle body and

the air cleaner box.
208569
7. Connect the MAFsehsOr electrical connector.
(
208553
Drive Belt Replacement;. A/C

Removal Procedure
1. Remov~ the a:~~essory clrive belLRefer to Drive
Belt Replacement - j\ccessory.
2. Pdsition a hex-head socket on the belt
tensioner bolt.
3. Rotate the air conditioning (A/C) drive belt
tensioner clockwise to relieve the tension on the
drive belt. (
4. Remove the A/C drive belt from the crankshaft
balancer and A/C compressor.
· 5. ·Clean and inspect the A/C belt surfaces of the
balancer and compressor pulley.
551463
Installation Procedme
1. Route the A/C belt over the crankshaft balancer.
2. Rotate the A/C belt tensioner clockwise to
relieve the tension.
3. Install the drive belt between the idler and the
tensioner and over the compressor pulley.
4. Inspect the drive belt to ensure that the belt is
properly aligned on all the pulleys.
5. Install the accessory drive belt. Refer to Drive Belt
Replacement - Accessory.
551463
Drive Belt Idler Pulley Replacement -
Accessory
) Removal Procedure
1. Remove the accessory drive belt. Refer to Drive
Belt Replacement - Accessoty'.
2. Remove the drive belt idler pulley bolt.
3. Remove the drive belt idler pulley.
220582
1. Install the drive belt idler pulley.
Notices.
Important: Be sure the idler pulley is fully seated
against the shoulder on the generator bracket before
tightening the bolt.
2. Install the drive belt idler pulley bolt.
Tighten
Tighten the drive belt idler pulley bolt to
50 N-m (37 lb ft).
Replacement - Accessow
220582
Drive Belt Idler Pulley Replacement - A/C

Removal Procedure
1. Remove the air conditioning (A/C) drive belt.
Refer to Drive Belt Replacement - AIC.
2. Remove the A/C drive belt idler pulley bolt (2).
3. Remove the A/C drive belt idler pulley (1 ).
3
220584
6-300 Engine Mechanical -<5.7L Engine
1. Install the A/C drive belt idler pulley (1).
Notices.
Important: Be sure the idler pulley is fully seated
against the shoulder on the A/C compressor bracket
before tightening the bolt.
2. Install the A/C drive belt idler pulley bolt (2).
Tighten
Tighten the A/C drive belt idler pulley bolt to
50 N-m (37 lb ft).
3. Install the A/C drive belt. Refer to Drive Belt
Replacement - A/C.
3
220584
Drive Belt Tensioner Replacement -

Accessory
Removal Procedure
Belt Replacement - Accessol)I.
(
220581
Notices.
2. Install the drive belt tensioner bolts.
Tighten
Tighten the drive belt tensioner bolts to
50 N-m (37 lb ft).
Replacement - Accesso,y.
220581
Engine Engine Mechanical-5.7l 6-301
Drive Belt Tensioner Replacement - A/C ·
Removal Procedure
2. Remove the A/C drive belt tensioner bolt (3).
3. Remove the A/C drive belt tensioner (4).
3
220584
1. Install the A/C drive belt tensioner (4).
Notices.
Important: Be sure the tensioner is fully seated
against the compressor bracket before tightening
the bolt.
2. Install the A/C drive belt tensioner bolt (3).
Tighten
Tighten the A/C drive belt tensioner bolt (3) to
25 N-m (18 lb ft).
Replacement - AIC.
3
220584
Engine Mount Inspection
Notice: Broken or deteriorated mounts can cause
misalignment and destruction of certain drive (
train components. When a single mount breaks, the
remaining mounts are subjected to abnormally
high stresses.
reason, do not use a jack under the oil pan, any
sheet metal, or the crankshaft pulley. Lifting the engine
in an unapproved manner may cause component
damage.
1. Measure the engine movement at the engine
mounts in order to check for damage to the
rubber portions of the mount.
~ .1. Apply the park brake.
1.3. Firmly apply the primary brakes.
1.4. Have an assistant stand to the side of the
vehicle to observe for engine movement.
1.5. Slightly load the engine in reverse and
drive. If the engine moves more than
24 mm (0.945 in) from the at rest position,
in either direction, check the engine
mount attachment.
2. If the engine mount attachment is within
specifications, replace th.e engine mount.
3. Replace the engine mount also if any of the
following .conditions exist:
.. Heat check cracks cover the hard rubber (
surface.
• The rubber cushion is separated from the
metal plate of the mount.
• There is a split through the rubber cushion.
4. If the mount is loose, lower the engine and tighten
the bolts or the nuts to the engine frame or the
bracket. Refer to Fastener Tightening
Specifications.
Engine Support Fixture

Tools Required
• J 28467-90A Engine Support Adapters
• J 41044 Engine Support Adapters
• J 42451 Engine Support Adapter Kit
• J 28467-B Universal Engine Support Fixture
• J 36462-A Engine Support Adapter Leg
1. Remove the exhaust gas recirculation (EGR)
valve pipe bolts (2, 3, and 4).
2. Remove the EGR valve pipe (1) and solenoid.
551485
3. Remove two strut mounting nuts from the left and
right strut towers.
4. Screw the engine support fixture adapters
J 28467-90A onto the strut tower studs.
5. Set the engine support adapters J 41044-1 and
J 41044-2 over the fixture adapters J 28467-90A
on each strut tower.
6. Secure with the wings nuts provided.
7. Place the cross bar J 28467-3 into the engine .
support adapters J 41044-1 and J 41044-2.
8. Secure with the quick release pins.
9. Install the fixture support leg J 28467-2A through
the cross bracket J 28467-1A on the top of the
cross bar J 28467-3. J 28467-90A
10. Place the rubber padded foot of the front support
J 28467-4A on the radiator support.
11. Install the tube of the front support J 28467-4A
through the large hole in the support leg
J 28467-2A until level. 578405
12. Install the quick release pin.

13. Install the support leg J 36462-A through the
cross bracket J 28467-1 A on the top of the
cross bar J 28467-3.
14. Bolt the lifting brackets to the cylinder heads.
15. Thread lift hooks J 28467-50 and J 28467-8
or (8A) into the support hook brackets J 28467-6A.
16. Place the support hook brackets J 28467-6A over
the cross bar J 28467-3 and connect the hooks to
) the lifting brackets.
17. Tighten the large wing nuts J 28467-34.
Engine Mount Replacement (left)

Removal Procedure
208553
)
Support Fixture. (
Information.
6. Remove the left oxidation catalytic converter.
Refer to Oxidation Catalytic Converter
Replacement (5.7L Left) in Engine Exhaust.
208569
7. Remove the engine mount heat shield nuts.

8. Remove the engine mount heat shield.
220590
9. Remove the engine mount bracket to

crossmember bolts.
11. Raise the left side of the engine using the support
fixture in order to remove tension on the
engine mount.
Information.
220588
13. Remove the erigine mount bracket to block studs.
14. Remove the engine mount assembly.
J 15. Separate the upper and lower mount on
the b~nch.
220591
Installation ,Procedure.
1. Loosely install the upper and lower mount
together on the bench.
2. Install the engine mount assembly.
3. Loosely install the engine mount bracket to
block studs.
5. Lower the left side of the engine using the support
fixture.
Information.
220591

Notices.
7. Install the engine mount bracket to
crossmember bolts.
Tighten
0
Tighten the engine mount bracket to
crossmember bolts to 58 N·m (43 lb ft).
e Tighten the engine mount bracket to block
studs to 50 N-m (37 lb ft).
8. Tighten the engine mount through bolt and
mount nut.
Tighten
• Tighten the engine mount through bolt to
95 N·m (70 lb ft).
)
" Tighten the engine mount through bolt nut to
80 N·m (59 lb ft).
220588
6-306 Engine Mechanical -·5.7L Engine
9. Install the engine mount heat shield.
10. Install the engine mount heat shield nuts.
Tighten (
Tighten the engine mount heat shield nuts to
1O N·m (89 lb in).
11. Install the left oxidation catalytic converter. Refer
to Oxidation Catalytic Converter Replacement
(5. 7 L Left) in Engine Exhaust.
' 13. Remove the engine support fixture.
220590
208569

16. Connect the MAF sensor electrical connector.
208553
Engine Mount Replacement (Right)
Removal Procedure
1. Disconnect the intake air temperature (IAT}
208553

Support Fixture.
Information.
208569
6. Disconnect the oil level sensor electrical

connector (1 ).
487459
7. Remove the negative battery cable lead to engine
block bolt (1 ).
Replacement (5. 7 L) in Engine Electrical.
(
211595
9. Remove the engine mount bracket to

crossmember bolts.
11. Raise the right side of the engine using the
support fixture in order to remove tension on
the engine mount.
Information.
(
220585
13. Remove the engine mount bracket to block bolts.

14. Remove the engine mount assembly.
15. Separate the upper and lower mount on
the bench.
220586
Installation ·Procedure
1. Loosely install the upper and lower mount
together on the bench.
2. Loosely install the engine mount bracket to
block bolts.
4. Lower the right side of the engine using the
support fixture.
Information.
220586

Notices.
6. Install the engine mount bracket to

crossmember bolts.
Tighten
• Tighten the engine mount bracket to
crossmember bolts to 58 N·m (43 lb ft}.
) • Tighten the engine mount bracket to block
bolts to 50 N·m (37 lb ft}.
7. Tighten the engine mount through bolt and
mount nut.
Tighten
• Tighten the engine mount through bolt to
95 N·m (70 lb ft}.
• Tighten the engine mount through bolt nut to
80 N·m (59 lb ft).
220585

Replacement (5.7L) in Engine Electrical.
9. Install the negative battery cable lead to engine
block bolt ( 1) .
Tighten
Tighten the negative battery cable lead to engine
block bolt (1) to 32 N·m (24 lb ft)
)
4
211595
6-310 Engine Mechanical - 5.7L Eng int:!
10. Connect the oil level sensor electrical
connector (1 ).
11. Lower the vehicle. (
12. Remove.the engine SLJpport fixture.
487459
208569
14. Connect the IATsensor electrical connector~

208553
Intake Manifold Replacement
) Removal Procedure
1. Drain the cooling system. Refer to Draining and
Information
3. Remove the transmission fluid level indicator
tube bolt.
5. Relieve the fuel system pressure. Refer to
Fuel Pressure Relief Procedure in Engine
Controls - 5.7 L.
Important: Cap the fittings and plug the holes w.hen

separating fuel system components in order to prevent
dripping of fuel and/or dirt and other contaminants
from entering the fuel system.
6. Disconnect the fuel line from the fuel raiL
7. Disconnect the vapor line from the fuel vapor
purge valve.
220597
8. Disconnect the intake air.temperature (IAT)

208553
10. Remove the air intake duct from;the throttle body·
(
208569
11 .. Disconnect the ·idle air control (IAO) valve , .

electrical connector from the throttle body.
12. Disconnect the throttle .position sensor (TPS)
electrical connector from the throttle body: ·
13. Remove the accessory drive .. belt,Refer.to Drive
Belt Replacement - Accessory.
220606
14. Disconnect the exhaust gas'recirctJlation (EGR).

solenoid electrical connector.
220595
Engine Engine Mechanical - 5.7L 6-.313
15. Remove the EGR valve pipe bolts (2, 3, and 4).
16. Using mild force, pull the EGR valve pipe (1) up
out of the intake manifold.
17. Remove the 0-ring seal from the EGR valve
pipe (1 ).
18. Discard the exhaust manif.old gasket (5) and
0-ring seal.
551485
19. Unsnap the cruise control cable .from the throttle

lever, if equipped.
• Push the cruise cable connectorforward to
unsnap.
• Unsnap the cable from the engine bracket.
220601
20. Remove the accelerator cable from the

throttle lever. ·
220602
6-314 Engine Mechanical -5.7L Engine
21. Remove the accelerator control·cable and cruise·
control servo bracket.
(
220603
22. Disconnect the right side .fuel injector electrical

connectors.
220605
23. Disconnect the left side fuel injector electrical

connectors.
24. Disconnect the secondary air injection (AIR)
25. Remove the fuel rail. Refer to Fuel Rail and
Injectors Removal.
220608
26. Remove the fresh air tube from the throttle body
and rocker cover.
551464
27. Remove the vapor vent tube from the

throttle body.
220621
28. Remove the throttle. body. heater oµtlet hose from

the throttle body.
220620
6-316 Engine Mechanical "' 5.7L Engine
29. Removethe evapora.tive emission (EVAP)
canister purge tube.
(
220615
30. Remove the canister purge valve ana .bracket

from the intake manifold.
220617
31: Disconnect the knock sensor harness electrical

connector (4).
379365
32. Disconnect the manifold absolute pressure (MAP)
33. Disconnect the vacuum hose from the vacuum
port on the MAP sensor housing.
34. Disconnect all the remaining electrical connections
from the intake manifold.
35. Remove the intake manifold. Refer to Intake
Manifold Removal.
220609
1. Install the intake manifold. Refer to Intake
Manifold Installation.
2. Connect the MAP sensor electrical connector.
3. Connect the vacuum hose to the vacuum port on
the MAP sensor housing.
220609
4. Connect the knock sensor harness electrical

connector (4).
379365
5. Install the canister purge valve and bracket to the
intake manifold.
(
220617
6. Install the EVAP canister purge tube.
220615
7. Install the throttle body heater outlet hose to the

throttle body.
220620
8. Install the vapor vent tube hose to the
throttle body.
220621
9. Install the fresh air tube to the throttle body and

rocker cover.
10. Install the fuel rail. Refer to Fuel Rail and Injectors
Installation.
551464
11. Connect the left side fuel injector electrical

connectors.
12. Connect the AIR solenoid electrical connector.
220608
13. Connectthe right side fuel injector electrical
connectors.
14. Connect all remaining electrical connectors to the (
intake manifold.
220605

Notices.
15. · Install the accelerator control cable and cruise
control servo bracket.
Tighten
Tighten the accelerator control cable and cruise
control servo bracket nut to 10 N-m (89 lb in).
(
220603
16. Install the accelerator cable to the throttle lever.
220602
Engine Engine Mechanical - 5.7L 6-3.21
17. Install the cruise control cable to the throttle lever,
if equipped.
220601
Important: Do .not reuse EGR pipe gaskets or seals

during assembly, install NEW gaskets and seals.
18. Apply a light coatirig of clean engine oil to a NEW
0-ring seal and install the seal onto the EGR
valve pipe (1 ).
19. Install the EGR valve pipe (1) into the intake
manifold.
20. Finger start the EGR valve pipe (1) to intake
) manifold bolt (2).
21. Finger start the EGR valve pipe (1) to cylinder
head bolts (3).
22. Finger start a NEW EGR valve pipe exhaust
manifold gasket (5) and bolts (4).
Tighten
22.1. Tighten the EGR valve pipe to intake
manifold bolt (2) to 10 N·m (89 lb in).
22.2. Tighten the EGR valve pipe to cylinder
head bolts (3) to 50 N·m (37 lb ft). 551485
22.3. Tighten the EGR valve pipe to the exhaust
manifold bolts (4) to 30 N·m (22 lb ft).
)
Replacement - Accessory. (
25. Connect the TPS sensor electrical connector to

the throttle body.
26. Connect the IAC sensor electrical connector to
the throttle body.
220606
208569
28. Connect the MAF sensor electrical connector to
the intake duct.
! 29. Connect the IAT sensor electrical connector to the
intake duct.
208553
30. Connect the fuel line to the fuel rail.

31. Connect the vapor line to the fuel vapor
purge valve.
Information
220597
33. Install the transmission fluid indicator tube bolt.

Tighten ·
Tighten the transmission fluid indicator tube bolt
to 50 N-m (37 lb ft).
35. Fill the cooling system. Refer to Draining and
208459
Vapor Vent Pipe Replacement
Removal Procedure (
1. Remove the intake manifold. Refer to Intake
Manifold Replacement.
551466
2. Remove the engine coolant air bleed pipe. Refer'

to Vapor Vent Pipe Removal.
550330
1. Install the engine coolant air bleed pipe. Refer to
Vapor Vent Pipe Installation.
550330
2. Install the intake manifold. Refe.r to Intake
Manifold Replacement.
551466
Engine Valley Cover Replacement

Removal Procedure
1. Remove the engine coolant air bleed pipe. Refer
to Vapor Vent Pipe Removal.
550330
2. Remove the engine valley cover. Refer to Engine

Valley Cover Removal.
65048
1. Install the engine valley cover. Refer to Engine (
Valley Cover Installation.
65048

Vapor Vent Pipe Installation.
0 • (""
.
' ,,,--,
. o·~
550330

Replacement (Left)
Removal Procedure
1. Relieve the fuel system pressure. Refer to
Fuel Pressure Relief Procedure in Engine
Controls - 5.7 L.
2. Disconnect the fuel line from the fuel rail.
purge valve.
220597
Engine Engine Mechanical - 5;7L 6-327
4. Remove the positive crankcase ventilation (PCV)
valve pipe from the rocker cover.
379366
5. Disconnect the ignition coil harness main electrical

connector.
6. Remove the spark plug wires from the
ignition coils.
spark plugs.
490925
8. Disconnect the secondary air injection (AIR) pump

hose from the AIR shutoff valve.
9. Separate the AIR pump hose, if necessary.
551472
10. Remove the AIR shutoff valve bracket nut.
11. Disconnect the AIR solenoid tube from the (
shutoff valve.
628105
12. Loosen the AIR shutoff valve bolt on the rear of

the cylinder head.
13. Slide the AIR shutoff valve off from the bolt.
567573
14. Remove the AIR shutoff valve hose clamps

and hose.
567570
Engine Engine Mechanical - 5.7L . 6-329
15. Remove the AIR pipe (with check valve), bolts
) and gasket from the left exhaust manifold.
16. Remove the valve rocker arm cover. Refer to
Valve Rocker Arm Cover Removal (Left Side).
551470
1. Install the valve rocker arm cover. Refer to Valve
Rocker Arm Cover Installation (Left Side).
Notices.
2. Install the AIR pipe (with check valve), NEW
gasket and bolts to the left exhaust manifold.
) Tighten
Tighten the AIR pipe bolts to 20 N·m (15 lb ft).
551470
3. Install the AIR shutoff valve hose and clamps.
567570
4. Slide the AIR shutoff.valve onto the bolt.
5. Tighten the AIR shutoff valve bolt on the rear ·Of (
the cylinder head.
Tighten
Tighten the AIR shutoff valve bolt to
20 N·m (15 lb ft).
567573
6. Install the AIR shutoff valve bracket nut.

Tighten
Tighten the AIR shutoff valve bracket nut to
12 N·m (106 lb in).
7. Connect the AIR solenoid tube to the shutoff valve.
8. Connect the AIR pump hose together, if
necessary.
(
628105
9. Connect the AIR pump hose to the AIR

shutoff valve .
.· ~
551472
10. Install the spark plug wires to the spark plugs.
) 11. Install the spark plug wires to the ignitions coils.
12. Connect the ignition coil harness main electrical
connector.
490925
13. Install the PCV valve pipe to the rocker cover.
379366
14. Install the fuel line to the fuel rail.

15. Install the vapor line to the fuel vapor purge valve.
220597
Replacement (Right) (
Removal Procedure
1. Remove the evaporator tube. Refer to Evaporator
Tube Replacement in Heating, Ventilation and Air
Conditioning.
2. Remove the heater hoses/pipes. Refer to Heater
Hose Assembly Replacement (5. 7 L) in Heating,
Ventilation and Air Conditioning.
3. Remove the secondary air injection (AIR) pump
hose from the hose clamps.
4. Disconnect the AIR pump hose from the
shutoff valve.
and gasket from the right exhaust manifold.
551467
6. Di$connect the ignition coi.1 harness main electrical

connector.
ignition coils.
spark plugs.
490925
(
9. Remove the. positive crankcase. ventilation (PCV)
v,3.lve pipe from the rocker cover. .· .
10. Remove the PCV valve pipe strap nut, if needed.
11 . Remove the PCV valve pipe frorh the intake
manifold, if needed.
Valve Rocker Arm Cover Removal (Right Side).
379367
1. lnstallthe valve rocker arm cover. Refer to 1/alve
Rockflr Arm· Cover Installation (Right Sidel
2. Install the PCV valve pipe to the intake manifold,
if removed.
Notices.
3. Install the PCV valve pipe strap nut, if removed.
Tighten
Tighten the. PCV valve pipe strap nut to
12 N·m (106 lb in). ·
4. Install the PCV valve pipe to the rocker cover.
379367
6. Install the spark plug wires to the ignition coils.
7. Connect the ignition coil harness main electrical
(
connector.
490925
8. Install the AIR pipe (with check valve), NEW

gasket and bolts to the right exhaust manifold.
Tighten
Tighten the AIR pipe bolts to 20 N-m (15 lb ft).
9. Connect the AIR pump hose to the shutoff valve.
10. Connect the AIR pump hose to the hose
clamps.
11. Install the heater hoses/pipes. Refer to Heater
Hose Assembly Replacement (5. 7 L) in Heating,
Ventilation and Air Conditioning.
12. Install the evaporator tube. Refer to Evaporator
Tube Replacement in Heating, Ventilation. and
Air Conditioning.
551467.

Replacement
Removal Procedure
1. Remove the valve rocker arm covers. Refer to
Valve Rocker Arm Cover Replacement (Right)
or Valve Rocker Arm Cover Replacement (Left).
2. Remove the valve rocker arms, push rods, and
pedestals. Refer to Valve Rocker Arm and Push
Rod Removal.
260140
Engine Engine Mechanical -5.7l 5.;335
Installation Procedure .
1. Install the valve rocker arms, push rods, and
pedestals. Refer to Valve Rocker Arm and
Push Rod Installation.
2. Install the valve rocker arm covers. Refer to Valve
Rocker Arm Cover Replacement (Left) or Valve
Rocker Arm Cover Replacement (Right).
260140
Valve Stem Oil,Sealand ValveSpring

Replacement · ·
Removal Procedure
Tools Required·
• J 22794 Spark Plug Port Adapter
• J 38606 Valve Spring Compressor (Head 0 on)
• J 42078 Valve Stem Oil Seal Installer
1. Remove the valve. rocker arms and pushmds.
Replacement.
2. Remove the spark plug from the cylinder to be
serviced.
14824
3. Install the J22794 to the spark plug hole.

4. Attach and apply compressed air to the J 22794
in order to retain the valves in their closed
position. ·
11517
5.;335 Engine Mechanical - 5.7L Engine
5. Compress the valve spring (4) using J 38606.
(
J 38606
31730
6. Remove the valve stem keys (1 ).

7. Release the valve spring compressor.
8. Remove the valve spring cap (2).
9. Remove the valve spring (3).
10. Remove the valve stem oil seal (4 or 8).
551480
(
Engine Engine Mechanical .. 5. 7L 6-337
) Important: The valve stem oil seal alignment and
position on the valve guide is critical. ·
An improperly installed valve stem oil seal may lead to
excessive oil consumption, increased vehicle
emissions, or component damage.
1. Install the valve stem oil seal onto the guide. I
1.1. Lubricate the valve guide and valve

stem oil seal with clean engine oil.
1.2. Install the valve stem oil seal onto the
$
valve stem.
1.3. Using the J 42078 Push the seal down until
the seal contacts the valve guide.
63193
2. Measure the valve stem oil seal for the properly

installed height.
There should be c;1. 18.1-19:1 mm (0.712~0.752 in) 18.1-19.1 mm
gap between the top edge of the oil seal body (0.712-0.752")
and the shim spring seat surface.
63158
3. Install the valve spring to J 38606.

4. Compress the valve spring using J 38606.
J 38606
31730
5. Install the valve spring cap (2).
6. Install the valve stem keys (1 ). (
6.1. use grease to.hold the keys (1) in place
.and remove the J 38606.
6.2. Ma~e sure the keys (1) seat.properly in the
groove of the valve (10 and 12) stern.
6.3 .. Tap the end to thevalve (6 and 7) stern
with a plastic faced hammer to seat the
keys (if necessary) ..
551480
(
7. Disconnect and remove the air supply
from J 22794.
8. Remove J 22794 from the spark plug hole.
11517
(
Engine Engine Mechanical -5.7L 5..;339
Notices.
9. Install the spark plug.
Tighten
Tighten the spark plug to 15 N-m (11 lb ft).
10. Install the valve rocker arms, pedestal, and valve
pushrods. Refer to Refer to Valve Rocker Arm
and Push Rod Replacement.
14824
Oil Level Indicator and Tube Replacement

Removal Procedure
1. Disconnect the exhaust gas recirculation (EGR)
220595

pipe (1 ).
5. Discard the exhaust manifold gasket (5) and
0-ring seal.
6. Remove the number 4 and 6 spark plug wires.
569980
6-340 Engine Mechanical ~ 5.7L Engi11e
7. Remove the number 4 and 6 ignition coils from
the coil bracket.
(
309850
8. Remove the oil level indicator from the

indicator tube.
565268
9. • Remove the oil level indicator tube bolt.

10. Remove the indicator tube from the engine block.
11. Remove the 0-ring from the tube.
'
565269
1. Clean the indicator tube.
2. Install a new 0-ring to the tube.
3. Install the oil level indicator tube.
4. Rotate the tube into the proper position.
Notice: Refer to Fastener Notice in Cautions· and
Notices.
5. Install the oil level indicator tube bolt.
Tighten
Tighten the oil level indicator tube bolt to
25 N·m (18 lb ft).
'
565269
6. Install the indicator 1o the indicator tube.
565268
7. Install the number 4 and 6 ignition coils to the coil

bracket.
Tighten
Tighten the ignition coil bolts to 12 N·m (106 lb in).
8. Install the number 4 and 6 spark plug wires.
309850
6-342 Engine Mechanical';. 5.71... Engine
Important: Do not reuse EGR pipe gaskets or seals
during assembly, install NEW gaskets and seals.
9. Apply a light coating of clean engine oil to. a NEW (
0-ring seal and install the. seal onto the E.GR
valve pipe (1 ).
10. Install the EGR valve plpe (1) into the intake
manifold.
manifold bolt (2).
head be.Its (3). ·
13. Finger start a NEW EGR valve pipe exhausl
Tighten
manifold bolt (2) to 10 N-m (89 lb in).
head bolts (3) to 50 N-m (37 lb ft).
13.3. Tighten the EGR valve pipe to the exhaust
551485 manifold bolts (4) to 30 N·m (22 lb ft).
14. Conneqtthe EGR solenoid electrical connector.
220595
Exhaust Manifold Replacement (left)

Removal Procedure
t. Remove the left .valve rocker arm cover. Refer to
Valve Rocket Arm Cover Replacement (Left).
2. Remove the spark plugs.
~.·. Lifting and Jacking the Vehicle in General
Information.
4. Remove the left side catalytic converter. Refer to
Oxidation Catalytic Converter Replacement
(5.7 L Left) in Engine Exhaust.
14824
5. Remove the left exhaust manifold bolts.
) 6. Remove the left exhaust manifold and gasket
7. Discard the gasket.
569981
8. Remove the heat shield bolts (3) and heat shield

(2) from the manifold (1 ), if required.
492586'
Important: Tighten the exhaust manifold bolts as
specified in the service procedure. Improperly installed
and/or leaking exhaust manifold gaskets may effect
vehicle emissions and/or on-board diagnostic (080) II
system performance.
The cylinder head exhaust manifold bolt hole threads
must be clean and free of debris and/or threadlocking
material.
Notices.
1. Install the heat shield (2) and heat shield bolts (3)
to the manifold (1 ), if required.
Tighten
Tighten the heat shield bolts (3) to
9 N-m (80 lb in).
492586
6·344 Engine Mechanical- 5.7L Engine
Important: Do not apply threadlock to the first three .
threads of the exhaust manifold bolts.
(
2. Apply a 5 mm (0.2 in) wide band of threadlo.ck
GM P/N 12345493 or equivalent to the threads
of the exhaust manifold bolts.
3. Install a NEW exhaust manifold gasket and the
exhaust manifold.
4. Install the exhaust manifold bolts.
Tighten
4.1. Tighten the exhaust manifold bolts a
first pass to 15 N-m (11 lb ft). Tightening
the exhaust manifold bolts beginning
with the center 2 bolts. Alternate from
side-to-side, and work toward the
outside bolts.
4.2. Tighten the exhaust manifold bolts a final
pass to 25 N-m (18 lb ft). Tighten the
exhaust manifold bolts beginning with the
s6se81 center 2 bolts. Alternate from side-to-side,
and work toward the outside bolts.
5. Using a flat punch, bend over the expos.ed edge
of the exhaust manifold gasket at the rear of the
cylinder head.
6. Install the left side catalytic converter. Refer to
8. Install the spark plugs. (
Tighten
Tighten the spark plugs to 15 N-m (11 lb ft).
9. Install the left valve rocker arm cover. Refer to
Valve Rocker Arm Cover Replacement (Left).
14824
(
Exhaust Manifold Replacement (Right)
Removal Procedure
Valve Rocker Arm Cover Replacement (Right).
2. Remove the right side catalytic converter. Refer to
(5. 7 L Right).
3. Remove the spark plugs.
14824
4. Disconnect the exhaust gas recirculation (EGA)

valve electrical connector. ·
220595

'pipe (1).
8. Discard the exhaust manifold gasket (5) and
0-ring seal.
569980
6-346 Engine Mechanical - .5.7L Engine
9. Remove the left exhaust manifold bolts.
10. Remove the left exhaust manifold and gasket. (
11 . Discard the gasket.
569980
12. RE:3move the heat shielci: bolts. (3) and heat..

shield (2) from the manifold (1).;if required.
492583
Installation .Procedure
and/or leaking exhaust manifold gaskets·may effect
vehicle emissions and/or on-board diagnostics (OBD) II
system performance.
must be clean and free of debris and/or threadlocking
material.
Notices.
1. Install the heat shield (2) and heat shield bolts (3)
to the manifold (1), if required.
Tighten (
Tighten the heat shield bolts (3) to
9 N-m (80 lb in).
492583
Important: Do not apply threadlock to the first three
) threads of the exhaust manifold bolts.
2. Apply a 5 mm (0.2 in) wide band of threadlock
3. Install a NEW exhaust manifold gasket and the
exhaust manifold.
Tighten
first pass to 15 N-m (11 lb ft). Tightening
the exhaust manifold bolts beginning
with the center 2 bolts. Alternate from
outside bolts.
center 2 bolts. Alternate from side-to-side, 569980
and work toward the . outside

. bolts. ..
5. Using a flat punch, bend over the exposed edge
cylinder head.
Important: Do not reuse EGR pipe gaskets or seals
during assembly. Install NEW gaskets and seals.
6. Apply a light coating of clean engine oil to a NEW
O~ring seal and install the seal onto the EGR
valve pipe (1 ).
7. Install the EGR valve pipe (1) into the intake
manifold.
manifold bolt (2).
head bolts (3).
10. Finger start a NEW EGR valve pipe exhaust
Tighten
manifold bolt (2) to 1O N-m (89 lb in).
head bolts (3) to 50 N,m (37 lb ft).·
551485
10.3; Tighten the EGR valve pipe to the exhaust
manifold bolts (4) to 30 N-m (22 lb ft).
6-348 Engine Mecharaical - 5.7l Engine
11 ..Connect the EGR valve electrical connector.
12. Install the spark plugs.

Tighten
Tighten the spark plugs to 15 N,m (11 lb ft).
13. Install the right side catalytic converter. Refer to
Oxidation· Catalytic Converter Replacement
(5. 7 L Right).
14. Install the valve rocker arm cover. Refer to Valve
Rocker Arm Cover Replacement (Right).
(
14824
Cylinder Head Replacement (Left)
~
1 Removal Procedure
to. Vapor· Vent Pipe Replacement.
2. Remove the power steering pump rear bracket.
Refer to Power Steering Pump Rear Bracket
Replacement in Power Steering System.
3. Remove the left side exhaust manifold. Refer to
Exhaust Manifold Replacement (Left).
Replacement.
2 5. Remove the harne.ss ground bolts (2 and 3) from
the ~ear of the cylinder head. (
4
379365
6. Remove the left side cylinder head. Refer to
Cylinder Head Removal (Left Side).
260146
1. Install the left side cylinder head. Refer to
Cylinder Head Installation (Left Side).
260146

Notices.
1
2. Install the harness ground bolts to the
cylinder head.
Tighten
Tighten the harness ground bolts (2 and 3) to
50 N-m (37 lb ft).
Replacement.
4. Install the left side exhaust manifold. Refer to
Exhaust Manifold Replacement (Left).
5. Install the power steering pump rear bracket.
Refer to Power Steering Pump Rear Bracket
Replacement in Power Steering.
6. Install the engine coolant air bleed pipe. Refer to 4
Vapor Vent Pipe Replacement.
379365
Cylinder Head Replacement (Right)
Removal Procedure (
to Vapor Vent Pipe Replacement.
2. Remove the right side exhaust manifold. Refer to
Replacement.
4. Remove the engine wiring harness clip bolt from
the cylinder head.
346049
5. Remove the transmission fill. tube bolt from the

cylinder head.
208459
6. Remove the right side cylinder head. Refer to

Cylinder Head Removal (Right Side).
260149
) 1. Install the right side cylinder head. Refer to
Cylinder Head Installation (Right Side).
260149
Notict1: Refer to Fa.stener Notice in Cautions and

Notices.
2. Install the transmission fill tube boltto the
cylinder head.
Tighten
Tighten the transmission fill tube bolt to
47 N·m (35 lb ft).
)
208459
3. Install the engine wiring harness clip bolt to the

rear of the cylinder head.
·Tighten
Tighten the engine wiring·tiarness clip bolt to
50 N-m (37 lb ft).
Replacement.
5. Install the right side exhaust manifold. Refer to
Vapor Vent Pipe Replacement.
346049
6-352 Engine Mechanical • 5. 7L Engine
Valve Lifter Replacement
Removal Procedure (
Tools Required
J 3049-A Valve Lifter Remover
1. Remove the cylinder head. Refer to Cylinder
Head Replacement (Right) or Cylinder Head
Replacement (Left).
2. Remove the valve lifter guide bolt.
3. Remove the valve lifter guide.
551476
Important: Some valve lifters may be stuck in their

bores because of gum or varnish deposits.
4. Use the J 3049-A or equivalent to remove the
valve lifters, if required.
31350
5. Remove the valve lifters from the lifter guide, if

necessary.
6. Organize or mark the lifters so that they can be
installed in the same location from which they
were removed.
63233
! Important: When reusing lifters, install the lifters in
their original locations.
1. Lubricate the valve lifters and engine block lifter
bores with clean engine oil.
2. Insert the lifter into the lifter guides.
Align the flat area on top of the lifter with the flat
area in the lifter guide bore. Push the lifter
completely into the guide bore.·
63233
3. Install the lifters and guide to the engine block.

Notice: Refer to Fastener Notice in· Cautions and
Notices:
4. Install the lifter guide bolt.·
Tighten
Tighten the lifter guide bolt to 12 N·m (106 lb in).
5. Install the cylinder head. Refer to Cylinder Head
Replacement (Right) or Cylinder Head
Replacement (Left).
551476
Crankshaft Balancer Replacement ·

Removal Procedure
Information.
4. Remove the right closeout cover and bolt.
208464
5. Unsnap the oil cooler lines from the clip at the
generator. (
341084
6. Remove the transmission oil cooler lines from the

radiator.
7. Remove the power steering cooler, if equipped ...
Refer to Power Steering Cooler Pipe/Hose
Replacement in Steering.
208321

Crankshaft Balancer Removal.
. r;;:,
64275
Balancer Installation.
2. Install the power steering cooler, if removed.
Refer to Power Steering Cooler Pipe/Hose
Replacement in Steering. ·
64275

Notices.
3. Install the transmission oil cooler lines to the

radiator.
Tighten
Tighten the oil cooler line connections to
27 N-m (20 lb ft).
208321
4. Snap the oil cooler lines into the clip at the

generator.
341084
5; Install the right closeout cover and bolt.
Tighten
(
Tighten the closeout cover bolt to
12 N·m (106 lb in).
Replacement (5. 7 L) in Engine Electrical:
Replacement - AIC.
9. Perform the crankshaft postion (CKP) system
variation learn procedure. Refer to CKP
Controls - 5. 7 L.
208464
Crankshaft Front Oil Seal Replacement '

Removal Procedure
2. Pry the crankshaft oil seal out from the front cover.
64275
1. Install a NEW crankshaft front oil seal (1). Refer
to Crankshaft Front Oil Seal Installation.
490689
64275
Engine Front Cover Replacement

Removal Procedure
Information.
2. Remove the cooling fan electrical connectors.
3. Remove the harness rosebud clips from the fan
shroud.
221692

208553
9. Remove the air conditioning (A/C) drive belt. (
Refer to Drive Belt Replacement - A/C.
208569
1O. Remove the upper radiator hose from the

water pump.
221676
11 . Remove the radiator hose from the water inlet

housing.
221671
12. Remove the two heater hoses from the
water pump.
282934
13. Remove the upper radiator support.
221697
14. Remove the fan shroud.

Belt Tensioner Replacement - Accessoty.
41692
6·360 Engine Mechanical - s~7L Engine
16. Remove the overflow hose from the radiator.
221645
17. Remove the throttle body heat.er hose from the .

radiator.
18. Remove the drive belt idler pulley. Refer to Drive
Belt Idler Pulley Replacement - Accesso,y.
19. Remove the water pump. Refer to Water Pump
Replacement (5.7 L) in Engine Cooling.
Information. (
220620
22. Remove the oil pan-to~tront cover bolts.
451709
Important: Do not slide the front cover/gasket across
the oil pan gasket or damage could result.
23. Remove the front cover-to-engine block bolts.
24. Remove the front cover and gasket.
25. Discard the front cover gasket.
26. Remove the crankshaft oil seal from the cover.
27. Discard the oil seal.
64278
Tools Required
J 41476 Front/Rear Cover Alignment-Crankshaft Oil
Seal Area
Important:
., Do not reuse the crankshaft oil seal or front cover
gasket.
) • Do not slide the front cover/gasket across the oil
pan gasket
• The special tool in this procedure is used to
properly align the crankshaft front oil seal.
• The crankshaft front oil seal MUST be centered in
relation to the crankshaft.
• An improperly aligned front cover may cause
premature front oil seal wear and/or engine
oil leaks.
1. Install a NEW crankshaft oil seal to the front cover.
64278
2. Apply a 5 mm (0.20 in) bead.of sealant GM
PJN 12378190 to the corner where the oil pan
meets the engine block.
3. Install the front cover, gasket and bolts on to the
engine.
4. Install the front cover bolts finger tight. Do not
overtighten.
6-362 Engine Mechanical ..; 5. 7L Engine
5. Install the oil pan-to-front.cover bolts until snug in
order to position the:cover at the pan rail.
(
451709
6. Install the J 41476 to the.front cover.

7. Align the tapered legs of the J 41476 with th~
machin~d alignn;ient surfaces on the front cover.
8. Install the crankshaftbalancer bolt until snug. Do
not overtighten.
Notices.
9. Tighten the oil pan bolts in the following order:
Tighten
(
9.1.. Tighten the oil pan-to-front cover bolts to
25 N-m (18 lb ft).
9.2. Tighten the. engine front cover bolts to
25 N-rn (18 lb ft).
10. Remove the J 41.476.
451712 13. Install the water pump. Refer to Water Pump
Replacement (5. 7 L) in Engine Cooling.
14. Install the drive belt idler pulley. Refer to Drive
Belt Idler Pulley Replacement - Accessol)I.
(
15. Install the throttle body heater hose to the
radiator.
220620
16. Install the overflow.hose to the radiator.

Tensioner Replacement - Accessory.
221645
18. Install the fan shroud.
41692
5...354 Engine Mechanical - 5.7L Engine
19. Install the upper radiator support.
Tighten
Tighten the radiator supporVair cleaner bolts to
(
12 N-m (106 lb in).
221697
20. Install the lower radiator hose to the water inlet

housing.
221671
21. Install the upper radiator hose to the water pump,.
221676
Engine Engine Mechanical m 5.7.L 5.;3fi~
22. Install the two heater hoses from the water pump.
\ 23. Install the A/C drive belt. Refer to· Drive Belt
! Replacement - A/C.
282934
24. Install the air ihtake duct.
208569
25. Cor1nect the MAF sensor electrical connector.

208553
28. Install the electrical connectors to the fan shroud.
29. Install the rosebud clips to the fan shroud.
(
221692
Crankshaft Rear Oil Seal Replacement

Removal Procedure
1. Remove the flywheel. Refer to Engine Flywheel
Replacement.
178458
2. Pry the crankshaft rear oil seal (1) out of the

rear cover.
490692
1. Install the crankshaft rear oil seal (1). Refer to
Crankshaft Rear. Oil .Seal Installation.
490692
2. Install the flywheel. Refer to Engine Flywheel

Replacement.
178458
Engine Rear Cover Replacement

Removal Procedure
1. Remove the flywheel. Refer to Engine Flywheel
Replacement.
2. Remove the oil pan-to-rear cover bolts.
178458
3. Remove the rear cover bolts.
4. Remove the re~r cover and gasket.
5. Remove the crankshaft oil seal from the cover. (
• Gasket sealing surfaces for excessive
scratches or gouging.
• Cover -to-oil pan threaded bolt holes for
damaged threads or debris.
• Crankshaft oil seal mounting bore for damage.
• Oil pan gasket for damage.
64282
Tools Required
J41476 Front/Rear Cover Alignment-Crankshaft Oil
Seal Area
Important:
• Do not reuse the crankshaft oil seal or rear cover
gasket.
• Do not slide the rear cover gasket across the oil
pan gasket. (
• The special tool in this procedure is used to
properly align the crankshaft rear oil seal.
• The crankshaft rear oil seal MUST be centered in
relation to the crankshaft.
• An improperly aligned rear cover may cause
premature rear oil seal wear and/or engine
oil leaks.
1. Apply a 5 mm (0.20 in) bead of sealant GM
P/N 12378190 to the corner where the oil pan
meets the engine block.
451897
2. Install the rear .cover, gasket and bolts to the

engine.
3. Tighten the rear cover bolts finger tight. Do not
overtighten.
4. Install the oil pan-to-rear cover bolts finger tight.
Do not overtighten.
64282
5. To properly align the rear cover, rotate the
crankshaft until two opposing flywheel bolt holes
~re para,llel. to the oil pan surface.
J 41476
1
6. Align the tapered legs of J 41476 so the legs
enter the rear cover oil seal bore.
7. Install the J41476 and bolts onto the rear of the
crankshaft.
8. Tighten the tool mounting bolts by hand until
snug. Do not overtighten.
9: Install the oil pan-to-cover bolts until snug in order
to position the cover to the pan rail.
Notices.
10. Tighten the oil pan-to-rear cover bolts in the
following order:
Tighten
10.1. Tighten the oil pan-to-rear cover bolts to
12 N-m (106 lb in).
451716
10.2. Tighten the rear cover bolts to
25 N-m (18 lb ft).
12. Install the rear oil seal. Refer to Crankshaft Rear
Oil Seal Installation.
13. Install the flywheel. Refer to Camshaft
Replacement.
178458
5;.370 Engine Mechanical - 5.7L Engine
Oil Pan Replacement
Removal Procedure (
Information.
3. Remove the oil drain plug.
309862
~ 178469
6. Remove the right side engine mount to

pradle bolts.
220585
7. Remove the left side engine mount to crad.le bolts.
220588

220629
9. Remove the intermediate steering shaft bolt:

10. Support the engine cradle using adjustable jack
stands.
220630
6-372 Engine Mechanical;. 5.7L Engine
11. Disconnect the oil level sensor connector, if
required.
(
220633
12. Remove the oil level sensor from the oil pan, if
required.
178467
14. Remove the right side closeout and bolt.
208464
Engine Engine Mechanical -, 5.7L 6-373
15. Remove the left side closeout and bolt.
208478
16. Loosen the six cradle bolts three or four turns.

17. Lower the cradle slightly using the cradle support,
using the adjustable jack stands.
It may be necessary to also raise the engine
using the supportfjxture.
18. Remove the bottom two transmission
bellhousing bolts.
~ 220632
19. Remove the oil pan bolts (1).

20. Lower the oil pan, position the pan until it can be
removed from around the oil pump screen.
21. Use care not to gouge, score, or damage the oil
pan sealing surface.
451962
Important: DO NOT allow foreign material to. enter
the oil passages of .the oil pan, cap or cover the
openings as required.
(
22. Drill out the oil pan gasket rivets (2) and remove
the gasket (1) from the oil pan.
23. Discard the old gasket and rivets.
384699
Important: The alignment of the struc,ural oil pan is
critical. The rear bolt hole locations ofthe oil pan ·
provide mounting points for the transmission
bellhousing. To ensure the rigidity of the powertrain
and correct transmission alignment, it is. important th.at
the rear of the block and the rear of th.e oil pan
must NEVER protrude beyond the engine 'block and
transmission bellhousing plane.
(
P/N 12378190 or equivalent 20 mm (0.8 in) long to
the engine block.
2. Apply the sealant directly onto the tabs of the
front cover gasket that protrudes into the oil
pan surface.
451897

P/N 12378190 or equivalent 20 mm (0.8 in) long
to the engine block. ·· ·
4. Apply the sealant directly onto the tp.bs of the rear
cover gasket that protrudes into the oil pan
surface. '
451898
5. Pre-assemble the oil pan gasket to the pan (2).
5.1. Install the gasket onto the pan (2).
5.2. Install the oil pan bolts (1) to the pan
through the gasket.
6. Install the oil pan (2), gasket and bolts (1) to the
engine block.
7. Snug the oil pan bolts (1) finger tight. Do not
overtighten.
8. Install the two lower bellhousing bolts to position
the oil pan correctly.
Notices.
9. Snug the lower bellhousing bolt finger tight. Do
not overtighten.
Tighten
9.1. Tighten the oil pan-to-block and oil
pan-to-oil pan front cover bolts to
25 N-m (18 lb ft). 451962
12 N-m (106 lbin). ,
9.3. Tighten the bellhousing bolts to
50 N-m (37 lb ft).
10. Raise the engine cradle and/or if necessary, lower
the engine.
11. Tighten the cradle bolts.
Tighten
• Tighten the upper four cradle bolts to
125 N·m (92 lb ft).
• Tighten the lower two cradle bolts to
145 N-m (107 lb ft).
~ 220632
12. Install the left side closeout and bolt.
Tighten
Tighten the left side closeout bolt to
12 N-m (106 lb in).
(
208478
13. Install the rlght side closeout and bolt.

Tighten
Tighten the right closeout bolt to
12 N·m (106 lb in).
208464
15. Install the oil level sensor to the oil pan, if

removed.
Tighten
Tighten the oil level sensor to 35 N-m (26 lb ft).
178467
16. Connect the oil level sensor electrical connector.
17. Remove the cradle support.
220633
18. Connect the· intermediate steering shaft bolt ,

Tighten
47 N-m (35 lb ft).
220630
mounting bolts.
Tighten
Tighten the shock absorbers bolts to
65 N-m (48 lb ft).
220629
6-378 Engine Mechanical .; 5.7L Engine
20. Install the left side engine mount cradle bolts.
Tighten
Tighten the engine mount to cradle bolts to (
58 N-m (43 lb ft).
220588
21. Install the right side engine mount cradle bolts.

Tighten
Tighten the right side engine mount cradle bolts
to 58 N-m (43 lb ft). ·
220585
22. Install the oil drain plug.

Tighten
Tighten the oil drain plug to 25 N-m (18 lb ft).
309862
Tighten
Tighten the.oil filter to 30 N,m (22 lb ft) ..
26. Change the engine oil. Refer to Engine Oil and
Oil Filter Change.
~ 178469
Oil Pump, Pump Screen and· Deflector

Replacement
Removal Procedure
.A
64278
2. Remove. the engine oil pan (2). Refer to Oil Pan

Replacement.
3. Remove the oil pump, pump screen and deflector.
Refer to Oil Pump, Pump Screen and Deflector
Removal.
451962
6.;.380 Engine Mechanical - 5.7L Engine
1. Install the deflector, pump screen and oil pump.
Refer to Oil Pump, Pump Screen and Deflector (
Installation.
2. Install the engine oil pan (2). Refer to Oil Pan
.Replacement.
451962

64278
Timing Chain and Sprockets Replacement

Removal .Procedure
1. Remove the oil pump. Refer to Oil Pump, Pump
Screen and Deflector Replacement.
64281
6-381
Eogin. e . ·
.
chain
d sprocket. Refer to
an Remova I.
R move the t1m1ng kets
2. T:ning Chain and Sproc .
63263
dure ·
Installation Pro~e in•and sprocket. _Refer to
1. Install
Timingthe ti~rnng
Cham an J~~rockets lnstallatt0n.
63263
. Refer to 01/. Pump' Pump

2. ,.Install the o1Lp~;~tor Replacement.
Screen and De ,
64281
Camshaft Replacement
Removal Procedure
1. Remove the valve lifters. Refer to Valve Lifter
(
Replacement.
2. Remove the radiator. Refer to Radiator
Replacement in Engine Cooling.
221724
3. Remove the timing chain and sprocket. Refer to

63263
4. Remove the camshaft. Refer to Cam.shaft

Removal.
63212
1. Install the camshaft. Refer to Camshaft
Installation.
63212
2. Install the timing chain and sprocket. Refer to

63263
3. Install the radiator. Refer to Radiator Replacement

in Engine Cooling.
4. Install the valve lifters. Refer to Valve Lifter
Replacement.
221724
6~384 Engine Mechanical - 5.7l Engine
Engine Flywheel Replacement
Removal Procedure
1. Remove the automatic transmission, if applicable.
(
Refer to Transmission Replacement (5. 7 L) in
2. Remove the automatic transmission flywheel, if
applicable. Refer to Engine Flywheel Removal.
178458
3. Remove the manual transmission, if applicable.

Refer to Transmission Replacement in Manual
Transmission - MM6.
4. Remove the manual transmission flywheel, if
applicable. Refer to Engine Flywheel Removal.
156166
1. Install the manual transmission flywheel, if
applicable. Refer to· Engine Flywheel Installation.
2. Install the manual transmission, if applicable.
Refer to Transmission Replacement in Manual
Transmission - MM6.
156166
Engine Engine Mechanical - 5.7l. 6-385
3. Install the automatic transmission flywheel, if
applicable. Refer to Engine Flywheel Installation.
4. Install the automatic transmission, if applicable.
Refer to Transmission Replacement (5. 7 L) in
178458
Engine Replacement
Removal Procedure
Tools Required
• J 39580 Engine Support Table
.. J 36221 Hydraulic Clutch Line Separator
) • J 39411 Flywheel Holding Tool
1. Disconnect the positive battery cable. Refer to
211587

208553
6-386 Engine Mechanical ~. 5.7L Engine
4. Remove the air intake duct resonator.
Recovery and Recharging in Heating, Ventilation (
6. Relieve the fuel system pressure. Refer to Fuel
Pressure Relief Procedure in Engine Controls.
Information
208569
8. Remove the oil pan drain plug.

10. Remove the front wheels. Refer to Tire and
Wheels.
12. Remove the left catalytic converter. Refer
to Oxidation Catalytic Converter Replacement (
13. Remove the right catalytic converter. Refer to
(5.7 L Right) in Engine Exhaust
14. Drain the transmission fluid, if equipped with a
Shaft Replacement - One Piece in Propeller Shaft.
16. Remove the torque arm. Refer to Torque
309862 Arm Replacement in Rear Suspension.
17. Remove the starter motor. Refer to Starter .Motor
(
transmission, unsnap the transmission range
selector lever cable from the range selector lever
at the transm.ission.
208264
19. ,Remove the retainer from the range selector

lever cable.
~ I
341079
20. Remove the range selector lever cable from the

cable bracket.
208276
disconnect the clutch actuator cylinder line from
the actuator cylinder using J 36221. (
22. Remove the left side front air deflector. Refer to
in Bumpers.
23. Remove the stabilizer bar bracket bolts.
24. Remove the stabilizer bar brackets.
43255
25. Remove the. intermediate steering shaft bolt and

shaft from the rack.
220630

(Radio Frequency) ground strap and cruise
control ground lead from the front rail.
346034
27. Disconnect the wheel speed sensor electrical
connectors.
346036
28. Remove the air conciitioning (A/C) compressor

and condenser hose bolt.
365448
30. Remove the front fuel pipe heat shield nuts (1 ).

31. Remove the front fuel pipe heat shield (2).
32. Disconnect the brake lines from the brake
pipe clip.
7c'
173551
35. Discard the 0-ring. (
282941
36. Remove the inlet and outlet heater hoses,from the

water pump.
36.1. Squeeze the hose clamp together with
pliers.
pump fitting.
36.3. Gently twist and pull the heater hose from
the water pump fitting.
(
282934
37. Disconnect the fuel line from the fuel rail.

purge valve.
220597
39. Remove the cruise control cable from the
throttle lever.
220601
Caution: In order to avoid possible irrjury or

vehicle damage, always replace the accelerator
control cable with a NEW cable whenever you
remove the engine from the vehicle.
In order to avoid cruise control cable damage,
position the cable out of the way while you remove
or install the engine. Do not pry or lean against
the cruise control cable and do not kink the cable.
You must replace a damaged cable.
) 40. Remove the accelerator control cable from the
throttle lever.
41. Unsnap and remove the accelerator and cruise
control cable from the throttle body bracket.
220602
42. Remove the cruise control and accelerator control

cables from the servo adjuster, if equipped.
6-392 Engine Mechanical- 5.7l Engine
221676
44. Remove the inlet hose from the water inlet.

45. Remove the brake booster vacuum hose.
46. Remove the front two brake lines from the brake
pressure modulator valve.
221671
47. Disconnect the secondary captured locks.

engine harness.
49. Disconnect the engine harness vacuum tube from
the bottom of the vacuum check valve.
346047
connectors.
) 51. Remove the PCM from the vehicle.
52. Remove the right side insulator panel. Refer to
53. Remove the hinge pillar trim panel. Refer to Trim
346043
54. Disconnect the engine wiring harness from the

346039
55. Remove the engine wire harness through the front

of dash. Place the harness on top of the engine.
56. Remove the floor shift control, if equipped. Refer
to Floor Shift Control Replacement in Automatic
57. Remove the transmission control, if equipped.
Refer to Shift Control Assembly Replacement in
Manual Transmission - MM6.
Information.
346041
60. Remove the cotter pins and nuts from the left and (
right upper ball joints.
61. Using J39549 separate the upper control arms
from the steering knuckles.
62. Support both steering knuckles.
63. Position the J 39580 below the vehicle.
64. Lower the vehicle until the crossmember is resting
on the J 39580.
65. Lay the engine wire harness on top of the engine.
220629
~ 220632
67. Remove the transmission support bolts.

68. Raise the vehicle and remove the engine and
transmission from the vehicle.
69. Secure the crossmember to the J 39580.
208587
Engine Engine Mechanical .. 5..7l 6·395
70. Position a hex-head socketon the belt tensioner
pulley bolt.
) 71. Rotate the drive belt tensioner clockwise to relieve
the tension on the drive belt.
72. Remove the drive belt from the tensioner and
pulleys.
551461

pulley bolt.
74. Rotate the air conditioning (A/C) drive belt
tensioner clockwise to relieve the tension on the
drive belt.
75. Remove the A/C drive belt from the crankshaft
balancer and A/C compressor.
551463
76. Disconnect the A/C compressor electrical

connector.
365446
6-396 Engine Mechanical - 5.7l Engh1e
77. Remove the A/C compressorbolts.
(
282955
79. Remove the power steering pump bolts, (4) and ·

pump brace (3). ·
80. Remove the power steering pump (1) from the
bracket (2).
81. Reposition the power steering pump to the
crossmember.
290570
82. Disconnect the generator electrical connector (3).
211624
Engine Engine Mechanical - 5.7l 6~397
83. Remove the positive cable nut from the generator.
84. Remove the positive cable from the generator.
85. Install a engine hoist the block.
211599
86. Remove the right side engine mount bracket to

blo.ck bolts and bracket.
220586
87. Remove the engine mount heat .shield nuts.

88. Remove the engine mount heat shield.
220590
89. Remove the left side engine mount bracket to
block studs and bracket.
90. With the aide of an assistant, raise the engine (
and transmission from the crossmember.
220591
91. Remove the harness clamp bolt (1). ·

1 92. Disconnect the following electrical connectors
from the transmission:
• 20-way connector (2)
• Vehicle speed sensor (3)
93. If equipped with an automatic transmission
481327
94. Remove the left side transmission closeout

and bolt.
208478
95. Remove the right side·transmission closeout
and bolt.
208464
96. Remove the flywheel to torque converter bolts.
208580
97. Remove the transmission to engine bolts.

98. Separate the transmission from the engine.
9~.. Attach the. J 21366 to the transmission.
100. If equipped with.a manual transmission, perform
the following:
208590
101. Remove the flywheel housing to engine bolts (2).
102. Separate the flywheel housing from the engine.
(
210528
103. Remove the pressure plate bolts (4). ·

1 104. Remove the pressure plate (3) and clutch
dJsc (2) from theflywheel (1 ).
105. Install the engine to a engine stand.
106. Remove the engine hoist.
441863
Tools Required ·
J 38836 Pilot Bushing Installer/Clutch Alignment Arbor
1. Install a Elrigirie hoist to the block
2. Remove the engine from the engine stand.
3. If equipped with a manual transmission, perform
the following:
4. Install the clutch disc and pressure plate to the
flywheel.
5. Install the pressure plate bolts finger tight.
6. Use the J 38836 to align the clutch disc splines
with the pilot bearing.
(
J 38836
71488
1
Notices.
7. Tighten the clutch pressure plate bolts.
Tighten
Tighten the clutch pressure plate bolts in 6
sequence (as shown) and evenly over
3 increments with the fourth increment to
70 N·m (52 lb ft).
3 2
5
71490
9. Install the flywheel housing to engine bolts (2).

lighten
Tighten the flywheel housing to engine bolts (2) to
50 N·m (37 lb ft). .. . '
1O. 11 equipped with an automatic transmission
210528
11. Remove the J 21366 from the transmission.

12. Install the transmission to engine bolts.
Tighten
Tighten the transmission to engine bolts to
50 N·m (37 lb ft). .
208590
13. Install the flywheel to torque converter bolts.
Tighten
Tighten the flywheel to torque converter cover (
bolts to 60 N·ni (44 lb ft).
208580
14. Install the right side transmission closeout

and bolt.
Tighten
Tighten the right side closeout bolt to
12 N·m (106 lb in).
208464
15. lnstal.1 the left side transmission closeout .and bolt.

Tighten
Tighten the left side closeout bolt to
12 N·m (106 lb in).
208478
16. Connect the following electrical connectors to the
transmission:
1
) • 20-way connector (2)
• Vehicle speed sensor (3)
17. Install the harness clamp bolt (1):
Tighten
Tighten the harness clamp bolt (1) to
2.5 N·m (22 lb in).
18. With the aide of an assistant, lower the engine
and transmission to the crossmember.
481327
19. Install the left side engine mount bracket,

and studs.
Tighten
Tighten the engine mount bracket studs to
50 N-m (37 lb ft).
220591
20. Install the engine mount heat shield.

21. Install the engine mount heat shield nuts.
lighten
Tighten the engine mount heat shield nuts to
10 N-m (89 lb ft).
220590
22. Install the right side engine mount bracket ·
and bolts.
Tighten (
Tighten the engine mount bracket boltsto ·
50 N:m (37 lb ft). .
23. Remove the hoist from the engine.
220586
24. Install the positive. cable to the generator;

25. Install the positive cable nut to the generator,
Tighten
Tighten the positive cable nutto the generator to
22 N·m (16 lb ft).
211599
26. Connect the generator electrical connector (3).
211624
,engine Engine Mechanical - 5.7l 6-405
27. Install the power steering pump (1) to the
bracket (2).
) 28. Install the power steering brace (3) and bolts (4).
Tighten·
Tighten the power steering pump bolts (4) to
25 N·m (18 lb ft).
3 2
290570

Tighten
, Tighten the AfC compressor bolts to
50 N·m (37 lb ft).
282955
31. Connect the A/C compressor electrical connector.
365446
32. Route the A/C belt over the crankshaft balancer.
33. Rotate the A/C drive belt tensioner clockwise to
relieve the tension. (
34. Install the drive belt between the idler and over
the tensioner (1) and onto. the compressor
pulley. . .
551463
35. Route the drive belt around the pulleys.

36. Position the hex-head socket on the belt tensioner
pulley bolt.
37. Rotate the drive belt te.nsio.n~r clockwise to relieve
tension.
38. Install the drive belt around the tensioners.
39. Remove the strap from the crossmember to
the J 39580.
40. Lower the vehicle and install the engine and (
transmission to the vehicle.
551461
41. Install the transmission support bolts.

Tighten
Tighten the transmission support bolts to
90 N-m (66 lb ft}.
' 208587
(
42. Install the front crossmember bolts. ,
Tighten
) • Tighten the four upper crossmember bolts to
125 N-m (92lb ft).
• Tighten t.he two lower crossmember bolts to
145 N-m (107 lb ft).
43. Raise and suitably support the ve.hicle. Refer to
Information.
44. Remove the J 39580 from below the vehicle.
45. Remove the support from both steering knuckles.
46. Install the upper control arm ball studs to the
steering knuckles.
47. Install the nuts to the left and right upper ball
joints.
~
I
Tighten
Tighten the upper control arm nuts to
53 N,m (39 lb ft).
48. Install cotter pins to the upper control arm nuts.
i 220632
mounting bolts.
Tighten
Tighten the shock absorber bolts to
65 N,m (48 lb ft).
51. Install the transmission control, if equipped. Refer
to Shift Control Assembly Replacement in Manual
Transmission - MM6.
)
52. Install the floor shift control, if equipped. Refer to
Floor Shift Control Replacement in Automatic
220629
53. Install the engine wire harness through the front

ofdash. · ·
346041
54. Connect the engine wiring harness to the 1/P
wiring harness.
55. Install the hinge pillar trim panel. Refer to Trim (
56. Install the right side insulator panel. Refer to
Closeout/Insulator Panel Replacement - Right
in lnstrumentPanel, Gauges and Console.
57. Install the PCM to the vehicle.
346039
58. Connect the PCM connectors to the PCM.

Tighten
Tighten the PCM connector bolts to
8 N-m (71 lb in).
346043
59. Connect the engine harness vacuum tube to the

bottom of the vacuum check valve.
60. Connect the forward lamp harness to the engine
harness.
61. Connect the secondary captured locks.
62. Install the front two brake pipes to the brake
pressure modulator valve.
63. Install the brake booster vacuum hose.
346047
Engine Engine Mechanical~ s~7l 5..409
64. Install the inlet hose to the water inlet.
221671
65. Install· the outlet hose to· the water pump.
221676
66. Install the cruise control and accelerator control

cables to the servo adjuster, if equipped. ·
296567
Caution: In order to avoirJ possible injury or
vehicle damage, always replace the accelerator
control cable with a NEW cable whenever you
remove the engine from the vehicle. (
In order to avoid cruise control cable damage,
position the cable out of the way while you remove
or install the engine. Do not pry or lean against
the cruise control cable and do not kink the cable.
You must replace a damaged cable.
67. Install the accelerator control cable to the throttle
body bracket.
68. Install a NEW accelerator control cable to the
throttle lever.
220602
69. Install the cruise control cable to the throttle lever;
220601
70. Connect the fuel line.Jo the fuel rail.

71. Connect the vapor line to the fuel vapor
purge valve.
220597
Engine Engine Mechanical - 5.7L 5..;411
72. Install the inlet and outlet heater hoses to the
water pump.
282934

Tighten
Information.
282941
76. Connect the brake lines to the brake pipe clip.

77. Install the front fuel pipe heat shield (2).
78. Install the front fuel pipe heat shield nuts (1 ).
Tighten
Tighten the front fuel pipe heat shield nuts (1) to
5 N-m (44 lb in).
7c!)
173551
6-412 Engine Mechanical-. 5.7L Engine
79. Install a new o~ring ..
nut at the condenser. (
Tighten
365450

82. Install the A/C compressor and.condenser
hose bolt.
Tighten
365448
83. Connect the wheel speed sensor electric.al

connectors.
\
(
346036
84. Install the RF ground strap and cruise control
ground lead from the front rail.
) 85. Install the wiring harness ground bolt.
Tighten
12 N·m (106 lb in).
346034
86. Install the intermediate steering shaft and shaft

bolt to the rack.
Tighten
Tighten the intermediate steering shaft bolt to
47 N·m (35 lb ft).
87. Install the stabilizer bar brackets.
88. Install the stabilizer bar bracket bolts.
Tighten
) Tighten the stabilizer bar bracket bolts to
55 N·m (41 lb ft).
89. Install the left side front air deflector. Refer to Air
Deflector Replacement - Front Bumper Fascia in
Bumpers.
220630

connect the clutch actuator cylinder line to the
actuator cylinder.
43255
transmission, install the range selector lever cable
to the cable bracket. (
208276
92. Install the retainer to the range selector

lever cable .
. ~
I
341079
93. Snap the transmission range selector lever cable

to the range selector lever at the transmission.
95. Install the torque arm. Refer to Torque Arm
Replacement in Rear Suspension.
96. Install the propeller shaft. Refer to. Propeller Shaft
Replacement - One Piece in Propeller Shaft.
97. Install the right side catalytic converter. Refer to
(5. 7 L Right) in Engine Exhaust.
98. Install the left side catalytic converter. Refer to
99. Install the front wheels. Refer to Tire and Wheel (
208264
101. Install the air intake duct resonator.
208569

103. Connect the MAF sensor. electrical connector.
208553
104. Connect the positive battery cable.

105. Refill the engine oil.
106. Refill the transmission fluid.
System Bleeding (Manual Bleeding) or
Hydraulic Brake System Bleeding (Pressure
Bleeding) in Hydraulic Brakes.
109. Bleed the clutch hydraulic system. Refer to
Clutch Pedal Replacement in Clutch.
110. Perform the crankshaft position (CKP)
Controls - 5.7 L.
211587
Engine Oil and Oil Filter Change
Removal Procedure (
1. Open the hood.
2. Remove the oil fill cap.
information.
4. Remove the oil pan drain plug.
6. Wipe the excess oil from the drain plug hole
and plug.
309862
7. Remove the oil filter from the engine block.;

Important: Check the old oil filter to ensure that the
filter seal is not left on the engine block.
8. Wipe the excess oil from the oil filter mounting.
178469
Notices.
1. Install the oil filter to the engine block.
Tighten
Tighten the oil filter to 30 N-m (22 lb ft).
~
(
178469
2. Install the drain plug to the oil pan.
Tighten
Tighten the drain plug to 25 N-m (18 lb ft).
4. Fill the engine with oil.
5. Remove the oil level indicator in order to check
the oil level.
6. Reinstall the oil level indicator.
7. Close the hood.
309862
Draining Fluids and Oil Filter Removal

Tools Required
J 41712 Oil Pressure Sensor Socket
Important: In order to completely drain the oil from
the oil pan internal baffling, the bottom of the oil
pan must be level during the oil drain procedure.
1. Remove the oil pan drain plug and allow the oil
to drain.
309862
2. Remove the engine oil filter.
~
)
178469
6-:418 En gme
· Mechanical - 5.7L
3. Remove the right Engine
plug and allow th:~~~~~1itnedblo_ck coolant drain
o rain.
(
63164
4. Remo~e the left front e .

plug (1f applicable) and :11ine
ow block coolant
the coolant to drain
drain.
63165
5. Re~ove the engine blo

applicable) and allo thck coolant heater (if
( w e coolant to drain.
65332
6. Use the J 41712 or equivalent in order to remove
the oil pressure sensor (if required).
J 41712
178483
Crankshaft Balancer Removal

Tools Required
• J 41816 Cranksl')aft Balancer Remover
• J 41816-2 Crankshaft End Protector
• J 42386·:A Flywheel Holding Tool
Notice: Refer to·. Fastener Notice in Cautions. and
Notices:
\ Important:
) • Do not reuse the crankshaft balancer bolt. Install
a NEW, crankshaft balancer bolt during final
assembly.
• Make sure that the teeth of the flywheel holding
tool mesh with the teeth of the engine flywheel.
1. Install the J 42386-A and bolts.
Use one M10-1.5 x 120 mm and one M10-1.5 x J42386-A
45 mm bolt for proper tool operation.
Tighten
Tighten the J 42386-A bolts to 50 N-m (37 lb ft).
260126
2. Remove the crankshaft balancer bolt.

Do not discard the crankshaft balancer bolt The
balancer bolt will be used during the balancer
installation procedure.
260154
3, Use the J 41816 and the J 41816-2 in order to
J 41816 remove the crankshaft balancer.
4. Remove the J 42386-A and bolts. (
J41816-2
156164

Important: Note the position and direction of the
engine flywheel before removal. The flywheel does not
use a locating pin for alignment and will not initially
seat against the crankshaft flange, but will be
pulled onto the crankshaft by the. engine flywheel
bolts. This procedure requires a three stage tightening
process.
1. Remove the engine flywheel bolts. (
2. Remove the automatic transmission engine ·
flywheel (if applicable).
178458
3. Remove the manual transmission engine flywheel

(if applicable).
156166
Clutch Pilot Bearing Removal
! Tools Required
J 43276 Clutch Pilot Bearing Remover J 43276
Notice: When using the J 43276 Clutch Pilot Bearing
Remover always secure the J 43276-1. Clutch Pilot
Bearing Remover tool body using a wrench. Do
not allow the J 43276-1 Clutch Pilot Bearing Remover
tool body to rotate. Failing to do so will cause
damage to the J 43276-1 Clutch Pilot Bearing
Remover tool body.
1. Remove the clutch pilot bearing using
the J 43276.
1.1. Install the J43276-1 into the clutch
pilot bearing.
1.2. Using a wrench, secure the J43276-1.
1.3. Insert the J43276-2 into the J43276-1.
1.4. Rotate the J43276-2 clockwise into
the J43276-1 until the clutch pilot bearing is 353275
completely removed from the crankshaft.
1.5. Rotate the J43276-2 counterclockwise to
remove the J4.3276-2 from the J43276~ 1.
1.6. Remove the J43276-1 from the tool body.
2. Discard the pilot bearing.
63195
)
Oil Level Indicator and Tube Removal
1. Remove the oil level indicator from the tube.
2. Remove the oil. level indicator tube bolt from the (
cylinder head.
3. Remove the oil level indicator tube from the .
engine b.lock.
Important: Inspect the 0-ring seal for cuts or damage.
The 0-ring seal may be reused if not cut or damaged.
4. Remove the 0-ring seal from the tube (if
required).
178459
Exhaust Manifold Removal (Left Side)

1. Loosen the Air Injection Reaction (AIR) hose
clamps and remove the hose assembly.
346024
Important: Do not remove the check valve from the

AIR pipe unless service is required.
and gasket from the left exhaust manifold.
spark plugs.
Do not remove the spark plug wires from the
ignition coils unless required.
346026
Important: Do not remove the oxygen sensor from
the manifold unless service is required.
4. Remove the oxygen sensor from the manifold (if
required).
346021
5. Remove the exhaust manifold, bolts and gasket.

492589
7. Remove the heat shield (2) and bolts (3)from the

manifold (1) (if required).
492586
Exhaust Manifold Removal (Right Side)
Important: Do not remove the Exhaust Gas (
Recirculation (EGR) valve from the pipe assembly
unless service is required.
1. Remove the EGR valve, gasket, and bolts.
178487
2. Remove the EGR valve pipe bolt. (1) from the

intake manifold.
492575
3. Remove the EGR valv13 pipe bolts (1) .and gasket

from the exhaust manifold.
492580
4: Remove the EGR valve pipe bolts from the
cylinder head.
) 5. Remove the EGR valve pipe assembly.
With mild force, pull the EGR valve pipe from the
intake manifold.
6. Remove the 0-ring seal from the EGR valve pipe
assembly.
7. Discard the exhaust manifold gasket and
0-ring seal.
178489
Important: Do not remove the check valve from the

Air Injection Reaction (AIR) pipe unless service is ·
required.
8. Remove the AIR pipe (with check valve), bolts,
and gasket from the right exhaust manifold.
spark plugs.
Do not remove the spark plug wires from the
) ignition coils unless required.
346029
Important: Do not remove the oxygen sensor from

the manifold unless service is required.
10. Remove the oxygen sensor from the manifold.
11. Remo.ve .the exhaust manifold, bolts, and gasket.
492592
6-426 Engine· Mechanical - 5. 7l Engine
13. Remove the heat shield (2) and bolts (3) from the
manifold (1) (if required).
(
492583
Water Pump Removal

1. Remove the water pump bolts.
2. Remove the water pump and gaskets.
3. Discard t~e water purnp gaskets.
309751
Throttle Body Removal

Important: The intake manifold, throttle body, fuel
injection rail, and fuel injectors may be removed as an
assembly. If not servicing the individual components,
remove the manifold as a complete assembly.
1. Remove the electrical wire harness connectors
from the throttle body.
2. Remove the engine coolant air bleed hose
and clamp.
3. Remove the throttle body bolts.
4. Remove the throttle body.
222051
5. Remove the throttle body gasket (1 ).
Important: DO NOT reuse the throttle body gasket.
Install a NEW gasket during assembly.
490580
Fuel Rail and Injectors Removal

injection rail and fuel injectors may be removed as an
remove the intake manifold as a complete assembly.
Caution: The fuel rail stop bracket must be
installed onto the engine assembly. The stop
bracket serves as a protective shield for the fuel
rail in the event of a vehicle frontal crash. If
the fuel rail stop bracket is not installed and the
vehicle is involved in a frontal crash, fuel could be
sprayed possibly causing a fire and personal
injury from burns.
1. Remove the fuel rail bolts.
Important: Do not separate the fuel injectors from the
fuel rail unless component service is required.
Use cleanliness and care when handling the fuel
system components.
222050
Do not allow dirt or debris to enter the fuel injectors or
fuel rail components, cap ends as necessary ....
2. Remove the fuel rail (with injectors), lifting evenly
from both sides of the fuel rail until all the injectors
have left their bores.
)
Intake Manifold Removal
injection rail, and fuel injectors may be removed as an (
remove the manifold as a complete assembly.
1. Remove the Manifold Absolute Pressure (MAP)
sensor (if required).
58838
2. Disconnect the knock sensor wire harness

connector (1) from the fuel rail stop bracket [2).
490736
3. Remove the Positive Crankcase Ventilation [PCV)

valve pipe from the left rocker cover (if required).
379366
4. Remove the PCV valve pipe strap nut.
5. Remove the PCV valve pipe from the right rocker
) cover and intake manifold.
) 379367

injury from burns.
6. Remove the intake manifold bolts (1) and fuel rail
stop bracket (2).
490927
)
7. Remove the engine coolant air bleed clamp and
hose from the throttle body.
8. Remove the intake manifold. (
178557
9. Remove the intake manifold-to-cylinder head

gaskets (1 ).
10. Discard the gaskets.
490579
11. Remove the throttle cable bracket (2) and bolt (1)
from the manifold (if required).
490573
Engine Engine Mechanical· 5.7L 6-431
Vapor Vent Pipe Remc:>Val
'
1. Disconnect the knock sensor wire harness
retaining clips from the pipe.
2. Remove the engine coolant air bleed pipe bolts
and studs.
3. Remove the pipe and gaskets.
363239
4. Remove the gaskets from the pipe.

5. Discard the gaskets.
64262
6. Remove the hose (2) from the pipe (1):
490724
6-432. Engine Mechanical - 5.7L Engine
Engine Valley Cover Removal
1. Remove the knock sensor wire harness.
(
309859
2. Remove the knock sensors.
309864
3. Remove the. valley cover bolts.

4. Remove the valley cover and gasket.
5. Discard the valley cover gasket.
65048
6. Remove the knock sensor oil seals (1) from the
cover (2).
1~
I
I
490851
Valve Rocker Arm. Cover Removal

(Left Side)
Important: Do not remove the Positive Crankcase
Ventilation (PCV) valve grommet from the cover unless
service is required.
If the grommet has been removed from the cover, a
NEW grommet must be installed.
1. Remove the ignition coil and bracket assembly
) and bolts.
309727

3. Remove the valve rocker arm cover..
)
4. ·Remove the gasket (1) from the cover.
The bolt grommets may be reused if not damaged. (
6. Remove the ignition coils, wire harriess, and bolts

from the bracket (if required).
309850
Valve Rocker Arm Cover Removal .
' '
(Right Side)
Important: Do not remove the oil fill tube from the
cover unless service is required.
If the oil fill tube has been removed from the cover,
install a NEW tube during assembly.
and bolts.
309721
3. Remove the valve rocker arm cover:
260084
4. Remove the oil fill .cc;1p from the oiLfiU tube.

5. Remove the.oil fill tube (if required).
6. Discard the oil fill tube.
260110
7. Re.move the gasket (1) from the cover. .

The bolt grommets may be reused if not damaged.
490696
6-436 Engine Mechanical· 5.7L Engine
9. Remove the ignition coils, wire harness, and bolts
from the bracket (if required).
(
309850
Valve Rocker Arm and Push Rod Removal

lmportanJ: P,ace valve rocker arms, valve pushrods,
and pivot support, in a rack so that they can be
installed in the same location from which they were
removed.
1. Remove the valve rocker arm bolts.
2. Remove the valve rocker arms.
260140
3. Remove the valve rocker arm pivot support.
260141
4. Remove the pushrods.
260142
Cylinder Head Removal (Left Side)

1. Remove the spark plugs from the cylinder head.
Important: The M11 cylinder head bolts are NOT
reuseable. Install NEW M11 cylinder head bolts during
assembly.
Notice: After remdval, place the cylinder head on
) two wood blocks to prevent damage.
260146
4. Remove the gasket.

6. Discard the M11 cylinder head bolts.
63169
Cylinder Head Removal (Right Side)
1. Remove the spark plugs from the cylinder head.
(
Important: The M11 cylinder head bolts are NOT
reuseable. Install NEW M11 cylinder head bolts during
assembly.
Notice: After removal, place the cylinder head on
two wood blocks to prevent damage.
260149
4. Remove the gasket. ·

6. Discard the M11 cylinder head bolts.
63170
Valve lifter Removal

Tools Required
J 3049-A Valve Lifter Remover
1. Remove the valve lifter guide bolts (1 ).
2. Remove the valve lifters and guide.
63230
Important: Some valve lifters may be stuck in their
bores because of gum or varnish deposits.
3. Use the J 3049-A or equivalent in order to remove
the valve lifters (if required).
31350
4. Remove the valve lifters from the guide.

5. Organize or mark the components so that they
can be installed in the same location from which
they were removed.
Refer to Separating Parts.
63233
Oil Filter, Adapter and Pan Cover Removal

~ 178469
6~440 Engine Mechanical- 5.7L Engine
2. Rernove the oil pan cover, bolts, and gasket
(
178471
4. Remove thE> oil filter fitting {1') and bypass

y~lve (2) (ifrequired).
490699
Oil Pan Removal

Important: The original oil pan gasket is retained and
aligned to the oil pan by rivets. When installing a
new gasket, it is not necessary to install new oil pan
gasket rivets.
DO NOT reuse the oil pan gasket. When installing the
oil pan, install a NEW oil pan gasket.
It is not necessary to remove the oil level sensor prior
to oil pan removal. Remove the oil level sensor if
1. Remove the left closeout cover and bolt.
178477
2. Remove the right closeout cover and bolt.
178480
3. Remove the oil level sensor from the oil pan (if
required).
178467
4. Remove the oil pan bolts.

5. Remove the oil pan.
178558
Important: DO NOT allow foreign material to enter
the oil passages of the oil pan, cap or cover the
openings as required. (
6. Drill (3) out the oil pan retaining rivets (2)
(if required).
7. Discard the gasket and rivets.
384699
8. Remove the oil pan baffle bolts and baffle ·

(if required).
178491
Engine Front Cover·Removal

1. Remove the front cover bolts.
. c;;:, 2. Remove the front cover and gasket.

3. Discard the front cover gasket.
64278
Engine Engine Mec.hanical • 5.7L 6-443
4. Remove the crankshaft front oil seal (1) from
the cover.
490689
Engine Rear Cover Removal

1. Remove the rear cover bolts.
2. Remove the rear cover and gasket.
3. Discard the rear cover gasket.
64282
4. Remove the crankshaft rear oil ~eal (1) from

the cover.
490692
6-444 Engine Mechanical :- 5.7L Engine
Removal
1. Remove the oil pump screen bolt and nuts.
2. Remove the oil pump screen with 0-ring seal.
3. Remove the 0-ring seal from the pump screen.
4. Discard the 0-ring seal.
64268
5. Remove the remaining crankshaft oil

deflector nuts.
6. Remove the crankshaft oil deflector.
64270
7. Remove the oil pump bolts.

Important: Do not allow dirt or debris to enter the oil
pump assembly, cap ends as necessary.
8. Remove the oil pump.
64281
Engine Engine Mechanical - 5.7L 6·445
Timing Chain and Sprockets Removal·
J Tools Required
· " J 8433 Two Jaw Puller
" J 41816-2 Crankshaft Pilot
• J 41558 Crankshaft Sprocket Remover
Notice: Do not turn the crankshaft assembly after the
timing chain has been removed in order to prevent
damage to the piston assemblies or the valves.
1. Remove the camshaft sprocket bolts.
2. Remove the camshaft sprocket and timing chain.
63263
3. Use the J 8433, the J 41816,2, and.the J 41558 in

order.to remove the crankshaft sprocket.
J 8433-1
63189
4. Remove the crankshaft sprocket.
156150
5. Remove the crankshaft sprocket key (if required).
156149
Camshaft· Removal
1. Remove the camshaft sensor bolt and the sensor.
260128
2. Remove the camshaft retainer bolts and ttie

retainer.
63211
l:11gine . Engine Mechanical - 5.7L 6-447
Notice: All camshaft journals are the same diameter,
3. Remove the camshaft.
3.1. Install the three M8-1.25 x 100 mm bolts.in
the camshaft front bolt . holes. ·
3.2. Using the bolts as a handle, carefully rotate
and pull the camshaft out of the
engine block. ·
3.3. Remove the bolts from the front of the
camshaft.
63212
Piston, Connecting Rod,;,~md Bearing

Removal
Tools Required
• J41556 Connecting Rod Guide
.. J 24270 Cylinder Ring Ridge Remover
Important: The connecting rods and the bearing caps
are NOT interchangeable.
) 1. Use the J 24270 in order to remove the cylinder
bore ring ridge (if required).
1.1. Turn the crankshaft until the piston is at the
bottom of the stroke.
1.2. Place a cloth on top of the piston.
1.3. Use the J 24270 or equivalent in order to
remove cylinder ring ridge.
J 24270
1.4. Turn the crankshaft so the piston is at the
top of the stroke.
1.5. Remove the cloth. 11497
1.6. Remove the cuUing debris from the cylinder

and piston. ·
6,-448 Engine Mechanical -5.7L Engine
Important: Using a paint stick or etching tool, place
matchmarks or numbers on the connecting rods and
the connecting rod caps. The connecting rods and I
caps MUST be assembled to their original position and \
direction.
A stamping mark on the side of the connecting rod at
the crank journal may effect component geometry.
Mark the top of the piston to the specific cylinder bore.
2. Remove the connecting rod bolts.
Important: Mark, sort, or organize the connecting rod
bearings so they may be installed to their original
position and location.
3. Remove the connecting rod cap.
53223
4. Install the .J 41556 to the connecting rod.

J 41556
63186
5. Use a hammer and tap lightly on the end of the

J 41556 in order to remove the piston and
connecting rod assembly from the cylinder bore.
64285
6. Upon removal of the piston and connecting rod
assembly, assemble the connecting rod cap and
bolts onto the matching connecting rod.
53223
Crankshaft and Bearings Removal

Tools Required
O J 41818 Crankshaft Bearing Cap Remover
O J6125-18 Slide Hammer
Important: The crankshaft bearing caps are machined

with the engine block for the proper clearances.
Mark or identify each crankshaft bearing cap location
and direction before removal. The crankshaft
bearing caps MUST be installed to their original
position and direction.
Do not reuse the bearing cap MS side bolts.
Remove the bearing cap MS side bolts prior to cap
removal.
1. Remove the crankshaft position sensor bolt.
2. Remove the crankshaft position sensor.
55322
3. Remove the crankshaft bearing cap MS side bolts.

4. Remove the bearing cap M10 bolts and studs.
Note the M10 stud locations.
156155
6-450 Engine Mechanical- 5.7L Engine
Notices,
(
Tighten
Tighten the J 41818 bolts to 11 N-m (100 lb in).
6. Install the J 6125-18 to the J 41818 in order to
remove the crankshaft bearing caps.
63188
7. Remove the bearing caps.
156152
8. Remove the crankshaft.
156151
Important: Use. care. when handling the crankshaft.
Avoid damage to the crankshaft position sensor
reluctor ring teeth. Nicks, burrs or other damage to the
teeth may effect On-Board Diagnostics (OBD) II
system performance.
9. Lay the crankshaft onto two wooden V-blocks or
other protective surface.
156153
10. Remove the crankshaft bearings from .the bearing

caps and the engine block.
11. Mark, sort, or organize the crankshaft bearings so
they may be installed to their original position and
location. Refer to Separating Parts.
64293
Engine Block P,lug Removal

Important: Do not remove the engine block front oil
gallery plug unless service is required.
If the front oil gallery plug is removed for service, a
NEW oil gallery plug must be installed.
1. Remove the oil pressure sensor (if not previously
removed) using the J 41712 or equivalent.
178483
2. Remove the engine block right rear coolant plug.
63164
3. Remove the engine block coolant heater (if

applicable).
65332
4. Remove the engine block left front coolant plug (if

applicable).
53165
5. Remove the engine block left front oil gallery plug.
63167:
6. Remove the engine block left rear oil gallery plug.

7. Inspect the block plug sealing washers.
If the block plug and heater sealing washers are
not damaged, they may be used during assembly.
64923
6-454 Engine Mechanical - 5. 7L Engine
8. Remove the engine block rear.oil gallery plug.
9. Inspect the 0-ring seal of the rear oil gallery plug.
If the 0-ring seal is not cut or damaged, the plug (
and 0-ring seal may be use during assembly.
63228 (
.--------------------, Important: Remove the front oil gallery plug only if

If the front oil gallery plug is removed, a NEW oil
gallery plug must be installed.
10. Remove the engine block front oil gallery plug.
64295
(
Engine Block Clean and Inspect
J 8087 Cylinder Bore Checking Gauge
1. Clean the following areas:
Notice: Do not use a caustic solution to clean the
aluminum engine block.
Important: When cleaning an engine block in a
thermal type oven, do not exceed 232°C (450°F).
• The engine block in the solvent, remove all
sludge, dirt, or debris. ·
Refer to Cleanliness and Care.
damage.
• Dry the block with compressed air.
• The gasket surfaces
Refer to Replacing Engine Gaskets.
4974
• The coolant passages
• The oil galleries
• The main bearing caps
• The engine block cylinder head bolt holes for
threadlocking material
Thread repair driver tool J 42385-107 may be
used to clean the threads of old threadlocking
material.
2. Inspect the following areas:
• The cylinder walls for excessive scratches,
gouging, or ring ridge
• The coolant jacket for cracks
• The valve lifter bores for excessive scoring
or wear
• The crankshaft bearing webs for cracks
• The gasket sealing surfaces for excessive
scratches or gouging
• The oil galleries for restrictions
• All threaded bolt holes for damage
3. Measure the following areas:
• The cylinder bores for taper
• The cylinder bores for excessive ring ridge at
the top of the cylinder
Measuring Cylinder Taper
1. Adjust the micrometer to 96.0 mm (3.78 in).
2. Insert the bore gauge into the micrometer and
zero the bore gauge dial.
3. Use a bore gauge and measure the cylinder bore (
for taper.
Slide the bore gauge up and down throughout the
length of the cylinc::ler bore. Check the bore
both parallel and perpendicular to th.e centerline of
the crankshaft.
Recoridition cylinders with less than _0.018 mm
(0.0007 in) wear or taper with a hone.
Cylinders with more than 0.018 mm (0.0007 in)
wear or taper must be fitted with an oversize
piston.
4972
Cylinder Boring and Honi_ng

Boring Procedure
1. A 0.25 mm (0.01 in) oversize s~rvice piston and
piston ring set are av_ailable for the LS1 engine.
Important: Do not bore the cylinder liners on the
LS1 engine.
2. It is recommended to hone the cylinder to achieve
proper fit for the oversize piston. (
Refer to the Cylinder Honing information for the
proper honing procedure.
Honing Procedure
1. When honing the cylinders, follow the
manufacturer's recommendations for equipment
use, cleaning, and lubrication. Use only clean,
sharp stones of the proper grade for the amount
of material you remove. Dull, dirty stones cut
unevenly and generate excessive heat. Do
186747 not hone to final clearance with a coarse or
medium-grade stone. Leave sufficient metal so
that all stone marks. may be removed with
fine-grade stones. Perform final honing with a
fine-grade stone, honing the cylinder to the proper
clearance.
2. During the honing operation, thoroughly clean the
cylinder bore. Repeatedly check the cylinder bore
tor fit with. the selected piston.
All measurements of the piston or the cylinder
bore should be made with the components
at normal room temperature.
3. When honing a cylinder for fit to an oversize
piston, first perform the preliminary honing
with a 100 grit stone.
4. Perform final cylinder honing with a 240 grit stone
and obtain a 45 degree cross hatch pattern.
A 240 grit stone is preferred for final honing. If a
(
240 grit stone is not available, a 220 grit stone
may be used as a substitute.
5. When honing to eliminate taper in the cylinder,
make full strokes the complete length of the bore.
Repeatedly check the measurement at the.
top, the middle, and the bottom of the bore.
6. The finish marks should be clean but not sharp.
The finish marks should also be free from
imbedded particles and torn or folded metal.
7. By measuring the selected piston at the sizing
point and by adding the average of the clearance
specification, you can determine the final
cylinder honing dimension required.
8. When finished, the reconditioned cylinder bores
should have less than or meet the specified
out-of-round and taper requirements.
9. After final honing and before the piston is checked
for fit, clean the cylinder bores with hot water and
detergent. Scrub the bores with a stiff bristle
brush and rinse the bores thoroughly with
hot water. Do not allow any abrasive material to
remain in the cylinder bores. This abrasive
material may cause premature wear of the new
piston rings and the cylinder bores. Abrasive
material will also contaminate the engine oil and
may cause premature wear of the bearings.
After washing the cylinder bore, dry the bore with
a clean rag.
1o. Perform final measurements of the piston and the
cylinder bore.
11 . Permanently mark the top of the piston for the
) specific cylinder to which it has been fitted.
12. Apply clean engine oil to each cylinder bore in
order to prevent rusting.
Deglazing Procedure
Using a ball type or self centering honing tool, deglaze
the cylinder bore lightly. Deglazing should be done
only to remove any deposits that may have formed.
Use a 240 grit stone of silicone carbide or equivalent
material when preforming the deglazing procedure.
A 240 grit stone is preferred for final honing. If a
240 grit stone is not available, a 220 grit stone may be
used as a substitute.
490757
Crankshaft and Bearings Clean and
Inspect
Cleaning Procedure
(
lmportant:.Use care when handling the crankshaft.
Avoid damage to the bearing surfaces or the lobes of
the crankshaft position reluctor ring. Damage to the
teeth of the crankshaft position reluctor ring may effect
On-Board Diagnostics (OBD) II system performance.
1. Clean the crankshaft with solvent.
2. Thoroughly clean all oil passages and inspect for
restrictions or burrs.
damage.
3. Dry the crankshaft with compressed air.
156153
Inspection Procedure:
Tools Required
• J 7872 Magnetic Base Dial Indicator Set
Important: The .reluctor ring teeth should not have
imperfections on the rising or falling edges.
Imperfections of the reluctor ring teeth may effect
OBD II system performance. (
1. Perform a visual inspection of the crankshaft for
damage.
2. Inspect the crankshaft position reluctor ring lobes
for damage.
156153
3. Inspect the crankshaft journals for wear(1).

Journals should b.e smooth with no signs of
scoring, wear, or damage. ;
4. Inspect the crankshaft journals for grooves or
scoring (2).
5. Inspect the crankshaft journals for scratches or
wear (3).
6. Inspect the crankshaft journals for pitting or
imbedded bearing material (4).
156170
7. Inspect the crankshaft key (1), keyway (2), and
threaded hole (3) for damage.
188090
8. Measure the crankpins for the out-of-round. ·

9. Measure the crankpins for taper.
35207
10. Measure the crankshaft thrust wall width.

A crankshaft with a thrust wall width in excess of
26.2 mm (1.0315 in) must be replaced.
) 26.14 - 26.2mm
(1.029 - 1.0315)
490749
6-460 Engine Mechanical - 5. 7L Engine
11. Measure the crankshaft runout..
Use wooden V blocks or a fixture· to support the
crankshaft on the front and rear journals. (
12. Use the J 7872 in order to measure the crankshaft
runout at the front and rear intermediate journals.
13. Use the J 7872 in order to measure the runout of
the crankshaft rear flange.
14. Use the J 7872 in order to measure the runout of
the crankshaft position reluctor ring. Reluctor ring
runout should be measured 1.0 mm (0.04 in)
below the ring teeth.
If the reluctor ring has runout in excess of
0.25 mm (0.01 in), replace the crankshaft.
J7872
35210
Important: A loose or damaged,crankshaftoiJgallery,

plug must be replaced. ·· · ·
15. Inspect the rear crankshaft oil gallery plug for a

loose fit or leaking.
63238
(
16. Inspect crankshaft bearings for craters or pockets.
Flattened sections on the bearing halves also
indicate fatigue.
52051
17. Inspect the crankshaft bearings for excessive

scoring or discoloration. ·
18. Inspect the crankshaft bearings fordirt or de.bris
imbedded into the bearing material. ·
52053
19. Inspect the crankshaft bearings for improper

seating indicated by bright, polished sections of
the bearing.
If the lower half of the bearing is worn or
damaged, both upper and lower halves should be
replaced.
Generally, if the lower half is suitable for use, the
upper half should also be suitable for use.
52056
Measuring Main Bearing Clearance
Tools Required
• J 41818 Crankshaft Bearing Cap Remover (
• J 6125-18 Slide Hammer
Important: The crankshaft main bearings are a
precision insert type. Main bearing caps are machined
with the engine block for proper clearance and
cannot be shimmed or filed for bearing fit. If the
clearances are found to be excessive, new bearings
and/or engine block and cap repair or replacement
may be required.
Do not rotate the crankshaft while gauging plastic is
between the crankshaft journal and the bearing
surface.
The crankshaft bearing clearances are critical.
Excessive bearing clearance may effect crankshaft
156155 position sensor signals and may effect On-Board
Diagnostics (OBD) II system operation.
Important: Remove the bearing cap .side bolts prior to
cap removal.
1. Remove the bearing cap M8 side bolts.
2. Remove the bearing cap M10 bolts and studs.
156152
(
Notice: Refer to Fastener Notice in Cautions and.
Notices.
I 3. Install the J 41818 to the bearing cap.
Tighten
Tighten the J 41818 bolts to 11 N-m (tOO lb in). J 41818
4. Install the J 6125-18 to the J4181S in order to
remove the bearing cap.
63188
5. Remove,the bearing cap and lower bearing.
64293
6. Install gauging plastic onto the crankshaft journal.

Install the gauging plastic the full width of
crankshaft bearing journal.
4980
7. Install the bearing, bearing cap, bolts and studs.
Tighten
7.1. Tighten the inner bolts (1-10) a first pass in (
sequence to 20 N-m (15 lb ft).
7.2. Tighten the inner bolts (1-10) a final
pass.in sequence to 80 degrees using
the J 36660-A.
19 7.3. Tighten the outer studs (11-20) a first pass
9 in sequence to 20 N·m (15 lb ft).
7.4. Tighten the outer studs (11-20) a final
pass in sequence to 53 degrees using
the J 36660-A.
10
20 7.5. Tighten the side cap bolts to
25 N-m (18 lb ft).
Tighten the bolt on one side of the bearing
cap and then tighten the bolt on the
opposite side of the same bearing cap.
63214
Important: Remove the bearing cap side bolts prior to

cap removal.
8. Remove the bearing cap M8 side bolts.
156155
9. Remove the bearing cap bolts and studs.
156152
10. Use the J 41818 and the J 6125-18 in order to
remove the bearing cap.
63188
11. Measure the,gcJ.uging plastic at its widest area

using the scale supplied with the plastic
gauging kit.
• If the gaugirig plastic shows irregularity in the
journal exceeding 0.025 mm (0.001 in),
remove the crankshaft and measure the journal
with a micrometer.
• If the bearing clearance is greater than
0.054 mm (0.00212 in), select and install an
undersized bearing set, and measure the
clearance with gauging plastic. 0
• If clearance cannot be brought to
specifications, replace the crankshaft or grind
the crankshaft for use with tt1e next
undersized bearing.
4981
12. Measure the crankshaftend play.

12. i. Thrust the crankshaft forward or rearward.
12.2. Insert a feeler gauge between the
center crankshaft bearing and the
bearing surface of the crankshaft and
measure t.he bearing clearance.
The proper crankshaft end play clearance is
0.04-0.2 mm (0.0015-0.0078 in):
12.3. If the bearing clearance is not within
specifications:
0 Inspect the thrust surfaces for nicks,
gouges or raised metal. Minor
imperfections may be removed with a
fine stone.
" Replace the thrust bearings and
measure the end play.
O It the correct measurements cannot be
obtained, repair the crankshaft thrust
surfaces or replace the crankshaft.
64316
6"'.466 Engine Mechanical - 5.7L Engine
Measuring Connecting Rod Bearing Clearance
Tools Required
J 36660-A Torque Angle Meter (
Important: Connecting rod bearings are a precision
insert type. Connecting rods are of a powdered
metal design and cannot be shimmed or filed for
bearing fit. If clearances are found to be excessive, a
new bearing and/or connecting rod are required.
Do not rotate the crankshaft while gauging plastic is
between the crankshaft journal and the bearing
surface.
1. Remove the bearing cap, bearing half and bolts.
53223
2. Install the gauging plastic onto .the connecting rod.

bearing journal. Install the gauging plastic the full
width of the journal.
0 (
(
4980

Notices.
3. Install the bearing cap, bearing, and bolts.
Tighten
3.1. Tighten the connecting rod bolts first pass
to 20 N·m (15 lb ft).
3.2. Tighten the connecting rod bolts final pass
to 60 degrees using the J 36660-A.
4. Remove the bearing cap, bearing, and bolts.
53223
5. Measure the gauging plastic at its widest area
using the scale supplied with the plastic
gauging kit. . .
The connecting rod bearing clearance should be
0.015-0.076 mm (0.0006~0.003 in).·
4981
C,rankshaft Balancer Clean and Inspect

1. Cleari the crankshaft balancer in solvent.
2. Clean the belt grooves. of all dirt or debris with a
wire brush.
3. Dry the crankshaft balanc~r with compressed air.
4. Inspect.the crankshaft balancer for the following:
• Worn, grooved, or damaged hub seal surface
A crankshaft balancer hub seal surface with
) excessive scoring, grooves, rust or other
damage must be replaced.
Minor imperfections on the hub seal surface
may be removed with polishing compound
or fine grade emery cloth.
Important: In order for the belt to track properly, the
belt grooves should be free of all dirt or debris.
• Dirty or damaged belt grooves
The balancer belt grooves should be free of
260155
any nicks, gouges, or other damage that
may not allow the ,belt. to track properly.
Minor imperfections may be removed with a
fine file.
• Worn, chunking or deteriorated'rubber between
the hub and pulley
)
6.;.468 Engine Mechanical - 5.7l Engine
1. Clean the flywheel in solvent.
2. Dry the flywheel with compressed air, (
3. Inspect the manual transmission flywheel for the
following:
.. Pitted surfaces (1)
" Grooves or scoring (2)
" Rusted surface (3)
• Damaged ring gear teeth (4)
• Loose or improperly positioned ring gear
The ring gear has an interference fit onto the
flywheel and should be positioned completely
against the flange of the flywheel.
• Missing, bent, or damaged pressure plate
locating pins
The two locating pins are installed into the
flywheel and spaced 170 degrees apart.
188086
4. Inspect the automatic transmission flywheel .for

the following:
• Damaged· ring gear teeth
• Stress cra:cks around the flywheel-to-crankshaft
bolt hole locations
Important: Do not attempt to repair the welded areas
that retain the ring gear to the flywheel plate. Install
a new flywheel.
• Welded areas that retain the ring gear on1o the
flywheel for cracking (
178458
Piston and Connecting Rod Disassemble ·

Tools Required
J 24086-C Piston Pin Remover/Installer
1. Using piston ring pliers, remove the piston rings
from the piston. ·
490763
2. Install fork insert J 24086-920 into fixture
J 24086-10 Piston Pin Remover/Installer Base ..
533475
3. 1.nstall the piston and connecting rod assembly

onto J 24086-10. J 24086-BSA
4. Install the J 24086-107 into the piston pin
and J 24086-88A through the fixture and
into J 24086-107.
533478
Notice: After the installer hub bottoms on the support

assembly, do not exceed 35 000 kPa (5,000 psi)
pressure, this could cause damage to the tool.
J 24086-88A
5. Press the piston pin from the piston and
· connecting rod assembly.
6. The piston and pin are a matched set and are not
to be serviced separately. Mark, sort or organize
the piston and the matching piston pin.
533480
5..;470 Engine Mechanical-5. 7( Engine
Clean and Inspect (Piston and Pin)
lmporta.nt: Replace the pistons and the pins that are (
damaged or show signs of excessive wear.
The piston ar;id the pin are a matched set. If service is
required, replace the piston and the pin as an
asse.mbly.
Do notwire brush any part of the piston.
1. Clean the varnish from the piston and the pin with
cleaning solvent.
2. Dry the piston and the pin with compressed air.
64180
3. Clean the piston ring grooves with a suitable ring

groove cleaning tool.
4. Clean the oil lubrication holes and slots.
4977
5: Inspect the piston and the pin for the following:

• Cracks in the piston ring lands, the piston skirt,
or the pin bosses ·
• Piston ring grooves for nicks, burrs, or warpage
which may cause the piston ring to· bind
MINOR· imperfections may be removed from
the piston with a fine. file.
• Scuffed or damaged skirts (2)
• Eroded areas at the top of the piston (1)
• Scoring to the piston pin bore (3) or the
piston pin
2
156168
Engine Engine Mechanical - s.7L 6-471
Important: Measurements of components should be
taken with the components at normal room
temperature.
)
6. Measure the piston ring-to-piston ring groove side
clearance.
6.1. Insert the edge of the piston ring into the
piston ring groove.
6.2. Roll the piston ring completely around the
piston.
• If binding is caused by a distorted piston
ring groove, MINOR ring groove
imperfections may be removed with a
fine file.
• If binding is caused by a distorted piston
ring, replace the piston ring.
4969
7. Measure the piston ring side clearance with a

feeler. gauge.
8. If side clearance is not within specifications, try
another piston ring set.
9. The proper piston ring-to-piston ring groove side
clearance is:
• The top. compression ring side clearance is
0.04-0.085 mm (0.00157-0.003346 in).
• The second compression ring side clearance is
0.04-0.08 mm (0.00157-0.003149).
• The oil control ring side clearance is
0.01-0.22 mm (0.0004-0.00866).
10. If proper piston ring-to-piston ring groove side
clearance cannot be achieved, replace the
piston and pin assembly.
22934
11. To determine piston pin-to-bore clearance, use a

micrometer and measure the piston pin.
4976
6-472 .. Engine Mechanical - 5?L E11gine
12. To determine piston pin-to-bore clearance, use an
inside micrometer and measure the piston
pin bore.
Important: The piston and pin are a matched.set. If
(
the clearance is not within specifications, replace
the piston and pin as an assembly.
13. To determine the proper piston pin-to-bore
clearance, subtract the piston pin diameter
from the piston pin bore diameter. ··
The proper piston pin-to-bore clearance is
0.01-,-0.02 mm (0.0004-0.00078).
4975
14. Measure the piston for out-of-round.

14.1. With the micrometer at a right angle to the
piston, measure the piston at 11 nim
(0.433 in) from the bottom of the skirt.
14.2. Measure the piston at two different points
and compare the readings.
14.3. If the piston is more than 0.018 mm
(0.0007 in) out-of-round, replace the
piston and pin as an assembly.
(
188016

Clean and Inspect (Connecting Rod and
Bearings)
Important: The powdered metal connecting rod and
cap are machined for the proper clearances. The
connecting rod and the cap must be used as
an assembly with no repair or modifications to either
mating surface.
Do not attempt to repair the connecting rod or the cap
mating surfaces. If service is required, the connecting
rod and the cap must be replaced as an assembly.
1 . Clean the connecting rod and the cap in solvent.
Important: Replace the connecting rod if the bolt
hole threads are damaged. Do not attempt to repair (
the bolt hole threads of the connecting rod.
2. Clean the connecting rod threaded bolts holes.
64180
Caution: Wear safety glasses ih order to avoid eye
damage.
3. Dry the connecting rod with compressed air.
4. Inspect the connecting rod for the following:
• Twisting
• Nicks or gouging in the bearing bore
• Damage to the bearing locating slots in the
bearing bore
• Proper fit of the connecting rod and the cap
mating surfaces
156169
5. Measure the connecting rod bearing bore for

out-of-round.
If the measurement exceeds 0.008 mm
(D.0003 in), replace the connecting rod assembly.
156167
6-474 Engine Mechanical-5.7L Engine
6. Inspect the connecting rod bearings for craters or
pockets. Flattened sections on the bearing halves
also indipate fatigue.
(
52051
7. Inspect the connecting rod bearings for excessive

scoring or discoloration.
8. Inspect the connecting rod bearings for dirt or
debris imbedded into the bearing material..
52053
9. Inspect the connecting rod bearings for improper

seating indicated by bright, polished sections of
the bearing.
52056
Engine Engine Mechanical - 5. 7L . 6-475
Clean and Inspect (Measuring Piston Ring
J End Gap)
Important: Do not attempt to file the end of the piston
ring for fit in the cylinder bore.
Important: Measure the piston ring in the cylinder in
which the piston ring will be used.
1. Place the piston ring into the cylinder bore.
2. Push the piston ring into the bore 6.5 mm (0.25 in)
below the piston ring travel area.
3. Insert a feeler gauge and measure the piston ring
end gap.
• The proper top compression ring end gap is
0.23-0.38 mm (0.009-0.0149 in).
• The proper second compression ring end gap
is 0.44-0.64 mm (0.0173-0.0251 in).
• The proper oil control ring end gap is
0.18-0.69 mm (0.007-0.0271 in).
4968
Piston Selection
Important: Measurements of all components shou.ld
be taken with the components at normal room
temperature.
For proper piston fit, the engine block cylinder bores
must not have excessive wear or taper.
A used piston and pin set may be reinstalled if, after
cleaning and inspection, they are within specifications.
) 1. Inspect the engine block cylinder bore for
scoring or other damage.
2. Inspect the piston and the piston pin.
Refer to Piston, Connecting Rod, and Bearings
Clean and Inspect (Piston and Pin).
3. With a micrometer or caliper at a right angle to
the piston, measure the piston 11 mm (0.433 in)
from the bottom of the skirt.
4. Record the piston diameter.
188016
5. Adjust the micrometer to the recorded piston

diameter.
J 8087
6. Insert the bore gauge into the micrometer and
zero the bore gauge dial.
4974
7. Use a bore gauge and measure the cylinder bore
diameter. Measure at a poiht 64 mm (2.5 in) from
the top of the cylinder bore.
8. Record the cylinder bore diameter. (
9. Subtract the piston diameter from the cylinder
bore diameter in order to determine piston-to-bore
clearance.
J 8087 The proper piston-to-bore clearance should be ·
between 0.018-0.054 mm (0.0007-0.00212 in).
10. If the proper clearance cannot be. obtained, select
another piston and measure for the clearances.
If the proper fit cannot be obtained, the cylinder
bore may require honing for an oversize piston or
block replacement. · ·
i 1 . When the piston-to-cylinder bore clearance is
within specifications, permanently mark the top
of the piston for installation to the proper cylinder.
4972
Piston and Connecting Rod Assemble

Tools Required
J 24086-C Piston Pin Remover/Installer Set
Important: Assemble the piston for the specific
cylinder with the connecting rod for the corresponding
crankshaft journal. ·
The piston and connecting rod MUST be assembled
properly. · (
1. Install fork insert J 24086-920 into
fixture J 24086-10.
J 24086-10
533475
Caution: A void contact with HOT components.

Wear safety glasses and protective gloves to
avoid personal injury.
Notice: Applying excessive l1eat. to the connecting rod
may damage or distort the· rod. Rod temperature
SHOULD NOT exceed 315°C (600°F). At this
temperature the end of the connecting rod will turn a
straw color upon visual inspection.
2. Use a torch and apply MILD heat to the pin end

of the connecting rod.
Mild heating of the connecting rod will ease in
piston and pin assembly.
3. With the piston and connecting rod properly
assembled, both the flat flange area of the
connecting rod and the alignment mark on the top (
of the piston will be facing the front of the
engine.
63227
4. Assemble the piston, connecting rod and adapter
J 24086-16A and install onto fixture J 24086-10.
J 24086-16A
533488
5. Adjust installation pin J 24086-9 to 1-8.
J 24086-9
533486
Notice: After the installer hub bottoms on the support

assembly, do not exceed 35 000 kPa (5,000 psi)
pressure, this could cause damage to the tool.
6. Insert pin J 24086-9 through fixture J 24086~10
and to the piston pin.
7. Press pin J 24086~9 until the installer bottoms on
fixture J 24086-10.
533483
8. Measure the piston (1), pin (3), and connecting
rod (2) for proper assembly.
8.1. Place the piston and connecting rod (
assembly onto a table or other flat
surface.
Lay the flat top of the piston (1) onto the
table surface.
8.2. Slide the connecting rod (2) and pin (3) to
one side and hold firmly against the inside
of the piston (1 ).
8.3. Measure the pin (3) for proper installation.
A properly installed piston pin should
protrude 1.27 mm (0.05 in) from the side of
the piston.
63156 (
Important: When installing the piston rings onto the
piston, use a ring expanding plier type tool. Do not roll
the piston rings into the grooves of the piston.
Use caution and care to expand the piston rings only
slightly larger than the Outside Diameter (OD) of
the piston.
9. Using piston ring pliers, install the piston rings
onto the piston.
9.1. Install the oil control ring spacer in the
groove.
9.2. Install the lower oil. control ring.
The oil control rings do not have a dimple
or orientation mark and may be installed-
in either direction.
9.3: Install the upper oil control ring ...
9.4. Stagger the three oil control ring end°gaps
a minimum of 90 degrees.
9.5. Using piston ring pliers, install the lower ·
compression ring.
490763
The lower compression ring has a dimple or
orientation mark and must face the top of
the piston.
9.6. Using piston ring pliers, install the upper
compression ring.
The upper compression ring does not have
a dimple or orientation mark and may be
installed in either direction.
(
9.7. Stagger the compression ring end gaps a
minimum of 25 mm (1.0 in).
Camshaft Bearing Removal
. Tools Required
) J 33049 Camshaft Bearing Remover/Installer
Important: A loose camshaft bearing may be caused
by an enlarged, out .of round or. damaged engine
block bearing bore. ·
.1. Prior to bearing removal, inspect the camshaft
bearings for loose fit in the engine. block
bearing bores.
Refer to Camshaft and Bearings Clean and
Inspect.
2. Repair or replaGe the components as required.
63163
3. Select the expanding driver (4-8) and

washer (2 or 3) from the tool usage information.
4. Assemble the tool. 15~ ~1
10
66100
5. Insert the tool through the front of the engine

block and into the bearing.
6. Tighten the expander assembly (15) nut .until snug.
7. Push the guide cone (1) into the frontcamshaft
bearing to align the tool. · ·
8. Drive the bearing from the block bore.
Important: To remove the front camshaft bearing,
operate the tool from the rear of the block using the
guide cone (1) in the rear camshaft bearing bore.
9. Repeat the above procedures to remove
the remaining bearings.
63219
Tool Usage Information
t14 ; \ _,.,.--1 Bearing, Expander, and Expander Driver (
15~
Information
tJ--13 f!!:§§ 2 • Th.e tool consists of a guide cone (1), driving
~12 @)-'" washers (2 or 3), expander bearing drivers (4-8),
00-11 4~3 driverbars (9 or 10), expander jaws (11),
expander sleeve (12), expander cone (13),.
rm~ expander shaft (14), and expander assembly (15).
@;OJ • Expander bearing driver number one .inside

diameter is 28.575-37.465 mm (1.12S:-1.475 in)
and is used with the expander assembly and
~
the small washer.
• Expander bearing driver number two inside
10
9
@ID
8
diameter is 37.465-43.18 mm (1.475-1.7 in) and
is used with number one expanding driver and
the small washer.
@00 • Expander bearing driver number three inside
66100 is used with number two expanding driver and
the large washer.
• Expander bearing driver number four inside
diameter is 48.895-54.61 mm (1.925-2.15 1n) and
is used with number three expanding driverand
the large washer.
• Expander bearing driver number five inside
is used with number four expanding driver and
the large washer.
• Expander bearing driver number six inside (
diameter is 60.325-68.326 mm (2.375-2.69 in)
and is used with number five expanding driver and
the large washer.
Tool Assembly and Operation
1. Select the proper expanding driver and washer
from the expanding driver and washer information.
Important: To install or remove the expanding driver,
always push on or pull from the ends.
Pressure on the outside diameter may cause a bind
against the rubber expanding sleeve.
2. Place the expanding driver onto the expander
assembly.
3. Check to insure that the separation lines between
the segments of the expanding driver align with
the separation lines of the expander assembly.
4. Place the guide cone over the driving bar (with
the small end of the cone facing the driver
assembly).
5. Place the driving washer over the .threaded
portion of the expander assembly.·
64183
6. Screw the expander assembly (with driving
washer) onto the driving bar.
It may be necessary to install the driver bar
extension for removal of the inner bearings.
7. Insert the tool into a inner camshaft bearing and
tighten until snug.
Operate the tool from the front or rear of the
engine block.
On some engine blocks the nut on the expander
assembly is inaccessible except from either
end. In this case you must use a socket and
extension to enlarge and reduce the expander
assembly.
8. Slide the nylon cone into the front or rear camshaft
bearing (this will properly align the tool}.
9. Drive the bearing out of or into the engine block.
10. Repeat the procedure for the additional inner
bearings.
11. For the two end bearings (front and rear), remove
the nylon cone and driver bar extension.
12. Drive the bearings out of or into the engine block.
63219
Camshaft and Bearings Clean and Inspect

Tools Required
• J 7872 Magnetic Base Dial Indicator Set 2
O J 8520 Camshaft Lobe Lift Indicator
1. Clean the components in solvent.

damage.
3. Inspect the camshaft bearing journals (1) for
4. Inspect the camshaft valve lifter lobes (2) for
5. Inspect the threaded bolt holes (3) in the front of
the camshaft for damaged threads or debris.
6. Inspect the camshaft sprocket pin (4) for damage.
7. Inspect the camshaft position reluctor ring for 3
nicks or damage. 188095
8. Inspect the camshaft retainer plate for wear or a
damaged sealing gasket.
If the camshaft retainer plate sealing gasket is not (
cut or damaged, it may be reused. \
63211
9. Inspect the camshaft bearings for proper fit in the

engine block. The camshaft bearings have an
interference fit to the engine block and should not
be loose in their engine block bearing bores.
10. Inspect the camshaft bearings for excessive wear
or scoring.
Bearings with excessive scoring or wear must be
replaced. ·
63163
11. Measure the camshaft journals for wear and

out-of-round with a micrometer.
• A camshaft with bearing journals that measure
more than 0.025 mm (0.001 in) out-of-round,
must be replaced.
• A camshaft with bearing journal diameters that
measure less that 54.99 mm (2.164 in), must
be replaced.
35212
12. Measure the camshaft lobes for wear with a
micrometer.
) • A camshaft with an intake lobe that measures
46.67 mm (1.8376 in) or less, must be
replaced.
• A camshaft with an exhaust lobe that measures
46.67 mm (1.8376 in) or less, must be
replaced.
260130
13. Measure the camshaft runout.

13;1: Mount the camshaft in wooden V-blocks or
between centers on a fixture.
13.2. Check the runout of the intermediate
camshaft bearing journals using
the J 7872.
13.3. If camshaft runout exceeds 0.05 mm
(0.002 in), the camshaft is bent and
) should be replaced.
J7872
64297
)
Measuring Camshaft lobe lift
Important: Measuring camshaft lobe lift is a procedure
used to determine if the camshaft lobes have worn. (
This test is to be performed prior to engine
disassembly and with the camshaft and valve train
components installed in the engine.
1. Measure camshaft lobe lift using J 8520.
1.1. Remove the valve rocker arms and bolts
1.2. Install the dial indicator mounting stud
into the valve rocker arm bolt hole.
1.3. Assemble the components of the J 8520
and position onto the stud.
1.4. Position the shaft of the dial indicator onto
the end of the pushrod.
i .5. Rotate the face of the dial indicator to zero.
1.6. Slowly rotate the crankshaft clockwise
until the dial indicator obtains its highest
and lowest readings.
1.7. Compare the total lift shown to
specifications.
• The proper lobe lift for the intake lobes
is 7.43 mm (0.292 in).
• The proper lobe lift for the exhaust lobes
is 7.43 mm (0.292 in).
1.8. Remove the tool.
2. Compare measurements to specifications.
If the readings are not within specifications,
64967
remove the camshaft. Inspect and/or replace (
components as required.
Camshaft Bearing Installation

Tools Required
J 33049 Camshaft Bearing Remover/Installer
Important: A loose camshaft bearing may be caused
by an enlarged, out of round or damaged engine
block bearing bore.
1. Prior to bearing removal, inspect the camshaft
bearings for loose fit in the engine block
bearing bores.
2. Repair or replace the components as required.
63163
(
Engine Engine Mechanical - 5.7L 5.;4a5
'3. Select the expanding driver (4-8) and
washer (2 or 3) from the tool usage information.
4. Assemble the tool. 15~
t14 /;g-1
u-13
~12
00-11 4@y-3
rm ®50)
@:o)
@;(®.
10
rum
9(00)
66100
5. Insert the tool through the front of the engine

block and to. the bearing bore.
6. Install the new bearing onto the tool.
7. Tighten the expander assembly nut until snug.
8. Push the guide cone into the front camshaft
bearing to align the tool.
9. Properly align the oil hole in the bearing with the
') oil gallery in the engine block.
10. Drive the bearing into the block bore.
Important: To install the front camshaft bearing,
operate the tool from the rear of the block using the
guide cone in the rear camshaft bearing bore.
11. Repeat the above procedures to install the
remaining bearings.
12. Check the installed bearing for proper alignment
of the oil gallery holes. J 33049
63219
Timing Chain and Sprockets Clean and

Inspect
1. Clean the components with cleaning solvent.
damage:
3. Inspect the timing chain for binding or wear.
156158
4. Inspect the camshaft and crankshaft sprockets for:
i • Worn teeth (1)
• Damaged teeth (2) (
• Chipped teeth (3)
• Worn valleys between the sprocket teeth
188097
5. Inspect the crankshaft sprocket keyway for wear.

6. Inspect the crankshaft sprocket oil pump drive
splines for wear.
156150
Valve Rocker Arm and Push Rods Clean

and Inspect
Important: Parts. that are to be reused must be
marked, sorted or organized for assembly.
1. Mark, sort, or organize the components for
assembly.
2. Clean the components with cleaning solvent.
damage.
4. Inspect the valve rocker arms bearings (2) for
binding or roughness.
5. Inspect the valve rocker arm pushrod sockets (3)
and valve stem mating surfaces (1 ). These
surfaces should be smooth with no scoring or
exceptional wear.
490772
6. Inspect the pushrods for worn or scored ends.
These surfaces should be smooth with no scoring
or exceptional wear.
7. Inspect the pushrods for bends. RoU the pushrod
on a flat surface to determine if the pushrod
is bent.
8. Inspect the pushrod oil passages for restrictions.
260142
9. Inspect the pivot supports for cracks, wear, or

other damage.
260141

Inspect
Important: Components that are to be reused must
be marked, sorted or organized for assembly.
1. Mark, sort, or organize the components for
assembly.
2. Clean the components in cleaning solvent.
damage.
178485
4. Inspect the valve lifters for the following:
• Bent or broken clip (1)
• Worn pushrod socket (2) (
" Scllffed or worn sides (3)
If the valve lifter shows wear, inspect the
engine block lifter bores for wear or damage.
• Flat spots on the roller (4)
• Loose or damaged pin (5)
• Plugged oil hole (6)
• Worn or damaged roller bearing
The roller should rotate freely with no binding
or roughness.
5. Inspect the valve lifter guides for the following:

• For cracks or damage
• Excessive wear in the lifter mounting bores
63233
Cylinder Head Disassemble
Tools Required
J 8062 Valve Spring Compressor
Important: Remove the spark plugs from the cylinder
head with the components at room temperature.
Mark, organize, or sort the cylinder head components
for assembly. Return the components to their
original location during assembly.
Do not remove the cylinder head expansion plugs (8)
or valve seats (9 and 11) unless service is required.
1. Remove the spark plugs from the cylinder heads.
64108
2. Use the J 8062 in order to compress the valve

spring.
260151
)
3. Remove the valve stem keys (2).
4. Remove the valve spring cap (3).
5. Remove the valve spring (4). (
6. Remove the valves (10 and 12).
7. Remove th.e valve stem oil seal (5).
8. Remove the valve spring shim (6).
12
64108
9. Remove the cylinder head expansion plugs (1) (if

required).
490662
1O. Remove the coolant sensor from the left
cylinder head.
260086
11. Remove the coolant plug from the right

cylinder head.
260157
Cylinder Head Clean and Inspect

• J 8089 Carbon Removing Brush
• J 9666 Valve Spring Tester
damage.
Important: When cleaning an cylinder head in a
thermal type oven, do not exceed 204°C (400°F).
1. Clean the following components:
Important: Be careful not to scuff the chamber.
• Use the J 8089 in order to remove the
carbon from the combustion chambers.
• Gasket surfaces
) • Valve stems and heads on a buffing wheel
• Bolt hole threads. Remove all dirt, debris, or
threadlocking material from the bolt holes.
4957
2. Inspect the following:
2.1. The cylinder head (1) for cracks in the
exhaust ports and combustion chambers (
2.2. The cylinder head for external cracks in the
water chambers
2.3. The gasket surfaces for excessive scratches
or gouging.
2.4. The bolt hole threads for debris or damaged
threads.
Refer to Thread Repair or Thread Repair
1 Specifications.
3. Inspect the cylinder head for warpage.
64318
(
4. Inspect the valve springs for squareness.
40075
5. Use the J 9666 in order to measure the valve

spring tension.
Replace the spring if the spring tension is less
than 310 N (70 lb) at 45.75 mm (1.80 in).
4960
Valve Guide Reaming/Valve and Seat

Grinding
Valve Guide Reming
Tools Required
J 37378-1 Valve Guide Reamer
Important: Excessive valve stem-to-guide clearance
may cause a noisy valve train, premature valve
stem oil seal wear, component damage, and/or
excessive engine oil consumption.
Insufficient valve stem-to-guide clearance will result in
noisy or sticking valves. Valves that are too tight
may disturb engine smoothness or lead to component
damage.
1. Measure the valve stem-to-guide clearance using
) a dial indicator.
Valve stem-to-guide clearance may also be
obtained by using a micrometer to measure the
valve stem diameter and a ball type measuring
gauge to measure the guide bore.
65822
2. A valve stem (1) and guide (2) with clearance in
excess of 0.093 mm (0.0037 in) must be repaired
or the components replaced. (
156172
3. Inspect the valve stems for excessive scoring,

2 wear, or warpage.
.. A valve stem that has excessive
scoring (3 or 4) or wear (4 or 6) must be
·replaced.
" A valve guide that is worn and has excessive
stem-to-guide clearance should be reamed
and valves with oversize stems installed.
3
4. Measure the valve stem diameter. A valve stem
with a diameter less than 7.95 mm (0.313 in)
(
must be replaced. Position the tip of the
dial indicator at the top of the valve guide.
4 If the va.lve stem diameter is within specifications,
a.nd the stem-to-guide clearance is excessive,
the valve guide must be reamed oversize and a
valve with oversize stem .installed.
5
6
156174
5. Ream the valve guide using the J 37378-1.

6. Clean the guide bore of all metal shavings and
debris.
572270
7. Install the valve (2) (with oversize stem) into the
cylinder head (1 ).
1
8. Inspect the valve for proper fit,
Move the valve back and forth in the guide. The
valve should move freely with no resistance
or drag. ·
572278
Valve and Seat Grinding

2
Important:
• Reconditioning the valve seats is very important.
The seating of the valves must be perfect for
the engine to deliver optimum power and
performance. Several different types of equipment
are available for grinding valve seats.
• Another important factor is the cooling of the valve
head. Good contact between the valve and the 3
,seat will ensure that heat will be properly
dissipated.
" The recommendations of the manufacturer of the
equipment should be followed carefully to obtain 4
the 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 5
proper centering of the tool pilot in the guide.
6
• Valves that are pitted must be refaced to the
proper angle. Valve stems that show excessive 156174
wear, or valves that are warped excessively must
be replaced. When a valve head that is warped
excessively is refaced, a knife edge may be
ground on part or all of the valve head due to the
amount of metal that must be removed. Knife
edges lead to breakage, burning or pre-ignition
due to heat localizing on this knife edge. If
the edge of the valve head is less than 1.25 mm
(0.05 in) after grinding, replace the valve.
• Several different types of equipment are available
for refacing valves. The recommendation of the
manufacturer of the equipment should be carefully
followed to obtain the proper results.
• DO NOT reface intake valves. Intake valves with
excessive wear or damage MUST be replaced.
6r496 Engine Mechanical- 5.7l Engim!
1. Inspect the valve for the following:
• Burnt or eroded areas (1)
• A worn margin (2) · (
• A bent stem (3)
•·A worn or scored stem (4)
• A worn key groove (5)
• A worn stem tip (6)
2. Inspect the valve face for the following:
• Worn or no margin (1 or 4)
• Pitted surfaces (2)
• Burnt or eroded areas (3)
3 2
156173
3. Inspect the valve margin. (

The exhaust valve may be refaced if the margin is
greater than 1.25 mm (0.05 in) thick before
grinding.
4. Reface pitted exhaust valves on a suitable valve
refacing. machine.
5. Replace the valve if the margin is less than ·
1.25 mm (0.05 in) thick after grinding.
6. If the valve face has been ground, it may be
necessary to shim the valve spring to obtain
the proper spring insta.lled height. Refer to .
Cylinder Head Assemble.
4955
(
Engine Engine Mechani.cal "'. 5.7l 6~497
7. Inspect for a loose valve seat (9 or 11) in the
cylinder head (1 ). The valve seat has an
) interference fit to the cylinder head.
8. Clean the valve guide (7) bores with a sui\able
tool. Remove all carbon or dirtfrom th.e bores.
The valve guide must be clean forthe seat
grinding tool to obtain proper results:
9. Grind the valve seat.
The recommendations of the manufacturer of the
equipment should be followed carefully to
obtain the 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 the toolpilot in the guide.
10. Inspect the valve seats.
• The valve seats should be concentric to within
0.05 mm (0.0021in) total indicator reading.
• If the valve seat has been ground, it may be
necessary to shim the valve spring to attain
the proper spring installed height.
Refer to Cylinder Head Assemble.
) 64108
Cylinder Head Assemble

Tools. Required
• J 42078 Valve Stem Oil Seal Installer
1. Clean the cylinder head valve spring shim area.
Important: When reusing the valves and related
components, install the parts to their original location.
2. Install the valves (1 O and 12) into the proper port.
3. Install the valve spring shim (6).
64108
Important: The valve stem oil seal alignment and
position on the valve guide is critical.
An improperly i.nstalled valve stem oil seal may lead to (
excessive oil consumption, increased vehicle
emissions, or component damage.
4. Install the .valve stem oil seal (5).onto the
guide (7). · · ·
'
$ 4.1. Lubricate the valve guide (7) and valve
stem (5) oil seal with clean engine oil.
4.2. Install the valve stem off seal onto the valve
stem. Push the seal down until the seal
contacts the valve.guide.
4.3. Use. the J 42078 in order to install the valve
stem oil seal.
Push or lightly tap the tool until the tool
bottoms against the valve spring shim (6).
63193
5. Measure the valve stem oil seal for the properly

installed height.
18.1-19.1 mm Specification
(0.712-0.752") There should be a 18.1-19.1 mm (0.712-0.752 in)
gap between the top edge of the oil seal body
and the valve spring shim surface.
63158
(
Eogioe Engine Mechanical - 5.7L 6.-499
6. Install the valve spring (4).
7. Install the valve spring cap (3).
) 64108
8. Compress the valve spring (4) using the J 8062.

9. Install the valve stem keys (2).
9.1. Use grease to hold the keys (2) in place
and remove the J 8062.
9.2. Make sure the keys (2) seat properly in the
groove of the valve stem (10 and 12).
9.3. Tap the end to the valve stem (10 and 12)
with a plastic faced hammer to seat the
keys (if necessary).
260151
10. Measure the valve spring installed height using
a ruler.
Measure from the base of the valve spring to the (
top of the valve spring.
Specification
• If the installed height exceeds 46.25 mm
(1.82 in), install a valve spring shim of
approximately 0.5 mm (0.02 in) thick.
• Do not shim the valve spring to obtain less
than the specified height.
Do not assemble the components without a
spring shim on the cylinder head.
11. Install the remaining valves (10 and 12),
springs (4) and other components.
64315
12. Install sealant GM P/N 12346004 or equivalent to

the threads of the coolant sensor.
Notices.
13. Install the coolant sensor into the left
cylinder head.
Tighten
Tighten the coolant sensor to 20 N·m (15 lb ft).
(
260086
14. Install the coolant plug to the right cylinder head.

Tighten
Tighten the coolant plug to 20 N-m (15 lb ft).
260157
15. Apply threadlock GM P/N 12345382 or equivalent
to the sides of the cylinder head expansion
) plugs (1 ).
16. Install the expansion plugs into the cylinder head.
A properly installed plug should be slightly below
flush with the face of the head.
490662
Oil Pump Disassemble

Important: The internal parts of the oil pump assembly
are not serviced separately (excluding the spring). If
the oil pump components are worn or damaged,
replace the oil pump as an assembly.
1. Remove the oil pump cover bolts.
65055
65057
lmportant:·Mark or identify the gears for assembly.
3. Remove the drive gear.
(
65058
4. Remove the driven gear.
--
65060
5. Remove the pressure relief valve plug.
I (
e 65064
Engine Engine Mechanical - 5.7l 5..,503
6. Remove the pressure reliefvatve spring.
65068
7. Remove the pressure relief valve.

8. Inspect the oil pump components.
Refer to· Oil Pump Clean and Inspect.
65076
Oil Pump Clean and Inspect

important: The internal parts of the oil pump assembly
are not serviced separately (excluding the spring). If
the oil pump components are worn or damaged,
replace the oil pump as an assembly.
The oil pump pipe and screen are to be serviced as
an assembly. Do not attempt to repair the wire
mesh portion of the pump and screen assembly.
1. Clean the parts in solvent.
damage.
2. Dry the parts with compressed air.
3. Inspect the oil pump housing and the cover for
cracks, excessive wear, scoring, or casting
) imperfections.
4. Inspect the oil pump housing-to-engine block oil
gallery surface for scratches or gouging.
5. Inspect the oil pump housing for damaged bolt
hole threads.
65060
6. Inspect the relief valve plug and plug bore for
damaged threads.
7. Inspect the oil pump internal oil passages for (
restrictions.
I
e 65064
8. Inspect the drive gear and driven gear for

chipping, galling or wear.
Minor burrs or imperfections on the gears may be
removed with a fine oil stone.
65060
9. Inspect the drive gear splines for excessive wear.
65058
Engine Engine Mechanical -5.7l 6-505
10. Inspect the pressure relief valve and bore for
scoring or wear.
The valve must move freely in the bore with no
restrictions.
65076
11. Inspect the oil pump screen for debris or

restrictions.
12; Inspect the oil pump screen for broken or loose
wire mesh.
64268
Oil· Pump Assemble·<·

Important: Prior to assembling the oil pump, coat all
wear or internal surfaces with clean engine oil.
1. Install the driven gear into the pump housing.
Install the driven gear with the orientation mark
facing the pump cover.
65060
2. Install the drive gear into the pump housing.
65058
65057

Notices.
4. Install the pump cover bolts.
Tighten
Tighten the oil pump cover bolts to
12 N-m (106 lb in).
65055
5. Install the regulator valve.
65076
6. Install a NEW regulator valve spring.
65068
7. Install the pressure relief valve plug.

Tighten
Tighten the pressure relief valve plug to
12 N-m (106 lb in).
8. Inspect the oil pump for smoothness of operation
by rotating the drive gear.
)
.
I
e 65064
Engine Front Cover Clean and Inspect
Important: Do not reuse the crankshaft oil seal. Install
a NEW crankshaft oil seal during assembly. (
Do not reuse the front cover-to-engine block gasket.
1. Remove the crankshaft oil seal (1) from the
front cover.
2. Clean the cover in solvent. Remove the sealant
from the cover oil pan surface.
damage.
3. Dry the cover with compressed air.
4. Inspect the gasket sealing surfaces for excessive
5. Inspect the cover-to-oil pan threaded bolt holes
for damaged threads or debris.
6. Inspect the crankshaft oil seal mounting bore for
damage.
490689
Engine Rear Cover Clean and Inspect

Important: Do not reuse the crankshaft oil seal. Install
a NEW crankshaft oil seal during assembly.
Do not reuse the rear cover-to-engine block gasket.
1. Remove the crankshaft oil seal (1) from the
rear cover.
2. Clean the cover in solvent. Remove the sealant
from the cover oil pan surface. (
damage.
3. Dry the cover with compressed air.
5. Inspect the cover-to-oil pan threaded bolt holes
for damaged threads or debris.
6. Inspect the crankshaft oil seal mounting bore for
damage.
490692
Engine Valley Cover Clean and Inspect

Important: Do not reuse the valley cover knock .
sensor oil seals .. In.stall NEW oil seals during assembly.
Do not reuse the valley cover gasket. Install a NEW
1~ gasket during assembly.
1. Remove the knock sensor oil seals (1) from the
I
I valley cover (2).
2. Clean the valley cover in solvent.
damage.
3. Dry the valley cover with compressed air.
Refer to Replacing Engine Gaskets. (
5. Inspect the valley cover oil seal bores for
excessive scratches or gouging.
490851
Va.Ive Rocker Arm Cover Clean and
Inspect
Important:
" Do not reuse the valve rocker arm cover gasket.
" Remove the ignition coils from the bracket before
cleaning the bracl<et in solvent. Do not submerge
the ignition coils in solvent.
a Do not remove the oil fill tube from the cover
unless service is required.
" If the oil fill tube has been removed from the
rocker arm cover, install a NEW tube during
assembly.
and bolts from the rocker cover (if required).
309727
2. Remove the ignition coils and bolts from the

bracket (if required).
309850
3. lnsp~ct the tube for a loose fit or damage.

4. Remove the oil fill cap and .tube from. the right
cover (if required).
260110
6-5.10 Engine Mechanical - 5.7L Engine
5. Remove the gaskets (1) from the covers.
6. Remove the cover mounting bolts (with
grommets). (
Cover mounting bolts and grommets that are not
damaged may be reused during assembly.
7. Clean the covers and coil brackets in solvent.
490696

damage.
9. Inspect the ventilation system passages for
restrictions.
10. Inspect the gasket grooves for damage.
11. Inspect the coil bracket threaded bolt holes for
damaged threads or debris. (
260085
12. Inspect the coil mounting brackets for cracking,

stripped bolt hole threads, or other damage.
13. Inspect the ignition coils for exterior damage and
bent or broken connector pins.
309850
Oil Pan Clean and Inspect
Important:
• Do not reuse the oil pan cover gasket. Install a
NEW cover gasket during assembly.
• Do not reuse the oil pan to engine block gasket.
• When installing a NEW oil pan gasket, it is not
necessary to install the rivets that retain the
NEW gasket to the pan.
1. Remove the oil level sensor from the pan.
178467
2. Remove the oil pan cover, gasket, and bolts.
178471
3. Remove the oil pan drain plug and 0-ring seal.
178475
4. Remove the oil pan baffle bolts and baffle.
178491
5. Drill, out (3) the oil pan gasket retaining rivets (2)
(if required).
6. Remove the gasket (1) from the oil pan.
7. Clean the oil pan in solvent. Be sure to thoroughly
clean all of the oil passages and recesses of
the pan.
8. Clean the oil pan gasket surfaces. Refer to
Replacing Engine Gaskets.
Caution: Wear safety glasses in order to avoid eye (
damage.
9. Dry the oil pan with compressed air.
scratches or gouging. Refer to Replacing Engine
Gaskets.
384699
11. Inspect the oil pan oil level sensor seal surface for
damage.
If the 0-ring seal of the sensor is not cut or
damaged, it may be reused.
178467
12. Inspect the oil pan drain plug and threaded drain
hole for damaged threads.
The drain plug 0-ring seal may be reused if not
cut or damaged.
178475
13. Inspect the oil filter sealing surface for scratches

or gouging.
14. Inspect the oil passages for restrictions.
~ 178469
15. Inspect the oil filter fitting (1) for a loose fit or
damaged threads.
16. Inspect the oil filter bypass valve (2) for proper
operation.
Lightly push the bypass valve into the bore. The
valve spring should reseat the valve to the
proper position.
490699
Intake Manifold Clean and Inspect
Cleaning Procedure (
Important: Do not reuse the intake
manifold-to-cylinder head sealing gaskets.
1. Remove the Manifold Absolute Pressure (MAP)
sensor from the rear of the intake (the MAP
sensor is to be reinstalled upon completion of the
cleaning and inspection procedures).
2. Inspect the sealing grommet on the MAP sensor.
The grommet should not be torn or damaged.
58838
3. Remove the throttle body and bolts.
222051
4. Remove the throttle body gasket (1 ).

490580
Engine . Engine Mechanical - 5.7L 6-515
6. Remove the accelerator control cable bracket (2)
and bolts (1) (if required),
490573
7. Remove the fuel rail with injectors.

Refer to Fuel Rail and Injectors Removal.
222050
8. Remove and discard the intake

manifold-to-cylinder head gaskets (1).
490579
9. Clean the intake manifold in solvent.
" Clean the intake manifold gasket grooves:
• Clean the intake manifold vacuum passages at (
the rear of the intake.
damage.
10. Dry the intake manifold with compressed air.
11. Upon installation of the intake manifold, install
NEW manifold-to-cylinder head gaskets.
178557
Inspection Procedure
1. Inspect the throttle body bolt inserts for looseness
or damaged threads.
222051
2. Inspect the fuel rail bolt inserts for loosen!3ss or

damaged .threads. · '
3. Inspect the intake manifold vacuum passages for
debris or restrictions.
222050
Engine Engine Mechanical - 5.7l 6.;517
Important: The rear Manifold Absolute
Pressure (MAP) sensor housing is retained to the
intake manifold by push-in-place snap·lock design.
The rear MAP sensor housing is sealed at the intake
manifold by an 0-ring seal.
4. Inspect the rear MAP sensor housing.
• Inspect for damaged or broken vacuum fittings,
damaged MAP sensor mounting bore, or
broken MAP sensor retaining tab.
• Inspect the rear MAP sensor housing for
looseness or poor sealing to the intake
manifold. Repair or replace the components as
necessary.
5. Inspect the composite intake manifold assembly
for cracks or damage.
Inspect the areas between the intake runners.
6. Inspect all the gasket sealing surfaces and
grooves for cracking or damage.
58838
7. Inspect the fuel injector bores for excessive

scoring or damage.
8. Inspect the intake manifold cylinder head deck for
warpage.
8.1. Locate a straight edge across the intake
manifold cylinder head deck surface.
8.2. Insert a feeler gauge between the intake
manifold and the straight edge.
J A intake manifold with warpage in excess of
0.5 mm (0.02 in), must be replaced.
9. Upon completion of inspection, install the MAP
sensor to the manifold.
222050
Exhaust Manifold Clean and Inspect

Important:
• Do not reuse the exhaust manifold-to-cylinder
head gaskets. Upon installation of the exhaust
manifold; install a NEW gasket. A improperly
installed gasket or leaking exhaust system may
effect On-Board Diagnostics (OBD) II system
performance.
• Remove the oxygen sensor prior to cleaning the
manifold, do not submerge the oxygen sensor
in cleaning solvent.
1. Remove the oxygen sensor from the manifold.
2. Clean the exhaust manifold (1) and heat shield (2)
in solvent.
damage.
3. Dry the exhaust manifold with compressed air.
492586
5.;51 s Engine Mechanical - 5.~7L Engine
4. Inspect the exhaust manifold air injection
reaction (AIR) passages for restrictions.
5. Inspect the AIR flange threaded bolt holes threads (.
. for damage. .
6. Inspect the AIR flange gasket surface for
excessive scratches or gouging.
7. Inspect the exhaust manifold-to-cylinder head
gasket• surface for excessive scratches or
gouging.
8. lnsp~ct the. right side manifold exhaust gas .
recirculation (EGA) flange sealing surface for
excessive scratches or gouging: . .
9. Inspect the right side manifold EGRflange bolt
hole threads tor damage. .
10. Inspect for a loose or damaged. heat shield (2) or
missing bolts (3),
346026
11. Inspect the take down studs tor damaged threads.
220594
12. Use a straight edge and a feeler gauge and

measure the exhaust manifold cylinder head deck
tor warpage.
A exhaust manifold deck with warpage in excess
of 0.25 mm (0.01 in), may cause an exhaust
leak and may effect OBD II system performance.
Exhaust manifolds not within specifications
must be replaced.
66607
\
Engine Mechanical - 5.7L 6-519

Vapor, Vent Pipe Clean and Inspect
lmporta~o not reuse the engine coolant air bleed
pipe gaskets."'Ue_on installation of the pipe, install
NEW gaskets.
1. Remove the engine coolant air bleed hose,
clamps, and sealing gaskets from the pipe.
64262
2. Clean the pipe (1) and hose (2) in solvent.

damage. ·
1
3. Dry the pipe with compressed air.
4. Inspect the pipe for damage or restrictions.
5. Inspect the gasket and hose sealing surfaces for
damagE3.
6. Inspect the hose (2) for restrictions, cracking
or wear.
The hose may be reused if not damaged.
490724
Water Pump Clean and Inspect

1 . Remove the old gasket f.rom the water pump
sealing surfaces. Refer to Replacing Engine
Gaskets.
2. Clean all dirt and debris from the water pump
housing.
3. Inspect the water pump for the following:
• Gasket sealing surfaces for excessive
scratches or gouging
• Hose sealing surfaces for scratches or gouging
• Restrictions within the internal coolant
passages
309751
··· • Excessive side-to-side play in the pulley shaft
" A loose belt pulley or a pulley with excessive 1 2
wear or scoring on the belt tracking area
(
• Leakage at the water outlet housing or rear
cover gasket
• Leakage at the water pump vent hole
A stain around the vent hole is acceptable. If
leakage occurs (dripping) with the engine
running and the c6oling system pressurized,
replace the water pump.
Thread Repair
General Thread Repair
Tools Required
J 42385-200 General Threads Kit
320670
1. Drill outthe. threads of the damaged hole (1 ):

• M6 inserts require a minimum drill depth of
15 mm (0.59 in).
2
• MS inserts require a minimum drill depth of
20 mm (0.79 in). . ..
~ M1 o ins~rts requir~ a mi~imum drill. depth of
23.5 m.m (0.93 in).
2. Using compressed air, cle~n out any chips.
(
···t·· ~···
.
.
.. J
', . ·. '.
320675
The thread repair process involves a solid, thin walled,

self-locking, carbon steel, bushing type insert (1):
During the bushing installation process, the. driver tool
expands the bottom external threads of the insert
into the base material (2). This action mechanically
:;:__
locks the insert in place. Also, when installed to ~
the proper depth, the flange of the insert will be seated
against the counterbore of the repaired hole.
~
Caution: Wear safety glasses in order to avoid eye ·320672
damage.
3. Counterbore the hole to the full depth permitted
by the tool (1 ).
Important: The use· of a cutting type fluid
GM P/N 1052864, WD 40®, or equivalent is 4. Using compressed air, clean out any chips.
recommended when performing the drilling,
counterboring, .and tapping procedures.
Driver oil MUST be used on the installer driver tool.
The tool kits are designed for use with either a suitable (
tap wrench or drill motor.
1 2
'
320670 313567
5. Using a tap wrench (2), tap the threads of the 10. Install the insert (2) onto the driver tool (1).
drilled hole.
• M6 inserts require a minimum tap depth of 1
15 mm (0.59 in).
• M8 inserts require a minimum tap depth of
20 mm (0.79 in).
• M10 inserts require a minimum tap depth of
23.5 mm (0.93 in).
\) 6. Using compressed air, clean out any chips.
7. Spray cleaner GM P/N 12346139, P/N 12377981,
or equivalent into the hole.
8. Using compressed air, clean any cutting oil and
chips out of the hole.
313572
11 . Apply thread lock Loctite® 277, J 42385-109 ( 1), or

equivalent to the insert OD threads (2).
313562
Important: Do not allow oil or other foreign material to

) contact the outside diameter (OD) of the insert.
9. Lubricate the threads of the installer tool (2) with
the driver oil (1 ).
6-522 Engine Mechanical - 5c"7l Engine
Cylinder Head Bolt Hole Thread Repair
Tools Required
• J 42385-100 Cylinder Head/Main Bearing Boit Kit (
• J 42385-300 Fixtures and Hardware Kit
320673
12. Install the insert (2) into the hole.

Install the insert until the flange of the insert
contacts the counterbored surface. Continue to
rotate the installer tool (1) through the. insert.
The installer tool will tighten up before screwing
completely through the insert. This is acceptable.
You are forming the bottom threads of the
insert and mechanically locking the insert to the
base material threads.
(
1
2
313560
1. The cylinder head bolt hole thread repair kit

consists of the following items:
• Drill (1)
• Tap (2)
• Installer (3)
• Sleeve (4)
• Alignment Pin (5)
• Bushing (6)
" Bolts (7)
• Fixture Plate (8)
320675
13. Inspect the insert for proper installation into

the hole.
A properly installed insert (1) will be either flush or
slightly below flush with the surface of the base
material (2).
(
15 13 11 12 14
'-"""' ......... .........
[°7 3
6
1
2
5
4 :]
260150
Caution: Wear safety glasses in order to avoid 6.. Cylinder head bolt holes l-c-8 are the deep holes
eye damage. · · andwill be drilledwithoutthe drill sleeve.
Cylinder head bolt holes 9 and 10 are the
Important: The use of a cutting type fluid GM ,
P/N 1052864,. WD 40®, or equivalent is recommended shallower holes, driUing MUST be done with the
drill sleeve in place.
when performing the drilling and tapping procedures.
Driver oil MUST be used on the insfallerdrivertool.
The tool kits are designed for use with ej_ther 'a s.uitable
tap wrench or drill m.otor. ·
2. Install the fixture plate (3), bolts (1 ), and
bushing (2) onto the engine block deck, ..
Position the fixture plate and bushing over the
hole that is to be repaired (4).
313570
7. Install the sleeve (2) onto the drill (1) (if required).
313577
3. Position the alignment pin (1) through the

bushing and into the hole.
4. With the alignment pin in the desired hole, tighten
the fixture retaining bolts (2).
5. Remove the alignment pin from the hole.
309861 377637
Important: During the reaming process, it is necessary 11. In order to tap the new threads to the proper
to repeatedly remove the drill and clean the chips depth, rotate the tap into the hole until the
marks (1 or 4) on the tap align with the top of the
from the hole.
drill bushing (3).
8. Drill out the threads of the damaged hole. For the deeper cylinder head bolt holes (1-8),
Drill the hole until the stop collar of the drill bit or rotate the tap until the upper mark on the tap (4)
the sleeve contacts the bushing. aligns with th~ top of the drill bushing.
9. Using compressed air, clean out any chips. For the shallower cylinder head bolt
holes (9 and 10), rotate the tap until the lower
mark on the tap (1) aligns with the top of the drill (
bushing.
12. Remove the fixture plate (2), bushing (3),
and bolts.
13. Using compressed air, clean out any chips.
14. Spray cleaner GM P/N 12346139, P/N 12377981,
or equivalent into the hole.
15. Using compressed air, clean any cutting oil and
320667
1O. Using a tap wrench, tap the threads of the

drilled hole.
(
Engine
313572
~·~
· terial to
other foreign· ma J 42385-109
2 77 •___e_a_ds (1), or
.
not allow oil or f the insert. 18. Appy
I ·threadlock
equ1vae ~octite\ID
1 nt to the mse rtI_ ,o~·~D_:t::.:.hr __(2)
Important: Dotside diameter (OD_) o I totil (2) w.ilh
contact the ou ds of the instal er . .
Lubricate t~e threa
16. driver oil (1 ). .
fue . ~1
1 . '
2
. (1) into the hole.
' I the insert an d driver
. mark on t h e
19. lnstal . tool until the f the
313567 Rotate. ·ns
the wit
d~1vhetrhe deck surface o
I
17. Install the .mse rt (2) onto the driver tool (1 ). tool a 19 k fore screwing
engine bloc . I will tighten up be ·s acceptable.
The installer too h the insert. This I of the
completely th~o~~he bottom !hre~~s insert to the
You
. rtare
andformmhanically
mec locking
mse
base ma terial threads.
)
6-526 Engine Mechanical -5:7l Engine
Main Cap Bolt Hole Thread Repair
Tools Required J 42385-306
(
• J 42385-100 Cylinder Head/Main Bearing Bolt Kit
• J 42385-300 Fixtures and Hardware Kit
1 3 4
I
,'
377630
2. Install the fixture plate, bolt, and bushing, onto the

engine block. ,
Position the fixture plate and bushing over the
hole that is to be repaired.
3. Position the alignment pin in the desired hole and
tighten the fixture retaining bolts.
tr ~ 8 7
6
313556
(
19
1. The main cap bolt hole thread repair kit consists 9
of the following items:
• Drill (1)
• Tap (2) 10
20
• Installer (3)
• Fixture Plate (4)
• Long Bolts (5)
• Short Bolts (6)
63214
• Alignment Pin (7)
• Bushing (8) 4. Drill out the damaged hole.
The outer bolt hole locations (11-20) have the
shallower counterbores. Use sleeve J 42385-316
with the drill.
Drill until the stop collar of the drill bit or the
sleeve contacts the bushing.
(
'
2
'
377637 313567
6. Using a tap wrench, tap the threads of the 11. Install .the insert (2) onto the driver tool (1 ).
drilled hole.
In order to tap the new threads to the proper·
depth, rotate the tap into the hole until the mark
on the tap aligns with the top of the bushing.
For the deeper main cap holes (1-i 0), rotate the
tap until the upper mark (4) on the tap aligns
with the top of the bushing (3).
For the shallower main cap holes (11-20), rotate
) the tap until the lower mark (1) on the tap
aligns with top of the bushing (3).
8. Spray cleaner GM P/N 12346139, or equivalent
into the hole.
9. Using compressed air>clean any cutting oil and
313572
12. Apply threadlock Loctite® 277, J 42385-109 (1), or

equivalent to the insert OD threads (2).
313562
) Important: Do not allow oil or ot11er foreign material to

contact the outside diameter (OD) of the insert.
10. Lubricate the threads of the installer tool (2) with
the driver oil (1 ).
Service Prior to Assembly
• Dirt or debris will cause premature wear of the
rebuilt engine. Clean all the components. (
Refer to Cleanliness and Care.
• Use the proper tools to measure components
when checking for excessive wear. Components
3 that are not within the manufacturers specifications
must be repaired or replaced.
2 • When the components are reinstalled into an
engine, return the components to their original
location, position and direction.
• During assembly, lubricate all the moving parts
with clean engine oil. This 'Nill provide initial
lubrication when the engine is first started.
377635
Important: The fixture plate and bushing remains

installed onto the engine block during the insert
13. lnstaUthe insert and driver (1) through the fixture
plate and bushing and into the hole.
Rotate the driver tool until the mark on the tool (3)
aligns with the top of the bushing (2).
The installer tool will tighten up before screwing
completely through the insert. This is acceptable. (
You are forming the bottom threads of the
insert and mechanically locking the insert to the
base material threads.
(
Engine Engine Mechanical -5.7L 6.;.529
Engine Block Plug Installation
J
Tools Required
(
Important:
• Engine block plug (oil gallery and coolant) sealing
washers may be reused if not bent, scored or.
otherwise damaged.
• Apply the proper amount and type of sealant to
the sealing washer as recommended in the
service procedure.
1. Apply a 3.175 mm (0.125 in) bead of sealant
GM P/N 12346004 or equivalent to. the engine
block coolant· heater sealing washer (if applicable).
Refer to SeaJers, Adhesives, and Lµbricants.
Notices.
2. Install the engine block coolant heater to the
engine block (if applicable). 65332
Tighten
Tighten the block coolant heater to
40 N·m (30 lb ft) ..
3. Apply a 3:175 mm (0.125 in) bead of sealant
GM P/N 12346004 or equivalent to the engine
block left front coolant drain plug sealing washer
(if applicable).
4. Install the engine block left front coolant drain
plug (if applicable).
) Tighten
Tighten the block left front coolant drain plug to
60 N-m (44 lb ft).
63165
)
6".'.530 Engine Mechanical - 5.7L Engine
5. Apply a 3.175 mm (0.125 in} bead of sealant
block right rear coolant drain plug sealing washer.
6. Install the engine block right rear coolant (
drain plug.
Tighten
Tighten the block right rear coolant drain plug to
60 N-m (44 lb ft).
63164

block left front oil gallery plug sealing washer.
8. Install the engine block left front oil gallery plug.
Tighten
Tighten the block left front oil gallery plug to
60 .N·m (44 lb ft).
' ',,.)
. .
63167

block left rear oil gallery plug sealing washer.
10. Install the engine block left rear oil gallery plug.
Tighten
Tighten the block left rear oil gallery plug to
60 N·m (44 lb ft).
64923
11. Inspect the engine block rear oil gallery plug and
0-ring seal. ·If the 0-ring seal on the plug is not
cut or damaged, the rear oil gallery plug may
be reused.
12. Lubricate the 0-ring seal with clean engine oil.
13. Install the block rear oil gallery plug into the
oil gallery bore.
A properly installed oil gallery plug will protrude
0.8-1.4 mm (0.0315-0.055 in) beyone the
rear face of the block.
63228
Important: The engine block front oil gallery plug

should not be removed unless service is required.
the sides of the NEW front oil gallery plug.
15. Install a NEW engine block front oil gallery plug {if
required). Install the front oil gallery plug into the
oil gallery.bore 2.2-2.8 mm (0.0086-0.0.j 1 in)
below flush. ·
64295
the threads of the oil pressure sensor.
J 41712 17. Use the J 41712 or equivalent in order to install
the oil pressure sensor.
(
Tighten
Tighten the oil pressure sensor to
20 N·m (15 lb ft).
178483

Tools Required
Important:
• Crankshaft bearing clearances are critical.
Excessive crankshaft bearing clearance may effect
crankshaft position sensor signals and/or
On-Board Diagnostics (OBD) II system (
performance.
• Crankshaft bearing caps must be installed to the
proper location and direction.
• When installing the crankshaft bearings, align the
locating tabs on the bearings with the locating
notches in the engine block journal bore and the
bearing cap.
• Always install crankshaft bearings with their
machined partner. Do not file bearings or
64293 mix bearing halves.
" To prevent engine block oil leakage, install NEW
M8 crankshaft bearing cap side bolts.
The crankshaft bearing cap M8 side bolts have a
sealant patch applied to the bolt flange.
1. Install the crankshaft thrust bearings to the engine
block and center bearing cap.
2. Install the remaining crankshaft bearings to the
engine block and bearing caps.
3. Lubricate the bearing surfaces and crankshaft
journals with clean engine oil.
(
Engine Engine Mechanical - 5.7.l 6-533
Notic~: To maintain proper crankshaft end play, use
extreme care during crankshaft installation. Avoid
) scoring or damaging the thrust bearing.
4. Install the crankshaft.
156151
Important: The bea.ring caps must be installed in the

proper location and direction.
5. Install the crankshaft bearing caps (with bearings)
into the engine block.
6. Start the M10 bolts and studs.
7. Tap th.e bearing caps into place with .a
plastic-faced hammer.
156152
8. Install the NEW M8 bearing cap side bolts.
156155
Notices.
9. Tighten the bearing cap bolts and studs. (
Tighten
Tighten the inner M1 O bearing cap bolts first pass
in sequence to 20 N-m (15 lb ft).
Important: To properly align the crankshaft thrust
i9 bearings, the final thrust of the crankshaft MUST be in
9 the forward direction.
10. Using a plastic faced hammer, tap the crankshaft
rearward then forward to align the thrust bearings.
10
20 Tighten
10.1. Tighten the inner M10 bolts final
pass in sequence 80 degrees using
the J 36660-A.
10.2. Tighten the outer M10 bolts first pass in
sequence to 20 N-m (15 lb ft).
· 63214
10.3. Tighten the outer M10 bolts final
pass in sequence 53 degrees using
the J 36660-A.
10.4. Tighten the bearing cap side M8 bolts to
25 N-m (18 lb ft).
Tighten the bolt on one side of the bearing
cap and then tighten the bolt on the
opposite side of the same bearing cap.
11. Install the crankshaft position sensor.
. 11.1. Inspect the crankshaft position sensor (.
0-ring seal. If the 0-ring seal is not cut or
damaged, it may be used.
11.2. Coat the 0-ring seal with clean engine oil.
11.3. Install the sensor. Align the notch in the
sensor retaining bracket with the bolt hole
in the block.
11.4. Install the sensor bolt.
Tighten
Tighten the crankshaft position sensor bolt
to 25 N-m (18 lb ft).
55322
(
Engine Engine Mechanical - 5. 7L 5;.535
12. Measure the crankshaft end play.
12.1. Thrust the crankshaft forward or rearward.
12.2. Insert a feeler gauge between the·
center crankshaft bearing and the
bearing surface of the crankshaft arid
measure the bearing clearance.
The proper crankshaft end play Clearance is
0.04-0.2 mm (0.0015-0.0078 in).
12.3. If the bearing clearance is not within
· specifications, inspect the thrust surfaces
for nicks, gouges or raised metal.
Minor imperfections may be removed with
a fine stone.
64316

Installation
Tools Required
" J 41556 Connecting Rod Guide
" J 8037 Piston Ring Compressor
Important: The piston and cylinder bore have been
measured and the bore has been sized for the proper
clearance. Install the piston and connecting rod
assembly into the proper cylinder bore.
The piston alignment mark MUST face the front of the
engine block.
1. Lightly lubricate the following components with
clean engine oil:
• The piston
• The piston rings
• The cylinder bore 64180
• The bearing surfaces

2. Stagger the oil control ring end gaps a minimum
of 90 degrees.
3. Stagger the compression ring end gaps a
minimum of 25 mm (1.0 in).
4. Install the J 41556 to the connecting rod.
5. Install the J 8037 onto the piston and compress
the piston rings.
6-536 Engine Mechanical a; 5.7L Engine
Important: The piston alignment mark MUST facing
the front of the engine block.
6. Install the piston and connecting rod assembly (
into the proper cylinder bore.
6.1. Hold the piston ring compressor firmly
against the engine block. Using a wooden
hammer handle, lightly tap the top of
the piston until all of the piston rings enter
the cylinder bore.
6.2. Use the J 41556 to guide the connecting
rod end onto the crankshaft journal.
63217

J 41556
63186
(
8. Identify the type of connecting rod bolt. 1 2
O The first design connecting rod bolt (1) can be
identified by a single dimple/mark on the

head of the bolt and no retaining sleeve on the
bolt shank.
• The second design connecting rod bolt (2) can
be identified by two dimples/marks on the
head of the bolt and a retaining sleeve (3) on
the bolt shank. 3
568498

Notices.
Important:
O When replacing connecting rod bolts, both bolts
MUST be of the same design for each connecting

rod assembly.
The use of different design connecting rod bolts
on the same connecting rod assembly may lead to
uneven clamploads and/or connecting rod
bearing bore distortion.
• Position the connecting rod cap onto the
connecting rod properly.
Align the flat side of the connecting rod cap with
the flat side of the connecting rod.
9. Install the bearing, cap, and bolts.

Tighten
9.1. Tighten the first design bolts a first pass
evenly to 20 N·m (15 lb ft). 53223
9.2. Tighten the first design bolts a final pass to

60 degrees using the J 36660-A.
9.3. Tighten the second design bolts a firstpass
evenly to 20 N·m (15 lb ft).
9.4. Tighten the second design bolts a final pass
) to 75 degrees using the J 36660-A.
s.:.53a Engine Mechanical·~ 5.7L Engine.
10. Inspect the connecting rods for proper orientation
onto the crankshaft journal.
11. With the pistons-and connecting rods installed, (
use a soft faced mallet and lightly tap each
connecting rod assembly parallel to the crankpin
to make sure that the rods have s.ide clearance.
12. Measure the connecting rod side clearance using
a feeler gauge or a dial indicator. Connecting rod
side clearance should be within 0.11-0.51 mm
(0.0043-0.02 in).
63227
Camshaft h1stallaticm
Important: If camshaft replacement is required, the
valve lifters must also be replaced.
1. Lubricate the camshaft journals and the bearings
with clean engine oil.
2. Install three MB-1.25 x 100 mm (MB-1.25 x 4.0 in)
bolts into the camshaft front bolt holes.
Notice: All camshaft journals are the same diameter, (
3. Using the bolts as a handle, carefully install
the camshaft into the engine block.
4. Remove the th.ree bolts from the. front of the
camshaft.
63212

Notices.
Important: Install the retainer plate with the sealing
gasket facing the engine block.
The gasket surface on the engine block should be
clean and free of dirt or debris. ·
5. Install the camshaft retainer and the bolts.
Tighten
Tighten the. camshaft retainer bolts to
25 N-m (18 lb ft};
6. Inspect the camshaft sensor 0-ring seal. If the
0-ring seal is not cut or damaged, it may be
reused.
7. Lubricate the 0-ring seal with clean engine oil. (
63211
8. Install the camshaft sensor and bolt.
Tighten
Tighten the camshaft sensor bolt to
25 N·m (18 lb ft).
260128

Tools Required
J 41665 Crankshaft Balancer and Sprocket Installer
1. Install the key into the crankshaft keyway (if
previously removed).
156149
2. Tap the key (1) into the keyway until both ends. of
the key bottom onto the crankshaft.
490871
3. Install the crankshaft sprocket onto the front of the
crankshaft. Align the crankshaft key with the (
crankshaft sprocket keyway.
156150
4. Use the J 41665 in order to install the crankshaft

sprocket.
Install the sprocket onto the crankshaft until fully
seated against the crankshaft flange.
5. Rotate the crankshaft sprocket until the alignment
mark is in the 12 o'clock position.
63199
Important:
• Properly locate the camshaft sprocket locating pin
with the camshaft sprocket alignment hole.
• The sprocket teeth and timing chain must mesh.
• The camshaft and the crankshaft sprocket
alignment marks MUST be aligned properly.
Locate the camshaft sprocket alignment mark in
the 6 o'clock position.
6. Install the camshaft sprocket and timing chain.
63263
7. If necessary, rotate the camshaft or crankshaft
sprockets in order to align the timing marks.
Notices.
8. Install the camshaft sprocket bolts.
Tighten
Tighten the. camshaft sprocket bolts to
35 N-m (26 lb ft).
156158

Installation
Important: Inspect the oil pump and engine block oil
gallery passages. These surfaces must be clear
and free of debris or restrictions.
1. Align the splined surfaces of the crankshaft
sprocket and the oil pump drive gear and
) install the oil pump.
2. Install the oil pump onto the crankshaft sprocket
until the pump housing contacts the face of the
engine block.
Notices.
3. Install tht3 oil pump bolts.
Tighten
Tighten the oil pump bolts to 25 N·m (18 lb ft).
64281
4. Install the crankshaft oil deflector.

5. Lubricate a NEW oil pump screen Osring seal with
clean engine oil.
6. Install the NEW 0-ring seal onto the oil pump
screen.
64270
6-542 Engine Mechanical -5.7L Engine
Important: Push the oil pump screen tube completely
into the oil pump prior to tightening the bolt. Do not (
allow the bolt to pull the tube into the pump.
Align the oil pump screen mounting brackets with the
correct crankshaft bearing cap studs.
7. Install the oil pump screen.
8. Install the oil pump screen bolt and the
deflector nuts.
Tighten
8.1. Tighten the oil pump screen bolt to
12 N-m (106 lb in).
8.2. Tighten the crankshaft oil deflector nuts to
25 N·m (18 lb ft).
64268
Engine Rear Cover Installation

Tools Required
• J41480 Front/Rear Cover Alignment (Oil Pan
Surface)
• J 41476 Front/Rear Cover Alignment (Crankshaft
Oil Seal Area)
Important:
• Do not reuse the crankshaft rear oil seal or the
(
engine rear cover gasket.
• Do not apply any type sealant to the rear cover
gasket (unless specified).
• The special tools in this procedure are used to
properly align the engine rear cover at the oil
pan surface and to center the crankshaft
rear oil seal.
• The crankshaft rear oil seal will be installed after
the rear cover has been installed and aligned.
Install the rear cover without the crankshaft
oil seal.
- The crankshaft rear oil 'seal MUST be
centered in relation to the crankshaft.
- The oil pan sealing surface at the rear cover
and engine block MUST be aligned within
specifications.
- An improperly aligned rear cover may cause
premature rear oil seal wear and/or engine
assembly oil leaks.
63228
1. Inspect the rear oil gallery plug for proper
installation.
(
Engine Engine Mechanical - 5;7L 6-543
2. Install the rear cover gasket, rear cover and bolts,
) 3. Tighten the bolts finger tight Do not overtighteh.
64282
Notice: Refer to Fastener Notice in Cautions and,

Notices.
Important: Start .the J 41480.tool-to-rear cover bolts.
Do not tighten the bolts· at this time.
4. Install the J 414$0 and bolts.
Tighten
Tighten the tool-to~engine block bolts to
) .25N·m (181b ft).
64204
Important: To properly align the rear cover, the

J 41476 must be installed onto the rear of the J 41480
crankshaft with the tool mounting bolts parallel to the
oil pan surface.
5. Rotate the crankshaft until two opposing flywheel
bolt holes are parallel to the oil pan surface.
J 41476
63243
6".'544 Engine Mechanical -5.7L Engine
Important: The tapered legs of the alignment tool
must enter the rear cover oil seal bore.
6. Install the J 41476 and bolts onto the rear of the
(
crankshaft.
Tighten
· 6.1. Tighten the tool mounting bolts until snug:
Do not overtighten.
6.2. Tighten the J 41480 tool-to-rear cover bolts
evenly to 12 N·m (106 lb in).
6.3. Tighten the rear cover bolts to
25 N-m (18 lb ft).
7. Remove the tools.
65286
8. Measure the oil pan surface for flatness (rear

cover-to-engine block).
8.1. Place a straightedge onto the engine.block
and rear cov~r oil pan sealing 9urfaces.
Avoid contact with the portion of the gasket
that protrudes into the oil pan surface.
8.2. Insert a feeler gauge between the rear.
cover and the straight edge. The cover (
must be flush with the oilpanor no more
than 0.5 mm (0.02 in) below flush'.
9. If the rear cover-to-engine block oil pan surface
alignment is not within specifications, repeat the
cover alignment procedure.
10. If the correct rear cover-to-engine block alignment
at the oil pan surface cannot be obtained, replace
the rear cover.
63240
Crankshaft Rear Oil Seal Installation
) Tools Required
J 41479 Crankshaft Rear Oil Seal Installer
Important:
• Do not lubricate the oil seal inside diameter (ID) or
the crankshaft surface.
• Do not reuse the crankshaft rear oil seal.
1. Lubricate the outside diameter (OD) of the oil
seal (1) with clean engine oil.
DO NOT allow oil or other lubricants to contact
the seal surface.
2. Lubricate the rear cover oil seal bore with clean
engine oil.
DO NOT allow oil or other lubricants to contact
the crankshaft surface.
490692
3. Install the J 41479 cone (2) and bolts onto the

rear of the crankshaft. J 41479
4. Tighten the bolts until snug. Do not overtighten.
5. Install the rear oil seal onto the tapered
cone (2) and push the seal to the rear cover bore.
6. Thread the J 41479 threaded rod into the tapered
cone until the tool (1) contacts the oil seal.
) 7. Align the oil seal'onto the tool (1).
8. Rotate the handle of the tool (1) dockwise until
the seal enters the rear cover and bottoms into
the cover bore.
9. Remove the tool.
63200
)
6"-546 Engine Mechanical - 5.7l Engine
Engine Front Cover Installation
Tools Required (
• J 41480 Front/Rear.Cover Alignment (Oil Pan·
Surface)
• J 41476 Front/Rear Cover Alignment (Crankshaft
Oil Seal Area)
Important:
• Do not reuse the 9ranksha,ft oil seal or the engine
front cover gasket.
• Do not apply any type sealant to the front cover
gasket (unless specified). · · ·
• The special tools in.this procedure are used to
properly align the engine front cover at the .oil
pan surface and to center the crankshaft
front oil seal.
- All gasket surfaces should be free of oil or
other foreign material during assembly.
64278
The crankshaft front oil seal MUST be centered
in relation to the crankshaft.
- The oil pan sealing surface at the front cover
and engine block MUST be aligned within
specifications. ··
- An improperly aligned front cover may cause
premature front oil seal wear and/or engine
assembly oil leaks. ·
1. Install the front cover gasket, cover, and bolts
onto the engine. (
2. Tighten the cover bolts finger tight. Do not
overtighten. ·
Notices.
Important: Start the tool-to-front cover bolts. Do not
tighten the bolts at this time.
3. Install the· J 41480. .
lighten
Tighten the tool-to-engine block bolts to
25 N,m (18 lb ft).
63182
(
Important: Align the tapered legs of the tool with the
machined alignment surfaces on the front cover.
5. Install the crankshaft balancer bolt.
Tighten
5.1. Tighten the crankshaft balancer bolt by
hand until snug. Do not overtighten.
5.2. Tighten the J 41480.
5.3. Tighten the engine front cover bolts to
25 N·m (18 lb ft).
6. Remove the tools.
63185
7. Measure the oil pan surface flatness (front

cover-to-engine block).
7.1. Place a straight edge across the engine
block and front cover oil pan sealing
surfaces. ·
Avoid contact with the portion of the gasket
that protrudes into the oil pan surface.
7.2. Insert a feeler gauge between the front
) cover and the straight edge tool. The
cover must be flush with the oil pan surface
or no more than 0.5 mm (0.02 in)
below flush.
8. If the front cover-to-engine block oil pan surface
alignment is not within specifications, repeat the
cover alignment procedure.
9. If the correct front cover-to-engine block alignment
cannot be obtained, replace the front cover.
0.0-0.5mm
(0.0 - 0.02")
63242
)
Crankshaft Front Oil Seal Installation
Tools Required
J 41478 Crankshaft Front Oil Seal Installer
(
Important: Do not lubricate the oil seal sealing
surface.
Do not reuse the crankshaft front oil seal.
1. Lubricate the outer edge of the oil seal (1) with
clean engine oil.
2. Lubricate the front cover oil seal bore with clean
engine oil.
490689
3. Install the crankshaft front oil seal onto the

J 41478 J 41478 guide.
4. Install the J 41478 threaded rod (with nut, washer,
guide, and oil seal) into the end of the crankshaft.
5. Use the J 41478 in order to install the oil seal into
the cover bore.
5.1. Use a wrench and hold the hex on the
installer bolt.
5.2. Use a second wrench and rotate the (
installer nut clockwise until the seal
bottoms in the cover bore.
5.3. Remove the tool.
5.4. Inspect the oil seal for proper installation;
The oil seal should be installed evenly and
completely into the front cover bore.
63177
Oil Pan Installation

Important: The alignment of the structural oil pan is
critical. The rear bolt hole locations of the oil pan
provide mounting points for the transmission housing.
To ensure the rigidity of the powertrain and correct
transmission alignment, it is important that the rear of
the block and the rear of the oil pan are flush or
even. The rear of the oil pan must NEVER protrude
beyond the engine block and transmission
housing plane.
Do NOT reuse the oil pan gasket.
It is not necessary to rivet the NEW gasket to the
oil pan.
It is not necessary to remove the oil level sensor prior (
to oil pan installation.
178491
Notices.
1. Install the oil pan baffle and bolts (if previously
removed).
Tighten
Tighten the oil pan baffle bolts to
12 N·m (106 lb in).
2. Apply a 5 mm (0.2 in) bead of sealant
GM P/N 12378190 or equivalent 20 mm (0.8 in)
long to the engine block. Apply the sealant directly
onto the tabs of the front cover gasket that
protrude into the oil pan surface. Refer to Sealers,
Adhesives, and Lubricants.
63176
3. Apply a 5 mm (0.2 in) bead of sealant

) GM P/N 12378190 or equivalent 20 mm (0.8 in)
long to the engine block. Apply the sealant directly
onto the tabs of the rear cover gasket that
protrude into the oil pan surface. Refer to Sealers,
Adhesives, and Lubricants.
63175
)
Important: Be .sure to align the oil gallery passages in
the oil pan and engine block properly with the oil pan
gasket. · (
4. Preassemble the oil pan gasket to the pan.

4.1. Install the gasket onto the oil pan.
4.2. Install the oil pan bolts to the pan and
through the gasket. ·
5. Install the oil pan, gasket and b.olts to the
engine block, ' '
6. Tigbten .bolts finger tight. Dq not overtighten.
7. Place a straight edge across the rear of the engine
block and the rear of the oil pan at the
transmission housing mounting surfaces.
178558
8. Align the. oil pan until the. rear of engine block and
rearof oil pan are flush or even.
Tighten
8.1. Tighten the oil pan-to-block and oil
pan-to-front cover bolts to 25 N·m (18 lb ft).
12 N·m (106 lb in).
9. Measure the oil pan~to-engine block alignment.
9.1.· Place a straight edge across the rear of
(
the engine block and rear of oil pan a1 the
transmissiohhousing mounting surfaces.
'SJm:j] Important: The rear of the oil pan must .NEVER

protrude beyond the engine block and transmission
housing mounting surfaces.
<.::=J 0.0 -- 0;25 mm
(o.o - 0.010")
_..,jl.,._.·.
· II · .
9.2. Insert a feeler gauge between the straight
edge and the oil pan transmission housing
mounting surface and check to make
sure that there is no more than a 0.25 mm
178474
(0.01 in) gap between the pan and
straight edge.
9.3. If the oil pan alignment is not within
specifications, remove the oil pan and
repeat the above procedure.
(
10. Install the oil level sensor.
) Tighten
Ti,ghten the oil level sensor to 13 N·m (115 lb in).
178467
Oil Filter, Adapter, Pan Cover Installation

Notices.
1. Install a NEW oil pan cover gasket, the cover and
the bolts.
Tighten
Tighten the oil pan cover bolts to
) 12 N·m (106 lb in).
178471
2. Install a new oil filter bypass valye (2) into the oil
pan (if required).
3. Install the oil filter fitting (1 ).
Tighten
Tighten the oil filter fitting to 55 N-m (40 lb ft).
490699
Tighten (
~ 178469
5. lnstallthe oil pan drain plug.

Tighten
Tighten the oil pan drain plug to 25 N·m (18 lb ft).
309862
Valve Lifter Installation

Important: When reusing valve lifters, install the lifters
to their original locations.
If camshaft replacement is required, the valve lifters
must also be replaced. .
1. Lubricate the valve lifters and engine block valve
lifter bores with clean engine oil.
2. Insert the valve lifters into the lifter guides.
Align the flat area on the top of the lifter with the
flat area in the lifter guide bore. Push the lifter
completely into the guide bore.
63233
3. Install the valve lifters and guide assembly to the
engine block.
Notices.
4. Install the valve lifter guide bolt (1).
Tighten
Tighten the valve lifter guide bolt to
12 N,m (106 lb in).
63230
Cylinder Head Installation (left Side)

Tools Required
Important: Do not reuse the M11 cylinder head bolts.
Install NEW M11 cylinder head bolts during assembly.
Do not use any type sealant on the cylinder head
The cylinder head gaskets must be installed in the
proper direction and position.
damage.
Notice: Clean all dirt, debris, and coolant from the
engine block cylinder head bolt holes. Failure to
remove all foreign material may result in damaged
threads, improperly tightened fasteners or damage to
components.
1. Clean the engine block cylinder head bolt holes (if
63235
required).
Th re.ad repair tool J 42385-107 may be. used to
clean the threads of old threadlocking material.
2. Spray cleaner GM P/N.12346139, PIN 12377981,
or equivalent into the h.ole.
3. Clean the cylinder head bolt holes with
compressed air.
4. Check the cylinder head locating pins for proper
installation.
5. Install the NEW left cylinder head gasket onto the
locating pins.
(
63169
Important: When properly installed, the tab on.the left

cylinder head gasket will be located left of center, or
closer to the front of the engine, and the words
"This Side Up", and the engine displacement, will be.
visible.
6. Inspect the gasket for proper installation.
490861
7. Install the cylinder head onto the locating pins and

the gasket.
8. Install the NEW M11 cylinder head bolts.
9. Apply a 5 mm (0.2 in) band of threadlock
GM P/N 12345382 or equivalentto the threads of
the MB cylinder head bolts.
Refer to Sealers, Adhesives, and Lubricants.
10. Install the M8 cylinder head bolts.
260146
Notices.
)
11. Tighten the cylinder head bolts.
Tighten
11.1. Tighten the M11 cylinder head
bolts (1-10) a first pass in sequence
to 30 N-m (22 lb ft). 15 13 11 12 14
:J
bolts (1-10) a second pass in sequence to 3 1 5
90 degrees using the J 36660-A. 6 2 4
bolts (1,2,3,4,5,6,7,8) to 90 degrees and
the M11 cylinder head bolts (9 and
10) to 50 degrees a final pass in sequence
to using the J 36660-A.
11 .4. Tighten the MS cylinder head
bolts (11, 12, 13, 14, 15) to 30 N-m (22 lb ft).
Begin with the center bolt (11) and
alternating side-to-side, work outward 260150
tightening all of the 9olts.
Cylinder Head lnstallaUon (Right Side)

Tools Required
Important: Do not reuse the M11 cylinder head bolts.
Install NEW M11 cylinder head bolts during assembly.
) Do not use any type sealant on the cylinder head
The cylinder head gaskets must be installed in the
proper direction and position.
damage.
Notice: Clean all dirt, debris, and coolant from the
engine block cylinder head bolt holes. Failure to
remove all foreign material may result in damaged
threads, improperly tightened fasteners or damage to
components.
1. Clean the engine block cylinder head bolt holes
63235
(if required).
Thread repair tool J 42385~107 maybe used to
clean the threads of old threadlocking material
2. Spray cleaner GM P/N 12346139, P/N ~2377981,
or equivalent into the hole. ·
3. Clean the. cylinder head bolt holes with
compressed air.
4. Check the cylinder head locating pins for proper
installation.
6-5.56 Engine Mechanical - 5.7L Engine
5. Install the NEW right cylinder head gasket onto
the locating pins.
(
63170
Important: When properly installed, the tab on.the

right cylinder head gasket will be located right of ·
center, or closer to the front of the engine, and the
words "This Side Up", and the engine displacement will
be visible.
6. _Inspect the gasket for proper installation.
490854
7. Install the cylinder head onto the locating pins and

~~~~ .
8. Install the NEW M11 cylinder head bolts.
9, Apply a 5 mm (0.2 in) band of threadlock
GM P/N 12345382 or equivalent to the threads of
the M8 cylinder he~d bolts.
1o. Install the M8 cylinder head bolts.
260149
Notices.
11. Tighten the cylinder head bolts.
Tighten
bolts {1-10) a first pass in sequence
to 30 N·m (22 lb ft).
11.2. Tighten the M11 cylinder head 15 13 11 12 14
..._,,, ..._,,, ..._,,,
:J
bolts (1-10) a second pass in sequence to
90 degrees using the J 36660-A. 3 1 5
11.3. Tighten the M11 cylinder head 6 2 4
bolts (1,2,3,4,5,6,7,8) to 90 degrees and
the M11 cylinder head bolts (9 and
10) to 50 degrees a final pass in sequence
to using the J 36660-A.
11.4. Tighten the MS cylinder head
bolts {11,12,13,14, 15) to 30 N-m {22 lb ft).
Begin with the center bolt {11) and
alternating side-to-side, work outward
tightening all of the bolts. 260150

Installation
Important: When reusing the valve train components,
always install the components to the original location
and position.
Valve lash is net build, no valve adjustment is required.
) 1. Lubricate the valve rocker arms and pushrods
2. Lubricate the flange of the valve rocker arm bolts
Lubricate the flange or washer surface of the bolt
that will contact the valve rocker arm.
3. Install the valve rocker arm pivot support.
260141
Important: Make sure that the pushrods seat properly

to the valve lifter sockets.
4. Install the pushrods.
260142
Important: Make sure that the pushrods seat properly
to the ends of the rocker arms.
(
DO NOT tighten the rocker arm bolts at this time.
5. Install the rocker arms and bolts.
260140
6. Rotate the crankshaft until number one piston is

at top dead center of compression stroke.
In this position, the crankshaft and camshaft
sprocket marks will be aligned, cylinder number
one rocker arms will be off lobe lift, and the
crankshaft sprocket key will be at the 1:30
position. While viewing from the rear of the engine,
the additional crankshaft pilot hole (non-threaded) (.
will be in the 10:30 position. .
The engine firing order is i ,8,7,2,6,5,4,3.
Cylinders 1,3,5 and 7 are left ban.k.
Cylinders 2,4,6, and 8 are right bank.
Notices.
7. With the engine in the number one firing position,
tighten the following valve rocker arm bolts:
Tighten
• Tighten exhaust valve rocker arm bolts 1, 2, 7,
156158
and 8 to 30 N-m (22 lb ft).
• Tighten intake valve rocker arm bolts 1, 3, 4,
8. Rotate the crankshaft 360 degrees.
9. Tighten the following valve rocker arm bolts:
Tighten
• Tighten exhaust valve rocker arm bolts 3, 4, 5,
• Tighten intake valve rocker arm bolts 2, 6, 7,
(
! (left Side)
Important: All gasket surfaces should be free of oil or
DO NOT reuse the .valve. rocker arm cover gasket.
The valve rocker arm cover bolt grommets may
be reused.
1. Install a NEW cover gasket (1) into the valve
rocker arm cover.
490696
2. Install the valve rocker arm cover onto the

cylinder head.
Notices.
3. Install the cover bolts with grommets.
Tighten
) 12 N-m (106 lb in).
260085
4. Install the. ignition coils, wire harness, and bolts

onto the mounting bracket.
Tighten
Tighten the ignition coil bolts to 12 N-m (106 lb in).
309850
6-560 Engine Mechanical i-. 5.7L Engine
to the threads of the bracket bolts.
6. Install the ignition coils and bracket assembly and (
bolts onto the rocker cover.
Tighten
Tighten the ignition coil bracket bolts to
12 N-m (106 lb in).
7. Install the crankcase ventilation hose.
309727

(Right Side)
DO NOT reuse the valve rocker arm cover gasket.
The valve .rocker arm cover.bolt grommets may
be reused.
If the oil fill tube has been removed from the valve
(
rocker arm cover, install a NEW oil fill tube during
assembly.
1. Lubricate the 0-ring seal of the NEW oil fill tube
2. Insert the NEW oil fill tube into the rocker arm
cover and rotate the tube clockwise until locked
in the proper position.
3. Install the oil fill cap into the tube and rotate
clockwise until locked in the proper position.
260110
4. Install a NEW gasket (1) into the valve rocker

arm cover.
490696
Notices.
5. Install the valve rocker arm cover onto the

cylinder head.
6. Install the cover bolts with grommets.
Tighten
12 N-m (106 lb in).
260084
7. Install the ignition coils, wire harness, and bolts

onto the mounting bracket.
Tighten
Tighten the ignition coil b.olts to 12 N·m (106 lb in).
309850
'
to the threads of the bracket bolts.
9. Install the ignition coils and bracket assembly and '
bolts to the rocker cover.
Tighten
Tighten the ignition coil bracket bolts to
12 N·m (106 lb in).
10. Install the crankcase ventilation hoses to
the cover.
309721
Engine Valley Cover Installation
Important: All gasket surfaces should be free of oil or (
1. Install NEW knock sensor oil seals (1) into the
1~ valley cover (2).
Lubricate the seal surfaces with clean engine oil.
I
I
490851
2. Install the valley cover and NEW gasket.

Notices.
3. Install the valley cover bolts.
Tighten
Tighten the valley cover bolts to 25 N-m (18 lb ft).
65048
4. Install the knock sensors.

Tighten
Tighten the knock sensors to 20 N-m (15 lb ft).
309864
5. Install the knock sensor wire harness.
309859
Vapor Vent Pipe Installation

Important: Install the pipe gaskets properly onto
the pipe:
Position the gasket 0-ring seal onto the nipple portion
of the pipe.
1. Install the gaskets onto the engine coolant air
bleed pipe.
64262
Important: Route the knock sensor wire harness over

the top of the engine coolant air bleed pipe. The pipe
and knock sensor wire harness should be installed
in a manner as to allow the removal of the wire
harness without requiring the removal of the pipe.
2. Install the pipe and gaskets onto the
cylinder heads.
Notices.
3. Install the pipe bolts and studs.
Install the two pipe studs to the front of the
engine.
Tighten
Tighten the pipe bolts and studs to
i2 N·m (106 lb in).
363239
4. Install the hose and clamp (2) onto the pipe.
.490724
Intake Manifold Installation

injection rail and fuel injectors may be removed as an
assElmbly. If. not servicing the individual con;iponents,
install the intake manifold as a complete assembly.
1. Install. NEW intake manifold-to-cylinder head
gaskets (1 ).
(
490579
2. Install the manifold to the engine.
178557
to the threads of the intake manifold bolts (1).
instaJled onto the engine assembly. The stop
injury from burns.
4. Install the fuel rail stop bracket (2).
490927

Notices.
5. Install the intake manifold bolts.
lighten
0·..___1---·o,....._5_....,,o a
5.1. Tighten the intake manifold bolts a first pass 4
in sequence to 5 N,m (44 lb in). (@ @) @) (@
5.2. Tighten the intake manifold bolts a final
) pass in sequence to 10 N-m (89 lb in).
©
@ @) @) @)
6 2 3 9
Q . - - -......,0,......--~Q
63222
6. Install the knock sensor wire harness

connector (1) onto the fuel rail stop bracket (2).
490736
5.;.555 Engine Mechanical - 5.7L Engine
7. Install the Ma.nifold Absolute Pressure (MAP)
sensor (if previously removed).
(
58838
8. Install the accelerator control cable bracket (2)

and bolts (1 ).
Tighten
Tighten the bracket bolts to 10 N-m (89 .lb in).
490573
(
Engine Engine Mechanical - 5. 7L 5;.557
9. Install the Positive Crankcase Ventilation (PCV)
valve pipe to the right rocker cover and intake
) manifold.
10. Install the PCV strap and nut onto the right front
vapor vent pipe stud.
Tighten
Tighten the PCV strap nut to 12 N-m (106 lb in).
379367
11. Install the PCV valve pipe to the left rocker cover.
379366
Fuel Rail and Injectors Installation
Important: DO NOT reuse fuel injector 0-ring seals. (
Install NEW fuel injector 0-ring seals during assembly.
1. Lubricate the NEW fuel injector 0-ring seals
2. Install the o~ring seals onto the fuel injectors.
3. Install the fuel rail (with fuel injectors) into
the intake manifold.
Press evenly on both sides of the fuel rail until all
of the injectors are seated in their bores.
4. Apply a 5 mm (0.2 in) band of threadlock
GM P/N 12345382 or equivalent to the threads of
the fuel rail bolts.
bracket serves as a protective shield for the tuel
222050 rail in the event of a vehicle frontal crash. If
injury from burns.
Notices. '
5, Install the fuel rail bolts.
Tighten
Tighten the fuel rail bolts to 10 N·m (89 lb in). · (
Throttle Body Installation

Important: DO NOT reuse the throttle body gasket.
1. Install the throttle body gasket (1) to the intake
manifold.
490580
(
Notice: Refer to Fastener Nqtice in Cautions and
Notices.
2. Install the throttle body and bolts.
Tighten
Tighten the throttle body bolts to
12 N-m (106 lb in).
3. Install the engine coolant airbleed hose
and clar:np.
222051
Water Pump Installation

Notice: DO NOT use cooling system seal tabs (or
similar compounds) unless otherwise instructed. The
use of cooling system seal tabs (or similar compounds)
may restrict coolant flow through the passages of
the cooling system or the engine components.
Restricted coolant flow may cause engine overheating
and/or damage to the cooling system or the engine
\ components/assembly.
}
1. Install the water pump and NEW gaskets.
2. Install the water pump bolts.
Tighten
2.1. Tighten the water pump bolts a first pass to
15 N·m (11 lb ft).
2.2. Tighten the water pump bolts a final pass to
30 N·m (22 lb ft).
309751
Exhaust Manifold Installation (Left ?ide)

vehicle emissions and/or On-Board Diagnostic (OBD) II
system performance.
must be clean and free of debris or threadlocking
material.
Important: Do not apply sealant to the first three
threads of the bolt.
2. Install the exhaust manifold and NEW exhaust
manifold gasket.
492589
Notices.
3. Install the exhaust manifold bolts. (
Tighten
first pass to 15 N·m (11 lb ft}. Tighten
the exhaust manifold bolts beginning with
the center two bolts. Alternate from
outside bolts.
pass to 25 N·m (18 lb ft). Tighten the
exhaust manifold bolts beginning with 1he
center two bolts. Alternate from side-to-side,
left cylinder head.
5. Install the heat shield (2) and bolts (3).
Tighten
Tighten the heat shield bolts to 9 N·m (80 lb in).
492586
6. Install the Air Injection Reaction (AIR} pipe (with

check valve), NEW gasket and bolts.
Tighten
Tighten the AIR pipe to exhaust manifold bolts to
20 .N·m (15 lb ft}.
(
346026
7. Install the oxygen sensor into the intake manifold.
Tighten
Tighten the oxygen sensor to 42 N-m (31 lb ft).
346021
Exhaust Manifold Installation (RightSide)

vehicle emissions and/or on-board diagnostic (OBD) II
system performance.
) must be clean and free of debris or threadlocking
material.
Do not reuse exhaust gas recirculation (EGR) valve
and pipe gaskets or seals during assembly. Install
NEW gaskets and 0-ring seal.
Important: Do not apply sealant to the first three
threads of the bolt.
Refer to Sealers, Adhesives, and Lubricants. 492592
2. Install the exhaust manifold gasket and exhaust
manifold.
Notices.
lighten
3.1 . Tighten the exhaust manifold bolts first pass
to 15 N-m (11 lb ft). Tighten the exhaust
manifold bolts beginning with the center
two bolts. Alternate from side-to-side, and
work toward the outside bolts.
3.2. Tighten the exhaust manifold bolts final
center two bolts. Alternate from side-to-side,
of the exhaust manifold gasket at the front of the
right cylinder head.
5 . .Install the heat shield (2) and bolts (3).
Tighten
(
Tighten the heat shield bolts to 9 N·m (80 lb in).
492583
6. Install the air injection .reaction (AIR) pipe (with

check valve), NEW gasket and bolts.
Tighten
Tighten the AIR pipe to exhaust manifold bolts to
20. N·m (15 lb ft).
~
346029
7. Install the AIR tubing and clamps.
346024
8. Install the oxygen sensor into the intake manifold.
Tighten
Tighten the oxygen sensor to 42 N·m (31 lb ft).
346021
9. Apply a light coating of clean engine oil to a NEW

0-ring seal and install the seal onto the EGA
valve pipe. ·
10. Insert the EGA pipe into the .intake manifold.
178489
11. Start the EGA valve pipe to inta.ke manifold

bolt (1 ).
Do not tighten the bolt at this time.
12. Install the EGR valve pipe to cylinder head bolts.
Do not tighten the bolts at this time.
492575
6-574 Engine Mechanical.; 5.7L Engine
13. Install a NEW EGR valve pipe exhaust mani1old
gasket and bolts (1 ).
Tighten
(
manifold bolt to 10 N-m (89 lb in).
head b.olts to 50 N·m '(37 lb ft).
13.3. Tighten the EGR valve pipe to exhaust
manifold bolts to 30 N·m (22 lb ft).
492580
14. Install the EGRvalve, a NEW gasket and bolts.

Tighten
14.1. Tighten the EGR valve bolts a first pass to
1O N·m (89 lb in).
14.2. Tighten the EGR valve bolts a final pass
to 25 N·m (18 lb ft).
178487
Oil level Indicator and Tube Installation

1. Inspect the 0-ring seal for cuts or damage. If the
oil level indicator tube 0-ring seal is not cut or
damaged, it may be reused.
2. Lubricate the 0-ring seal with clean engine oil:
3. Install the 0-ring seal onto the oil level
indicator tube.
4. Install the oil level indicator tube into the engine
block and rotate into proper position.
Notices.
5. Install the tube bolt to the right cylinder head.
Tighten
Tighten the oil level indicator tube bolt to (
25 N-m (18 lb ft).
6. Install the oil level indicator into the tube.
178459
Clutch Pilot Bearing Installation
) Tools Required
J 38836 Pilot Bushing Installer/Clutch
1. Install a 5/8 inch washer ( 1) onto the J 38836 or J 38836
equivalent.
The washer serves as a stop. against the
crankshaft face and will assist in installing the
bearing to the proper depth.
2. Install the new pilot bearing (2) onto the tool.
-2
260131
3. Install the new pilot bearing into the crankshaft

using the J 38836.
490867
4. Inspect the clutch pilot bearing for proper
installation.
A properly installed clutch pilot bearing will be (
installed until flush to the rear face of the
crankshaft.
63195 (
Engine Flywheel Installation
Important: Note the position and direction of the
engine flywheel before removal. The flywheel does not
use a locating pin for alignment and will not initially
seat against the crankshaft flange, but will be
pulled onto the crankshaft by the engine flywheel
bolts. This procedure requires a three stage tightening
process.
1. Install the manual transmission engine flywheel to
the crankshaft (if applicable).
156166
(
2. Install the automatic transmission engi'ne flywheel
to the crankshaft (if applicable).
178458

to the threads of the flywheel bolts.
Notices.
4. Install the engine flywheel bolts.
Tighten
4.1. Tighten the engine flywheel bolts first pass
in sequence to 20 N-m (15 lb ft).
4.2. Tighten the engine flywheel bolts
second pass in sequence to
50 N·m (37 lb ft) .
.4.3. Tighten the engine flywheel bolt.s final pass
in sequence to 109 N·m (7 4 lb ft). ,
63174
Crankshaft Balancer Installation

Tools Required
• J 41665 Crankshaft Balancer and Sprocket
Installer
• J 42386-A Flywheel Holding Tool
Important: The crankshaft balancer installation and
bolt tightening involves a four stage tightening process.
The first pass ensures that the balancer is installed
completely onto the crankshaft. The second, third and
fourth passes tighten the new bolt to the proper
torque.
The used crankshaft balancer bolt will be used only
during the first pass of the balancer installation J 42386-A
procedure. Install a NEW crankshaft balancer bolt and
tighten as described in the second, third and
fourth passes of the balancer bolt tightening procedure.
260126
Important, Make sure. the teeth. of the tool engage the
engine flywheel teeth.
Notices.
1. Install the J 42386-A and bolts.
Use one M 10-1.5 x 120 mm and one
M 10-1.5 x 45 mm bolt for proper tool operation.
Tighten
Tighten the J 42386-A bolts to 50 N·m (37 lbft).
Important: The balancer should be positioned onto
the end of the crankshaft as straight as possible prior
to tool installation.
2. Install the balancer onto the end of the crankshaft.
260154
(
3. Use the J 41665 in order to. install the balancer.
3.1. Assemble. the threaded rod, nut, washer
and installer.
Insert the smaller end of the installer into
the front of the balancer.
3.2. Use a wrench and hold the hex end of the
threaded rod.
3.3. Use a second wrench and rotate the
installation tool nut clockwise until the
balancer is started onto crankshaft.
c::,
3.4. Remove arid reverse the installation tool.
Position the larger end of theinstaller
agairist the front of the1 balancer.
3.5. Use a wrench and hold the hex end of the
threaded rod.
J 41665-1
3.6. Use a second wrench and .rotate the
installation tool n'ut clockwise until the
balancer is installed onto the crankshaij.
· 63187
3.7. Remove the balancer installation tool.
(
4. Install the used crankshaft balancer bolt.
Tighten
Tighten the crankshaft balancer bolt to
3.30 N·m (240 lb ft).
5. Remove the used crankshaft balancer bolt.
Important: The nose of the crankshaft should be
recessed 2.40-4.48 mm (0.094-0.176 in) into
the balancer bore.
6. Measure for a correctly installed balancer.
If the balancer is not installed to the proper
dimensions, install the J 41665 and repeat the
63245
7. Install the NEW crankshaft balancer bolt.

Tighten
7.1 . Tighten the crankshaft balancer bolt a
first pass to 50 N·m (37 lb ft).
7.2. Tighten the crankshaft balancer bolt a
second pass to 140 degrees using
the J 36660-A.
) 8. Remove the J42386-A.
260154
Engine Set-Up and Testing

Important: After overhaul, the engine should be tested
before installation into the vehicle. If a suitable test
stand is not available, the following procedure can be
used after the engine is installed into the vehicle.
1. Fill the crankcase with the proper quantity and
grade of engine oil.
2. Add engine oil supplement GM P/N 12345795 or
equivalent.
3. Fill the cooling system with the proper quantity
and grade of coolant.
5. Crank the engine several times. Listen for any
unusual noises or evidence that parts are
binding.
6. Start the engine and listen for unusual noises.
6-580 Engine Mechanical - 5.7l . Engine
7. Check the vehicle oil pressure gauge or light and 9. Listen for sticking lifters and other unusual noises.
confirm that the engine has acceptable oil 10. Inspect for fuel, oil and/or coolant leaks while (
pressure. the engine is running.
If necessary, istall an oil pressure gauge and
measure the engine oil pressure. 11. Perform a final inspection for the proper engine oil
8. Run the engine speed at about 1000 RPM until and coolant levels. ··
the engine has reached normal operating
temperature.

Engine Component Description
5.7 liter lS1 V-8
·309875
The 5.7 Liter V-8 engine is identified as RPO-LS1 ring incorporated between the fourth and fifth bearing
and VIN-G. journals. The camshaft timing sprocket is mounted (
to the front of. the camshaft and is ddven by the ·
Camshaft and Drive System
crankshaft sprocket through the camshaft timing chain.
A billet steel one piece camshaft is supported by
five bearings pressed into the engine block. The
camshaft has a machined camshaft sensor reluctor
Engine Engine Me.chanical- 5.7L 6-581
The crankshaft sprocket is splined and drives the oil The cable actuated throttle body assembly bolts to the
pump driven gear. A. retaining plate mounted to front of the intake manifold. The throttle body is
the front of the engine block maintains camshaft sealed to the intake manifold by a One piece push in
location. place silicone gasket. The fuel rail assembly with
eight separate fuel injectors is retained to the intake
Crankshaft by four bolts. The injectors are seated in their
The crankshaft is cast nodular iron. The crankshaft is individual manifold bores with. 0-ring seals. to. provide
supported by five crankshaft bearings. The bearings sealing. A fuel rail stop bracket is retained at the
are retained by crankshaft bearing caps which rear of the left fuel rail by the intake manifold mounting
are machined with the engine block for the proper bolts. A snap fit Manifold Absolute Pressure (MAP)
alignment and clearance. The crankshaft journals are sensor housing is mounted at the rear of the manifold
undercut and rolled. The center main journal is the and sealed by an 0-ring seal. The MAP sensor is.
thrust journal. A crankshaft position reluctor ring installed and retained to the MAP sensor housing. An
is mounted at the rear of the crankshaft. The reluctor externally mounted Exhaust Gas Recirculation (EGA)
ring is not serviceable separately. pipe assembly installs into the top front of the
intake manifold. The EGA pipe assembly is sealed to
Cylinder Heads the intake manifold by an 0-ring seal and is,retained
The cylinder head assemblies are cast aluminum and to the manifold by one bolt. There are no coolant
have pressed in place powdered metal valve guides passages within the intake manifold.
and valve seats. Passages for the Engine Coolant Air
Bleed system are at the front and rear of each Oil Pan
cylinder head. There are no exhaust gas passages The structural oil pan is cast aluminum. Incorporated
within the cylinder head. The cylinder head design has into the design are the oil filter mounting boss, ·
changed. Valve rocker arm covers are now retained drain plug opening, oil level sensor mounting bore,
to the cylinder head by four center mounted rocker arm and oil pan baffle. The oil pan cover and oil level
cover bolts. sensor mount to the side of the oil pan. The alignment
of the structural oil pan to the rear of the engine
Engine Block block and transmission bell housing is critical.
The engine block is a cam~in-block deep skirt
90 degree V configuration with five crankshaft bearing Piston and Connecting Rod Assemblies
caps. The engine block is aluminum with cast in The pistons are cast aluminum. The pistons use
place iron cylinder bore liners. The five crankshaft two compression rings and one oil control ring ·
bearing caps each have four vertical M1 O and assembly. The piston is a low friction, lightweight
two horizontal M8 mounting bolts. The camshaft is design with a flat top and barrel shaped skirt. ·
supported by five camshaft bearings pressed into The piston pins are chromium steel. They have a
the block. floating fit in the piston and are retained by a press fit
in the connecting rod. The connecting rods are ..
Exhaust Manifolds powdered metal. The connecting rods are fractured at
The exhaust manifolds are one piece cast iron design. the connecting rod journal and then machined for
The exhaust manifolds direct exhaust gasses from the proper clearance.
the combustion chambers to the exhaust system. Each
manifold has a single inlet for the Air Injection Valve Rocker Arm Cover Assemblies
Reaction (AIR) system and the left exhaust manifold The valve rocker arm covers are cast aluminum and
has a threaded opening for installation of an use a pre-molded silicone gasket for sealing. Mounted
oxygen sensor. Exhaust system gasses are directed to each rocker cover is an ignition coil and bracket
from the right exhaust manifold through the Exhaust assembly. Incorporated intO the covers are the oil fill
Gas Recirculation (EGA) pipe assembly and valve tube, the Positive CrankcaseVentilation (PCV)
to the intake manifold. The EGA pipe assembly system passages, and the engine fresh air passages.
is retained to the exhaust manifold by two bolts and Rocker arm cover design has changed. The covers
sealed at the exhaust manifold flange with a gasket. are now retained to the cylinder head by four center
Each manifold also has an externally mounted mounted rocker cover bolts.
heat shield that is retained by bolts.
Valve Train
Intake Manifold Motion is transmitted from the camshaft through the
The IAFM or integraged air fuel module is a one piece hydraulic roller valve lifters and tubular pushrods to the
composite design that incorporates brass threaded roller type rocker arms. The valve lifter guides
inserts for mounting the fuel rail, throttle cable bracket, position and retain the valve lifters. The valve rocker
throttle body, and EGR inlet pipe. The intake arms for each bank of cylinders are mounted on
manifold is sealed to the cylinder heads by pedestals (pivot supports). Each rocker arm is retained
eight separate non-reuseable silicone sealing gaskets on the pivot support and cylinder head by a bolt.
which press into the grooves of the intake housing. Valve lash is net build.
Drive Belt System Description New Product Information
The drive belt system consists of the following The purpose of New Product Information is to highlight
compor:ients: . or indicate important product changes from the (
• The drive belt previous model year.
• The drive belt tensioner Changes may include one or more of the
following items:
• The drive belt idler pulley
• Torque values and/or fastener tightening strategies
• The crankshaft balancer pulley
• Changed engine specifications
• The accessory drive component mounting
brackets • New sealants and/or adhesives
• The accessory drive components • Disassembly and assembly procedure revisions
- The power steering pump, if belt driven • Engine .mechanical diagnostic procedure revisions
- The generator • New special tools required
- The A/C compressor, if equipped • A component comparison from the previous year
'- The engine cooling fan, i.f belt driven Torque Values and/or Fastener Tightening
- The water pump, if belt driven Strategies
- The vacuum pump, if equipped • The new service thread repair tools .and service
- The air compressor, if equipped procedures are identified.
The drive belt system may use one belt or two belts. Refer to Thread Repair, Thread Repair
The drive belt is thin so that it can bend backwards Specifications, and Fastener Tightening
and has several ribs to match the grooves in the Specifications for additional information.
pulleys. There also may be a V-belt style belt used to • A second design connecting rod bolt may be
drive certain accessory drive components. The used. The proper fastener tightening value MUST
drive belts are made of different types of rubbers be used with the correct bolt.
(chloroprene or EPDM) and have different layers or Refer to Piston, Connecting Rod, and Bearing
plys containing either fiber cloth or cords for Installation.
reinforcement.
Both sides of the drive belt may be used to drive the
New Sealants and/or Adhesives (
different accessory drive components. When the No sealant or adhes.ive changes from the previous
back side of the drive belt is used to drive a pulley, year. Refer to Sealers, Adhesives, and Lubricants.
the pulley is smooth. Engine Mechanical Diagnostic
The drive belt is pulled by the crankshaft balancer Procedure Revisions
pulley across the accessory drive component pulleys. '
Base Engine Misfire, Valve Train, and other diagnostic
The spring loaded drive belt tensioner keeps
information is now provided in table form. Potential
constant tension on the drive belt to prevent the drive
or probable causes are supplied for each specific
belt from slipping. The drive belt tensioner arm will
concern.
move when loads are applied to the drive belt by the
accessory drive components and the crankshaft.
The drive belt system may have an idler pulley, which
is used to add wrap to the adjacent pulleys. Some
systems use an idler pulley in place of an accessory
drive component when the vehicle is not equipped with
the accessory.
(
New Special Tools Required Engine Identification
The proper thread repair procedures for aluminum
cylinder blocks and cylinder heads have been added.
Refer to Thread Repair.
A Component Comparison from the Previous
Year
" Exhaust manifolds are a cast iron design with bolt.
on heat shields.
Refer to Engine Component Description.
" The vapor vent pipe, located above the engine
valley cover will now be referred to as the
engine coolant air bleed pipe.
Refer to Disassembled Views.
363593
The 5.7 Liter LS1 engine has two locations where

information is stamped on the blockto identify·
the component. Location one (1) is the primary
stamping location. Location two (2) is the secondary
stamping location. Both stamping locations contain the
engine identification .numbers.
)
Lubrication
Lubrication Flow Schematic (
~·~
(
~
m
t
9 u
63257
Engine lubrication is supplied by a gerotor type oil in the event the filter becomes restricted. At the rear
pump assembly. The pump is mounted on the front of of the block, oil is then directed to the upper main
the engine block and driven directly by the crankshaft oil galleries which are drilled just above the camshaft
sprocket. The pump gears rotate and draw oil from assembly. From there oil is then directed to the
the oil pan sump through a pick-up screen and pipe. crankshaft and camshaft bearings. Oil that has entered
The oil is pressurized as it passes through the the upper main oil galleries also pressurizes the
pump and is sent through the engine block oil galleries. valve lifter assemblies and is then pumped through
Contained within the oil pump assembly is a pressure the pushrods to lubricate the valve rocker arms
relief valve that maintains oil pressure within a and valve stems. Oil returning to the pan is directed
specified range. Pressurized oil is directed through the by the crankshaft oil deflector. Oil temperature,
lower gallery to the full flow oil filter where harmful pressure and crankcase level are each monitored by
contaminants are removed. A bypass valve is
individual sensors. (
incorporated into the oil pan which will permit oil flow
Oil Pump Assembly
64190
Legend
(1) Driven Gear (5) Plug
(2) Oil Pump Housing (6) Drive Gear
(3) Pressure Relief Valve (7) Cover Bolt
(4) Pressure Relief Valve Spring (8) Cover
) Cleanliness and Care Replacing Engine Gaskets

• Throughout this section, it should be understood Gasket. Reuse and Applying Sealants
that proper cleaning and protection of machined
surfaces and friction areas is part of the repair Tools Required
procedure. This is considered standard shop J 28410 Gasket Remover
practice even if not specifically stated.
• Do not reuse any gasket unless specified.
O When any internal engine parts are serviced, care
• Gaskets that can be reused will be identified in
and cleanliness is important. the service procedure.
• When components are removed for service, they
• Do not apply sealant to any gasket or sealing
should be marked, organized or retained in a
surface unless called out in the service
specific order for reassembly.
information.
Separating Components
., At the time of installation, components should be
installed in the same location and with the same • Use a rubber .mallet to separate components.
mating surface as when removed. • Bump the part sideways to loosen the
• An automobile engine is a combination of many components.
machined, honed, polished and lapped surfaces • Bumping should be done at bends or reinforced
with tolerances that are measured in millimeters or areas to prevent distortion of parts.
thousandths of an inch. These surfaces should
be covered or protected to avoid component
damage.
O A liberal coating of clean engine oil should be
applied to friction areas during assembly.

• Proper lubrication will protect and lubricate friction
surfaces during initial operation.
)
Cleaning Gasket Surfaces • Apply the pipe joint compound to a clean surface.
• Remove all gasket and sealing material from the Use a bead size or quantity as specified in the (
part using the J 28410 or equivalent. procedure. Run the bead to the inside of any bolt
holes. Do not allow the sealer to enter any
• Care must be used to avoi.d gouging or scraping blind threaded holes, as it may prevent the bolt
the sealing surfaces .. from clamping properly or cause component
• Do not use any other method or technique to damage when the bolt is tightened.
remove sealant or gasket material from a part. • Apply a continuous bead of pipe joint compound
• Do not use abrasive pads, sand paper, or power to one sealing surface. Sealing surfaces to be
tools to clean the gasket surfaces .. resealed must be cl.ean and dry.
- These methods of cleaning can cause • Tighten the bolts to specifications. Do not
damage to the component sealing surfaces. overtighten.
- Abrasive pads also produce a fine grit RTV Sealer
that the oil filter cannot remove from the oil.
• Room Temperature Vulcanizing (RTV) sealant
- This grit is abrasive 9nd has been known to
hardens when exposed to air. This type sealer
cause internal engine damage.
is used where two non-rigid parts (such as
Assembling Components. the intake manifold and the engine block) are
assembled together.
• When assembling components, use only the
sealant specified or equivalent in the service • Do not use Room Temperature Vulcanizing (RTV)
procedure. sealant in areas where extreme temperatures are
expected. These areas include: exhaust
• Sealing surfaces should be clean and free of
manifold, head gasket, or other surfaces where a
debris or oil.
gasket eliminator is specified.
• Specific components such as crankshaft oil seals
• Follow all safety recommendations and directions
or valve stem oil seals may require lubrication
that are on the container.
during assembly.
To remove the sealant or the gasket material,
• Components requiring lubrication will be identified
in the service procedure. refer to Replacing Engine Gaskets
• When applying seala.nt to a component, apply the • Apply RTV to a clean surface. Use a bead size as (
amount specified in the service procedure. specified in the procedure. Run the bead to the .
inside of any bolt holes. Do not allow the sealer to
• Do not·allow the sealant to enter into any blind enter any blind threaded holes, as it may
threaded holes, as it may prevent the bolt prevent the bolt from clamping properly or cause
from clamping properly or cause component damage when the bolt is tightened.
damage when tightened.
• Assemble components while RTV is still wet
• Tighten bolts to specifications. Do not overtighten. (within 3 minutes). Do not wait for RTV to
skin over.
Use of RTV and Anaerobic Sealer ~ Tighten bolts to specifications. Do not overtighten.
Pipe.Joint Compound Anaerobic Sealer
Important: Three types of sealer are commonly used • Anaerobic gasket eliminator hardens in the
in engines. These are RTV sealer, anaerobic gasket absence of air. This type sealer. is used where
eliminator sealer, and pipe joint compound. The correct two rigid parts (such as castings) are assembled
sealer and amount must be used in the proper together. When two rigid parts are disassembled
location to prevent oil leaks. DO NOT interchange the and no sealer or gasket is readily noticeable;
three types of sealers. Use only the specific sealer the parts were probably assembled using a gasket
or the equivalent as recommended in the service eliminator.
procedure. • Follow all safety recommendations and directions
• Pipe joint compound is a pliable sealer that does that are on the container.
not completely harden. This type sealer is used To remove the sealant or the gasket material,
where two non-rigid parts (such as the oil pan and refer to Replacing Engine Gaskets
the engine block) are assembled together.
• Apply a continuous bead of gasket eliminator to
• Do not use pipe joint compound in areas where one flange. Surfaces to be resealed must be
extreme temperatures are expected. These clean and dry.
areas include: exhaust manifold, head gasket, or
• Spread the sealer evenly with your finger to get a
other surfaces where gasket eliminator is uniform coating on the sealing surface.
specified.
• Do not allow the sealer to enter any blind threaded (
• Follow all safety recommendations and directions holes, as it may prevent the bolt from clamping
that are on the container.
properly or cause damage when tightened.
To remove the sealant or the gasket material,
refer to Replacing Engine Gaskets
Important: Anaerobic sealed joints that are partially Caution: Refer to Fastener Notice in Cautions and
) torqued and allowed to cure more than five minutes Notices.
may result in incorrect shimming and sealing of When working on the engine, remember that the
the joint. 12-volt electrical system is capable of causing short
circuits. When performing any work where electrical
Do not allow the sealer to enter any blind threaded
terminals may possibly be grounded, disconnect
holes, as it may prevent the bolt from seating properly
the ground cable of the battery at the battery.
or cause damage when the bolt is tightened.
Any time you remove the air cleaner, cover the intake
" Tighten bolts to specifications. Do not overtighten. opening. This procedure protects against the
" Af1er properly tightening the fasteners, remove accidental entrance of foreign material. Foreign
the excess sealer from the outside of the joint. material may follow the intake passage into the
cylinder. This condition causes extensive damage
when you start the engine.
Separating Parts
In the mechanical procedures described in this
Important: Many internal engine components will section, generally no references will be made to the
develop specific wear patterns on their friction removal of optional equipment such as the power
surfaces. steering pump, the air conditioning compressor, etc.
If you need to remove any optional equipment in order
VVhen disassembling the engine, internal components
to perform .other service, refer to the appropriate
MUST be separated, marked, or organized in a
section of this service manual for the specific
way to ensure reinstallation to their original .location information.
and position.
Separate, mark, or organize the following components: Tools and Equipment
" Piston and the piston pin Special tools are listed and illustrated throughout this
• Piston to the specific cylinder bore section with a complete listing at the end of the
section. These tools (or their equivalents) are specially
" Piston rings to the piston designed to quickly and safely accomplish the
• Connecting rod to the crankshaft journal operations for which they are intended. The use of
• Connecting rod to the bearing cap these special tools will also minimize possible damage
to engine components. Some precision measuring
A paint stick qr etching/engraving type tool are tools are required for inspection of certain critical
recommended. Stamping the connecting rod components. Torque wrenches and a torque angle
or cap near the bearing bore may affect meter are necessary for the proper tightening of
component geometry. various fasteners.
" Crankshaft main and connecting rod bearings To properly service the engine assembly, the following
items should be readily available:
.. Camshaft and valve lifters
• Approved eye protection and safety gloves
" Valve lifters, guides, pushrods, pivot supports and
rocker arms • A clean, well-lit, work area
.. A suitable parts cleaning tank
• Valve to the valve guide
" A compressed air supply
O Valve spring and shim to the cylinder head
• Trays or storage containers to keep parts and
location
fasteners organized
• Engine block main bearing cap location and " An adequate set of hand tools
direction
• Approved engine repair stand
• Oil pump drive and driven gears
" An approved engine lifting device that will
adequately support the weight of the components
Installation Precautions
Important: Follow the engine service information
below. This information is important in order to prevent
damage and in contributing to reliable engine
performance.
In order to avoid damage to the engine oil pan, use a
block of wood between the jack and the oil pan.
) Ensure that the block of wood extends past the
complete width of the oil pan. Due to the small
clearance between the oil pan and the oil pump
screen, jacking against the oil pan may cause the oil
pan to bend against the pump screen. This condition
results in a damaged oil pick-up unit.
(
J 3049-A J 8037
Valve Lifter Remover Piston Ring Compressor
14487
J 6125-18 J 8062
Valve Spring Compressor
Slide Hammer
(head off-vehicle)
4865 3414
J 7872 J 8087
(
Magnetic Base Dial Cylinder Bore
Indicator Set Checking Gauge
35463 5110
J 8001 J 8089
Dial Indicator Set Carbon Removal Brush
3415 35464
(
J 8433 J 24086-C
Two Jaw Puller Piston Pin Remover/Installer
216164 14495
J 8520
J 24270
Camshaft Lobe Lift Dial
Indicator Set Cylinder Ridge Remover
3408 3412
. J 9666 J 28410
) Valve Spring Tester Gasket Remover
5112 54479
J 21366
J 28428-E
Converter Holding Strap
Leak Detector Kit
47935
62292
J 22794
Spark Plug Port Adapter J 28467-90A
Engine Support Adapters
26998
)

(
J 28467-B J 37378-1
Universal Support Fixture Valve Guide Reamer
220640
J 33049 J 38836
Camshaft Bearing
Pilot Bushing Installer/Clutch
Remover/Installer
5118 18093
J 36221 J 38606
Hydraulic Clutch Line
Separator
Valve Spring Compressor (
105916 40271
J 36462-A J 39411
Engine Support Adapter Leg Flywheel Holding Tool
220642 54471
J 36660-A J 39549
Torque Angle Meter Ball Joint/Tie Rod Separator
3413 181116
(
Illustration Tool Number/Description Illustration Tool Number/ Description
J.39580 J 41479
Engine Support Table
. Installer
82341 64249
J 41480
J 39580,500 Front and Rear .Cover
Engine SupportTable Top Alignment (at oil pan
surface)
74284 64211
)
J 41044 ©D Ill® J 41556
Engine Support Adapters Connecting Rod Guide
(i,);))j B
220634 64260
J 41476 J 41558
0 0
Front and Rear Cover
Crankshaft Sprocket
Alignment(at crankshaft
Remover
sea.I a.rea)
64207 98060
J 41478 J 41665
Crankshaft Front Oil Seal Crankshaft Balancer and
lnstalle'r Sprocket Installer
64248 64240

(
J 41712. J 42078
Oil Pressure Sensor Socket Valve Stem Oil Seal Installer
9192 98042
J 41798 J 42386
Engine Lifting Brackets Flywheel Holding Tool
74283 54471
J 41816 J 42385-100
Crankshaft Balancer Thread Repair Kit (Cylinder
Remover Head/Main Bearing Bolt) (
54474 54577
J 41816-2 J 42385-200
Thread Repair Kit (General
Crankshaft End Protector
Threads)
98058 54577
J 41818 J 42385-300
Crankshaft Bearing Cap Thread Repair Kit (Fixtures
Remover and Hardware)
38515 54577
(
Illustration Tool Num.ber/ Description Illustration Tool Number/ Description
/fl £1 J 42451
Engine Support Adapter Kit
J 43276
Clutch Pilot Bearing
Remover
~ JJ
-
220638 355040
(=@ J 42907
Oil Pressure Testing Tool
13545
)
6-594 Engine Cooling Engine
Engine Cooling
(
Specifications
Specification
Accelerator and Cruise Control Servo Cable Adjuster Bolt 8N,m 71 lb in
Air Cleaner Bolt 12 N,m 1061bin
Air Conditioning Condenser Tube Nut 16 N·m 12 lb ft
Coolant Heater Bolt (3.8 L) 2N,m 181bin
Coolant Heater (5.7 L) 40N-m 30 lb ft
Coolant Recovery Reservoir Bolt 12 N·m 1061bin
Cooling Fan Blade Nut 6N·m 531bin
Cooling Fan Motor Bolt 6N·m 531bin
Drive Belt Tensioner Bolt 50 N-m 37 lb ft
EGR Valve Outlet Pipe Bolt 29N,m 21 lb ft
EGR Valve Outlet Pipe Nut 29N·m 21 lb ft
Engine Block Coolant Drain Hole Plug (5.7 L) 60 N·m 44 lb ft
Engine Coolant Temperature Sensor (3.8 L) 25 N·in 18 lb ft
Engine Coolant Temperature Sensor (5.7 L) 20N,m 15 lb ft
Evaporator Tube Bolt 16N,m 12 lb ft
Knock Sensor (3.8 L) 19N·m 14 lb ft
Radiator Air Lower Deflector Screw 10 N·m 891bin (
Radiator Drain Cock 2N·m 181bin
Transmission Oil Cooler Line Fitting (radiator end) 27N·m 20 lb ft
Vapor Vent Pipe Stud/Bolts (5.7 L) 12 N·m 1061bin
Water Outlet Bolt (3.8 L) 27N,m 20 lb ft
Water Outlet Bolt (5.7 L) 10N·m 891bin
Water Pump Bolt (3.8 L) 15 N·m + 80 degrees 11 lb ft + 80 degrees
Water Pump Bolt (5.7 L) 30N-m 22 lb ft
Water Pump Pulley Bolt (3.8 L) . 13 N-m 115 lb in
Engine Cooling System Specifications

I Specification
Application I Metric I English
3.8 L (VINK)
Manual Transmission I 11.8 liters I 12.5 quarts
Automatic Transmission I 11.6 liters I 12.3 quarts
5.7 L (VIN G)
Manual Transmission I 14.5 liters I 15.3 quarts
Automatic Transmission I 14.3 liters I 15.1 quarts
(
Engine Engine Cooling 6"'.595
)
Coolant Radiator I·· 1.000
Coolant Recovery Reservoir 1.000
Coolant Recovery Reservoir Hose 1.000
Electric Engine Cooling Fan Motor 1.000
Engine Coolant Thermostat 1.000
.
Engine Coolant Temperature Sensor (3.8 L) 1.000
Engine Coolant Temperature Sensor (5.7 L) 3.000
Engine Electric Coolant Fan 1.000
Engine Electric Cooling Fan Shroud Kit 1.000
••
Radiator Air Lower Baffle 1.000
Radiator Air Upper Baffle. 1.000
Radiator Fill Cap 1.000
Radiator Inlet Hose 1.000
Radiator Outlet Hose 1.000
Vapor Vent Pipe (5.7 L) 1.000
Water Pump . 1.000
. ...

Cooling System Schematic Icons
.I.con Icon Definition
)
19384
Refer to 080 II Symbol Description Notice in Caution and Notices.
)
Cooling Fan Schematics (V6 VIN K) c:»
I
c.n
..I --- _ _ _ _ _ _ _ _
Power
(RofAtAII Timesi
} - - - ., Engine
!Loe I CD
en
m
COOL FAN Distribution COOL I W' ·
I MaxiFuse® Schematics In J? FAN I mlig . :::i
I 40 A Wiring Systems MiniFuse® 1Harness Junction IDEsc! c.c
I
Js 10A I
Block 1 :::i
(1)
~
L - - - -1- - - - - - - - - - rm - - - - - - rm -J- - - - - .I
Power 3 RED I 402 0.35 ORN I 1640 0
0
,,
Distribution
Schematics In
...------~~~~~~~~~~~~~~~~-r'--~~~~~~~~~~~~~~~~~~~~~~~~~~--,
8169
2.
Wiring Systems :::i
3 RED 1402 c.c
5179 ..
0.35 ORN I 1640
0.35 ORN I 1640
0.35 ORN I 1640
3 RED I 402
-r-----r---------:.1- - - - - -..T- - - -- -- - - - -
3WHTI 504
- - - - - - - - - -;;;r- -- -.;;r=-:
I)·1 Q1~· - -·-· __,
Engine ..
W . . I C3 83 Engine Cooling I
~~
1nng I Engine , Cooling Fan 2
Hrun~,
Junction I Mini Relay -------- M1m Relay · ____ . , I
Block 1 1 •••• :
I C8 810 C10 _ _ _ _ _ B4
_ _ _ _ _B6 _ ____ .i
IL81- l c1! - - - - - - - - -
---- - - - - - - - - - - - - - - - - - - - - - - - - - 3 WHT 504
0.35 8167
3 LT BLU 409 DK BLU 473 3 WHT 504
~ Left ~ Engine
B 0.35 DK BLU 473 B Right
0.35 DK GRN I 335 8166
Engine O35 M Cooling
M Cooling
Fans DK BLU 473 Fan
H C100 A
J J, C100 A 3 BLK 150
l
3 GAY 532 3 BLK 8113
150 /
Ground /
0.35 DK GAN 335 . 0.35 DK BLU 473 . . Distribution 11>- - - - - .., .
--=:.: :.-.:.-.:. --= :.-:.-.:. --= ..J} ~1Cool_~~ -

Schematics In
... -----------
6 - - - - - - - - - - - - - - - - - :.-.:.-.:. - - , Powertrain Wiring!ystems
I J Cooling
Fan Relay 1
I "· ...f Control
PCM
C1 =BLU
Fan Relay
._ -·f 2 and 3
- JI! Control
I Control
I Module (PCM)
I A
1 BLK
150
3 BLK I 150
I JI! C2=CLR - ,,- m

'"-----------------
~ ---------~-----..1~ ~G106 =
c.c
:::J
502404 (1)
~ ~ ~
~· -~ ~
Cooling Fan Schematics (V8 VIN G) m

:::I
--------- ;;w: - - - - - - - - - - {
[HotAtAII Timesi
c~o~ -- ~ E~Qine
rsJ 111·
COOL FAN Distribution J7 FAN I Wmng
MaxiFuse® Schematics MiniFuse® Harness
~
1
1 K1 40 A J6 In Wiring 10 A
1Junction
~ __________ ~~m:, __________ . . : ____ ~ Block 1
Power
Distribution 3 RED 3 REDl402 0.35 ORN I 1640
Schematics
In Wiring
Systems
402 8169
3 REDl402
[B
0.35 ORN I 1640
8179
A
3 REDl402 3WHTl504 0.35 ORN I 1640
0.35 ORN I 1640
-------·-------- ,- -·----·-
~T"-----~-, Engine
CoolIng
Fan
Relay #1
..
I ~ . \, I "''"'
- :....:.... - - + - "- - - , Engine
Cooling
··· ···=·· •, "'"'"

Fan
•w··
I
onng
I Harness
Junction
:Block 1
I
I
'-- . ----·-----.1
0.35 3WHT 504
L__ _ .____ _ 8167
DKBLUr73 4 1
0.35 DKBLU 473 3 WHT 504
8166. . 1
B
~
0.35
DKBLUl473
:~g~~e
Cooling
Fan
J J, C100 H.I. C100
A
I I
I
3 GRYl532 3 BLKl150 m
:::I
0.35 DK GRN 335 . DK BLU1473
0.35 .. + 3BLK
150 .
Ground
Distribution
. / /+s113
/
(C
:::I
Cl)
33 C2 Schematics I!>- - -'
42 C1 _____ - - - - - , - - :- - - - , Powertrain In Wiring 0
r - - Cociling- - - - - - - - - - - ~~i
1~21ay I Control ~ 3 BLKl150 0
I } Fan Relay 1 PCM "·--·f 2 and 3 I Module (PCM) 1 BLK 2.
I •---·f Control C1=BLU .§i. Control I ,._ :::I
.§i_ C2=RED -:- P 150 (C
L-------------------
I -=- -----------J~ G106 m
•·
c.n
w
488034 I "'-I
Component locator
Cooling System Components (
Cooling System Cooling System
Engine Cooling Fans Behind the radiator
Power and Grounding
Wiring Systems
compartment, rear of the .wheelhouse Views in Engine Controls
(V8 VIN G) . Engine Controls
Engine to forward lamp IJarness, in lhe lnline Harness Connector
C100 (10 cavities) engine compartment, above the right End Views in Wiring
Wiring Systems
wheelhouse Systems
Attached to the top left side of the radiator · Harness Routing Views in
G106 -
support Wiring Systems
Attached to the left front frame rail, forward
G109 of the brake pressure mod~lator ~alve ·
Wiring Systems
-
bracket
7 cm (2.8 in) from the electronic throttle ·
8113
- -
module breakout
.In the forward lamp harness,
8166 approximately 14 cm (5.5 in) from G105 - - (
breakout
approximately 6 cm (2.4 in) from the main
8169
branch into the engine wiring harness
- -
junction block .1 breakout
In the forward lam harness, approximately
8179 25 cm (9.8 in) from the engine wiring. - -
harness junction block 1 breakout
(
Engine Coo I.mg 6-599
Engine System _
Cooling Component
_ _ _ _Views
_ _ __Cooling~Fa~n~s'..__ _ _ _ _ ~
2
legend
(1) Cooling Fan 2 (2) Cooling Fa~n~1'.__ _ _ _ _ __
Cooling System Connector End Views Right Engine Cooling Fan Motor
Left Engine Cooling Fan Motor (
-
-
~0 0~
~0 0~
62489
. • 1203-3769
Connector Part
62489
• 1203-3769 .. 630 Series (BLK)
Connector Part
• 2 Way FMetri-Pack Circuit
Information
630 Series (BLK) Pin Wire Color No. Function
Circuit A BLK 150 Ground
Pin Wire Color No. Function B WHT 504 Cooling Fan Motor Feed
A . . GRY 532 Cooling Fan Motor Feed
B LT BLU 409 Cooling. !=an Motor Feed
(
Engine Engine Cooling 6-601

Engine Overheating
Step Action Value Yes No
DEFINITION: Engine temperature lamp comes ON and stays ON, or the temperature gauge shows hot, or coolant overflows
from the reservoir .onto the ground while the engine is running.
Check for a.loss of coolant. Refer to Loss of Coolant.
1 - -
Is there a loss of coolant? . Go to Step 2
1. Check for weak engine coolant solution.
2. Perform a concentration test. Refer to Coolant
2
Concentration Testing.
-
·,
Does the engine still overheat? Go to Step 3 System OK
1. Check for obstructed radiator air flow or bent
radiator firis.
2. If necessary, r$move or relocate added-on parts that
3 -
block air to the radiator.. Clean away any bugs,
leaves, or other debris.
Poes .the engine still overheat? .
Go to Step 4 System OK
1. Check for a loss of system pressure.
2. Perform a radiator fill cap pressure test. Refer to
4 Pressure Cap Testing.
-
1. Check for a faulty Engine Coolant Temperature (ECT)
sensor. Refer to one of the following procedures:
• OTC P0117 Engine Coolant Temperature (ECT)
Sensor Circuit Low Voltage in Engine
Controls-3.8L.
Sensor Circuit High Voltage in Engine
Controls-3.8L.
5
-
Sensor Circuit Low Voltage in Engine
Controls-5.?L.
Sensor Circuit High Voltage in Engine
Controls-5. 7L.
2. If necessary, replace the sensor.
1. Check for a damaged coolant recovery reservoir.
2. Check for a leaking or kinked reservoir hose.
6 3. If necessary, reroute the reservoir hose or replace the -
recovery reservoir. Refer to Coolant Recovery
Reservoir Replacement.
1. Check for a loose accessory drive belt.
2. Check the tension of the drive belt. Refer to the
following procedures:
e Drive Belt Replacement in Engine
7 -
Mechanical - 3.8L.
• Drive Belt Replacement - Accessory in Engine
Mechanical - 5.7L.
) 1. Check for advanced or retarded ignition timing.

8 2. If necessary, adjust the timing. -
.
Engine Overheating (cont'd)
1. Check for blocked cooling system passages.
(
2. Flush the cooling system. Refer to Flushing.
9 -
3. If necessary, remove and inspect the cylinder head.
1. Check for an incorrect or damaged cooling fan
blade(s).
2. Check for the correct fan blade(s) part number.
10 -
3. If necessary, replace the fan blade(s). Refer to
Cooling Fan Replacement - Electric.
1. Check for inoperative cooling fans. Refer to Electric
Cooling Fan Diagnosis (Description) in Engine
Controls - 3.8 L or Electric Cooling Fan Diagnosis in
11 Engine Controls - 5.7 L. -
2. If necessary, replace the cooling fan and motor. Refer
to Cooling Fan Replacement - Electric.
1. Check for a stuck closed thermostat. Refer to
Thermostat Diagnosis.
2. If necessary, replace the thermostat.
~ For the 3.8 L engine, refer to Thermostat
12 -
Replacement (3.8 L).
• For the 5.7 L engine, refer to Thermostat
1. Check for a faulty coolant pump. (
2. If necessary, replace the coolant pump.
e For the 3.8 L engine, refer to Water Pump
13 Replacement (3.8 L). -
• For the 5.7 L engine, refer to Water Pump
1. Check the radiator cooling capacity.
2. Check if the radiator is the proper size for the vehicle.
14 3. If necessary, determine the proper radiator size and - -
replace the radiator. Refer to Radiator Replacement.
Loss of Coolant
Step Action Value Yes .· No
1. Check for a wrong or defective radiator fill cap.
2. Perform a cap pressure test. Refer to Pressure Cap
1 124 kPa (18 psi)
Testing: If necessary, replace the fill cap.
Is there still a coolant loss? Go to Step 2 System OK
1. Check for a distorted radiator fill neck.
2. If the upper sealing area of the fill neck is distorted,
2 use a wood block and a mallet to reshape the neck in -
order to fit the cap.
Is there still a coolant loss? Go to Step.3 System OK
1. Check for a leaking coolant recovery reservoir.
2. Check for a loose or damaged reservoir hose.
3 3. If the reservoir or hose is damaged, replace the -
reservoir or the hose. Refer to Coolant Recovery
Reservoir Replacement.
Engine Engine Cooling 6·603
Loss of Coolant (cont'd)
Step Action Value Yes No ..
1. Check for any lo.ose or damaged radiator hoses or

..
heater hoses.
4 2. Re-seat the hoses and clamps. If necessary, replace -
the hoses and the clamps. ·
I
1. Check for a water pump gasket leak.
2. If necessary, replace the water pump gasket.
Is there still a coolant loss? Go to Step6 · System OK
1. Check for a seal leak at the water pump. ·.
2. If the seal is leaking, replace the water pump.

Is there still a coolant loss? Goto Step 7 System OK
1. Check if the cylinder head bolts are tightened to
specification. Refer to the following procedures:
• Fastener Tightening Specifications in Engine
Mechanical - 3.8L
• Fastener Tightening Specifications in Engine
Mechanical - 5.7L
) 2. Tighten the cylinder head bolts to the specification. If
necessary, replace the cylinder head gasket. Refer to
··1,•
one of the following procedures:

7
• Cylinder Head Replacement (Left) in Engine
-
Mechanical 3.8L
• Cylinder Head Replacement (Right) in Engine
Mechanical 3.8L
• Cylinder Head Replacement (Left) in Engine
Mechanical-5.7L. ·
• Cylinder Head Replacement (Right) in Engine
Mechanical-5. 7L.
·,I•
Is there still a coolant loss?
.
Goto Step 8 System OK
1. Check for any coolant leaks at the radiator.
2. Inspect the radiator.
8 3. If necessary, replace the radiator. Refor to .Radiator -
Replacement.
Is there still a loss of coolant? Go to Step 9 System OK
1. Check the following for leaks:
O The intake manifold
• The cylinder head gasket

.• The engine block coolant drain hole plug or the
9 1, knock.sensor - . ;
-
• The heater core
2. Make the necessary repairs or replace the
components as necessary in order to repair the leak.
)
Thermostat Diagnosis Tools Required
• J 24731-188 188°F Tempilstick
Thermostat Test • J 24731-206 206°F Tempilstick (
The coolant thermostat can be tested using a 1. Use a tempilstick in order to find the opening and
temperature (tempi!) stick. The temperature stick is a the closing temperatures of the coolant thermostat.
pencil like device. It has a wax material containing • J 24731-188 tempilstick melts at 87°C (188°F).
The thermostat should begin to open.
certain chemicals which melt at a given temperature.
Temperature sticks can be used to determine a • J 24731-206 tempilstick melts at 97°C (206°F).
The thermostat should be fully open.
thermostat's operating range, by rubbing 87°C (188°F)
2. Replace the coolant thermostat if it does not
and 97°C (206°F) sticks on the thermostat housing.
operate properly between this temperature range.
Engine Fails To Reach Normal Operating Temperature
Notice.: When adding coolant, use DEX-COOL® coolant. If
silicated coolant is added to the system, premature engine,
heater core or radiator corrosion may result. In addition,
the engine coolant will require change sooner-at
50,000 km (30,000 mi) or 24 months.
1 1. Check the level of the coolant in the coolant recovery -
reservoir. The coolant level should be at the FULL
COLD mark.
2. Add engine coolant as necessary.
Does the engine reach normal operating
temperature now? System OK Go to Step 2
1. Check for a blockage in the coolant passages.
2. Flush the cooling system or flow check the radiator.
2 Refer to Flushing. -
Does the engine reach normal operating
temperature now? System OK Go to Step 3 (
1. Check to see if the correct type of thermostat was
installed.
2. Check if the thermostat is stuck in the open position.
Refer to Engine Overheating.
3. If necessary, replace the thermostat.
3 - -
Replacement (5. 7 L)
Does the engine reach normal operating temperature? System OK
Coolant Concentration Testing All new GM vehicles are produced with coolant that
can be accurately measured with a hydrometer;
Cleaning The Instruments however, when the type and quality of coolant being
measured is unknown, such as a customer vehicle that
Tools Required has accumulated mileage, the use of the refractometer
• J 23688 Coolant and Battery Fluid Tester is recommended.
(Fahrenheit Scale) Coolant testers J 23688 (Fahrenheit Scale) or J 26568
O J 26568 Coolant and Battery Fluid Tester (Centigrade Scale) can be used to check the
(Centigrade Scale) antifreeze protection of the coolant. Make sure the
Some coolant manufacturers mix other types of glycol refractometer markings are correct. Unless J 23688 or
into their coolant formulations. Propylene glycol is J 26568 has a provision for temperature correction,
the most common new ingredient. test the temperature at which J 23688 or J 26568
is calibrated. If the coolant is warmer or cooler, 1he
A hydrometer does not always provide a correct reading may be incorrect. Follow the manufacturer's
measurement of freeze protection when anything other direction on using J 23688 or J 26568.
than ethylene glycol and water is being tested. The
degree of inaccuracy varies depending on the
proportion of other glycols present in the coolant.
2. Ensure that the dropper is free of any previous
sample before starting the testing procedure.
3. Dip the end of the plastic dropper i.nto the coolant
without removing it from the tester. Be sure to
J 23688 or
insert the tube slightly below the fluid level.
J 26568
4. Press and release the bulb to draw a sample of
coolant.
13712
1. To clean, swing back the plastic sample cover

located at the slanted end of the J 23688 or
J26568.
2. Wipe clean both the prism and the bottom of the
sample cover.
3. Dry them with a tissue or a clean soft cloth.
402834
4. Close the sample cover.
5. Bend the plastic tube around the J 23688 or
Testing Procedure J 26568 so that the tip can be inserted in the
) sample cover opening.
6. Eject a few drops of the coolant onto the
measuring prism by pressing the bulb. Take
a reading.
7. The J 23688 and the J 26568 are equipped with
an eyeguard that can be used in two positions.
when wearing eyeglasses, the eyeguard should be
folded back; when no eyewear is worn the
eyeguard should be extended. Proper positioning
of the eyeguard will help eliminate stray light
and improve image quality.
13709
1. Release the clear plastic dropper, located on the

side of the J 23688 or J 26568 should be used to
draw the test sample.
Important: The temperature scale is reversed from a Calibrating Testers
standard thermometer scale. Readings below The J 23688 and the J 26568 are factory calibrated
O degrees are on the upper half of the scale. The and sealed. The testers should not require adjustment. (
scale is not visible until a sample is placed on If adjustment is required, perform the following
the prism. If the concentration of the solution tested is
adjustment procedure:
greater than the limits of the scale, the shadow will
not be visible. 1. Make sure the temperature of the J 23688 and
the J 26568 is between 21 and 29 degrees
Centigrade (70 and 85 degrees Fahrenheit).
2. Using distilled water, take a reading.
3. If the reading departs from a O degrees Centigrade
(32 degrees Fahrenheit) reading on the scale
3.1. Remove the sealant covering the scre,v.
3.2. Turn the screw in the direction necessary to
adjust the reading to the O degrees
Centigrade (32 degrees Fahrenheit) line.
l!Tlportant: Never remove the screw from the J 23688
or the J 26568.
3.3. Reseal the screw using silicone sealant.
Cooling System leak Testing

Leak Testing Procedure (On Vehicle)
402832
Tools Required
8. To take a reading, point the J 23688 or the J 24460-01 Cooling System and Cap Pressure Tester
J 26568 toward any light source and look into the .
eyepiece. Caution: Under pressure, the temperature of (
the solution in the radiator can be considerably
higher, without boiling. Removing the radiator cap
1...0 0 - - - -
while the engine is hot (pressure is high), will
0 BOl6S%)
·40(47")·
cause the solution to boil instantaneously, with
·OOIS3%).
explosive force. The solution will spew out
over the engine, fenders, and the person removing
the cap. Serious bodily injury may result.
Flammable antifreeze, such as alcohol, is not
1.250
== a:
~
~10(44%)
·5(41%)
0('!8%)
recommended for use at any time. Flammable
antifreeze could cause a serious fire.
== :e
1.200 -
•&(34%)
1.,.. -==
-=o
w
~ +t0(3fl%}
Caution: In order to help avoid being burned, do
-=- a:
-= UJ not remove the radiator cap while the engine
1.100 ==-- and the radiator are hot. Scalding fluid and steam
BATTISRY
CHARGE can be blown out under pressure if the cap is
+25(12%/
SPECtFfC
GRAVITY PFIOPOYLEN&
removed too soon.
GLYCOL
+U'° (10%) 1. After the system has cooled, remove the
"F radiator/surge tank pressure cap.
FREE2E POINT
('loGLYCOLaY\IOl.UME)
13713
9. The coolant freeze point reading is taken where

the dark and light portions of the scale meet.
Take the coolant reading on the right-hand scale.
10. To obtain the best contrast between the light and
dark portions of the scale, tilt the J 23688 or the
J 26568 toward a light source. if the edge between
the light and dark shadow is not sharp, the
measuring prism was not sufficiently clean and
dry or there was not enough fluid on the
measuring prism.
J24460-01
11658 1375
2. Connect the cooling system tester J 24460-01 to 6. Check the radiator/surge tank cap with J 24460-01
the radiator/surge tank. in order to ensure the cap maintains the correct
pressure.
3. Apply normal system operating pressure. Do not
exceed 138 kPa (20 psi). 7. If the radiator leaks during the pressure test, mark
the leak area so the leak can be located once the
radiator has been removed from the vehicle.
Testing Procedure (Off Vehicle)
Tools Required
) J 24460-01 Cooling System and Cap Pressure Tester
Notice: Do not use boil-out tanks or any other tank
that has been used for copper or brass radiators. The
remaining solutions or chemicals in these tanks
could cause radiator failure.
1. Plug the inlet and outlet tubes. Make sure the
drain cock is closed.
2. Attach the J 24460-01 to the radiator.
3. Apply pressure to the radiator. Do not exceed
138 kPa (20 psi) of pressure. '
4. Observe the gauge for any pressure loss.
5. Run water over the repair area and look for any
bubbles. If a large tank is available, the radiator
can be submerged in order to check for air
1374
bubbles.
4. Watch the gauge needle for an indication of a
leak. Examine all cooling system connections
and components, including the radiator and the
heater core, for leaking coolant.
5. Tighten the hose connections or repair as
required.
)
Pressure Cap Testing Notice: When adding coolant, it is important that you
use GM Goodwrench DEX-COOL® or HAVOLINE®
Radiator Fill Cap Inspection Procedure DEX-COOL® coolant. If Coolant other than (
• Check the cap for a weak spring washer or DEX-COOL® or HAVOLINE® DEX-COOL® is added to
damage to the gasket. If the spring washer the system the engine coolant will require change
is weak, or damaged replace the cap. sooner-at 50 000 km (30,000 mi) or 24 months.
• Check the inner sealing surface of the radiator 1. Park the vehicle on a level surface.
neck for damage or debris. 2. Remove the coolant recovery reservoir fill cap.
Pressure Testing Procedure · 3. Remove the radiator pressure cap.
Tools Required 3.1. Slowly rotate the cap counter clockwise
J 24460-01 Cooling System Pressure Tester until the cap reaches the stop. Do not
1. Clean the radiator fill cap. press down while turning the radiator
pressure cap.
3.2. Wait until any remaining pressure, indicated
by a hissing sound, is relieved.
3.3. After all the pressure is relieved, press
down on the pressure cap and continue to
rotate the pressure cap counter clockwise.
01
4. Open the radiator drain cock.
5. Open the air bleed vent located on top of the
water outlet. Open the air bleed vent two or
three turns ..
6. Place a shop towel under the bleed valve in order
to prevent coolant from splashing onto the EGR
valve outlet pipe.
7. Remove the engine knock sensors, located on
either side of the engine block.
Important: Store used engine coolant in the proper
(
manner, such as in a used engine coolant holding
tank. Do not pour used engine coolant down a drain.
1375 Ethylene glycol antifreeze is a very toxic chemical.
2. Install the cap on the J 24460-01. Do not dispose of coolan.t into the sewer system
3. In order to obtain the minimum holding pressure, or ground water. This is illegal and ecologically
slowly pump the J 24460-01. unsound.
" If the cap fails to hold 83 kPa (12 psi) of 8. Allow the system to drain completely.
pressure, replace the cap. Filling Procedure
" If a new cap is installed, coat the gasket with
engine coolant. Notice: Refer to Fastener Notice in Cautions and
Notices.
Repair Instructions 1. Close the radiator drain cock.
Tighten
Draining and Filling Cooling
Tighten the radiator drain cock to 2 N-m (18 lb in).
System (3.8 l)
2. Install the engine knock sensors.
Draining Procedure
Tighten
Caution: As long as there is pressure in the
Tighten the knock sensor to 19 N·m (14 lb ft)
cooling system, the temperature can be
considerably higher than the boiling temperature 3. Add enough water to fill the coolant system.
of the solution in the radiator without causing 4. Run the engine until the thermostat opens.
the solution to boil. Removal of the pressure cap
while the engine is hot and pressure is high 5. Stop the engine. Repeat the draining procedure
will cause the solution to boil instantaneously - until the drained fluid is colorless.
possibly with explosive force - spewing the 6. Remove, clean, and then reinstall the coolant
solution over the engine, fenders and the person recovery reservoir. Refer to Coolant Recovery
removing the cap. Reservoir Replacement.
7. Complete the following steps in order to .fill the Filling Procedure
cooling system: Notice: Refer to Fastener Notice in Cautions and
) 7.1. Close the air bleed vent when the bubbles Notices.
disappear and only the coolant is visible.
1. Close the radiator drain cock.
7.2. Fill the radiator to below the fill neck.
Tighten
7.3. Fill the coolant recovery reservoir to the
FULL HOT mark.
2. Install the coolant drain hole plugs.
7.4. Install the coolant recovery reservoir cap.
Tighten
8. With the radiator pressure cap removed, run the
engine until the engine reaches normal operating Tighten the drain hole plugs to 60 N·m (44 lb ft).
temperature. The radiator inlet hose will 3. Add enough water to fill the coolant system.
become hot. 4. Run the engine until the thermostat opens.
9. With the engine idling, add coolant to the radiator 5. Stop the engine. Repeat the draining procedure
until the coolant level reaches the bottom of the until the drained fluid is colorless.
filler neck.
6. Remove, clean, and reinstall the coolant recovery
10. Install the pressure cap. The arrows on the cap reservoir. Refer to Coolant Recovery Reservoir
must line up with the vent tube. Replacement.
11. After the engine reaches normal operating 7. Complete the following steps in order to fill the
temperature, check for coolant leaks. coolant system:
7 .1. Fill the radiator to below the fill neck.
Draining and Filling Cooling
7.2. Fill the coolant recovery reservoir to the
System (5.7 l) FULL HOT mark.
Drail1ing Procedure 7.3. Install the coolanfrecovery reservoir cap.
Caution: As long as there is pressure in the 8. With the radiator pressure cap removed, run the
cooling system, the temperature can be engine until normal operating temperature is
considerably higher than the boiling temperature reached. The radiator inlet hose will become hot.
of the solution in the radiator without causing 9. With the engine idling, add coolant to the radiator
the solution to boil. Removal of the pressure cap until the coolant level reaches the bottom of the
while the engine is hot and pressure is high fill neck.
will cause the solution to boil instantaneously - 10. Install the pressure cap.
possibly with explosive. force - spewing the
11. After the engine reaches normal operating
solution over the engine, fenders and the person
temperature, check for coolant leaks.
removing the cap.
Notice: When adding coolant, it is important that you Flushing
use GM Goodwrench DEX-COOL® or HAVOLINE®
DEX-COOL® coolant. If Coolant other than Important: Store used engine coolant in the proper
DEX-COOL® or HAVOLINE® DEX-COOL® is added to manner, such as in a used engine coolant holding
the system the engine coolant will require change tank. Do not pour used engine coolant down a drain.
sooner-at 50 000 km (30,000 mi) or 24 months. Ethylene glycol antifreeze is a very toxic chemical.
1. Park the vehicle on a level surface. Do not dispose of coolant into the sewer system
or ground water. This is illegal and ecologically
2. Follow the steps below to remove the radiator
pressure cap: unsound.
• Slowly rotate the cap counterclockwise until You can use various methods and equipment to flush
the cap reaches the stop. Do not press the cooling system. If special equipment is used
down while turning the radiator pressure cap. (such as a back flusher) follow the manufacturer's
instructions. However, always remove the thermostat
• Wait until any remaining pressure, indicated by before flushing the system.
a hissing sound, is relieved.
• After all the pressure is relieved, press down Engine Coolant Recycling
on the cap and continue to rotate the Whenever the cooling system needs maintenance or
pressure cap counterclockwise. repairs, remove and. replace the coolant with new
3. Open the radiator drain cock. coolant.
4. Remove the engine block coolant drain hole plugs. Important: Do not. recycle coolant on vehicles
5. Inspect the engine coolant: manufactured with GM Goodwrench DEX-COOL®.
) • Discolored - follow the flush procedure below. • Recover the used coolant.
• Normal in appearance - Continue with the " Store the coolant in a used coolant holding tank.
next step. • Submit the used coolant for recycling on a
6. Allow the system to drain completely. regular basis.
Radiator Cleaning
Caution: NEVER spray water on a hot radiator. The
resulting steam could cause personal injury. (
Notice: The radiator fins are necessary for good heat
transfer. Do not brush the fins. This may cause
damage to the fins, reducing heat transfer.
Important: Do not brush the radiator fins. The radiator
fins are necessary for good heat transfer. Brushing
damages the fins and reduces heat transfer.
Clean the front face of the radiator annually.
• Clean the front face of the condenser.
• Remove bugs, leaves, etc. by blowing compressed
air through the radiator.
Blow the air from the rear toward the front. If
compressed air is not available a water hose can
be used to force water through the radiator.
Use water only with the engine not running
and cool.
Coolant Recovery Reservoir Replacement

Removal Procedure
1. Remove the battery. Refer to Battery Replacement
in Engine Electrical.
2. Remove the coolant recovery reservoir hose from
the radiator.
221645
3. Remove the accelerator and cruise control servo

cable bolts, if equipped with a 5.7 L engine:
4. Reposition the accelerator and cruise control
servo cable adjuster, if equipped with a
5.7 L engine.
221646
5. Remove the coolant recovery reservoir bolt.
221653
6. Remove the wiring harness rosebud clip from the

reservoir neck.
7. Remove the coolant recovery reservoir.
221650

the reservoir.
9. Clean the coolant recovery reservoir with soap
and water. Thoroughly rinse the reservoir.
221663
1. Install the coolant recovery reservoir hose to the
reservoir.
(
2. Install the coolant recovery reservoir.
221663
3. Install the wiring harness rosebud clip to the

reservoir neck.
221650

Notices.
4. Install the coolant recovery reservoir bolt.
Tighten
Tighten the coolant recovery reservoir bolt to
12 N·m (106 lb in).
221653
5. Position the accelerator and cruise control servo
cable adjuster, if equipped with a 5. 7 L engine.
6. Install the accelerator and cruise control servo
cable bolts, if equipped with a 5. 7 L engine.
Tighten
Tighten the accelerator and cruise control servo
cable adjuster bolts to 8 N·m (71 lb in).
221646

radiator.
8. Install the battery. Refer to Battery Replacement
in Engine Electrical.
9. Add engine coolant to the FULL COLD mark on
the reservoir.
221645
Coolant Recovery Pipe Replacement

Removal Procedure
1. Remove the coolant recovery reservoir. Refer to
Coolant Recovery Reservoir Replacement.
2. Remove the coolant recovery hose and grommet
from the reservoir.
221663
1. Install the coolant recovery hose and grommet to
the reservoir.
(
2. Install the coolant recovery reservoir. Refer to
Coolant Recovery Reservoir Replacement.
221663
Radiator Hose Replacement - Inlet (3.8 l)

Removal Procedure
Fil/ing Cooling System (3.8 L).
208554
3. Remove the air intake duct resonator .•
554755
221680
5. Remove the inlet hose (1) from the radiator.
349794
1. Install the inlet hose (1) to the radiator.
349794
221680
3. Install the air, intake duct resonator.
554755
4. Connect the IAT sensor electrical connector:

5. Fill the cooling system. Refer to Draining and
Filling Cooling System (3.8 L).
208554
Radiator Hose Replacement - Inlet (5.7 L)
Removal Procedure
Filling Cooling System (5. 7 L}.
2. Disconnect the intake air temperature sensor (IAT)
208553
208569

2
349797
6; Remove the inlet hose from the power steering
cooler, if equipped.
221666
7. Remove the inlet hose from the water pump.
221676
1. Install the inlet hose to the water pump.
221676
2. Install the inlet hose to the power steering cooler,
if equipped.
221666

2
349797
208569
7. Refill the cooling system. Refer to Draining (
and Filling Cooling System (5. 7 L).
208553
Radiator Hose Replacement -

Outlet (3.8 L)
Removal Procedure
208554
554755
Information.
221689
6. Remove the outl.et hose (2) from th.e radiator.

7. Remove the hose support from the fan shroud.
349794
1. Install the outlet hose support to the fan shroud.
2. Install the outlet hose (2) to the radiator.
349794
4. Install the outlet hose to the water pump.
221689
554755

208554
Radiator Hose Replacement -
Outlet (5.7 l)
Removal Procedure
1 . Drain the cooling system. Refer to Draining and
Filling Cooling System (5. 7 L).
208553
208569
5. Remove the ou'tlethose from the water outlet.

Information.
221671
6~624 Engine Cooling Engine
7. Remove the outlet hose (2) from the radiator.
2
349797
2 1. Install the outlet hose (2) to the radiator.
349797
3. Install the outlet hose to the water outlet.
221671
208569
5. Connect the IAT sensor electrical·connector.

7. Refill the cooling system. Refer to Draining
208553
Throttle Body Heater Hose Replacement -

Inlet (5. 7 L)
Removal Procedure
2. Disconnect the throttle position sensor (TPS)
electrical connector, if necessary.
3. Reposition the hose clamps at the throttle body
and engine coolant air bleed pipe.
4. Remove the throttle body heater inlet hose from
the throttle body.
5. Remove the throttle body inlet hose from the
engine coolant air bleed pipe.
220621
1. Install the throttle body inlet hose to the engine
coolant air bleed pipe.
2. Install the throttle body heater inlet hose to the
(
throttle body.
and engine coolant air bleed pipe.
4. Connect the TPS electrical connector, if
necessary.
220621
Throttle Body Heater Hose Replacement -

Outlet (5. 7 l)
Removal Procedure
and radiator.
3. Remove the throttle body heater outlet hose from (
the throttle body.
4. Remove the throttle body outlet hose from the
radiator.
220620
1. Install the throttle body outlet.hose to the radiator.
2. Install the throttle body heater outlet hose to
the throttle body.
and radiator.
220620
Cooling Fan Replacement - Electric
Removal Procedure
Caution: Keep hands, tools, and clothing away
from the electric engine coolant fans in order
to help prevent personal injury. These fans are
electric and can turn on whether or not the engine
is running. The fans can start automatically with
the ignition in the ON position.
1. Disconnect the intake air temperature (IAT) and
mass airflow (MAF) sensors electrical connectors,
if equipped with the 5.7 L engine.
208553
2. Remove the air intake duct resonator, if equipped

208569

intake air temperature (IAT) sensor, if equipped
vvith the 3.8 L engine.
208554
(
554755
5. Disconnect the rosebud clips from the fans.
211602
6. Disconnect the coolant fan electrical connectors

from the fans.
221692
Engine Engin~ Cooling 6~629
7. Remove the air cleaner bolts.
8. Remove the air cleaner.
221697
9. Remove the electric engin~ coolant fan. The fan

will slide off of the radiator.
41692
10. Remove the fan blade nut.

Caution: If a fan blade is bent or damaged in any
way, do not repair or reuse the damaged part.
Always replace a bent or damaged fan blade. ·Fan
blades that have been damaged can not be
assured of proper balance and could fail and fly
apart during subsequent use. This creates an
extremely dangerous situation.
The fan blades must remain in proper balance. You
cannot assure fan blade balance once a fan blade
has been bent or damaged. A fan blade that is not in
proper balance could fail and fly apart during use,
creating an extremely dangerous situation.
11. Remove the fan blade.
12. Inspect for the following conditions:
• Bent or cracked fan blades
• Smoothness of the fan blade mating surfaces
• Remove burrs or other imperfections as
necessary
342281
1. Install the fan blade.
Notices.
2. Install the fan blade nut.
Tighten
Tighten the fan blade nut to 6 N·m (53 lb in).
342281
3. Install the electric engine coolant fan. The fan will

slide into place on the radiator.
41692
4. Install the air cleaner.

5. Install the air cleaner bolts.
Tighten
Tighten the air cleaner bolts to 12 N·m (106 lb in).
221697
6. Connect the coolant fan electrical connectors to
the fans.
221692
7. Connect the rosebud clips to the fans.
211602
8. Install the air intake duct resonator, if equipped

554755
9. Connect the electrical connector to the IAT
sensor, if equipped with the 3.8 L engine.
208554

208569
11 . Connect the IAT and the MAF sensors electrical

connectors, if equipped with the 5. 7 L engine.
208553
Cooling Fan Motor Replacement - Electric
Removal Procedure
1. Remove the cooling fan. Refer to Cooling Fan
Replacement - Electric.
2. Remove the cooling fan motor.
342295
Notices.
1. Install the cooling fan motor.
Tighten
Tighten the cooling fan motor bolts to
6 N-m (53 lb in).
2. Install the cooling fan. Refer to Cooling Fan
Replacement - Electric.
342295
Cooling Fan Relay Replacement

Removal Procedure
1. Remove the cover from the number 1 underhood
electrical center.
2. Remove the cooling fan relay from the underhood
electrical center. Refer to Electrical Center
Identification Views in Wiring Systems.
401242
1. Install the cooling fan relay to the underhood (
electrical center. Refer to Electrical Center
Identification Views in Wiring Systems.
2. Install the cover to the number 1 underhood
electrical center.
401242
Thermostat Housing Replacement (3.8 l)

Removal Procedure
1 . Open the radiator drain cock.
2. Drain the engine coolant to a level below the
thermostat.
Notices.
3. Close the radiator drain cock. (
Tighten
Tighten the radiator drain cock to 2 N·m (18 lb in).
4. Disconnect the exhaust gas recirculation (EGR)
valve electrical connector.
221704
5. Remove the EGR valve outlet pipe bolt from the

6. Remove the EGR valve outlet pipe nut from the
EGR valve adapter.
7. Remove the EGR valve pipe.
221706
221680
9. Remove the water outlet bolts (1 ). ,

10. Remove the water outlet (2). 1
~)
349798
1. Install the water outlet (2). 1
Notices.
2. Install the water outlet bolts (1 ).
Tighten
Tighten the water outlet bolts (1) to
27 N-m (20 lb ft).
349798
s.:.636 Engine Cooling Engine
221680
4. Install the EGR valve pipe.

5. Install the EGR valve outletpipe nut from the
EGR valve adapter.
Tighten
Tighten the EGR valve outlet pipe nut to
29 N·m (21 lb ft}.
6. Install the EGR valve outlet pipe bolt from the
Tighten
(
Tighten the EGR valve outlet pipe bolt to
29 N-m (21 lb ft).
221706

8. Add engine coolant.
221704
Thermostat Housing Replacement (5.7 L)
Removal Procedure
1. Open the radiator drain cock. Drain the engine
coolant to a level below the thermostat.
Notices.
Tighten
3. Remove the radiator outlet hose from the water
outlet.
221671
4. Remove the water outlet housing bolts.

5. Remove the water outlet.
221708
1. Thoroughly clean the water outlet and water pump
surfaces.
Notices.
3. Install the water outlet bolts.
Tighten
Tighten the water outlet bolts to 10 N-m (89 lb in).
221708
4. Install the radiator outlet hose to the water outlet.
5. Add engine coolant.
(
22167f
Thermostat Replacement (3.8 L)

1 Removal Procedure
1. Remove the water outlet (2). Refer to Thermostat
Housing Replacement (3.8 L).
2. Remove the engine coolant thermostat (3).
349798
1 1. Install the engine coolant thermostat (3).
2. Install the water outlet (2). Refer to Thermostat
Housing Replacement (3.B L).
349798
Thermostat Replacement (5. 7 l)
Removal Procedure
1. Remove the water outlet. Refer to Thermostat
Housing Replacement (5. 7 L).
2. Remove the thermostat.
221709
1. Install the thermostat.
2. Install .the water.outlet. Refer to Thermostat
Housing Replacement (5. 7 L).
221709
Thermostat Bypass Pipes

Replacement (3.8·L)
Removal Procedure
Belt Tensioner Replacement in Engine
Mechanical - 3.8 L.
2. Remove the thermostat bypass upper (1) and/or
lower (2) pipe.
500325
1. Install the thermostat bypass upper (1) and/or (
lower (2) pipe.
2. Install the drive belt tensioner. Refer to Drive
Belt Tensioner Replacement in Engine
Mechanical - 3.8 L.
'
500325
Water Pump Replacement (3.8 L)

Removal Procedure
1. Open the radiator drain cock. Drain the engi1ne
coolant to a level below the thermostat.
Notices.
Tighten
3. Loosen the water pump pulley bolts.
5. Remove the radiator inlet hose from the
water pump.
221689
6. Remove the water pump pulley bolts.

7. Remove the water pump pulley.
221711
8. Remove the water pump bolts (1 ).
9. Remove the water pump (2).
10. Remove the water pump gasket (3).
11. Clean all of the gasket mating surfaces, including
the water pump bolts.
11687
Tools Required
1. Install a new water pump gasket (3).
2. Install the water pump (2).
3. Install the water pump bolts (1 ).
Tighten
)
Tighten the water pump bolts (1) to
15 N-m (11 lb ft). Use J 36660-A to torque the
water pump bolts (1) an additional 80 degrees.
11687
4. Connect the radiator inlet hose to the water pump.

5. Install the water pump pulley and the bolts.
Tighten
Tighten the water pump pulley bolts to
13 N-m (115 lb in).
Replacement in Engine Mechanical - 3.8 L.
7. Add the engine coolant.
8. Start the engine. After the engine reaches normal
operating temperature, check for coolant leaks.
221689
Water Pump Replacement (5.7 L)
Removal Procedure
(
Lifting ahd Jacking the Vehicle in General
Information.
2. Disconnect the coolant fan electrical connectors.
3. Drain the cooling system. Refer to Draining
550332

208553
7. Remove the air intake,ductresonatoL
208569
8. Remove the outlet hose from the water outlet.
221671
9. Remove the inlet hose from the coolant pump.
221676
10. Remove the air cleaner bolts ..

11. Remove the air cleaner I upper radiator support.
221697
2
(
349797
13. Remove the electric engine coolant fans.

Belt Replacement - Accessory in Engine
Mechanical - 5.7 L.
41692
15. Remove the drive belt tensioner pulley from the

co9lant pump.
220581
16. Remove the throttle body heater outlet hose from
the radiator.
220620
17. Remove the coolant pump bolts.
550333
18. Remove the coolant pump.

19. Remove the coolant pump gaskets.
20. Clean all gasket mating surfaces, also clean the
water pump bolts.
550334
1. Install the coolant pump and gaskets to the
engine block.
550334

Notices.
2. Install the coolant pump bolts.
Tighten
Tighten the coolant pump bolts to
30 N-m (22 lb ft).
550333
3. Install the throttle body heater outlet hose to the

radiator.
220620
Engine Engine Cooling . 6-647
4. Install the drive belt tensioner to the coolant pump.
Tighten
Tighten the drive belt tensioner bolt to
50 N·m (37 lb ft).
5. Install the accessory drive belt. Refer to Drive
Belt Replacement - Accesso,y in Engine
Mechanical - 5. 7 L.
220581
6. Install the electric engine cooling fans.
41692

2
349797
8. Install the air cleaner I upper radiator support.
9. Install the air cleaner bolts.
Tighten (
Tighten the air cleaner bolts to 12 N,m (106 lb in).
221697
10. Install the inlet hose to the coolant pump.
221676
11. Install the outlet hose to the water outlet.
221671
Engine Engine Cooling 5,.549
208569

208553
15. Connect the coolant fan electrical connectors.

16. Refill the.cooling system. Refer to Draining and
Filling Cooling System (5. 7 L);
550332
Engine Coolant Temperature Sensor
Replacement (3.8 L)
(
Removal Procedure
2. Disconnect the engine coolant temperature (ECT)
sensor electrical connector (2).
439428
Important: Care must be taken when handling the

ECT sensor. damage to the sensor wilLaffect proper
operation of the fuel injection system.
3. Remove the ECT sensor.
349800
1. Coat the ECT sensor threads with sealer GM
P/N 12346004 or equivalent.
2. Install the ECT sensor into the engine.
Notices.
3. Tighten the ECT sensor.
Tighten
Tighten the ECT sensor to 25 N-m (18 lb ft).
349800
4. Connect the ECT sensor electrical connector (2).
439428
Engine Coolant Temperature Sensor

Replacement (5.7 l)
Removal Procedure
2. Disconnect the engine coolant temperature (ECT)
) 3. Remove the number 1 spark plug wire.
Important: Care must be taken when handling the
ECT sensor. Damage to the sensor will affect proper
operation of the fuel injection system.
4. Remove the ECT sensor.
550336
1. Coat the ECT sensor threads with sealer GM
P/N 12346004 or equivalent.
2. Install the ECT sensor.
Notices.
3. Install the ECT sensor.
Tighten
Tighten the ECT sensor to 20 N·m (15 lb ft).
4. Install the number 1 spark plug wire.
5. Connect the ECT sensor electrical connector.
550336
Drain Cock Replacement
Removal Procedure
(
1 . Drain the cooling system. Refer to Draining and
2. Remove the radiator drain cock.
457901
1. Install the radiator drain cock.
457901
Fan Shroud Replacement ·.

Removal Procedure .
1. Remove the radiator upper support. Refer to
Radiator Support Replacement.
2. Remove the fan shroud:
O Move the fan shroud up in order to clear the
four mounts.
" Move the fan shroud down in order to remove
it from the vehicle.
185073
3. Remove the cooling fan brackets from the fan.·
shroud.
349792
1. Install the cooling fan brackets to the fan shroud.
349792
2. Install the fan shroud into the four retaining tabs

on the radiator.
3. Install the radiator upper support. Refer to
Radiator Support Replacement.
185073
6.;654 Engine .Cooling Engine
Radiator Replacement
Removal Procedure
(
1. Recover air conditioning system. Refer to
Refrigerant Recovery and Recharging in HVAC
Systems with A/C - Manual.
Filling Cooling System (3.8 L) or to Draining and
3. Remove the radiator inlet hose. Refer to Radiator
Hose Replacement - Inlet (3.8 L) or to Radiator
Hose Replacement - Inlet (5. 7 L).
4. Remove the radiator outlet hose. Refer to Radiator
Hose Replacement - Outlet (3.8 L) or to Radiator
Hose Replacement - Outlet (5. 7 L).
5. Remove the evaporator tube bolt.
6. Remove the evaporator tube from the condenser.
221720
7. Remove the upper oil cooler line from the. radiator.

Information.
9. Remove the lower oil cooler line from the radiator.
208321
1O. Remove the air conditioning condenser. tube nut.

11. Remove the condenser tube from the condenser.
221721
the radiator.
14. Remove the electric engine coolant fans. Refer to
221645
15. Remove the radiator from the vehicle.
221724
16. Remove the condenser from the radiator.
221726
1. Install the condenser to the radiator.
(
221726
2. Install the radiator to the vehicle.

3. Install the electric engine coolant fans. Refer to
221724
4. Install ,the coolant recovery reservoir hose to the

radiator.
Information.
221645
6. Install the condenser tube to the condenser.
Notices.
7. Install the condenser tube nut.
Tighten
Tighten the A/C condenser tube nut to
16 N-m (12 lb ft).
221721
8. Install the lower oil cooler line to the radiator.

Tighten
Tighten the lower oil cooler line to
27 N·m (20 lb ft).
10. Install the upper oil cooler line to the radiator.
Tighten
Tighten the upper oil cooler line to
27 N-m (20 lb ft).
208321
11. Install the evaporator tube to the condenser;

12. Install the evaporator tube bolt.
Tighten ~
Tighten the evaporator tube bolt to
i6 N·m (12 lb ft). -~
13. Install the radiator outlet hose. Refer to Radiator
Hose Replacement - Outlet (3.8 L) or to Radiator
Hose Replacement - Outlet (5. 7 L).
14. Install the radiator inlet hose. Refer to Radiator
Hose Replacement - Inlet (3.8 L) or to Radiator
Hose Replacement - Inlet (5. 7 L).
Filling Cooling System (3.8 L) or to Draining and
) 16. Recharge the air conditioning system. Refer to
Refrigerant Recovery and Recharging in HVAC
Systems with A/C - Manual.
221720
6.;ij58 Engine Cooling Engine
Radiator Support Replacement
Removal Procedure (
1. Disconnect the intake air temperature (IAT) and
mass airflow (MAF) sensors electrical connectors,
if equipped with the 5.7 L engine.
208553

208569

sensor electrical connector, if equipped with the
3.8 L engine.
208554
554755
5. Release the retaining strap latches.

6. Lift the top of the air cleaner housing off.
7. Remove the air filter element.
245337
8. Remove the air cleaner I radiator support bolts.

9. Remove the radiator support.
221697
1. Install the radiator support.
Notices.
2. Install the air cleaner I radiator support bolts
Tighten
Tighten the air cleaner bolts to 12 N·m (106 lb in).
221697

554755
4. Connect the IAT sensor electrical .connector, .if

equipped with the 3.8 L engine.
208554
Engine Coo I.m g 5.;551
Engine .1 intake duct resonator, if equipped
5. Install th~ ; ~ engine.
with the ·
208569
6 F sensors el~ctrical
Connect th\' IAT
_ connectors, and thewith
equipped MAthe 5·7 L engine.
d . tor Air
. Baffle Assemblies and
Ra ia
Deflectors (Lower)
I Procedure screws (3).

Remova
1 Remove the air lower
. air lower affle retainers (4).
cleflectorb
2
. Remove the radiator . lower baffle (1 ).
· diator air
3 Remove the ra ;nent damage.
4: Inspect for any comp
11689
1. Install the radiator air lower b~ffle (1 ). ·
2. Install the radiator air lower baffle retainers (4).
Notices.
3. Install the radiator air lower deflector screws (3).
Tighten
Tighten the radiator air lower deflector screws to
10 N-m (89 lb in).
11689
Radiator Air. Baffle Assemblies and

Deflectors (Upper)
Removal Procedure
1. Remove the radiator air upper baffle from the
retainers (3).
2. Remove the radiator air upper baffle (1) from the
radiator (2).
(
11690
1. Install the radiator air upper baffle (1) to the
radiator (2).
2. Install the radiator air upper baffle to the
retainers (3).
11690
Engine Engine Cooling 6~66~
Coolant Heater Replacement (3.8 L)
Removal Procedure
Information.
3. Disconnect the electrical cord from the coolant
heater.
298431
4. Loosen the coolant heater bolt.

Important: When removing the engine coolant heater
from the engine block, be careful not to score the
machined surface of the plug hole.
5. Remove the coolant heater from the engine block.
6. Clean the engine coolant heater hole. Remove
any burrs, sealer, paint or other rough spots.
298427
Important: The heater element must not touch the
engine block inner wall in the installed position
or damage to the engine block and coolant heater
could result.
1. Apply a coat of engine coolant heater lubricant,
GM P/N 12345996 or equivalent, to the 0-ring
and walls of the coolant heater hole.
298427
Notices.
2. Install the coolant heater into the coolant hole (
using the following steps:
. . .. '
• Insert the heating element end of the heater
into the engine block.
• Une up the heater with the plug hole and push
it straight into place.
• Rotate the heater so that the center electrical
contact and bolt are in line horizontally.
• Tighten the bolt so that the yoke presses
against the engine block inner wall.
Tighten
Tighten the coolant heater bolt to
2 N-m (18 lb in).
3. Connect the coolant heater electrical cord to the
heater.
5. Refill the engine cooling system. Refer to Draining
and Filling Cooling System (3.8 L).
298431
Coolant Heater Replacement (5.7 l)

Removal Procedure
Information.
Filling Cooling System (5. 7 L). ·
3. Disconnect the electrical cord from the coolant
heater.
298433
(
Important: When removing the engine coolant heater
from the engine block, be careful not to score the
machined surface of the plug hole.
4. Remove the coolant heater from the engine block.

5. Clean the engine coolant heater hole. Remove
any burrs, sealer, paint or other rough spots.
550337
Important: The heater element must not touch the
engine block inner wall in the installed position
or damage to the engine block and coolant heater
could result.
1. Apply a coat of engine coolant heater lubricant,
GM P/N 12345996 or equivalent, to the 0-ring
and walls of the coolant heater hole.
) 2. Finger start the coolant heater to the engine block.
Notices.
3. Tighten the coolant heater.
Tighten
Tighten the coolant heater to 40 N·m (30 lb ft).
550337
4. Install the coolant heater electrical cord to the

heater.
298433
Coolant Heater.Cord Replacement (3.8 L)
Removal Procedure
(
1. Disconnect the heater cord from the block heater.
2. Route the block heater end of the cord under
the power steering rack lines.
3. Cut the heater cord strap at the power steering
reservoir.
298431
4. Cut the heater cord strap at the fuse block center.

5. Remove the.heater cord from the vehicle.
298430
1. Install the heater cord and a new strap to the fuse
block center.
298430
2. Route the cord up under the power steering
rack lines.
3. Install a new heater cord strap to the power
steering reservoir.
4. Connect the heater cord to the coolant heater.
298431
Coolant Heater Cord Replacement (5.7 l)

Removal Procedure
1. Disconnect the heater cord from the block heater.
2. Cut the heater cord strap at the power
steering line.
298433
3. Cut the heater cord strap at the fuse block center.

4. Remove the heater cord from the vehicle.
298430
1. Install the heater cord to the vehicle.
2. Install the heater cord and a new strap to the fuse (
block center.
298430
3. Install the heater cord and a new strap to the

power steering line.
4. Connect the heater cord to the coolant heater.
298433
Cooling System Description upper hose into the radiator. There, the coolant
temperature is lowered, and the coolant is drawn again
The cooling system consists of the following major
into the engine by the water pump to provide
components:
passenger compartment heat and defrost. The coolant
• Radiator recovery reservoir provides a coolant fill point. The
• Coolant recovery reservoir reservoir is translucent for coolant level viewing.
• Cooling fans
• Thermostat Coolant Description
• Water pump This vehicle has a newly developed engine coolant.
" Engine coolant air bleed pipe GM Goodwrench® DEX-COOL® was developed to last
• Engine coolant temperature (ECT) sensor for 240 000 km (150,000 mi) or 5 years, whichever
occurs first. Follow the instructions in Draining
• Transmission oil cooler
and Filling Cooling System. Make sure only GM
• All related hoses Goodwrench® DEX-COOL® (silicate-free) or Havoline®
• Fan shroud DEX-COOL® is used when coolant is added or
• Fan motor/blade changed.
The cooling systems functions is to maintain an A 50/50 mixture of DEX-COOL® and clean drinkable
efficient engine operating temperature during all water will provide the following protection:
speeds and under all operating conditions. Cooling
systems are designed to remove about Notice: Pure coolant can be added to raise the boiling
one-third (30 to 35 percent) of the heat produced in point of the coolant, but too much will affect the
the combustion chambers by the burning of the air-fuel freezing point. Do not use a solution stronger than
mixture. The engine is very inefficient while cold. 70 percent, as the freeze level rises rapidly after this
Therefore the cooling system includes a devise point. Pure coolant will freeze at -22°C (-8°F).
(thermostat) that prevents normal cooling action during • Give freezing protection down to -37°C (-34°F).
engine warm-up. The thermostat allows the engine
parts to reach their .normal operating temperature more • Give boiling protection up to 129°C (260°F).
quickly. This shortens the inefficient cold-operating • Protect against rust and corrosion.
time. When the engine reaches its normal operating O Help keep the proper engine temperature.
temperature, the cooling system begins to function.
The cooling system removes excess heat when • Let the warning lights and gauges work correctly.
the engine is hot, and slowly or not at all when th.e
engine is cold or warming up. Coolant Recovery System Description
The coolant absorbs heat as it passes through the The cooling system has a separate plastic, translucent
engine. Then the hot coolant flows through a radiator coolant recover reservoir. The reservoir, also caner
in. which the heat in the coolant is passed on to a recovery tank or expansion tank, is partly filled with
the air that is flowing through the radiator. The cooled coolant and is connected to the overflow tube on
coolant then flows back through the engine. This the radiator fill neck to the reservoir by the O\/erflow
circulatior:i of the coolant continually removes heat from tube. The coolant in the engine expands as the engine
the engine. The coolant is kept in circulation by the heats up. Instead. of dripping out the overflow tube
water pump. onto the ground and being lost from the cooling system
Water jackets are designed to keep the cylinder block completely, the CQOlant flows into the reservoir.
and cylinder heads cool. The water jackets are
When the engine cools, a vacuum is created in the
open spaces. between the outside wall of the cylinder
cooling system. The vacuum siphons some of
and the inside of the cylinder block and head. The
the coolant back into the radiator from the reservoir. In
coolant can circulate freely around the engine
effect, a cooling system with a recovery reservoir is
hot spots. These hot spots include the following:
a closed system. Coolant can flow back and forth
• Valve guides between the radiator and the reservoir. This occurs as
• Valve seats the coolant expands and contracts from heating
• Upper parts of the cylinder walls and cooling. Under normal conditions, no coolant
When the engine is running at the normal operating is lost.
temperature, coolant flows into the block and through An advantage to the use of a coolant recovery
the water jackets surrounding the cylinders. Vapor reservoir is that it eliminates almost all air bubbles
is vented off through the engine coolant air bleed pipe. from the cooling system. Coolant without bubbles
Then coolant is forced through the head gasket absorbs heat much better than coolant with bubbles in
openings and into the cylinder head water jackets. In it. Although the coolant level in the recovery reservoir
the heads, the coolant flows around the combustion goes up and down, the radiator and cooling system
chambers and valve seat, picking up additional are kept full. This results in maximum cooling
heat. From the heads, the coolant flows through the efficiency.
Throttle Body Coolant System Description Coolant Heater Description
The fuel injection system has coolant passages in The engine coolant heater is used to heat the engine
coolant prior to vehicle start up, making it easier to (
the throttle body, The heated coolant flow through
start the engine in very cold climates. It is installed into
these passages improves the cold weather driveability the engine block at a water jacket plug location. An
of the vehicle. engine coolant heater cord is routed inside the engine
compartment. The heater is rated at 600 watts and
uses a 110 volt ac power supply.
Radiator Assembly Description
47015 (
The radiator is a heat exchanger that removes heat In a typical radiator, there are five fins per inch.
from the coolant passing through it. The radiator holds Radiators used in vehicles that have factory installed
a large volume of coolant in close contact with a air conditioning have seven fins per inch. This
large volume of air so that heat will transfer from the provides the additional cooling surface required to
coolant to the air. The radiator core is divided into handle the additional heat load imposed by air .
two separate compartment~ cool.an.t passes throygh conditioning.
one, and air passes through the other. The aluminum The inlet (4) and outlet (9) tanks are molded with high.
radiator core (1) is a crossflow tube and fin design. temperature nylon-reinforced plastic. A high
A tube and fin radiator consists of a series of temperature rubber gasket (2, 12) seals the tank
tubes extending from side to side on the radiator core. flange edge. The tanks are clamped to the core with
The tubes run from the inlet tank (4) to the outlet clinch tabs. The tabs are part of the aluminum
tank (9). Fins are placed around the outside of • header at each end of the core (1 ). A plastic
the tubes to improve heat transfer. Air passes between serviceable drain cock (7) and rubber seal is used.
the fins. As the air passes by, it absorbs heat from
The integral transmission oil cooler (3) is housed inside
the fins which have,· in turn, absorbed heat from
the outlet (4) tank. The cooler provides the automatic
the coolant.
transmission fluid cooling capacity. This maintains
a fairly constant temperature under all operating
conditions.
(
Pressure Cap Description
Radiator Fill Cap
Caution: Under pressure, the temperature of the
solution in the radiator can be considerably higher,
without boiling. Removing the radia.tor cap while
the engine is hot (pressure is high), will cause the
solution to boil instantaneously, with explosive
force. The solution will spew out over the engine,
fenders, and the person removing the cap.
Serious bodily injury may result. Flammable
antifreeze,.such as alcohol, is not recommended
for use at any time. Flammable antifreeze could
cause a serious fire.
48305
The cooling system is sealed and pressurized by a valve. When the pressure gets too high, it raises the
radiator pressure cap. There are two advantages valve so that the excess pressure can escape into the
to sealing and pressurizing the cooling system. recovery reservoir.
• Increased pressure raises the boiling point of the The radiator pressure cap also has a vacuum vent
coolant. This increases the efficiency of the valve. This valve protects the system from developing
cooling system. a vacuum that could collapse the radiator. When
• Sealing the cooling system reduces coolant losses the engine is shut off and cools, the coolant volume is
from evaporation and permits the use of the reduced. Cold coolant takes up less space than hot
recovery reservoir. coolant. As the temperature of the coolant drops,
As .the pressure goes up~ the boiling point goes up. a vacuum develops in the cooling system. To prevent
Therefore, the coolant can be safely run at a excessive vacuum from developing, the vacuum
temperature higher than 212 degrees F valve opens to allow outside air or coolant from the
(100 degrees C) without boiling. The higher the recovery reservoir to flow into the cooling system. This
coolant temperature, the greater the difference relieves the vacuum that could otherwise cause
between it and the outside air temperature. This outside air pressure to collapse the radiator.
difference in temperature is what causes the cooling
system to work. The hotter the coolant, the faster
the heat moves from the radiator to the cooler passing Engine Cooling Fan Description - Electric
air. This means that the pressurized, sealed cooling The cooling fans are located behind the radiator.
system can take heat away from the engine faster. The cooling fans are driven by an electric motor. The
Therefore, the cooling system works more efficiently cooling fan motors both have five blades that are
when the coolant is under higher pressure. each 312 mm (12.3 in) in diameter. One cooling fan
However, the cooling system can be pressurized too will start and run and then both cooling fans will
much. If the pressure in the system gets too high, run depending on the. amount of cooling the
it can damage the radiator and blow off the hoses. To radiator needs.
prevent this the radiator cap has a pressure relief
The advantage of the electric fan is less power drain
on the engine and less fan noise. Also, there is
no fan belt to inspect, adjust, or replace. This means (
less cooling system maintenance.
The engine cooling fan relays provide the current
required for the motors based on a low current signal
received from the powertrain control module (PCM).
Cooling Fan Relay Description

The cooling tan relays are used to control the high
current flow to power the cooling fan motors. Both fans
operate together. When minimum cooling is required,
the PCM energizes cooling fan relay #1 and both
fans operate at low speed, since the fans are
connected in series through cooling fan relay #2
and #3. When maximum cooling is required, the PCM
energizes all three cooling fan relays. The left fan 3
is still powered through cooling fan relay #1, but is now
grounded through cooling fan relay #3. The right fan 13706
is now powered directly through cooling fan The wax pellet element (40 in the thermostat expands
relay #2 and both fans operate at high speed. with increasing temperatures, and contracts with
decreasing temperatures. The element connects
Water Pump Description through a piston (1) to a thermostat valve (2). When
the element is heated, pressure is exerted against
The die-cast water pump is a centrifugal vane impeller a rubber diaphragm (3) which forces the thermostat
type. The pump consists of a housing, with coolant valve to open. As the element is cooled, the
inlet and outlet, and an impeller. The impeller is a flat contraction allows a spring (5) to close the thermostat
plate mounted on the pump shaft with a series of valve. While the coolant is cold, the thermostat
flat or curved blades, or vanes. When the impeller valve remains closed. This prevents circulation of (
rotates, the coolant between the blades is thrown coolant through the radiator. At this point, coolant is
outward by centrifugal force. Then the coolant is forced only allowed to circulate throughout the engine
through the pump outlet and into the cylinder block. block and heater core in order to allow the engine to
The pump inlet is connected by a hose to the bottom of warm quickly. As the engine warms, the element
the radiator. Coolant from the radiator is drawn into expands and the thermostat valve opens. This permits
the pump to replace the coolant forced thmugh coolant to flow through the radiator, where the heat
the outlet. dissipates to the atmosphere.
The impeller shaft is supported on one or more
bearings. A seal prevents<c:;oolant from leaking out Engine Coolant Temperature Sensor
around the bearings. The water pump uses sealed Description
bearings, \J\fhich never need lubrication. With a sealed The engine coolant temperature (ECT) sensor is a
bearing, grease cannot leak out, and dirt and water variable resistance device. The ECT sensor resistance
cannot get in. · determines the position of the temperature gauge.
As the temperature increases, the ECT sensor
Thermostat Description resistance decreases. This allows for more current to
flow through the gauge, causing a higher temperature
The thermostat is a coolant flow control components reading. · ·
that utilizes a temperature sensitive wax-pellet
element (4). Its purpose is to close off the coolant
passage when the engine is cold. Now coolant
circulation is restricted, causing the engine to reach
normal operating temperature more quickly. Also, after
warm-up, the thermostat keeps t.he engine running
at a higher temperature than it would without a
thermostat. The higher operating temperature
improves engine efficiency and reduces exhaust
emissions.
The thermostat performs the following functions: (
" Controls the flow of coolant through the radiator
" Enables controlled engine warm up
.. Assists in coolant temperature control
Air Baffles and Seals Description Special Tools and Equipment
A deflector redirects air flow. Deflectors are installed Illustration Tool Number/ Description
under the vehicle and redirects the air flow beneath the
vehicle to flow through the cooling system. The
defleciors perform the following functions:
• Reduce drag
o Prevent front end lift J 23688
• Increase radiator cooling Coolant Tester
(Fahrenheit Scale)
Air baffles are used to direct air into the radiator and
A/C condenser. Air seals ensure that air passes
through, and does not bypass, the radiator and the
A/C con.denser. A missing, damaged, or incorrectly
1409
installed baffle or seal may cause the engine to
overheat.
J 24460-01
Cooling System and Cap
Pressure Tester
1405
J 24731
) Tempi! Stick
23570
J 26568
Coolant Tester
(Celsius Scale)
12869
J 36660
Torque Angle Meter
3413
6-674 Engine Electrical Engine
Engine Electrical
Specifications (
Specification
ABS/SIR Electrical Ground Stud 14 N-m 10 lb ft
Accelerator and Cruise Control Servo Cable Adjuster Bolt (5.7 L) 7.5N-m 66lbin
Battery Hold Down Retainer Bolt 18 N·m 13 lb ft
Battery Side Terminal Adapters 15 N-m 11 lb ft
Coolant Recovery Reservoir Bolt 12 N-m 106 lb in
Engine Wiring Harness Ground Bolt to Engine Block (5.7 L) 25N-m 18 lb ft
Forward Lamp Wiring Harness Grommet Bolt 2N-m 71 lb in
Forward Lamp Harness Ground Stud 16 N-m 12 lb ft
Generator Brace Bracket Bolt (3.8 L) 50N·m 37 lb ft
Generator Bracket Bolt (5.7 L) 50N·m 37 lb ft
Generator Mounting Bolt (5.7 L) 50 N·m 37 lb ft
Generator Bolt (to drive belt tensioner lower) (3.8 L) 50 N·m 37 lb ft
Generator Bolt (to drive belt tensioner upper) (3.8 L) 30 N-m 22 lb ft
Generator Rear Brace Bolt (3.8 L) 25 N-m 20 lb ft
Generator Bolt (to rear brace) (3.8 L) 30N-m 22 lb ft
Generator Mounting Bolt (5.7 L) 50 N-m 37 lb ft
Generator Mounting Bolt (rear to generator) (5.7 L) 25 N-m 18 lb ft
Ignition Coil Bolt (5.7 L) 12 N·m 1061bin
Ignition Coil Bolt (3.8 L) 4N-m 351bin
Ignition Control Module Bolt {3.8 L) 3N-m 271bin (
Ignition Control Module Nut 30 N-m 22 lb ft
Left Front Forward Lamp Wiring Ground Bolt 10 N·m 891bin
Lift Bracket to Ignition Control Module Bolt (3.8 L) 25 N·m 18 lb ft
Negative Battery Cable Bolt 15 N-m 11 lb ft
.Negative Cable to Engine Block Stud Nut (3.8 L) 22 N-m 16 lb ft
. Negative Cable to Engine Block Bolt (5.7 L) 32N·m 24 lb ft
. Negative Cable at Ground Terminal Nut 6N,m 531bin
Positive Battery Cable Bolt 15 N·m 11 lb ft
Positive Cable RF Ground Nut {3.8 L) 25 N-m 18 lb ft
Positive Cable Nut to Generator Output Stud 22N-m 16 lb ft
Positive Cable to Fuseblock Stud Nut 14 N·m 10 lb ft
Positive Cable to Starter Nut 10 N-m 891bin
Right Front Ground Bolt 10 N-m 891bin
Spark Plug (New Installation) (5.7 L) 20N-m 15 lb ft
Spark Plug (Subsequent Installation) (5.7 L) 15 N-m 11 lb ft
Spark Plug (3.8 L) 27N-m 20 lb ft
Starter Motor Bolt {3.8 L) 47N-m 35 lb ft
Starter Motor Bolt (5.7 L) 50N·m 37 lb ft
Starter Motor Stud (3.8 L) 45N-m 33 lb ft
Starter Motor Shield Nut (3.8 L) 10 N-m 891bin
Starter Motor Shield Bolt (to transmission brace) (3.8 L) 10 N-m 891bin
Starter Motor Shield Bolt (to engine block) (3.8 L) 30 N-m 22 lb ft
Wiring Harness Ground Bolt 12 N-m 1061bin
Wiring Harness Starter Lead Nut 2N-m 18 lb in
Engine Engine Electrical 6-675
Battery Usage
Application Description
' 3.8 L (VINK)
Catalog Number 674
'
Cold Cranking Amperage (CCA) 690
Load.Test (AMPS) 345
Replacement Model Number 75B-84
Reserve Capacity Minutes 90
5.7 L (VIN G)
Catalog Number 670
· Cold Cranking Amperage (AMPS) 525
Load Test (AMPS) 260
Replacement Model Number 75-60
Reserve Capacity Minutes 90
Battery Temperature vs Voltage Drop

Degrees Celsius (°C) Degrees Fahrenheit (°F) Voltage
Temperature vs Minimum Voltage
21 70 9.6
10 50 9.4
0 32 9.1
-10 14 8.8
-18 0 8.5
Below -18 Below O 8.0
) Starter Motor Usage

No Load Test at 11.5 Volts
Starter Motor PG-260
Current Draw (AMPS) 60-125
Pinion Speed (RPM) 2900-3400
Pinion Clearance 0.25 mm (0.01 in)-4.06 mm (0.16 in)
Starter Solenoid Switch
Hold-in Windings 5-15 Amps
Both Windings 30-50 Amps
Generator Usage
·.
Engine 3.8 L (VIN K) and 5.7 L (VIN G)
Rated Amperes 105
Model Type CS-1300
Spark Plug Usage

Engine Application Sparl Plug Type Spark Plug Gap - Metric Spark Plug Gap - English
3.8 L (VINK) 41-921 1.524 mm 0.060 in
5.7 L (VIN G) 41-931 1.524 mm 0.060 in
Spark Plug Wire Resistance 3. Connect an ohmmeter lead to each end of the
plug wire.
Tools Required
4. Gently twist the wire while watching the ohmmeter (
J 39200 Digital Multimeter reading.
l. Remove the spark plug wire to be tested. 5. If the ohmmeter reads above 10,000 ohms,
Ensure that the plug wire terminals are clean replace the wire.
before proceeding: 6. If the resistance of the wire being tested is not
2. Use the J .39200 on the high scale. within 3,000 - 10,000 ohms replace the wire.
1. Electronic Ignition Control Module 2.000
Generator 2.000
Generator Brace Bracket (3.8 L) 2.000
Generator Bracket (5.7 L) 2.000
Generator Rear Brace (3.8 L) 2.000
Generator Rear Bracket (5.7 L) 2.000
Ignition Coil 2.000
Negative Battery Cable 2.000
Positive Battery Cable 2.000
Starter Motor 2.000
Starter Motor Shield 2.000
Spark Plug 2.000
Spark Plug Wire 2.000
Schemat.ic and Routing Diagrams

(
Engine Electrical Schematic Icons
19384
Refer to 080 II Symbol Description Notice in Caution and Notices.
19385
(
Starting and Charging Schematics (Battery and Ignition Switch) m
:::,
ce.
Power 19 RED 1
r ., Battery
!L c I
0 :::J
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Distribution
+ - - - ~- ~ Junction
~c
Schematics In
Wiring Systems
19 RED 1 Block
5YEL 5 32BLK 1 (VINK}
r------
I Power
- - - ., Engine Wiring
IGN I
Harness
I" - - - - - - ., Engine Wiring
S:f'.lTR ® 1 Harness
19 RED 1 (VIN G)
~
,,
Distribution
I Schematics in
I H11
MaxiFuse® 1 Junction Block 2 I
I Wiring Systems
I
K2 50A I
. __
I H10 ~~~use : Junction Block 2
----..i c
L------ ---J Starter
Power
5 RED 2 0.8 PPWWHT 1035 Solenoid ..
Distribution __5_.R_E_D _ _5_R_E_D_---t A Starter
___S_1_83
Schematics in 2 2 Relay ~
Wiring Systems ~
-------------------- - P100 1 (VINK)
8170
1 (VING)
.. - - - - - - - - - - - - - - - - "'.Ignition 0.8 PPL/WHT 1035 0.8 PPL/WHT 1035
;i
I Power I Switch
I Distribution I
I Schematics in Ace Start I Generator
Wiring Systems ~·.,
I / I
I Lock•·.,. ___ _... -·• Bulb - I J C101
I Olf R1.1n Test I
1..----------------J
A C2
0.5PPWWHT 1035
5YEL 5
B 13 BLK 50
Starter
Relay
m
::,
0.5 PPL/WHT 1035 0.5 PPL/WHT 1035 32 BLK 50 (VINK) (Q
Ground :::,
~ 19BLK 50 (VIN G) Distribution
Schematics in
Cl)
23 C2 85 Wiring Systems m
r - - - cr;;;;k., Powertrain
I PCM Signal I Control
I C1_=BLU I Module ~
~ ~=~L~ __ ~ (PCM) ~
I
'"c;;'nk, Instrument
I Signal I Cluster
I~
1..-..11~
r - - - .J
l'
-
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e!..
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G100 G101 a,
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en
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502408 .......
Starting and Charging Schematics (Starter Relay and Starter Solenoid) 0,
I
0,
......
C2000
!Loe I ClO
~
f°.
0..5 PPLNVHT 35 loEsc!
:::::s
cc
:::::s
C'D
~
!Automatic!
m
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5·
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Starting and Charging Schematics {Battery, Generator and Powertrain Control Module) m
::s
(Q
!Loe I ::Ii
(1)
Battery I"' - - ., Power
Junction I
Block I
I. - -
_I _ _..
i
.I
Distribution
Schematics In
Wiring Systems
(SJc
'" - -v;;:;; - -v;;:;; - - - - - - - - - - ., Powertrain
I PCM PCM I Control
I
C1=BLU
c1--BLU Generator
Terminal L
I Module
I C2=CLEAR C2=RED Output I (PCM)
19 RED 1
'-------------------.! 61 C2(VIN K) ~
~
15 C2 (VIN G) '
0.35 RED 225
32BLK 13 RED 1 (VIN Kl

19RED 13 BLK 1 (VIN G)
Starter B
s F Generator
Solid State Regulator
Ground
Dislribulion
Schematics In 32 BLK 50 (VIN Kl
Wiring Systems 19 BLK 50 (VIN G)
TL _13- ,BLK 50 Rectifier

Bridge'--+-----'
' G101 G100 O')

I
en
-..J
502413 (0
Component Locator
Engine Electrical Components (
Body Control Module Body Control Module
Body Control Under the right side of the IP near the
Component Views in Connector End Views in
Module (BCM) blower motor
Body Control Systems Body Control Systems
Cruise Control
Clutch Pedal Engine Electrical
Mounted to the clutch pedal bracket Component Views in
Position (CPP) Switch Connector End Views
Cruise Control
Power and Grounding
Wiring Systems
Engine Electrical Engine Electrical
Generator (V6 VIN K) On the front right side of the engine
Instrument Panel,
Gauges, and Console
Engine Electrical
Generator (VB VIN G) On the front left side of the engine Component Views in
Connector End Views
Instrument Panel,
Gauges and Console
Mounted near the base of the steering Engine Electrical Engine Electrical
Ignition Switch
column Component Views Connector End Views
Gauges and Console Gauges and Console
Engine Controls
Park/Neutral Position Under the center console, on the base of Shift Lock Control
Connector End Views in
.Switch the shift control lever Component Views in
Engine Controls (
Powertrain Control · Power and Grounding
Module (PCM). Component Views in
Powertrain Control
. Engine Controls
(VB VIN G) Engine Controls
Starter Motor Engine Electrical
(V6 VINK)
On the bottom left side of the engine
Component Views
-
Starter Motor Engine Electrical
(VB VIN G)
On the bottom right side of the engine
Component Views
-
Starter Solenoid On the bottom .left side of the engine, Engine Electrical
(V6 VIN K) above the starter motor Component Views -
Starter Solenoid On the bottom right side of the engine, Engine Electrical
(VB VIN G) above the starter motor Component Views
-
Engine to forward lamp harness, in the lnline Harness Connector
C101 (10 cavities) engine compartment, above the right End Views in Wiring
Wiring Systems
wheelhouse Systems
Engine to forward lamp harness, in the
C102 (1 cavity) engine compartment, above the right
Wiring Systems
-
wheelhouse
C200A (17 cavities) End Views in Wiring
Systems
C200B (18 cavities) End Views in Wiring
Systems
C200D (48 cavities) End Views in Wiring
Systems
Engine Engine Electrical 6;..681
Engine Electrical Components (cont'd)
Systems
G100 (V6 VIN K)
above the A/C compressor Wiring Systems
-
G100 (V8 VIN G)
above the starter solenoid Wiring Systems
-
In the engine compartment, attached to Harness Routing Views in
G101 -
the front of the left wheelhouse Wiring Systems
P100 -
P110 -
8170 approximately 13 cm (5.1 in) from - -
G 106 breakout
8183 approximately 10 cm (4 in) from the engine - -
wiring harness junction block 1 breakout
Engine Electrical Component Views
Base of Steering Column
(
2
374168
Legend
(1) Steering Column (4) Isolation Diode (Wipers)
(2) Ignition Switch (5) Forward Lamp Harness
(3) Headlamp Dimmer Switch
(
Front Left Side of Engine (V6 VIN K)
)
374175
Legend
(1) Generator
lower Right Sid.e of Engine (VS VIN G)
374313
Legend
(1) Engine Mount Bracket (4) Starter Motor
(2) A/C Compressor (5) Starter Solenoid
(3) Battery Cable
(
l.ower left Side of Engine (V6 VIN K)
374318
Legend
(1) Starter Solenoid (4) Lower Control Arm
(2) Starter Motor (5) Steering Gear
(3) Oil Level Switch (6) Left Engine Mount
Engine Electrical Connector End Views Ignition Switch (C2)
Clutch Pedal Position (CPP) Switch (
R
·0G
i:--
392027
Connector Part • 1201-0966

295466 Information • 5 Way F 56 Series (BLU)
• 1203-3711 Circuit
Connector Part Pin Wire Color No. Function
480 Series (BLK) A YEL 5 Ignition Crank Output
Circuit B RED 2 Fused Battery Feed
c PNK 3 Ignition 1 Output
A PPUWHT 1035 Starter Relay Coil Feed
D Not Used
Clutch Pedal Position
B DKGRN 1433 E BRN 4 Ignition Accessory Output
Switch (CPP) Output
Generator Diagnostic Information and

Procedures
(
A Diagnostic Starting Point - Engine
E::::::::::l Electrical
I I Begin the system diagnosis by reviewing the system
Description and Operation. Reviewing the Description
(~o~o[§J~c@l
and Operation information will help you determine
the correct symptom diagnostic procedure when
a malfunction exists. Reviewing the Description and
Operation information will also help you determine
if the condition described by the customer is normal
operation. Refer to Symptoms - Engine Electrical
289326 in order to identify the correct procedure for diagnosing
the system and where the procedure is located.
e 1218-6568
Connector Part
Information • 4 Way F Metri-Pack Symptoms - Engine Electrical
150 Series Sealed (BLK)
Circuit Important: Review the system operation in order to
Pin Wire Color No. Function familiarize yourself with the system functions. Refer to
A - - Not Used one of the following operations:
Generator Regulator " Starting System Operation
B RED 225
Reference Voltage " Battery Operation
C-D - - Not Used .. Charging System Operation
• Ignition System Operation
• Inspect for aftermarket devices which could affect
the operation of the Engine Electrical System.
Refer to Checking Aftermarket Accessories (
in Wiring Systems .
.. Inspect the easily accessible or visible system
Intermittent • Starter No Load Test
Faulty electrical connections or wiring may be the " Battery Common Causes of Failure
cause of intermittent conditions. Refer to Testing for • Battery Check
Intermittent and Poor Connections in Wiring Systems.
" Battery Terminal Check
Symptom list • Battery Hydrometer Displays Yellow Dot
Refer to a symptom diagnostic procedure from the .. Battery Not Operating Properly
following list in order to diagnose the symptom: • Battery Electrical Drain/Parasitic Load Test
• Starter Solenoid Does Not Click " Generator Not Operating Properly
• Starter Solenoid Clicks, Engine Does Not Crank • Generator Assembly Check
• Engine Cranks/Cranks Slowly, but Does Not Start • Spark Plug Visual Diagnosis
• Starter Motor Noise Diagnosis • Spark Plug Wires Not Operating Properly
Starter Solenoid Does Not Click
Step Action Value(s} Yes .. No
1 necessary inspections? - - Engine
Go to Step 2 Electrical
Attempt to start the vehicle. Go to Testing for
Does the starter solenoid click audibly? Intermittent and
in Wiring
Systems Go to Step 3
1. Remove the starter relay from engine wiring harness
junction block 2.
2. Connect a test lamp between the starter relay
terminal C6 and battery voltage. Refer to Circuit
3 Testing in Wiring Systems. -
Go to A
3. While obseNing the test lamp, turn the ignition switch Diagnostic
to the START position. System Check -
Does the test lamp illuminate? Go to Step 4 Theft Deterrent
Connect a test lamp between the engine wiring harness
junction block 2 terminal C4 and ground. Refer to Circuit
4 Testing in Wiring Systems. -

1. Connect a test lamp between the engine wiring
harness. junction block 2 terminal B4 and ground.
Refer to Circuit Testing in Wiring Systems.
2. Place the transmission in PARK or NEUTRAL
5 (automatic) or press the clutch pedal (manual). -
3. While observing the test lamp, turn the ignition switch

to the ST ART position.
Repair the open in circuit 2 between the engine wiring
harness junction block and S183. Refer to Wiring Repairs
6 in Wiring Systems. - -
Did you complete the repair? Go to Step 18,
1. Install the starter relay into the engine wiring harness
junction block 2.
2. Disconnect circuit 6 (the PPL wire) from the starter
solenoid.
3. Connect a test lamp between circuit 6 and ground.
7 Refer to Circuit Testing in Wiring Systems. -
4. Place the transmission in PARK or NEUTRAL
(automatic) or press the clutch pedal (manual).
5. While obseNing the test lamp, turn the ignition switch
to the START position.
Does the test lamp illuminate.? Go to Step 15 Go to Step 12
Starter Solenoid Does Not Click (cont'd)
Test for and repair an open or a poor connection in (
circuit 1433 from the engine wiring harness junction
block 2 terminal 84 to the transmission range switch
terminal F (automatic) or the clutch pedal position switch
8 terminal B (manual). Refer to Circuit Testing or Testing for -
Intermittent and Poor Connections and Wiring Repairs or
Test for and repair a poor connection at the transmission
range switch (automatic) or the clutch pedal position
9 switch (manual): Refer to Testing for Intermittent and Poor -
Connections and Connector Repairs in Wiring Systems.
Test for and repair an open in circuit 1035 from the
transmission range switch terminal E (automatic) or the
clutch pedal position switch terminal A (manual) to C200D.
10 Refer to Circuit Testing and Wiring Repairs in Wiring -
Systems.
Did you find and repair an open? Go to Step 18 Go to Step 11
Adjust or replace the transmission range switch
(automatic) or the clutch pedal position switch. Refer to
one of the following procedures:
• Park/Neutral Position Switch Adjustment in Automatic
11 Transmission - 4L60-E - -
• Park/Neutral Position Switch Replacement in
Automatic Transmission - 4L60-E
• Clutch Pedal Position Switch Replacement in Clutch
Did you complete the replacement or adjustment? Go to Step 18
Test for and repair a poor connection at the starter relay.
(

Test for and repair an open or a poor connection in
circuit 6. Refer to Circuit Testing or Testing for Intermittent
13 and Poor Connections and Wiring Repairs or Connector -
Replace the starter relay. Refer to Starter Motor Relay
14 Replacement. - -
Test for and repair a poor connection in circuit 1 at the
positive battery terminal and the starter solenoid. Refer to
15 Testing for Intermittent and Poor Connections and -
Test for and repair an open in circuit 1. Refer to Circuit
16 Testing and Wiring Repairs in Wiring Systems. -
Did you find and repair an open? Go to Step 18 Go to Step 17
Replace the starter. Refer to Starter Motor Replacement
17 (3.8 L) or Starter Motor Replacement (5.7 L). - -
18 -
(
Starter Solenoid Clicks, Engine Does Not Crank
Important: To avoid misdiagnosis, perform the following procedures:
• Battery Terminal .Check
• Battery Check
Did you review th.e system operation and perform the Go to Symptoms
Go to Step 2 Electrical
Does engine crank? Intermittent and
in Wiring
1. (Automatic transmission) Set the gear selector to the
PARK position.
..
(Manual transmission) Set the park brake and place
the transmission in neutral.
3 2. Turn the ignition switch to the START position. QsQ.5V
3. Use a DMM to measure the voltage from the battery
positive terminal to the starter solenoid terminal B.
Is the voltage equal to the specified value? Go to Step 4 Go to Step 5
1. Turn the ignition switch to the START position. '
2. Use a DMM to measure the voltage from the battery
4 negative terminal to G100. B. Refer to Circuit Testing 0-0.5V
in Wiring Systems.
Is the voltage equal to the specified value? Go to Stepl Go to Step 6
Replace the battery positive cable. Refer to Battery Cable
Replacement (3.8 L Positive) or Battery Cable
5 Replacement (5. 7 L Positive). - -
Replace the negative battery cable. Refer to Battery Cable
Replacement (3.8 L Negative) or Battery Cable
6 Replacement (5. 7 L Negative). - -
Replace the starter. Refer to Starter Motor Replacement
7 (3.8 L) or Starter Motor Replacement (5. 7 L). - -
Did you complet\3 the repair? Go to Step 8
8 -
Did you correct the condition? System OK Goto Step 3
Engine Cranks/Cranks Slowly, but.Does Not Start
Go to Step2 Electrical
Does the engine start? Intermittent and
in Wiring
1. The battery is fully charged.
2. Turn the ignition switch to the START position.
3 3. Wait 15 seconds and measure the voltage at the > 9.5 V
battery while cranking the engine. Refer to Circuit
Testing in Wiring Systems.
Is the reading greater than the specified value? Go to Step 4 Go to Step 5
Measure the voltage between the negative battery terminal
and the engine block while cranking the engine. Refer to
4 Circuit Testing in Wiring Systems. > 0.5 V
Load test the battery. Refer to Battery Electrical
5 Drain/Parasitic Load Test. -
Is the battery OK? Go to Step 8 Go to Step 9
Replace the negative battery cable. Refer to Battery Cable
Replacement (3.8 L Negative) or Battery Cable
6 Replacement (5. 7 L Negative). -
Does.the starter solenoi.d continue to click and the engine
to crank slowly or not at all? Go to Step 7 Go to Step 11
Measure the voltage between the B+ terminal and the
7
starter solenoid terminal B while cranking the engine.
> 0.5 V
(
Repair or replace the starter motor. Refer to Starter Motor
Replacement (3.8 L) or Starter Motor Replacement (5.7 L).
8 -
Does the starter solenoid continue to click and the engine
Replace the battery. Refer to Battery Replacement.
9 Does the starter solenoid continue to click and the engine -
Replace the positive battery cable. Refer to Battery Cable
Replacement (3.8 L Positive) or Battery Cable
10 Replacement (5.7 L Positive). - -

11 -
Starter Motor Noise Diagnosis
Do you hear a high pitched whine during cranking (before
1
the engine fires) but the engine cranks and. fires normally?
Reduce the distance between the starter pinion and the
2 flywheel. - -
Has the noise stopped? System OK
As the key is being turned, do you hear a high-pitched
whine after the engine fires?
3 -
(The engine cranks and fires normally. This is often
diagnosed as starter hang-in or a weak solenoid.) Go to Step 4 Go to Step 5
Increase the distance between the starter pinion and the
flywheel.
4
(Flywheel runout makes this appear to be intermittent.)
- -

Is there a loud "whoop" (It may sound like a siren if the
5 engine is rewed while the starter is engaged) after the -
engine fires, but while the starter is still held engaged? Go to Step 6 Go to Step 7
Replacement (3.8 L) or Starter Motor
6 2. Check the starter motor clutch. - -
3. Replace the worn parts.

Do you hear a rumble, a growl, or in severe cases a knock
7 as the starter is coasting down to a stop after starting the -
engine? Go to Step 8 System OK
1. Remove the starter motor. Refer to Starter
) Motor Replacement (3.8 L) or Starter Motor
8 2. Check for a bent or unbalanced starter armature. - -
3. Replace worn parts.
Starter No load Test 8. If the starter motor energizes and the pinion
rotates, then, while maintaining 10 Volts on
1. Remove the starter motor. Refer to Starter the voltmeter, check the current draw on the (
Motor Replacement (3.8 L) or Starter Motor ammeter and the pinion speed on' the RPM
Replacement (5. 7 L). indicator.
• Turn OFF the switch.
2. Turn OFF the carbon pile.
• Compare the values to the starter
specifications table. Rerer to Starter
Motor Usage.
- If the current draw and the pinion
speed (RPM) are within the specifications,
then the starter motor is good.
- If the current draw or the pinion
speed (RPM) is not within the specifications,
then replace the starter motor. Refer to
Starter Motor Replacement (3.8 L) or Starter
Motor Replacement (5. 7 L).
Battery Common Causes of Failure
If the vehicle's battery tests good but st.ill fails to
perform well, the following are some of the more
common causes:
• A vehicle accessory was left on overnight.
O The driving speeds have been slow with frequent
stops (stop-and-go driving).

• The electrical load has exceeded the generator
1052 output (particularly with the addition of aftermarket
equipment).
Caution: Keep fingers, tools, and any other • Existing conditions in the charging system,
objects away from the opening in the drive end including the following possibilities: (
housing while making electrical connections. The - An electrical short \
strong shifting action of the starter solenoid - A slipping belt
can cause severe personal injury or damage to - A bad generator
components as the drive pinion moves into • The battery has not been properly maintained,
the cranking position. including the following situations:
- A failure to keep the terminals tight
3. Make connections as shown with the switch open. - A failure to keep the terminals clean
4. Close the switch. - A loose battery hold-down
" Power failure caused by an existing mechanical
5. Adjust the carbon pile in order to obtain 10 Volts. condition in the electrical system, such as a
6. Compare the readings of the current, the short or pinched wire.
RPM's, and the voltage. Refer to Starter • The car is in storage for extended periods of time.
Motor Usage. • Extended cranking periods caused by spark
plug fouling.
7. If the pinion does not shift into the cranking • The hydrometer has been read incorrectly.
position or the pinion does not rotate, then • There has been an insufficient ampere-hour
turn OFF the switch immediately. Ensure that the charge rate for a discharged battery.
test electrical connections were properly made. • There is a burned out charge indicator bulb
If so, then replace the starter motor. causing a NO CHARGE condition.
• There is a continuous current draw on the battery
through excessive parasitic drain.
• The battery is old.
(
Battery Check • Do not expose the battery to open flames or
sparks.
Caution: Batteries produce explosive gasses.
Batteries contain corrosive acid. Batteries supply .. Do not allow battery acid to contact the eyes
levels of electrical current high enough to or the skin.
cause burns. Therefore, to reduce the risk of - Flush any contacted areas with water
personal injury while working near a battery: immediately and thoroughly.
• Always shield your eyes. - Get medical help.
" A void leaning over the battery whenever
possible.
Battery Check
Step Action Normal Result(s) Abnormal Result(s)*
1. Inspect the following areas for • The battery case, the battery Refer to Battery Replacement.
battery acid: tray, and the surrounding area
• The battery case are dry.
• The battery tray • The battery is not cracked,
1 broken, or damaged.
• The area around and
underneath the battery tray
2. Inspect the battery for a
cracked, broken, or
damaged case.
Compare the Cold Cranking The ratings of the vehicle battery Refer to Battery Replacement.
Amperage (CCA) and the Reserve meet or exceed the CCA and the RC
Capacity (RC) of the battery or the of the original equipment
2
Original Equipment (OE) specification.
specification. Refer to
Battery Usage.
Inspect the battery hydrometer for a The battery hydrometer displays a • If the battery hydrometer has a
green dot. green dot. dark dot (no green dot visible),
test the condition of the battery.
Refer to Battery Not Operating
Properly.
3
• If the battery hydrometer has a
yellow dot, check the battery for
low electrolyte. Refer to Battery
Hydrometer Displays Dark or
Yellow Dot.
Turn the ignition key to START and The engine cranks normally and • Engine does not crank or cranks
check to see if the engine cranks starts. slowly, refer to Battery Not
normally and starts. Operating Properly.
• Engine cranks normally but does
not start, refer to Engine Cranks
but Does Not Run in Engine
Controls - 3.8 L or Engine
4 Cranks but Does Not Run in
Engine Controls - 5.7 L.
• Engine starts but does not start
overnight or after a couple of
days, refer to A Diagnostic
Starting Point - Engine Electrical
and Battery Electrical
Drain/Parasitic Load Test.
1. Inspect the battery for proper • The battery is firmly held in place • Install the battery in the battery
installation and retention in the in the tray and the hold-down bolt tray correctly. Refer to Battery
5 battery tray. is properly tightened. Replacement.
2. Inspect the battery terminals for • The battery terminals are clean • Refer to Battery Terminal Check.
clean and tight connections. and tight.
* Refer to the appropriate symptom diagnostic table for the applicable abnormal result.
Battery Terminal Check
Step Action Vatue(s) Yes No
1. Turn the ignition key to the OFF position. (
2. Attempt to rotate the negative battery cable connector
1
clockwise with light finger pressure.
-
Does the. negative connector rotate? Go to Step 2 Go to Step 3
Use a torque wrench in order to verify .the torque to loosen
2 the negative battery terminal bolt. 10 N·m (7 lb ft)
Is the torque above the specified value? Go to Step 4 Go to Step 3
Disconnect the negative battery cable. Refer to Battery
3 Negative Cable Disconnect/Connect Procedure. - -
Is the cable disconnected? Go to Step 5
Ensure the negative battery cable is disconnected.
Inspect for the following conditions and repair as needed:
• The cable bolt is too long or misformed at the end.
4 • There is foreign material present inside the nut in the - -
battery terminal.
• Damage to the battery terminal face or cable
connector ring.
Rotate the positive battery cable connector clockwise with
5 light finger pressure. -
Does the positive connector rotate? Go to Step 6 Go to Step 7
..
Use a torque wrench in order to verify the torque to loosen
6 the positive battery terminal bolt. 10 N·m (7 lb ft)
Is the torque above the specified value? Go to step 8 Go to Step 7
Disconnect the positive battery cable.
7 - -
Is the cable disconnected? Go to Step 9
Ensure the positive battery cable is disconnected.
(
Inspect for the following conditions and repair as needed:
• The cable bolt is too long or misformed at the end.
8 • There is foreign material present inside the nut in the - -
battery terminal.
• Damage to the battery terminal face or cable
connector ring. ·
1. Clean and wire brush the lead face of both battery
terminals and the metal contact rings in both cable
connectors.
2. Remove the bolts from the cable connectors in order
to provide access to the connector rings as needed.
9 - -
3. If eithe.r the battery terminals or the cable rings are
excessively damaged or corroded, replace as
needed.
Are the metal connecting parts clean and in good
condition? Go to Step 10
1. Connect the positive battery cable to the battery
positive terminal.
10
2. Tighten the cable bolt to the specified value.
15 N·m (11 lb ft) -
Is the cable bolt properly tightened? Go to Step 11
1. Connect the negative battery cable to the battery
negative terminal.
11
2. Tighten the cable bolt to the specified value.
15 N·m (11 lb ft) -
Battery
Is the cable bolt properly tightened? Terminals OK
(
Battery Hydrometer Displays Yellow Dot
Was the Battery Check performed? Go to
1 -
Go to Step 2 Battery Check
Tap the hydrometer lightly on top with the handle of a
small screwdriver to dislodge any air bubbles inside the
2 battery. -
Is the hydrometer dot still yellow? Go to Step 4 Go to Step 3

3 Does the hydrometer display a green or dark dot? - Hydrometer OK . Go to Step 4
Replace the battery. Refer to Battery Replacement
4 - -
Visually inspect the hydrometer in the new battery.
5
Does the hydrometer display a green dot?
6 Does the hydrometer display a yellow dot? - Go to Step 7 Go to Step 9
Tap the hydrometer lightly on top with the handle of a
small screwdriver to dislodge any air bubbles inside the
7 battery. -
Is the hydrometer dot still yellow? Go to Step 4 Go to Step 8
8 Does the hydrometer display a green dot? - Go to Step 11 Go to Step 9
9 Does the hydrometer display a dark dot? - Go to Step 10 -
Charge the battery. Refer to Battery Charging.
10 - -
Was the battery recharged? Go to Step 11
Check the charging system for proper operation. Refer to
11 A Diagnostic Starting Point - Engine Electrical. - -
Is the charging system OK? Hydrometer OK
Battery Not Operating Properly
Tools Required 3. Follow the instructions for testing the battery
outside of the vehicle.
(
• J 4.2000 Digital Battery Tester
• J 39200 Digital Multimeter 4. Replace the battery only if the. second test
• GM PIN 12303040 Battery Side Terminal Adap\ers shows a REPLACE BATTERY .result.
Caution: Refer to Battery Disconnect Caution For warranty purposes, use the test code
in Cautions and Notices. from the,second test.
Important: The battery test using the J 42000 Battery .. , Use the approved terminal adapters.
Tester requires correct connections to the battery Do hot use any common bolts or a combination of
terminals. A failure to obtain the correct connections bolts, nut, and washers as adapters when
during the testmay result in replacing the battery testing the battery.
unnecessarily. Adhere to the following instructions in
Use the test adapters that are provided with the
order to avoid an incorrect diagnosis due to poor
connections: J 42000 tester or GM part number. 12303040
terminal. adapters. If the adapters that are provided
• When testing the vehicle with the battery cables ' with.the J.42000 tester requirereplacement,
still connected, rock the J 42000 clips back and
only use adapters with the GM part
forth on the terminal .bolt in order o cut through any
number 12303040. Any other adapters may not
coating or oxidation that may be present on
contact the correct areas of the battery terminal,
the bolt.
causing resistance that may resultin an invalid
Even new bolts contain a protective coating that battery test result.
may insulate or cause a resistance in the test
circuit. • In order to test the top terminal, threaded stud
batteries outside of the vehicle, use GM part
• If it is uncertain that correct connections can be
made to the battery terminal bolts in the vehicle, number i 2303040 ·adapters.
perform the following steps: Do not connect the .tester to the plain threaded
1. Disconnect the battery cables. terminals. ·
2. Install the test adapters on the terminals. Important: For warranty purposes, always place the
3. Follow the instructions for testing the battery test code displayed by the tester on the repair (
outside of the vehicle. order. The number is a unique identifier that describes
• If a REPLACE BATTERY result is obtained for a the test data for a particular battery at a particular time.
battery tested in the vehicle with the battery While the test code may occasionally repeat when
cables connected, perform the following steps: retesting the same battery, it is more likely that
1. Disconnect the battery cables. a different code will result each time the battery is
2. Install the approved adapters. tested.
Battery Not Operating Properly

Has the Battery Check been performed? Go to
1 - Go to Step 2 Battery Check
Is the battery in the vehicle, with the battery cables
2 -
connected? Go to Step 4 Go to Step 3
i . Lightly wire brush the lead faces of both battery
terminals.
3
2. Install the terminal adapters to both of the terminals.
- -
Are the adapters installed? Go to Step 5
2. Turn the electrical loads and all accessory lights to
4
the OFF position.
- -
Are all of the electrical loads and accessory lights OFF? Go to Step 5
Battery Not Operating Properly (cont'd)
Important: When testing the battery in the vehicle,
connect the tester directly to the cable bolts. Do not
connect either of the tester clamps to a remote terminal,
such as a junction block or a jump start terminal. The use
of a remote terminal will cause invalid test results.
1. Connect the red clamp on the J 42000 to the adapter
or the cable bolt on the battery positive terminal.
5 2. Connect the black clamp on the tester to the adapter -
or cable bolt on the battery negative terminal.
3. Rock both of the tester clamps back and forth in
order to cut through to the bare metal.
The message GM MICRO 410 should appear for a short
time on the tester display, and then change to
SELECT TEST.
Does the display read SELECT TEST? Go to Step 9 Go to Step 6
Does a CHECK CONNECTION message appear on the
6 -
J 42000 display? Go to Step 7 Go to Step 8
Inspect the tester connections to the battery terminal
adapters or cable bolts for the following conditions:
• Both sides of each tester clamp must make the correct
contact.
• Ensure that the red clamp is connected to the positive
post and the black clamp is connected to the
7 negative post. -
• If the adapters or the bolts appear corroded, rock the
clamps back and forth in order to ensure a correct
connection.
Use a wire brush in order to clean the adapters or
cable bolts, if needed.
Does the tester display now read SELECT TEST? Go to Step 16 Go to Step 11
Use J 39200 in order to test the battery voltage with the
8 J 42000 tester connected. 5.5 V
Is the voltage at or below the specified value?: Go to Step 24 Go to Step 28
Use the scroll keys on the J 42000 tester in order to select
either IN-VEHICLE or OUT-OF-VEHICLE testing,
depending on the following conditions:
• Use IN-VEHICLE testing if the battery cables are
9 connected to the battery. -
• Use OUT-OF-VEHICLE testing if the battery cables
are disconnected and the terminal adapters are
installed.
Was IN-VEHICLE testing selected? Go to Step 10 Go to Step 11
The display on the tester will show ALWAYS TEST AT
BATTERY TERMINAL, and then change to SELECT
10 RATING. -
Does the display read SELECT RATING? Go to Step 12 Go to Step 36

For OUT-OF-VEHICLE testing, the display on the tester
will show USE TERMINAL ADAPTERS, and then change
11 to SELECT RATING. -
Does the tester display read SELECT RATING? Go to Step 12 Go to Step 36

Step· Action Value(s) Yes No
Important: Refer to Battery Usage for the correct rating
(
for the vehicle's OE battery. If a battery with a lower CCA
rating has been installed in the vehicle, the battery may
not perform properly during the use of the vehicle even if
the battery passes the test using the J 42000 tester.
i2 1. Use the scroll keys on the J 42000 tester in order to - -
select the CCA rating on the battery label.
'
2. Press the ENTER key on the tester.
TESTING will appear briefly on the display, followed by the
resu Its of the test.
Are the results of the test displayed? Go to Step 13
13 Does GOOD BATTERY appear on the J 42000 display? - Bo to Step 13 Go to Step 14
14 Does GOOD-RECHARGE appear on the display? - Go to Step 24 Go to Step 15
15 Does CHARGE & RETEST appear on the display? - Go to Step 28 Go to Step 16
16 Does REPLACE BATTERY appear on the display? - Go to Step 25 Go to Step 17
17 Does BAD CELL-REPLACE appear on the display? Go to Step 27 Go to Step 18
Does SURFACE CHARGE DETECTED appear on the
18
display?
19 Does SELECT TEMP appear on the display? - Go to Step 32 Go to Step 20
Does SYSTEM NOISE-CHECK LOADS, alternating with
20 -
RETESTING, appear on the display? Go to Step 33 Go to Step 36
1. Press the CODE button on the J 42000.
2. For warranty purposes, write the displayed code on
21 the repair order.
-
Is the green dot visible in the battery's hydrometer? Go to Step 23 Go to Step 22
Charge the battery. Refer to Battery Charging.
(
22 -
. ls the green dot visible in the hydrometer? Go to Step23 Go to Step 38
The battery is OK. Install the battery. Refer to Battery
23 Replacement. - -
Is the action complete? System OK
i. Press the CODE button on the J 42000.
2. For warranty purposes, write the displayed code on
24 the repair order. - -
3. Charge the battery. Refer to Battery Charging.
Is the green dot visible in the hydrometer? Go to Step 23
Was the battery tested in the vehicle with the battery
25 cables still attached?
1. Turn the ignition key to the OFF position.
26 Procedure. - -
3. Disconnect the positive battery cable.
Are the actions complete? Go to Step 3
2. For warranty purpose, write the displayed code on
3. Replace the battery. Refer to Battery Replacement.
2. For warranty purpose, write the displayed code on
3. Charge the battery. Refer to Battery Charging.
Is the green dot visible in the battery hydrometer? Go to Step 2
-
Important: Surface charge removal is only necessary
when the tester detects that a surface charge may affect
the results of the test. The tester will not compl,ete the
testing sequence until the surface charge is removed.
Follow the tester prompts in order to remove the surface
29 charge by turning the vehicle's headlights ON and OFF. If -
the sequence is followed properly, the tester will
automatically complete the test. If the sequence is not
followed properly, the tester will display the message
DISCONNECT AND RETEST.
Does the DISCONNECT AND RETEST message appear? Go to Step 30 Go to Step 31
Disconnect the tester from the battery terminals.
30
Is the action complete?
-
Go to Step 2
-
The tester will display the word RETESTING and show the
CCA rating that was selected for the test. If the test is
31 successfully completed, the test results will be displayed. -
Do the test results appear on the display? Go to Step 13 Go to Step 35

Important: Temperature compensation is only necessary
when the tester detects that the battery temperature may
affect the results of the test.
1. Use the scroll keys in order to indicate whether the
internal temperature of the battery is above or below
0°c (32°F). Use the temperature of the battery to
32 which the battery has been exposed for the past -
several hours in order to estimate the temperature.
2. Push the ENTER key.
The tester will briefly display the RETESTING message
and the CCA rating selected for the test. The test results
will then show on the display.
Do the test results show on the display? Go to Step 13 Go to Step 36
The tester detects that a vehicle electrical load is not
present (such as a light is on or the ignition key is not in
33 the OFF position). - -
Turn OFF all of the system electrical loads .
.Are all of the system electrical loads OFF? Go to Step 34
The J 42000 automatically retests the battery. A
RETESTING message and SYSTEM NOISE message on
the display alternates up to 5 minutes while all circuits
34 power down. The test results will then display on the -
tester.
Are the test results displayed on the tester? Go to Step 13 Go to Step 35
An undetected load or parasitic drain can cause the
alternating RETESTING and SYSTEM NOISE messages
to continue for more than 5 minutes.
35 1. Disconnect the J 42000 tester. - -
2. Eliminate all electrical drains. Refer to Battery
Electrical Drain/Parasitic Load Test.
Are all electrical loads and parasitic drains eliminated? Go to Step 2
A J 42000 problem is indicated. Inspect the tester for
36 correct operation. -
Is the tester operating properly? Go to Step 2 Go to Step 37
Repair or replace the tester.
37
Is the action complete?
- -
Go to Step 1
A problem exists with the battery's built-in hydrometer.
38 Replace the battery. Refer to Battery Replacement. - -
Is the action complete? System OK
s.:.100 Engine Electrical Engine
Battery Hydrometer Displays Dark or 4. A low electrolyte (5) level can be caused by any
Yellow Dot of the following conditions:
• Prolonged charging (
• An excessive charge
1
• A broken case
• Excessive battery tipping
5. When finding a battery in this condition it may
indicate high charging voltages caused by a
faulty charging system. The charging and electrical
systems should be checked.
6. If there is a cranking complaint, inspect for trouble
in the charging or electrical systems.
7. If a cranking complaint exists and is caused by
the battery, the battery should be replaced.
5
Battery Electrical Drain/Parasitic
Load Test
Tools Required
• J 38758 Parasitic Draw Test Switch
• J 39200 Digital Multimeter
• A Fused Jumper Wire
(
405478
1. The battery has a built-in hydrometer (1 ). The

hydrometer lens provides a visual indication of
the condition of the electrolyte.
2. Tap lightly on the lens and observe the built-in
hydrometer (1 ).
3. Under normal operation, one of three color
conditions on the hydrometer (1) is possible:
• Green ball. visible (2).
This condition indicates a sufficient state of
electrolyte (5) charge (65 percent or above) for
normal charging system operation. 208241
• Dark lens (3) (Green ball not visible) Caution: Refer to Battery Disconnect Caution in
This condition indicates an insufficient state of Cautions and Notices.
electrolyte (5) charge below 65 percent).
Recharge the battery before further testing. 1. Disconnect the negative battery cable. Refer to
" Clear lens (4) (or Yellow lens). Procedure.
This condition indicates that the electrolyte (5)
is low. The battery electrolyte (5) cannot be
refilled. Replace the battery.
(
1 1
405480 405483
2. Install the male end of the J 38758 (1) to the 5. Turn the test switch (1) ON.
negative battery terminal.
Notice: Do not turn the parasitic draw test switch to
the OFF position with the engine running. Damage will
occur to the vehicle's electrical system.
6. Road test the vehicle. Activate all accessories,

including the air conditioning system and radio.
7. Turn OFF the ignition switch. Remove. the key.
Important: This allows the electronically timed
components to power down, preventing false parasitic
drain readings.
8. Wait 15 minutes before continuing the test.
405481
3.. Turn the test switch (1) OFF.

4. Connect the negative battery cable (2) to the
female end of the test switch.
405486
9. Connect the fused jumper wire (1) to the

terminals of the test switch.
10. If the fuse does not fail, the J 39200 can be
installed. A current of less than 10 amps is
present.
405487 405490
11. Turn the test switch (1) ON. 15. Turn the test switch (1) OFF. Current is now .
flowing through the ammeter option of J 39200.
12. Remove the fused jumper wire.
16. Wait one minute.
17. Wait until the current reading is 2 amps or less.
1
405488
13. Set the J 39200 to the 10A scale (1 ).

405495
Important: If an ammeter other than the J 39200 is 18. Turn the test switch to (1) ON.
used, ensure that the vehicle does rot have a
high current drain that would damage the ammeter 19. Switch the J 39200 from the 1OA setting to the
when connected to the circuit. 2A setting.
14. Connect the J 39200 to the terminals (2) of the

test switch.
(
ei5[ggABR~!
. BA"TT WINDOWS
® @1sc: 5:1 e ®17[:15 :1

{NOT USED) IP DIMMER ACCY (NOT RADIO
. USED)
405490 310933
20. Turn the test switch (1) to OFF. 26.1. To find the source of the excessive
loa.d perform the following:
21. Read the current in milliamps. This is the parasitic
drain value. 26.2. Remove the courtesy lamp fuse
(number 8). Note the J 39200 reading.
22. Note the battery reserve capacity. Refer to
Battery Usage. 26.3. lf,the parasitic load is still excessive start
removing the remaining fuses.
23. Divide the battery reserve capacity by 4, this will
be the parasitic drain number. 26.4. Keep the. courtesy lamp fuse out during
diagnosis, so the. door can remain open.
24. The parasitic drain number should not exceed 114
of the battery's reserve capacity. 27. Continue removing the fuses one at a time,
starting with the fuses .that are hot all the
25. If the parasitic drain number exceeds 114 of the time. When the voltage drops across the J 39200,
battery's reserve capacity go to step 27. note the last fuse removed. The current drain
comes from the circuit or circuits protected
by that fuse.
28. Repair the circuit and perform the parasitic load
test again to verify the repair.
405483
26. Turn the test switch (1) to ON.

Notice: The test switch must be in the ON position
) .when removing the fuses in order to maintain
continuity in the electrical system. This avoids 208241
damaging the digital multimeter due to accidental 29. Connect the negative battery cable. Refer
overloading, such as a door being opened to change to Battery Negative Cable Disconnect/Connect
a fuse. Procedure.
6-704 engine Electrical Engine
Generator Not Operating Properly
Test Description
(
9. If the test has shown the generator to be OK,
however the condition remains, test the PCM or its
control circuit(s) to the generator.
Generator Not Operating Properly
Step Action Value{s) Yes No
Did. you review the system operation and perform the Go to Symptoms
1 necessary· inspections? - - Engine
Go to Step2 Electrical
..
Important: The green POWER lamp of the tester should
remain illuminated while the tester is being used.
1. Turn OFF the ignition.
Connect the red lead of the J 41450-8 Generator
2
Electronic Tester to the generator output terminal.
-
2. Connect the black lead of the J 41450-8 Generator
Electronic Tester to the metal generator housing.
Does the green POWER lamp on the tester illuminate? Go to Step 5 Go to Step 3
Measure the. voltage from the output terminal of the
3 generator to the generator metal housing. B+
Does the voltage measure equal to the specified value? Go to Step 13 Go to Step 4
Measure the voltage from the output terminal of the
4 generator to the battery negative terminal. 8+
Does the voltage measure equal to the specified value? Go to Step 11 .. Go to Step 10
;
Caution: Batteries produce explosive gasses. Batteries
contain corrosive acid. Batteries supply levels of
electrical current high. enough to cause burns. (
Therefore, to reduce the risk ofpersonal injury while
working near a battery:
• Always shield your eyes•
.. Avoid leaning over the batterywhenever possible;
• Do not expose the battery to open flames or
sparks.
(
• Do not allow battery acid to contact the eyes or
the skin.
- Flush any contacted areas with water
immediately and thoroughly.
5 - Get medical help. -
Turn OFF completely the load tool before connecting or
disconnecting a carbon pile load tester to the battery.
Otherwise, sparking at the terminals could cause battery.
gasses to explode and cause personal injury.
1. Connect a carbon pile tester to the vehicle
Important: Ensure that all generator output circuit wires
pass through the. inductive probe.
2. Connect an inductive ammeter to the output circuit of
the generator.
3. Disconnect the generator harness connector.
4. Locate the matching harness connector on the
J 41450,8, and connect the connector to the
generatqr. ·
Does the red DIAGNOSTIC lamp on the tester illuminate? Go to Step 6 Go to Step 12
1. Start the engine and allow it to idle for 30 seconds.
6 2. Increase the engine speed to 2500 RPM. -
Does the red DIAGNOSTIC lamp on the tester illuminate? Go to Step 14 Go to Step 7.
(
Generator Not Operating Properly (cont'd)
1. Maintain the engine speed at 2500 RPM.
Important: If the generator is not capable of producing the
Load Test amps, operate the generator at it's maximum
possible output.
7 -
2. Turn ON the load of the carbon pile tester and
increase the load until the generator output is equal ··
to the Load Test value given in Generator Usage.
Does the red DIAGNOSTIC lamp on the tester illuminate? Go to Step 14 Go to Step B
1. Maintain the engine speed at 2500 RPM and
continue to operate the generator at the load
test value.
2. Measµre the voltage drop from the output terminal of ·
8 the generator to the positive terminal on the battery. 0 ..5V
Refer to Circuit Testing and Connector Repairs in
Wiring Systems.
Does the voltage measure greater than the
specified value? Go to Step 10 Go to Step 9
1. Maintain the engine speed at 2500 RPM and
continue to operate the generator at the load
test value.
2. Measure the voltage drop from the battery negative
9 terminal to the metal housing .of the generator. Refer 0.5V
to Circuit Testing and Connector Repairs in Wiring
Systems.
Does the voltage measure greater than the
specified value? Goto Step 11 Go to Step 15
:
Repair the high resistance or an open in the output circuit
of the generator. Refer to Circuit Testing and Connector
10 Repairs in Wiring Systems.
- -
Did you complete the repair? Go to Step 1.5
Repair the high resistance or open in the ground circuit of
the generator. Refer to Circuit Testing and Connector
1. Disconnect the J 41450-8 tester harness connector
from the generator, but leave the alligator clips
connected so that the green POWER lamp remains
illuminated.
12
2. Connect a jumper lead, with an in-line 100-ohm
-
resistor between the J 41450-8 tester harness
connector terminal B and a good ground.
Does the red DIAGNOSTIC lamp illuminate? Go to Step 14 Go to Step 13
There is a problem with the J 41450-8. Refer to the
manufacturers instructions, how to test the J 41450-8 for
13 proper operation. - -
Has the J 41450-8 tester been replaced? Go to Step2

Replace the generator. Refer to Generator Replacement
14 (3.8 L) or Generator Replacement (5.7 L). - -
Operate the vehicle in order to verify the repair.
15 -
Did you correct the condition? System OK Go to Step2
Generator Assembly Check Diagnosis
On Vehicle Inspection Procedure Tool Required
J 39200 Digital Multimeter
(
When the charging system is operating normally, the
voltmeter will read between 11-16 volts when the To diagnosis the CS-1300 charging system, use the
engine is running. If the voltmeter operates abnormally, following procedure .
.or if an undercharged or overcharged battery 1. Inspect the accessory drive belt for damage or
condition occurs, the following procedure may be used wear. Service or replace as necessary.
to diagnosis the chargin~ system.
2. Inspect the wiring.
An undercharged batteiy is often caused by
accessories being left on overnight, or by a hood or 3. Check for an undercharged or overcharged
battery condition (voltage lower than 11 volts
instrument panel compartment lamp that stays on.
or higher than 16 volts), refer to Generator Not
Noise from a generator may be ca[Jsed by a Operating Properly.
loose drive pulley, loose mounting bolts, worn or dirty
bearings, faulty diode or faulty stator. A magnetic • Detach the wiring harness connector from the
whining noise may be heard from the CS-130D generator.
generator. This is considered a normal condition. • With the ignition switch in the ON position and
the engine not running, connect the J 39200 as
Precautions a voltmeter from a ground to the L terminal in
To avoid damage to the electrical equipment, always the wiring harness connector. Connect the F or
observe the following precautions: the I terminal for the. gauge equipped vehicles.
• Do not reverse the connections to the generator. At least one terminal should have battery
voltage.
• Do not short across or ground any of the
terminals in the charging circuit, unless otherwise • Zero volts indicates an open circuit between the
directed by instructions. terminal and the battery. Connect as required.
• Never disconnect the generator BAT terminal while • Reconnect the wiring harness connector to the
the generator is. operating. generator.
• When connecting a battery charger or a booster Important: Disconnect the negative battery cable
battery, follow the procedure in Jump Starting before removing or installing a series-type ammeter at
in Case of Emergency. the generator battery terminal. (
• Do not attempt to disassemble CS-130D • Install an ammeter at the generator output
generator. Damage to the generator could result. terminal. With the load off, install .a carbon pile
Trouble in the charging system will show up as one or load test across the battery terminals. Start
more of the following conditions: the engine and run at 2500 RPM. Make sure
this is done at ambient temperature.
• An abnormal voltmeter reacling
, • Measure the voltage across the battery, using
• An undercharged battery condition (with slow the J 39200 If the voltage is above 16 volts,
cranking or a dark hydrometer) replace or repair the generator.
• An overcharged battery condition (with electrolyte • Turn on the accessories and place a load on
leaks or a yellow hydrometer). Refer to Battery the battery with the carbon pile to obtain
Hydrometer Displays Dark or Yellow Dot. maximum generator output. Maintain voltage at
13 volts or above. Use an ammeter to check
amperage. Compare output to amperage rating
in Generator Usage.
(
Spark Plug Visual Diagnosis
Worn or dirty plugs give satisfactory operation at idling
speed, but under operating conditions they frequently
fail, Faulty plugs are indicated in a number of ways:
., Poor fuel economy
" Power loss
O
Loss of speed
O Hard starting
., Poor engine performance
Spark plugs may also fail due to the following
conditions:
e Carbon fouling
" Excessive plug gap
" Broken insulators
Fouled plugs are identified by black carbon deposits.
The black deposits are usually the result of 1053
slow-speed driving and short runs where sufficient 1. Normal service is a mixture of idling, low speed,
engine temperature is seldom reached. Worn pistons, and high speed operation.
rings, faulty ignition, over-rich air/fuel mixture and O Occasional high speed driving is essential to
spark plugs which are too cold will also result in carbon
good spark plug.performance.
deposits. Excessive gap wear, on plugs of low
mileage usually indicated the engine is operating at • Increased combustion heat burns away excess
high speeds or loads that are consistently greater than carbon deposits, which accumulate from
.normal or that a plug which is too hot is being used. frequent idling or stop~and~go driving .
Electrode wear may also be the result of plug 2. The heat resistant, insulating boot covers the
) overheating due to insufficient spark plug torque or too spark plug terminal.
much spark plug torque. An excessively lean air/fuel • The· boot extends over a portion of the spark
mixture will also result in excessive electrode wear. plug insulator. ·
Broken insulator are usually the result of improper • These boots prevent engine misfiring.
installation or carelessness when regapping the plug. 3. Corona ·discharge is a steady blue light appearing
Broken upper insulators usually result from a poor (in darkness) around the insulator, just above the
fitting wrench or an outside impact. The cracked shell crimp.
insulator may not show up right away, but will as soon O Do not mistake this for a shorted insulator.
as oil or moisture penetrates the crack. The crack This is visible evidence of a high-tension field.
may not be visible. Broken lower insulators usually
result from carelessness when regapping and • This has no effect on ignition system
performance. ·
generally are visible. This type of break may result
from the plug operating too hot, which may happen in • This discharge repels dust particles.
periods of high-speed operation or under heavy • This leaves a clear ring on the insulator just
loads. When regapping a spark plug, always make the above the shell. ·
gap adjustment by bending the ground (side) O This is not evidence that combustion gases
electrode. Spark plugs with broken insulators should are escaping.
always by replaced.
Resistor type spark plugs with tapered seats are used.
No gasket is needed on these plugs. These spark
plugs are a High Efficiency (HE) spark plug that has a
fine wire electrode, nickel plated shell and a platinum
pad across from the electrode.
Spark Plug Visual Diagnosis
Step Action I Value(s) Yes No
DEFINITION: A visual inspection of the spark plug firing end.
(
1. Remove the spark plug from the engine.
2. Note which cylinder the plug is from.
1 -
Do you see a brown to grayish tan deposit with a slight
electrode wear? Go to Step 2 Go to Step 3
1. This is normal wear.
2. Clean, regap and reinstall the plug.
1.524 mm
2 3. Tighten the plug, refer to Fastener Tightening
(0.060 in)
-
Specifications.
3 Do you see dry, fluffy, black carbon deposits? - Go to Step 4 Go to Step 6
This indicates poor ignition output, refer to. Spark Plug
4 Wire Resistance. - -
Is the ignition coil(s) to the spark plug connections.OK? Go to Step 5
Repair or install new parts as necessary.
5
- System OK
-
Do you see wet, oily deposits with very little

6
electrode wear?
- Go to Step 7 Go to Step B
1. This results from either the break-in of a new or
recently overhauled engine. 1.524 mm
7
2. Or from failed piston rings. 0.060 in
Degrease, gap and reinstall the spark plug. Go to Step 5 Go to Step 11
Do you see. red, brown, yellow and/or white colored
8 -
coatings on the insulator? Go to Step 9 Go to Step 11
(
These are the by-products ofcorribustion.
9
Is the insulator heavily coated?
-
Go to Step 10 Go to Step 2
1. Gap and install new spark plug(s),
2. Tighten the spark plug, refer to Fastener Tightening 1.524 mm
10
Specifications.
-
(0.060 in)
Are there heavy deposits of dark colored coatings,
11
especially on the side of the plug facing the intake valve? - Go to Step 12 Go to Step 13
1. This is the result of failed intake valve seals.
2. Or from excessive valve stem to valve guide
clearances.
12
3. This may not occur in all cylinders.
- -
4. Repair or install new parts as necessary.
Is there a shiny, yellow glaze coating on the spark plug
13 -
insulator? Go to Step 14 Go to Step 15
1. These are the melted by-products of combustion.
2. Avoid wide open throttle after long periods of low
speed operation. 1.524 mm
14
3. Gap and install new spark plug(s). Refer to Fastener (0.060 in)
-
Tightening Specifications.
15 Are the insulator tips blistered or burned? - Go to Step 17 -
16 Are the electrodes badly eroded? - Go To Step 17 - (

Spark Plug Visual Diagnosis (cont'd)
1. This is the result of overheating.
2. The spark plug heat range may be too hot.
17 3. The fuel octane rating may be to low for the -
application, refer the customer to the Owners Manual
for correct fuel rating.
Is the plug heat range correct? Go to Step 18 Go to Step 21
Check the torque value to ensure good spark plug seat
18 contact. Refer to Fastener Tightening Specifications -
Are the spark plugs tightened according to specifications? Go to Step 19 Go to Step 10
Check for a misfiring engine, refer to OTC P0230 Fuel
Pump Relay Control Circuit for V6 or OTC P0300 Engine
19 Misfire Detected for V8 in Engine Controls. -
Is the vehicle operating properly?. Go to Step 20 Go to St(:Jp 10

1. Check for a lean/rich fuel mixture, refer to Fuel
System Diagnosis for V6 or Fuel System Diagnosis
20 for V8 in Engine Controls. - -
2. Repair or install new parts as necessary.
Gap and install the correct spark plug(s). Refer to Spark
21 Plug Usage. - -
$park Plug Wires Not Operating Properly 3. With the engine ON, inspect for any arcing to
ground or othe.r components. Replace the
1. Inspect the spark plug gap. Adjust the gap as spark plug wires as needed.
needed.
4. Check the spark plug wires for proper resistance.
2. Inspect the spark plug wires for any obvious cuts, Refer to Spark Plug Wire Resistance.
burns, or damage. Replace the wires as needed.
Repair Instructions
Starter Motor Relay Replacement (
Removal Procedure
1. Open .and remove the cover to the numbe~ 2
underhood electrical center. · ·
2. Remove the starter motor relay. Heter to Electrical
Center Identification \(~ews in \1\/iring ·systems.
401242
1. Install the starter motor relay. Refer to Electrical
Center Identification. Views in Wiring Systems.
2. Install and close the cover on the number 2
underhood electrical center.' · ·· · ··
401242
Engine Engine Electrical 6~711
Starter Motor Replacement (3.8 L)
Removal Pro,cedure
Important: This engine was designed for starter motor
mounting without shims. However, if single or double
shims have been added to correct a noise or
engagement condition, reinstall the shims in their
original location to ensure proper pinion-to-flywheel
engagement.
Procedure.
Information.
3. Remove the starter motor shield. Refer to Starter
Shield Replacement (3.8 L). 43571
4. Remove the starter motor bolt.
5. Remove the starter motor stud.
6. Lower the starter motor from the engine block.
7. Remove the positive cable to starter motor nut (1 ).
8. Remove the positive cable from the starter motor.
211604
9. Remove the wiring harness starter lead nut from
the starter.
10. Remove the starter lead and washer. (
11 . Remove the starter motor.
211623
Installation Procedure·
1. Lift the starter motor i_nto position~
2. Install the starter lead. and washer to the .starter.
Notices.
3 . Install the wiring harness starter lead nut.
Tighten
Tighten the wiring harness starter lead nut to (
2 N-m (17 lb in).
211623-
4. Install the positive cable to the starter.

5. Install the positive cable to starter motor nut (1).
Tighten
Tighten the positive cable to starter motor nut (1)
to 1O N·m (89 lb in).
6. Raise the starter motor to the engine block.
211604
7. Install the starter motor bolt.
Tighten
Tighten the starter motor bolt to 47 N·m (35 lb ft).
8. Install the starter motor stud.
Tighten
Tighten the starter motor stud to 45 N·m (33 lb ft).
9. Install the starter motor shield. Refer to Starter
Shield Replacement (3.8 L).
Procedure.
43571
Staner Motor Replacement. (5. 7 L)

Removal Procedure
Important: This engine was designed for starter motor
mounting without shims. However, if single or double
shims have been added to correct a noise or
engagement condition, reinstall the shims in their
original location to ensure proper pinion-to-flywheel
engagement.
I
Procedure.
1
Information.
3. Remove the left side oxidation catalytic converter.
Refer to Oxidation Catalytic Converter 550622
Replacement (5. 7 L Left) in Engine Exhaust.
4. Remove the starter motor bolts:
5. Lower the starter motor from the engine block.
)
6. Remove the wiring harness starter lead n1..1tfrorri
the starter.
7, Remove the wiring harness starter lead and (
washer from the starter.
211617
8. Remove the positive cable to starter motor

nut (3).
9. Remove the positive cable (4) from the
starter motor.
10. Remove the starter motor.
211595
11. Remove the starter motor shield, if necessary.
550624
1. Install the starter motor shield, if necessary.
550624
2. Lift the starter motor into position.

3. Install the positive cable (4) to the starter motor.
Notices.
4. Install the positive battery cable to starter motor
nut (3).
3
Tighten
Tighten the positive battery cable to starter motor
nut (3) to 10 N-m (89 lb in).
211595
5. Install the wiring harness starter lead and washer

to the starter motor.
6. Install the wiring harness starter lead nut.
Tighten
Tighten the wiring harness starter lead nut to
2 N-m (18 lb in).
7. Raise the starter motor to the engine block.
211617
8. Install the starter motor bolts.
Tighten
Tighten the starter motor bolts to 50 N-m (37 lb ft). (
9. Install the left side oxidation catalytic converter.
Refer to Oxidation Catalytic Converter
Replacement (5. 7 L Left) In Engine Exhaust.
Procedure.
·.~
550622
Starter Pinion Clearance Check

The pinion clearance cannot be adjusled. Improper
clearance is an indication of worn parts. In order
to check the pinion clearance, perform the following
procedure:
1. Disconnect the starter motor field connector from
the solenoid M terminal.
2. ,lns1,1late the starter motor field connector, carefully.
3. Connect a 12 V battery from the solenoid switch (
terminal to the solenoid frame.
4. Momentarily flash a jumper lead from the solenoid
motor terminal to the solenoid frame. This will
shift the pinion into the cranking position.
The pinion will remain in the cranking position
until the battery is disconnected.
5. Push the pinion back toward the commutator end
to eliminate thrust movement.
1038
6. Measure the distahcebetween the'piriion and the

pinion stop collar.
The clearance should be from
0.25-4.06 mm (0.010-0; 160 in).
1039
Starter Shield Replacement (3.8 L)
Removal Procedure
Information.
2. Remove the starter motor shield bolts (1 and 3)
and nut (2).
3. Remove the starter motor shield from the vehicle.
211622
1. Install the starter motor shield to the vehicle.
and Notices.
2. Ins.tall the starter shield nut (2) and
bolts (1 and 3).
Tighten
• Tighten to starter motor shield bolt (1) to
30 N-m (22 lb ft).
• Tighten the starter motor shield bolt (3) to
10 N-m (89 lb in).
• Tighten the starter motor shield nut (2) to
1O N-m (89 lb in).
211622
Starter Shield Replacement (5.7 L)

Removal Procedure
. Replacement (5. 7 L).
2. Unsnap the starter motor shield from the starter
solenoid.
550624
1 . Snap the starter motor shield to the starter
solenoid. ·
(
550624
Battery Charging
Before Charging
Notice: Turn OFF the ignition when connecting or
disconnecting the battery cables, the battery charger
or the jumper cables: Failure to do so may damage the
PCM or other electronic components.
Important: Do not use the boost, the jump start or the
crank setting for prolonged charging of batteries if (
the charger is equipped with these settings. Using any
of these settings for a prolonged period may cause
gassing or spewing of electrolyte through the
vent hole.
1. Ensure that the electrolyte and the plates are at
room temperature before charging the battery. An
extremely cold battery may not accept the ·
current for several hours after the charger is
started,
2. Always stop charging, or reduce the charging
rate, if either of the·following conditions exists:
.. The battery temperature .is. .52°C (125°F)
orh~he~ · · · ·
O Electrolyte spews or gasses violently 'through
the vent holes. . ·· ·
3. Replace the baUery when either of the following
conditions exist:
" The hydrometer is clear or yellow.
• The battery is frozen.
(
Engine Engine Electrical 5;.719
Charge Time Required • Most chargers have an override or a bypass
The time required to charge a battery will vary function so that the charger will turn on and
depending on the following factors: charge a low voltage battery.
• The size of. the battery; A. higher capacity battery 4. The required battery charge time varies according
which is completely discharged requires more to the voltage capabilities of the battery charger.
time to charge than a smaller capacity battery. Replace the battery only if the charge current
is not measurable after the following charge times.
• The battery temperature; The colder the battery,
the more time it takes to charge. • 16 Volts or more - up to 4 hours
• The battery charger capacity (in Amperes); The • 14-15.9 Volts - up to 8 hours
higher the charger amperage, the less time it • Less than 13.9 Volts - up to 16 hours
will take to charge the battery. 5. Reserve capacity rating:
• The battery state-of-charge; A completely • The reserve capacity rating on the battery
discharged battery requires more than twice as label is the n,umber of Ampere-hours of charge
much charge as a half~charged battery. required in order to produce the green
While Charging hydrometer dot. · ·
• For example, if the battery has a reserve
Tools Required
capacity rating of 90 (expressed in
GM PIN 12303040 Battery Terminal Adapters Ampere-hours), the battery would be recharged
1. Do not charge a battery with a green hydrometer as follows:
dot unless it has just been discharged, such as in - · 10 Ampere charge x 9 hours =
cranking. · ' 90 Ampere hours
2. When charging, the adapters should be snug - 30 Ampere charge x 3 hours =
against the battery t~rminals to keep resistance 90 Ampere hours
to a minimum. ·
.. If the green hydrometer dot is not visible after
3. Make sure all battery terminals are clean and tight. an Ampere-hour charge equal to twice the
Tighten reserve capacity rating, replace the battery.
Tighten the battery side terminal adapters to 6. After charging, load test the battery. Refer to
15 N·m (11 lb ft). Battery Electrical Drain/Parasitic Load Test.
4. Best results occur when charging a battery that is
at room temperature. A battery that is extremely Battery Charge low or Completely
cold may not accept current for several hours.
Discharged
5. Charge the battery until the hydrometer has a
green dot. 1. Measure the battery voltage at the battery
terminals using a digital multimeter (DMM).
6. Inspect the battery every half hour after starting
O A reading of less than 11 V indicates that the
the battery charger.
initial charging will be very low.
7. Tap the hydrometer lightly to dislodge any air
bubbles. The bubbles may cause a false • It could take some time before the battery
indication. accepts current in excess of a few
8. After charging, load test the battery. milliamperes.
2. Set the battery charger on the highest setting.
Charging Procedure
3. If necessary, disable the polarity protection
1. Measure the battery voltage: circuitry:
• Measure the voltage at the battery • This circuitry, available on most chargers,
terminals using a voltmeter. prevents charging unless the charger leads are
• A reading of less than 11 Volts indicates that properly connected to the battery terminals.
the charge current is low. • A completely discharged battery may not have
• The battery will take longer to accept a current enough voltage to activate this circuitry, even
higher than 2 milliamps. though the leads are properly connected,
2. Set the battery charger on the highest setting. implying that the battery will not accept
3. If necessary, disable the polarity protection a charge.
circuitry: • Most chargers have an override or a bypass
• This circuitry, available on most chargers, function so that the charger will turn ON
prevents charging unless the charger leads are and charge a low voltage battery.
properly connected to the battery terminals. 4. The required battery charge time varies according
• A completely discharged battery may not have to the voltage capabilities of the battery charger.
enough voltage to activate this circuitry, even A charger of less than 14 volts could take up
though the leads are properly connected, to 16 hours before it appears to be accepting
implying that the battery will not accept current, followed up by several hours of the
a charge. appearance of charging.
6-720 Engine El.ectrical Engine
5. To determine the amount of hours. the battery Jump Starting in Case of Emergency
may need to be charged, the following calculation
can be made: Caution: Batteries produce explosive gasses.
Batteries contain corrosive acid. Batteries supply (
• The reserve capacity rating on the battery levels of electrical current high enough to
label is the number of ampere2hours of charge cause burns. Therefore, to reduce the risk of
required iri order to produce the green personal injury while working near a battery:
hydrometer dot.
• After the meter on the charger starts to show .. Always shield your eyes.
current flow, note the number of amps being " A void leaning over the battery whenever
accepted. possible. '
• Determine the reserve capacity of the battery. O
Do notexpose the battery to open flames or
Refer to Battery Usage. sparks. ·
• Divide the reserve capacity by the number of O Do not allow battery acid to contact the eyes
amps shown on the meter to determine how or the skin.
many hours of charging is needed.
- Flush any contacted areas with water
6. When the green dot appears in the hydrometer, immediately and thoroughly.
discontinue charging.
- Get medicaf help.
7. If the green hydrometer dot is not visible after an
ampere-hour charge equal to twice the reserve
Notice: Push starting the vehicle can, .under some
capacity rating, replace the battery. Refer to conditions, cause damage to the catalytic converter
Battery Replacement. and an automatic transmission.
8. After charging, load test the battery. Refer to This vehicle has a· 12 Volt, negative ground electrical
Battery Electrical Drain/Parasitic Load Test. system. Make sure the vehicle or equipment being
used to jump start the engine is also 12 Volt, negative
ground. Use of any other type of system will damage
the vehicle's electrical components.
(
1. The following procedure is a typical battery to
battery hookup for jump starting.
2. The booster battery (4) and the discharged
battery (3) should be treated carefully when using
jumper cables. Do not cause sparks.
3. Position the vehicle with the charged (booster)
battery (4) so that the jumper .cables will reach.
Do not let the vehicles touch.
4. Attach the end of one jumper cable (6) to the
positive terminal of the booster battery (4).
5. Attach the other end of the same cable (2) to the
positive terminal of the discharged battery (3).
6. Attach one end of the second jumper cable (5) to
the negative terminal of the booster battery (4).
Caution: Do not connect a jumper cable directly to
the negative terminal of a discharged battery to
prevent sparking and possible explosion of
battery gases.
7. Attach the other end of the second jumper
cable (1) to a good engine ground (engine lift hook
or generator bracket) at the discharged battery (3).
405500
8. Start the engine of the vehicle that is providing

the boost (4).
2
9. Start the engine of the vehicle with the discharged
battery (3).
10. Disconnect the negative jumper cable (1) from the
engine ground of the battery (3) that was boosted.
11. Remove the other end of the negative jumper
cable (5) from the booster battery (4).
12. Remove the positive jumper cable (6) from the
booster battery (4).
Important: Do not let the cable end touch any metal
while the other cable end is still connected.
13. Remove the positive jumper cable (2) from the
other battery (3).
405501
Battery Negative Cable
Disconnec1:/Connect Procedure
Removal Procedure
(
3
Caution: Refer to SIR Caution in Cautions and
Notices.
1. Record· all the vehicle preset radio stations.
2. Record the customers's radio Theftlock® code (if
applicable).
3. Turn all the lamps and accessories off ..
4. Turn the ignition switch to the OFF position (3).
341078

5. Disconnect the negative battery cable bolt.
208241
Notice: Refer to Fastenef'Notice in· Cautions and
Notices.
Important: Clean any existing oxidation from the
contact face of the battery terminal and battery cable
using a wire brush before installing.
1. Install the negative battery cable bolt.
Tighten
Tighten the negative battery cable bolt to
15 N-m (11 lb ft).
208241
2. Turn the ignition switch to the ACC position (1).
3. Unlock the Theftlock® radio (if applicable). Refer
to Radio/Audio System Operation-Theftlock in
)
Entertainment.
3
4. Reprogram the radio stations to the previous
settings.
5. Set the clock to the current time.
6. Turn the ignition key to the LOCK position (2) and
remove the key.
341078
Battery Cable Replacement (3.8 L Positive)

Removal Procedure
1. Remove .the battery. Refer to Battery
Replacement.
2. Remove the positive cable from the stud on the
fuseblock:
• Open the positive cable cap.
) • Remove the positive cable to fuseblock
stud nut.
• Remove the positive cable from the
fuseblock stud.
211614
3. Remove the positive cable from the rosebud clip

at the power steering reservoir.
211610
4. Remove the wiring harness ground bolt and radio
frequency (RF) ground strap and cruise control
ground lead from the front rail.
(
346034
5. Remove the positive cable from the generator:

• Slide the boot down revealing the positive
terminal stud.
• Remove the positive cable nut from the
generator input stud. ·
• Remove the positive cable.
6. Remove the positive cable rosebud clip from the
engine lift bracket.
(
43670
7. Remove the positive cable rosebud clips from the

cooling fans.
Information.
211607
9. Remove the positive/negative cable from the
engine mount stud:
• Remove the positive cable RF ground nut (2).
• Remove the RF ground strap.
1O. Remove the starter motor shield. Refer to Starter
11 . Remove the positive cable from the starter
solenoid:
• Remove the positive cable to starter motor
nut (1).
• Remove the positive cable from the harness
conduit.
211604
1. Install the positive cable to the harness conduit.
Notices.
2. Install the positive cable to starter motor nut (1 ).
Tighten
to 10 N-m (89 lb in).
3. Install the starter motor shield. Refer to Starter
4. Install the positive/negative cable to the engine
mount stud:
• Install the RF ground strap.
• Install the positive cable RF ground nut (2).
Tighten
Tighten the positive cable RF ground nut to
211604
25 N,m (18 lb ft).
5. Install the wiring harness bolt and RF ground
strap and cruise control ground lead to the
front rail.
Tighten
12 N·m (106 lb in).
346034
6. Install the positive cable rosebud clip at the power
steering reservoir.
211610
8. Install the positive cable rosebud clips at the

.cooling fans.
211607
9. Install the positive cable rosebud clip to the

engine lift bracket.
10. Install the positive cable to the generator.
9 Install the positive cable to the stud.
• Install the positive cable nut to the generator

output stud.
Tighten
output stud to 22 N-m (16 lb ft).
• Slide the boot over the generator output stud.
43670
Engine Engine Electrical 6~727
11. Install the positive cable to the stud on the
fuseblock:
• Install the positive cable to the fuseblock stud.
0 Install the positive cable to fuseblock
stud nut.
Tighten
Tighten the positive cable to fuseblock stud
nut to 14 N-m (10 lb ft).
~ Close the positive cable cap.
12. Install the battery. Refer to Battery Replacement.
211614
Battery Cable Replacement

(3.8 l Negative)
Removal Procedure
1. Remove the battery. Refer to Battery
Replacement.
2. Remove the negative cable nut at the ground
terminal.
) 3. Remove the ground lead from the
wheelhouse stud
· 211588
4. Remove the battery cable rosebud clip from the

accumulator bracket.
211593
5. Remove the negative cable nut from the engine
block stud.
6. Remove the negative cable from the harness (
conduit.
43679
1. Install the negative battery cable to the harness
conduit.
2. Install the negative cable to the· engine block stud.
Notices.
3. Install the negative cable nut to the engine
block stud. ·
Tighten
(
Tighten the negative cable nut to engine block
stud to 22 N-m (16 lb ft).
43679
4. Install the battery cable rosebud clip to the

211593
5. Install the ground lead to the wheelhouse stud.
6. Install the negative cable nut at the ground
terminal.
Tighten
Tighten the negative cable nut at the ground
terminal to 6 N-m (53 lb in).
211588
Battery Cable Replacement (5.7 L Positive)

Removal Procedure
Replacement.
2. Remove the positive cable from the stud on the
fuseblock.
• Open the positive cable cap.
• Remove the battery cable to fuseblock
stud nut.
• Remove the positive cable from the
fuseblock stud.
Intormation.
211614
4. Remove the conduitrosebud clips at the

cooling fans.
211602
5. Remove the wiring harness ground bolt and radio
frequency.(RF) ground strap and cruise control
ground lead at the front· rail. · (
346034
6. Remove the positive cable from the generator..

terminal stud.
generator output stud.
211599
7. Remove the positive cable to starter motor

nut (3).
8. Remove the positive cable (4) from the
starter motor.
9.. Remove the positive cable from the harness
conduit.
211595
1. Install the positive cable to the harness conduit.
2. Install the positive cable (4) to the starter motor.
Notices.
3. Install the positive cable to starter motor nut (3).
Tighten
to 10 N-m (89 lb in).
211595
4. Install the positive cable to the generator:

• Install the positive cable.
• Install the positive cable nut to the generator
output stud.
Tighten
Tighten the positive cable nut to the
generator output stud to 22 N-m (16 lb ft).
) • Slide the boot over the positive terminal stud.
211599
5. Install the wiring harness ground and RF ground

strap and cruise control ground lead bolt to the
front rail.
Tighten
Tighten the wiring harness ground·and RF ground
strap and cruise control ground lead bolt to
12 N-m (106 lb in).
346034
6. Install the conduit rosebud clips .at the
cooling fans.
211602
8. Install the positive cable to the stud onthe

fuseblock:
• .Install the positive cable to the fuseblock stud.
• Install the positive cable to fuseblock
stud nut.
Tighten
Tighten the positive cable to fuseblock stud
nut to 14 N-m (10 lb ft).
• Close the positive cable cap.
(
211614
Battery Cable Replacement

(5.7 L Negative)
Removal Procedure
Replacement.
2. Remove the negative cable nut at the ground
terminal.
3. Remove the ground lead from the
wheelhouse stud.
211588
4. Remove the battery cable rosebud clip from the
211593
5. Remove the negative cable to.e11gine block

bolt (1 ).
6. Remove the ground lead (2) from the
engine block.
7 .. Remove the negative battery cable from the
harness conduit.
211595
Installation Proce.dure
1. Install the negative cable to the harness conduit.
2. Install the ground lead (2) to the engine block.·
Notice:. Refer to Fastener Notice in Cautions and
Notices. ·· · · · · ·
3. Install the negative cable to engine block bolt (1 ).
Tighten
Tighten the negative cable to engine block bolt (1)
to 32 N·m (24 lb ft).
4'
211595
4. Install the battery cable rosebud clip at the
(
211593
5. Install the ground lead to the wheelhouse stud.

6. Install the negative cable nut at the ground
terminal.
Tighten
Tighten the negative at cable ground terminal nut
to 6 N-m (53 lb in).
(
211588
Battery Hold Down Retainer Replacement

Removal Procedure
1. Loosen the battery hold down retainer bolt.
2. Remove the battery hold down retainer and bolt.
43660
Engine Engine Electrical 6Q735
1. Install the battery hold down retainer and bolt.
and Notices.
2. Tighten the battery hold down retainer bolt.
Tighten
Tighten the battery hold down retainer bolt to
18 N,m (13 lb ft).
43660
Battery Replacement
Removal Procedure
Procedure.
208241
2. Disconnect the positive battery cable bolt.
211587
6-"736 Engine Electrical . Engine
3. Remove the battery hold down retainer bolt.
4. Remove the battery hold down retainer.
(
43660
5. Remove the battery from tile battery tray/coolant

recovery reservoir.
221643
1. Install the battery to the battery tray/coolant
recovery reservoir.
221643
2. Install the battery hold down retainer.
Notices.
3. Install the battery hold down retainer bolt.
Tighten
Tighten the battery hold down retainer bolt to
18 N·m (13 lb ft).
43660
4. Connect the positive battery ca.ble bolt.

Tighten
Tighten the positive battery cable bolt to
15 N-m (11 lb ft).
211587

Procedure.
208241
Battery Tray Replacement
Removal Procedure
(
Replacement.
the radiator.
221645
3. Remove the accelerator and cruise control

servo cable adjuster bolts, if equipped with a
5.7 L engine.
4. Reposition the accelerator and cruise control
servo cable adjuster.
221646
5. Remove the coolant recovery reservoir bolt.
221653
6. Remove the wiring harness rosebud clip from the
reservoir neck.
7. Remove the coolant recovery
reservoir/battery tray.
221650

the reservoir/battery tray.
221663
reservoir/battery tray.
2. Install the coolant recovery reservoir/battery tray.
221663
s. 740 Engine Electrical Engine
3. Install the wiring harness rosebud clip to the
reservoir neck.
(
221650
Notice:Refer to Fastener Notice in Cautions and

Notices.
4. Install the coolant recovery reservoir bolt.

Tighten
Tighten the coolant recovery reservoir bolt to
12 N-m (106 lb in).
221653
5. Position the accelerator and cruise control servo

cable adjuster, if equipped with a 5.7 L engine.
6. Install the accelerator and cruise control servo
cable adjuster bolts.
Tighten
Tighten the accelerator and cruise control servo
cable adjuster bolts to 7.5 N-m (66 lb in).
221646
radiator.
9. Add engine coolant to the FULL COLD mark
on the reservoir.
221645
Underhood Fuse Block Replacement

Removal Procedure
The underhood electrical center is part of the forward
lamp wiring harness. The underhood electrical
center and harness must be replaced as a complete
assembly.
Procedure.
2. Starting inside the vehicle, disconnect the
accel/cruise servo cable adjuster electrical
connectors (1 ).
407641
3. Disconnect the following connectors from the

steering column (1 ):
.1
• Ignition switch (2)
• Wiper/washer (3)
Cut the insulator from around the connector.
• Dimmer switch (4)
407643
5q42 Engine Electrical Engine
4: Disconnect the electronic throttle control (ETC)
electrical connector (1 ), if equipped with a
3,8 L engine. (
5. Disqonnect the rosebud clips (2) from the
dash mat.
Information.
407645
7. Disconnect the secondary air injection (.AIR) pump

connector, if equipped with a 5.7 L engine.
·,:5J·
550628
8. Disconnect the vacuum tank hose from the

vacuum tank.
/
282928
9. Remove the park/turn signal (3) and marker
lamp (1) connector from the lamp (2).
10. On Pontiac, disconnect the side marker lamp
connector.
407630
11. Remove the side repeater lamp (Export only).
379374
12. Remove the harness clips (1) from the fender rail.
(Export only)
407632
13. On Chevrolet, disconnect the connector from the
fog lamp.
14. Remove the rosebud clip from the front (
bumper beam.
550635
15. On Pontiac, disconnect the connector from the

fog lamp.
16. Remove the clip from the front bumper beam.
' 550631
17. Remove the secondary lock retainer.(3).

18. Disconnect the headlamp jumper harness (2) from
the forward lamp harness (1 ).
--- 2
407626
(
19. Disconnect the inline headlamp connector (1)
from the forward lamp harness. ·
20. Disconnect the rosebud clip (5) from the front
end panel.
21. Route the following through the front end
panel hole.
• Fog lamp connector (2)
• Park/turn signal connector (3)
• Side marker connector (4), Pontiac only
3 2 1
407623
23. Remove the captured secondary lock (1') from the

connector.
24. Disconnect the ETC connector (2) from the
throttle body, if equipped with a 3.8 L engine.
407647
25. Disconnect the washer pump.electrical

connector (1 ).
26. Disconnect the windshield washer fluid hose (2)
from the pump.
407637
27. Disconnect. the forward lamp wiring harness
rosebud clips (1) from the tie bar.
1
(
407640
28. Disconnect the cooling fan electrical connectors,·

29. Disconnect the harness rosebud clips.
Replacement.
550332
31. Remove the right front ground bolt .(2).

32. Remove the forward lamp wiring ground (3) from
the tie bar.
33. Remove the harness from the outboard of the)
battery tray (1 ).
34. Remove the forward lamp harness headlamp
branch through the hole in the front panel.
407633
35. Remove the forward lamp harness ground
stud (1 ).
36. Remove the forward lamp harness ground (2).
37. Disconnect the electronic throttle actuator
electrical connector (3), if equipped with a
5.7 L engine.
407622
38. Disconnect the secondary captured locks.

engine harness.
40. Disconnect the forward lamp harness vacuum
tube from the top of the vacuum check valve.
346047
41. Remove the speed sensor connector (1) from the

mid rail.
42. Disconnect the harness rosebud (2) clip at the
coolant fill neck.
407621
43. Remove the positive battery cable from the stud
on the fuseblock:
43.1. Open the positive cable cap, (
43.2. Remove the po$itive cable.to fuseblock
stud nut
43.3. Remove the positive cable from the
fuseblock stud.
211614
44. Remove the ABS/SIR electrical ground stud (1)

from .the wheelhouse panel.
45. Remove the ABS/SIR electrical grounq
terminal (2) from the wheelhouse.
407616
46. Disconnect the 30 way connect9r ( 1) from the

brake pressure module valve.
407617
47. Disconnect the brake fluid level sensor
connector (1) from the master cylinder.
48. Remove the wheel speed sensor connector (2)
from the mid rail.
407618
49. Remove the underhood electrical center from the

wheelhouse bracket.
50. Remove the air inlet grille panel. Refer to Air Inlet
Grilfe Panel Replacement in Body Front End.
51. Disconnect the wiper motor electrical connector.
406433
52. Remove the wipe motor harness branch from the

plenum extension.
53. Remove the windshield washer fluid hose from
the plenum extension.
54. Remove the forward lamp wiring harness grommet
bolt (2).
55. Remove the harness rosebud clip at the left
wheelhouse panel.
56. Gently, remove the forward lamp harness from
inside the vehicle through the front of dash
opening.
57. Remove the forward lamp wiring harness from the
vehicle.
407620
1. Install the forward lamp wiring harness to the (
vehicle.
2. Route the forward lamp harness through the front
of dash in the interior of the vehicle.
3. Install the harness rosebud clip to the left
wheelhouse panel.
Notices.
4. Install the forward lamp wiring harness grommet
bolt (2).
Tighten
Tighten the forward lamp wiring harness grommet
bolt (2) to 2 N-m (18 lb in).
5. Install the windshield washer fluid hose to the
plenum extension.
6. Install the wiper motor branch to the plenum
407620
extension.
7. Connect the wiper motor electrical connector.
8. Install the air inlet grille panel. Refer to Air Inlet
Grille Panel Replacement in Body Front End.
9. Perform the following to install the underhood
electrical center to the wheelhouse· bracket:
9.1. Tilt the forward lamp harness bracket
outboard.
9.2. Insert the tab on the bracket into the hole in
the wheelhouse bracket.
9.3. Roll bracket back inboard.
(
9.4. Secure bracket by sliding down into tabs on
tie bar.
406433
(
10. Install the wheel speed sensor connector (2) to
the mid rail.
11. Connect the brake fluid level sensor connector (1)
to the master cylinder.
407618
12. Connect the 30 way connector (1) to the brake

pressure module valve.
407617
13. Install the ABS/SIR electrical ground terminal (2)

to the wheelhouse.
14. Install the ABS/SIR electrical ground stud (1) to
the wheelhouse panel.
Tighten
Tighten the ABS/SIR electrical ground stud (1) to
14 N-m (10 lb ft).
407616
15. Install the harness ground wire (2) to the tie bar.
16. Install the left front forward lamp wiring ground (
bolt (1 ).
Tighten
Tighten the left front forward lamp wiring ground
bolt (1) to 1O N-m (89 lb in).
407614
17. Install the positive battery to the stud on the

fuseblock:
17 .1. Install the positive cable to the
fuseblock stud.
17.2. Install the positive cable to fuseblock
stud nut.
Tighten
Tighten the positive cable nut to fuseblock (
stud to 14 N·m (10 lb ft).
17.3. Install the positive battery cable cover.
211614
18. Connect the harness rosebud (2) clip to the

coolant fill neck.
19. Install the speed sensor connector (1) to the
mid rail.
407621
Engine Engine Electrical 5,.753
20. Connect the forward lamp harness vacuum tube
to the top of the vacuum check valve.
21. Connect the forward lamp harness to the engine
harness.
22. Connect the secondary captured locks.
346047
23. Connect the electronic throttle actuator electrical

connector (3), if equipped with a 5.7 L engine.
24. Install the forward lamp harness ground (2).
25. Install the forward lamp harness ground stud (1 ).
Tighten
Tighten the forward lamp harness ground stud (1)
to 16 N-m (12 lb ft).
407622
26. Route the forward lamp harness headlamp branch

through the hole in the front panel.
27. Tuck the harness into the opening forward of the
battery tray (1 ).
28. Install the forward lamp wiring ground (3) to the
tie bar.
29. Install the right front ground bolt (2).
Tighten
Tighten the right front ground bolt (2) to
1ON·m (89 lb in).
407633
31 . Connect the rosebud clips.
32. Connect the cooling fan electrical connectors.
(
550332
33. Connect the forward lamp wiring harness rosebud

clips (1) to the tie bar.
1
407640
34. Connect the windshield washer fluid hose (2) to.

the pump.
35. Connect the washer pump electrical connector (1 ).
407637
36. Connect the ETC connector (2) to .the throttle
body, if equipped with 3.8 L engine.
37. Install the captured secondary lock (1) to the
connector.
Information.
407647
39. Route the following through the front end

panel hole:
• Side marker connector (4), Pontiac only
• Park/turn signal connector (3)
• Fog lamp connector (2)
40. Connect the rosebud clip (5) to the front
end panel.
J 41. Connect the inline headlamp connector (1) to the
forward lamp harness.
3 2 1
407623
42. Connect the headlamp jumper harness (2) to the

forward lamp harness (1 ).
43. Install the secondary lock retainer (3).
-- 2
407626
44. On Pontiac, install the clip (3) to the front
bumper beam.
45. Connect the fog lamp connector (2) to the lamp. (
3 2
407629
46. On Chevrolet, install the rosebud clip to the front

bumper beam.
47. Connect the fog lamp connector to the lamp.
550635
48. Install the harness clips (1) to the fender rail.

(Export only)
(
1
407632
49. Install the side repeater lamp. (Export only)
379374
50. Install the park/turn signal (3) and marker (1)

connector to the lamp (2).
51. On Pontiac, connect the side marker lamp
connector.
407630
52. Connect the vacuum tank hose to the

vacuum tank.
/
282928
53. Connect the AIR pump connector; if equipped
with a 5.7 L engine.
(
550628
55. Con.nect the rosebud clips (2) to the dash mat

56. Connect the ETC electrical c6nnector~(1 ), if
equipped with a 3.8 L engine.
407645
57. Connect the following connector to the steering

column (1):
1
• Dimmer switch (4)
• Wiper/washer (3)
Install a tie strap around the connector
between the black and pink wires.
• Ignition switch (2)
407643
58. Connect the accel/cruise servo cable adjuster
electrical connectors (1 ).
1
407641

Procedure.
208241
Ground Strap Replacement

Removal Procedure
1. On the 3.8 L engine, remove the positive/negative
cable from the engine mount stud.
" Remove the positive cable radio
frequency (RF) ground nut (2).
" Remove the harness clamp from the stud.
" Remove the RF ground strap.
211604
2. On the 5.7 L engine, remove the engine wiring
harness ground bolt from the block (1 ).
3. Disconnect and reposition the oxygen sensor (
353688

ground strap and cruise control ground lead from
the frame rail.
5. Remove the tape attaching the ground strap to
the wiring harness.
6. Remove the ground strap from the vehicle.
346034
1. Install the ground strap to the vehicle.
2. Wrap new tape around the ground strap and the
wiring harness. .
Notices.
3. Install the wiring harness ground bolt and RF
ground strap and cruise control ground lead to
the frame rail.
Tighten
12 N·m (106 lb in).
346034
4. On the 5.7 L engine, connect and position the
oxygen sensor electrical connector.
5. Install the engine wiring harness ground bolt (1) to
the block.
Tighten
Ti,ghten the engine wiring harness ground bolt (1)
to 25 N-m (18 lb ft).
353688
6. On the 3.8 L engine, install the p9sitive/negative

cable to the engine mount stud. ·
• Install the RF ground strap.
• Install the harness clamp from the stud.
• Install the positive cable RF ground nut (2).
Tighten
Tighten the positive cable RF ground
nut (2) to 25 N-m (18 lb ft).
211604
Generator Bracket Replacement (3.8 L)

Removal Procedure
1. Remove generator rear brace. Refer to Generator
Brace Replacement.
2. Remove the fuel rail from the upper intake
manifold. Refer to Fuel Rail Assembly
Replacement in Engine Controls - 3.8 L.
3. Remove the generator brace bracket bolts.
4. Remove the generator bracket from the
cyl,inder head.
165246
1. Install the generator bracket to the cylinder head.
Notices.
2. Install the generator brace bracket bolts.
Tighten
Tighten the generator brace bracket bolts to
50 N·m (37 lb ft).
3. Install the fuel rail to the upper intake manifold.
Refer to Fuel Rail Assembly Replacement in
4. Install the generator rear brace. Refer to
Generator Brace Replacement.
165246
Generator ·Bracket Replacement

(5.7 L Front)
Removal Procedure
1. Remove the accessory drive belt idler pulley.
Refer to Drive Belt Idler Pulley Replacement -
Accessory in Engine Mechanical - 5.7 L.
3. Remove the generator bracket bolt and bracket.
(
550637
Notices.
1. Install the generator bracket and. bolt.
Tighten
Tighten the generator bracket bolt to
50 N·m (37 lb ft).
Replacement(5.7 L).
3. Install the accessory drive belt idler pulley. Refer
to Drive Belt Idler Pulley Replacement - Accessory
in Engine Mechanical - 5.7 L.
550637
Generator Bracket Replacement
(5.7 L Rear)
Removal Procedure
1. Remove the generator rear mounting bolt (to 1
generator) (1 ).
2. Remove the generator rear mounting bolt (to
engine) (2).
3. Remove the generator rear bracket.
-~
2
211626
1. Install the generator rear bracket.
2. Install the generator rear mounting bolt (to
generator) (1) hand tight. 1
Notice:. Refer to Fastener Notice in Cautions and
Notices.
3. Install the generator rear mounting
bolt (to engine) (2).
) Tighten
O Tighten the generator rear mounting bolt (to
-~
generator) (1) to 25 N-m (18 lb ft). 2
O Tighten the generator rear mounting bolt (to
engine) (2) to 50 N-m (37 lb ft).
211626
Generator Brace Replacement

Removal Procedure
1 . Remove the generator. Refer to Generator
2. Remove the canister purge solenoid. Refer to
EVAP Canister Purge Valve Replacement in
Engine Coritrols - 3.8 L.
3. Remove the generator rear brace bolts (5).
4. Remove the generator rear brace (4) from the
vehicle.
487452
1. Install the generator rear brace (4) to vehicle.
Notice: Refer to Fastener Notice in Cautions (
and Notices.
2. Install generator rear brace bolts (5).
Tighten
Tighten the generator rear brace bolts (5) to
25 N-m (18 lb ft).
3. Install the canister purge solenoid. Refer to EVAP
Canister Purge Valve Replacement in Engine
Controls - 3.8 L
487452
Generator Replacement (3.8 L)

Removal Procedure
1. Disconnect the· negative battery cable. Refer to
Procedure.
2. Remove the accessory drive belt. Refer to Drive (
3. Disconnect the generator electrical connector.
211637

.. Slide the boot down revealing the positive
terminal stud.
5. Remove the canister purge solenoid. Refer to
EVAP Canister Purge Valve Replacement in
43670
6. Remove the generator rear brace bolt (6).
7. Remove the generator bolts (2, 3).
8. Remove the generator (1) from the drive belt
tensioner:
487452
1. Install the generator (1) to the drive belt tensioner.
Notice:. Refer. to Fastener Notice in Cautions and
Notices.
2. Install the generator bolts (2, 3).
Tighten ·
• Tighten the generator bolt (2) to
30 N·m (22 lb ft).
• Tighten the generator bolt (3) to
50 N·m (37 lb ft).
3. Install the generator brace bolt (6).
Tighten
Tighten .the generator brace bolt (6) to
30 N-m (22 lb ft).
4. Install the canister purge solenoid. Refer to EVAP
Canister Purge Valve Replacement in Engine
Controls-3.8 L.
487452
5. Install the positive cable to the generator.

• Install the positive cable to the generator
output stud.
• Install the positive cable to the generator
output stud nut.
Tighten
output stud to 22 N-m (16 lb ft).
• Slide the boot over the generator output stud.
43670
6. Connect the electrical connector to the generator.
Replacement in Engine Mechanical-3.8 L.
(
Procedure.
211637
Generator Replacement (5. 7 L)

Removal Procedure
Procedure.
Belt Replacement - Accessory in Engine
Mechanical-5.7 L (
Information.
terminal stud.
211599
5. Remove the generator rear bracket mounting

bolt (1 ).
6. Remove the transmission oil cooler lines from the
oil cooler clip.
211626
7. Remove the front generator mounting bolts and oil
cooler clip.
211628
8. Disconnect the generator electrical connector (3).

9. Remove the generator from the vehicle.
211624
1. Install the generator to the vehicle.
2. Connect the generator electrical connector (3).
211624
6:-768 ~ngine Electrical Engine
Notice: Refer to Fa.stener Notice in Cautions and
Notices.
3. Install the front generator mounting bolts and oil (
cooler clip.
Tighten
Tighten the generator mounting bolts to
50 N-m (37 lb ft).
4. Install the transmission oil cooler lines to the oil
cooler clip.
5. Install ttie generator rear bracket mounting

bolt (1 ).
Tighten
Tighten the rear bracket mounting bolt (1) to
25 N·m (18 lb ft).
211626
6. Install the positive cable tothe generator:

• Install the positive cable.
• lnstall.ttie ppsitive cable nut to the generator
output stud.
Tighten
Tighten the positive cable nut to the
generator output stud to 22 N·m (16 lb ft).
• Slide the boot over the positive terminal stud.
Replacement - Accessory in Engine
Mechanical-5. 7 L.
Procedure.
211599
Generator Splash Shield Replacement
Removal Procedure
1. Remove the generator splash shield from the tie
strap on the steering rack.
211633
2. Reniove the generator splash shield nuts.

3. Remove the generator splash shield.
211632
1. Install the generator splash shield.
2. Install the generator splash shield nuts.
211632
5;..770 Engine Electrical Engine
3. Install the generator.splash shield to the tie s1rap
on the steering rack. ·
(
211633
Spark Plug Wire Harness Replacement

(3.8 L Right Bank)
Removal Procedure
3
1. Turn the ignition to OFF (3) or to LOCK (2).
Information.
(
341078
Notice: Twist the spark plug boot one-half turn in

order to release the boot. Pull on. the spark plug boot
only. Do not pull on the spark plug wire or the wire
could be damaged. ··
3. Disconnect the number 4 and number 6 plug

wires from the spark plugs.
5. Disconnect the number 2 plug wire from the
spark plug.
211645
6. Disconnect the even (2, 4, 6) spark plug wires
from the ignition coils.
7. Remove the spark plug wire harness.
43661
Important: The lower tabs of the heat shield must
extend over the hex on the spark plug in order
to complete installation of the heat shield and the boot
on the spark plug.
1. Install the spark plug wire harness.
2. Connect the even (2, 4, 6) spark plug wires to the
ignition coils.
J 3. Connect the number 2 plug wire from the
spark plug.
Information.
43661
5. Connect the number 4 and number 6 plug wires

. to the spark plugs.
6. Lower the vehicl.e.
211645
5;;772 Engine Electrical Engine
(3.8 L Left Bank)
Removal Procedure (
1. Disconnect the odd numbered plug wires (1, 3, 5)
from the ignition coils. ·
order to release the boot. Pull on the spark plug boot
only. Do not pull on the spark plug wire or the wire
could be damaged.
Information.
43661
3. Remove the plug wires from the spark plugs.

4. Remove the spark plug wire harness from .the
vehicle.
211642
Important: The lower tabs of the heat shield must
extend over the hex on the spark plug in order
to complete installation of the heat shield and the boot
on the spark plug.
1. Install the spark plug wire harness to the vehicle.
211642
4. Connect the odd numbered plug wires (1, 3, 5) to
the ignition coils.
43661
Spark Plug Wire Harness

Replacement cs:
7 L)
Removal Procedure
order to release the boot. Pull on the spark plug boot
only. Do not pull on the spark plugwire or the wire
could be damaged,
1. Disconnect the spark plug wire at each spark plug.
• Twist each spark plug 1/2 turn.
• Pull only on the boot in order to remove the
wire from each spark plug.
2. Disconnect the spark plug wire from the
ignition coil.
• Twist each spark plug boot 1/2 turn.
• Pull only on the boot in order to remove the
wires from the ignition coil.
211641'
1. Install the spark plug wires at the ignition coil.
2. Install the spark plug wire to each spark plug.
3. Inspect the wires for proper installation:
• Push sideways on each boot in order to inspect
the seating.
• Reinstall any. loose boot.
211641
Spark Plug Replacement
Removal Procedure
(
1. Remove the spark plug wires. Refer to Spark Plug
Wire Harness Replacement (3.8 L Right Bank),
(3.8 L Left Bank) or Spark Plug Wire Harness
Notice: Allow the engine to cool before removing the
spark plugs. Attempting to remove the spark plugs
from a hot engine may cause the plug threads to seize,
causing damage to cylinder head threads.
Notice: Clean the spark plug recess area before
removing the spark plug. Failure to do so could result
in engine damage because of dirt or foreign material
entering the cylinder head, or by the contamination of
the cylinder head threads. The contaminated
threads may prevent the proper seating of the new
plug. Use a thread chaser to clean the threads oi any
14324 contamination.
2. Loosen each spark plug one or two turns.
3. Brush or use compressed a:ir to)emove any dirt • ·
from around the spark plugs.
4. Remove the spark plugs one at a time an.d place
a
each plug in tray markE?d with the corresponding
cylinder numbers; · · ·
1. Inspect each spark plug gap. Adjust each plug as· (
needed.
Specification
Spark plug gap: 1 ,524 mm (0.060 in):,
2. Hand start the spark plugs in the corresponding
cylinders.
Notice: Refer to Fastener Notice in Cautions and.
Notices.
3. Tighten the spark plugs.
Tighten
• Tighten the 3.8 L engine spark plugs to
27 N,m (20 lb ft).
• Tighten the 5. 7 L engine spark plug on aNEW'.
cylinder head to 20. N·m (15. lb ft).
• Tighten the 5.7.L engine spark plug on·
subsequent
.
installations ,to 15 N·m (11 lb 'ft).
' ; ' ' ,,
14824
4. Install the spark.plug wires. Refer to Spark Plug
Wire Harness Replacement (3.8 L. Righi Bank),
Spark Plug Wire Harness Replacement ·
(3.8 L Left Bank) or Spark Plug Wire Harness
(
lgniUon Coil Replacement (3.8 L)
Removal Procedure
control module.
2. Disconnect the spark plug wires from the coil
being serviced.
211652
3. Remove the ignition coil bolts (2).

4. Remove the ignition coil (1) from the module (4).
5. Remove the ignition coil seal (3), if required.
379371
1. Install the ignition coil seal (3), if removed.
2. Install the ignition coil (1) to the module (4).
Notices.
3. Install the ignition coil bolts (2).
Tighten
Tighten the ignition coil bolts (2) to
4 N-m (35 lb in).
379371
4. Connect the spark plug wires to.the coil.
5. Connect the electrical connector from the control
module. (
Tighten
Tighten the ignition control module bolt to
2.5 N:m (22 lb in).
211652
Ignition Coil Replacement (5.7 L)

Removal Procedure
1. Disconnect the main electrical connector feeding
the ignition coils.
2. Disconnect the ignition coil harness connectors.
3. Disconnect the spark plug wire at the ignition coil.
211648
4. Remove the ignition coil mounting bolts.

5. Remqve the ignition coiL
309850
lnstaNation Procedure
1'. Install the ignition coil.
Notices.
2. Install the ignition coil mounting bolts.
Ti,ghten
Tighten the ignition coil mounting bolts to
12 N-m (106 lb in).
309850
3. Connect the spark plug wire at the ignition coil.

4. Connect the ignition coit harness connector.
5. Connect the main electrical connector feeding the
·ignition coils.
211648
Ignition Coil Module Replacement (3.8 L)

Removal Pro,cedure
1. Loosen the control module electrical
connector bolt.
2. Remove the control module electrical connector
from the module.
3. Remove the spark plug wires from the ignition
control module.
211652
4. Remove the ignition control module nuts.
5. Remove the engine lift bracket to ignition control (
module bolt.
6. Remove the ignition control module/coils.
43664
7. lay the module/coils on a clean work surface.

5 1 8. Remove the ignition coil bolts (2) from all the
coils (1 ):
9. Remove the ignition coils (1) from the module (4).
10. Remove the ignition coil seals (3).
11. Remove the module (4) from the module
bracket (5). ,
379371
1. Install the module (4) to the module bracket (5).
2. Install the ignition coil seals (3):
3. Install the ignition coils (1) to the module (4).
Notice: Refer. to. Fastener Notice in Cautions
and Notices.
4. Install the. ignition coil bolts (2).
Tighten
Tighten the ignition coil bolts (2) to
4 N-m (35 lb in).
379371
5. Install the ignition control module/coils.
6. Loosely install the engine lift bracket to ignition
control module bolt.
7. Install the ignition control module nuts.
Tighten
• Tighten the ignition control module nuts to
30 N-m (22 lb ft}.
• Tighten the engine lift bracket to ignition
control module bolt to 25 N-m (18 lb ft).
43664
8. Install the spark plug wires to the ignition control

module.
9. Install the control module electrical connector to
the module.
10. Tighten the control module electrical
connector bolt.
Tighten
Tighten the ignition control module bolt to
\)
3 N·m (27 lb in).
211652
Starting System Description Starting System Circuit Description (
When the ignition switch is turned to tbe START Starter Circu'it Operation
position, the battery voltage is applied to the starter .
motor solenoid, and both of the starter motor solenoid When the ignition switch is moved to the START
windings are energized. The pull-in windings work position voltage is applied to the normally open
together magnetically in order to puU in and hold the contact~ of the starter relay. Voltage is also applied
plunger. The plunger then move~ the shift lever.. through .either the park neutral position switch..
This action causes the starter dnve to rotate as 1t (automatic transmi\3sion) when _in park or neutra_l o~
engages with the flywheel on the engine. At.th.a same the clutch pedal position switch (manual transm1ss1on)
time, the plunger also closes the starter moto~ . when the clutch pedal is depressed, to the starter
solenoid switch contacts. Full battery voltage 1s applied relay coil. The body control module (BCM) energizes
directly to the starter motor, whi.ch iii tum cranks the the starter relay by grounding one side of the relay
engine. coil only when the theft deterrent system has not been
activated.
As soon as the coritacts close, the voltage is no
longer applied through the pull-in windings, since the When the starter relay is energized, the normally open
battery voltage is applied to both ends of the contacts close completing the circuit to the starter
windings. The hold-in winding remains energized, and solenoid. When the starter solenoid circuit is
the magnetic field is strong enough to hold the completed, both the hold-in windings and the pull-in .
plunger, the shift lever, ~nd the st~rter drive c_ontacts windings are energized. The circuit through the pull-in
in place in order to continue cranking the engine. winding is complete~ through the st~rter motor. .
The windings work together magnetically to pull in and
When the ignition switch is moved from the START hold in the p_lunger. The_ plungern1oves the shift ·.
position, the battery voltage is removed from th~ . lever. This action causes the drive assembly to rotate
starter motor solenoid and the junction of the windings. as it engages the flywhe~I ring gear on the engine: .
Voltage is applied from the contacts through both . At the same time the plunger also closes the solenoid
windings in order to ground at the. end of the hold-in switch contacts in the starter solenoid. Full battery
windings. However, thevoltageapplied to the . voltage is then applied directly to the starter _motor and
pull-in winding is now opposing the voltage applle~ it cranks the engine.
when the winding was first energized. The magnetic
fields of the pulHn and hold-in windings now As soon as the solenoid switch contacts close, voltage (
oppose each other. The return spring then causes the is no longer applied to the pull-in winding since. .
starter drive to disengage and the contacts to open battery voltage is applied to both ends of the w1~ding.
simultaneously. As soon as the contacts open, The hold-in winding remains energized and c~ntinues
the starter circuit is turned off. ·· to hold the plunger, the shift lever, ~nd the dnve .
assembly solenoid switch contacts in place to continue
cranking the engine.
Starting System Operation
When the ignition switch is released from the START
When the ignition switch is turned to the start position, position, battery voltage is removed from the
battery voltage is sent to the starter solenoid two windings. Voltage is applied through the motor
contacts. This_ energizes the solenoid windings and contacts and both windings to ground. However,
causes movement of the solenoid plunger and the direction of current flow through the windings is
shift lever which causes the drive pinion to engage the reversed. The magnetic fields of the two windings now
engine flywheel ring gear and the solenoid switch oppose one another. The return spring, aided by
contacts to close. When the solenoid switch contacts the opposing magnetic fields of the windings,
close, the starter motor is energized and cranking disengages the drive assembly which opens the
takes place. As the engine starts, the pinion overrun solenoid switch contacts. Once the contacts open, the
clutch protects the motor armature from excessive starter circuit is turned off.
speed until the ignition switch is op~ned. Once
the solenoid windings are de-energized, the return
spring causes the pinion to disenQag~_. In or?er
to prevent excessive overrun, the 1grnt!on switch should
be opened immediately when the engine starts.
(
Battery Description Battery Diagnosis
Caution: Batteries generate hydrogen gas which is If the battery tests good but still fails to perform
extremely flammable and may explode violently satisfactorily, the following are some of the more
if ignited by a spark or a flame. Battery acid common causes:
is extremely corrosive and causes severe personal • A vehicle accessory was left on overnight.
injury if the acid comes into contact with the • The driving speeds have been slow with frequent
skin- blindness if the acid comes into contact with stops (stop-and-go driving).
the eyes. In order to avoid severe personal
• The electrical load has exceeded the generator
injury, use extreme precaution when servicing the
output (particularly with the addition of aftermarket
battery or battery-related components.
equipment).
• Existing conditions in the charging system,
including the following possibilities:
- An electrical short
- A slipping belt
- A bad generator
- A bad generator voltage regulator
O The battery has not been properly maintained,
including the following situations:

- A failure to keep the terminals tight
- A failure to keep the terminals clean
- A loose battery hold-down
• Existing mechanical conditions in. the electrical
5
system, such as any short or pinched wires,
attributing to power failure.
4 3 • The car is in storage for extended periods of time.
• Plug fouling, causing extended cranking periods.
) 405476 • The hydrometer has been read incorrectly.
A maintenance free battery is standard on all vehicles. • There has been an insufficient Ampere-hour
There are no vent plugs in the cover. The battery is charge rate for a discharged battery.
completely sealed except for two small vent holes • There is a burned out charge indicator bulb
in the side. These vent holes allow the small amount causing a NO CHARGE condition.
of gas that is produced in the battery to escape. " There is a continuous current draw on the battery
The battery consists of the following components: through excessive parasitic drain.
• Hydrometer lens (1) • The battery is old.
" Negative terminal (2)
• Hold-down ramp· (3) Battery Operation
• Positive terminal (4) The battery supplies current to operate the starting
motor and the ignition system when the engine is being
" Battery grids (5)
started. The battery has three major functions in the
The battery has three functions in the electrical electrical system:
system:
1. Provides a source of energy for cranking the
• Provides electrical current when the vehicle's engine
electrical nee.ds exceed the generator's output.
2. Acts as a voltage stabilizer for the electrical
• Stabilizes current surges in the charging system in system ·
order to protect electrical systems.
3. For a limited time, it can provide energy when the
• Stores electrical energy for the starting system. electrical load used exceeds the output of the ·
The battery specification label contains important generator ·
information about the following: · The battery is an electrochemical devise.. This means
• The test ratings the battery uses chemicals to produce electricity.
• The original model number The amount of electricity it can produce is limited. As
the chemicals in the battery are used up, the
• The recommended replacement model number battery runs down, or is discharged. It can be
• The cold cranking Amps (CCA) recharged by supplying it with electric current from a
battery charger, or from the vehicle generator.
The used up chemicals are then returned to their
original condition, so the battery becomes recharged.
5.,752 Engine Electrical Engine
Battery Tray and Hold-Down Retainer Charging System Operation.
Description
Clean any corrosion from the battery tray/coolant (
recovery reservoir and the hold down clamp prior to
installing the battery: Ensure the carrier is in good
condition in order to hold the battery securely and keep
the battery level. Ensure there are no parts or tools
in the battery tray/coolant recovery reservoir
before installing the battery. lnorder to prevent the
battery from shaking in the tray, tighten the hold down
bolt to the specification noted. Refer to Fastener
Tightening Specifications
Charging System Description

The charging system consists of the following
components:
.. The battery
• The generator (CS-1300) 7
• A voltage regulator 405471
O Indicator lamp or voltmeter circuitry The charging system provides voltage to the
battery and to the vehicle electrical systems. The
CS-Series Generators generator's voltage regulator controls the rotor's field
current to meet these needs.
Current flows (1) through the ~lip rings (8) to the rotor
winding (2) in order to create a magnetic field (3).
The engine-driven rotor (4) is rotated by the engine
within the stator (5). This rotation creates an
alternating current (AC) voltage in the stator (
windings (6). The AC voltage go€1s to the rectifier
bridge (7). The rectifier bridge converts this AC voltage
to direct current (DC) voltage. The DC voltage is
delivered from the generator's output terminal to the
battery and the electrical systems through a fusible
link (11). Theregulator grounds circuit 225 (10) when
the charging system voltage is abnormal: This
information causes the PCM to send a class 2
message to the instrument panel cluster, which
activates the CHECK GAGES lamp.
The voltage regulator limits system voltage by
controlling the rotor field CLJrrent. When the field
ccurrent is on, the regulator switches the rotor field on
and off at a fixed rate of about 400 cycles per second.
405469
By varying the overall on/off time, correct average field
Model CS-Series generators (1) feature a high current for proper system voltage control is maintained.
ampere output per pound of weight. The CS stands At high speeds, the on time may be 1o percent .and the
for charging systems. The 130 is the measurement, in off time may be 90 percent. At low speeds, and with
millimeters, of the outside diameter of the stator high electrical loads, the on/off time may be 90 percent
laminations and the D is for dual internal fans. The and 1Opercent respectively. The voltmeter reads
delta stator, rectifier bridge, and the rotor with slip rings battery voltage when the engine is not running and
and brushes, are electrically similar to other reads charging system voltage when the engine is
CS series generators. The CS-1300 generator uses a running. The normal indication is between 11 and
conventional pulley and dual internal fans to cool 16 volts.
the slip ring end frame, rectifier bridge and voltage
regulator.
The generator's rotor shaft (2) is rotated by the engine
drive belt. The rotor shaft rotates the generator's
rotor. The generator produces the electrical current
(
that charges the battery. The generator also provides
energy to the vehicle's electrical systems when the
engine is running.
The generator uses only two connections-battery Ignition System Description (3.8 l)
positive and the L terminal, in addition to the ground
The electronic ignition system controls fuel.combustion
I path through the generator bracket. Use of P, I, and
by providing a spark to ignite the compressed
S terminals is optional. The P terminal is connected to
air/fuel mixture at the correct time. To provide optimum
the stator and may be connected externally to a
engine performance, fuel economy, and control of
tachometer or other devise. The I terminal can be
exhaust emissions, the PCM controls the spark
connected directly to battery voltage to power
advance of the ignition system. The electronic ignition
the generator instead of, or in addition to, the
system does not use the conventional distributor
L terminal which must be stepped down. This
and coil. The electronic ignition system has the
S terminal may be connected to an external voltage
following advantages over the conventional. mechanical
source, such as voltage near the battery, for voltage
distributor system:
control. If the S terminal is not used, internal generator
voltage is used for control. O
No moving parts
The CS-130D generator must be replaced. Do not • Less maintenance required
disassemble the CS-130D generator. " Remove mounting capability
O
No mechanical load on the engine
Charging System Operation • More coil cool down time between firing
The charging system has two jobs: • Elimination of mechanical timing adjustments
1. To put back into the battery the current used to " Increased available ignition coil saturation time
start the engine
The electronic ignition system consists of
2. To handle the load ofthe lights, ignition, radio, three twin-tower ignition coils, an ignition control
and other electrical and electronic equipment module, a dual Hall-effect crankshaft position sensor,
while the engine is running. an engine crankshaft balancer with interrupter
The charging system includes the generator, regulator, rings attached to the rear, related connecting wires,
and battery, with connecting wires. and the Ignition Control (IC) and fuel metering portion
The generator converts mechanical energy from the of the PCM.
engine into electrical energy. It keeps the battery The three twin-tower ignition coils are individually
in a charged condition and handles electrical loads mounted to the ignition control module. Each end of a
while the engine is running. The alternator produces coils secondary winding is attached to a spark
alternating current (ac) inside the stator windings. plug. Each cylinder is paired with the cylinder that is
Diodes convert this ac into direct current (de). opposite it. These two spark plugs are on top
dead center at the same time. When the ignition coil
Charging System Circuit Description fires, both plugs fire at the same time to complete
the circuit. The cylinder on compression is said to be
Charging Circuit Operation the event cylinder and the one on exhaust is the
The generator provides voltage to operate the waste cylinder. The cylinder on the exhaust stroke
electrical system and to charge the battery. A magnetic requires very little of the available energy to fire
field is created when current flows through the rotor the plug. The remaining energy will be used as
windings. This field rotates as the rotor is driven by the required by the cylinder on the compression stroke.
engine, creating an AC voltage in the stator windings. The same process is repeated when the cylinders
The AC voltage is then converted to a DC voltage reverse roles. This method of ignition is called a waste
by a rectifier bridge. This DC voltage is then supplied spark ignition system.
through circuit 1 to the electrical system at the The electronic ignition system consists of the following
battery terminal. components:
The amount of output voltage is controlled by the ~ Crankshaft position sensor
current supplied to the rotor. The solid state regulator ~ Crankshaft balancer interrupter rings
in the generator controls the current supplied to
~ Camshaft position sensor
the rotor. The rotor current is a series of electrical
pulses supplied by the regulator. When the ignition • Ignition coils
switch is first placed in the RUN position, the • Ignition control module
pulse width is very narrow. This causes the rotor to • Powertrain control module (PCM)
produce a weak magnetic field. This will produce
a lower output voltage to the vehicle's electrical For a more complete and detailed description of the
system. Once the engine is running, the regulator above information refer to Electronic Ignition (El)
monitors the output voltage through an internal wire System Description in Engine Controls-3.8 L
and changes the pulse width accordingly.
Ignition System Description (5.7 l) The electronic ignition system consists of the following
components: ·
The electronic ignition system controls fuel combustion
by providing a spark to ignite the compressed .. Crankshaft position sensor (
air/fuel mixture at the correct time. To provide optimum .. Crankshaft position sensor reluctor wheel
engine performance, fuel economy, and control of .. Camshaft position sensor
exhaust emissions, the PCM controls the spark " Ignition coils
advance of the ignition system. The electronic ignition
• Powertrain control module (PCM)
system does not use the conventional distributor
and coil. The electronic ignition system has the For a more complete and detailed description of the
following advantages over a conventional mechanical above information refer to Electronic Ignition (El)
distributor system: System.Description in Engine Controls-5.7.L
• No moving parts Ignition System Operation

• Less maintenance required The ignition system supplies high-voltage surges to
• Remove mounting capability the spark plugs in the engine cylinders. These surges
• No mechanical load on the engine produce electric sparks across the spark plug gaps.
The heat from the sparks ignites, or sets fire to,
• More coil cool down time between firing · the compressed air-fuel mixture in the combustion
• Elimination of mechanical timing adjustments chambers. When the engine is idling, the spark
appears at the plug gap just as the piston nears top
• Increased available ignition coil saturation time dead. center (TDC) on the. compression .stroke.
The ignition system on this vehicle feature a multiple When the engine is operating at higher speeds, or
coil ignition and is known as coil near plug. The with part throttle, the spark is advanced. It is moved
secondary ignition wires are short compared with a ahead and occurs earlier in the compression
distributor ignition system wire. Eight ignition stroke. This gives the compressed mixture more 1ime
coils/module are individually mounted above each to burn and deliver its energy to the pistons.
cylinder on the rocker cov.ers. The coil/mo.dules
are fired sequentially. There is ah Ignition Control (IC)
circuit for each ignition coil/module. The eight ignition
control circuits are connected to the PCM. All (
timing decisions are made by the PCM, which triggers
each coil/module individually.
(
GM P/N 12303040
J 38758
Battery Side
Parasitic Draw Test Switch
Terminal Adapters
3431 3432
J 21008 J 39200
Self Powered Test Light Digital Multimeter
8439
J 35590
J 41450-8
CS Electronic Generator
Current Clamp
Tester
95591 162176
J 35616-A J 42000
Connector.Test Adapter Kit Digital Battery Tester
8917 404758
6-786 Engine.Controls- 3.8L Engine
Engine Controls - 3.8l

(
Specifications
Temperature vs Resistance
oc OF OHMS
Temperature vs Resistance Values (Approximate)
100 212 177
90 194 241
80 176 332
70 158 467
60 140 667
50 122 973 .
45 113 1188
40 104 1459
35 95 1802·
30 86 2238
25 77 2796
20 68 3520
15 59 4450
iO 50 5670
5 41 7280
0 32 9420
-5 23 12300
-10 14 16180
(
-15 5 21450
-20 -4 28680
,.
-30 -22 52700
-40 -40 100700

Specification
A/C Refrigerant Pressure Sensor 6N-m 53 Lb In
Camshaft Position Sensor (CMP) Retaining Bolt 10 N-rri 89 Lb In
·.
Crankshaft Balancer Bolt 150 N·m + 114° 111 Lb Ft+ 114°
Crankshaft Position Sensor (CKP) Bolts 20 N-m 15 Lb Ft
Engine Coolant Temperature Sensor (ECT) 25 N-m 18 Lb Ft
Engine Oil Level Switch 20 N-m 15 Lb Ft
Exhaust Gas Recirculation Valve (EGR) Bolts 25 N-m 18 Lb Ft
Fuel Filter Fitting 30 N·m 22 Lb Ft
Fuel Pipe Front Clip Bolt 4.5 N·m 40 Lb In
Fuel Pipe Rear Clip Bolt 5.5 N-m 49 Lb In
Fuel Pipe Shield Bolt 5 N-m 44 Lb In
Fuel Pipe Shield Nuts 5 N-m 44 Lb In
Fuel Pipe Shield Studs 5N-m 44 Lb In
Fuel Rail Attaching Nuts or Bolts 10 N-m 89 Lb In (
Fuel Sender Assembly Attaching Nuts 6.5 N·m 58 Lb In
Fuel Tank Retaining Strap Bolts 33 N·m 25 Lb Ft
Heated Oxygen Sensor 42 N-m 31 Lb Ft
Engine Engine Controls - 3.SL 6-787
Specification
Ignition Coil Retaining Bolts 4.5 N·m 40 Lb In
Ignition Control Module Retaining Bolts 30 N·m 22 Lb Ft
Knock Sensor 19 N·m 14 Lb Ft
Spark Plug 2.7 N-m 20 Lb Ft
Throttle Body Nuts or Bolts 10 N-m 89 Lb In
Fuel System Specifications If you're using fuel rated at the recommended octane
or higher and you hear heavy knocking, your
If you have the 3800 V6 engine (VIN Code K), use engine needs service .. But don't worry if you hear a
regular unleaded gasoline rated at 87 octane or higher. little pinging noise when you're accelerating or driving
If you have the 5.7L V8 engine (VIN Code G), use up a hill. That's normal, and you don't have to buy
premium unleaded gasoline rated at 91 octane a higher octane fuel to get rid of pinging. It's the heavy,
or higher for best performance. You may use middle constant knock that means you have a problem.
grade or regular unleaded gasolines, but your Notice: Your vehicle was not designed for fuel that
vehicl,e may not accelerate as well. contains methanol. Do not use methanol fuel
It is recommended that the gasoline meet specification which can corrode metal parts in your fuel system and
which have been developed by the American also damage plastic and rubber parts. This kind of
damage would not be covered under your warranty.
Automobile Manufactures Association (AAMA) and
endorsed by the Canadian Motor Vehicle If your vehicle is certified to meet to meet California
Manufacturers Association for better vehicle Emission Standards (indicated on the under hood
performance and engine protection. Gasolines emission control label), it is designed to operate on
meeting the AAMA specification could provide fuels that meet Califomia specifications. If such
improved driveability and emission control system fuels are not available in states adopting California
emissions standards, your vehicle will operate
performance compared to other gasolines. For more
satisfactorily on fuels meeting federal specifications,
information, write to: American Automobile
but emission control system performance may be
Manufacturer's Association, 7430 Second Ave,
affected. The malfunction indicator lamp on your
Suite 300, Detroit Ml 48202. instrument panel may turn on and/or your vehicle may
Be sure the posted octane for premium is at least 91 fail a smog-check test. If this occurs, return to your
(at least 89 for middle grade and 87 for regular). If authorized dealer for diagnosis to determine the cause
the octane is less than 87, you may get a heavy of failure. In the event it is determined that the
knocking noise when you drive. If it's bad enough, it cause _of the condition is the type of fuels used, repairs
can damage your engine. may not be covered by your warranty.
Some gasolines that are not reformulated for low
emissions may contain an octane-enhancing additive
called methylcyclopentadienyl manganese
tricarbonyl (MMT); ask your service station operator
whether or not the fuel contains MMT.
6-788 Engine Controls - 3.8L Engine
Emission Hose Routing Diagram (
Emission Hose Routing Diagram
226742
Legend
(1) Fuel Pressure Regulator
(2) To Vacuum Brake Booster
(3) EVAP Servi9e Port
(4) Intake Manifold (
(5) To EVAP Caniste.r (Behind the Left
Rear Tire)·
(6) Throttle Body
(7) PCV Valve
(8) EVAP Canister Purge Solenoid Valve
(9) To Accessory
(10) Manifold Vacuum Source
(
Engine Engine Controls - 3.8L sqag
Emission Hose Routing Diagram (EVAP Control System Overview)
1
20
14
17 16
13 12
19 18
200517
Legend
(1) EVAP Vent Valve/Solenoid (10) Fuel Filler Pipe
(2) EVAP Vent Valve/Solenoid Ignition Feed (11) Check Valve (Spitback)
Circuit Terminal (12) Modular Fuel Sender Assembly
(3) EVAP Vent Valve/Solenoid Control Circuit (13) Fuel Limiter Vent Valve (FLVV)
Terminal
(14) PressureNacuum Relief Valve (Optional)
(4) EVAP Vent Valve/Solenoid Filter
(15) EVAP Canister
(5) EVAP Vapor Lines
(16) EVAP Canister Purge Valve/Solenoid
(6) Fuel Tank Pressure Sensor
Ignition Feed Circuit Terminal
(7) Fuel Tank Pressure Sensor Ground Circuit
Terminal (17) EVAP Canister Purge Valve/Solenoid
Control Circuit Terminal
(8) Fuel Tank Pressure Sensor Signal Circuit
Terminal (18) Intake Manifold Vacuum Source
(9) Fuel Tank Pressure Sensor Circuit 5 Volt (19) EVAP Canister Purge Valve/Solenoid
Reference Circuit Terminal (20) EVAP Service Port
6-790 Engine Controls - 3.8L Engine
Engine Controls Schematic Icons
Refer to ESD Notice in Cautions and Notices. (
19384
Refer to 080 II Symbol Description Notice in Cautions and N'otices.
19385
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Engine Controls Schematics (Power and Ground) m
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0.50RN 340 0.5 PNK/BLK 439 0.8 PPLJWHT 1035 8206 - - - - - -,.. Schematics In
0.35 PNK 39 Wiring Systems
0.8 A3
G E C101 Power ... - - - - - - - - - - - - ., Instrument
Distribution I Instrument~ Malfunction I Cl st
8170 --~O-P3_':_H_T_
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Schematics In
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I Voltage (B+) Voltage Voltage C1=BLU I Module
I C2=CLEAR I
PCM PCM PCM PCM .,,. I (PCM)
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Engine Controls Schematics (Ignition Controls, Knock Sensors) m
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Electronic Brake ,._
Control Module P"4
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Position (CMP)
Crankshaft
Position (CKP)
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0.8 RED/BLK 645 WHT Power
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0.8 0.8YEL 573 0.5 PNK!239

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CMP/CKP CKP 18x CKP Ignition
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Sensor
Positive Voltage Signal Voltage
Signal
5V
12V
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Sensor
Signal
18x
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Signal
3x
Reference
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0.35 BLU/BLK 647 TAN/BLK 424 ::s
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I"Bank 2 Bank 1 Engine
I KS Signal KS Signal Speed
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______ !3
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Ignition
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499305
Engine Controls Schematics (Fuel Pump Controls) O')
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Level
l
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Engine Controls Schematics (Fuel Injectors) m
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499307
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Engine Controls Schematics (MAP, ECT, IAT Sensors) I
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Powertram .. - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - ,
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I . -=- C2=CLEAR I j. m
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L - - - - - - - - -.. . - -.- - - - - - - - - - - - - - - - - - - - - - - - -
<e.
:::s
499308 (I)
·~·
Engine Controls Schematics (Heated.Oxygen Sensors) m

::::,
(,Q
5·
!Hot In RUN, Bulb Test And START 1·
r - - - - - - - - -Engine
- .,
!Loe j CD
I Power I W',
I Distribution
I Schematics
in Wiring
ENG SEN I mng
MiniFuse ® I Harness
20 A Junction.
[SJc
I.. Systems
_ _ _ _ _ _ _ ___ ...I Block 2
0.8 PNK 539 ~
B C105
~
Power
Distribution
Schematics in +- - - -... ......0.8 PNK 539
Wiring Systems ......
...... -... 8104
r '· ·._ - ·- · : - - - - - - - - - - - - - - - - - - - - . - - - - - - - - - - - - - - - - - - ·- : - ., Powertrain

I Bank 1 Bank 2 . PCM Bank 1 1Control
I c 1=BLU . I Module
I H02S 1 H02S 1 H02S 1 . . H~2S 1 . .. . C2=CLEAR H02S 2 H02S 2, (PCM)
Signal Low Lew ... · Signal . Low Signal
1. - - 12 C2 - 27 C1 - - - - - - - - 29 C1 - 10 C2 - - . - - - - - - - - - - 28 C1 . 11 C2 .&..
. ~
· 0.8
PPL/WHT 1665 0.8.PPL 1666
0.8 GRY 1981
0.8 0.8 PNK 539
PNK 539 0.8 0.8 TAN 1667 0.8 PNK 539 0.8
TAN/WHT 1653 DK BLU 1980
D B A A B D A B D
H.eated Oxygen Heated Oxygen Heated Oxygen m

::::,
Sensor Bank 1, Sensor Bank 2, Sensor Bank 1,
(,Q
Sensor 1 Sensor1 Sensor2
::::,
CD
0
c
0.8
BLK 450
0.8 BLK 450
c c
0.8.BLK 450
-
0
::::,
' "'I
0
in
8108 , .Ground
450' '-- - - - - - - -a
. Distribution
1 BLK Schematics In
-=- G112 Wiring Systems
enI
......
(,I)
499309 ......
Engine Controls Schematics (MAF Sensor, EVAP System, EGR Valve)
l I
~
!Hot In RUN, Bulb Test And START
;o:er-
I Distribution
Schematics In
J7
: Wiring Systems J6 20 A
ENG SEN
MiniFuse ®
iHot In RUN, Bulb Test And START
- - - - - - - - - - - - - - - - Po;r - - - -
Distribution
Schematics In
Wiring Systems GB 15 A
- - - - ~ Engine
G9 ENG CTRL I Wiring
MiniFuse ® Harness
1 Junction
I
.... ;G; -
: va1ve
I lgniti.on
Positive
I Voltage
J
12v - - - - - "' Powertrain
PCM
C1=BLU
C2=CLEAR
: Control
I
I
Module (PCM)
Ai.
11111'
m
:::s
(Q
:::s
CD
L, - - - - - - - - - - - - - - - - - - - - - - - - _ - _ _ _ _ Block 2
_ _ _ .,
!.----------"~
4 C2 ()
-
0.8 PNK 539 Power 0.5 PNK 239 P100
Distrlbulion 0
B C105 Schematics In 0.35 LT BLU 697 Manifold Air :::s
Wiring Systems 0.5 PNK 239 8182 Pressure -c
(MAP) 0
-Po_w_e_r- - - . G C100 + 0.5 PNK 239 ui'
~-----·
0.8 PNK 539
Distribulion
Schematics In
02 C200B
Sensor
A
I
0.5 PNK 239 C200D
8104 Wiring Systems !,. _ _ _ _ _ _
8107 0.5 PNK 239
0.8 PNK 539 A2 C405B 0.35 GRY 598
0.35 YEL 492
AIC405D
0.5 PNK 239
c A
A 0.35 PNAK 239
Ignition MAF Mass Airflow
Positive Sensor (MAF) Sensor E D
Voltage Signal
1. . 5l?J;;
Evaporative [ ] ] Evaporative
Ground
Emission (EVAP) Emission II
B [ ] Canister (EVAP) I...___J,..-_-_-_-_-_-_-_-_-1_-
_--_ _____ l
Purge Canister
B Solenoid Bl Vent A B c
Valve Solenoid
Valve
0.35 WHT 1310
0.35 BLK/WHT 451 0.35 BRN 1456
B C4050
B2IC405B 0.35
0.35 DK BLK 552
GRN/WHT 428 0.5WHT 1310
C C230 0.35GRY 435
Ground 0.5WHTt310
Distribution P110
1
8110
Schematics In
Wiring Systems
Powertrain ~ MAF -
Control I S~nsor
69 '--------
76
- - -,
•
C1 2 C2
J
EVAP canister - - - - - EVAP Canister - - -
Purge Valve vent Valve
32
J C1 28 C2 31 C1
EGR - EGR - - - - - Sensor - - - - - - - - ~
Valve Pin~~ Ground I
Module (PCM) 1 Signal ····T Driver ····T Driver ····T Control Posmon PCM
3 BLK 451 Ji. Ji. Ji. Signal I
jJ, I ~ ~ ~ ~ C1=BLU I
3BLK ~ I C2=CLEAR I
451 I I m
L------------------------------------------------J :::s
'!:!.
:::s
499312 CD
___/
Engine Contr.ols .Schematics (VSS, Cruise, Generator, Engine. Oil Level) m

::s
(Q
!L c I0
5·
(D
:
I l:l.
. ~ · ~:ut - PCM
C1=BLU
:)*::i~!f~ :
i-- Output I
~!~~~:;CM)
}J ~c
~--- -=- SV - - - - - - - - - - C2=CLEAR - - - - - - - - ~~t~:iltlon---------=- - - - ____ 1~ ~
~
55 C1 0.35 TAN/BL~r464 - - - - - - - - - - - - - - - - - - - 61 C2
0.35 DK GRN/WHT 817

P110
r """". ., Instrument
I vss I Cluster
~1"!!.ut ~-- ~ .·
F
0.35 TAN/81.:K 464

I C105
o.35 RED 225
A
K C220 88 ~ 9 C1 B
· r TPSP;it;n .,Electronic B.rake r-T;;;non., Generator
I Input I Control Module I 1nput I · Ground
0.35 DK GRN/WHT 817 1 TPS Position I (EBCM) Distribution
0_35 DK GRN/WHT •817

1 Output
.. _ _ -
· I >
..;.Ii,-.~.
I
L.--.1
I .----<11 Schematics
In Wiring
Systems
27 C1 ~.
3 BLK 451
0.35 DK.GRN/WHT 817. 0_35 ORN/BLK 463

sno
A1 C200D 0.35. BLK/WHT 451
C200A
0.35 D~GRN/W: 817
I ., Cruise
D C105
A
Engin.e
Oil
ii---3---il ¥:!;:~
r -
I I Control Level
I I Module Speed Switch m
8 3 BLK 451 ::s
... - ..I C.Q
-------- ::s
8 A C2 (D
0.35 ORN/BLK 463
0.35 YEL 400. 0
-
0.35 BRN 1174 0
0.35 PPL 401 ::s
" "'I
1~~~e1
0
~-------~~i1~-- ~~1-
I
64 65 71 C1
- - - - - - - - - - - - - - - - - - - P C M ____
C1 =BLU
.·
58 C2
Signal
-----~6~~~~~a,n
I Module
'vi
(.,)
()0
r
I C2=CLEAR I (PCM) A
I sv -=- 5V I PJ>
1.-----------------------------------------------------J ~
Cl')
©
©
I
"""
499313
Engine Controls Schematics (TAC Module, Brake Switch, Cruise) O')
I
co
0.35 BRN I
Hot In RUN, Bulb Test Or ST@ I
Hot At All Timesl I I
Loe
0
0
1
r-- , Engine r - - - - - - - - - , Engine
Power
Atlc:::o aa A I Distribution
I Schematics
ETC
I Wiring
I Harness
I Power
Distribution
I Schema.tics J9
I
I
W'.
1nng
TCS BATT Harness 1°E I
m
::I
(C
8
I
'" ,- , Cruise Control I lnWirlng i Junction I In Wiring MiniFuse® 1 Junction C
0.5 BRN 86 I I Release (Brake) I Systems MiniFuse® :::,
10A I Block 2 I Systems JB 20 A I Block 1 (D
F C100 I J;···· I Switch I I I I
1,,; - .!I (Closed w/o
!.------ -----.11 1.---------.11 0
r- -- - - -
PCM
- - -
0.5 BRN 86
- - - 2~ - ~, p I
Cruise owe rain
B brake
rt 0:5 PNK 139 depressed)
-
0
::I
" "I
0
I C1=BLU Control I Control B C250 ti)
I C2=CLEAR Release I Module
: (PCM) 0.5 PNK 139 w
: TAC TAC Signal
I JI.
co
1. -'!-~ ___
I Serial Serial
~a!! _ _ _ _ _ _ .1 ~
0.5 PNK
139
C A/C Compressor
Relay 0.8 ORN 1540
r
14 -----15 C1 MIC215
'" - , Stop Lamp(rCC
0.35TAN 800
0.35 r- - ~is: ~- - - - - - - - - - -a Multi- : : Switch
ORN/ 1061
BLK
P110
! 7--~;;----------- --
: OFFe_____ R/A OFFe ••••.•..• -~1/A :
!~°" 0.8 LT BLU 20
~- C, Exterior
Lights
I ON . - - - - - - - - - - - 9~ - - I 8243 - - - - - + Schematics
F C220 D C230
~ ___ ___ =1s~,~~T- ___ ~ 0.8 LT BLU 20
In Lighting
Systems
0.35
ORN/ .1061
BLK
0.35 TAN 800
C200D
L
I ______ ~
I ____________ ~
I C2~.; PNK
5 339
A4
C200D
C200A
A5 C200A P100 P100
0.8 LT BLU 20
Cruise Control
0.5GRY ·397 0.5 GAY/BLK 87 0.8 LT BLU
0.35 8154 Schematics In
ORN/ 1061 20 Cruise Control
BLK 0.8 LT BLU 20
0.5
- ------ P100 DKBLU 84 P100
16 18 20 8 21 7 9 3
~ - - - TAC- - - - TAC - - - - - - - - - Cruise' - - Cruise - - - - - - Cruise - - - Ignition - - Brake - - - - - - - - - Battery - - ., Throttle
I
Serial Serial On/Off , Set/Coast Resume/Accel Positive Switch .. Posttlve Actuator
I Data Data Signal Signal Signal Voltage Signal Voltage IControl
: , 1(TAC)
1.------------------------------------------------------------~M~·
JI.
~ m
~
499314
s·
(I)
Engine Controls Schematics (TAC Module, TAC).
~ ---------------------------------------------------------- ~ l~~~:!~r !L0cI

·I
I
I
I
·,··
.
·
·
TP
Sensor 2
Signal
TI TP.
sv .
· .
T
TP
Sensor1
Ground
P.
·
TI
.
I Control
J
1 (TAC)
I Module
>~+
[S] ES
TAC
IL. _ G.!_O~d _ _
TAC
2r~n! ______-_
_
_ __ ~~d- _
Sensor2
_ _ _
TP
~or! _
MotorDriver
.:°: ___ ~i _
MotorDriver
_ _ _ _ _ _
TP Sensor1
~n_:or_: _ !~~ ___ =_ I 1 ,._..,.
~~
17 5 P100 22 24 23 . 13 1 11 12 10 I+ I
0.8
BLKJWHT 451 A.
P100 · 0.35 BLK 476 ~
0.35 DK GAN 485
gfl<JWHT 451 o.35
BLK/WHT Fuel
0.8BRN 582
8 171 451 D
Pump 0.35 GRY/BLK 1687
Relay
0.8
BLKIWHT 451 P100
B H C101
0.35GRY 597 0.8 YEL 581 0.35 BLK 470
0.8
BLKJWHT 451
0.8
BLKJWHT 451 0.35 PPL 486
B A c D E F H G
5V 5V Motor Motor 5V 5V Throttle
REF Drive Drive REF RTN TPS1 Actuator
RTN
Low Hi Control
Throttle Throttle Ji m
Position Position ~ ::,
(.Q
Sensor2 Sensor1
::,
(f)
Ground 0
-
0.8 BLKJWHT Distribution 0
Schematics ::I
451 In Wiring ~
Systems 0
Cf)
3 BLK 451
3BLK
451
G110
en
I
QO
0
499316 ..r,.
Engine Contrpls Schematics (Secpnd Gear Start, Cruise Control Switches) en
.I
co
!Loe I
0
IHotln RUN! N
r------,1p
I G3 GUAGES 1Fuse m
I H3 Fuse 9 I Block ::::s
I H4 10 A I !oEsc! C.C.
L.- - - - .......... .I ::::s
CD
~ 0
-
0.5 PNK 39
Power 0
0.35GRY 48 ::::s
c Distribution
'" -}- - - "' Cruise Control

Schematics In
Wiring Systems
+---- 8206
[B '"'Ii
0
I (Anticipate) I (Clutch) cir
____
._I l:--·· ....I Switch
0.8 PNK 39
A (,.)
D
~ - - - - - - - - - - - ~te;or- - --i- --- ~:~~nd
B
~
cor
0.35 BLK/WHT 451 I
I
I
~- - - - ---rwltch) -
(Momentary
-
~~:ing
Schematics In
Ughlfng
Systems - - -
I
f!\ 2nd
W Gear
-
Indicator
- - - ~
I Start
I Switch
I (Chevroletw/o NW9)
F E A
A B C270
0.35
BRN/ 1571 0.35 PPL/WHT 1572
WHT
0.35 BLK!WHT 451 0.35GRY 48 A13 C4 C200D

----------------- C200B
C200A
P100
0.35
5215 0.35 BLK/WHT BRN/ 1571 0.35 PPL/WHT 1572
,--,------- 451
WHT
: -----------.i·
1 0.8 BLK/WHT 451 0.35 GRY 48
I E B C220 C --------'--------~ C105
1
P 10 0.35 BRN/WHTf 157·.·1 0.35 PPL/WHTf .1572
.! 0.8 BLK!WHT 451 _ GRY
0 35 48
. - . .
1------ 1---------!l
Ground
Distribution 18 21 C2 2 C1
~c:~n~ics ..... - - - - 8110 ~ ~.:ate ::rtG;:i;ch 2n~.Gear - - PCM - ~6~~~~ram
Systems I Swhch Si nal • lnd1cator . IM d I A.
3 BLK 451 1 Ignition 9 .. ---· control C1=BLU O Ue ,-
I
T
- 3 BLK I F 12V -=- -=- C2=CLEAR I {PCM) ~ m
451 · ~G110 ~------~-------------------------------.1 ::::s
(Q
::::s
499318 CD
.. _ /
Engine Controls.Schematics (Automatic Transmission, Brake Switch) .... m

:::,
l l cc
!Loe I
lHot In RUN, Bulb T""t And START lHot In RUN, Bulb T<><:t And START
5'
r - ...... - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - PoWer - - - - - .- - - ., Engine (D
I ~~~f
~ution ENG SEN Distribution ENG CTRL I Wiring
I Schematics In MlnlFuse® Schematics In MiniFuse® I Harness
I Wiring Systems JS 20 A Wiring Systems 15 A I · •
Junction lbEsc!
1.. _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ ·- __ ...:. ...,. Block 2
0.8 PNK 539

B 0105
0.5 PNK 239
~
0.8 PNK 539
$104 - - - - - - - - -+
Power
Distribution 0.5 PNK 239
Power
[B
Schematics In
Distribution
P110 Wiring Systems G 0100 Schematics In
Wiring Systems
0.8 PNK 539· 0.5 PNK 239
CIC220
t
--- .-----...J
0.8 PNK 539
C C2 Automatic
r -
1
- -J-· - - - .,•switch
Stop Lamp/TCC Transmission
r-. - - - - - - - - -. . . -~--. .·.-
I I (Open with I
I TCC/Shift I brake pedal I
I Interrupt I depressed) I
r···· I 0.5 RED 839 0.5 RED 839 0.5 RED 839 0.5 RED 839
II
I.... ______ ...
D 02
Switch II
I
: I
I
I
I
A
6~~~':rter
Clutch
Solenoid
(TCC SOL.)
[J]
A ..
6~n~~~er
Clutch
Pulse Width
Modulation
[]1. []1 ~~f~:1: . []1 ~~fe~~:
B .
;~fe~.:i:
(3-2 SS)
Valve
Assembly
A
· (2-3 SS)
Valve
A
(1-2 SS)
Valve
0.8 PPL 420
D 0220
[_ ~5~ :-=~- MT1"8:~1~~~-~- 05~1m~-~ MLTG+~ -__j
T U S B A 01
m
:::,
cc
:::,
P110 (D
0.8 PPL 420
30 01
0.5 TAN/BLK 422
79 _________ ?~
0.5 BRN 418
0.5 WHT 687
__________ ~~ 02
0.5 YELJBLK 1223
44
0.5 LT GRN 1222
__________ 1 01
-a
0
:::,
ui"
PowCeortnrat:onl ~ =eh,- -----------:. . ---- -,-;c~ ;:- - - -t. -.T.~;;~ ;o~ -, -3.:; ss - - - .~,- 2-3-SS - - -} ~-;s; - -~: - )
. c Valve / Valve ' . Valve . Valve Valve
Module I Signal ----T Control ·----Teontrol ··--·T Assembly . . •••••, Assembly ·---·T Control C1=BLU I
~ (PCM) I ! . ! ! ! !
.. - - - - - - - - - - - - --- - -- - - - - - - - - - - - - - - - - - - ---- -- ........ ·- - - --- - -- - --- - -· - - .,
= . Control Control C2=CLEAR I
~ 0)
I
ex,
Q
499319 w
Engine Controls Schematics (Automatic Transmission,. Park Neutral. Position Switch) 0)
I
CC)
Q
~
;1::1,
..r - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - ., Powertram Auto oc
I I
I PCM I Control . Trans Shift m
::s
~
Lock Control
Transmlsi,lon Transmission Transmission TFT C1=BLU Module (PCM)
I
I
Range A
Input .
Range B
Input
Range c
Input
Sensor
Signal
C2=CLEAR
I
I
4
Jll1*
Schematics In
Automatic c.e.
::s
Transmission
- - - - - - - - - -17 - - -- - --- -- - --68 ~"--6. CD
~
L - -
22 C1 - - - - - - - - - -
57 - - - - - - - - - - - - - -.- - - -
C2 - - - - - - .J
~
0
0.5 PNK 1224 0.5 DK BLU 1225 0.5 RED 1226 0.5 YELJBLK 1227
0.5 ORN/BLK 434
__o_.5_0_R_N_/_B_LK
_ _,
[B -
0
::s
' "'I
0
in"
8234
434
A w
00
0.5 ORN/BLK 434 r
Automatic
N . ______________ f:I __________ .F _____________ ~ C1 Transmission
B
r - 0.5PNJ-1224 - - - 0.5DKBLU~225 - - 0.50RNr1226 - - - - 0.5BRNt227 - - . .- - - .- - - . - - - ~ r - ;-;--- - - - .,Park
~1 El ol Ar Automatic
I
I ·
I
I P
·
1.
'Neutral
I Position
Transmission ·
Fluid Pressure 1
I ~
. R•,,_,. , ··
l
.-·" 2 I•switch
(Automatic
REV 03 04 (TFP) Manual I
4
N ·if»··· D I Transmission)
•. __ ,
Switch Swttch Switch Valve Position
switch I . • I
I I
LO
Transmission
Flu Id
L--------.l
A
Switch · .02 Temperature 0.5 LT BLU 1229 0.5 PPL.1228
, •••• Switch (TFT) 0.35 BLK/WHT 451
Sensor 8215 - - - - - .,
;.~~~-~:~;~ 1
= BY. H C220 0.8 BLK/WHT 451 Ground
- - - - - - - - - -·- - - - - - - - - - - - - - - - 0.5GRY'k.452 - - - - - - -------
-------c C1 E C220
Distribution
Schematics
I
0.35 In Wiring
1229 ORN/BLK 434 0.8 BLK/WHT 451 Systems
0.5 GRY 720
0.5
------------ P110
_ _ _ _ ...J
T
E RED/BLK 1228
Fuel Tank 3BLK
Unit
451
r -
I Valve Low
46
;;-;0-;:.,-.. - - - - -. 1···- ..
------~.?
PC SOL
r-. ---:r.·.:·-. .
------'-_1_6 C2
PNP - - - - - - - - .,Powertrain
SWitch PCM I Control
I · va1ve High . . c 1=BLU I Module (PCM)
I C2=CLEAR I A. .
L - - - - - - - -
..-
- - - -- - -
12V
- -
· 12V
- - - - - - - - - - - .J~
,-
.
m
::s
u;i
::s
499321 CD
Engine Controls Schematics (A/C ·HVAC Control) m
:::,
c.c
IHot In RUN, Bulb Test·And STARTI
,. -P;;-w; - ..,.. - - - - - - , Engine .. - - - - - -
Power
IHotlnRUNi
---·--·,1p·
·· I
!Loe l 5·
(D
Distribution G7 A/C CRUISE I Wiring Distribution HVAC Fuse

~c
1 Harness I
Schematics GS MlnlFuse® Schematics Fuse 6 Block
15 In Wiring E2 20 A 1
In Wiring A : Junction
.. _s~t~:_ _ _ _ ____ J Block 2 .Systems
~
.. - -·,- - - - - - - - - .I
0.5 PNK 139
Multi- 0.5 PNK S165 1 BRN 241
function
Lever
C1--------«11----~
139
0.5 PNK 139
Power
Distribution _ _..;..1..;::B"""R;;;;..N'------11111 S248
[B
Schematics In 241
0.5 PNK 139 Wiring Systems
r -
I
I
I
:
-
[(gJ
-
08
- - - -
010
- - -
~~pressor
Relay
- - .,

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2000 Chevrolet Camaro

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Cautions and Notices

Cau1ions and Notices ........................................ 3 SIR Special Tool Caution .................................. 6

Cautions and Notices

Gasoline/Gasoline Vapors Caution Safety Goggles and Fuel Caution

General Information ........................................ 0-3 Maintenance .................................................. 0-35

in 25.4 mm (°F-32) I 1.8 I = I ~c

Power 25/64 0.390625 9.92187

hp 0.745 kW 13/32 0.40625 10.31875

Position Definition Character Description

A VIN derivative can be used to determine if a vehicle

VIN Derivative Position Equivalent VIN Position

MFD. BY GENERAL MOTORS CORP.

GVWR GAWR FRT GAWR RR

The primary location of the VIN derivative for the

The Tire Placard is permanently located on the edge

The secondary location of the VIN derivative for the

The engine is also stamped with a VIN derivative

The transmission ID and the VIN derivative for the

The transmission identification (ID) number indicates

The transmission model identification is located on a. ·

sEv1cE PARTS 10ENT1FicZ'i,6t1 £' "';oc,/r:.r0,;;,~;;·rt;0;i1)

Federal law requires that General Motors label certain Legend

The Service Parts Identification Label aids the seNice

W52 36U Exterior Color, Fern Green

new, international standards. The following are the legend

A prevailing torque nut is designed to develop an

Prevailing Torque Specifications (English-Size Fasteners)

Important: Refer to the thread repair kit

4. Thread the thread insert onto the mandrel of the.

1. Determine the size, the pitch, and the depth of the

CCP Climate Control Panel

avg average C02 Carbon Dioxide

AWD All Wheel Drive Coax Coaxial -~

Abbreviation Meaning Abbreviation Meaning

Abbreviation Meaning Abbreviation Meaning

) Abbreviation Meaning Abbreviation Meaning

Abbreviation Meaning Abbreviation Meaning

syn synchronizer VDV Vacuum Delay Valve

TPM Tire Pressure Monitoring WHT White

.,,.._ .,_,. ,,..,,..,,.,

12. Stake the other end of the retainer:

Caution: To avoid any vehicle damage, serious

Notice: When you are jacking or lifting a vehicle at

For lifting the vehicle, various lift points are

Position the front lift (suspension contact) as follows: ·

Important: The front hoist pads must not contact the (

Important: When lifting the vehicle with a floor jack,

VERIFY CUSTOMER CONCERN

CHECK FOR BULLETINS

5.1 5.2 5.3 5.4

7 REPAIR AND VERIFY FIX

Special Tools and Equipment

Maintenance and Lubrication

Fluid and lubricant Recommendations

Explanation of Scheduled Services 140 +4

For the engine oil and oil filter changing procedure

Mechanical - 5.7 L. 196359